Abstract:
The subject invention is a bracketless rearview mirror assembly ( 10 ) that is inexpensive and provides an easy assembly technique to attach the mirror assembly to a side of a motor vehicle ( 12 ). The mirror assembly includes a case ( 14 ) with a reflective mirror ( 16 ) and a guide mechanism ( 26 ). The motor vehicle ( 12 ) includes a mounting surface ( 48 ) with an opening ( 52 ) disposed between an inner side ( 48 ) and an outer side ( 50 ). A connector ( 42 ) is positioned between the case ( 14 ) and the inner side ( 48 ) of the mounting surface ( 46 ) of the vehicle. An adjustment mechanism ( 20 ) extends from inside the case, through the guide mechanism ( 26 ) and the connector ( 42 ), to the inner side ( 48 ) of the mounting surface ( 46 ). The adjustment mechanism ( 20 ) can be a simple handle ( 68 ) for manual adjustment or a harness ( 84 ) for encapsulating electronic controls for electrically adjusted mirrors. The mirror assembly ( 10 ) also allows the case ( 14 ) to move about the guide mechanism ( 26 ) and adjustment mechanism ( 20 ) to fold inward toward the vehicle ( 12 ).

Description:
TECHNICAL FIELD  
       [0001]     The present invention relates to a rearview mirror assembly with a bracketless mounting feature for attaching the mirror assembly to a side of a vehicle, and, more particularly, the present invention relates to a rearview mirror assembly with a mounting feature adaptable for various adjustment mechanisms.  
       BACKGROUND OF THE INVENTION  
       [0002]     Traditional side rearview mirror assemblies are expensive and difficult to assembly in a mass-manufacturing environment. They require a mounting bracket that attaches a housing of the mirror assembly to a side of a motor vehicle. This bracket adds to the overall cost of the mirror assembly. Additionally, the design of the bracket becomes specific to one particular vehicle since it is an exterior trim piece and must cooperate with the overall design scheme of the vehicle. Creating different brackets for different vehicles also adds to the cost of the mirror assembly.  
         [0003]     In addition to the bracket having a specific design for aesthetic reasons, the bracket may also vary in its design to accommodate different mirror adjustment mechanisms. Today, some vehicles use a manual adjustment mechanism with a simple handle extending from the mirror to the interior of the vehicle. Higher priced vehicles include electrically adjustable side rearview mirrors. These higher priced vehicles use additional components to adjust the mirror. Depending upon which adjustment mechanism is desired in the vehicle, a separate mounting bracket would be necessary to accommodate the necessary components of each adjustment mechanism. Again, the need for different brackets adds to the cost of the vehicle.  
         [0004]     Also, the use of a mounting bracket makes the assembly of the mirror to the vehicle difficult and time consuming. An assembly that would eliminate the use of a mounting bracket is highly desired.  
         [0005]     There remains a need in the automotive industry for a side rearview mirror assembly that is inexpensive to manufacture, yet easy to assemble and able to accommodate a variety of adjustment mechanisms. The present invention, as described below, fulfills each of these needs.  
       SUMMARY OF THE INVENTION  
       [0006]     The subject invention is a mirror assembly having a mounting surface with an inner and outer side and an opening disposed therebetween. The mirror assembly also includes a case with a reflective mirror disposed with the case. Positioned within the case is a guide mechanism having a first aperture. A connector is positioned between the case and the inner side of the mounting surface and includes a second aperture. Finally, the mirror assembly also includes an adjustment mechanism.  
         [0007]     A further understanding of the present invention will be had in view of the description of the drawings and detailed description of the invention, when viewed in conjunction with the subjoined claims. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]     Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:  
         [0009]      FIG. 1  is a perspective view of a motor vehicle with a mirror assembly of the subject invention;  
         [0010]      FIG. 2  is an exploded view of the mirror assembly with a handle adjustment mechanism for manual adjustment of a mirror;  
         [0011]      FIG. 3  is an exploded view of the mirror assembly with a harness adjustment mechanism for electrical adjustment of the mirror;  
         [0012]      FIG. 4A  is an outer perspective view of a connector of the mirror assembly;  
         [0013]      FIG. 4B  is an inner perspective view of the connector of the mirror assembly;  
         [0014]      FIG. 5  is a perspective view of an inner side of a mounting surface of the motor vehicle;  
         [0015]      FIG. 6  is a perspective view of a guide mechanism of the mirror assembly of the subject invention;  
         [0016]      FIG. 7  is a perspective view of the handle adjustment mechanism of the mirror assembly;  
         [0017]      FIG. 8  is an inner perspective view of the handle adjustment mechanism extending through the connector and into the inner side of the mounting surface of the motor vehicle;  
         [0018]      FIG. 9  is a perspective view of the mirror assembly of the subject invention having a handle adjustment mechanism;  
         [0019]      FIG. 10  is a perspective view of the mirror assembly of the subject invention having the harness adjustment mechanism;  
         [0020]      FIG. 11  is a perspective view of the mirror assembly of the subject invention having the harness adjustment mechanism and the case moveable; and  
         [0021]      FIG. 12  is a perspective view of the case of the mirror assembly. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]     Referring to the Figures, wherein like numerals indicate like or corresponding parts throughout the several views, a mirror assembly is generally shown at  10  in  FIG. 1 . The mirror assembly  10  is shown attached to the side of a motor vehicle generally shown at  12 . The subject invention includes a mirror assembly  10  having three distinct embodiments—a handle mirror assembly  10 , an electrically actuated mirror assembly  10  and a moving case mirror assembly  10 . All three embodiments have the components described herein and shown in  FIGS. 2 and 3 .  
         [0023]     The mirror assembly includes a case  14  having a generally rectangular shape and a reflective mirror  16  disposed within said case  14 . The shape of the reflective mirror  16  and case  14  of the present invention, however, can be of any shape. The reflective mirror  16  includes a back plate  18  that is connected to an adjustment mechanism  20 . The adjustment mechanism  20  has a first end  22  and a second end  24 . The first end  22  of the adjustment mechanism  20  is attached to the back plate  18  of the reflective mirror  16  by conventional means commonly used in the art.  
         [0024]     The case  14  also includes a guide mechanism  26 . The guide mechanism  26  has a first aperture  28 . With the first end  22  of the adjustment mechanism  20  connected to the back plate  18  of the reflective mirror  16 , the second end  24  extends through this first aperture  28  of the guide mechanism  26  to an outer side of the case  14 . The guide mechanism  26  also includes wings  30  extending from each side of the first aperture  28 . An inner side  32  of the guide mechanism  26  faces the reflective mirror  16  while an outer side  34  faces the motor vehicle. The outer side  34  of the guide mechanism  26  includes a rib  36  and a knob  38 . The rib  36  is used to fixedly position the guide mechanism  26  to the case  14  in the handle mirror assembly  10  and electrically actuated mirror assembly  10 . The case  14  receives the rib  36  in a slot (not shown) to fixedly position the guide mechanism  26  in the case  14 . The knob  38  is used in the third embodiment of the moving case mirror assembly  10 . The case  14  in the moving case embodiment includes a plurality of grooves  40 . These grooves  40  receive the knob  38  of the guide mechanism  26  as the case  14  rotates about the guide mechanism  26  and the adjustment mechanism  20 . Rotating the case  14  permits the mirror assembly  10  to be folded inward against the exterior side of the vehicle  12 . Folding the mirror assembly  10  inward reduces the overall width of the vehicle thereby assisting when shipping the vehicle  12  or parking the vehicle  12  in confined spaces.  
         [0025]     In order to attach the case  14  of the mirror assembly  10  to the vehicle  12  a connector  42  is positioned between the case  14  and the vehicle  12 . The connector  30  contains a second aperture  44  that also receives the second end  24  of the adjustment mechanism  20 . The motor vehicle  12  includes a mounting surface  46  having an inner side  48  and an outer side  50 . The mounting surface  46  is positioned on the side of the vehicle  12 . The mounting surface  46  includes an opening  52 . This opening  52  receives the connector  42  and the second end  24  of the adjustment mechanism  20 . The connector  42  also includes a threaded hole  54  for receiving a screw  56 . The screw  56  is positioned at the inner side  48  of the mounting surface  46  and threadably engages the threaded hole  54  to fixedly attach the connector  42  to the vehicle  12 . To further secure the connector  42  to the vehicle  12 , the connector  42  includes at lease one locking knob  58  that engages an extension  60  in the mounting surface  46 . The preferred embodiment illustrates the use of two locking knobs  58  that engage two extensions  60  in the mounting surface  46 , however, only one locking knob  58  is required. The locking knob  58  requires that the connector  42  be properly oriented for insertion through the opening  52  of the mounting surface  46 . Once inserted through the opening  52 , the connector  42  is rotated and then secured to the vehicle  12 . In addition to the screw  56 , the connector  42  also includes a lip  62  having a locking boss  64 . The locking boss  64  is received in a locking embossment  66  on the outer side  50  of the mounting surface  46 . Therefore, to properly connect the mirror assembly  10  to the vehicle  12 , the connector  42  is orientated to be inserted through the opening  52  of the mounting surface  46  by passing the locking knob  58  through the extension  60  in the mounting surface  46 . Once properly inserted, the connector  42  is rotated and the locking boss  64  is received in the locking embossment  66 . The lip  62  is positioned flat against the outer side  50  of the mounting surface  46 . Finally, the screw  58  is threadably engaged with the threaded hole  54  of the connector  42 .  
         [0026]     The adjustment mechanism  20  in all three embodiments extends through the first aperture  28  of the guide mechanism  26 , the second aperture  44  of the connector  42  and the opening  52  in the mounting surface  46 . Accordingly, the second end  24  of the adjustment mechanism  20  is positioned on the inner side  48  of the mounting surface  46  and thereby inside the vehicle  12  and accessible to an operator.  
         [0027]     In the first embodiment, the handle mirror assembly  10 , the adjustment mechanism  20  is a handle  68 . The handle  68  has a generally tubular shape with and angled extension  70  at the second end  24 . The angled extension  70  begins when then handle  68  reaches the inner side  48  of the mounting surface  46 . The extension  70  angles toward the operator of the vehicle  12  for manual adjustment of the reflective surface  18 . The handle  68  also includes a locking mechanism  72  positioned at the inner side  48  of the mounting surface  46 . The locking mechanism  72  is used to limit the vertical adjustment of the reflective surface  18 . The locking mechanism  72  is shown as a rectangular extension on the handle  68 . The locking mechanism  72  interferes with the connector  42  when moved to maximum upper or lower positions. The interference prevents any further vertical adjustment of the reflective surface  18 . The width of the second aperture  44  of the connector  42  limits the horizontal adjustment of the reflective surface  18  in the case  14 . The horizontal stroke of the handle  68  is limited when the handle  68  contacts a side surface of the second aperture  44  of the connector  42 . To position the handle  68  within the case  14  the adjustment mechanism  20  includes a lip  74 . Positioned between the lip  74  and the inner side  32  of the guide mechanism  26  is a biasing device  76 . The biasing device  76 , most commonly a spring, urges the guide mechanism  26  against the case  14  and the locking mechanism  72  of the handle  68  against the connector  42 , thereby properly positioning the components of the mirror assembly  10 . Furthermore, the portion of the handle  68  positioned in the first aperture  28  of the guide mechanism  26  has a flattened surface  78  on one side of the tubular handle  68 . This flattened surface  78  mates against a plane  80  within the first aperture  28  of the guide mechanism  26 . The mating of the flattened surface  78  and the plane  80  prevents rotation of the handle  68  within the mirror assembly  10 . Again, this ensures that the components of the mirror assembly  10  are properly positioned.  
         [0028]     In the second embodiment, the electrically actuated mirror assembly  10 , the adjustment mechanism  20  includes an electric motor  82  and a harness  84 . The electric motor  82  is positioned within the case  14  and is connected to the back plate  18  of the reflective mirror  16 . The electric motor  82  actuates movement of the back plate  18  and reflective mirror  16  within the case  14 . The electric motor  82  receives power and control signals through electrical controls  86 . The electrical controls  86  are connected to the electric motor  82  and extend to inside the vehicle  12 . The controls  86  are contained within the harness  86 . The harness  84  encapsulates the electronic controls  86  and extends from the electric motor  82  to the inside of the vehicle  12 . The harness  84 , typically made of plastic, also includes a plurality of strengthening ribs. Similarly configured like the handle  68 , the harness  82  also includes a lip  74  and a flattened surface  78 . A biasing device  76  is positioned between the lip  74  and the inner side  32  of the guide mechanism  26 . As with the handle  68 , the flattened surface  78  mates against the plane  80  in the first aperture  28  of the guide mechanism  26  to prevent rotation. The electronic controls  86  extend through the harness  84  and into the vehicle  12 . The vehicle  12  will include a control mechanism (not shown) in which the operator commands movement of the reflective mirror  16  within the case  14  and a signal is sent through the electrical controls  86  and received by the electric motor  82 .  
         [0029]     The final embodiment, the moving case mirror assembly  10 , only uses the adjustment mechanism  20  to properly position the components of the mirror assembly  10 . This embodiment only includes the harness  84 . The harness  84  is positioned as in the electrically actuated mirror assembly  10 . The biasing device  76  is positioned between the lip  74  and the inner side  32  of the guide mechanism  26  to properly position the components of the assembly  10 . The harness  84  is left hollow. A plug (not shown) conceals the second end  24  of the harness  84  positioned inside the vehicle  12 . The plug is strictly provided for aesthetic purposes. The mirror assembly  10  is adjusted by moving the case  14  about the guide mechanism  26 . The knob  38  positioned on the outer side  34  of the guide mechanism  26  is received in one of a plurality of grooves  40  in the case  14 . The operator manually adjusts the mirror assembly  10 . There are no control mechanisms or handles. At a maximum position, the mirror assembly  10  is flat against the side of the vehicle  12 .  
         [0030]     All three embodiments utilize the same components, thereby reducing the manufacturing costs for producing the vehicle  12 . All assemblies  10  use the same case  14 , guide mechanism  26  and connector  42 . The only component that varies is the type of adjustment mechanism  20  either the handle  68 , electric motor  82  with harness  84  or the harness  84  alone. The simplicity of alternating the adjustment mechanism  20  to accommodate various options with each vehicle  12  reduces the overall production costs and assembly efforts.  
         [0031]     Those skilled in the art can now appreciate from the foregoing description that the broad teachings of the present invention can be implemented in a variety of forms. Therefore, while this invention has been described in connection with particular examples thereof, the true scope of the invention should not be so limited, since other modifications will become apparent to the skilled practitioner upon a study of the drawings, specification and following claims.