Modular extending mirror

[0002] This application claims benefit to U.S. provisional Application No. 60/141,043 Jun. 24, 1999.

[0003] 1. Field of Invention

[0004] The present invention relates generally to a mirror assembly for use on an automotive vehicle.

[0005] 2. Background of Invention

[0006] Automotive vehicles typically include a pair of exterior rearview mirror assemblies mounted to opposite side of the vehicle for providing the occupant of the vehicle a rearward reflective view from the vehicle. These mirror assemblies commonly include a base for mounting the mirror assembly to the vehicle and an elongated support arm coupled to the base for supporting a mirror housing or shell. A glass mirror pane is mounted within the housing for providing the reflective view from the vehicle. It is also known to pivotally mount the support arm to the base to provide pivotal movement of the housing from an extended, unfolded position, projecting laterally from the side of the vehicle, to a folded position collapsed against the side of the vehicle. This pivotal movement of the mirror assembly effectively reduces the overall width of the vehicle and assists in preventing damage to the mirror assembly caused by impact with external stationary objects. It is also known to provide manual or power operated pivoting movement of the mirror assembly by mounting a pivot mechanism in the base of the assembly.

[0007] It is further known to provide a mirror assembly that is extendable from a retracted position adjacent the side of the vehicle to an extended position spaced outwardly, or laterally, from the side of the vehicle to increase or expand the field of rearward view from the vehicle. Such mirror assemblies are often employed on sport utility vehicles, trucks, and/or vans to expand the field of view from the vehicle when used from towing a secondary vehicle or trailer. These mirror assemblies typically includes some form of track mechanism coupled between the housing and the support arm for sliding the housing along the support arm. The mirror assembly may be extended or retracted by manually sliding the housing along the support arm. Alternatively, a motor and gear drive mechanism may be provided for automatically moving the housing along the support arm between the retracted and extended position. The prior art includes a motor and gear drive mechanism mounted to the housing. The additional size and weight of the motor and gear drive mechanism in the housing adds stress the support arm and its attachment to the base and vehicle.

[0008] Therefore, it is desirable to reduce the size, mass, and weight in the housing of the mirror assembly to reduce the load and stress on the support arm and base supporting the support arm and housing.

[0009] The subject invention relates to a mirror assembly for use on an automotive vehicle comprising a support base adapted to be fixedly mounted to the vehicle. The mirror assembly includes at least one support arm extending longitudinally between a first end and a second end. The first end is pivotally supported by the support base and the second end extends laterally from the support base. The mirror assembly further includes a collar pivotally coupled between the support arm and the support base for pivoting the support arm about a generally vertical axis between an operative position extending laterally from the vehicle and a folded position pivoted adjacent and generally parallel to the vehicle. A housing is coupled to the support arm and slidable therealong between a retracted position adjacent the first end and an extended position adjacent the second end, spaced from the first end. The mirror assembly also includes a mirror pane operatively coupled to the housing for providing a reflective view from the mirror assembly. A drive mechanism is housed within the collar and operatively coupled to the housing for moving the housing between the retracted position and the extended position. A pivot mechanism is also housed within the collar and operatively coupled between the support base and the support arm for pivoting the support arm between the operative position and the folded position.

[0010] Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

[0011] FIG. 1 is an exploded perspective view of a mirror assembly according to the subject invention;

[0012] FIG. 2 is a side sectional view of a pair of support arms and collar mounted to a support base showing a pivot mechanism and drive mechanism housed within the collar of the mirror assembly;

[0013] FIG. 3 is an enlarged sectional view of section 3 of FIG. 2 showing a portion of the drive mechanism and a clutch mechanism;

[0014] FIG. 4 is a top view of a motor assembly of the drive mechanism;

[0015] FIG. 5 is a cross-sectional view taken along line 5—5 of FIG. 4;

[0016] FIG. 6 is an exploded perspective view of the drive mechanism; and

[0017] FIG. 7 is a top perspective view of the drive mechanism.

[0018] Referring to the Figures, wherein like numerals represent like or corresponding parts throughout the several views, an exterior rearview mirror assembly for an automotive vehicle is generally shown at 10 in FIG. 1. The mirror assembly 10 includes a support base 12 adapted to be fixedly mounted to the vehicle (not shown). The support base 12 includes a planar mounting plate 14 having a plurality of bosses 16 for receiving fasteners, such as screws, to fixedly secure and mount the mirror assembly 10 to the vehicle. The mirror assembly 10 is typically mounted to an A-pillar or side door panel of the vehicle as conventionally known in the art. The support base 12 further includes a base plate 18 extending outwardly and generally perpendicular from the mounting plate 14. The base plate 18 includes a circular and planar mounting shell 20 in the center thereof. The mirror assembly 10 further includes an upper support arm 22 and a spaced apart and parallel lower support arm 24. Each of the support arms 22, 24 are elongated, hollow tubular cylinders extending between a first end 26 and a second end 28. The mirror assembly 10 also includes a collar 30 pivotally coupled between the support arms 22, 24 and the support base 12 for pivoting the support arms 22, 24 about a generally vertical axis, shown at A, between an operative position extending laterally from the vehicle and a folded position pivoted adjacent and generally parallel to the vehicle. The collar 30 is defied by a generally cylindrical, hollow tubular body forming an upper chamber 32 and a lower chamber 34. The upper chamber 32 and lower chamber 34 are partially separated and spaced apart by a generally horizontal slot 36. The first ends 26 of the upper and lower support arms 22, 24 are fixedly secured, by welds or the like, to the upper chamber 32 and lower chamber 34, respectively, of the collar 30. The collar 30 is further pivotally mounted to the support base 12 by the base plate 18 being received within the slot 36 as will be further described hereinbelow.

[0019] The mirror assembly 10 further includes a mirror housing 40 coupled to the upper and lower support arms 22, 24 and slidable therealong between a retracted position adjacent the first ends 26 and an extended position adjacent the second ends 28, spaced from the first ends 26. The housing 40 includes an outer shell 42 defining a concave cavity 44 and having a peripheral rim 46 defining an opening into the cavity 44. The housing 40 further includes a hollow upper tubular sleeve 48 and a spaced apart hollow lower tubular sleeve 50 extending outwardly from the outer shell 42. The second ends 28 of the upper and lower support arms 22, 24 are slidably received in the upper tubular sleeve 48 and lower tubular sleeve, respectively for supporting the housing 40 on the arms 22, 24 between the retracted and extended positions.

[0020] The mirror assembly 10 also includes a mirror support bracket 52 received with the cavity 44 of the housing 40 and fixedly secured to the outer shell 42 by fasteners or the like mounted to bosses 54 extending from the back wall of the shell 42. The bracket 52 includes a flat, planar bracket plate 56 having mounting bosses 58 projecting therefrom and a hollow, elongated tube 60 defining a cylindrical bore 62 therethrough. The tube 60 is fixedly secured, by fasteners, welds, or the like, to the plate 56 extends from the plate 56 to be received in the lower tubular sleeve 50 such that the open end of the tube 60 is aligned flush with the open end of the sleeve 50. A manual or power mirror adjustor 62 is mounted to the bosses 58 on the bracket plate 56 for supporting a glass mirror pane 64. The glass mirror pane 64 provides a reflective view from the mirror assembly 10 to the occupant of the vehicle. The adjustor 62 provide for manual or power angular adjustment of the glass mirror pane 64 relative to the housing 40 to adjust the angle of the reflective view to the occupant. The description and operation of the adjustor 62 is fully set forth in applicant's U.S. Pat. No. 5,467,230 which is incorporated herein by reference in its entirety.

[0021] Still referring to FIG. 1 the mirror assembly 10 includes a pivot mechanism 70 housed within the collar 30 and operatively coupled between the support base 12 and the collar 30 or upper support arm 22 for pivoting the support arms 22, 24 and housing 40 between the operative position and the folded position. More specifically referring to FIGS. 1 and 2 the pivot mechanism 70 includes a bottom portion 72 supported and mounted to the mounting shelf 20 of the base plate 18 and a top portion 74 mounted to a top cap 76 of the upper chamber 32 in the collar 30. The top portion 74 rotates in the clockwise and counterclockwise direction relative to the bottom portion 72. The pivot mechanism 70 is capable of providing both manual and power actuated pivoting movement of the collar 30, support arms 22, 24 and thus housing 40, between the operative, or unfolded position, and the folded position. The operation and detailed description of the pivot mechanism 70 is fully set forth in applicant's U.S. Pat. Nos. 5,703,731; 5,703,732; and 5,684,646, which are incorporated herein by reference in their entirety.

[0022] Referring back to FIG. 1, the mirror assembly 10 further includes a drive mechanism, generally shown at 80, having at least a portion housed within the collar 30 and operatively coupled to the housing 40 for moving the housing 40 along the support arms 22, 24 between the retracted and extended position. The drive mechanism 80 includes a motor assembly 82 mounted within the lower chamber 34 of the collar 30. The drive mechanism 80 further includes a drive shaft 84 extending from the motor assembly 82 through the lower support arm 24 and tube 60. The drive shaft 84 includes a first end 86 rotatably coupled to the motor assembly 82 and a second end 88 rotatably coupled to the tube 60 of the mirror support bracket 52 for driving the bracket 52 and housing 40 between the retracted and extended positions. Referring to FIGS. 1, 2 and 3, the drive shaft 84 is an elongated, cylindrical drive screw having external helical threads 90. The drive mechanism 80 includes a drive nut 92 having internal helical threads 94, shown in FIG. 3 for mating threaded engagement with the threads 90 on the drive screw 84 or movement therealong between the first and second ends 86, 88.

[0023] Referring to FIGS. 4-7, and particularly FIG. 6, the motor assembly 82 includes a cylindrical motor housing 100 having an opened top 102 and a cap 104 for closing the opened top 102. The cap 104 has a plurality of downwardly extending bosses 106 for receiving fasteners, such as screws, to secure the cap 104 to the housing 100. The motor assembly 82 further includes an electric motor 108 for rotating an integrally attached driving worm gear 110. The motor 108 is stored and secured with the housing 100 as shown in FIG. 7. The motor assembly 82 further includes a driven worm gear 112 rotatably secured to the housing 100 by a gear shaft 114 and seated perpendicular to and in mating engagement with the driving worm gear 110. The housing 100 include a pair of spaced apart shaft support collets 116, 118 for supporting the first end 86 of the drive screw 84 within the housing 100. A pair of bearings 120, 122 are rotatably coupled about the first end 86 of the drive screw 84 with the end 86 inserted through an opening 124 in the housing 100 and seated on the collets 116, 118, respectively, for allowing the drive screw 84 to rotate on the collets 116, 118. Finally, the motor assembly 82 includes a drive gear 124 secured to the first end 86 of the drive screw 84 and meshed with the driven worm gear 112. The operation of the motor assembly 82 will be described in detail below.

[0024] Referring to FIGS. 1, 2 and 3, the drive mechanism 80 further includes a clutch mechanism 130 coupled between the drive shaft 84 and the support bracket 52 for selectively actuating the drive mechanism 80 to manually slide the housing 40 along the support arms 22, 24 between the retracted and extended positions. More specifically, the clutch mechanism 130 includes a spring bias member, such as a coil spring, 132 seated within the bore of the tube 60 and around the drive shaft 84, as shown in FIG. 3. The spring 132 is compressed between a shoulder 134 inside the tube 60 and the drive nut 92. The clutch mechanism 130 further includes a retaining ring 136 forming a through is fixedly secured to the inside of the tube 60 on the opposite side of the drive nut 92 room the spring 132. The fixed retaining ring 136 maintains the spring 132 in compression between the shoulder 134 and the drive nut 92.

[0025] The motor assembly 82 of the drive mechanism 80 is therefore completely housed contained within the collar 30. The remaining portions of the drive mechanism are housed and contained in the lower support arm 24. Additionally the pivot mechanism 70 is also completely housed and contained within the collar 30. Therefore, the size, mass and weight of the pivot mechanism 70 and drive mechanism 80 is removed from the mirror housing 40 to reduce the torque and stress on the mirror housing 40 supported by the arms 22, 24 and base 12.

[0026] In operation, the mirror assembly 10 may be manually actuated or power actuated between the operative, unfolded, position and the folded position as well as between the retracted position and extended position. In order to power actuate the mirror assembly 10 between the operative position and folded position, electrical power is sent to the pivot mechanism 70 to rotate the top portion 74 relative to the bottom portion 72 in either the clockwise or counterclockwise direction. The pivot mechanism 70, in turn, forces the collar 30, support arms 22, 24 and mirror housing 40 to rotate about the support base 12. To manually actuate the mirror assembly 10, the housing 40 or support arms 22, 24 are simply pivoted about the support base. The pivot mechanism 70 allow both power and manual actuation as disclosed in applicant's U.S. Patents referenced above.

[0027] In order to power actuate the minor assembly 10 between the retracted position and the extended position, electrical power is sent to the motor 108. The motor 108 rotates the driving worm gear 110 in either the clockwise or counterclockwise direction, as desired. The driving worm gear 110 rotates the driven worm gear 112 and drive gear 124 on the drive screw 84. During power actuation, the spring 132 compresses the drive nut 92 against the retaining ring 136 with sufficient force to frictionally interlock the drive nut 92, ring 136 and tube 60 of the support bracket 52. Therefore, the drive screw 84 will rotate within the drive nut 92, transferring the drive nut 92 along the longitudinal length of the drive screw 84. The housing 40 is, therefore, extended or retracted along the support arms 22, 24 between the retracted and extended positions, or anyway position therebetween. In order to manually actuate the mirror assembly 10 between the retracted and extended positions, a manual force is simply applied to the housing 40 to slide the housing 40 along the support arms 22, 24, toward or away from the support base 12. The drive mechanism 80, and particularly the clutch mechanism 130, must therefore also allow the drive nut 76 to freely rotate about a stationary drive screw 84. Specifically, when there is no power supplied to the motor 108, the gears 110, 112 and 114 are locked and prevent the drive screw 84 from rotating in either the clockwise or counterclockwise direction. When a sufficient force is applied to the housing 40 along the longitudinal direction of the support arms 22, 24, the support bracket 52 pushes or pulls on the tube 60. The drive nut 92 is operatively coupled to the tube 60 between the spring 132 and ring 136. The drive nut 92 is also coarsely threaded onto the drive screw 84. With the drive screw 84 locked against rotation, the drive nut 92 is able to overcome the compression force of the spring 132 and rotate about the drive screw 84. The rotation of the drive nut 92 about the drive screw 84 transfers the drive nut 92 longitudinally along the length of the drive screw 84 and allows the housing 40 to slide along the support arms 22, 24 between the retracted and extended positions. The spring 132 also provides enough compression and friction force between the drive nut 92, ring 136 and tube 60 to maintain the housing 40 in any position along the support arms 22, 24 between the retracted and extended positions.

[0028] It should be appreciated that the pivot mechanism 70 and drive mechanism 80 may be interchanged between the upper and lower chambers 32, 34 of the collar 30 without varying from the scope of the invention. It should also be appreciated that the mirror assembly 10 may only include a single support arm 22 or 24 supported by the collar 30.

[0029] The invention has been described in an illustrative manner, and it is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation.

[0030] Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practised other than as specifically described.