Optical: systems and elements – Mirror – With support
Reexamination Certificate
2000-03-23
2001-11-20
Shafer, Ricky D. (Department: 2872)
Optical: systems and elements
Mirror
With support
C359S603000, C359S604000, C359S606000, C248S477000, C248S479000, C248S481000
Reexamination Certificate
active
06318870
ABSTRACT:
BACKGROUND OF THE INVENTION
The present invention relates generally to interior rearview mirror assemblies for vehicles and more particularly, to a toggle assembly for a prismatic interior rearview mirror movable between day and night, full and partial reflecting positions.
Interior rearview mirrors for vehicles are typically pivotally mounted to a base or mounting arm via a ball and socket joint providing adjustment to accommodate different sizes of drivers. Typically, a dual ball and socket joint assembly is used to increase adjustability over a single ball and socket joint and comprises a mounting base, which is secured to an interior surface of a windshield or to a headliner or console of the vehicle, and an arm which pivotally receives a ball on the mounting base and further pivotally receives a second ball extending forwardly from the mirror assembly. A prismatic mirror may further comprise a toggle assembly which is actuatable to pivot the mirror assembly relative to the arm via movement of a toggle actuating tab. The toggle assembly extends from the mirror assembly and is connected with the ball at the mirror assembly. The ball member typically comprises aluminum, while the toggle assembly may comprise a plastic material, in order to facilitate flexing as the actuating tab is moved to pivot the mirror relative to the arm. The toggle and mirror assemblies are assembled together manually via pivot axles and axle supports or the like and thus require manual handling and alignment of parts after the individual components are formed.
The ball member of the mirror assembly typically comprises zinc or aluminum in order to provide a low cost strong and durable ball for pivotal engagement with the mounting arm. The ball member may then be clamped tightly within the arm to frictionally support the mirror assembly in a secured position, thereby enhancing vibration performance of the mirror assembly. Vibration concerns are greater with many mirror assemblies, which include additional electronic accessories, such as map reading lights or the like, which add weight to the basic mirror assembly and thus require additional support at the joints to hold the mirror in a selected orientation. While the zinc ball allows for tight clamping by the arm, the zinc ball member further adds to the overall mass of the mirror system.
Because the ball member of the mirror assembly typically comprises zinc, aluminum, or other metal, it is often not painted, such that it does not match the color of the mirror assembly or trim of the vehicle. While the ball member is painted in some applications, concerns then arise with respect to frictional variation between the ball and socket joint due to variation in paint thickness along the surface of the ball. Furthermore, the additional process of painting the ball after it is formed adds to the cost of the mirror assembly.
Often, indicators and/or accessories may be placed at the mirror or at the dashboard or instrument panel of the vehicle. As mentioned above, inclusion of such items to the mirror adds to the weight of the mirror which may then require additional support for the mirror. Also, placement of such items at the dashboard or instrument panel makes the indicators or accessories inconvenient to view by a driver or passenger of the vehicle, since the person has to look down from their view of the road in front of the vehicle in order to see and access the indicators and/or accessories.
Therefore, there is a need in the art for a color-matched ball member and toggle actuating tab. The ball member should provide for uniform frictional resistance when retained within a ball and socket joint. Preferably, the ball member will further resist vibration such that the ball member will be useful for modern, heavier mirror assemblies with added features. Preferably, the ball and toggle will provide a reduction in the overall mass of the mirror assembly over the prior art ball and toggle assemblies.
SUMMARY OF THE INVENTION
The present invention is intended to provide a low cost and light weight ball and toggle assembly for a day
ight prismatic, interior rearview mirror assembly for vehicles. The assembly is formed from different materials, which have different strength and flexural characteristics, such that the ball comprises a strong, substantially rigid material, while the toggle portion of the assembly comprises a softer, more flexible material.
According to a first aspect of the present invention, a ball and toggle assembly adapted for an interior rearview mirror assembly of a vehicle comprises a body member and a toggle member. The body member comprises a ball member and a base, which are unitarily formed from a first polymeric material which comprises a first flexural modulus. The toggle member comprises a hinge and an actuator tab, which are unitarily formed from a second polymeric material which comprises a second flexural modulus. The body member and toggle member are joined together for support in a mirror housing of the rearview mirror assembly, with the first flexural modulus being greater than the second flexural modulus.
Preferably, the body member, including a ball member and base, comprises a filled polymeric resin material, while the toggle member comprises a polyolefin material. Preferably, the toggle member is molded at least partially around the body member and may be molded through a plurality of openings to mechanically secure the toggle member to the body member. Preferably, the body member and the toggle member are formed in a common color. The body member and/or the toggle member may be formed in a color to match the color of the mirror assembly or trim within the vehicle. For example, one or both members could be molded from a pigmented plastic material, so it could be molded as a dark color, such as black, gray, dark burgundy, dark blue, or any other dark colors, or a light color, such as white, beige, light gray, or other light colors.
According to another aspect of the present invention, an interior rearview mirror assembly for a vehicle comprises a mirror housing, a prismatic, reflective element and a ball and toggle assembly mountable to the housing. The reflective element is supported by the mirror housing. The mirror housing and reflective element are pivotable relative to the vehicle between a first, high reflective position and a second, low reflective position. The ball and toggle assembly is mountable at a forward surface of the mirror housing and comprises a body member and a toggle member. The body member comprises a first polymeric material having a first flexural modulus and includes a mounting member and a base. The toggle member comprises a second polymeric material having a second flexural modulus, which is less than the first flexural modulus. The toggle member comprises a hinge and an actuator tab. The body member and the toggle member are joined together. The toggle member is pivotally mounted at the mirror housing such that movement of the actuator tab about the hinge causes pivotal movement of the mirror housing and reflective element between the high and low reflective positions. The mounting member is pivotally interconnectable to a mirror mount secured to the vehicle such that the mirror assembly, including the housing, reflective element and ball and toggle assembly, is also pivotally adjustable relative to the mirror mount.
According to yet another aspect of the present invention, a mirror mount assembly comprises a mounting base, an accessory housing and at least one accessory positioned within the accessory housing. The mirror mount assembly is adapted for mounting to an interior surface of a windshield of a vehicle and for pivotally mounting an interior rearview mirror assembly thereto. The mounting base is for mounting at the interior surface of the windshield and includes a ball member for pivotal connection to the mirror assembly. The accessory housing extends generally downwardly from the mounting base. Preferably, the accessory comprises an illumination source or indicator, but may otherwise, or
Beck Jerry L.
Spooner Ralph A.
Donnelly Corporation
Shafer Ricky D.
Van Dyke Gardner, Linn & Burkhart, LLP
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