Note: Descriptions are shown in the official language in which they were submitted.
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THIS APPLICATION IS A DIVISIONAL APPLICATION OF APPLICATION
SERIAL NUM~ER 398,178, FILED MARCH 11, 1982 and entitled
VEHICLE MIRROR ASSEMBLY, now Canadian Paten~ No 1,180,213.
PIVOT ACTUATOR FOR A VEHICLE MIRROR ASSEMBLY
This invention relates to mirror assemblies for
vehicles, and more particularly, to an improved rearview
mirror assembly for mounting within a vehicle. The assembly
allows movement between a full light-reflectivity day
position and a reduced light-reflec~ivity night position
with a simplified, more reliable structure.
Rearview mirror assemblies allowing movement
between day and night light-reflectivity positions have been
used for many years. Governmental concern for strength,
bending resistance, breakaway ability, and other safety
requirements, a~ well as recent concern for weight and cost
reduction in vehicles to provide energy savings, have
dictated a re-examination of existing mirror assembly
designs.
In the past, different day/night rearview mirror
assemblies had been designed for different vehicles and the
varying requirements of different countries in which
automobiles or other vehicles are manufactured. In the
United States, not only must the inside rearview mirror for
a passenger car provide a predetermined field of view, but
it must be mounted so that it is stably supported, is both
horizontally and vertically adjustable, and can deflect,
collapse or break away from its supported position without
leaving sharp edges when subj~cted to a predetermined force
in the forward direction within predetermined angular
boundries.
In the European Economic Community, motor vehicle
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regulations require that a rearview mirror assembly be able
to withstand a static load test i.ncluding the support of a
25 kilogram weight at one edge while any bracket support and
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1 the opposite edge are fixedly restrained for one minute.
The assembly must pass the test without breaking or, i the
assembly does break, Wit]lOUt ~lass fragmen.ts being released.
Alternately, the mirror may be macle of safety glass.
Certain manufacturing difficulties have also been
discovered wi~h prior known assemblies. For instance, in
the manufacture of certain rearview mirror assemblies it is
necessary to heat and form a rectilinear lip on a molded
case into a rounded edge covering the pcriphery of the
mirror elemen~ after its insertion within a case. Diffi-
culty has been experienced in consistently obtaining uniform
mirror retaining lips in such assemblies. In addition, it
was ~esire~ to more easily obtain positive control of the
day/night pivoting action of the mirror assembly, especially
in varying weather and climatic conditions.
lYith respect to assemblies which include a sub-
stantially rigid case with a pivot actuator including a
flexible portion which provides resilience during pivoting,
it was desired to obtain greater strength through the
assembly area in which the pivot actuator was mounted.
Further, it is necessary that a mirror assembly
meet minimum vibration standards so as to present a clear
image when vie~ed by the driver of ~he vehicle, all while
maintaining strength suficient to meet the above-noted
governmental regulations. ~ reduction in the complexity of
prior assemblies was also desired to both decrease costs and
simpli~y manufacturing requirements without sacrificing
functional features.
The present invention was develoyecl as a simpli-
fied, reliable, inside, day/night rearview mirror assembly
for use in virtually all currently manufactured general use
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vehicles. The objective was to provide a mirror assemblyusQful in varying climatic conditions and which takes into
account the governmental safety requirements for the major
vehicular producing countries of the world. The present
mirror assembly was thus designed and produced in
recognition of the need for a simplified structure for
retaining a mirror element within a case, the need to keep
manufacturing rejection rates of the assemblies to a
minimum, the need for simpler, more positive control of the
day/night pivoting action while providing fewer overall
parts, and the need to maintain strength, reduced weight,
and resistance to vibration during use.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a
simplified~ reliable, inside day/night rearview mirror
assembly for vehicles which is adapted to provide easier
assembly and smaller manufacturing rejection rates,
simplified retention of the mirror element within the case,
proper resistance to vibration during use, fewer overall
parts, more positive control of da~/night positioning, and
proper strength with reduced weight. In addition, the
present invention provides the capability of use with a
one-piece mirror support bracket as disclosed in commonly
assigned Canadian Patent No. 1,180,212. Together with such
bracket, the present rearview mirror assembly takes into
account the governmental vehicle safety regulations in both
the United States and the European Economic Community and
provides easier, less costly manufacturing while maintaining
the proper strength and vibration requirements, all with a
minimal overall weight. The combination of the present
rearview mirror assembly and the mirror support bracket is
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disclosed and claimed in commonly assigned Canadian Patent
No. 1,178,835.
. In one aspec~, the present invention provides a
pivot actuator for a day/night rearview mirror assembly ~or
vehicles including a pair of spaced pivot axles, rigid body
means for holding the axles apart at a predetermined spacing
and being substantially rigid and inflexible between the
pivot supports and axles, and at least one pivot limiting
tab e~tending from the rigid body means for limiting
movement between at least a day and a night position; pivot
means for pivoting the actuator when received in a day/night
rearview mirror case; and moun~ing means for mounting a
bracket for securing the actuator to a support.
In anothex aspect of the invention, the back o~
the case of the mirror assembly curves outwardly to an area
of maximum overall case depth to facilitate flexing of the
case during pivoting of the pivot means. Multifaceted pivot
limiting stop tabs are provided on the pivot actuator for
positive control of the pivotal case movement between day
and night positions and to allow easier insertion o~ the
actuator within the case. In addition, the mounting means
on the pivot actuator may be either a socket ~or receiving a
ball member from a support bracket or an outwardly extending
ball member to be secured in a suitable support bracket.
In addition, the stop tabs allow easier insertion
of the actuator within the case than with prior known
actuators and provide more positive control of day/night
pivotin~ afte.r assembly. The present assembly incorporates
fewer overall parts while ma.intaining strength, vibratio.n
resistance and minimal weight. In addition, the assembly is
fully compatible with a support bracket such as that shown
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in Canadian Patent Nos. 1,178,~35 and 1,180,212 to allowproper use and operation in a wide range of vehicles as well
as proper safety breakaway and adjustability features when
so combined.
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.
BRIEF DESCRIPTION OF THE DRAWINGS
.
Fig. 1 is a front perspective view of the rearview
mirror assembly of the p~esent invention together with a
suitable, breakaway-type, mirror mounting bracket;
Fig. 2 is a rear view of the rearview mirror
assembly of the present invention together with the mirror
mounting bracket shown in Fig~ 1~
Fig. 3 is a front plan view of the molded mirror
case of the present invention;
Fig~ 4 is a top sectional view of the mirrox case
of Fig. 3 illustrating a glass mirror element mounted
therein and taken along plane IV~IV of Fig. 3;
Fig. 5 is a side sectional view taken along plane
V~V of Fig. 4;
Fig. 6 i5 a side sectional view of the mirror case
and mirror element together with the pivot actua~or mounted
therein similar to Fig. 5,
Fig. 7 is a rear view of a first embodiment of the
pivot actuator of the present invention;
Fig. 8 is a front view of the pivot actuator shown
in Fig. 7;
Fig. 9 is a side sectional view of the pivot
actuator taken along plane IX~IX of Fig. 8;
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Fig. 10 is a sectional view of the mirror caseshowing the mirror element as supported at the end of the
case taken along plane X-X of Fig. 12;
Fiy. 11 is a side sectional view of the case
during insertion of the pivot actuator of Figs. 7-9 into the
case:
Fig. 12 is a front plan view of the case with the
pivot actuator of Figs. 7-9 mounted therein;
Fig. 13 is a front view of a second embodiment of
the pivot actuator of the present invention;
Fig. 14 is a rear view of the pivot actuator as
shown in Fig. 13;
Fig. 15 is a side view of the pivot actuator shown
in Figs-. 13 and 14;
Fig. 16 is a side sectional view of the pivot
actuator taken along plane XVI-XVI of Fig~ 14; and
Fig. 17 is a side sectional view of the actuator
taken along plane XVII-XVII of Fig. 13.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Re~erring now to the drawings in greater detail,
Figs. 1-6 illustrate a first embodiment of the inside
rearview mirror assembly 10 including a molded, resinous
mirror case 12 receiving a mirror element 14 and a rigid
pivot actuator or toggle member 60 or 60'. Actuator 60 or
60' is pivotally mounted in -the case and preferably molded
from resinous material as will be described more fully
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1 hereinafter. Mirror element 14 is a prism of transparent
glass, Plexiglas (trademark), plastic or other transparent,
rigid material having a layer of reflective material 16
~Fig. 5) placed on its rear surface. Preferably, element
14 is a glass prism having a taper of 3 35' + 0 10' and
a maximum thickness of 0.218 + .015 inches. The overall
element is 9.27 ~ .015 inches by 2.265 + .015 inches with
rounded corners, slightly curved edges, and a frosted non-
glare edge all around. Such re1ective layer may be coated
with a protective primer paint layer followed by a flexible
resilient polyvinyl chloride plastisol layer 18 or a cover~
ing of tape for safety reasons to prevent scattering of
glass fragments should the mirror be broken.
In the preferred embodiment, layer 18 has a thick-
ness of approximately 0.015 to 0.045 inches which thickness
tapers and becomes less adjacent the edges of the mirror
element 14 (see Figs. 5 and 6). The reflective layer 16 is
normally covered with a protective layer of primer paint
over which the plastisol layer 18 is applied. The primer
paint is preferably a heat sensitive adhesive and includes
a pigment or hiding the reflecti~e layer on the mirror.
Acceptable products include Daubond* DC-8660 by Daubert
Chemical Co. of Oakbrook, Illinois or product No. A 1103 B,
by B. F. Goodrich Chemical Company, of Cleveland, Ohio.
Both have adhesive bonding qualities when heated.
After application of these various layers, the
mirror element and layers are cured by heating to a tempera-
ture of approxima~ely 175-200 F. At this approximate
temperature, the PVC plastisol 18 is chemically converted to
polyvinyl chloride. Sufficient plastisizer is originally
included in the plastisol to leave the cured layer 18
trademark
~2V63S9
1 inherently resilient, flexible and impressionable at all
~emperatures to wllich vehicles including such mirrors are
normally subjected, namely, a range of~40 F. to 190 F.
Althou~h ap?lication of the PVC layer 18 is
prefera~ly ~one is plastisol form, the PVC in non-plastisol
form may be injection molded onto the back of the mirror.
W}len P~C is injection-molded on the mirror back, it has
been found that an additional layer of bondillg agent or
adhesive beneath the plastisol layer, ~hich securely bonds
the plastisol layer to the mirror element, is preferred.
Such suitable heat sensitive adhesive is product No.
J 1199-B, produced by ~rmstrong Cork Company, of Cincinnati,
O]lio. Other materials llaving the above characteristics of
resiliency and flexibility over a wide temperAture range,
which may also be used for layer 18~ include polyvinyl
acetate, polyurethane and silicone sealants.
As shown in Figs. 5 and 6, the planar front
s~lrface and planar rear surface of mirror element 14 are not
parallel thereby definin~ the prism and enabling adjustment
of tlle mirror assembly for day and night use ~o reduce the
overall intensity of the light reflected from the mirror.
Tl)us, when tlle assembly is pivoted (Fig. 6) such that the
case positions the mirror element witll incident li~ht
reflected off the coated rear surface 16, substantially all,
approximately 8~ percellt of the light hitting that surface
will be reflectetl. I!o~ever, ~hen the case is pivoted Suc]
that ligl!t is reflected off the front, uncoated surface,
only approximately 4 percent of the incident light will be
reflected. Glare ill t}le eyes of the driver viewing the
mirror is thereby reduced.
As noted above, the rearview mirror assembly 10 is
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designed to be used with a support bracket 15 of the type
disclosed in either Canadian Pat~nt Nos. 1,178,835 and
1,180,212~ Bracket 15 enables the mounting and adjustment
of assembly 10 on a support which is typically secured on a
windshield of a vehicle to provide proper adjustment for all
sizes of drivers for such a vehicle. Bracket 15, which
forms no part of the present in~ention, is alsG described
and claimed in combination with the present rearview mirror
assembly in Canaclian Patent No~ 1,17~,835 noted above.
As is best seen in Figs~ 3-6, molded mirror case
12 includes a contoured, curved back 20 and a continuous
peripheral side wall 22 which extends around the entirety of
the case outllning the periphery of mirror element 14 when
received thereinO Side wall 22 defines top 22a, bottom ?2b,
and ends 22c and 22d. As shown in Figs. 5 and 6 t the
thickness of the case back 20 is substantially uniform and
preferably 2.5 mm while peripheral side wall 22 tapers
outwardly to an increased thickness, preferably 3.0 mm,
toward the front of the case where it merges with a
continuous, inwardly ex-tending mirror element retaining lip
24. Lip 24 extends around the entirety of side wall 22 and
has a curved outer shape ending at inner edge 26 and an
inclined under surfa~e 28 adapted to face the mirror element
14. Inclined surface 28 prevents the lip from catching on
the corner of the glass when the case flexes~ The curved
outer surface of the lip 24 cooperates with the bevel 19 on
the rear surface of mirror element 14 when the mirror
element is snapped into the case 12 by camming the lip and
peripheral side wall combination outwardly in the manner
shown in Fig. 10. Lip 24 extends inwardly over the entire
peripheral ~dge
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1 of the mirror element a predetermine~l distance, 2.5 mm in the
preferred embodiment, and is calculated to mask any edge
defects in the glass or other mirror element and also to
retain the mirror element in I)lace evcn wllen the case flexes
during pivoting of the day/night pivot actuator as set forth
below.
As shown in ~igs. Z and 5 9 the c~se back curves
outwardly to an area of maximum tllickness approximately at
the central portion of the case as deined by a contour line
30 whicll extends from points 3Z, 33 adjacent the upper
corners at ei~her end of the case do~n~ardly in a gentle
curve toward the middle of the case intermediate upper and
lo-~er corner apertures 34 and 36 but immediately adjacent
the bottom portion of'tl-e uppermost aperture 34. Contour
line 30 not only defines an increased depth for ~he overall
case, but also facilitates flexure of side walls 22 l~hen the
pivot actuator is pivoted within the case and/or the mirror
element 14 is snapped in place during assembly of the mirror
assembly. Along with ribs 5~, 52, thc contour of the case
~0 also increases longitu~inal bendin~ resistance or stiffness
hclping to meet ~overnmental re~ulations This contour
provides a some~hat bulbous shape to the mirror assembly as
sllo~Yn in Figs. 4-6, 10 and 11.
As shown in Figs. 3 and 4, mirror case 12 also
includes pairs of alignedj parallel, upstanding mirror
supports 38, 40 on the intcrior of opposite ends 22c, 22d of
the case. ~s shown i,n lig. 5, tl~ese upstandin~ supports
e~tend different distances to support the varying thic~ness
of the prismatic mirror element 14 wllen retained in case 12
beneath inclined surface 28 of lip 24. lYhen snapped in
pl~ce, lip 24 tigl~tly retains the mirror element ag~inst'
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only supports 38, 40 to prevent any vibration or movement of
the mirror element within the case. The mirror element is
not supported by any other portions of the case.
As is best seen in Figs. 3 6, the central,
interior portion of case 12 includes a support area for
pivot actuator or toggle member 60~ The support area
includes rectilinear, parallel, support walls 42, 44 each of
which includes a free, rectilinear top edge which is spaced
behind layer 18 of mirror element 14 when received in case
12, and is generally parallel to coated rear surface 16 as
shown in Fig. 5. Each of the support walls 42, 44 includes
a cutout or opening 46, 48, respectively, having nonparallel
top and bottom edge surfaces which converge toward top wall
22a. Openings 46~ 48 are bounded by an area of increased
thickness 47, 49 on the interior surface of each wall 42l
44, respectively, to strengthen the wall around the opening.
Openings 46, 48 are designed to receive the pivot limiting
stop tabs from pivot actuator 60 as described hereinafter.
In order to strengthen the support area and case in its
central section, a pair of upstanding, molded sùpport ribs
50, 52 extend generally rectilineaxly and parallel to one
another but are spaced slightly apart across the area
bètween walls 42, 44. Rib 50 is generally aligned with the
contour line 30 defining the area of maximum depth of the
case in the area between walls 42, 44 immediately under
aperture 34.
Molded integrally and extending inwardly from the
inside surfaces of support walls 42, 44 are aligned pairs of
pivot supports 54a, 54b and 56a, 56b which support the top
and bottom pivot axles of *he pivot actuator or toggle
member 60 respectively. Pivot supports 54a, 54b each
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1 include an axle support wall 55 (Fig. 5) having an inside
surface contour including cylin~rical surfaces of two
different radii joined by a planar surface 53 designed to
match tlle exterior contour of the upper pivot axles stubs on
the pivot actuator 60. Axle suppor~ walls 55 are, in turn,
supported by ribs 57 cxtending betwe~n the upper sicles of
the walls 55 and the upper side wall 22a of the case.
Similarly, lower pivot supports 56a, 56b inclu(le
axle support walls 58 sup})ortetl by additional rib 59 ex-
tendin~ between the axle support and bottom side wal~
portion 22bA Axle support 58 includes an inner, partially
cylindrical uniform raclius surface opening generally toward
an opposed, ali~ne~ one of the upper pivot supports 54a,
5~b. As will be more fully describe~ below, pivo~ actuator
60 is designed to be snapped in l)lace be~ween the sets of
pivot supports 54, 56 and between support walls 42, 44 after
molding of the case and prior to insertion of the mirror
element 14.
Referring now to ~igs. 7-9, a first embodiment 60
of the pivot actuator or to~le member is shown. Actuator
60 inclucles a pair of spaced pivot axles 62, 64 designed to
be received in supports 54a an~ b, 56a and b, respectively,
a rigid bocly 66 including a series of stren~thenin~ ribs or
braces 67, a pair of opposed pivot limiting stop tabs 68a,
68b on opposite sides of the body 66, a mounting soc~et 70
extendillg olltwardly from the upper pivot a~le 62, and a
pivot mcmber inclllcling lowcr pivot axlc 64 adapted to cnable
pivotal movement of the actuator between at least two
positions, i;e., the forward or day and the rcarwarcl or
night position whell mountecl withill ~he case.
Up~)er pivot axle 62 inclucles a pair of stub axles
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1 62a, 62b extending parallel to one another and in opposite
directions from the upper side edges of the body 66 of
actuator 60. Stub axles 62a, 62b have cylindrical surfaces
of different radii joined by a planar surface in the same
fashion as the inside surfaces of axle supports 55 on pivot
supports S4a and b in case 12. The larger cylindrical
surface extencls ap~roximately one thircl to one ~uarter of
the way arouncl tlle pivot axle, the increased raclii providin~
the stub axle with greater strengtll. Ilowever, the smaller
cylindrical radius.portion enables the actuator to be more
easily fitted in pivot su~ports 54a and b. Rigid body
portion 66 includes a pair of diverging legs which are
chanrlel-shaped in section extendin~ between the pivot ~xles.
These legs provide a general V-sllape for the body section as
best seen in ~ig. 8. The challnel-shal)e ~rovicles weigllt
reduction wilile the cross braces, such as those shown at 67
in Figs. 7 and 9, both within tlle side wall of aach di-
verging leg and bet-~een tl-e legs themselves, provide sig-
nificantly increasecl strength and rigidity for the body
portion without ad~ing signifîcant ~eight. The ront
s~lrfaces 65 of the diverging legs G6 lie in a common plane
sligl~tly offset from t]~e center lines of the pivot axles 62,
6~. .
At the lower eclges of the legs of the actuator
pivot axle 64 is joined by a flexible, integrally molded
living hinge 72. ~rojectin~ clownwarclly from tilC bottom of
pivot axle 64 is a I-ivot or fin~er tal) 74 llavillg inte~ral
ribs molclecl thereon for ease in gri~ping. Living hinge 72,
tab 7~ an~ pivot axle 64 togetller form an over-center hinge
assembly in com~inatioll ~ith the rigid bocly 66 which operates
as more ~ully describecl hereinafter.
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Pivot limi~ing s-top tabs 68a, 68b, which ex~end
from the opposite side surfaces of the rigid body 66, each
include multiple facets or planar surfaces intersecting one
another as shown in Figs. 6-8 and 11. The front surfaces 76
of stop tabs 68 are designed to engage the upper edge of
cutout apertures 46, 48 in support walls 42, 44 to limit the
pivotal movement of the actuator to its day position (Fig.
11)~ On the opposite side of each stop member, facets 73
provide a stop surface limiting pivotal movement of the
actuator 60 to its night position (Fig. 11). Inclined
facets 80 provide camming surfaces helping insertion of the
actuator between the support walls 42, 44 when it is
assembled within the case.
As shown in Fig. 9, the molded socket 70 has a
central axis "A" which extends outwardly at an obtuse angle
with respect to the plane of front surfaces 65 of legs 66.
Socket 70 has a slightly elongated or egg shape and is not
perfectly spherical such that a ball member from a support
bracket does not touch socket wall 71 at all places ~Fig~
9). Socket wall 71 has a substantially uniform thickness
adapted to provide sufficient support or a ball member but
allow ins~rtion of such a ball without fracturing. Wall 71
is strengthened by braces 69. Inclined, conical lead-in
surface 82 facili-tates snap-in insertion of a spherical ball
membe- from a mounting bracket or the like to be received in
the socket as described in Canadian Patent No. 1,178,835.
Aperture 84 results from removal of a mold pin during
manufacture. When received in case 12, socke-t 70 is adapted
to project through upper corner aperture 34, while pivot tab
74 extends through lower corner aperture 36 as shown in Fig.
6.
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1 Alternately, as sllown in ~igs. 13-17, a revised
form 60' of-the pivot actuator i5 shown wherein like numerals
indicate li~e parts to those sho~n in embodiment 60. Actua-
tor G0' includes an out-~ardly extending ball mcmber 86 in
place of socket 70. Ball mcmber 86 is molded into support
area 85 at the apex of the diverging legs ~hich form body 66
SUCh ~11at it extends outwar~ly from upper pivot axle 62.
Ball member 8(1 preferably includes a zinc die cast or other
metallic s~herical ball 37 nec~ 88 and a base including
parallel circular members ~9 and 90 abou~ which is molde(l
support area 85. Ball portion 87 is designed for receipt in
a syherical cup or other receiving member in a mountin~
bracket extending between the pivot actuator and a support
such as a metallic button on the windshield of a vehicle.
The central axis of ball member 86 extends at the same an~le
as does the axis A of socket 70 ~ith respect to the planar
surfaces of diverging legs 65 and thus extends through
upper corner aperture 34 l~hen received in case 12. Accord-
ingly, del~ending on t~hether actuator 60 or 60' is chosen
the assem~led rearview mirror may be used Wit]l varying
support brackets wllile continuing to provide complete
~djustability for viewing by varying sizes of (lrivers.
. Preferably, both case 12 and actuators 60 or 60'
are molded in one piece from resinous, tilermoplastic material
such as a homopolymer or copolymer of polypropylene. SUC11
material has been found to have the necessary strength and
rigiclity for forming tlle actuators 60, 60'. Yet in the
configuration of tlle case 12, these ma~erials have tlle
necessary flexil~ility antl resiliency to function as in-
tended. Preferably, actuators 60, 60 are molded from a
homol)olymer of polypropylene such as Hercules*6523 macle
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* trademark
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by Hercules,* Inc. of Wilmington, Delaware, or equivalent.
Hercules 6523 has the following properties:
Flexural modulus (ASTM D790B)--250,000 psi;
Hardness ~ASTM D 785A)--99 (Rockwell R scale);
Deflection temperature (ASTM D648)--212 F. (66
psi);
Notched Izod impact strength (ASTM D 256A)--0.8
ft.-lbs./in (at 73F.)
A preferred polypropylene copolymer for case 12 is Hercules
7523 or equivalent. Hercules*~523 has the following pro-
perties:
Flexural modulus (ASTM D790B)--185,000 psi;
Hardness (ASTM D785A)--80 (Rockwell R scale);
Deflection temperature (ASTM D648)--81 F. (at 66
psi);
Notched Izod impact strength (ASTM D256A)--2.5
ft.-lbs.~in (at 73 P~)
It has been found that the actuator, mirror
element and case can be best assembled within a predeter-
mined time period after completion of the molding of the
case so as to utilize the case while its temperature remains
above a predetermined level at which the case has a greater
flexibility and lesser resiliency which facilitates assembly.
Initially, the cylindrical surfaçes of pivot supports 56a,
56b are coated with a suitable lubricant such as a grease
sold as Lubriplate ~trademark) 930-2 by Firske Bros. Refinery,
Newark, New Jersey. The grease provides consistency in the
pivot torque for movement between day and night positions. One
of the actuators 60 or 60' lS then inserted as shown in Fig.
11 such that socket 70 or ball member 86 projects through
aperture 34 while pivot tab 74 and pivot axle 64 are
* trade~arks
0~3~
,
1 r3tated such that pivot tab 74 extends througll lo~er corner
aperture 36. Inclined surfaces gO of pivot limiting stop
tabs 68a, 68b are brought into engagement with the recti-
linear upper edge surfaces of support walls 42, 44 while
pivot stub axles 62a, 62b are ~ein~ pushed into and seated
within the cylindrical surfaces of pivot supports 54a, 54b
all as s~lown in Fig. -11. Thereafter, sufficicnt force is
applied in the direction of the arrow in Fig. 11 to forcc
actuator 60 downwardly between support walls 42, 44 sucll
tllat inclined~cammitlg surfaces 80 on the pivot limitin~ stop
t~bs 68a, 68b force walls 42, 44 to bul~e outwardly allowing
the pivot stop tabs to pass between them and into apertures
46, 48. Since case lZ is at an elevated temperature, the
sup~ort walls 42, 44 have a greater degree of flexibility
and lesser resiliency than after a longer period of cooling,
thereby facilitating the above insertion process. lYhen stop
tabs 68a, 6Bb are received within apertures 46, 48, the
lower pivot axle 64 is seated in pivot supports 56a, 56b as
shown in Fig. 6.
Inasmuch as actuators 60, 60' include rigid bodies
66 which maintain a predetermined spacing between axles 62,
64, an interference fit is provided bet~een the pivot axles
of the actuator and the pivot supports of case 12 by making
the distance Y (Fig. 7) between the outside surfaces of the
pivot axles slightly greater than the distance X (Fig. 5),
the greatest distance between the cylin~rical surfaces of
thc pivot supports. ~ccordill~ly; wllen actuator 60, 60' is
snappe~ into place as ~escribed above, this ;nterference,
W]lic]l is .030 inches in tile prefcrred embo~iment, flexes the
side walls 22 and a portion of the case bac~ 20 outwarclly in
~he manner sllown in phantom in Fi~. 11. This provides a
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1 prestressed condition which causes the lower axle 64 to bow
slightly intermediate the supports 56a, 56b as shown in- Fig.
12. After the assembled case and actuator have cooled
sufficiently to ambient, normal temperatures, the resiliency
of the resinous 9 thermoplastic ma-terial at those temper-
atures constantly biases the over-center pivot assembly on
the ac.tuator into one or the other o~ its two positions as
limited by tl~e stop tabs within apertures 46, 4~. Accord-
lngly, the case itsel~ acts as a spring member urging the
pivot actuator to either its day or night position and
maintaining the actuator in that position. ~he preferred
flip angle of movement between the day and night positions
of actuator 6~ or 60' is 5 29- ~ 0 3~)' using the pivot
limiting stop tabs 68 and apertures 46, 48.
~efore tlle case has cooled to ambient temper-
atures, however, the increased flexibility and reduced
resiliency of the contlnuous side IYalls 22 o~ the case 1
facilitates insertion of the prism mirror element 14 by
snapping it into position as shown in Fig. lU. Such in-
Z sertion is facilitated by bevel 19 on the rear edge corner
of the mirror element camming a~ainst the rounded suriace of
lip ~4 adjacent edge 26 such that the top 9 bottom and end
surfaces of the case are flexed outwardly ~Fig. lU). rhis
allows inward movement of.the mirror element to a position
under lip 24 and agalnst suppor.ts 38, 40. Thereafter, the
continuous lip flexes inwardly from its expanded position to
retain the edge of the mirror element un~er the lip ~4.
It has been iound that, with the preferred ma-
terials noted above, the insertion of hoth the actuator 60
or 6U' and the mirror element 14 is best achieved within one
to three minutes after removal of the case from the mold so
. - 18 -
;3~
1 as to take a~vantage of the greater 1exibility and lesser
resiliency of the case at an elevated temperature. There-
after, the case cools ~o retain mirror element and actuators
in position and to l)rovide the pres~ressed, biasing force
described above.
During use of the mirror assembly described above,
it will be noted that, as shown in Fig. 6, pivotal movement
of the tab 74 bett~een its (lay and night position incrcascs
the distance between axles 62, 64 wllen tab 74 and llinges 72
are generally parallel to tl-e fron~ surface 65 of rigid body
66 and until the actuator is over-center toward one position
or the other. Such increased distance flexes the continuous
side walls and a l~ortion of case back 20 outwardly (Fi~s. 10
and ll) a~ainst tne natural resiliency of the case providing
a pre~etermined force level W]liC]l must be overcome by a
pivoting torque or force appliecl against pivot tab 74. Once
such force is applied and the pivot tab is moved ovcr
center, the biasing force of the case will snap the actuator
into its opposite position as limited by the surfaces on
pivot limiting stol) tabs 68 within apertures 46, 48. ~e-
pending on the magnitude of the interferellce it bet~een
actuator 60 or 60' and supports 547 56, and the stiffness
and resiliency of the case and ac~uator, ~hicl) can be varied
by the amount of case set or coolîng allowe~ before actuator
insertion, such pivoting ~orce w.ill preferably be between
about one and three pounds. This is sufficient to allow
movement between day and night p.ositions wllile provi~ing
goo~ feel an~ kecping the actuator in one of its positions
after movemcnt in accord with desircd dcsigll objectives.
In addition, pivot limiting sto~. tabs 68 ~rovide positive
assurance against prematur.e removal of the pivot actuator or
-- 19 --
~ 3L;~C~63~
1 toggle assembly from pivot supports 54, 56 such as could
occur by a sharp force applied against the mirror assembly
tending to move the pivo~ actuator forwardly to~ards the
mirror element when mounted in a vehicle. l'he closed aper-
tures 46, 48 which limit movement of the pivot stop tabs 68
effectively prevent such removal of the actuator after
assembly.
~ccordingly, tlle ~resen~ invention provides a
simplified, highly reliable rearvie~ mirror assembly l~hich
provides requisite strength t~ith lightness, fewer overall
parts compared to prior known mirror assemblies, simplified
assembly procedures coupled with consequent rcduction in
rejection rates for the assemblies~ and more posi,tive
control of tl-e day/night pivotin~ action. In addition~ the
assembly is adapted to meet safety requirements for major
vehicle producin~ countries.
~ ilc several forms of tl~e invention llave been
sho~n and described, other forms ~ill now be apparent to
those skilled in the art. Therefore, it will be un~erstood
that tlle embodiments shown in the dra~ings and described
above are merely for illustrative ~urposes, and are not
intended to limit the scopc of the invention wllicll is
defincd by the clnims wllicll follow.
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