U.S. patent application number 09/840528 was filed with the patent office on 2002-01-17 for extendable exterior rearview mirror assembly for vehicles.
This patent application is currently assigned to Donnelly Corporation, a corporation of the State of Michigan. Invention is credited to Hoek, Steven G., van de Ven, Michiel P., Whitehead, Peter J..
Application Number | 20020006001 09/840528 |
Document ID | / |
Family ID | 27016823 |
Filed Date | 2002-01-17 |
United States Patent
Application |
20020006001 |
Kind Code |
A1 |
Whitehead, Peter J. ; et
al. |
January 17, 2002 |
Extendable exterior rearview mirror assembly for vehicles
Abstract
An extendable exterior rearview mirror assembly includes a
mounting bracket, a mirror subassembly, and a support which is
supported by the mounting bracket. The mirror subassembly is
supported by the support and is mounted for selective movement
along the support arm to one of a plurality of viewing positions.
The mirror subassembly includes a housing, a reflective element,
and an actuator which supports the reflective element on a forward
facing wall of the housing. The rearview mirror assembly further
includes a clamping assembly which provides a force to urge
frictional engagement between the housing and the support to limit
movement of the mirror subassembly along the support. In preferred
form, the support extends into the housing and frictionally engages
an exterior surface of the forward facing wall.
Inventors: |
Whitehead, Peter J.;
(Holland, MI) ; Hoek, Steven G.; (Holland, MI)
; van de Ven, Michiel P.; (Zeeland, MI) |
Correspondence
Address: |
VAN DYKE, GARDNER, LINN AND BURKHART, LLP
2851 CHARLEVOIX DRIVE, S.E.
P.O. BOX 888695
GRAND RAPIDS
MI
49588-8695
US
|
Assignee: |
Donnelly Corporation, a corporation
of the State of Michigan
414 East Fortieth Street
Holland
MI
49423
|
Family ID: |
27016823 |
Appl. No.: |
09/840528 |
Filed: |
April 23, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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09840528 |
Apr 23, 2001 |
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09573502 |
May 16, 2000 |
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6239928 |
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09573502 |
May 16, 2000 |
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09399875 |
Sep 20, 1999 |
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6116743 |
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Current U.S.
Class: |
359/872 ;
359/838; 359/871; 359/879 |
Current CPC
Class: |
B60R 1/078 20130101 |
Class at
Publication: |
359/872 ;
359/838; 359/871; 359/879 |
International
Class: |
G02B 005/08; G02B
007/182 |
Claims
We claim:
1. An extendable exterior rearview mirror assembly comprising: a
mounting bracket for mounting to a vehicle; a mirror subassembly
having a housing and a reflective element; a clamp; and a support
mounted on said mounting bracket for pivotal movement between a
normal operating position and a folded position, said support
extending laterally outward from said bracket when said mirror
assembly is mounted to the vehicle and said support is in said
normal operating position and, further, extending into said
housing, said clamp being positioned in said housing and mounting
said mirror subassembly to said support and permitting selective
movement of said mirror subassembly along said support to one of at
least two viewing positions, said clamp applying a force to urge
frictional engagement between said support and said housing to
limit movement of said mirror subassembly along said support until
such a force is applied to said mirror subassembly sufficient to
overcome said frictional engagement between said support and said
housing.
2. The extendable exterior rearview mirror assembly according to
claim 1, wherein said support comprises a single support arm.
3. The extendable exterior rearview mirror assembly according to
claim 1, further comprising a load distributing member, said load
distributing member and said clamp urging frictional engagement
between said support and said housing.
4. The extendable exterior rearview mirror assembly according to
claim 3, wherein said support moves relative to said load
distributing member when said mirror subassembly is moved along
said support.
5. The extendable exterior rearview mirror assembly according to
claim 3, wherein said clamp includes a longitudinal passage, said
load distributing member positioned in said passage, and at least a
portion of said support extending through said longitudinal
passage.
6. The extendable exterior rearview mirror assembly according to
claim 3, wherein said load distributing member comprising an
elongate member having a longitudinal extent extending along at
least a portion of said support.
7. The extendable exterior rearview mirror assembly according to
claim 6, wherein said load distributing member comprises an
arcuate-shaped elongate member, said support having an arcuate
bearing surface and a generally planar bearing surface, said load
distributing member contacting said arcuate bearing surface and
urging said generally planar bearing surface to engage said
housing.
8. The extendable exterior rearview mirror assembly according to
claim 8, wherein said support includes a composite body, said
composite body including an elongate webbed member having said
arcuate bearing surface and a plate bearing member having said
generally planar bearing surface.
9. The extendable exterior rearview mirror assembly according to
claim 1, wherein said housing includes a mirror casing, said clamp
urging frictional engagement between said support and said mirror
casing.
10. The extendable exterior rearview mirror assembly according to
claim 9, wherein said mirror casing includes a casing wall defining
a cavity, said reflective element supported in said cavity, and
said clamp urging said support into frictional engagement with said
casing wall.
11. The extendable exterior rearview mirror assembly according to
claim 10, further comprising a positioning device, said positioning
device supporting said reflective element on said casing wall.
12. The extendable exterior rearview mirror assembly according to
claim 11, wherein said positioning device comprises an electrical
actuator.
13. The extendable exterior rearview mirror assembly according to
claim 1, further comprising a driver assembly, said driver assembly
selectively applying a force in said laterally outward direction to
move said mirror subassembly along said support.
14. The extendable exterior rearview mirror assembly according to
claim 13, wherein said driver assembly includes a motor, said motor
mounted to said mirror casing and selectively moving said mirror
subassembly along said support.
15. The extendable exterior rearview mirror assembly according to
claim 14, wherein said driver assembly further includes a threaded
rod, said threaded rod drivingly coupled to said support and being
driven by said motor to move said mirror subassembly along said
support.
16. An extendable exterior rearview mirror assembly comprising: a
mounting bracket for mounting to a vehicle; a mirror subassembly
having a housing, a reflective element, and a positioning device,
said housing having a mirror casing, said positioning device
supporting said reflective element in said mirror casing; a clamp;
and a support mounted to said mounting bracket, said support
extending from the vehicle in a laterally outward direction and
into said housing when said mirror assembly is mounted to a
vehicle, said clamp mounting said mirror subassembly on said
support and applying a force to urge frictional engagement between
said support and said mirror casing to limit movement of said
mirror subassembly along said support, and said mirror subassembly
sliding along said support to one or more extended positions when a
force is applied to said mirror subassembly of sufficient magnitude
to overcome said frictional engagement between said support and
said mirror casing.
17. The extendable exterior rearview mirror assembly according to
claim 16, wherein said mirror casing includes a back wall, and said
positioning device supporting said reflective element on said back
wall.
18. The extendable exterior rearview mirror assembly according to
claim 17, wherein said positioning device is mounted to said back
wall.
19. The extendable exterior rearview mirror assembly according to
claim 17, wherein said clamp applies a force to said support, said
force urging said support into frictional engagement with said
mirror casing.
20. The extendable exterior rearview mirror assembly according to
claim 19, wherein said clamp urges said support into frictional
engagement with said back wall of said mirror casing.
21. The extendable exterior rearview mirror assembly according to
claim 19, further comprising a load distributing member, said clamp
and said load distributing member urging said support into
frictional engagement with said mirror casing.
22. The extendable exterior rearview mirror assembly according to
claim 21, wherein said support includes an arcuate bearing surface
and a generally planar bearing surface, said load distributing
member engaging said arcuate bearing surface of said support arm
and urging said generally planar bearing surface into frictional
engagement with said mirror casing.
23. The extendable exterior rearview mirror assembly according to
claim 22, wherein said load distributing member comprises an
arcuate-shaped load distributing member.
24. The extendable exterior rearview mirror assembly according to
claim 23, wherein said load distributing member includes a
plurality of inwardly projecting ribs, at least one of said ribs
contacting said arcuate bearing surface of said support arm to urge
said support into frictional engagement with said mirror
casing.
25. The extendable exterior rearview mirror assembly according to
claim 24, wherein said load distributing member further includes a
plurality of exteriorly positioned ribs, said clamp contacting said
exteriorly positioned ribs to urge said support into frictional
engagement with said mirror casing.
26. The extendable exterior rearview mirror assembly according to
claim 25, wherein said exteriorly positioned ribs are offset from
said inwardly projecting ribs to thereby form a plurality discrete
spring members in said load distributing member.
27. The extendable exterior rearview mirror assembly according to
claim 16, wherein said housing further includes a cover coupled to
said mirror casing, said cover defining a second cavity in said
housing, said support extending into said second cavity for
frictionally engaging said mirror casing.
28. The extendable exterior rearview mirror assembly according to
claim 16, wherein said reflective element comprises a first
reflective element, and said mirror subassembly having a second
reflective element.
29. The extendable exterior rearview mirror assembly according to
claim 28, wherein said one of said first and second reflective
elements comprises a convex reflective element.
30. The extendable exterior rearview mirror assembly according to
claim 16, wherein said clamp defines a longitudinal passage, a
portion of said support extending into said longitudinal passage of
said clamp, and said clamp including a load distributing member in
said passage to urge said support into frictional engagement with
said mirror casing.
31. The extendable exterior rearview mirror assembly according to
claim 16, wherein said positioning device comprises electrical
actuator, said electrical actuator providing adjustment of said
reflective element about at least one axis.
32. The extendable exterior rearview mirror assembly according to
claim 16, wherein said mirror casing includes a bearing member,
said clamp urging said support into frictional engagement with said
bearing member to limit movement of said mirror subassembly along
said support.
33. The extendable exterior rearview mirror assembly according to
claim 32, wherein said bearing member comprises a metal plate.
34. An extendable exterior rearview mirror assembly comprising: a
mounting bracket adapted for mounting to a vehicle; a mirror
subassembly having a housing, a reflective element, and an
actuator, said housing including a mirror casing wall; a clamp
assembly; and a support mounted to said mounting bracket for
pivotal movement between a normal operating position wherein said
support extends laterally outward from the vehicle in a folded,
break-away position wherein said support is folded toward the
vehicle, said mirror subassembly being supported on said support by
said clamp assembly, said clamp assembly mounting said support to
said casing wall and providing a force, said force providing
frictional engagement between said support and said casing wall to
releasably clamp said mirror subassembly on said support to limit
the movement of said mirror subassembly along said support, said
support moving relative to said clamp when a sufficient force is
applied to said mirror subassembly to overcome said frictional
engagement wherein said mirror subassembly moves along said support
to one of a plurality of viewing positions.
35. The extendable exterior rearview mirror assembly according to
claim 34, wherein said support frictionally engages one side of
said casing wall, said actuator being mounted to another side of
said casing wall.
36. The extendable exterior rearview mirror assembly according to
claim 34, wherein said mirror subassembly includes a cover secured
to said housing, said cover and said casing wall defining a second
cavity therebetween, said support extending into said second
cavity.
37. The extendable exterior rearview mirror assembly according to
claim 35, wherein said support includes a planar side, said
clamping assembly urging said planar side of said support into
frictional engagement with said casing wall.
38. The extendable exterior rearview mirror assembly according to
claim 34, wherein said support includes an elongated webbed body,
said elongated webbed body including an arcuate bearing surface,
said clamp assembly bearing on said arcuate bearing surface to urge
said support into frictional engagement with said casing wall.
39. The extendable exterior rearview mirror assembly according to
claim 35, wherein said clamp assembly includes an arcuate-shaped
bearing surface engaging said arcuate bearing surface of said
support to urge said support into frictional engagement with said
casing wall.
Description
[0001] This is a continuation-in-part application of copending
application entitled EXTENDABLE EXTERIOR REARVIEW MIRROR ASSEMBLY
FOR VEHICLES, Ser. No. 09/399,875, filed Sep. 20, 1999, the
disclosure of which is herein incorporated by reference in its
entirety.
TECHNICAL FIELD AND BACKGROUND OF THE INVENTION
[0002] The present invention relates to an exterior rearview mirror
for mounting on a vehicle and, more particularly, to an extendable
exterior rearview mirror for mounting on a vehicle which can be
extended when the vehicle is being used for towing, for example
towing a trailer, camper, or the like.
[0003] Until recently, towing mirrors included a fixed support or
frame, which was rigidly mounted to the vehicle body, and a
reflective element supported on and spaced from the vehicle body by
the support or frame to provide rearview viewing of the towed
object. For example, U.S. Pat. No. 3,119,591 to A. J. Malecki
illustrates a typical rigidly mounted towing mirror assembly.
However, these fixed extended rearview mirror assemblies increase
the width of the vehicle often hampering normal maneuvering through
passages including garage door openings, drive-through services,
and the like. Furthermore, they are more vulnerable to being
damaged or causing damage than conventional exterior rearview
mirrors especially when used by an inexperienced driver. In some
cases, the width of the vehicles was increased beyond the maximum
width allowed by conventional vehicle transport trucks which
deliver the vehicles to the dealership. Therefore, these mirror
assemblies often required installation at the dealership which
ultimately increased the cost of the vehicle.
[0004] More recently, several extendable exterior rearview mirrors
have been developed. For example, in U.S. Pat. No. 5,513,048 to
Chen and U.S. Pat. No. 5,489,080 to Allen, extendable rearview
mirrors are disclosed which include telescoping members. The
position of the mirror subassembly, which includes a reflective
element and reflective element housing, is fixed in position by
threaded fasteners, which require tools for adjustment. However,
these assemblies tend to increase the vibration of the mirror
assembly especially when the mirror subassembly is in the outboard
position. This increased vibration is particularly problematic in
mirror assemblies that incorporate mechanical or electrical
actuators since they increase the weight of the mirror casing.
Other solutions have included providing nesting mirror reflectors
with one of the mirror reflectors supported in a housing that is
extendable from the mirror casing, such as described in U.S. Pat.
No. 4,998,812 and 4,907,871 to Hou. While these assemblies
incorporate a single arm mounting arrangement, the assembly is
complicated and requires a dual reflection system that ultimately
increases the cost of the assembly, as well as the weight of the
mirror casing. Heretofore, commercially available exterior mirrors
have used a twin arm arrangement in order to increase the stiffness
of the mounting attachment, such as disclosed in U.S. Pat. No.
5,483,385 to Boddy. Such twin arms provide support to the mirror
casing in a manner that minimizes mirror reflector vibrations when
the vehicle travels on roads. However, use of such twin arm
arrangements dictates a relatively large assembly with multiple
mounting components, which increases material cost and assembly
time. Hitherto, use of a single arm extendible mirror assembly has
not met with commercial success because of the reduced stiffness
associated with prior art designs which result in increased
vibration.
[0005] Consequently, there is a need for an extendable rearview
mirror assembly that can provide for an extended field of view when
towing and yet can be retracted to a normal operating position
where it does not hamper maneuverability of the vehicle. In
addition, the extendable rearview mirror assembly should have
minimal impact on the vibration characteristics of the mirror
assembly and be relatively easy to adjust between non-towing and
towing positions without the need for tools.
SUMMARY OF THE INVENTION
[0006] Accordingly, the present invention provides an improved
vehicular extendable exterior rearview mirror assembly which is
especially suitable for use on vehicles when towing. The exterior
rearview mirror assembly is adjustable to a plurality of viewing
positions between a normal non-towing use position and a fully
extended position, allowing an adjustable field of view to the rear
of the vehicle. Additionally, the mirror assembly may include a
break-away assembly to permit the mirror assembly to be folded to a
break-away position in the event the mirror assembly strikes an
object. Furthermore, the mirror assembly may include a power fold
mechanism which allows the mirror subassembly to be folded or
retracted to a folded position when the vehicle is driven into
tight spaces, for example parking garages and the like.
[0007] According to one aspect of the invention, the extendable
exterior rearview mirror assembly includes a mounting bracket, a
mirror subassembly, a clamp, and a support which is mounted for
pivotal movement on the mounting bracket between a normal operating
position and a folded, break-away position. The support extends
laterally outward from the mounting bracket when the mirror
subassembly is mounted to the vehicle and the support is in its
normal operating position. The support extends into the housing of
the mirror subassembly, where the clamp is positioned to mount the
mirror subassembly onto the support. The clamp applies a force to
urge frictional engagement between the support and the housing to
limit movement of the mirror subassembly along the support but
permits selective movement of the mirror subassembly along the
support to one of at least two viewing positions when a force of
sufficient magnitude is applied to the subassembly to overcome the
friction between the support and the housing.
[0008] In one aspect, the support comprises a single support arm.
In other aspects, the mirror assembly further includes a load
distributing member, which together with the clamp urges frictional
engagement between the support and the housing. In another aspect,
the support moves relative to the load distributing member when the
mirror subassembly moves along the support.
[0009] In yet other aspects, the clamp includes a passage, such as
a longitudinal passage, in which the load distributing member is
positioned. At least a portion of the support extends into the
passage to be urged by the clamp into frictional engagement with
the housing. In further aspects, the load distributing member
comprises an elongate member having a longitudinal extent extending
along at least a portion of the support. Preferably the load
distributing member comprises an arcuate-shaped elongate member.
The support arm has an arcuate bearing surface and a planar side
with a plurality of line bearing surfaces, with the load
distributing member contacting the arcuate bearing surface and
urging the line bearing surfaces to frictionally engage the
housing.
[0010] In further aspects, the support arm comprises a composite
elongate body which includes an elongate webbed member having the
arcuate bearing surface and a plate bearing member which provides
the line bearing surfaces.
[0011] In other aspects, the housing includes a mirror casing, with
the clamp urging the support into frictional engagement with the
mirror casing. For example, the mirror casing may include a casing
wall which defines a cavity, with the reflective element supported
in the cavity by the casing wall. The clamp urges the support arm
into frictional engagement with the casing wall.
[0012] In yet further aspects, the mirror assembly includes a
positioning device, which supports the reflective element on the
casing wall. For example, the positioning device may comprise an
electrical actuator.
[0013] In another aspect, the extendable exterior rearview mirror
assembly further includes a driver assembly which selectively moves
the mirror subassembly along the support arm.
[0014] According to another form of the invention, an extendable
exterior rearview mirror assembly includes a mounting bracket, a
mirror subassembly, and a support. The mirror subassembly includes
a housing, a reflective element, and an actuator. The housing
includes a mirror casing. The support is mounted to the mounting
bracket and extends from the vehicle in a laterally outward
direction and into a housing of the mirror subassembly when the
mirror assembly is mounted to the vehicle. The mirror assembly
further includes a clamp which mounts the mirror subassembly on the
support. The clamp applies a force to the support to urge
frictional engagement between the support and the mirror casing to
limit movement of the mirror subassembly along the support. The
mirror slides along support to one or more extended viewing
positions when a force is applied to the mirror subassembly in the
laterally extending direction sufficient to overcome the friction
between the support and the mirror casing.
[0015] In further aspects, the mirror casing includes a back wall.
The actuator preferably supports the reflective element on the back
wall. The clamp applies a force which urges the support into
frictional engagement with the back wall. Preferably, the clamp
includes a load distributing member which urges the support into
frictional engagement with the back wall and, further, distributes
the force from the clamp along the length of the support positioned
in the clamp. For example, the support preferably includes an
arcuate bearing surface and a planar bearing surface. The load
distribution member preferably comprises an arcuate elongate member
which engages the arcuate bearing surface of the support arm and
urges the planar bearing surface of the support into frictional
engagement with the exterior portion of the back wall of the mirror
casing.
[0016] In yet further aspects, the arcuate elongate member forming
the load distributing member may include a plurality of inwardly
projecting elongate ribs, which contact the arcuate bearing surface
of the support. In addition, the arcuate member may include a
plurality of exteriorly positioned elongate ribs, which are
contacted by the clamp to mount the mirror subassembly on the
support. Preferably, the exteriorly positioned elongate ribs are
offset from the inwardly projecting elongate ribs which thereby
form discrete spring members in the load distributing member.
[0017] In other aspects, the housing further includes a cover which
is coupled to the mirror casing and defines a cavity into which the
support extends for frictionally engaging the mirror casing.
[0018] As will be understood, the exterior rearview mirror assembly
of the present invention provides numerous advantages over prior
known extendable rearview mirror assemblies. The exterior rearview
mirror assembly incorporates a single support arm for mounting the
mirror subassembly to a vehicle on which the mirror subassembly can
be moved to a plurality of extended positions to provide an
adjustable extended field of view and which can be quickly
retracted to a normal operating position where it does not hamper
the maneuverability of the vehicle or increase the width of the
vehicle. In addition, the exterior rearview mirror assembly can be
adjusted either manually or by the use of a driver, which can be
operated by a remote control within the vehicle cabin. Thus, the
single arm extendable mirror assembly of the present invention
provides a compact assembly with excellent vibrational performance
when mounted and used on a vehicle. Hitherto, such excellent
vibrational performance is achieved and has been achieved
commercially such as by using twin arm extendable mirror assemblies
such as described in U.S. Pat. No. 5,483,385 to Boddy. Achieving an
acceptable and user appreciable or enjoyable exterior mirror
assembly performance when the assembly is mounted to the vehicle
while using a single arm is a significant advantage as this allows
a more compact design and thus, a more consumer appreciable or
appealing design.
[0019] These and other objects, advantages, purposes and features
of the invention will become more apparent from the study of the
following description taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a front elevation view of an extendable exterior
rearview mirror assembly of the present invention;
[0021] FIG. 2 is a similar view to FIG. 1 with a mirror subassembly
in an extended position;
[0022] FIG. 3 is a plan view of the mirror assembly of FIG. 1
illustrating the mirror subassembly in a folded position;
[0023] FIG. 4 is an exploded perspective view of the mirror
assembly of FIG. 1;
[0024] FIG. 5 is a partial cross-section view of the exterior
rearview mirror assembly of FIG. 1 illustrating an optional driver
assembly of the present invention;
[0025] FIG. 6 is an exploded perspective view of a second
embodiment of the support arm mounting arrangement;
[0026] FIG. 7 is an enlarged partial cross-sectional view taken
along line VII-VII of FIG. 4;
[0027] FIG. 8 is a similar view to FIG. 7 illustrating the mounting
arrangement of the second embodiment of the support arm mounting
arrangement of FIG. 6;
[0028] FIG. 9 is a similar view to FIG. 7 illustrating a third
embodiment of the mounting arrangement of the support arm of the
mirror assembly;
[0029] FIG. 10 is a similar view to FIG. 7 illustrating a fourth
embodiment of the mounting arrangement of the support bracket of
the mirror assembly;
[0030] FIG. 11 is an enlarged view of the connection of the support
arm assembly of FIG. 10 as viewed along line XI-XI in FIG. 10;
[0031] FIG. 12 is a perspective view of a third embodiment of an
extendable rearview mirror assembly of the present invention;
[0032] FIGS. 12A and 12B are exploded perspective views of the
exterior rearview mirror assembly of FIG. 12;
[0033] FIG. 12C is an enlarged side view of a load distributing
member of the mirror assembly of FIG. 12B;
[0034] FIG. 12D is an enlarged view of a second embodiment of the
load distributing member of FIG. 12C;
[0035] FIG. 13 is a back elevation view of the mirror casing and
support arm of the exterior rearview mirror assembly of FIG. 12
with a cover removed illustrating the mirror casing in a
non-extended position along the support arm;
[0036] FIG. 14 is a similar view to FIG. 13 illustrating the mirror
casing in an extended position along the support arm;
[0037] FIG. 15 is a back perspective view of the mirror casing and
support arm illustrated in FIG. 13;
[0038] FIG. 16 is a back elevation view of a fourth embodiment of
the exterior rearview mirror assembly of the present invention
illustrating an extendable mirror casing similar to the second
embodiment incorporating a driver;
[0039] FIG. 17 is a back top perspective view of the mirror
assembly of FIG. 16 illustrating the mirror casing in an extended
position;
[0040] FIG. 18 is a back perspective view similar to FIG. 17
illustrating the mirror casing in an extended position; and
[0041] FIG. 19 is a partial cross-section view taken along line
XIX-XIX of FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0042] Referring to FIG. 1, an exterior rearview mirror assembly 10
of the present invention is illustrated. Rearview mirror assembly
10 includes a mirror subassembly 12 which is mounted to a mirror
mounting bracket 14 by a mono support arm 16. As will be more fully
described below, mirror support arm 16 provides for extension of
mirror subassembly 12 to a plurality of extended positions from
mirror mounting bracket 14 so that the occupant of the vehicle can
have an adjustable extended field of view rearward of the vehicle.
Furthermore, mounting bracket 14 preferably comprises a break-away
mounting assembly, such that mirror subassembly 12 can be moved
from a normal operating position (shown in solid in FIG. 3) toward
a folded, break-away position adjacent the vehicle body (shown in
phantom in FIG. 3).
[0043] As best seen in FIGS. 1 and 4, mirror subassembly 12
includes a mirror casing or housing 18 and a reflective element
assembly 20, which is mounted in housing 18 by a positioning device
22, preferably an electrically operated actuator. Such electrical
actuators may incorporate resistive track or Hall Effect sensors.
It should be understood that other positioning devices may be used,
including manually operated actuators, a remote manually operated
actuator, such as a BODEN cable actuator or the like. Housing 18 is
preferably injection molded from a suitable plastic, such as nylon,
acrylonitriale butadiene styrene (ABS) or suitable resinous
plastic, or the like which is commercially available under the
trademark TERLURAN KR2889.RTM. by BASF Company of Wyandotte, Mich.
Alternatively, other resinous, melt processible plastics or
moldable materials such as mineral filled or glass filled nylon or
polyester or polypropylene can be used to form housing 12. A
suitable nylon is 13% glass modified nylon 6:6 sold as ZYTEL
71G13L.RTM. by I. E. DuPont de Nemours & Company of Wilmington,
Del. or PA123G13BK-47 by Bay Resins, Inc. of Millington, Md.. A
suitable polypropylene is TENITE P6M4Z-007.RTM. by Eastman Chemical
Products of Kingsport, Tenn. Alternately, housing 18 may comprise a
reinforced nylon plastic, thermo plastic, polypropylene, or other
similar thermo plastic or thermoset materials.
[0044] Referring to FIG. 4, actuator 22 is mounted to mirror
housing 18 by an actuator bracket 24, which is rigidly mounted to a
rear wall 26 of housing 18 on a plurality of mounting bosses 28 by
fasteners 30. Fasteners 30 extend through respective mounting
openings 32 provided in actuator bracket 24. In this manner
actuator bracket 24 is rigidly mounted to mirror housing 18. To
mount actuator 22 to bracket 24, actuator 22 includes a plurality
of mounting tabs 34, which include mounting openings 36 for
receiving fasteners 38 which extend through tabs 34 to secure
actuator assembly 22 to mounting bosses 40 provided on actuator
bracket 24 and further on clamp 42, which will be more fully
described below.
[0045] Actuator 22 supports reflective element assembly 20 and
preferably provides for multi-axis positioning of reflective
assembly 20. As best seen in FIG. 4, reflective element assembly 20
includes a first reflective mirror element 44 and a second
reflector element 46. Each reflective mirror element 44 and 46 may
comprise a conventional nonelectro-optic or electrochromic flat or
planar reflective mirror element or a convex or
multiradiused/aspheric reflective mirror element. In preferred
form, reflective element 44 comprises a flat or planar reflective
element while reflective element 46 comprises a convex or
multiradiused/aspheric reflective element to provide a wide angle
view or spotter mirror. For example, each reflective element may
comprise a metallic reflector coated glass or plastic substrate,
such as a thin chromium alloy reflector coating or a non-metallic
reflector coating such as the dichroic layer described in U.S. Pat.
No. 5,207,492 to Roberts et al. or a reflector comprising a silicon
reflective layer such as described in U.S. Pat. No. 5,535,056 to
Caskey et al. which are herein incorporated by reference in their
entireties. Alternately, the reflective elements may comprise a
variable reflective electro-optic element, such as an
electrochromic mirror element comprising one of several types of
electrochromic elements, for example an element of the
electrochemichromic type which is disclosed in U.S. Pat. No.
5,140,455 issued to Varaprassad et al. or maybe the solid state
type such as disclosed in, for example, U.S. Pat. No. 4,712,879
issued to Niall R. Lynam et al.; U.S. Pat. No. 5,910,854; and U.S.
patent application Ser. No. 08/238,521, filed Mar. 5, 1994, by
Varaprassad et al. now U.S. Pat. No. ______, all commonly assigned
with the present application to Donnelly Corporation of Holland,
Mich., the disclosures of which are herein incorporated by
reference in their entireties. Reflective assembly 20 further
includes a reflective element holder 48 which includes first and
second recessed support arm surfaces 48a and 48b for the respective
reflective elements and on which the respective reflective elements
are secured by, for example, an adhesive, adhesive tape, or the
like. Actuator 22 includes a movable member 22a which is mounted to
the rearward surface 50 of reflective element holder 48 to provide
adjustment of the orientation of the reflective elements about one
or more axes and, more preferably, about horizontal and vertical
axes, as will be understood by those skilled in the art.
[0046] Support arm 16 includes an elongated body 52, which extend
into housing 18 through an opening 54 provided in end wall 52d of
housing 18. Support arm 16 further includes a mounting portion 58
which includes a transverse bore 60 for receiving a mounting
bushing 62 which pivotally mounts support arm 16 to mounting
bracket 14. Support arm 16 preferably comprises a reinforced
elongate box shaped member preferably formed from a suitable
plastic, for example thermoplastic polymer resin, or thermoset
polymer resin or may be a metal element, such as aluminum or a zinc
die casting. As best understood from FIGS. 4 and 5, arm 16 includes
a top wall 52a, opposed side walls 52b, 52c, and two end walls 52d,
52e. Extending transversely between side walls 52b, 52c and top
wall 52a are a plurality of spaced reinforcing webs 118 which
create interstices or openings therebetween. Reinforcing webs 118
increase the stiffness of arm 16 without the corresponding increase
in weight normally associated with a solid support arm.
[0047] In the illustrated embodiment, mounting bracket 14 includes
a base 64, a base gasket 66, and a base cover 68. Base cover 68 is
secured to base 64 by fasteners 70, which extend through mounting
openings 72 provided in base 64 and into corresponding mounting
bosses 74 provided on the inner surface 76 of base cover 68.
Projecting outwardly from base 64 are a pair of upper and lower
mounting flanges or ears 78a and 78b, which extend into a
corresponding pair of upper and lower flange covers or hollow ears
80a and 80b which project outwardly from base cover 68. Bushing 62
extends between upper and lower mounting flanges 78a and 78b and is
preferably journaled in both upper and lower mounting flanges 78a
and 78b to load both flanges. Previous designs with bushings
journaled in only one bracket flange have exhibited vibration
performance degradation. With both ends of the bushing journaled in
the mounting flanges, the mounting flanges are subjected to reduced
bending moments, thus reduced wear and tear on the connection.
Extending rearwardly from base 64 are a plurality of mounting
bosses 82, which align with corresponding mounting openings 84
provided in base gasket 66, which receive a corresponding plurality
of mounting fasteners 86 which secure base 64 and, in turn, cover
68 directly to the vehicle, for example the vehicle door frame or
panel.
[0048] In order to fix the position of mirror subassembly 12,
mirror mounting bracket 14 includes a spring 88, which biases the
lower surface 58a of mounting flange 58 into frictional engagement
with the upper surface 80b' of lower flange cover 80b. In this
manner, in order to move mirror subassembly 12 and support arm 16
to a folded, break-away position, as shown in FIG. 3, a force must
be applied to mirror subassembly 12 or support arm 16 to overcome
the friction between mounting flange 58 and lower flange cover 80b
and to compress spring 88. It should be understood, that other
break-away mounting arrangements may be used to mount support arm
16 to mounting bracket 14.
[0049] As best seen in FIGS. 1, 2, and 4, mirror assembly 10
preferably includes support arm covers 90 and 92 which extend over
mounting portion 58 and over an end portion of elongated body 52
and are preferably sized such that when mirror housing is in its
retracted position, covers 90, 92 abut housing 18 and base cover 68
and together form a substantially continuous outer shell which
provides an aesthetic mirror assembly and further reduces the
aerodynamic drag of the mirror assembly.
[0050] As previously described, support arm 16 extends into opening
54 of housing 18 and is further mounted to actuator bracket 24.
Actuator bracket 24 includes a clamp assembly 94 for frictionally
holding support arm 16. Clamp assembly 94 includes clamp member 42,
a bearing member 96, and a pair of plate springs 98 and 100.
Referring to FIGS. 4, 5, and 7, actuator bracket 24 includes a body
24a with an upper planar portion 102 and a lower frame portion 104
which is offset toward rearwall 26 of housing 18 by a generally
horizontal web 106 which together with lower frame portion 104 and
clamp assembly 94, define a support arm receiving passage 108 (FIG.
7). Clamp 42 and bearing member 96 comprise L-shaped members and
are secured to respective mounting openings 94a provided on body
24a of bracket 24 by fasteners 94b and belleville or compression
washers 94c to provide vertical and lateral support for arm 16
against web 106 and lower frame portion 104. In the illustrated
embodiment, actuator bracket 24 includes angled mounting blocks 24a
and downwardly depending mounting tabs 24b with openings 94a formed
therein for receiving fasteners 94b. Further, clamp 42 includes
upper and lower mounting tabs 42a with respective mounting openings
42b through which fasteners 94b extend to secure clamp 42 to
actuator bracket 24. Bearing member 96 is preferably a metal
bearing member, for example stainless steel, which provides a
smooth guide surface for arm 16 when arm 16 is moved through
passage 108. Clamp 42 and the body of actuator bracket 24 is
preferably a plastic material similar to housing 18. Plate springs
98 and 100 preferably comprise metal wave springs, for example
spring steel springs, which include undulating or sinusoidal
cross-sections to form opposed contacting surfaces 98a, 98b, 100a,
and 100b, respectively, to clamp support arm 16 between springs 98,
100 and bearing member 96 in passage 108. Thus springs 98, 100
apply a biasing force to support arm 16 to urge support arm 16 into
frictional engagement with bearing member 96, as will be more fully
described below.
[0051] As best seen in FIG. 7, support arm 16 extends into passage
108 and is frictionally held in place by clamp member 42 and
bearing member 96 and further by wave springs 100 and 98, which are
respectively positioned beneath web portion 106 and adjacent lower
frame portion 104. Wave spring 98 and 100 urge support arm 16 into
frictional engagement with bearing member 96 to limit movement of
mirror subassembly 12 along support arm 16. When a force, which may
be manually applied or applied via an electric driver, a pneumatic
driver, such as an air slide, or a gas driver, sufficient to
overcome the friction between support arm 16 and bearing member 96
is applied to mirror subassembly 12 along an axis of extension 110,
mirror subassembly 12 moves along support arm 16 to a desired
location along support arm 16 in one of at least two viewing
positions and, more preferably, in one of a plurality of viewing
positions between the fully retracted position and the fully
extended position until the force is released. The outermost or
fully extended position is defined by a stop 112 which projects
from side 52b of elongated body 52 and which abuts a notch 114
provided on outer edge 96a of bearing member 96. In order to
provide a symmetrical bearing member 96 that can be used on either
a right hand side or left hand side exterior rearview mirror
assembly, bearing member 96 preferably includes a second notch 116
on opposed free edge 96b to provide a stop for a right hand mirror
assembly (not shown).
[0052] As previously noted, wave springs 98, 100 preferably
comprise metal wave springs, and more preferably comprise stainless
steel wave springs. Similarly, bearing member 96 preferably
comprises a metal bearing member, and more preferably a stainless
steel bearing member to provide a smooth contact between bearing
member 96 and support arm 16. As best seen in FIG. 5, wave springs
98, 100 bear on support arm 16 with contacting surfaces 98a and
100a at discrete lines or points of contact. Since springs 98 and
100 have undulating cross-sections, springs 98 and 100 permit
varying compression across their lengths and, further, can
accommodate lateral movement perpendicular to their axis of
compression. Because springs 98 and 100 provide varying
compression, springs 98 and 100, therefore, are able to absorb
manufacturing tolerances of the various components, including the
actuator bracket 24, support arm 16, clamp 42, and bearing member
96 while maintaining a sufficient biasing force to provide
substantially uniform friction between support arm 16 and actuator
bracket 24 so that mirror subassembly 12 will exhibit a substantial
uniform stiffness in its various viewing positions.
[0053] As best seen in FIG. 15, support arm 16 preferably comprises
a hollow support arm which is reinforced by webs or ribs 118; thus,
support arm is sufficiently stiff and yet light weight to reduce
the overall weight of the exterior rearview mirror assembly 10.
Furthermore, support arm 16 preferably includes a cover 120 which
is secured to ribs 118 by fasteners 120a to enclose the space or
interstices 122 between the ribs 118 so that when subassembly 12 is
fully extended the hollow design of arm 16 will be hidden from
view. Additionally, ribs 118 preferably include a plurality of
openings 118a, 118b which are respectfully aligned to form
transverse passages through arm 16 to permit cable or wiring to
extend through the arm to power and/or communicate with various
devices, including for example the actuator, the reflective
element, which is typically an electrochromic element, a heater
pad, which may be mounted to the reflective element to remove ice
or snow and, further, to permit a threaded rod 126 to move through
arm 16, as will be more fully described below. Preferably, the
cable or wiring is harnessed and more preferably, harnessed as a
telescopic or extendable harness, such as a spring loaded
retractable harness, including, for example a retractable reel, to
accommodate the extended positions of the mirror subassembly.
Alternately, the cable or wiring may extend through the support arm
and exit the support arm, for example through the distal end of the
support arm, to enter the mirror casing and, further, optionally
includes a take-up portion so that when the mirror subassembly
moves along the support arm the cable or wiring will accommodate
the relative movement between the mirror subassembly and the
support arm.
[0054] The cables and wiring may be used as part of a digital
electrochromic mirror system, including a LIN interface and a
digital electrochromic drive circuit (such as described in
copending U.S. Pat. application entitled DIGITAL ELECTROCHROMIC
CIRCIUT WITH A VEHCILE NETWORK SUCH AS A CAR AREA NETWORK OR A
LOCAL INTERCONNECT NETWORK, filed by Niall R. Lynam and John P.
Drummond on Mar. 31, 2000, the disclosure of which is hereby
incorporated by reference herein in its entirety) to minimize the
number or wires or cables in the mirror assembly and yet provide a
variety of functions. It should be understood that the mirror
assembly may include other network formats or communication
formats, such as LAN, CAN, BLUETOOTH, by Motorola, Inc.. and the
like and communicate with other devices or components within the
vehicle as part of a car area network (CAN) or multiplex system,
such as is disclosed in commonly assigned U.S. Pat. No. 5,798,575,
issued to O'Farrell et al., PCT International Application published
Sep. 25, 1997, under International Publication No. WO 97/34780, by
Fletcher et al., PCT International Application No. PCT/IE98/00001,
filed Jan. 9, 1998, by John P. Drummond et al. and published Jul.
16, 1998, under International Publication No. WO 98/30415, the
disclosures of which are hereby incorporated herein by reference in
their entireties, a Local Interconnect Network (LIN), or similar
communications protocols, which may support the control of
mechatronic nodes in automotive distributor applications, to
similarly reduce the cabling or wiring.
[0055] In preferred form, mirror assembly 10 includes a driver
assembly 124 to permit remote adjustment of the position of mirror
subassembly 12 along support arm 16. As best seen in FIG. 10,
driver assembly 124 includes a motor 125, transverse threaded rod
126, and a reduction gear 128 which is mounted on rod 126. Motor
125 is preferably housed in support arm 16 and includes a drive
gear 134 for engaging reduction gear 128. For example, motor 125
may be mounted to upper or top wall 52a of arm 16. Threaded rod 126
is mounted to extend through aligned openings 118b provided in ribs
118 and further to extend through end wall 52d of bracket 16
through an opening 142 for mounting to end wall 144 of housing 18.
Optionally, openings 118b may be threaded; however, to maintain the
manual override option, described below, in preferred form, each of
the openings 118b may include flexible threads or clutch fingers
similar to reduction gear 128. Rod 126 is fixedly mounted to end
wall 144, for example, by a mounting block 146. In this manner,
when motor 125 is actuated, drive gear 134 engages reduction gear
128 to move up and down threaded rod 126 to thereby move mirror
subassembly 12 along support bracket 16. Reduction gear 128
preferably includes a plurality of flexible threads or threaded
fingers 138 for engaging the threads of rod 126. Fingers 138 form
clutch fingers and release from rod 126 when a sufficient force is
applied to housing 18 along axis 110 to permit manual adjustment of
the position of mirror subassembly 12 along support arm 16 and,
further, to provide a safety release in the event that there is an
obstruction that prevents mirror subassembly 12 from moving along
axis 110. It can be appreciated that the clutch formed by the
flexible threads or fingers also permits a manual override of the
motor, for example in the event that the motor is inoperable, such
as when there is a power failure, thereby providing a fail safe
"limp home" manual override.
[0056] In order to further reduce the vibration of reflective
element assembly 20, mirror assembly 10 includes one or more spring
dampeners 150. Spring dampeners 150 comprise generally L-shaped
members with a mounting flange 152 for securing to the rearward
surface 50 of reflective element support holder 48 for example by
an adhesive or the like. Projecting from mounting flange 152 is an
arm 154 which includes a raised portion 156 for extending under a
corresponding tab or flange 158 provided on actuator bracket 24.
Arm 154 frictionally engages the lower surface 160 of tab 158,
which is preferably recessed. In addition, free edge 162 of tab 158
includes a bulbous or enlarged portion 164 which guides arm 154
under tab 158 during the assembly process. Vibration dampener 150
acts as a spring and absorbs and dampens the vibration in
reflective element assembly 20.
[0057] It can be understood from the foregoing that mirror
subassembly 12 is selectively movable along support arm 16 so that
mirror subassembly 12 can be positioned in a plurality of extended
positions, including an outmost outboard position or towing
position for viewing rearward portions of the vehicle, including
towed objects. Additionally, mirror subassembly 12 can be retracted
to a normal operating position close to the vehicle door. It should
be understood further that the mirror subassembly 12 can be moved
to an infinite number of positions between the fully retracted
position to the fully extended position or a plurality of defined
or discrete positions defined, for example by stops or the like.
Mirror subassembly 12 can be also pivoted about mounting bracket 14
between a normal operating position to a folded break-away position
close to the vehicle body. In addition, rearview mirror assembly 10
may include a power-fold mechanism. A "powerfold" mechanism is
typically operated and actuatable/deactuatable from within the
vehicle cabin either by a user operator switch or by a speed sensor
that folds the mirror out when a predetermined vehicle velocity is
sensed and that upon activation by the driver causes a folding
portion of the exterior mirror assembly, for example housing 18, to
fold or move or pivot about a fold-away axis, for example bushing
62, on a non-folding portion, for example bracket 14, of exterior
mirror assembly 10, from its normally extended viewing position
wherein mirror assembly 10 provides a field of view to a compact,
folded position wherein the rearwardly facing side of the folding
portion is disposed generally parallel to the vehicle body.
"Powerfold" exterior rearview mirrors are conventional and,
therefore, the specific details of the "powerfold" mechanisms are
omitted herein. In many European countries, "powerfold" exterior
rearview mirror assemblies are used during parking to reduce the
width of the vehicle. Preferably and desirably, the vehicle system
associated logic includes a powerfold enablement inhibitor so that
the powerfold mechanism operates only when the mirror is in the
retracted, non-extended position. If the mirror subassembly is
electrically extendable, for example, a control is preferably
provided that retracts the mirror subassembly along the support arm
to its retracted, non-extended position before folding the mirror
subassembly and support arm inwardly toward the vehicle.
Alternatively, the entire arm and mirror subassembly may fold in;
thus, folding the extended mirror subassembly, including a fully
extended mirror subassembly. These and other features may be
included in rearview mirror assembly 10.
[0058] For example, mirror subassembly 12 may incorporate a heater
pad, for example the heater disclosed in U.S. Pat. No. 5,151,824, a
signal light or security light disclosed in U.S. Pat. Nos.
5,669,705; 5,497,305; 5,497,306; 5,371,659; 5,669,704; 5,863,116
and co-pending application Ser. No. 09/102,414 filed Jun. 22, 1998,
for VEHICLE EXTERIOR MIRROR SYSTEM WITH SIGNAL LIGHT, co-pending
application Ser. No. 09/174,747 for UNIVERSAL EXTERIOR VEHICLE
SECURITY LIGHT, filed Oct. 19, 1998, all commonly assigned to
Donnelly Corporation of Holland, Mich., the disclosures of which
are incorporated herein in their entireties. In addition, other
electrical or electronic components may be mounted in housing 12
such as an interface transaction system described in U.S. pending
patent application entitled A VEHICLE MOUNTED REMOTE TRANSACTION
INTERFACE SYSTEM, filed by Martin DeVries and Niall R. Lynam on
Apr. 8, 1998, Ser. No. 09/157,428, and/or an electronic module,
which may include one or more electrical or electronic devices such
as antennas, circuitry for rain sensors, heating elements and the
like as described in pending U.S. Pat. application entitled MODULAR
REARVIEW MIRROR ASSEMBLY INCLUDING ELECTRONIC MODULES, Ser. No.
08/702,228, filed Aug. 23, 1996, by Niall Lynam et al. and which
are commonly assigned to Donnelly Corporation of Holland, Mich.,
the disclosures of which are herein incorporated by reference in
their entireties. Other features which may be added to the vehicle
mirror subassembly 12, include global positioning system antennas
and/or receivers, as disclosed in commonly assigned U.S. patent
application Ser. No. 08/569,851, filed Dec. 8, 1995, by Roger L.
Veldman and Desmond O'Farrell for A VEHICLE GLOBAL POSITIONING
SYSTEM NAVIGATIONAL AID, now U.S. Pat. No.______; and blind spot
detection systems, such as disclosed in U.S. Pat. Nos. 5,786,772
and 5,929,786, the disclosures of which are hereby incorporated
herein by reference. Other features which may be incorporated or
combined with the features of the present invention include blind
spot detectors, sensors, for example control sensors for control
circuit including control circuits for electrochromic elements,
temperature sensors for controls or indicators, heading sensors;
intelligent highway control systems (IHCS); intrusion detectors;
antennas, such as the GPS antenna, car phone antennas, radio
antenna and the like; microphones; speakers; garage door opener
transmitters and antennas; an automatic toll booth payment system,
such as a PASS.TM. system; transceivers; a node and/or controller
for a vehicle multiplex and/or car area network; a remote
transaction system; or telecommunication devices, such as
ONSTAR.TM. found in General Motors' vehicles of Detroit, Mich., or
RESCU.TM. available form Ford Motor Company of Detroit, Mich. In
addition, one or more cameras may be incorporated into the rearview
mirror assembly. These cameras may be forward or rearward facing
depending on the application. For example, cameras may be used as
part of a headlamp control system such as disclosed in U.S. Pat.
No. 5,796,094, a rearview vision system for vehicles such as
disclosed in U.S. Pat. No. 5,670,935 and in PCT Publication No.
96/38319, AN IMAGE CAPTURING SYSTEM, such as disclosed in pending
U.S. Pat. Application Ser. No. 09/199,909, filed Nov. 25, 1998, all
commonly assigned to Donnelly Corporation of Holland, Mich. and
incorporated by reference herein in their entireties. Also, a
headlamp control from the type disclosed in commonly assigned U.S.
Pat. No. 5,715,093 issued to Kenneth L. Schierbeek and Niall R.
Lynam for AUTOMATIC REARVIEW MIRROR SYSTEM WITH AUTOMATIC HEADLIGHT
ACTIVATION, the disclosure of which is hereby incorporated by
reference, may be included in mirror subassembly 12. For other
features, reference is made to U.S. Pat. No. 5,798,575, which is
commonly assigned to Donnelly Corporation of Holland, Mich., the
disclosure of which is incorporated in its entirety by reference
herein.
[0059] Referring to FIG. 7, a second embodiment of mirror assembly
210 is illustrated. Mirror assembly 210 is of similar construction
to mirror assembly 10 and includes a mirror subassembly 212, a
support arm 216, and a mounting bracket 214 but includes a modified
actuator bracket 224 and clamp assembly 294. Like numerals are used
to indicate corresponding parts in mirror assembly 10. Actuator
bracket 224 includes a body 224a with generally planar upper
portion 302 and a lower J-shaped portion 304. Upper portion 302
includes a plurality of mounting bosses 240 that project outwardly
from planar portion 302 for securing actuator 222 to actuator
bracket 224. J-shaped portion 304 is offset from upper portion 302
by a connecting web 306. As best seen in FIG. 8, clamp assembly 294
includes a generally L-shaped clamp member 242 with a downwardly
extending lip 243 for engaging an upwardly turned lip or flange 305
of lower portion 304 of body 224a. Clamp member 294 is rigidly
mounted to actuator bracket 224 by fasteners 294b which extend into
corresponding mounting holes or openings 294a on actuator bracket
224, similar to the previous embodiment. Clamp assembly 294 further
includes a pair of wave springs 298 and 300 for urging support arm
216 into frictional engagement with clamp member 242. Clamp member
242 preferably comprises a metal clamp, for example a stainless
steel clamp, to provide a planar and smooth surface and which
provides for a smooth movement of support arm 216 through actuator
bracket 224. In this embodiment, clamp 242 includes a pair of
notches 314 and 316, similar to insert 96. Clamp assembly 294
operates in a similar manner to clamp assembly 94 and, therefore,
reference is made therein for further details of the function of
clamp assembly 294.
[0060] Referring to FIG. 9, a third embodiment of clamp assembly
494 is illustrated. Clamp assembly 494 includes a clamp member 442
with first and second angled mounting flanges 442a for mounting to
corresponding mounting tabs 505 of actuator bracket 424. Similar to
the previous embodiments, wave springs 498 and 500 are positioned
between actuator bracket 424 and support arm 416 to urge support
arm 416 into frictional engagement with clamp member 442. Mounting
flanges 442a are secured to actuator bracket 424 by fasteners 494b
and preferably include belleville or compression washers 494c to
releasably lock the respective fasteners in a fully engaged
position. In this manner, the respective fasteners will not come
loose in response to the vibration associated with most exterior
rearview mirror assemblies.
[0061] A fourth embodiment of the clamp assembly 694 and actuator
bracket 624 is illustrated in FIGS. 10 and 11. Clamp assembly 694
comprises a clamp member 642 and a pair of wave springs 698 and
700. Similar to clamp member 242, clamp member 642 comprises a
generally L-shaped clamp with a downwardly depending flange or lip
643 which engages a corresponding upwardly extending flange or lip
705 of actuator bracket 624. Projecting outwardly from upper planar
portion 702 of actuator bracket 624 are a pair of threaded pins or
studs 702a which extend into corresponding openings 645 provided in
clamp 642. As best seen in FIG. 11, each opening 645 is formed at
the center of a plurality inwardly extending radial tabs formed in
clamp member 642. In this manner, studs 702a can be press fit into
openings 645 and yet will be rigidly held in place by the radial
tabs which respectively engage the threads on the respective studs
702a.
[0062] Referring to FIG. 12, a third embodiment 810 of the exterior
rearview mirror assembly of the present invention is illustrated.
Exterior rearview mirror assembly 810 includes a mirror subassembly
812 and a support 814 for mounting mirror subassembly 812 onto a
mounting bracket 816, which is adapted to mount to a vehicle. In
this embodiment, mirror subassembly 812 is mounted on support 814
for movement between a retracted normal operating position (as
shown) to a plurality of extended positions (a fully extended
position shown in FIG. 14) which are suitable when the vehicle is
used for towing. In preferred form, support 814 is mounted to
mounting bracket 816 as a break-away support such that when mirror
subassembly 812 is impacted, mirror subassembly 812 will pivot
about mounting bracket 816 to a folded, break-away position.
Furthermore, mirror subassembly 812 is mounted on support 814 so
that mirror subassembly 812 can be manually adjusted along support
814 to move mirror subassembly 812 to a desired extended position
without the use of tools, as will be more fully described
below.
[0063] Referring to FIGS. 12A and 12B, mirror subassembly 812
includes a housing 818 and a reflective element assembly 820, which
is preferably mounted in housing 818 by a positioning device 822.
Positioning device 822 provides for adjustment of the orientation
of reflective element assembly 820 about one or more axes.
Preferably, positioning device 822 comprises an electrical
actuator, as previously described, which provides adjustment about
two axes, as is known in the art. Housing 818 includes a mirror
casing 824 which defines a cavity 826 in which reflective element
assembly 820 and actuator 822 are mounted. Housing 818 further
includes a cover 828 which mounts to the forward facing side of
mirror casing 824 and together with mirror casing 824 defines a
second cavity 830 into which support 814 extends, as will be more
fully described below. The terms "forward facing" and "rearward
facing" as used herein refer to when the mirror assembly is mounted
to a vehicle. "Forward facing" means in a direction toward the
front of the vehicle, while "rearward facing" refers to a direction
toward the rear of the vehicle.
[0064] Mirror casing 824 is formed by a casing wall 832 which
defines cavity 826 and includes a back wall 834 on which actuator
822 is mounted. As best seen in FIG. 12A, back wall 834 includes a
plurality of webs 834a, which provide reinforcement to back wall
834, and a plurality of mounting bosses 838 for mounting
positioning device 822 to mirror casing 824. In addition, exterior
surface 834b of back wall 834 or forward facing side of mirror
casing 824 includes a generally L-shaped lower mounting flange 836
for mounting support 814 and cover 828 onto casing 824. Cover 828
includes a pair of mounting bosses 828a, which receive fasteners to
secure cover 828 to exterior surface 834b of back wall 834 of
mirror casing 824. In addition, cover 828 includes a pair of
downwardly depending positioning flanges 828b which engage
corresponding openings 836a (FIG. 15) provided in lower mounting
flange 836 of mirror casing 824.
[0065] Reflective element assembly 820 is of similar construction
to reflective element assembly 20 of the first embodiment and
includes a first reflective element 844 and a second reflective
element 846 which are supported on a reflective element holder 848
similar to holder 48. Reflective element 844 may comprise a
conventional non-electro-optic flat or planar reflective mirror
element or a convex or multi-radiused/aspheric reflective mirror
element. In preferred form, reflective element 844 comprises a flat
or planar reflective element, while reflective element 846
preferably comprises a convex or multi-radiused/aspheric to provide
a wide angle view or "spotter" mirror. For further details of
reflective elements 844 and 846, reference is made to the first
embodiment.
[0066] Referring to FIG. 12B, support 814 includes an elongated
body 850 which includes a mounting portion or flange 852 for
pivotally mounting to bracket 816. Bracket 816 includes a base 864
and a pair of spaced mounting flanges 854 and 856 which project
outwardly from base 864. Flange 852 is mounted between flanges 854
and 856 by a pivot or mounting pin 858. Bracket 816 also includes a
base cover 868 which is secured to base 864 by fasteners, in a
similar manner to the first embodiment. A bottom wall 856a of lower
flange 856 includes a transverse opening 856b through which
mounting pin 858 extends to couple support 814 to bracket 816. In
addition, flange 856 includes a cavity in which a spring 860 is
positioned for urging flange 852 into frictional engagement with
upper flange 854. Pin 858 extends through spring 860 and through a
transverse opening 852a provided in flange 852 of support 814 and,
further, through a bearing member 862, which is positioned, such as
by press fitting, in upper flange 854. Upper surface 852b of flange
852 includes a plurality of radially arranged projections 852c
which cooperate with a corresponding plurality of radially arranged
recesses formed on bearing member 862 to releasably fix the
position of support 814 relative to bracket 816 and yet permit
pivoting of support 814 on pin 858 when mirror subassembly 812 is
impacted with a sufficient force to overcome the compressive force
of spring 860. For examples of other suitable break-away mounting
arrangements, reference is made to copending U.S. patent
application entitled PIVOT SUPPORT FOR ADJUSTABLE REARVIEW MIRROR,
filed Mar. 25, 1998, Ser. No. 09/047,846, by Peter Whitehead,
commonly assigned to Donnelly Corporation of Holland, Mich., the
disclosure of which is incorporated by reference herein.
[0067] In addition to flange 852, support 814 includes a pair of
guide flanges 870 which project upwardly and downwardly from flange
852 to form stops for support 814 and further form bearing surfaces
for flanges 854 and 856 and cover 868 to provide a smooth pivoting
action of support 814 about bracket 816. In preferred form,
elongate body 850, flange 852, and flanges 870 comprise hollow
members which are reinforced by a plurality of webs 872 in order to
reduce the weight of support 814 while providing adequate stiffness
to support mirror subassembly 812. Support 814 may be formed from a
plastic, such as an engineered plastic including, for example a
mineral filled nylon, more preferably, a glass filled nylon, and is
most preferably formed from a light weight metal material, for
example aluminum or the like.
[0068] Referring again to FIG. 12B, support 814 further includes a
plate member 874 which includes a planar portion 876 for extending
over elongate body 850, and upper and lower flange portions 878,
which align with and cover flanges 870, and a circumferential
flange portion 880, which covers flange 852 to provide a decorative
appearance to support 814 when mounted to bracket 816. Planar
portion 876 includes longitudinal elongate ribs 876a, which provide
linear line bearing surfaces for elongate body 850, as will be more
fully described below. Plate member 874 is preferably secured to
support 814 by fasteners or other suitable means, including by an
adhesive or by welds and positioned between upper and lower flanges
850c of body 850 whereby plate member 874 is mounted flush with
casing facing side 850d of elongate body 850. As noted, ribs 876a
provide linear bearing surfaces for support arm 814, as will be
more fully described below. In preferred form, elongate body 850
includes a D-shaped cross-section with an arcuate surface 850a on
one side and planar surface 850b, which is provided by planar
member 876, for facing mirror casing 824. In addition, plate member
874 also includes a second pair of flanges 879 which project
upwardly and downwardly from planar portion 876 to define stops for
support 814 when support 814 is fully extended from mirror
subassembly 812, which will be more fully described in reference to
clamp assembly 884 below.
[0069] As best seen in FIGS. 13 and 14, when arm 814 is extended
into passage 830, support 814 is mounted to mirror casing 824 by a
clamp assembly 884. In preferred form, clamp assembly 884 includes
a clamp 886 with an arcuate body 886a and a load distributing
member 882. Clamp 886 is preferably formed from a light weight but
strong material, and more preferably, from a reinforced polymer,
such as mineral filled nylon, and most preferably clamp 886 is
formed from a 30% glass filled nylon. Together, clamp 886 and load
distributing member 882 define an elongate D-shaped passage 888
(FIG. 15) when mounted to casing 824 for receiving elongate body
850 of support 814 and which urge support 814 into frictional
engagement with mirror casing 824 to releasably fix the position of
mirror subassembly 820 along support 814. In preferred form, mirror
casing 824 includes a bearing member 834c mounted to exterior
surface 834b of back wall 834, which provides a wear plate.
Preferably, bearing member 834c comprises a low friction plate,
such as metal, including aluminum, plastic, an acetyl material, or
the like.
[0070] Referring to FIGS. 12A and 12C, load distributing member 882
includes an elongate arcuate body having an arcuate inner surface
882a for engaging arcuate surface 850a of body 850 and an arcuate
outer or exterior surface 882b, which is engaged by clamp 886.
Preferably, load distributing member 882 is formed from a low
friction material, such as an engineering polymer resin, such as
nylon, acetyl, or the like. Load distributing member 882 also
includes retaining flanges 883 at its opposed ends to provide stops
and restrain member 882 in clamp 886 when support 814 is moved
through passage 888 (FIG. 15). As best seen in FIGS. 13 and 14,
retaining flanges 883 bear against the opposed free edges 889 of
arcuate portion 886a whereby member 882 is restrained in passageway
888. Inner surface 882a of member 882 preferably includes a
plurality of elongate ribs 885 for frictionally engaging arcuate
surface 850a of support 814 and which are aligned along the
direction of extension of support 814. By providing a plurality of
elongate ribs 885, member 882 is able to accommodate variations in
manufacturing tolerances of support elongate body 850.
[0071] Referring to FIGS. 13-15, clamp 886 includes a pair of
mounting flanges 886b and 886c which extend upwardly and
downwardly, respectively, from arcuate portion 886a for mounting
clamp 886 to mirror casing 824 to thereby urge support 814 into
frictional contact with bearing member 834. Furthermore, outer
surface 886a' of arcuate portion 886a preferably includes a
plurality of ribs or webs 887 which provide reinforcement to
arcuate portion 886a which assures that clamp 886 will apply
generally uniform pressure to load distributing member 882. Flanges
886b and 886c are mounted to mirror casing 824 by a plurality of
fasteners 887a which extend through corresponding mounting openings
887b and 887c and through corresponding openings 834c' of bearing
member 834c and then turn to a corresponding plurality of mounting
openings provided in back wall 834 of mirror casing 824. Thus,
clamp 886 and member 882 are rigidly mounted to outer surface 834a
of back wall 834.
[0072] As best understood from FIGS. 12, 12A, and 12B, when an
extension force is applied to mirror subassembly 812 in a direction
indicated by arrow A in FIG. 11, which is of sufficient magnitude
to overcome the friction between support 814 and bearing member
834, housing 818 moves or slides on elongate body 850 of support
814. Housing 818 slides on support 814 to one of its extended
positions until such force is released. As best seen in FIG. 14,
when mirror subassembly 812 is fully extended along support 814,
flanges 879 of plate member 874 bear against flanges 883 of bearing
member 882 which in turn bear against flanges or free edges 889 of
clamping member 886, thus providing stops for support 814 or
subassembly 812. Likewise, when a force is applied in a direction
opposite to arrow A, housing 818 will move toward the vehicle body,
with flanges 870 providing stops.
[0073] Referring to FIG. 12D, a second embodiment 882' of the load
distributing member of the present invention is illustrated. Member
882' is of similar construction to member 882 and includes an
elongate body having an arcuate cross-section defining an outer
arcuate bearing surface 882b' and an inner arcuate surface 882a'.
Inner arcuate bearing surface 882a' includes a plurality of
longitudinal ribs 885a' which extend along the axis of extension of
the support (814) similar to ribs 885. In addition, outer surface
882b' includes a plurality of longitudinally extending projections
885b'. Projections 885b' are offset from projections 885a' to form
regions of flexibility which form localized spring members along
the elongated body of load distributing member 882'. In this
manner, member 882' provides a biasing or spring force to support
814.
[0074] Similar to mirror assembly 10, mirror assembly 810 includes
a cable or wiring which extends through support 814 to power and/or
communicate the various components in housing 818. The cable or
wiring is preferably harnessed and, more preferably, harnessed as a
telescopic or extendable harness, such as a spring loaded harness
so that the harness can extend and retract assisted by a spring to
accommodate the relative movement between the housing and the
support. A suitable spring loaded harness may include, for example,
a retractable reel. Alternately, as best seen in FIGS. 13 and 14,
cable or wiring 895 may extend through the support arm and exit the
support arm, for example through the distal end of the support arm,
to enter the mirror casing through an opening 896 in back wall 834a
and, further, optionally includes a take-up portion 897 so that
when the mirror subassembly moves along the support arm the cable
or wiring will accommodate the relative movement between the mirror
subassembly and the support arm.
[0075] Referring to FIGS. 16-18, the numeral 910 generally
designates a fourth embodiment of the exterior rearview mirror
assembly of the present invention. Mirror assembly 910 includes a
mirror subassembly 912 (shown with cover removed) and a support 914
for mounting mirror subassembly 912 onto a mounting bracket similar
to mounting bracket 816. Mirror subassembly 912 includes a housing
and a reflective element assembly supported in the housing similar
to the previous embodiment. The housing includes a mirror casing
924, which is of similar construction to mirror casing 824, and a
cover (not shown), also similar to cover 828. Therefore, reference
is made to the third embodiment for further details of the housing,
casing 924 and the cover. Support 914 extends into the housing and
frictionally engages housing similar to support 914 and is mounted
in housing by clamping assembly 984. Therefore, reference is made
to the second embodiment for further details of support 914 and
clamp assembly 984 as well.
[0076] In the illustrated embodiment, exterior rearview mirror
assembly 910 is a motor driven extendable mirror assembly and
includes a driver 990 for moving mirror subassembly 912 of exterior
rearview mirror assembly 910 along support 914 between a fully
retracted position (FIG. 16) and a plurality of extended positions,
including a fully extended position (FIG. 17), similar to the
previous embodiment. In this manner, in contrast to applying a
manual force to the mirror subassembly, the mirror subassembly is
extended in response to a force included by driver 990.
[0077] As best seen in FIGS. 16 and 17, driver 990 includes a motor
991 and a threaded rod 992. Motor 991 is enclosed in a motor
housing and includes a worm drive gear (not shown) which engages
threaded rod 992 to drive threaded rod 992, which is supported in
housing 991a. Both motor 991 and threaded rod 992 are mounted in a
fixed arrangement to mirror casing 924, preferably on back wall 934
of casing 924. Mounted on threaded rod 992 is a threaded coupler
993. As best seen in FIG. 19, threaded coupler 993 extends from
threaded rod 992 behind clamp 986 and member 982 of clamp assembly
984 to elongate body 950 of support 914. In this manner, when motor
991 is actuated and drives coupler 993 along threaded rod 992,
housing 918 moves along support 914. It should be understood, that
motor 991 may be selectively actuated to move the mirror
subassembly to a plurality of intermediate positions between a
fully extended position (FIGS. 17 and 18) and a fully retracted
position (FIG. 16). In addition, driver 990 may incorporate a
clutch mechanism (not shown), such as described in reference to
FIG. 5 or as described in copending U.S. patent application Ser.
No. 09/267,532, filed Mar. 12, 1999, the disclosure of which is
incorporated by reference herein in its entirety. In this manner, a
manual force may be used to extend or retract the mirror
subassembly and override the driver.
[0078] It should be understood that the mirror assembly of the
present invention provides an extendible mirror subassembly that is
supported by a unitary support. The support extends into the
housing wherein the support frictionally engages a portion of the
interior of the housing so that the mirror subassembly can be moved
along the support either manually or by a driver without tools. In
addition, the housing includes a mirror casing, which defines a
first cavity in which the reflective element is supported,
preferably by a positioning device, and a cover which defines a
second cavity into which the support extends to frictionally engage
the mirror casing. The mirror assembly incorporates a clamp which
generates a force of sufficient magnitude to urge a portion of the
support into frictional engagement with the housing, and more
preferably with the mirror casing, to provide a substantially rigid
and stable mounting arrangement and yet of a magnitude to permit
manual adjustment of the mirror subassembly along the support. By
providing two cavities, one for the reflector and its associated
support structure and the other for the support arm, the assembly
provides increased available mounting surface without reducing the
rigidity of the mounting arrangement. In this manner, the mirror
assembly is easier to assemble and further exhibits improved
vibration performance.
[0079] While several of the forms of the invention have been shown
and described other forms will now become apparent to those skilled
in the art. For example, the reflective assembly may include a
single reflective element. Furthermore, the actuator may comprise a
manual or remote controlled actuator, for example a BODEN cable
actuator, as previously noted. Further, other break-away mechanisms
may be employed to mount the mirror subassembly on to the mounting
bracket. In addition, although the present invention is described
as including single or mono support arm, the concept of the
invention may be used with dual mounting or support arms as well.
Reference is also made to U.S. Pat. Nos. 5,903,402 and 5,969,890
and U.S. patent application Ser. Nos. 09/310,162, filed May 10,
1999, and 09/312,377, filed May 14, 1999, for other details which
may be incorporated in to the mirror assembly of the present
invention, the entire disclosures of which are herein incorporated
by reference in their entireties. Changes and modification to the
specifically described embodiments can be carried out without
departing from the principles of the invention, which is intended
to be limited only by the scope of the claims as interpreted
according to principles of patent law including the Doctrine of
Equivalents. Therefore, it will be understood that the embodiments
shown in the drawings and described above are merely for
illustrative purposes only and are not intended to limit the scope
of the invention which is defined by the claims that follow.
* * * * *