United States Patent (19)
`Catlin et al.
`
`||||||IIII
`USO05721646A
`11) Patent Number:
`5,721,646
`45
`Date of Patent:
`Feb. 24, 1998
`
`54 EXTERIOR REARVIEW MIRROR FOR
`WEHICLES
`
`4,372,517 2/1983 Welch et al. ............................ 248,267
`4,403.829 9/1983 Thujiuchi et al. ...................... 350/.289
`
`75 Inventors: Michael R. Catlin, Holland; Edward
`A. Gahan, Fennville, both of Mich.
`(73) Assignee: KAM Truck Components, Inc.,
`Holland, Mich.
`
`21 Appl. No.: 604,758
`22 Filed:
`Feb. 23, 1996
`(51) Int. Cl. .................. G02B5/08; G02B 7/182;
`A47G 1/24
`52 U.S. Cl. .......................... 359/865; 359/872; 359/877;
`248/476
`(58) Field of Search .................................... 359/855, 864,
`359/865, 871, 872, 877; 248/476, 481
`
`S
`
`(List continued on next page.)
`FOREIGN P.
`DOC
`2043982 7/1992 Canada.
`0287181A2 10/1988 European Pat. Of..
`0310261A1 4/1989 European Pat. Off. .
`0490734A
`6/1992 European Pat. Off..
`0590510A1 4/1994 European Pat. Off. .
`262.8042 9/1989 France.
`2649953 1/1991 France.
`2409748 9/1975 Germany.
`7905320.6 11/1981 Germany.
`1186443 7/1989 Japan.
`WO 9530495 1/1995 WIPO.
`
`Primary Examiner-Paul M. Dzierzynski
`Assistant Examiner-Mark A. Robinson
`Attorney, Agent, or Firm-Van Dyke, Gardner, Linn &
`Burkhart, LLP
`References Cited
`ABSTRACT
`57
`U.S. PATENT DOCUMENTS
`in,
`a PP------------ B: An exterior rearview mirror assembly for vehicles such as
`B. 3.
`D. 302,964 8/1989 fgede.
`... Di 2/87
`trucks, vans and recreation vehicles provides reduced weight
`D.368,
`5/1991 Neff.
`52, and vibration and improved stability. The assembly includes
`D. 3 sis37
`8/1991 Richardson et al. .
`... D2/87
`a mirror mount securing a reflective mirror element to an
`D. 325,017 3/1992 Richardson et al. .
`... D2/187
`elongated support bracket, and a mirror housing secured to
`... 248/47
`the support bracket and shielding the mirror element, mount
`3,346229 10/1967 Carson, Jr. .......
`... 350/293
`and support bracket. The support bracket spans the interior
`3,375,053 3/1968 Ward ........
`... 350/.293
`of the housing from adjacent one end of the housing to
`3,408,136 10/1968 Travis .
`... 30.299
`adjacent the other end, is spaced from the side and rear walls
`3,476,464 11/1969 Clark ........
`3,596,079 7/1971 Clarket al. .
`... 24.0/7.1
`of the housing, and has spaced, elongated support members
`3,610,736 10/1971 Bateman ......
`: and at least one brace member extending between the
`3,788,734
`1/1974 McDuffee, Sr. .
`350.289
`support members. Preferably, the brace members ae
`3,830,561 8/1974 La Fave et al. .
`... 350/304
`arranged in an X-pattern along the bracket length, while the
`4,022.520 5/1977 Scifies .............
`... 350/288
`mirror mount is an electric actuator providing remote adjust
`4,027.953 6/1977 Jacob ...
`... 350/.289
`ment of the mirror element about multiple axes. In one form.
`4,094.591
`6/1978 Lafont ..........
`... 350/.289
`the bracket may include a covering wall over the brace
`4,101.206 7/1978 Oskam et al. ...
`... 350/.289
`members and support members to increase rigidity and
`4,116,538 9/1978 Oskam .............
`... 350/.289
`reduce vibration. Also, the bracket may support tWO spaced
`4,190,326 2/1980 Brodbeck .......
`... 350/.289
`actuators for separate, independent adjustment of a planar
`4,234,246 11/1980 Wunsch et al...
`... 250303
`4,268,120 5/1981 Jitsumori ......
`... 350/.289
`mirror element and a convex mirror element.
`4,281,899 8/1981 Oskam .....
`... 350/.289
`4,283,117 8/1981
`62 Claims, 8 Drawing Sheets
`4,295,708 10/1981
`
`56
`
`
`
`SMR USA
`Exhibit 1034
`Page 001
`
`

`

`5,721,646
`Page 2
`
`U.S. PATENT DOCUMENTS
`350/.289
`4.464,016 8/1984 Weber et all
`2 r w ry
`bef ca. ..........................
`4,488,778 12/1984 Polzer et al. ............................ 35063
`4,498,738 2/1985 Kumai..................................... 350,637
`4,502,759 3/1985 Herzog et al.
`... 350/636
`4,504,116 3/1985 Sharp .............
`... 350/637
`4,504,117 3/1985 Mittelhauser ..
`... 350/636
`4,540,252 9/1985 Hayashi et al. .
`... 350/634
`4,555,166 11/1985 Enomoto .....
`... 350/634
`it: E.
`E.
`wa? 79
`rester ........
`4,632,594 12/1986 Del Tufo et al.
`403/322
`4,648,693 3/1987 Losch ..............
`... 350,636
`4.648.737 3/1987 Lake, Jr. et al.
`... 403,322
`4,670.679 6/1987 Koot et al. .....
`... 310/99
`4,693,571 9/1987 Kimura et al...
`... 350/634
`4,701,037 10/1987 Bramer.....
`... 350/634
`4,730,913 3/1988 Boothe.
`... 350/604
`4,740,068 4/1988 Fisher.......
`... 350/634
`4,757,786 7/1988 Ellegard ...
`... 123/2
`4,763,381
`8/1988 Williams .............................. 5/250.01
`
`as
`
`4,778.265 10/1988 Fingerie et al. ........................ 350/604
`4,787.726 11/1988 Hendricks ............................... 350/637
`4,804,257 2/1989 Schmidt et al. .............. 350/626
`4,818,090 4/1989 Righi...
`... 350/634
`4,877,214 10/1989 Toshiaki et al. .
`348/483
`4,929,074 5/1990 Urban ...........
`... 350/625
`4,973,147 11/1990 Fujita et al. ............................ 350/637
`4,973,820 11/1990 Mittelhauser ........................... 219/219
`4,988,178
`1/1991 Eifert ...........
`... 350/631
`5,015,824 5/1991 Monter et al. .......................... 219/29
`5,042,932 8/1991 Pent ........................................ 359/874
`5,044,739 9/1991 do Espirito Santo ................... 359/864
`1
`5,073,019 12/1991 Ferreira do Espirito Santo ..... 359/872
`l/1992 McKee ........................... ... 359/876
`5,082,361
`5,110,019 5/1992 Lang et al.
`359/874
`5,111,125 5/1992 Barrs ....................................... 318/603
`5,115,352 5/1992 do Espirito Santo ...
`. 359/855
`5,238,214 8/1993 Syamoto et al......
`248/544
`5,294,084 3/1994 Syamoto et al. ........................ 248/544
`5,615,054 3/1997 Lang et al. .............................. 359,844
`
`
`
`SMR USA
`Exhibit 1034
`Page 002
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 1 of 8
`
`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 003
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 2 of 8
`
`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 004
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 3 of 8
`
`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 005
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 4 of 8
`
`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 006
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 5 of 8
`
`5,721,646
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`
`
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`
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`FG.2
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`SMR USA
`Exhibit 1034
`Page 007
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`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 6 of 8
`
`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 008
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 7 of 8
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`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 009
`
`

`

`U.S. Patent
`
`Feb. 24, 1998
`
`Sheet 8 of 8
`
`5,721,646
`
`
`
`SMR USA
`Exhibit 1034
`Page 010
`
`

`

`5,721,646
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`O
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`20
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`25
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`1.
`EXTERIOR REARVIEW MRROR FOR
`WEHICLES
`BACKGROUND OF THE INVENTION
`This invention relates to rearview minors for vehicles and,
`more particularly, to exterior mirrors for use on larger
`vehicles, such as trucks, vans, recreational vehicles and the
`like which may be adjusted between one of several desired
`viewing positions.
`Exterior rearview minors for vehicles are widely used on
`both automobiles which are primarily designed as passenger
`vehicles as well as on and larger, heavy transport or utility
`vehicles, such as trucks, vans and recreational vehicles
`(RV's). In automobiles and light trucks, it is desirable to
`position the exterior rearview mirror as close as possible to
`the car body to enable a better field of view for the vehicle
`driver. Typically, such mirrors are mounted on rigid mount
`ing plates or specially designed supports secured in the
`opening of the side window or to the vehicle side door.
`For larger, heavier vehicles, such as heavy trucks and
`semis, however, motor vehicle regulations in the United
`States and elsewhere require that exterior mirrors be spaced
`apart on the vehicle cab or tractor by at least 102 inches or
`more. As a result, to provide such wide spacing, the exterior
`mirrors on opposite sides of the truck cab or tractor are
`normally mounted on long support arms which creates a
`greater force moment acting on the rearview mirror at the
`end of the arms. A typical mounting is to the door of the
`truck cab which, in most cases, is not reinforced. Together
`with the fact that heavy truck suspensions are usually much
`stiffer and less resilient than those in automobiles and light
`trucks, the larger force moment and lack of reinforcement in
`the support areas on which the long truck mirror support
`arms are mounted creates significantly greater vibration
`during driving and use than in automobiles, light trucks and
`other smaller passenger-type vehicles.
`In view of the greater vibration encountered with exterior
`rearview mirrors in larger vehicles, such as heavy trucks and
`semis, many prior known rearview mirror assemblies have
`proven to allow unsatisfactory levels of vibration. For
`example, many prior known exterior truckmirror assemblies
`have insufficient structural rigidity to resist vibration, or
`were constructed with centers of gravity displaced from the
`axis of support tending to accentuate any encountered vibra
`tion and road shocks. In addition, many current truck mirror
`assemblies have tended to be heavy which further accentu
`ates the vibration encountered in heavy trucks. In addition,
`many of the prior known rearview mirror assemblies have
`incorporated non-aerodynamic designs in which the reflec
`tive mirror elements visible to the driver are mounted flush
`with the edge of the mirror housing. These designs suffered
`from severe wind buffeting and buildup of mist and dirt on
`the mirror viewing surface such that the driver's ability to
`view objects in the mirror was significantly reduced. When
`55
`coupled with the increased vibration present in such
`assemblies, overall visibility with such mirror assemblies
`was inadequate.
`The present exterior rearview mirror assembly was con
`ceived in recognition of the above and related problems and
`is adapted to improve visibility with and operation of such
`mirrors.
`
`30
`
`2
`vans, recreational vehicles and the like, including those
`vehicles subject to specific regulations with regard to wide
`spacing and positioning of exterior rearview mirrors.
`The exterior rearview mirror assembly of the present
`invention provides a support with improved linear and
`torsional stiffness and rigidity as well as improved position
`ing of the center of gravity whereby vibration and conse
`quent image blurring in the mirror is reduced. In addition,
`the mirror provides reduced mass and weight. Further, the
`assembly has an increased natural frequency which prevents
`resonance in normal vehicle operating ranges to help stabi
`lize the mirror. The reduced weight and vibration also
`reduces stress on any mirror arms or supports which attach
`the mirror assembly to the vehicle.
`In one form, the invention is an exterior rearview mirror
`assembly for vehicles, such as trucks, comprising at least
`one reflective mirror element, an elongated support bracket,
`and a mirror mount securing the mirror element to the
`support bracket to locate the mirror element in a viewing
`position. A mirror housing is secured to the support bracket
`and shields the support bracket, mirror mount and mirror
`element, the housing having first and second end walls, first
`and second side walls, a rear wall, and a peripheral rim
`defining an interior space within the housing and an opening
`adjacent the mirror element. The support bracket spans the
`interior space of the housing from a position adjacent the
`first end to a position adjacent the second end and is also
`spaced from the side walls and rear wall of the housing. The
`support bracket includes spaced, elongated support members
`and at least one brace extending between the support mem
`bers such that the assembly has reduced weight and vibra
`tion and improved stability.
`Various embodiments of the exterior rearview minor
`assembly may include a single, planar reflective mirror
`element preferably adjustably mounted on the support
`bracket to allow movement to various viewing positions. In
`a preferred embodiment, the mirror mount is an electric
`actuator which is controllable from a remote location, such
`as the truck cab, by a driver or passenger in the vehicle, to
`change the mirror element viewing position. The mirror
`element together with a support plate are releasably secured
`to the actuator at the center of gravity of the mirror element
`by a rotatable, bayonet mounting and latch assembly. Thus,
`the mirror element is easily field replaceable for service and
`repair, which also allows access to the actuator for service or
`replacement. Preferably, each end of the support bracket
`includes amounting stud which extends through the housing
`for attachment to a suitable support arm or arms mounted on
`the vehicle. The mounting studs are preferably aligned on a
`common axis to allow fixed positioning or pivotal move
`ment of the entire assembly, depending on the type of
`support arms used.
`The support bracket of the present invention preferably
`includes a plurality of braces extending between the support
`members, which braces are spaced from one another and
`define openings therebetween. Preferably, a series of pairs of
`such braces are provided with the braces in each pair
`intersecting in an X-shaped pattern. Additional braces may
`optionally extend between the points of intersection. The
`support bracket provides increased torsional and linear stiff
`ness and rigidity to reduce vibration in the overall mirror
`assembly, and is also curved to position the center of gravity
`of the assembly as close as possible to the support axis.
`In yet another modified form of the support bracket, a wall
`is provided along the side of the support bracket which faces
`the mirror element to further reduce vibration by increasing
`the natural frequency as well as the stiffness and rigidity of
`the bracket.
`
`35
`
`45
`
`50
`
`SUMMARY OF THE INVENTION
`Accordingly, the present invention provides an improved,
`exterior rearview mirror assembly for vehicles, and espe
`cially larger transport vehicles, such as heavy trucks, semis.
`
`65
`
`SMR USA
`Exhibit 1034
`Page 011
`
`

`

`3
`In other features of the invention, a pair of reflective
`mirror elements is provided in the assembly, each mirror
`element preferably mounted at spaced locations on the
`support bracket. These mirror elements may be either planar
`or convex. The mirror mounts preferably allow adjustment
`of the viewing position of each mirror element and are
`preferably electrically operated actuators to allow position
`ing of each mirror element from a remote location, such as
`the cab of the vehicle.
`In yet other embodiments of the invention, the mirror
`element may be an electro-optic mirror element adapted to
`reduce the amount of reflected light when an electrical
`voltage is applied to the element. Preferably, such element is
`an electrochromic mirror element. In addition, any of the
`reflective mirror elements may be provided with electrical
`resistance-type heating pads to melt ice and snow which
`may collect on the viewing surface.
`Further, in the preferred embodiments of the invention.
`the reflective mirror elements are recessed within the mirror
`housing from the plane defined by the peripheral rim sur
`rounding the viewing opening of the housing. Such recessed
`positioning reduces wind buffering and creates an area of
`low air turbulence adjacent the mirror surface to prevent
`mist and dirt from collecting on the mirror.
`Accordingly, the present invention provides an exterior
`rear view mirror assembly for vehicles including trucks, vans
`and the like, which has reduced vibration, increased stability
`and reduced weight to provide clearer viewing images for
`the vehicle driver. The assembly includes a unique support
`bracket which spans the interior of the mirror housing and
`supports the mirror elements on adjustable mounts, the
`support bracket being spaced from the housing walls and
`having support members and interconnecting braces and an
`optional stiffness improving wall to increase torsional and
`linear rigidity, and the natural frequency of the support
`bracket. In addition, the bracket positions the center of
`gravity of the mirror and mirror mounts as closely as
`possible to the axis of support of the assembly to further
`reduce vibrations. Mirror wobble is also reduced by center
`ing the mirror element center of gravity on each actuator.
`The mirror assembly provides several variations to match
`the features desired by the vehicle driver including one or
`two mirror elements, electrical actuation of each mirror
`element from a remote location, planar or convex viewing
`surfaces, an electro-optic mirror element for reduced glare,
`heating elements to prevent ice and snow buildup, and an
`aerodynamic housing design to reduce the buildup of mist
`and dirt on the viewing surface.
`These and other objects, advantages, purposes and fea
`tures 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 a first embodiment
`of the exterior rearview mirror assembly of the present
`invention having portions of the mirror element broken
`away to reveal the heating element and internal support
`structure;
`FIG. 2 is a front elevation of the mirror assembly of FIG.
`1. having portions of the mirror element and portions of the
`mirror housing broken away to reveal the support structure;
`FIG. 3 is a partially sectional. side elevation of the mirror
`assembly of FIGS. 1 and 2 taken along plane III-III of FIG.
`2;
`FIG. 4 is a sectional, plan view of the rearview mirror
`assembly of FIGS. 1-3 taken along plane IV-IV of FIG. 2;
`
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`4
`FIG. 5 is a side elevation of the support bracket of the
`mirror assembly of FIGS. 1-4;
`FIG. 6 is a front elevation of the support bracket of the
`FIG. 5;
`FIG. 7 is an enlarged. sectional, side elevation of area VII
`of FIG. 3;
`FIG. 8 is a fragmentary, perspective view of the center
`section of the support bracket of FIGS. 5 and 6;
`FIG. 9 is a fragmentary, rear elevation of the mirror
`element support plate and releasable mounting assembly
`thereon for securing the mirror element and mirror element
`support plate to the mirror mountfactuator;
`FIG. 10 is a fragmentary, exploded, perspective view of
`the releasable mounting assembly of FIG. 9;
`FIG. 11 is a front elevation with portions of the mirror
`element broken away of a second embodiment of the exte
`rior rearview mirror assembly of the present invention;
`FIG. 12 is a partially sectional, side elevation of the
`rearview mirror assembly of FIG. 11 taken along plane
`XI-XII of FIG. 11;
`FIG. 13 is an exploded, front perspective view of the
`modified support bracket and electric actuator of the rear
`view mirror assembly of FIGS. 11 and 12;
`FIG. 14 is a rear perspective view of the modified support
`bracket and mirror actuator of FIG. 13;
`FIG. 15 is a fragmentary, exploded, perspective view of a
`modified form of the releasable mounting assembly for
`releasably securing the reflective mirror element to the
`actuator of FIGS. 11-14;
`FIG. 16 is a front perspective view of a third embodiment
`of the exterior rearview mirror assembly of the present
`invention;
`FIG. 17 is a front elevation with portions broken away of
`the rearview mirror assembly of FIG. 16;
`FIG. 18 is a sectional side elevation of the rearview
`mirror assembly of FIG. 17 taken along plane XVIII-XVIII
`of FIG, 17;
`FIG. 19 is an exploded, front perspective view of the
`modified support bracket and mirror actuators for the rear
`view mirror assembly of FIGS. 17 and 18;
`FIG. 20 is a rear perspective view of the support bracket
`and actuators of FIG. 19; and
`FIG. 21 is an enlarged, side sectional view of the mirror
`element and support plate of area XXI-XXI of FIG. 18.
`DESCRIPTION OF THE PREFERRED
`EMBODMENTS
`Referring now to the drawings in greater detail, FIGS.
`1-10 illustrate a first embodiment 10 of the exterior rearview
`mirror assembly of the present invention which is especially
`adapted for use on large vehicles, such as heavy trucks, vans,
`recreational vehicles and the like. Assembly 10 includes a
`reflective mirror element 12, resistive heating element 14
`applied to the rear surface of mirror element 12, mirror
`mount/actuator 16, support bracket 18, and a one-piece,
`aerodynamically designed housing or shell 20 supported by
`bracket 18. As shown in FGS. 3 and 4 mirror mount 16 is
`adapted to provide adjustable movement of mirror element
`12 to various viewing positions abouthorizontal and vertical
`adjustment axes, preferably by remote control from the
`vehicle cab or passenger compartment when the actuator is
`electrically operated. Support bracket 18 spans the interior
`space of the mirror housing from adjacent one end to
`adjacent the opposite end and supportsmountfactuator 16 to
`
`SMR USA
`Exhibit 1034
`Page 012
`
`

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`5,721,646
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`10
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`15
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`25
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`30
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`35
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`5
`reduce vibration and weight and increase stability of the
`overall assembly, as will be more fully explained below.
`As shown in FIGS. 1-4, mirror element 12 is a rectangular
`sheet or panel of glass having rounded comers, preferably
`having a thickness of 0.063-0.125 inches. A reflective
`coating 22 of a conventional chrome alloy or other metals or
`materials is applied by conventional coating methods to the
`front or first surface of mirror element 12, preferably pro
`viding reflection of at least about 55 percent of the light
`incident thereon. A resistive heating element or pad 14
`having a rectangular configuration is preferably adhered to
`the rear surface of mirror element 12 with a suitable adhe
`sive or tape. Preferably, heater pad 14 is an electrical
`resistance type element having a grid pattern of conductive
`ink applied to a mylar carrier substrate and is available from
`ITW Chronomatic of Chicago, Ill. When electrical voltage is
`applied by means of wires connected to the heater element
`and a power source in the vehicle, heater pad 14 provides
`increased temperature which is conducted through the mir
`ror element 12 to meltice or snow which may have collected
`on the first or exposed surface of the mirror element.
`Mirror element 12 and heating element 14 are preferably
`supported and adhered to a generally planar mirror element
`support plate or member 24, best seen in FIGS. 3, 4, 9 and
`10. Support plate 24 is preferably injection molded from a
`resinous plastic, such as 30% glass filled nylon, and has a
`rectangular shape corresponding to the shape of mirror
`element 12. Plate 24 includes a rear wall 26 and an out
`wardly extending peripheral side edge or rim 28 which
`defines a forwardly facing recess in which mirror element 12
`is preferably secured by an adhesive, double-faced tape, or
`the like. One or more holes 29 (FIG.9) in rear wall 26 allow
`connection of wires to heater pad 14 as described below. As
`explained more fully hereinafter, a releasable, bayonet-type
`mirror mounting assembly 91 is molded on the rear wall 26
`of support plate 24 such that the subassembly of the mirror
`element 12, heaterpad 14 and support plate 24 can be easily
`secured or removed as a unit from mirror mount/actuator 16.
`Preferably, support plate 24 also includes raised, molded,
`radially extending fibs 30.
`Mirror mount 16 is preferably an electrically-operated,
`adjustable mounting assembly or actuator of the type sold
`under Model No. 530 by IKU USA, Inc. of Three Rivers,
`Mich. Electrical actuator 16 is of the type disclosed in U.S.
`Pat. Nos. 4,101,206 and/or 4,116,538, the disclosures of
`which are hereby incorporated by reference herein.
`Alternately, actuator 16 could be of the type disclosed in
`U.S. Pat. No. 4281,899, the disclosure of which is also
`incorporated by referenced herein. Actuator 16 provides
`adjustment of the supported mirror element about two
`perpendicular axes, namely, a horizontal and vertical axis,
`for example, and includes a pair of electric motors 16a, 16b
`and rack and pinion gearing for movement of an actuator
`member to which support plate 24 is connected. Of course,
`other suitable electrically operated or manually operated
`adjustable mirror mounts could be used to support the mirror
`element 12, any heater pad 14 and support plate 24 on
`support bracket 18, as desired. As is shown in FIG. 3,
`actuator 16 is connected to a source of electrical power in the
`vehicle by means of a power cord 32 including a wire
`harness having wires 34 which extend through a strain relief
`grommet 36 and include releasable blade-type connectors 38
`enabling the actuator to be easily disconnected for repair or
`replacement. Optionally, a manually adjustable, pivotal mir
`ror mount may be substituted for actuator 16.
`Mirror support bracket 18 is an elongated, truss-type
`bracket, preferably sand or die cast from a lightweight metal
`
`6
`or metal alloy, such as 319, 356 or 380 aluminum alloy or
`magnesium, and electrostatically powder painted to provide
`increased stiffness and rigidity with reduced weight. Bracket
`18 includes elongated, generally parallel side members 40
`which extend the entire length of the bracket and curve into
`forwardly extending ends 42. Support members 40 are
`interconnected by a series of braces 44 which, in the
`preferred embodiment, form an X pattern which extends
`along the length of the bracket. Thus, braces 44 are formed
`in pairs 44a, 44b, 44c., 44d, 44e and 44fin which the braces
`intersect one another as well as joining the side members and
`define openings 46therebetween. If desired, additional brace
`members 48 may be provided between the points of inter
`section of braces 44 such that they extend along the elon
`gated axis of bracket 16 across the openings 46 between the
`points of intersection of braces 44. Braces 48 generally
`extend parallel to support members 40. If desired, additional
`cross braces 50 may be positioned to extend generally
`perpendicular to support members 40 and to intersect braces
`48. At the approximate center of bracket 16 is a series of
`three upstanding securing posts 52 interconnected by walls
`54. Posts 52 receive securing screws 56 which extend
`through actuator 16 to fasten the actuator to the support
`bracket (FIG. 2).
`At opposite ends of bracket 18 are ends flanges 42 which
`extend toward the mirror element 12 from support members
`40. End flanges 42 are supported by pairs of triangularly
`shaped gussets 58 and include outwardly extending molded,
`annular bosses or projections 60, each having a tapered
`aperture 62 therethrough for receipt of a mounting post or
`stud 64 (FIG. 7).
`As shown in FIGS. 3 and 5, support members 40 and
`braces 48 each are generally planar and lie in planes which
`are substantially parallel to one another. The center section
`of left support member 40 is recessed at 41 and 43 to provide
`clearance for portions of actuator 16 and to provide access
`for wiring leading to the actuator. In addition, the height of
`each of the support members 40 and braces 44, 48 and 50 is
`increased in the center section of the support bracket to
`include a dimension A which is larger than the dimension B
`of the same members adjacent the ends of the bracket. This
`provides a greater bending moment and stiffness and, thus,
`greater resistance to bowing in and out and vibration,
`especially in the area where actuator 16 is supported.
`As constructed, support bracket 18 reduces vibration of
`the reflective minor element 12 due to the orientation of the
`X pattern braces 44a-44f, which orientation reduces both
`linear and torsional vibration. The additional braces 48, 50
`and the dimensions of both the support members and braces,
`as explained above, coupled with the openings between the
`braces provide increased stiffness and rigidity and reduced
`weight and mass for the bracket over prior known mirror
`supports, as well as an increased the natural frequency for
`the mirror support bracket. Through the use of lightweight
`sand or die cast metal alloys, such as aluminum or
`magnesium, the mass to stiffness ratio is reduced. Further.
`the curved configuration of the support bracket having ends
`which curve forwardly to provide a support axis extending
`through fastener posts 64, together with the support of the
`actuator 16 and mirror elements 12 on the side of the support
`bracket toward the mirror element substantially aligns the
`center of gravity of these elements with the pivot axis of the
`mirror assembly. Coupled with the use of thinner glass for
`the mirror element these features provide reduced vibration
`in the mirror assembly as well as avoidance of resonance
`when the assembly is mounted on appropriate support arms
`or brackets on the truck or other vehicle.
`
`45
`
`55
`
`65
`
`SMR USA
`Exhibit 1034
`Page 013
`
`

`

`7
`As is best seen in FIGS. 2, 3, 4 and 7, mirror housing 20
`is a relatively thin, one piece shell including a rear wall 70,
`opposing and top and bottom end walls 72,74 and opposing
`side walls 76.78. The end and side walls define a peripheral
`rim 80 lying in a defined plane, rim 80 being preferably
`covered with an extruded, resinous plastic edge trim 81
`which can include a desired color to match the housing.
`Optionally, trim81 may include a chrome coated mylar film.
`Preferably, housing 20 is vacuum formed from plateable
`grade ABS sheet plastic, is colored black or another desired
`color, or may be covered with a chrome layer. Each end 72,
`74 includes a through aperture 82, 84 (FIG. 7) into which
`boss 60 on the outer surface of the end flange of bracket 18
`projects. Thus, when a cortically headed, threaded screw 64
`is passed through each aperture 62 in the bracket, fastener
`posts or studs are provided which extend through apertures
`82.84 on a common axis generally parallel to the plane of
`rim 80 to provide a mounting or pivot axis for the entire
`assembly. Housing 20 is then secured on opposite sides of
`aperture 62 to end flanges 42 by means of a pair of screws
`86 at either end. These are the only connections of the
`housing to the support bracket. Housing 20 does not provide
`any structural support for the mirror actuator 16 or mirror
`element 12. Housing 20 is also preferably rounded as shown
`to include a smooth, aerodynamic shape, and shields the
`support bracket, actuator and mirror element from wind and
`weather. In addition, peripheral rim 80 extends beyond the
`viewing surface of mirror element 12 such that the mirror
`element is recessed toward rear wall 70 of the housing a
`distance sufficient to reduce wind buffeting from the vehicle
`to which the mirror is mounted and to create an area of low
`turbulence on the mirror surface which not only reduces the
`amount of wind buffering but also prevents mist and dirt
`from collecting on the mirror surface to thereby improve
`viewing in the mirror. With fastening posts 64 projecting
`through the housing 20 as shown, mirror assembly 10 may
`be mounted on suitable support arms extending outwardly
`from a vehicle, such as a truck cab, in a fixed position or for
`pivotal movement about the axis of posts 64 to rotate the
`entire assembly toward or away from the vehicle cab as
`desired and as specified by the support arm manufacturer.
`Spacer nuts and lock washers 88 may be provided on each
`post 64 for spacing the support arms or brackets away from
`the mirror housing.
`As shown in FIGS. 9 and 10, the releasable mounting
`assembly 90 for securing mirror element 12 and support
`plate 24 to the actuator 16 includes an upstanding, annular
`wall 91 substantially centered on the center of gravity of
`mirror element 12 and support plate 24 on rear wall 26.
`Extending radially outwardly from the outside surface of
`annular wall 91 at six equally spaced positions are hollow
`mounting projections 92 on the outside surface of wall 91
`each including a curved, T-shaped slot 94 in the top surface
`thereof. At four equally spaced positions intermediate
`mounting projections 92 are mounting posts 96 which
`include cylindrical projections adapted to receive mounting
`feet on the actuator 16. Also included on rear wall 26 of
`support plate 24 are a pair of upstanding retaining latch
`members 98, 100. Latch member 100 is cantilevered to
`provide a spring action. Each latch member defines a point
`or apex adapted to mate with a handle on rotatable retaining
`ring 102 as explained hereinafter.
`Mating with the T-shaped curved slots 94 in retaining
`projections 92 is an annular ba