U.S. patent application number 09/860361 was filed with the patent office on 2001-09-06 for rain sensor mount for use in a vehicle.
This patent application is currently assigned to Donnelly Corporation, corporation of the State of Michigan. Invention is credited to Lynam, Niall R..
Application Number | 20010018847 09/860361 |
Document ID | / |
Family ID | 21708444 |
Filed Date | 2001-09-06 |
United States Patent
Application |
20010018847 |
Kind Code |
A1 |
Lynam, Niall R. |
September 6, 2001 |
Rain sensor mount for use in a vehicle
Abstract
A mount for mounting a rain sensor includes a housing having an
access opening on first side and a port on second side for
positioning adjacent an inner surface of the vehicle windshield.
The second side is adapted for mounting to a vehicle windshield,
for example by a layer of adhesive which is interposed between the
housing and the windshield. Optionally, the housing includes an
access opening and a cover, which and covers the access opening. A
mirror mounting button is provided on either the housing or the
cover for mounting a rearview mirror assembly to the mount. A
biasing member is supported in the housing and is interposed
between the first side of the housing and a rain sensor positioned
in the housing, which urges a detecting surface of the rain sensor
to project through the port and to optically couple the rain sensor
to the vehicle windshield for detecting moisture on an outer
surface of the vehicle windshield. The biasing member may comprise,
for example, a helical spring or a urethane disc.
Inventors: |
Lynam, Niall R.; (Holland,
MI) |
Correspondence
Address: |
Catherine S. Collins
Van Dyke, Gardner, Linn & Burkhart, LLP
2851 Charlevoix Drive, S.E., Suite 207
P.O. Box 888695
Grand Rapids
MI
49588-8695
US
|
Assignee: |
Donnelly Corporation, corporation
of the State of Michigan
Holland
MI
|
Family ID: |
21708444 |
Appl. No.: |
09/860361 |
Filed: |
May 18, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09860361 |
May 18, 2001 |
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09003966 |
Jan 7, 1998 |
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6250148 |
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Current U.S.
Class: |
73/170.17 |
Current CPC
Class: |
B60R 11/0247 20130101;
B60S 1/0881 20130101; G02B 6/00 20130101; G02B 2027/012 20130101;
B60R 1/12 20130101; B60S 1/0822 20130101; B60S 1/0885 20130101;
B60R 2001/1223 20130101; B60S 1/0833 20130101; B60R 11/0241
20130101; B60R 2011/0033 20130101; G02B 2027/0118 20130101; B60R
2011/0026 20130101; B60R 1/04 20130101 |
Class at
Publication: |
73/170.17 |
International
Class: |
G01W 001/00 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. A rain sensor mounting assembly for mounting a rain sensor to a
vehicle windshield, said assembly comprising: a first mounting
member adapted to mount to the vehicle windshield and to receive a
rain sensor module, said first mounting member positioning said
rain sensor module adjacent an inner surface of the vehicle
windshield; said rain sensor module comprising a housing and a rain
sensor having a detecting surface, said rain sensor being contained
in said module, said rain sensor module being adapted to engage
said first mounting member for mounting said rain sensor module to
the windshield; a biasing member provided in said rain sensor
module, said biasing member for urging said detecting surface of
said rain sensor to optically couple to the inner surface of the
vehicle windshield for detecting moisture on the outer surface of
the vehicle windshield; and a second mounting member provided on
said rain sensor module for releasably mounting a rearview mirror
assembly to said module.
2. The rain sensor mounting assembly of claim 1, wherein said first
mounting member and said second mounting member are generally
aligned along a common axis when said rain sensor module is mounted
to the vehicle windshield in order to provide a mounting of a
rearview mirror assembly to said module generally coaxial with the
mounting of said module to the windshield.
3. The rain sensor mounting assembly of claim 1, wherein said first
mounting member encompasses an opening, and wherein said biasing
member urges said detecting surface of said rain sensor to
optically couple to the inner surface of the windshield at said
opening of said first mounting member.
4. The rain sensor mounting assembly of claim 3, wherein said first
mounting member comprises an annular member and with said opening
comprising a central opening in said annular member.
5. The rain sensor mounting assembly of claim 1, wherein said
second mounting member provides a breakaway mounting for the
rearview mirror assembly to said rain sensor module.
6. The rain sensor mounting assembly of claim 5, wherein said
second mounting member comprises a mirror mounting button
fabricated of one of a metal and a polymer.
7. The rain sensor mounting assembly of claim 6, wherein said metal
comprises one of a steel, a sintered steel, an aluminum, a zinc, a
titanium, and a nickel material.
8. The rain sensor mounting assembly of claim 6, wherein said
polymer comprises one of a nylon, an ABS, a polyolefin, and an
engineering resin material.
9. The rain sensor mounting assembly of claim 5, wherein said
rearview mirror assembly comprises a double pivot joint support
arm.
10. The rain sensor mounting assembly of claim 1, wherein said
biasing member comprises a resilient polymer material.
11. The rain sensor mounting assembly of claim 10, wherein said
resilient polymer material comprises one of a rubber, a silicone, a
urethane, an elastomeric, and a vinyl material.
12. The rain sensor mounting assembly of claim 10, wherein said
resilient polymer material comprises an internal structure of said
housing.
13. The rain sensor mounting assembly of claim 1, wherein said
detecting surface of said rain sensor comprises a resilient optical
material.
14. The rain sensor mounting assembly of claim 13, wherein said
optical material comprises one of a silicone and a plasticized
polymer material.
15. The rain sensor mounting assembly of claim 1 wherein said rain
sensor includes a light emitter and a light detector for detecting
presence of moisture on the vehicle windshield.
16. The rain sensor mounting assembly of claim 1, wherein said rain
sensor module includes electronic circuitry for generating an
electrical signal indicative of detection of moisture on the
vehicle windshield.
17. The rain sensor mounting assembly of claim 16, wherein said
rain sensor comprises electronic circuitry.
18. The rain sensor mounting assembly of claim 1, wherein said
housing is fabricated of one of a rigid metal and a rigid polymer
material.
19. The rain sensor mounting assembly of claim 1, wherein said
housing is fabricated of a polymer material and said second
mounting member is fabricated of a metal material.
20. The rain sensor mounting assembly of claim 1, wherein said
second mounting member is provided on said housing.
21. The rain sensor mounting assembly of claim 20, wherein said
second mounting member is provided on said housing by an integral
molding operation.
22. The rain sensor mounting assembly of claim 1, wherein said
second mounting member and said rain sensor module comprise a
unitary construction.
23. The rain sensor mounting assembly of claim 22, wherein said
unitary construction further comprises said rain sensor.
24. The rain sensor mounting assembly of claim 1, wherein said rain
sensor module received on said first mounting member has a
footprint less than about four square inches.
25. The rain sensor mounting assembly of claim 24, wherein said
rain sensor received on said first mounting member has a footprint
less than about two square inches.
26. The rain sensor mounting assembly of claim 1, wherein said
first mounting member includes a layer of adhesive for mounting
said first mounting member to the vehicle windshield.
27. The rain sensor mounting assembly of claim 26, wherein said
adhesive comprises one of a polyvinyl butyral material, an epoxy
material, a urethan material, an acrylic material and a silicone
material.
28. The rain sensor mounting assembly of claim 26, wherein said
layer of adhesive includes an opening whereby said detecting
surface of said rain sensor directly contacts the vehicle
windshield.
29. The rain sensor mounting assembly of claim 26, wherein said
detecting surface of said rain sensor contacts said layer.
30. The rain sensor mounting assembly of claim 1, wherein said
biasing member comprises a spring element.
31. The rain sensor mounting assembly of claim 30, wherein said
spring element comprises one of a helical spring element and a leaf
spring element.
32. The rain sensor mounting assembly of claim 1 wherein said
biasing member comprises a flexible polymer.
33. The rain sensor mounting assembly of claim 1, wherein said
biasing member comprises a urethane disc.
34. The rain sensor mounting assembly of claim 1, wherein said
housing substantially covers and conceals said first mounting
member from view from the interior cabin of the vehicle.
35. The rain sensor mounting assembly of claim 1, wherein said
module further includes a second sensor for detecting moisture on
the inner surface of the vehicle windshield.
36. The rain sensor mounting assembly of claim 1, wherein said
second mounting member provided on said rain sensor module is
adapted for releasably mounting a prismatic rearview mirror
assembly to said rain sensor module.
37. The rain sensor mounting assembly of claim 1, wherein said
second mounting member provided on said rain sensor module is
adapted for releasably mounting an electrochromic rearview mirror
assembly to said rain sensor module.
38. A rain sensor module assembly for attachment to a vehicle
windshield, said rain sensor module assembly comprising: a housing,
said housing having a first end adapted to releasably attach to a
support mounted to the inner surface of the vehicle windshield; a
rain sensor having a detecting surface, said rain sensor contained
in said housing; a biasing member provided in said module, said
biasing member for urging said detecting surface of said rain
sensor to optically couple to the inner surface of the vehicle
windshield for detecting moisture on the outer surface of the
vehicle windshield; and said housing having an opposing second end
provided with a mirror mounting button for releasably mounting a
rearview mirror assembly to said module.
39. The rain sensor module assembly according to claim 38, wherein
said first end includes a layer of adhesive for mounting said
housing to the vehicle windshield.
40. The rain sensor module assembly according to claim 39, wherein
said adhesive comprises one of a polyvinyl butyral material, an
epoxy material, a urethane material, an acrylate material, an
acrylic material, and a silicone adhesive material.
41. The rain sensor module assembly according to claim 39, wherein
said layer includes an opening, said rain sensor extending through
said opening of said layer to position said detecting surface of
said rain sensor for directly contacting the windshield.
42. The rain sensor module assembly of claim 39, wherein said
detecting surface of said rain sensor contacts said layer.
43. The rain sensor module assembly to claim 38, wherein said
mirror mounting button is integrally formed with said housing.
44. The rain sensor module assembly according to claim 38, wherein
said mirror mounting button is releasably secured to said
housing.
45. The rain sensor module assembly of claim 38, wherein said
biasing member comprises one of a helical spring element and a leaf
spring element.
46. The rain sensor module assembly according to claim 38, wherein
said biasing member comprises a urethane disc.
47. The rain sensor module assembly of claim 38 wherein said mirror
mounting button is adapted for releasably mounting a prismatic
rearview mirror assembly to said module assembly.
48. The rain sensor module assembly of claim 38 wherein mirror
mounting button is adapted for releasably mounting an
electrochromic rearview mirror assembly to said module
assembly.
49. A rain sensor mounting assembly comprising: a mounting member
encompassing an opening, said mounting member being adapted to
mount on an inner surface of a vehicle windshield; a housing having
a first end adapted to releasably attach to said mounting member; a
rain sensor having a detecting surface, said rain sensor contained
in said housing; a biasing member provided in said housing, said
biasing member for urging said detecting surface of said rain
sensor to optically couple to the inner surface of the vehicle
windshield for detecting moisture on an outer surface of the
vehicle windshield; and said housing having an opposing second end,
said second end including a mirror mounting button for releasably
mounting a rearview mirror assembly to said rain sensor mounting
assembly.
50. The rain sensor mounting according to claim 49 wherein said
mounting member includes a layer of adhesive for mounting said
mounting member to the vehicle windshield.
51. The rain sensor mounting according to claim 49 wherein said
mounting member includes an outer peripheral portion, said housing
releasably engaging said peripheral portion of said mounting
member.
52. The rain sensor mounting according to claim 50, wherein said
layer of adhesive includes a transverse opening, said rain sensor
extending through said transverse opening of said layer of adhesive
for directly contacting the inner surface of the windshield.
53. The rain sensor mounting according to claim 49, wherein said
housing includes a footprint, said footprint being less than the
about four square inches.
54. The rain sensor mounting according to claim 49, wherein said
housing includes a footprint, said footprint being less than the
about two square inches.
55. The rain sensor mounting according to claim 49, wherein said
housing includes a footprint, said footprint being less than the
about one square inch.
56. The rain sensor mounting according to claim 49, wherein said
first end of said housing substantially covers and conceals said
mounting member.
57. The rain sensor mounting assembly of claim 49, wherein said
mirror mounting button is adapted for releasably mounting a
prismatic rearview mirror assembly to said module assembly to said
rain sensor mount assembly.
58. The rain sensor mounting assembly of claim 49, wherein said
mirror mounting button is adapted for releasably mounting an
electrochromic rearview mirror assembly to said rain sensor mount
assembly.
59. A rain sensor mounting assembly for mounting a rain sensor to a
vehicle windshield, said rain sensor mounting comprising: a
mounting member adapted for mounting to the inner surface of the
vehicle windshield, said mounting member encompassing an opening;
said mounting member adapted to releasably receive a rain sensor
module, said rain sensor module comprising a rain sensor having a
detecting surface and a housing provided with a mirror mounting
button for releasably mounting a rearview mirror assembly to said
module, said detecting surface of said rain sensor for optically
coupling with the inner surface of the inner surface of the vehicle
windshield at said opening of said mounting member when mounted in
the vehicle for detecting moisture on the outer surface of the
vehicle windshield; said mounting member and said mirror mounting
button generally aligned along a common axis when said module is
received by said mounting member; said rearview mirror assembly
comprising a rearview mirror housing including a mirror element
therein, a support arm connected to said rearview mirror housing,
said support arm terminating in a mirror mount adapted to provide a
break-away connection to said mirror mounting button of said rain
sensor module; and wherein said support arm is connected to said
rearview mirror housing by a pivot joint to permit repositioning of
said reflective element and wherein said support arm is connected
to said mirror mounting button by a second pivot joint to permit a
further range of positions for said rearview mirror reflective
element.
60. The rain sensor mounting assembly according to claim 59,
wherein said mirror mounting button and said housing comprise a
unitary member.
61. The rain sensor mounting assembly according to claim 59,
wherein said mounting member includes a layer of adhesive for
mounting said housing to the vehicle windshield.
62. The rain sensor mounting assembly according to claim 61,
wherein said adhesive comprises one of a polyvinyl butyral
material, an epoxy material, a urethane material, an acrylate
material, an acrylic material, and a silicone material.
63. The rain sensor mounting assembly according to claim 61,
wherein said layer includes a transverse opening, said rain sensor
extending through said transverse opening whereby said detecting
surface of said rain sensor is positioned for directly contacting
the windshield.
64. The rain sensor mounting assembly according to claim 59,
wherein said rain sensor module housing includes a footprint, said
footprint being less than about four square inches.
65. The rain sensor mounting assembly according to claim 59,
wherein said second side of said rain sensor module housing
substantially covers and conceals said mounting member.
66. The rain sensor mounting assembly according to claim 59,
wherein said mounting member comprises an annular member having a
central opening defining said transverse opening, said rain sensor
module housing being secured to said annular member, and said rain
sensor being positioned in said central opening and being urged for
optically coupling said detecting surface of said rain sensor to
the vehicle windshield for detecting moisture on an outer surface
of the vehicle windshield.
67. The rain sensor mounting assembly of claim 59, wherein said
rearview mirror assembly comprises a prismatic rearview mirror
assembly.
68. The rain sensor mounting assembly of claim 59, wherein said
rearview mirror assembly comprises an electrochromic rearview
mirror assembly.
69. A rain sensor assembly for attachment to a vehicle windshield,
said rain sensor assembly comprising: a rain sensor module housing
a rain sensor, said rain sensor having a detecting surface, said
detecting surface being exposed at a first end of said module so as
to optically couple to the inner surface of the vehicle windshield
when said module is mounted in the vehicle for detecting moisture
on the outer surface of the vehicle windshield; a mirror mounting
button positioned on said module at a second end opposing said
first end; and wherein said detecting surface and said mirror
mounting button are substantially aligned along a common axis when
said rain sensor module is mounted in the vehicle.
70. The rain sensor assembly according to claim 69, wherein said
rain sensor module includes a footprint, said footprint being less
than about four square inches.
71. The rain sensor assembly according to claim 69, wherein said
rain sensor module includes a footprint, said footprint being less
than about two square inches.
72. The rain sensor assembly according to claim 69, wherein said
rain sensor module includes a footprint, said footprint being less
than about one square inch.
73. The rain sensor assembly according to claim 69, further
comprising a prismatic rearview mirror assembly, said prismatic
rearview mirror assembly releasably engaging said mirror mounting
button.
74. The rain sensor assembly according to claim 73, further
comprising a support arm supporting said prismatic rearview mirror
assembly on said rain sensor module housing, said support arm
including a first ball and socket connection to said prismatic
rearview mirror assembly and a second ball and socket connection to
said mirror mounting button.
75. The rain sensor assembly of claim 69, further comprising an
electrochromic rearview mirror assembly, said electrochromic
rearview mirror assembly releasably engaging said mirror mounting
button.
76. The rain sensor assembly according to claim 75, further
comprising a support arm supporting said electrochromic rearview
mirror assembly on said rain sensor module housing, said support
arm including a first ball and socket connection to said
electrochromic rearview mirror assembly and a second ball and
socket connection to said mirror mounting button.
77. The rain sensor assembly according to claim 69, wherein said
module is adapted to attach a rain sensor mounting member, said
rain sensor mounting member for attaching to the inner surface of
the windshield.
78. The rain sensor assembly according to claim 77, wherein said
rain sensor mounting module comprises a member having an opening,
said rain sensor module housing being secured to said rain sensor
mounting member, and said rain sensor being positioned in said
opening and being urged for optically coupling said detecting
surface of said rain sensor to be vehicle windshield for detecting
moisture on an outer surface of the windshield.
Description
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0001] This invention relates to a vehicular rearview assembly.
More particularly, the present invention relates to mounting of a
rain sensor within a rearview mirror assembly support.
[0002] Rain sensors for detecting moisture due to rain, road
splash, and the like on the outside of a vehicular windshield are
conventionally mounted to the inner cabin surface of the vehicle
windshield. Rain sensors typically comprise a light emitting diode,
an array of light emitting diodes which are paired with a photo
detector, or an array photo detectors. The rain sensor may detect
moisture by sensing a change in the amount of light refracted at
the outer windshield surface due to the presence or absence of
moisture or use other techniques such as sending backscattering of
light caused by raindrops.
[0003] Various mounting methods have been proposed with a common
method including optically coupling the rain sensor detector
usually to the inner cabin surface of the vehicle windshield. Rain
sensor detectors are conventionally coupled to the inner cabin
surface by use of an optical adhesive, or by using a removable
mount, for example a mount of a type disclosed in U.S. Pat. No.
4,871,917 to O'Farrell assigned to Donnelly Corporation of Holland,
Mich., the disclosure of which is incorporated by reference herein.
In removable mount constructions, such as are disclosed in the
Donnelly '917 Patent, the rain sensor detection surface, which
typically comprises a resilient optically clear polymer material,
such as a silicone material, is mechanically pressed between the
detector and the inner windshield surface by the mount.
[0004] Thus far, conventionally known means for mounting rain
sensor units to vehicle windshields have several disadvantages.
Optical adhesives are difficult and expensive to remove during
service replacement of a damaged windshield. Furthermore, the
optical adhesives, which are used to attach the rain sensors to the
inner surface of the windshield, may be visible from the outside of
the vehicle and, thus, can potentially detract from the vehicle
appearance and styling. Moreover, the attachment of the rain sensor
to the windshield either by bonding with an adhesive or by
mechanical attachment often creates a noticeable obstruction of the
forward field of view due to the separate and, frequently, bulky
housing provided for the rain sensor unit. Furthermore, the
location and bulky size of the rain sensor unit may further
increase the risk of potential injury of the vehicle occupants
should they impact the windshield in an accident.
[0005] In general practice, the windshield manufacturer often
attaches a mirror mounting button to the windshield , for example a
mounting button of the type disclosed in U.S. Pat. No. 4,930,742
assigned to Donnelly Corporation, which provides a releasable mount
for the rearview mirror assembly to the windshield, the disclosure
of which is incorporated in its entirety herein. When these
mounting buttons are attached to the windshield, the manufacturer
may need to attach a second structure, such as a mechanical guide
or rail to which the rain sensor is then later attached to the
vehicle, which would ultimately increase the cost of the
windshield.
[0006] More recently, rain sensors have been mounted within the
support arm of the interior rearview mirror assembly. These
constructions utilize the teaching of the Donnelly '917 patent as
follows. Referring to FIGS. 7-9, this prior art interior rearview
mirror assembly 300 includes a mirror housing 302 which supports a
reflective element 304 and which is mounted to the windshield W by
a support arm 306. Support arm 306 is coupled to housing 302 by a
ball and socket connection 307. The rain sensor 308 is mounted
inside support arm 306 and positioned to view the outside surface
of windshield W. Support arm 306 includes a biasing member 309 and
is adapted to releasably engage a mirror mounting button 310, which
is attached to the inner surface W' of the windshield W and
typically installed by the window manufacturer for coupling
rearview mirror assembly 300 to the windshield (FIG. 9). In this
system, mirror mounting button 310 is a ring shaped member 312 with
a hollow center 314, which is glued to the inner surface of the
vehicle windshield. Support arm 306 engages the outer rim of mirror
mounting button 310 when the mirror assembly 300 is attached to
button 310 during assembly of the vehicle at the vehicle assembly
plant or during service. The rain sensor is located within the
cavity of the support arm approximate the mirror mounting button
and is biased into contact with the glass surface through hollow
center 314 by biasing member 309. Support arm 306, however, only
provides a single point of articulation for housing 302, since it
must remain in a fixed position at the juncture of the support arm
and the windshield in order to maintain the alignment of the sensor
with the mounting button.
[0007] Although the aforementioned construction has several
advantages, it has numerous disadvantages that can limit its
widespread application in vehicles. By locating the rain sensor
within the support arm, the support arm must necessarily include a
cavity that is large enough to accommodate the rain sensor unit.
Furthermore, this construction requires that the articulation of
the mirror housing about the support arm be limited to a single
point at the juncture of the support arm to the housing. As
mentioned above, the juncture of the support arm to the mounting
button must remain fixed so that rain sensor maintains contact with
the inner surface of the windshield. Therefore, the present design
is limited for use on single pivot mirror supports and is
unsuitable for dual pivot mounting supports, which are commonly
used on a wide variety of vehicles. It is also necessary to stock a
special mirror design when a rain sensor is desired, which adds to
inventory requirements.
[0008] Referring to U.S. Pat. Nos. 4,936,533 and 5,100,095 both
assigned to Donnelly Corporation, the disclosures of which are
incorporated by reference in their entireties, dual pivot mounting
supports typically include a double ball joint which comprises an
outer tubular support arm member with sockets formed at both ends.
The sockets receive ball joints extending from the housing and
mirror mounts to provide a greater range of movement for the
rearview mirror assembly. Positioned in the cavity of the tubular
member is a helical spring which retains the respective ball joints
in the ends of the tubular support arm. Therefore, double ball
joint mirrors would appear to not be well suited to accommodate a
rain sensor unit within the support arm cavity.
[0009] Other considerations include vibration performance. The
presence of the rain sensor in the support arm increases the weight
of the rearview mirror assembly. With increased weight, potential
exists for detrimental effects on the mirror assembly vibration
performance. Furthermore, placement of the rain sensor in the
support arm limits the choice of rearview mirror suppliers since
only a limited number of mirror assembly support arm designs can
accommodate such mounting of the rain sensor. Additionally, most
countries have regulations that require mirror assemblies to break
away upon impact in an accident. With the design illustrated in
FIGS. 7-9, the choice of the mirror button design is, therefore,
also limited, thus placing potential limitation on the use of these
rain sensor mounts in certain countries.
[0010] Consequently, there is a need for an improved rain sensor
mount for a vehicle that overcomes the above disadvantages and
achieves its purpose in a manner that is economical and convenient
for the automaker. Furthermore the improved rain sensor mount
preferably provides broad application by allowing flexibility in
the choice of design. Moreover, the improved rain sensor preferably
is consistent with current safety goals and enhances the
performance of the interior rearview mirror assembly.
SUMMARY OF THE INVENTION
[0011] Accordingly, the present invention provides a new and unique
rain sensor mounting which is especially suitable for mounting on
an inner surface of a vehicle windshield for detecting moisture on
an outer surface of the windshield.
[0012] In one aspect, the invention provides a mount for mounting a
rain sensor which includes a housing having an access opening on a
first side or end and a port on a second side or end, preferably an
opposing side or end, for positioning adjacent an inner surface of
the vehicle windshield and which is adapted for mounting to a
vehicle windshield. A cover is secured to the housing and covers
the access opening. A mirror mounting button is provided on either
the housing or the cover for mounting a rearview mirror assembly to
the mount. A biasing member is supported in the housing and,
preferably, is interposed between the cover and a rain sensor
positioned in the housing. The biasing member urges a detecting
surface of the rain sensor to project through the port and to
optically couple to the vehicle windshield for detecting moisture
on an outer surface of the vehicle windshield. The biasing member
may comprise, for example, a helical spring, a leaf spring or a
urethane disc. The biasing member may also include an internal
structure of the housing that engages with the rain sensor when the
housing is received on a mounting member that encompasses an
opening (such as is described below) such that the detecting
surface of the rain sensor is urged to project through the opening
at the mounting member and intimately and, preferably, releasably
contact the inner surface of the windshield, and optically couple
therewith. For example, the internal cavity of the housing can
comprise a resilient polymer material (such as a rubber, silicone,
urethane, elastomeric (such as a thermoplastic elastomer), vinyl
(such as plasticized polyvinyl chloride) or similar material with
spring-like property) serving as a biasing member that urges the
detecting surface of the rain sensor forward to contact the
windshield when the unit is mounting in the vehicle. The biasing
member may comprise a flexible polymer or a resilient gasket that
compresses to urge the detecting surface of the rain sensor to
contact the windshield when mounted in the vehicle.
[0013] In one form, the mirror mounting button is secured to the
cover. The mirror mounting button may releasably secured to the
cover or may be integrally molded with the cover to form a unitary
member.
[0014] In other forms, the second side of the housing includes a
layer of adhesive for mounting the housing to the vehicle
windshield. For example, the adhesive may comprise a polyvinyl
butyral material, an epoxy material, a urethane material, an
acrylate material, an acrylic material, or a silicone adhesive
material. The adhesive layer may include an opening for receiving
the rain sensor whereby the detecting surface of the rain sensor
can directly contact the vehicle windshield for detecting moisture
on the outer surface of the windshield or the detecting surface can
contact and optically couple to the cured form of said
adhesive.
[0015] In yet another form, the mount includes an annular or like
member having a central opening and which is adapted to mount the
housing to the inner surface of the windshield. The port of the
housing is aligned with the central opening of the annular member
so that the rain sensor can extend through the port and through the
central opening and contact the inner windshield surface for
detecting moisture on an outer surface of the vehicle windshield.
The housing is preferably releasably secured to the annular member
so that the rain sensor can be serviced or replaced. In addition,
at least the second side of the housing substantially covers and
conceals the annular member.
[0016] According to another aspect of the invention, a rain sensor
mount includes a housing having a cover, which covers an access
opening in the housing, a means for mounting a rearview mirror
assembly to the housing, and a rain sensor, which is positioned in
the housing and includes a detecting surface. Furthermore, a
biasing member is interposed between a portion of the housing and
the rain sensor for urging the detecting surface of the rain sensor
to optical couple to the windshield of the vehicle for detecting
moisture on an outer surface of the windshield.
[0017] According to yet another aspect of the invention, a rearview
mirror assembly is disclosed which includes a rearview mirror
housing having a reflective element supported therein, a support
arm mounted to the rearview mirror housing that terminates in a
button attaching mirror mount, and a rain sensor module. The rain
sensor module includes a rain sensor module housing having a first
side or end and a second side or end, with the second side
preferably including a port. The second side is positioned adjacent
an inner surface of the vehicle windshield and is adapted to mount
the rain sensor module housing to the vehicle windshield. The rain
sensor module housing preferably also includes a cover, which
covers an access opening provide in the rain sensor module housing
and a rain sensor which is supported in the rain sensor module
housing. Alternately, the rain sensor module may be a unitary
member or construction wherein the rain sensor is housed,
preferably resiliently housed, within the cavity of the housing
such that the detecting surface of the rain sensor is positioned,
and preferably urged to protrude, at the second side (end) of the
housing that is opposite and opposing the first side (end). The
rain sensor includes a detector surface, which preferably is
extended though a port provided in the housing for optically
coupling the rain sensor to the inner surface of the vehicle
windshield. A mirror mount extends from the housing, for securing
the support arm to the housing. Furthermore, the rain sensor module
housing includes a biasing member supported therein which is
interposed between a portion of the rain sensor module housing and
the rain sensor for urging the detecting surface of the rain sensor
to optically couple the rain sensor to the vehicle windshield for
detecting moisture on an outer surface of the vehicle windshield.
The rain sensor module can be provided in a variety of
constructions, thus providing economic, convenience and flexibility
benefits to automakers and their suppliers. For example, the
housing of the rain sensor module and the mirror mount extending
therefrom can be a unitary construction (such as can be formed by
mechanically attaching or adhesively attaching a mirror mounting
button to an already formed housing, or by attaching the mirror
mounting button to the housing while the housing itself is being
formed, such as by integral molding as is known in the molding
arts), or the rain sensor, housing and mirror mount can be provided
as a unitary construction, such as a unitary rain sensor
module.
[0018] In one form, the support arm is secured to the rearview
mirror housing by a ball and socket connection to permit
repositioning of the reflective element. Additionally, and
preferably, the support arm may be secured to the mirror mount by a
second ball and socket connection to permit a greater range of
motion for the rearview mirror housing and provide a greater range
of positions for the reflective element.
[0019] As will be understood, the rain sensor mount of the present
invention provides numerous advantages over prior known rain sensor
mounting arrangements. For example, the rain sensor module can be
attached by the windshield manufacturer at the time of the
windshield fabrication and shipped to the automobile assembly plant
where the rearview mirror assembly can be attached to the rain
sensor module. Alternatively, the annular member may be attached to
the windshield by the windshield manufacturer at the time of
fabrication leaving the installation of the rain sensor module
assembly optional. For example, windshields with the rain sensor
mount pre-attached can be received at the vehicle assembly plant,
and the rain sensor module can be attached, and the rearview mirror
assembly also attached to the module, as the vehicle passes along
the vehicle assembly line. Furthermore, the rain sensor mount can
be mounted without detracting from the styling of the vehicle and,
moreover, without obstructing the view of the driver of the
vehicle. In addition, the rain sensor mount can be adapted to
support a wide range of rearview mirror assemblies and, notably,
rearview mirror assemblies with double ball joint support arms to
permit a greater range of motion of the mirror assembly housing
than the present rains sensor mounts permit. Thus, the present rain
sensor mount affords the automobile manufacturer greater
flexibility in its selection of the mirror assembly and the button
mount and therefore can accommodate most markets' regulations.
[0020] These and other objects, advantages, purposes and features
of the invention will become more apparent from a study of the
following description taken in conjunction with the drawings.
DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a partial fragmentary side elevation of a mirror
assembly mounted to a vehicle windshield of the present
invention;
[0022] FIG. 2 is an enlarged partial fragmentary side elevation of
the mirror assembly mounting of FIG. 1;
[0023] FIG. 3 is a front elevational view of the mirror mount of
FIGS. 1 and 2;
[0024] FIG. 4A is an exploded perspective view of a second
embodiment of the mirror assembly mounting of the present
invention;
[0025] FIG. 4B is a partial exploded perspective view of the second
embodiment of mirror assembly mounting of FIG. 4A;
[0026] FIG. 5 is a partial fragmentary side elevational view of a
third embodiment of the mirror assembly mounting of the present
invention;
[0027] FIG. 6 is an enlarged partial fragmentary side elevation of
the mirror assembly mounting of FIG. 5;
[0028] FIG. 7 is a front elevational view of a prior art mounting
button;
[0029] FIG. 8 is a side elevational view of the prior art mounting
button mounted to the inner surface of a windshield; and
[0030] FIG. 9 is a side elevational view of a conventional mirror
assembly incorporating a rain sensor unit in the support arm of the
mirror assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0031] Referring to FIGS. 1 and 2, a rain sensor module assembly 10
of the present invention is shown mounted to the inner surface 11
of a windshield 12. Rain sensor module assembly 10 is positioned on
inner surface 11 of windshield 12 for detecting moisture, such as
rain droplets, on the outer surface 13 and, optionally, on inner
surface 11 of windshield 12, as will be more fully explained
below.
[0032] Rain sensor module assembly 10 is mounted to inner surface
11 of windshield 12 by a rain sensor mounting button 17. Rain
sensor mounting button 17 is preferably adhered to inner surface 11
of windshield 12 by a layer 18 of adhesive such as an epoxy, a
polyvinyl butyral, a urethane, or a silicone adhesive material or
the like. In the illustrated embodiment rain sensor mounting button
17 is circular in shape having a solid annular outer portion 17a
and inner hollow open central portion 17b. Solid portion 17a of
rain sensor mounting button 17 may comprise a polymer material,
such as an engineering resin, a nylon or an ABS material, or can be
a metal fabrication such as zinc casting or a sintered steel
pressing or equivalent metal material such as steel, titanium,
nickel, aluminum and their alloys, or the like.
[0033] Rain sensor module assembly 10 includes rain sensor unit 22,
which is positioned in housing 14 and projects through an opening
or port 26 provided on a windshield facing side 20 of housing 14
and extends through inner hollow open central portion 17b of rain
sensor mounting button 17 to contact inner surface 11 of windshield
12. Rain sensor unit 22 preferably comprises a compact rain sensor
unit available from ITT Automotive Europe, GMBH of Frankfurt,
Germany. Rain sensor unit 22 includes a detecting surface 24 which
projects through an opening 28 provided in adhesive layer 18 so
that direct contact is achieved between inner surface 11 of
windshield 12 and detecting surface 24 of rain sensor unit 22, and
also includes a light emitting source 23a and a light detecting
source 23b along with associated electronic circuitry for
generating an electrical signal indicative of detection of moisture
on the outer surface of the windshield. Light is emitted by the
emitter, passes through the rain sensor detecting surface, is
refracted at the outer windshield surface, and re-enters the rain
sensor at its detecting surface to impinge the light detector of
the rain sensor, whose output is processed by electronic circuitry
to detect the presence/absence of moisture on the windshield. The
circuitry (in whole or in part) can be contained in the rain sensor
and/or within the housing of the module. Optionally, the electronic
circuitry can be located/share components with/receive input from
or deliver output electrical accessories in the vehicle, such as a
CAN bus, electronically equipped mirrors such as lighted mirror and
automatic dimming electrochromic mirrors, overhead consoles, and
similar electrically functioning vehicle components. Electrical
connectors 23 can be accommodated at the rain sensor module, such
as at or on its housing. The rain sensor can be separately
removable from the module for service, or can be an integral part
of the module so that a unitary module is provided by a supplier to
the automaker for mating with a windshield mounting member as the
vehicle passes along the vehicle assembly line (or at a local
ready-to-install windshield supply plant), and thereafter for
attachment thereto of a rearview mirror assembly. The electrical
signal output by the rain sensor can be used to automatically
operate the wiper system for the windshield and/or the backlite, or
operate other vehicular functions such as close a sunroof in the
event of rain or change the braking and/or traction characteristics
of the vehicle braking and/or traction control systems.
[0034] Housing 14 is adapted to urge rain sensor unit 22 into
optical contact with inner surface 11 of windshield. In the
illustrated embodiment, housing 14 includes a resilient member 32
for biasing detecting surface 24 into contact with inner surface 11
of windshield 12. Resilient member 32 preferably comprises a
helical spring, urethane disc, or the like. Resilient member 32 may
be integrally formed with housing 14 or may be interposed between
rain sensor unit 22 and a portion of housing 14, for example a
cabin facing side 14b or back portion or member 30 of housing 14.
Back portion 30, may preferably comprise a removable cover 30a
which permits access to rain sensor unit 22. Cover 30a is
positioned over an access opening 21 provided on housing 14 and is
mounted to housing 14 by releasable fasteners, such as clips,
screws, latches, or the like. In this manner, rain sensor unit 22
can be easily removed for service or replacement.
[0035] Housing 14 of rain sensor module assembly 10 is preferably
releasably or removably mounted or attached to rain sensor mounting
button 17 by attachment to solid portion 17a of rain sensor
mounting button 17, for example by mechanical means such as by
snap-on or twist-on attachment or, alternatively, by a releasable
adhesive layer. Rain sensor mounting button 17 may comprise of a
variety of shapes including square, rectangular, trapezoidal,
triangular and the like, with a central opening through which rain
sensor unit 22 extends to position detecting surface 24 into
contact with either the inner surface 11 of windshield 12 or the
outer surface of the adhesive layer 18. Preferably, the outer rim
of rain sensor mounting button 17 has a smooth edge radius for
safety purposes, for example an edge radius of greater than or
equal to two millimeters. Also, the attachment of rain sensor
module 10 to rain sensor mounting button 17 is preferably a
breakaway mount, which meets government and automaker safety
requirements upon impact during an accident. The mounting member
attached to the vehicle windshield such as rain sensor mounting
button 17 can have a wide variety of shapes and forms. It is
desirable that there be an adequate contact area with the
windshield surface to assure long term integrity of the joint
thereto under the loading conditions experienced during lifetime
use in the vehicle. The weight of the rearview mirror assembly
attached to the mirror mounting button of the rain sensor module
can vary from about 100 grams to about 500 grams, or even higher
dependent on the feature content of the mirror assembly. The rain
sensor module itself is preferably fabricated of lightweight
materials, and preferably weighs less than about 100 grams, more
preferably less than about 50 grams, and most preferably less that
about 25 grams. The mounting member may have a contiguous perimetal
portion encompassing a central opening (such as an annulus with a
central hole transverse therethrough so that a portion of the inner
surface of the windshield is exposed thereat), or the mounting
member can be non-contiguous (for example, two spaced apart rails
attached to the windshield encompassing an opening therebetween
where the detecting surface of the rain sensor can contact the
windshield, or the mounting member can be a single rail with an
adjacent portion of the inner surface of the windshield serving as
the opening for contacting of the rain sensor to the windshield).
Also, the rain sensor module can be received on the mounting member
such that its engagement on the support attached to the windshield
causes the detecting surface of the rain sensor to be urged forward
towards, and to contact, the windshield. The module itself, in
cooperation with its mounting member on the windshield, serves at
least partially as a biasing member.
[0036] Mounted to cabin facing side 14b of housing 14 is a mirror
mounting button 35 for mounting a mirror assembly 40 to rain sensor
module assembly 10. Mirror mounting button 35 is preferably mounted
to back portion 30 of housing 14 using conventional mechanical
attachment means, including fasteners and the like. Alternatively,
mounting button 35 may be molded with back portion 30 to form a
single integral unitary member or construction. Mirror mounting
button 35 provides a mount for one of a plurality of known types of
interior mirror assemblies. Preferably, mirror mounting button 35
and housing 14 are substantially coaxial and, furthermore, are both
coaxial with rain sensor mounting button 17. In this manner, rain
sensor mounting button 17, rain sensor module assembly 10 and
mirror assembly 40 are coaxially aligned and are mounted on
windshield 12 using the same footprint, thus, minimizing the
obstruction to the driver.
[0037] As best seen in FIG. 1, mirror assembly 40 comprises a
double-ball-joint interior mirror assembly which is detachably
mounted to mounting button 35 by a mirror mount 42. Mounting button
35 is preferably made from an engineering polymer material such as
a glass or mineral filled nylon or similar ensuring plastic cover.
Alternatively, mounting button 35 may be made from a zinc casting
or sintered steel pressing or equivalent metal material (such as
steel, nickel or nickel alloy, titanium, aluminum or the like),
and, preferably is adhered to back portion 30 which preferably
comprises a plastic material. Alternatively, mounting button 35 may
be mechanically or integrally molded therewith.
[0038] Mirror mount 42 engages the outer periphery of button 35 and
provides a breakaway connection so that upon an impact, interior
mirror assembly 40 will detach from button 35, thereby reducing the
risk of injury to passengers in the vehicle. Reference is made to
U.S. patent application Ser. No. 08/781,408 entitled BREAKAWAY
ACCESSORY MOUNTING ASSEMBLY FOR VEHICLES AND WINDSHIELD MOUNTED
BUTTON THEREFOR filed Jan. 10, 1997 by Ralph A. Spooner, which is
assigned to Donnelly Corporation of Holland, Mich., the disclosure
of which is incorporated by reference in its entirety herein, for a
preferred form of mounting button 35. Reference is also made to
U.S. Pat. Nos. 4,936,533 and 5,100,095 for examples of suitable
double ball joint rearview mirror assemblies.
[0039] Interior mirror assembly 40 includes a mirror housing 44,
which supports a mirror reflector element 46 and an actuator for
changing the mirror reflectivity of the mirror reflective element
46. Reflector element 46 may comprise a prismatic mirror element or
a variable reflectance electrochromic mirror element, for example
the reflective element 46 may comprise a conventional
non-electro-optic mirror element including metallic reflector
coated glass substrate such as with a thin chromium reflector
coating or may include a non-metallic reflector, such as a dichroic
such as is described in U.S. Pat. No. 5,207,492 to Roberts et al.
or may be a reflector comprising a silicon reflective layer such as
is described in U.S. Pat. No. 5,535,056 to Caskey et al. which is
herein incorporated in its entirety by reference. Alternatively,
reflective element 46 may comprise a variable reflective
electro-optic element such as an electrochromic mirror element and
may comprise one of several types of electrochromic elements--the
electrochemichromic type, such as that disclosed in U.S. Pat. No.
5,140,455 issued to Varaprasad et al. and commonly assigned with
the present application, the disclosure of which is hereby
incorporated herein by reference or may be of the solid state type
such as that disclosed in the U.S. Pat. No. 4,712,879 issued to
Niall R. Lynam et al., U.S. patent application Ser. No. 08/023,675,
filed Feb. 22, 1993 by Varaprasad et al., U.S. patent application
Ser. No. 08/193,557, filed Feb. 8, 1994 by Varaprasad et al., and
U.S. application Ser. No. 08/238,521, filed Mar. 5, 1994 by
Varaprasad et al., all commonly assigned with the present
application to Donnelly Corporation, the disclosures of which are
herein incorporated by reference. Such electrochromic elements
comprise an electrically responsive electrochromic medium that
modulates reflectivity from a reflective element. Such
electrochromic mirror elements are continuously variable and
exhibit multiple partial reflectant states as the voltage applied
thereto is varied. Alternatively, reflective element 14 may
comprise other electro-optic mirror elements, such as a liquid
crystal mirror and the like. Actuator 48 may comprise a manual flip
mechanism, for a conventional prismatic mirror element, or an
electrical actuator with circuitry for a variable reflectivity
electrochromic mirror element. The rearview mirror assembly may be
an electrically operated assembly such as the lighted mirror
assemblies described in pending U.S. patent application, entitled
MODULAR REARVIEW MIRROR ASSEMBLY, filed on Aug. 25, 1997 by
Jonathan E. DeLine, Roger L. Veldman, and Niall R. Lynam and
assigned to Donnelly Corp of Holland, Mich., which is herein
incorporated in its entirety by reference. Mirror housing 44 is
attached to mirror mount 42 by a support arm 50. Preferably, mirror
mount 42 and housing 44 each include ball joints 49a and 49b which
are secured in opposed ends of support arm 50 to provide a dual
pivot rearview mirror assembly. In this manner, mirror housing 44
may be pivoted about a first ball socket joint 51a and/or a second
ball socket joint 51b.
[0040] Referring to FIGS. 4A and 4B, a second embodiment 110 of a
rain sensor module assembly of the present invention is shown. Rain
sensor module assembly 110 includes a generally cylindrical housing
114 having one end 115a adapted for mounting on a rain sensor
mounting button 117, which in turn is mounted to windshield 12',
and a second end 115b which includes a mirror mounting button 135
for mounting an exterior mirror assembly (not shown in this
embodiment) to housing 114. Housing 114 is preferably formed from a
rigid polymer material, such as an engineering resin, a nylon, a
polyolefin, such a polypropylene and an ABS material or from a
rigid metal formed by a metal fabrication, such as die cast or the
like. Similar to the first embodiment, rain sensor mounting button
117, housing 114, and mirror mounting button 135 are preferably
substantially aligned along a common axis A to provide a
substantial coaxial mounting of a mirror assembly and rain sensor
module assembly 110, which minimizes the obstruction of the
driver's view through the windshield, and which minimizes the
overall assembly footprint, as well as optimizing appearance when
viewed from the outside of the vehicle.
[0041] Rain sensor mounting button 117 is preferably circular in
shape having a solid annular outer portion 117a and inner hollow
open central portion 117b. Solid portion 117a of rain sensor
mounting button 117 preferably comprises a polymer material, such
as an engineering resin, a nylon, a polyolefin such as
polypropylene and an ABS material or may be formed from a metal
fabrication, such as zinc casting or a sintered steel pressing or
equivalent metal material such as aluminum, titanium, nickel and
their alloys, or the like. Rain sensor mounting button 117 is
adhered to an inner surface 11' of windshield 12' by a layer 118 of
adhesive, for example an epoxy, a polyvinyl butyral, a urethane, or
a silicone adhesive material or the like. Layer 118 is interposed
between a windshield facing side 120 of outer portion 117a of rain
sensor mounting button 117 and windshield 12'. Preferably, layer
118 extends over at least a substantial portion of windshield
facing side 120 of rain sensor mounting button 117, preferably
terminating at or near the outer perimeter 117c of rain sensor
mounting button 117. It should be understood, however, that
discrete regions of adhesive layer may also be used to attach rain
sensor mounting button 117 to windshield 12.
[0042] Housing first end 115a is preferably adapted to rotate or
twist onto rain sensor mounting button 117 and is, preferably,
mounted to rain sensor mounting button 117 in a break-away mounting
so that housing 114 and the interior mirror assembly will detach
from rain sensor mounting button 117 when any one of the housing
and the mirror assembly are impacted. Mirror mounting button 135 is
mounted to second end 115b of housing 114 or may be integrally
molded therewith, similarly to button 35 described in reference to
the first embodiment.
[0043] Housing 114 includes a cavity 125 in which a rain sensor
unit 122 is positioned. Rain sensor module assembly 110 may include
rain sensor unit 122 as a separate component or may include rain
sensor unit 122 fixed to or encapsulated by housing 114 to form a
modular unit, which provides for a single step replacement
procedure. Rain sensor unit 122 and its associated electronic
circuitry 123 are supported and positioned in cavity 125 of housing
114 for viewing windshield 12' and are biased into optical contact
with windshield 12' by a resilient member 132, as will more fully
described below.
[0044] Similarly to the first embodiment, rain sensor unit 122
preferably comprises a rain sensor unit such as is available from
ITT Automotive Europe, GMBH. In this embodiment, rain sensor unit
122 has a disc or truncated cylindrical shaped body with a
detecting surface 124 formed on a windshield facing side 122a of
sensor unit 122, which preferably comprises a resilient optical
material, such as a silicone or a plasticized polymer, and which is
preferably a high transmitter of visible and near-infrared
radiation. The rain sensor unit is preferably of compact
construction. For example, the ITT unit is a cylindrical shaped
body with a circular end face of diameter about 3.3 cm
(cross-sectional area of about 8.6 square centimeters) and a body
length of about 1.2 cm. For compact mounting on the vehicle, it is
preferable that the cross-sectional area of the rain sensor module
be less than about four square inches, more preferably less than
about two square inches, and most preferably be less than about one
square inch provided that adequate contact area is provided for the
detecting surface of the module to the windshield for detection of
moisture on the outer windshield surface. The body length of the
rain sensor module is preferably less than about 1.5 inches, more
preferably less than about 1 inch and most preferably less than
about 0.75 inches. The ratio of cross-sectional diameter to body
length for the rain sensor module is preferably greater than 1,
more preferably greater than 2, most preferably greater than 3 in
order to assure adequate contact area to the windshield and minimum
rearward intrusion into the cabin of the vehicle by the rain sensor
module, and the rearview mirror attached thereto. Sensor unit 122
is positioned in central opening 117b of rain sensor mounting
button 117 with a cabin facing side 122b of rain sensor unit 122
being aligned with resilient member 132 so that when housing 114 is
mounted on rain sensor mounting button 117, rain sensor unit 122 is
biased toward windshield 12'. As described in reference to the
first embodiment, detecting surface 124 may be urged into direct
contact (where it may be optionally releasably adhered) with inner
surface 11' of windshield 12 through an opening 118a provided in
adhesive layer or may be urged into contact with adhesive layer 118
to similarly optically couple sensor unit 122.
[0045] Resilient member 132 may comprise a spring, such as a
helical spring or a urethane or plastic disc, which is positioned
in cavity 125. Alternatively, resilient member 132 may comprise a
resilient inner surface or member, such as a wall 132a, provided in
housing 114. For example, the interior of housing 114 may include a
spring-like polymer such as a rubber, a silicone, a urethane, an
elastomeric (such as a thermoplastic elastomer), a vinyl (such as
plasticized polyvinyl chloride) or similar resilient material that
urges the detecting surface of the rain sensor to intimately
contact and optically couple with the inner windshield surface when
the unit is mounted in a vehicle. As described previously,
resilient member 132 is aligned with rain sensor unit 122 and urges
detecting surface 124 into optical contact with inner surface 11'
of windshield 12. Therefore, regardless of whether rain sensor unit
122 is a separate component or an integral component of housing
114, it can be appreciate that the installation of rain sensor
module assembly 110 is greatly simplified. Rain sensor mounting
button 117 is adhered to the inner surface 11' of windshield 12',
typically by the windshield manufacturer, and then rain sensor unit
122 is placed in opening 117b and held in place and urged into
optical contact with windshield 12' by housing 114.
[0046] Referring the FIG. 5, a third embodiment 210 of the rain
sensor module assembly is illustrated. Rain sensor module assembly
210 is of a similar construction to rain sensor module assembly 10
and includes a housing 214 which is directly mounted to the inner
surface 11" of windshield 12". Rain sensor module assembly housing
214 is adhered to inner surface 11" of windshield 12" by a layer
218 of adhesive, for example an epoxy, a polyvinyl butyral, a
urethane, or a silicone adhesive material or the like. Layer 218 is
interposed between a windshield facing side 220 of housing 214 and
windshield 12". Preferably, layer 218 extends over at least a
substantial portion of windshield facing side 220 of housing 214
and preferably terminates at or near the outer perimeter 214a of
housing 214. It should be understood, however, that discrete
regions of adhesive layer may also be used to attach housing 214 to
windshield 12" , but this may be less desirable since it may
detract from the aesthetic appearance of the rain sensor
mounting.
[0047] Rain sensor module assembly 210 includes at least one rain
sensor unit 222 and associated electronic circuitry, which is
supported and positioned in housing 214 for viewing windshield 12".
Rain sensor unit 222 preferably comprises a rain sensor unit
available from ITT Automotive Europe, GMBH of Frankfurt, Germany,
and includes a detecting surface 224. Detecting surface 224
preferably comprises a resilient optical material, such as a
silicone or a plasticized polymer, and which is preferably a high
transmitter of visible and near-infrared radiation. As best seen in
FIG. 6, detecting surface 224 of rain sensor unit 222 is positioned
in and projects through an opening or port 226 provided in
windshield facing side 220 of housing 214. Furthermore, detecting
surface 224 projects through an opening 228 provided in layer 218
so that detecting surface 224 makes direct contact with inner
surface 11" of windshield 12". Thus, rain sensor unit 222 is
optically coupled with inner surface 11" of windshield 12".
Alternately, detecting surface 224 of rain sensor unit 222 may be
biased against and may contact the surface of adhesive layer 218
via opening 226 in housing 214. In this application, the detecting
surface 224 of sensor unit 222 may have little or no resilience.
Instead, the resiliency may be provided at the contact point with
the adhesive layer 218. Therefore, in this case adhesive layer 218
is preferably selected from materials which are resilient or
spring-like in their cured state, such as provided by polyvinyl
butyral and silicone adhesive, or the like.
[0048] Housing 214 includes a back portion or member 230, which may
comprise a removable cover 230a which is secured to housing 214 by
one or more fasteners, such as screws, clips, snaps, latches, or
the like. Housing 214 and back member 230 are preferably made from
a polymer material such as a nylon, ABS, engineering resin, a
polyolefin such as polypropylene or similar material. Removal of
cover 230a permits access to rain sensor unit 222 and its
associated circuitry for replacement or repair. Where back member
230 comprises a removable cover, housing 214 preferably includes an
access opening 221 which is sufficiently large to permit removal of
rain sensor unit 222 and its associated circuitry through the cabin
facing side 214b of housing 214. Alternatively, rain sensor module
assembly 210 may comprise a unitary modular assembly that can be
replaced as a unit.
[0049] Interposed between a portion of housing 214, for example
back member 230, and rain sensor unit 222 is a biasing member 232
which urges detecting surface 224 of rain sensor unit 222 into
direct contact with inner surface 11" of windshield 12" to thereby
optically couple to and contact the windshield surface under the
spring force of biasing member 232. Biasing member 232 preferably
comprises a resilient member, such as a helical spring or urethane
or plastic disc spring or the like. It should be understood that
when detecting surface 224 makes contact with the outer surface of
adhesive layer 218, biasing member 232 urges detecting surface 224
into contact with layer 218 to optically couple sensor 222 to
windshield 12".
[0050] As best seen in FIG. 4, a mirror assembly 40', which is
similar to the double ball joint interior mirror assembly 40 of the
first embodiment, is detachably mounted to housing 214 by a mirror
mount 42'. Mirror mount 42' is of similar construction to mirror
mount 42 and engages a mounting button 235, which is secured or
formed on back portion 230 of housing 214. Reference is made to the
first embodiment for materials and methods of forming or securing
mounting button 235 to the housing 214.
[0051] Mirror mount 42' engages the outer periphery of button 235
and provides a breakaway connection so that upon an impact, the
interior mirror assembly will detach from button 235, thereby
reducing the risk of injury to passengers in the vehicle. Similar
to the first embodiment, interior mirror assembly 40' includes a
mirror housing 44', which supports a mirror reflector element 46'
therein. In the illustrated embodiment, a conventional flip
actuator mechanism is shown, but it should be understood that other
actuators, including electrical actuators, may be included in
housing 44'. Mirror housing 44' is attached to mirror mount 42' by
a support arm 50', preferably a double ball and socket support arm
with a first ball socket joint 51a' between support arm 50' and
mirror mount 42' and a second ball socket joint 51b' between
support arm 50' and housing 44'. In this manner, reflective element
46' can be repositioned over a wide range of motion.
[0052] As described in reference to the first embodiment, detecting
surface 224 of rain sensor unit 222 may be alternatively biased to
contact adhesive layer 218. Preferably, the connection between
detecting surface 224 and adhesive 218 is sufficiently resilient to
absorb vibrations in windshield, which may be provided by adhesive
layer 218, when adhesive layer 218 is selected from the group of
adhesives that are resilient in their cured states as described in
reference to the first embodiment, or by detecting surface 224 of
rain sensor 222.
[0053] Optionally, module 210 may include a second rain sensor unit
222', which is similarly supported in housing 214 and projects
through a second port or opening 228' provided on windshield facing
side 214a of housing 214. Furthermore, housing 214 preferably
includes a second biasing member 232', which urges rain sensor unit
222' into optical contact with inner surface 11"of windshield 12"
for detecting moisture on the inner surface of windshield 12".
Second sensor unit 222' can be electrically coupled to a car area
network to control the defrost cycle or demisting cycle of the air
system of the vehicle. Optionally, the rain sensor electrical drive
can be electrically coupled to and/or share components with any
electrical drive or circuitry already present in the mirror
assembly 4' such as available in automotive electrochromic rearview
mirrors.
[0054] Rain sensor units 22, 122, 222 are preferably powered via
electrically connections to the vehicle ignition system and/or its
battery, which typically is twelve volts. Preferably, the signal
outputs from rain sensor units 22, 122, 222 are directed to the
vehicle windshield wiper controller or can be directed to a car
area network such as described in U.S. patent application Ser. No.
08/679,681 entitled VEHICLE MIRROR DIGITAL INTERACTIVE MIRROR
SYSTEM filed on Jul. 11, 1996 by O'Farrell et al., which is
assigned to the Donnelly Corporation of Holland, Mich., the
disclosure which is hereby incorporated by reference in its
entirety. Similarly, where a second rain sensor is employed that
detects moisture on the inner surface of the windshield, as
described above, the second rain sensor can be electrically coupled
to the car area network to control the defrost cycle or demisting
cycle of the air system of the vehicle. Optionally, the rain sensor
electrical drive can be electrically coupled to and/or share
components with any electrical drive or circuitry already present
in mirror assembly 40, 40' such as available in automotive
electrochromic rearview mirrors.
[0055] Rain sensor module assemblies 10, 110, 210 have many
commercially attractive advantages. As mentioned previously, rain
sensor mounting buttons 17 and 117 can be attached by the
windshield manufacturer at the time of fabrication of the
windshield and shipped to the automobile assembly plant fully
assembled. Optionally, the shape and size of the outer solid
portion 17a or 117a of rain sensor mounting button 17 or 117 may be
the same as that of the mirror button 35 so that mirror assembly 40
or 40' may mount directly onto rain sensor mounting button 17 or
117 in lieu of the rain sensor module assembly, which provides the
automaker with greater freedom of choice to include or not to
include a rain sensor unit in the vehicle. In the event that the
rain sensor unit is omitted, a blank insert may be placed to plug
opening 17b or 117b.
[0056] The size and dimensions of rain sensor mounting buttons 17,
117, rain sensor modules 22, 122, 222 and mirror mounts 42, 142,
242 are preferably generally commensurate in size so that the
installation of a rain sensor module assembly 10, 110, or 210 is
compact and unobtrusive. In preferred form, the footprint of rain
sensor module assembly 10, 110, 210 is less than about four square
inches. In a more preferred form, the footprint of rain sensor
module assembly 10, 110, 210 is less than about two square inches.
In a most preferred form, the footprint of rain sensor module
assembly 10, 110, 210 is less than about one square inch.
[0057] As previously described and as shown in the various figures,
it is desirable that the rain sensor mounting member attached to
the windshield and the rearview mirror mounting button provided on
the rain sensor module are generally aligned along a common axis
when the rain sensor module is mounted to the vehicle in order to
provide a mounting of a rearview mirror assembly to the rain sensor
module that is generally coaxial with the mounting of the rain
sensor module to the windshield. Such is shown in FIGS. 1 and 2
where the rain sensor mounting button 17, the rain sensor unit 22,
detecting surface 24 and mirror mounting button 35 are
substantially aligned along common axis AA, thus minimizing the
footprint presented by the assembly when installed to the
windshield in the vehicle.
[0058] Optionally, a ceramic black frit layer, as is commonly known
in the windshield fabrication art, can be used on the inner surface
11, 11', 11" of windshield 12, 12', 12" to hide the attachment of
location of rain sensor module 10, 110, 210. However, the center
portion of such a ceramic layer should include a central opening or
at least provide efficient transmission for the output of the light
emitters and the rain sensor unit at the point of contact a
detecting surface 24, 124, 224 to windshield 12, 12', 12" or to the
adhesive layer 18, 118, 218.
[0059] It should be understood that rain sensor module assembly 10,
110, 210 can accommodate a wide variety of mirror assemblies.
Therefore, rain sensor module assemblies 10, 110, 210 have broad
application and may be used in most countries. Furthermore, rain
sensor module assemblies 10, 110, 210 permit the automaker to have
essentially unlimited choices of mirror supplier. Moreover, rain
sensor module assemblies 10, 110, 210 do not increase the weight of
the respective mirror assembly and, therefore, do not negatively
impact the vibration characteristics of the mirror assembly. In
addition, as described above, rain sensor module assemblies 10,
110, 210 may optionally include a second rain sensor unit for
detecting moisture on the inner surface of the windshield. In this
embodiment, the second rain sensor may be similarly optically
coupled to the inner surface of the windshield and further, coupled
to the controls of the blower of the defrost and ventilation system
of the vehicle, for example via a car area network, in order to
activate the blower to demist the inner surface of the
windshield.
[0060] Also, while illustrated herein is a mount for application to
a vehicle windshield, the concept of this invention can also be
beneficially applied to other glass or other transparent panels.
Also, aspects of this invention can be applied to a variety of rain
sensor types including windshield contacting units where the
detecting surface contacts the windshield surface, and
non-windshield contacting units, such as are described in PCT
Application WO 94/27262 published Nov. 24, 1994 to Dennis Hegyl,
the disclosure of which is incorporated by reference in its
entirety herein, where the detecting surface of the rain sensor
does not contact the windshield surface, and is stood-off
therefrom. Also, the rain sensor module may optionally accommodate
sensor/circuit/displays for vehicle functions and accessories other
than for a moisture sensing function. For example, a compass sensor
such as a flux gate, magnetoinductive, magnetoresistive or
magnetocapacitive sensor and/or a compass display can be
accommodated at, within or on the rain sensor module. Other sensors
and/or displays can be similarly accommodated such as of vehicle
altitude and/or incline (of particular interest in sport utility
vehicles), seat occupancy, air bag activation enable/disable, and
headlamp intensity/daylight intensity photosensors, and their like.
Optionally, antennae, transmitters and receivers, along with any
associated displays and sensors, for geographic positioning
satellite (GPS) systems, pagers, cellular phone systems, pagers,
cellular phone systems, ONSTAR systems, security systems, tire
monitoring systems, remote fueling systems where vehicle fueling
and/or payment/charging for fuel is remotely achieved, remote
keyless entry systems, garage and/or security door opener systems,
INTERNET interfaces, vehicle tracking systems, remote car door
unlock systems, e-mail systems, toll booth interactions systems,
highway information systems, traffic warning systems, home access
systems and their like can be mounted at, within or on the rain
sensor module, or at, within or on the rearview mirror attached
thereto, or at, within or on a pod attached to the rain sensor
module or to the rearview mirror attached thereto. Therefore, it
will be understood that the embodiments shown in the drawings and
described above are merely for illustrative purposes, and are not
intended to limit the scope of the invention which is defined by
claims which follow.
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