Patent Document

This divisional application claims priority to Ser. No. 10/666,158 filed Sep. 19, 2003 now U.S. Pat. No. 6,820,987, which is a divisional application of and claims priority to Ser. No. 10/294,167 filed on Nov. 14, 2002, now U.S. Pat. No. 6,648,481, which is a divisional application of and claims priority to Ser. No. 09/456,156 filed on Dec. 7, 1999, now U.S. Pat. No. 6,505,944, which is a divisional application of and claims priority to Ser. No. 08/838,868, filed on Apr. 11, 1997, now U.S. Pat. No. 6,024,459. 

   BACKGROUND OF THE INVENTION 
   The present invention relates to an exterior rearview mirror assembly for a vehicle including a mirror which can be extended from a normal viewing position adjacent the vehicle to an outboard position for improved rearward viewing. 
   Exterior rearview mirror assemblies are typically used on all motor vehicles. Adjustable or extendable exterior, side-mounted rearview mirrors are also known in the art. Extendable mirrors provide improved rearward viewing, for example, when the vehicle is towing a trailer, camper or other towed item. These mirror assemblies typically incorporate a mounting bracket which extends from an exterior panel of a vehicle. In one prior art example, a rearview mirror is positioned on the mounting bracket and can be extended to an outboard location by loosening a fastener and sliding the mirror is positioned on an extension bracket located on a mounting bracket which can be rotated about a vertical axis to an outboard location for improved viewing. 
   However, such rearview mirror assemblies have certain problems, particularly with respect to the mounting brackets. These rearview mirror assemblies, especially those incorporating an extended mounting bracket, experience a great deal of vibration during operation of the vehicle. The mount structure used in the prior art mirrors are not able to withstand this vibration and, therefore, display a great deal of shaking in the mirror image during the operation of the vehicle. 
   Another problem in the prior art is the difficulty an operator experiences is adjusting the rearview mirror between an inboard and outboard position. An operator may only wish to use the outboard position temporarily, and it is important to allow easy and quick movement between the two positions. The prior art has not be able to successfully provide a extendable rearview mirror assembly that is easily moved between inboard and outboard positions and still able to withstand the vibration experienced by such assemblies during operation of the vehicle. 
   SUMMARY OF THE INVENTION 
   In one feature of this invention, a mirror is extended laterally outward from an inboard position to an outboard position where a secondary mirror surface is exposed, thereby providing improved lateral rearward viewing. In the inboard position, the secondary mirror surface is concealed behind the mirror and mirror frame in a mirror housing. The mirror assembly comprises structure to allow easy movement of the mirror and mirror frame laterally outward relative to a mirror housing from the inboard to the outboard position. The structure provides a secure amount at either position. 
   In other features of this invention, a mirror and at least a portion of a mirror housing are rotatable about a longitudinal horizontal axis which runs through the plane of the mirror. The longitudinal horizontal axis is offset from a central vertical axis of the mirror. Rotation of the mirror about the horizontal axis moves the mirror relative to the vehicle between inboard and outboard positions i.e., thereby providing improved lateral rearward vision to the operator of the vehicle. Again, the mount structure allows easy movement and provides a secure mount. 
   In one preferred embodiment of this invention, the extendable rearview mirror assembly includes a mirror shell having a post aligned with a longitudinal horizontal pivot axis offset from a central vertical axis of a mirror. The mirror is rotatably mounted in a mirror frame which is rotatably spring-loaded onto the post. The mirror frame is thus biased against the mirror shell for improved stability. The mirror frame has detents defining inboard and outboard positions, which are selectively received in a notch disposed in the mirror shell. In a most preferred embodiment, the mirror shell also has a reflective surface located behind the mirror and mirror frame in the inboard position, which is exposed when the mirror and mirror frame are rotated to an outboard position. 
   In another preferred embodiment of this invention, the mirror assembly includes a mirror shell which has a slot or groove running the horizontal length of the mirror shell. A pivot cap and pivot member are securely mounted onto a post which is attached to an exterior panel of a vehicle. The groove of the mirror shell is received on the post. The pivot member is rotatably spring-loaded into the mirror shell. The spring loading of the pivot member in the mirror shell biases the mirror shell against the post for improved vibrational stability. An operator of the vehicle is able to quickly and easily rotate the mirror and mirror shell about a longitudinal horizontal axis defined by the central axis of the pivot member. The mirror and mirror shell are rotated about the horizontal axis by pulling the mirror shell away from the post, thereby removing the post from the groove or slot, and rotating the mirror shell 180° to an outboard position. The groove is received on the post at this location and the spring loading biases the mirror shell against the post to provide stability. 
   In another preferred embodiment of this invention, the mirror assembly includes a mirror disposed in a mirror frame, which is slidable between inboard and outboard positions. The mirror frame is disposed in a mirror housing having a secondary mirror surface, which is concealed behind the mirror and mirror frame in the inboard position, but exposed in the outboard position, thereby providing improved rearward viewing. The mirror frame is disposed in a groove in the mirror housing with a plate biasing the mirror frame in the groove to provide a secure mount for the mirror and mirror frame during operation of the vehicle. 
   These and other features of the present invention will be best understood from the following specification and drawings, of which the following is a brief description. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a rearview mirror assembly in accordance with the invention herein; 
       FIG. 2  is a cross-sectional view of the mirror assembly of  FIG. 1  along line  2 — 2 ; 
       FIG. 3  is a cross-sectional view of the mirror assembly of  FIG. 1  with the mirror in an extended position; 
       FIG. 4  is a front elevation view of the mirror assembly of  FIG. 1 ; 
       FIG. 5  is a perspective view of an alternative rearview mirror assembly in accordance with the invention herein; 
       FIG. 6  is an exploded perspective view of the alternative mirror assembly of  FIG. 5 ; 
       FIG. 7  is a cross-sectional view of the mirror assembly of  FIG. 5  along line  7 — 7 ; 
       FIG. 8  is a perspective view of another alternative rearview mirror assembly in accordance with the invention herein; 
       FIG. 9  is an exploded perspective view of the alternative mirror assembly of  FIG. 8 ; 
       FIG. 10  is a cross-sectional view of the mirror assembly of  FIG. 8  along line  10 — 10 ; and 
       FIG. 11  is a cross-sectional view of the mirror assembly of  FIG. 8  with the mirror in an extended position. 
       FIG. 12  shows another embodiment of an inventive mirror which is particularly useful in original equipment applications. 
       FIG. 13  shows a rear view of the  FIG. 12  embodiment. 
       FIG. 14  is a cross-sectional view through the  FIG. 12  embodiment. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     FIG. 1  illustrates a novel rearview mirror assembly  20  which can be rotated between an inboard position and an extended, outboard position. The outboard position provides better viewing when the vehicle is pulling a trailer, camper or other towed item. The construction of the rearview mirror assembly  20 , particularly the mounting of a generally rectangular mirror  26  and a mirror frame  28  in a mirror frame  28  of the rearview mirror assembly  20 , is secure and resists typical vibrational forces exerted on rearview mirror assembly  20  during operation of the vehicle. Therefore, the rearview mirror assembly  20  provides improved rearward viewing without distortion in the mirror image. 
   As shown in  FIG. 2 , the rearview mirror assembly  20  includes an attachment member  22  for mounting a mirror shell  24  to an exterior panel of a vehicle. The mirror  26  is centrally mounted on the mirror frame  28  which is received in mirror shell  24 . A mounting post  30  extends along a longitudinal horizontal axis of the mirror shell  24  which is laterally offset from the central vertical axis C of the mirror shell  24 . The mirror frame  28  is mounted on post  30  and held in place by a nut or retainer ring  34 , which is received over and fixed to post  30 . As shown, there is slight clearance between post  30  and the mirror frame  28  such that the mirror frame  28  may rotate relative to post  30 . Alternatively, the two may be fixed for common rotation. Spring  32 , with nut or retainer ring  34 , biases mirror frame  28  rearwardly against a plate or backing  44 , which is fixed to mirror shell  24 . Mirror frame  28  includes detents  40  and  41 , one of which is selectively received in a notch  42  disposed in backing  44  and the other of which is received in notch  43 . Backing  44  may preferably contain a reflective mirror surface  46 , which provides additional rearward viewing for an operator of the vehicle when the mirror  26  is in the outboard position. 
   In an inboard position, a lateral edge  36  of mirror  26  is disposed adjacent the vehicle, detent  41  is received in notch  42 , detent  40  is received in notch  43 , and the reflective mirror surface  46  remains unexposed behind the lateral edge  36  of mirror  26  and mirror frame  28 . The mirror frame  28  and mirror  26  are disposed in the mirror shell  24  such that the circumference of the mirror frame  28  is aligned with the circumference of the mirror shell  24 . The spring  32  biases mirror frame  28  rearwardly against backing  44 , thereby maintaining the mirror frame  28  and mirror  26  in its inboard position and resisting vibrational forces on the mirror  26 . The mirror frame  28 , and hence mirror  26 , can be rotated about the central axis of the post  30  to an outboard position, which is shown in phantom lines in  FIG. 1 , as descried below. 
   As shown in  FIG. 3 , in an outboard position, the lateral edge  36  of mirror  26  is disposed remote from the vehicle, detent  40  is received in notch  42 , detent  41  is received in notch  43 , and the reflective mirror surface  46  is exposed for additional rearward viewing. The mirror  26  defines a plane. The mirror  26  and mirror frame  28  rotates about a longitudinal horizontal axis which extends through the mirror plane, and is generally perpendicular to the plane of the mirror  26 . In this embodiment, the central axis of the post  30  defines the longitudinal horizontal axis which travels through the plane of the mirror  26  about which the mirror  26  rotates. Preferably, the longitudinal horizontal axis is disposed midway between the central vertical axis and the outer lateral edge  38  of the mirror frame  28 . 
   As shown in  FIG. 4 , the operator of the vehicle can easily and quickly rotate the mirror  26  from an inboard to an outboard position for improved rearward viewing. First, the operator of the vehicle pulls the mirror frame  28  and mirror  26  outwardly along the longitudinal horizontal axis to move detent  41  outwardly from notch  42  and detent  40  out of notch  43 . This is shown in phantom line in  FIG. 2 . Mirror frame  28  and mirror  26  are then rotated 180° about the central axis of the post  30 . The spring  32  biases mirror frame  28  back rearwardly against mirror shell  24 . In an outboard position, the lateral edge  36  of the mirror  26  and mirror frame  28 , previously adjacent the vehicle, is disposed in a position remote from the vehicle. The distal or outer (in the inboard position) lateral edge  36  of the mirror  26  is rotated 180° to a position adjacent the vehicle. Detent  40  is now disposed in notch  42 , and detent  41  is now disposed in notch  43 . At the outboard position, the rearview mirror assembly  20  provides additional rearward viewing to an operator of a vehicle by positioning the mirror  26  farther laterally outwardly than it was in the inboard position. This outboard position is particularly helpful when the operator of a vehicle is pulling a trailer, camper or other towed item. Because of the mounting design, mirror  26  and mirror frame  28  are securely biased against the mirror shell  24 . The rearview mirror assembly  20  is thus able to resist the vibrational forces typically experienced by a rearview mirror assembly during operation of the vehicle. 
   As shown in  FIG. 5 , an alternative rearview mirror assembly  60 , which may be particularly useful in a heavy truck or camper-type vehicle, includes an L-shaped post  62  which has a lateral portion that attaches to the side of a vehicle  50  and a horizontal portion that attaches to the mirror shell  66 . A mirror  64  is centrally mounted on the mirror shell  66  in any known manner. In this alternative embodiment, the operator of the vehicle  50  is able to easily and quickly rotate the entire mirror  64  and the mirror shell  66  from an inboard position to an outboard position (shown in phantom lines) to provide improved rearward viewing. 
   As shown in  FIG. 6 , mirror shell  66  contains a slot or groove  68  which runs the length of the mirror shell  66 , and includes a pivot slot  70 . Preferably, the slot or groove  68  is triangular in cross-section, thus providing two contact lines, even if there is dirt on post  62  or in the slot or groove  68 . The pivot slot  70  receives a pivot member  72 . Pivot member  72  has a shaft  74  which is axially received in a bore  76  of pivot slot  70 . Pivot member  72  is rotatably mounted in pivot slot  70  by sliding shaft  74  through bore  76 . Coil spring  78  and a retainer ring  80  are axially received from the mirror side of mirror shell  66  onto shaft  74  of pivot member  72 . Pivot member  72  also includes a channel  82  on the opposed end to shaft  74  which is received on a portion of post  62 . Channel  82  is aligned with the slot or groove  68  such that post  62  is received in both. Pivot cap  84  also has a channel  86 , which, together with channel  82 , secures the pivot assembly on post  62 . Pivot cap  84  and pivot member  72  are securely mounted onto post  62  with screws  88 . 
   A pair of alternative grooves  68   a  allow further rotation positions for the mirror  26 . When post  62  is received in the alternative grooves  68   a , the mirror  26  will extend generally vertically, thus protecting the mirror. That is, when the post  62  is received in the alternative groove  68   a , the mirror  26  has rotated approximate 90° from the inboard position. 
   The mirror  26  has a generally rectangular shape that is defined by a longer dimension and a smaller dimension. The longer dimension extends generally parallel to a horizontal plane when the mirror  26  is in the inboard position, and the longer dimension extends generally vertical when the mirror  26  is in the outboard position. The outboard position is pivoted in a direction away from the vehicle from the inboard position. 
   As shown in  FIG. 7 , post  62  is disposed between pivot member  72  and pivot cap  84  in channels  82  and  86 . Post  62  is also disposed in slot or groove  68  for a substantial length of the horizontal portion of post  62 . Because pivot member  72  is spring loaded onto mirror shell  66  by the coil spring  78  and retainer ring  80 , and pivot member  72  is securely mounted onto post  62 , the mirror shell  66  is biased against post  62  with slot or groove  68  received on the post  62 , along the horizontal length of mirror shell  66 . The biasing of mirror assembly  60  against post  62 , allows the mirror assembly  60  to resist the vibrational forces typically experienced by mirror assemblies during operation of the vehicle. 
   The pivot axis of the mirror assembly  60  is aligned with the central axis of the pivot cap  84 , pivot member  72  and pivot slot  70 , which travels through the plane defined by mirror  64 . This axis defines a longitudinal horizontal axis about which the mirror  26  rotates and is laterally off-set from the central vertical axis C (see  FIG. 6 ) of the mirror shell  66  and mirror  64 . The mirror  64  and mirror shell  66  can be selectively rotated between inboard and outboard positions about the longitudinal horizontal axis. In the inboard position of the mirror assembly  60 , a lateral edge  90  (see  FIG. 5 ) of the mirror shell  66  is disposed adjacent the vehicle  50  and the post  62  is disposed in the slot or groove or slot  68 . When, for example, an operator is pulling a trailer, the operator may rotate the mirror shell  66  and mirror  64  to an outboard position by, first, pulling the mirror shell  66  and mirror  64  along the longitudinal horizontal axis defining the pivot axis away from post  62 , thereby displacing post  62  from the slot or groove  68 . Then, the mirror shell  66  and mirror  64  are rotated 180°, until post  62  is again aligned with the slot or groove  68 . Mirror shell  66  is then released and biased back to position the mirror shell  66  against the post  62  in an outboard position. 
   Because the pivot axis is offset from the central vertical axis of the mirror shell  66  and mirror  64 , the lateral edge ( 90   a  in  FIG. 5 ) of the mirror shell  66  and mirror  64  is now disposed farther outwardly than a lateral edge  92  of the mirror  64  and mirror shell  66  in the inboard position. Preferably, the longitudinal horizontal axis is disposed midway between the central vertical axis and the lateral edge  92  of the mirror shell  66 . 
   As shown in  FIG. 8 , another alternative rearview mirror assembly  100  comprises a mirror  102  disposed in a mirror frame  104  which can be extended from an inboard position to an outboard position to provides improved lateral rearward viewing to the operator of a vehicle. The mirror assembly  100  includes a mirror housing comprising a mirror shell  106  and a rim  108  which form a groove  110 . The mirror frame  104  is disposed in groove  110  and is slidable between an inboard position and an outboard position (shown in phantom lines). 
   As shown in  FIG. 9 , the mirror assembly  100  also includes an attachment member  112  (e.g., a post) which attaches the mirror frame  104  to an exterior panel of a vehicle. At the other end, the attachment member  112  slides into a sleeve  113  disposed in mirror shell  106  and is securely attached thereto to resist the vibrational forces experienced by the mirror assembly  100  during operation of the vehicle. Alternatively, the mount might extend through a bottom opening  113   a , depending on the vehicle. Mirror assembly  100  also includes a spring plate  120  and a bracket  122  which are disposed in mirror shell  106 . Bracket  122  is received on bosses  123  disposed in mirror shell  106  and over sleeve  113 . Bracket  122  is securely fixed in mirror shell  106  by tightening self-tapping screws  125  into bosses  123  in mirror shell  106 . Bracket  122  contains a channel  126  which receives sleeve  113  and also contains end posts  127 , which receive and support spring plate  120 . The spring plate  120  is securely attached to bracket  122  by heat staking the end posts  127  in openings  129  in the spring plate  120 . 
   As shown in  FIG. 10 , the mirror frame  104  contains a detent  114  disposed in a lateral edge adjacent the vehicle which is received in a notch  116  of the rim  108  when the rearview mirror assembly  100  is in the inboard position. The detent  114  and the notch  116  are biased into the mirror frame  104  at the inboard position and prevent the mirror frame  104  from sliding out of the inboard position without a predetermined pulling force being applied to the mirror frame  104 . A reflective mirror surface  115  is disposed in the mirror shell  106  adjacent the vehicle and concealed behind the mirror frame  104  in an inboard position. 
   As shown in  FIG. 11 , mirror frame  104  also contains a stop  118  which prevents the mirror frame  104  from completely sliding out of groove  110  and the mirror shell  106  when a pulling force is applied to the mirror frame  104 . When a pulling force is applied to the mirror frame  104 , detent  114  rides out of notch  116  from an inboard position toward an outboard position, until stop  118  prevents further movement of mirror frame  104 . Spring plate  120 , which is attached to bracket  122 , provides a bias force against mirror frame  104  to provide a secure mount at either position. 
   It is envisioned that the inventive mirrors could be provided with and adjustment motor by having the motor push against the mirror shell, rather than the mirror plate. In such an embodiment, the mirror would be mounted to the vehicle such that movement of the entire mirror shell relative to its mounting bracket would be affected to adjust mirror positioning. 
   Another mirror embodiment  150  as shown in  FIG. 12 , and is particularly useful in original equipment applications. The outer housing  152  has a mirror surface  154  and pivots relative to an inner housing  158 . A second mirror surface  156  is provided behind the outer housing  152 , such that when the outer housing  152  is in its extended position the second mirror surface  156  is visible. The vehicle body  160  mounts the inner housing  158  in any known fashion. 
     FIG. 13  is a rear view of the mirror embodiment  150 , showing the outer housing  152  in its extended position. The inner housing  158  carries a reflector  162 . A second reflector  164  may be mounted on the outer housing  152 . 
     FIG. 14  is a cross-sectional view through the embodiment  150 . As shown, the outer housing  152  may carry generally cylindrical boss  165  which is mounted in a cylindrical member  167  fixed to the inner housing  158 . The boss  165  rotates in the cylindrical member  167 , and defines an axis of rotation for the outer housing  152 . O-rings  157  may seal between cylindrical member  167  and boss  165 . As in the earlier embodiments, this axis of rotation is off center relative to the center of the mirror surface  154 , and thus by pivoting the outer housing  152  once achieves the extended position as shown in  FIGS. 12 and 13 . 
   A motor power pack  166  is provided which may adjust the mirror surface  154  as is know. Power packs having the ability to adjust the mirrors are incorporated in may vehicles, and may be of conventional structure and function. 
   The boss  165  may be provided with gear teeth  169  at a portion of its outer periphery. A gear  168  may be driven by a motor  170  such that the housing  152  may be power driven between its inboard and outboard position. Alternatively, this embodiment may also be manually moved between the inboard position and the outboard positions. A retainer clip and spring combination  182  are secured on an end  174  of the boss  165 , and biases the boss  165  against an inner ledge  175  of the cylindrical member  167 . This thus secures the outer housing  152  within the inner housing  158 . 
   A preferred description of this invention has been disclosed; however, a worker of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. For that reason, the following claims should be studied in order to determine the true scope and content of this invention.

Technology Category: b