Electric folding actuator for external mirrors

Abstract

An exterior rearview mirror assembly includes an electric folding actuator and a mirror head. The electric folding actuator includes an electrically operated motor that rotatably drives a pinion gear that is engaged with an output gear to pivot a housing portion relative to the output gear and a pivot post. The electric folding actuator includes a base that is fixed relative to the pivot post and a mounting arm, a first pinion gear, the housing portion, a lift element that is non-rotatably disposed at the base, and a spring element that urges the first pinion gear toward the base. The spring element acts on the base through the output gear and the housing portion when the mirror head is in a drive position. During electrically powered pivoting of the housing portion relative to the pivot post, the spring element acts on the base through the output gear and not through the housing portion or the lift element.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application 63 / 201,317, filed April 23, 2021, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This invention generally relates to the field of exterior rearview mirror assemblies for vehicles, and more particularly to the field of electrically folding exterior rearview mirror assemblies. Background Technology

[0004] A vehicle exterior rearview mirror assembly is known to include a foldable mirror assembly, such as an electrically folding mirror, wherein the lens portion is pivotable between a driving or use position and a folded or stored position via an actuator. Summary of the Invention

[0005] A rearview mirror assembly (e.g., an exterior rearview mirror assembly mounted on the side of a vehicle equipped with it) includes an electrically folding actuator system to pivot the lens portion of the mirror assembly between a driving or use position and a folded or stored position in response to user input. During operation of the electrically folding actuator, the actuator is used to lift the lens portion relative to a mounting base or arm (in the vehicle) such that reduced force and reduced friction are present at the dividing line seal between the lens portion and the mounting arm. The actuator includes a lifting element that limits rotation of an output gear relative to the base during electrically pivoting of the lens portion relative to the pivot column. The actuator is configured such that when the lens portion is in the driving position, a spring load is transmitted to the base via the output gear and a lower housing portion, and when the lens portion is electrically pivoted by operation of the actuator motor, the spring load is transmitted directly to the base via the output gear. During such electrically pivoting of the housing portion relative to the pivot column, in all dwelling positions of the lens portion relative to the base, the spring load is not transmitted through the housing portion or the lifting element. The actuator includes a flexible or resilient element that extends radially outward from the output gear to engage a wing at the housing portion, thereby limiting the rotation of the output gear relative to the housing portion in one direction.

[0006] One aspect of this disclosure provides a vehicle exterior rearview mirror assembly comprising: (i) a mounting arm having a first end configured to be attached to a side of a vehicle and a second end remote from the first end; (ii) a lens portion pivotally mounted to the second end of the mounting arm, wherein the lens portion includes a lens housing and a reflective element; and (iii) an electrically folding actuator. The electrically folding actuator includes an electrically operated motor that, when electrically operated, pivots the lens portion relative to the mounting arm between at least a folded position and a driven position. The electrically folding actuator includes a pivoting assembly comprising a pivot column and a base fixed relative to the pivot column and relative to the mounting arm (wherein the pivot column extends upward from a distal region of the mounting arm and establishes a pivot axis for the lens portion). The base has a base stop or cam surface (such as a ramp externally connected to the pivot column at the base). The electrically folding actuator further includes an output gear externally connected to the pivot column and having a lower cam surface. The electrically folding actuator further includes a housing portion attached to the lens portion (such as the lower housing portion of the housing of the electrically folding actuator), externally connected to the pivot column and having an upper cam surface. The electrically folding actuator further includes a lifting element that receives the pivot column through it and has a receiving portion configured (when the lifting element is lifted together with the lower housing portion) to receive a lower cam of the output gear therein, thereby limiting rotation of the output gear about the pivot column. A spring element is arranged between the upper surface of the output gear and the upper end of the pivot column (such as located at a radial protrusion ring, which is received in a groove or slot at least partially surrounding the upper end region of the pivot column, or welded or otherwise fixed to the upper end region of the pivot column). The spring element applies a downward biasing force to push the output gear downward along the pivot column toward the base. An electrically operated motor is arranged in the housing section and is operable (when powered or electrically operated) to rotatably drive a gear (such as a worm gear or similar element fixed to the motor output shaft), which meshes with an output gear to pivot the housing section relative to the output gear and the pivot column (to cause the housing section and lens section to move or rotate or pivot about a pivot axis defined by the longitudinal axis of the pivot column). When the lens section is in the drive position, the spring load of the spring element is directed through the output gear and the housing section to the base to provide stability to the lens section in the drive position. That is, when the lens section is in the drive position, the spring element acts on the base through the output gear and the housing section. During the electric pivoting of the housing section relative to the pivot column (i.e., during the operation of the motor being electrically operated to pivot the lens section), the spring load is directly transmitted to the base through the output gear. During the electric pivoting of the housing section relative to the pivot column, the spring load is not transmitted through the housing section. During the electric pivoting of the housing section relative to the pivot column, the spring load is not transmitted through the lifting element. In other words, during the electric pivoting of the housing portion relative to the pivot column, the spring element acts on the base through the output gear, not through the housing portion or the lifting element.The vehicle exterior rearview mirror assembly may include one or more optional features described below.

[0007] Optionally, when the lens unit is in the drive position, the lower cam surface of the output gear can engage with the upper cam surface of the housing portion. With the lens unit in the drive position, the lower surface of the housing portion can nest with the stop surface of the base. Furthermore, when the electric folding actuator operates to pivot the lens unit from the drive position to the folding position, the output gear can rotate relative to the pivot column, and the lower cam surface of the output gear disengages from the upper cam surface of the housing portion and engages with the upper cam surface of the base. As the output gear rotates relative to the pivot column, the lower cam surface of the output gear can travel along the upper cam surface of the base, and the lower cam surface of the output gear can be separated from the upper cam surface of the lower housing and the lifting element. Additionally, the rotation of the output gear relative to the pivot column is stopped by a cam on the upper cam surface of the base. For example, when the lower cam surface of the output gear engages with the uppermost protrusion of the upper cam surface of the base, the rotation of the output gear relative to the pivot column can be stopped. Furthermore, with the output gear's rotation stopped, further operation of the motor can rotate the housing portion, causing the housing portion and lifting element to rise upwards towards the output gear, without the spring load being transmitted through the housing portion or the lifting element. Therefore, when the output gear disengages from the upper cam surface of the housing portion and engages with the upper cam surface of the base, the spring element switches from acting on the housing portion through the output gear to acting on the base through the output gear. In other words, the spring element acts on the base through the output gear, not through the housing portion or the lifting element.

[0008] Furthermore, as the housing portion and the lifting element rise towards the output gear, the receiving portion of the lifting element can at least partially receive the lower cam on the lower cam surface of the output gear to limit the rotation of the output gear. With the lower cam on the lower cam surface at least partially received in the receiving portion of the lifting element, the first portion of each lower cam can be received in the receiving portion, while the second portion of each lower cam can engage with the upper cam surface of the base. The receiving portion of the lifting element can only partially receive the lower cam on the lower cam surface, so that the spring element acts on the base and not on the lifting element. Additionally, as the lens portion moves from the folded position towards the drive position, the housing portion can move upward relative to the base to lift the lens portion relative to the mounting arm.

[0009] Optionally, as the lens portion moves from the drive position toward the folded position, the housing portion moves upward relative to the base to lift the lens portion relative to the mounting arm. Furthermore, as the housing portion moves upward relative to the base, the lifting element can move to engage with the output gear to limit the rotation of the output gear relative to the pivot column. Optionally, during manual pivoting of the housing portion relative to the pivot column, the output gear and the housing portion can pivot together and sequentially relative to the pivot column. Optionally, during manual pivoting of the housing portion relative to the pivot column, as the lower surface of the housing portion travels along the stop surface of the base, the housing portion can move upward relative to the base.

[0010] Optionally, the electric folding actuator may include a resilient element located at the upper end of the output gear, having radially projecting flaps for engaging with corresponding flaps at the housing portion to restrict rotation of the housing portion relative to the output gear, thereby keeping the motor in a stop position. The resilient element may be radially flexible to allow movement of the flaps of the resilient element to prevent the motor from dwelling in other positions separate from the respective stop positions.

[0011] Optionally, the lifting element can be non-rotatably arranged at the base and longitudinally movable along the base and pivot post. Optionally, the lifting element is externally connected to the pivot post and arranged radially inward of the upper cam surface of the housing portion. Furthermore, the lifting element may include a portion of the housing portion, wherein the lifting element is non-rotatable relative to the base, and the housing portion is rotatable relative to the lifting element, and wherein the lifting element is longitudinally movable along the base and pivot post based on the longitudinal movement of the housing portion.

[0012] Optionally, the lower cam surface of the output gear may include one or more cams radially disposed along the lower surface of the output gear, wherein each of the one or more cams on the lower cam surface of the output gear includes: (i) an inner portion configured to engage with a receiving portion of the lifting element, and (ii) an outer portion located radially outward of the inner portion and configured to engage with an upper cam surface of the housing portion. Additionally, the inner portion of the one or more cams on the lower cam surface of the output gear is further configured to engage with a base cam surface of the base.

[0013] Optionally, the lifting element may include a lower cam surface configured to engage with a corresponding cam surface of the housing portion. The corresponding cam surface of the housing portion is located on the inner surface of the housing portion and is radially inward of the upper cam surface of the housing portion.

[0014] Optionally, the lens assembly can be pivotally mounted at the second end of the mounting arm. Optionally, when the lens assembly is in the drive position, the spring load of the spring element is transmitted to the base via the first gear and the housing portion. Furthermore, during electric pivoting of the housing portion relative to the pivot column, the spring load can be directly transmitted to the base via the first gear. Alternatively, during electric pivoting of the housing portion relative to the pivot column, the spring load may not be transmitted through the housing portion, and the spring load may not be transmitted through the lifting element.

[0015] These and other objectives, advantages, objects, and features of the present invention will become clearer when the following description is read in conjunction with the accompanying drawings. Attached Figure Description

[0016] Figure 1 It is a perspective view of an exterior rearview mirror assembly with an electrically folding actuator;

[0017] Figure 2 This is a top view of the exterior rearview mirror assembly, with the lens section pivoted to the driving or usage position;

[0018] Figure 3 This is a top view of the exterior rearview mirror assembly, with the lens section pivoted in a folded or non-use position;

[0019] Figure 4 This is a perspective view of the actuator of the exterior rearview mirror assembly;

[0020] Figure 5 yes Figure 4 Side view of the actuator in the middle;

[0021] Figure 6 and 7 yes Figure 4 Exploded perspective view of the actuator in the image;

[0022] Figure 8 yes Figure 4 Top view of the actuator in the middle;

[0023] Figure 9 This is a perspective view of the lower housing portion of the actuator;

[0024] Figures 10-12 This is a view of the actuator when the lens of the exterior rearview mirror assembly is in the driving position;

[0025] Figure 13 This is an enlarged view of the actuator, showing the engagement between the cam of the lower housing portion and the lower cam of the lower cam plate of the output gear when the lens portion of the external rearview mirror assembly is in the drive position.

[0026] Figure 14 and 15 This is a view of the actuator in a transitional phase during the electric pivoting of the lens section;

[0027] Figure 16 This is a view of the actuator when the lens of the external rearview mirror assembly is in the storage position;

[0028] Figure 17 and 18 These are the output gear and lower cam plate of the actuator;

[0029] Figure 19 This is a perspective view of the lower housing portion, lifting element, and base of another actuator;

[0030] Figure 20 yes Figure 19 A perspective view of the lifting element in the middle; and

[0031] Figure 21 yes Figure 19 A perspective view of the lower shell portion of the structure. Detailed Implementation

[0032] Referring now to the accompanying drawings and the exemplary embodiments depicted therein, the exterior rearview mirror assembly 10 for vehicle 11 includes a lens portion 12, the lens portion 12 including a mirror reflector element 14, the mirror reflector element 14 being received in and / or supported at or by the mirror housing or cover 16 of the lens portion 12. Figure 1 The lens assembly 12 includes a mounting portion 12a that is pivotally or movably mounted to a mounting arm or base or portion 18. The mirror assembly 10 includes a motor-folding mirror (where the lens assembly can be pivoted via an actuator assembly or adjustment device) and may include a detachable mirror (where the lens assembly can be manually pivoted about the mounting arm or base). The mounting arm or base 18 of the mirror assembly 10 is mounted at a side 11a of the main vehicle or subject vehicle 11, wherein the reflective element 14 provides the driver of the vehicle with a rearward field of view along the respective side of the vehicle, as discussed below. The mounting arm 18 has a first end 18a configured to be attached to the side 11a of the vehicle 11 and a second end 18b away from the first end 18a. The lens assembly 12 is pivotally mounted via the mounting portion 12a of the lens assembly 12 to the second end 18b of the mounting arm 18. The lens assembly 12 includes a mirror housing 16 and a mirror reflective element 14.

[0033] The mirror assembly includes a motorized folding mirror assembly, which includes an actuator 20 operable to pivot the lens portion 12 (including the mirror housing 16 and the reflective element 14) relative to a mounting arm or base 18. In response to user input, the actuator operates to pivot the lens portion 12 between a plurality of stop positions, including a use or drive position. Figure 2 ) and folding or storage location ( Figure 3 In the use or driving position, the lens portion 12 extends relative to the vehicle side and mounting arm 18 to provide a view to the driver rearward and along the corresponding side of the vehicle. In the folded or stored position, the lens portion 12 is folded and pivots inward relative to the mounting arm 18 from the extended position to be arranged along the vehicle side. The electric folding actuator 20 includes an electrically operated motor, and when the electric folding actuator is operated, the electric motor is electrically operated to pivot to pivot the lens portion relative to the mounting arm between at least the folded position and the driving position. The lens portion can also be manually pivoted to either the use position or the folded position. Optionally, the lens portion can also be pivoted to a fully forward position, wherein the lens portion 12 is pivoted or rotated beyond the driving position. A seal may be arranged along the junction between the mounting portion 12a of the lens portion 12 and the mounting arm or base 18. The actuator and mirror assembly may employ features of various aspects of the actuator and mirror assembly described in the following documents: U.S. Patent Nos. 11,173,843; 9,487,142; 9,067,541 and / or 7,887,202, and / or U.S. Patent Publication No. US-2021-0261053, and / or U.S. Patent Application Serial No. 17 / 452,414, filed October 27, 2021 (Attorney Docket No. DON09P4313), the entire contents of all of these documents are incorporated herein by reference.

[0034] As shown in Figures 4-8The lens actuator 20 includes a pivot assembly 21 having a base column structure having a pivot tube or column 22 and a base or stop 24 (which may be separate elements, combined together, or integrated into a single element), wherein the pivot column 22 provides or defines a pivot axis for the lens portion 12. The column 22 is fixedly attached to a mounting arm 18, and thus the base 24, fixed relative to the pivot column 22, is fixed relative to the mounting arm 18. The column 22 extends from the base stop 24 and passes through a lower housing or bracket 26, a lifting element 28, and an output gear 30. The actuator housing or lower housing or bracket 26 is rotatably arranged on the column 22 and houses the motor 32, and is non-rotatably arranged or attached to the lens portion 12. In other words, the lower housing 26 is rotatable about the pivot axis of the pivot column 22, and the lens portion 12 can be fixed to the lower housing 26 so that the lens portion 12 can pivot about the pivot column 22 based on the movement of the lower housing 26. The column 22 extends from the base 24 and passes through the lower housing 26, the lifting element 28, and the output gear 30, and through the upper resilient element 34, and has a retaining ring or locking ring 36 fixed to its upper end (thereby the retaining ring 36 can be received in a groove on the tube or column 22). The upper housing portion 38 is attached to the lower housing 26 and surrounds the base column 22, the motor 32, the stop, and the gear. The retaining ring 36 is rigidly fastened to the column 22, such that the retaining ring 36, the column 22, and the base 24 are practically equivalent to a single piece or element, and provide a ground reference for all movements and forces in the axial and rotational directions. The lifting element 28 is non-rotatably connected to the base 24 and the column 22 by a key. A resilient element 34 is arranged on the upper portion of the output gear 30 and configured to engage with the lower housing to facilitate motor parking. A spring or spring element 40 is arranged between the retaining ring 36 and the output gear 30 to push the output gear toward the base 24. The spring may engage a sliding washer 42 (e.g., a Teflon washer or the like) at the output gear to reduce friction between the spring end and the output gear.

[0035] Therefore, the pivot assembly 21 includes a pivot column 22 and a base 24 fixed relative to the pivot column and fixed relative to the mounting arm 18. The pivot assembly 21 further includes at least an output gear 30, a lower housing portion 26 attached to the lens portion 12, a lifting element 28 non-rotatably arranged at the base 24, and a spring element 40 arranged between the output gear 30 and the upper end of the pivot column 22. In the illustrated embodiment, the spring element 40 is rigidly received and fixed between a retaining ring 36 in a groove 22a formed along the upper end of the pivot column 22 and a sliding washer 42 at the output gear 30. The spring element 40 pushes the output gear 30 toward the base 24.

[0036] A motor 32 is disposed within the housing portion and actuated to rotatably drive a motor output gear 32a. The motor output gear 32a rotatably drives a main gear 33 of the housing, which meshes with the output gear 30 and rotates the lower housing 26 and upper housing 38 (collectively referred to as the housing) relative to the output gear about a pivot column 22 until engagement with a hard stop, thereby parking or stopping the motor, wherein the lens portion is limited to the extended or driven position by a stop. The actuator is configured such that the hard stop is provided in the appropriate position when the lens portion 12 is pivoted by the drive of the motor. A resilient element 34 of the actuator is used to stop the rotation of the output gear as it is engaged in the driven position. As the output gear begins to engage, the resilient element restricts or prevents further rotation of the housing relative to the gear and thus parking the motor. For example, the resilient element 34 may include one or more protrusions 34a radially distributed along the outer periphery of the resilient element and configured to engage with corresponding flaps or protrusions 38a disposed along the inner surface of the upper housing 38 when the lens section is pivoted to the drive or folded position. When the protrusions 34a of the resilient element 34 engage with the flaps 38a of the upper housing 38, the motor is engaged and stops operating. The positions of the protrusions 34a around the resilient element 34 and the positions of the flaps 38a around the upper housing 38 correspond to the drive and folded positions and the positioning of the stop in the drive and folded positions. Operating the motor to pivot the lens section in the drive and folded positions can be referred to as electric pivoting.

[0037] As shown in Figure 17 and Figure 18 The output gear 30 includes a lower cam element 31 attached to its lower end. The lower cam element 31 may include a separate component formed separately from and attached to the lower end of the output gear 30, or the output gear 30 and the lower cam element 31 may include integrally formed components. The lower cam element 31 is fixedly attached to the output gear 30 and includes a plurality of lower cams 31a projecting downward therefrom. The upper end of the output gear 30 includes a plurality of upper cams or protrusions 30a configured to engage with a resilient element 34, the resilient element 34 including radial protrusions 34a for contact with a flap 38a on the inner surface of the upper housing portion 38 (see [link]). Figure 7 The output gear 30 and the resilient element 34 may utilize the features of various aspects of the gears and elements and actuators described in the previously cited U.S. Patent Publication US-2021-0261053.

[0038] The lower cam 31a of the lower cam element 31 is configured to be at least partially received in a corresponding recess or receiving portion 28a located at the upper end of the lifting element 28, thereby limiting the rotation of the output gear 30 when the lifting element is lifted upward and the lower cam 31a is received in the recess 28a. The lifting element 28 rests in the lower housing 26, and the lower housing 26 is configured to lift or raise the lifting element 28 upward as the lower housing 26 is pivoted out of its stop (e.g., drive) position or state during the pivoting of the lens portion between the various stop positions. In other words, when the lens section 12 is pivoted between the driving and folded positions, the axial movement of the lower housing 26 along the pivot column 22 causes the lifting element 28 to move axially along the pivot column 22, and the lower cam 31a is received in the corresponding recess 28a of the lifting element 28 to prevent the pivoting or rotational movement of the output gear 30 by means of the fixed relationship between the output gear 30 and the lower cam element 31.

[0039] As shown in Figure 9 The lower inner surface of the lower housing includes a plurality of cams or protrusions 26a that project upward and are configured to engage with the lower cam 31a of the lower cam element 31 of the output gear 30. A lifting element 28 rests radially inward on the cam 26a, while the lower cam 31a spans the cam 24a of the base, the cam 26a of the lower housing 26, and the lifting element 28, such that they engage the cam 26a and can be received in the receiving portion 28a of the lifting element, as described later. That is, the cam 26a of the lower housing 26 is arranged radially toward the lower inner surface of the lower housing, and the lifting element 28 is arranged radially inward on the cam 26a of the lower housing, such that the cam 26a can engage with the lower cam 31a of the lower cam element 31 at a position outside the lifting element 28 (or around the outer peripheral edge). For example, the lifting element 28 can rest on the inner lower surface 26b of the lower housing, which is located inside the cam 26a and externally connected to an opening through the lower housing through which the pivot and base extend. The lower cam 31a is wide enough to engage the cam 26a of the lower housing 26 and be received in the receiving portion 28a of the lifting element 28. The cam 24a of the base 24 can extend along the pivot 22 through the center of the opening of the lifting element 28. That is, the lower cam surface of the output gear 30 includes one or more cams 31a, which include an inner portion configured to engage the receiving portion 28a of the lifting element 28 and an outer portion located radially outward of the inner portion and configured to engage the upper cam surface 26a of the lower housing 26. The inner portion of the cam 31a can also be configured to engage the cam 24a of the base 24. In addition, the inner side of the cam 31a may be partially received in the receiving portion 28a of the lifting element 28, so that when received in the receiving portion 28a, the cam 31a can remain engaged with the cam 24a of the base 24.

[0040] Optionally, the lifting element 28 can be integrated with or fixed relative to the lower housing 26. Since the lifting element 28 is axially movable along the pivot column based on the axial movement of the housing, it can form a non-rotatable portion of the lower inner surface of the lower housing 26. That is, the lifting element 28 can be formed together with the inner surface of the lower housing 26, while the rest of the lower housing is rotatable about the pivot column 22, which is rotatably fixed relative to the lifting element 28. Therefore, since the lifting element is externally connected to the pivot column and arranged radially inward of the upper cam surface of the lower housing, it can form part of the lower housing where the lifting element is non-rotatable relative to the base, the output gear, and the rest of the housing, while the rest of the housing is rotatable relative to the lifting element. Based on the longitudinal movement of the housing portion, the lifting element is longitudinally or axially movable along the base and the pivot column.

[0041] When the lens is in the driving position (see...) Figures 10-12 The lower cam 31a engages with the cam 26a of the lower housing 26, wherein the lower surface of the lower housing 26 engages with or is nested within the stop surface 24 of the base. (See also...) Figure 13 The upper cam 26a of the lower housing 26 protrudes upward above the upper surface of the lifting element 28, such that the lower cam 31a engages the upper cam 26a but not any part of the lifting element 28. Therefore, when in the drive position, the spring load is transmitted to the base 24 via the output gear 30, the lower cam plate 31, and the lower housing 26. The spring load does not pass through the lifting element 28, which rests against or on the lower housing portion when the lens is in the drive position, and is located below the lower cam 31a and lower cam plate of the output gear. In other words, when the lens is in the drive position, the spring element 40 acts on the base 24 via the output gear 30 and the lower housing 26. That is, when the lens is in the drive position, the lifting element does not engage with the output gear, and the output gear can rotate relative to the pivot column until the lifting element is lifted and engages with the lower cam 31a of the output gear during the electric pivoting of the lens and housing. In other words, when the lens is in the drive position, the spring load of the spring element (i.e., the force provided by the spring or biasing element acting on one or more parts of the actuator) is guided through the output gear (i.e., acting on the output gear through the engagement of the spring element with the output gear or the sliding washer at the output gear) and the lower housing (i.e., acting on the lower housing through the engagement of the output gear with the lower cam element and the cam engagement of the lower cam element with the lower housing) to the base (i.e., acting on the base through the engagement of the lower housing with the base at the pivot column). Guiding the limiting force of the spring element through the housing to the base increases the stability of the lens in the drive position.

[0042] During actuator operation, when motor 32 first operates to pivot the lens section from the drive position toward the storage position, the operation of motor 32 causes output gear 30 to rotate, displacing lower cam 31a from upper cam 26a, so that they subsequently engage cam 24a of base 24 (see...). Figure 14 In other words, the initial operation of the motor moves the lens section from the driven position to the folded position, causing the output gear to pivot about the pivot column 22 within the stationary housing until the lower cam 31a of the lower cam element 31 (which is rotatably fixed relative to the output gear 30) engages the cam of the base 24. As the output gear 30 rotates, the lower cam 31a switches from a state resting on the cam 26a of the lower housing 26 to a state moving along the cam 24a of the base 24. (See also...) Figure 14 and Figure 15 When the output gear rotates during this transition period, the lower cam 31a is positioned above the receiving portion 28a of the lifting element 28 and does not engage the lifting element 28. That is, the lower cam 31a is separated from the cam 26a of the lower housing 26 and the lifting element 28. Therefore, during this transition period, the spring force or spring load of the spring element 40 is guided directly to the base 24 through the output gear, and no spring load is applied to the lower housing or the lifting element, so that the spring element 40 acts on the base 24 through the output gear 30, but not through the lower housing or the lifting element. In other words, due to the engagement between the lower cam 31a and the cam 24a of the base 24 as the output gear 30 rotates and the separation of the lower cam 31a from the lifting element 28, the spring load from the spring element 40 is guided through the output gear 30 to the base 24. During the movement of the output gear 30, the spring load is not borne by the lifting element 28 or the lower housing 26. In other words, when the lower cam 31a at the output gear 30 disengages from the upper cam surface 26 of the lower housing and engages with the upper cam surface 24a of the base 24, the spring element 40 switches from acting on the lower housing 26 through the output gear 30 to acting on the base 24 through the output gear 30.

[0043] As the motor operates further, further rotation of the output gear 30 is stopped by the engagement between the lower cam 31a and the uppermost cam or protrusion 24b of the base 24, and the lower housing portion 26 rotates relative to the base 24. In other words, when the rotation of the output gear 30 is stopped by the engagement between the lower cam 31a and the uppermost cam 24b of the base 24, the operation of the motor 32 becomes to cause the housing to pivot or rotate about the output gear 30 and the pivot column 22. The main gear 33 travels about the output gear 30. Since no spring force acts on the lower housing 26, as the lower housing 26 rotates relative to the pivot column 22 and the base 24, the shape of the engaging or stopping surfaces between the lower housing 26 and the base 24 (see...) Figure 16The lower housing moves upward away from the stop or drive position and can be guided upward or disengaged from the stop position. The lifting element 28 rests along the inner lower surface of the lower housing 26 and thus rises along the pivot 22 with the lower housing 26 as the lower housing rotates relative to the pivot 22 and base 24. The housing and lifting element 28 thus move upward along the pivot 22 such that the lower cam 31a is received in the receiving portion 28a of the lifting element 28 to limit or prevent rotation of the output gear 30 during the pivoting of the lens section from the drive position to the storage position and then back to the drive position. In other words, when the lens section is pivoted from the drive position to the folded position, the lifting element 28 rises and engages with the lower cam 31a because the uppermost protrusion 24b of the base 24 prevents movement of the output gear, thus preventing movement of the output gear when the lens section is pivoted from the drive position to the folded position and when the lens section is pivoted from the folded position to the drive position. Although the lifting element 28 is used to limit the rotation of the output gear relative to the base and pivot column, the lifting element does not lift upward at the lower cam 31a, and a small clearance exists at the lower end of the lower cam and the lower end or bottom diameter of the receiving portion 28a of the lifting element 28, and the lower cam 31a rests on the cam of the base 24 (as can be seen in...). Figure 16 During the electric travel of the lower housing 26 around the output gear 30, the spring load path reaches the base 24 via the output gear 30 and the lower cam plate 31. Similarly, no spring load acts on the lower housing 26 or the lifting element during electric travel. In other words, the spring element does not act on the lower housing or the lifting element during electric travel. During the electric folding / unfolding of the lens section, the lifting element 28 restricts or prevents the rotation of the output gear 30. The receiving portion 28a of the lifting element 28 only partially receives the lower cam 31a, such that, through the partial reception of the lower cam 31a in the receiving portion 28a of the lifting element 28, the spring element acts on the base 24 and not on the lifting element 28.

[0044] Guiding the spring load to the non-rotating parts of the pivot assembly 21 during lens rotation reduces the torque on the pivot assembly, thereby increasing its lifespan and reducing the chance of jamming or failure. Guiding the spring load through the housing when the lens is in the driving position improves its stability in that position.

[0045] Therefore, as the housing and lens section are rotated toward the folded or stored position by the operation of the electrically operated motor, the housing is raised relative to the base while rotating, and this raising causes the lens section to rise and increases the gap between the lens section mounting portion 12a and the mounting arm 18, and thus reduces, limits or avoids pressure at the dividing line (the seal, which is arranged between the lens section mounting portion 12a and the mounting arm 18 and is located at the junction, and follows and fills the gap between the lens section and the base) during the pivoting movement of the lens section.

[0046] Therefore, the actuator provides controlled movement of the lens section 12 relative to the mounting arm 18, wherein when the lens section is in the drive position, the spring load is guided through the output gear 30 and the lower housing portion 26 to the base 24. Due to the spring load (i.e., the spring element acting on the base through the output gear and the lower housing), the lens section 12 is thus securely held in the drive position. During pivoting of the lens section 12 to the storage position, a cam is used to release the spring load from the housing, such that the spring element acts on the base through the output gear and not on the housing portion or the lifting element, allowing the housing to be lifted upwards to allow the lens section to pivot with reduced contact or no contact with the dividing line seal, and the lifting element 28 is used to maintain the output gear 30 rotatably engaged with the base 24, such that the output gear 30 does not rotate relative to the base 24 during the electrically pivoting movement of the lens section 12. Throughout the entire range of the electric folding / unfolding of the lens section 12, when the lens section 12 is in the drive position, the spring load never passes through the lifting element 28, but only through the lower housing portion.

[0047] The actuator thus electrically folds backward from the drive position to the storage position and electrically folds forward back to the drive position during normal operation of the motor 32, without requiring manual pivoting or folding of the lens section 12. During electric or electric folding from the drive position to the storage position, the output gear 30 rotates to move the lower cam 31a of the lower cam element 31 from engagement with the cam 26a of the lower housing portion 26 to engagement with the base 24. The spring load path changes or switches its path or direction from passing through the output gear 30 and the lower housing 26 to reach directly through the output gear 30 to the base 24. This allows the lower housing 26 and the lifting element 28 to be lifted or moved axially along the pivot column 22 without spring load. The lower housing straddles the lower stop ramp on the base 24 to provide, for example, a lift of 1.5 mm (or other amount of lift, depending on the specific application). The lower stop ramp is designed to allow the lower housing 26 and the base 24 to maintain constant surface contact when in contact.

[0048] Therefore, the base 24 includes a lower stop ramp, which is configured to guide the lower housing 26 (and thus the lens unit) vertically along the pivot column 22 when the lens unit is pivoted between the drive position and the folded position. When the motor 32 is initially powered to pivot the lens unit from the drive position to the folded position, and the motor 32 imparts rotational motion to the output gear 30 until further movement of the output gear 30 is blocked by the uppermost protrusion 24b of the base 24, the rotational motion caused by the operation of the motor 32 is applied to the housing, causing the lower housing 26 to pivot relative to the base 24 about the output gear 30 and the pivot column 22. As the lower housing 26 pivots relative to the base, the engagement between the outer lower surface of the housing and the lower stop ramp of the base 24 causes the lower housing 26 to follow the slope of the lower stop ramp and thus rise relative to the base 24 along the pivot column 22. In the normal electrically folded state, no spring load acts on the lower housing 26 when it is mounted on the lower stop ramp. This is because the lower cam of the output gear bounces off the base 24, which changes the path of the spring load to be applied directly to the base 24.

[0049] As the vehicle returns to the driving position, the lower housing 26 is forced to descend along a 1.5mm ramp by engaging the ramp feature of the cam 26a of the lower housing portion with the lower cam 31a of the lower cam element 31 at the output gear 30. In other words, as the lens portion pivots from the folded position to the driving position, the engagement between the lower cam 31a and the cam 26a of the lower housing 26 guides the engagement between the lower housing 26 and the lower stop ramp of the base 24, guiding the housing into the descending position in the driving position. When the lower housing 26 re-engages with or falls into engagement with the lower stop ramp of the base 24, the lifting element 28 descends along the pivot column and releases the lower cam 31a of the lower cam element 31. Once the lower housing 26 and the lifting element 28 have been lowered, further operation of the motor 32 causes the output gear 30 to rotate until the lower cam 31a of the lower cam element 31 at the output gear rides over the cam 26a of the lower housing portion 26. As a result, one or more protrusions 34a of the resilient element 34 engage adjacent stops on the inner surface of the upper housing 38, causing the motor to remain stationary.

[0050] Therefore, when the motor is engaged, the spring load is transmitted through the output gear 30 and through the lower housing 26 to the base 24. During the electric folding of the lens section, the spring load is transmitted directly to the base. In other words, the spring load is removed from or directed away from the lower housing 26 to allow the lower housing to rise along the pivot without resisting the spring load.

[0051] Therefore, the vehicle exterior rearview mirror assembly includes: (i) a mounting arm having a first end configured to be attached to a side of the vehicle and a second end remote from the first end; (ii) a lens portion pivotally mounted on the second end of the mounting arm, wherein the lens portion includes a mirror housing and a reflective element; and (iii) an electrically folding actuator. The electrically folding actuator includes an electrically operated motor that, when electrically operated, pivots the lens portion relative to the mounting arm between at least a folded position and a driven position. The electrically folding actuator includes a pivoting assembly comprising a pivot column and a base fixed relative to the pivot column and relative to the mounting arm (wherein the pivot column extends upward from a distal region of the mounting arm and establishes a pivot axis for the lens portion). The base has a base stop or cam surface (such as a ramp surface externally connected to the pivot column at the base). The electrically folding actuator further includes an output gear externally connected to the pivot column and having a lower cam surface. The electrically folding actuator further includes a housing portion (such as a lower housing portion of the housing of the electrically folding actuator) attached to a lens portion external to the pivot column and having an upper cam surface. The electrically folding actuator further includes a lifting element that receives the pivot column through it and has a receiving portion configured (when the lifting element is lifted together with the lower housing portion) to receive a lower cam of the output gear therein, thereby limiting rotation of the output gear about the pivot column. A spring element is arranged between the upper surface of the output gear and the upper end of the pivot column (such as at a radial extension ring, the radial extension ring being at least partially received in a groove or slot surrounding the upper end region of the pivot column, or welded or otherwise fixed to the upper end region of the pivot column). The spring element applies a downward biasing force to push the output gear downward along the pivot column toward the base.

[0052] An electrically operated motor is arranged in the housing section and is operable (when powered or operated) to rotatably drive a gear (such as a worm gear or the like fixed to the motor output shaft) that meshes with an output gear to pivot the housing section relative to the output gear and the pivot column (to cause the housing section and lens section to move, rotate, or pivot about a pivot axis defined by the longitudinal axis of the pivot column). When the lens section is in the drive position and the lower housing is in a lowered position along the pivot column, operation of the electrically operated motor can impart rotational movement of the output gear within the housing until the rotational movement of the output gear is stopped, such as by engagement between a lower cam element on the lower cam surface of the output gear and a cam element or protrusion of the base. Further operation of the motor imparts rotational movement of the housing about the output gear and the pivot column by engagement of the lower cam element of the output gear with the cam element of the base. As the lens section pivots from the folded position of the drive position, and as the housing section pivots about the output gear and the pivot column, the housing section and the lifting element are lifted or moved axially along the pivot column based on the engagement between the housing section and the stop surface of the base. When the housing portion and the lifting element are lifted, the lifting element receives the lower cam element of the output gear at its receiving portion, thereby preventing the output gear from rotating. Through the engagement of the lifting element with the lower cam element of the output gear, the lower housing pivots about the pivot column, and the output gear and the lifting element are either rotationally fixed or stationary.

[0053] With the lens section in the drive position, the spring load of the spring element is guided through the output gear and housing section to the base to provide stability to the lens section in the drive position. During the electric pivoting of the housing section relative to the pivot column (i.e., when the electric operating motor operates to pivot the lens section), the spring load reaches the base directly through the output gear. During the electric pivoting of the housing section relative to the pivot column, the spring load is not transmitted through the housing section. During the electric pivoting of the housing section relative to the pivot column, the spring load is not transmitted through the lifting element. In other words, during the electric pivoting of the housing section, the spring load is removed or guided away from the lower housing and lifting element. This allows the lower housing and lifting element to be lifted or moved axially along the pivot column without resistance or lifting against the spring load, thereby reducing the load on the electric motor and the wear on the lower housing and lifting element.

[0054] When the lens section is manually pivoted (e.g., from the drive position to the storage position or vice versa), the output gear and housing section pivot together and sequentially relative to the pivot tube and the base. When the lens section is manually pivoted, the housing section moves upward relative to the base along the surface of the lower stop surface of the base, providing clearance between the lens section and the mounting arm to reduce or eliminate compression of the dividing line seal during such pivoting motion.

[0055] The electrically operated folding actuator further includes a resilient element externally connected to a portion of the output gear (such as the upper portion of the output gear). The resilient element has outwardly radially projecting flaps that engage with corresponding inwardly radially projecting flaps at the upper housing portion to restrict rotation of the housing portion relative to the output gear, thereby residing the motor in a stop position. The output gear and the resilient element are formed and arranged such that the resilient element flexes radially inward to allow movement of the flaps of the resilient element in other positions, thereby residing the motor in other positions separate from the stop position.

[0056] Optionally, an additional stop interface may be formed between the lifting element and the lower inner surface of the lower housing to further reduce wear on the lifting element and other stop surfaces during manual pivoting of the lens section. (As shown in...) Figures 19-21 The electrically operated folding actuator may include a lower housing portion 126, which includes a cam 126a and a lower inner surface 126b located radially inward of the cam 126a. The lower inner surface 126b is configured to receive a lifting element 128. The lifting element 128 has a receiving portion 128a and a lower stop or cam 128b, the lower stop or cam 128b protruding from the lower surface of the lifting element 128 and configured to engage a corresponding stop 126c at the lower inner surface 126b of the lower housing portion 126. In other words, the lifting element 128 includes a lower cam surface or stop 128b configured to engage with a corresponding cam or stop 126c of the lower housing 126. The corresponding stop 126c of the lower housing 126 is disposed at the lower inner surface 126b and located radially inward of the cam 126a. When the lifting element 128 rests against the lower inner surface 126b of the lower housing portion 126, the lifting element 128 is located at a lower position within the housing, and thus further away from engaging with the lower cam of the lower cam element at the output gear. Therefore, when the lower cam of the lower cam element engages with the cam 124a and the uppermost protrusion 124b of the base 124, the lifting element 128 does not engage with the lower cam, and wear on the lifting element is reduced.

[0057] In other words, an additional stop is applied to the lifting element and the lower housing portion. During the period when the actuator is electrically folded from the drive position to the folding position and then manually folded forward back to the drive position, a stop located on the base can wear or deteriorate along with the stop on the lifting element. This wear is caused by the lower cam of the lower cam element at the output gear. To prevent / reduce this wear, an additional stop is added so that the lifting element is in a lower position during this event. With this change, when the mirror is folded from the folding position to the drive position, during this event, the lower cam of the lower cam element at the output gear will pass over the stop of the lifting element without contacting it.

[0058] The mirror assembly may adopt features of the mirror assembly described in the following documents: U.S. Patent Publications US-2021-0331625; US-2021-0316664; US-2021-0213880; US-2020-0353867 and / or US-2020-0223364, and / or U.S. Patent Nos. 10,099,618; 9,827,913; 9,487,142; 9,346,403 and / or 8,915,601, the entire contents of which are incorporated herein by reference. The lens assembly can be adjustablely arranged at the mounting arm, a portion of which extends through an opening in the lens assembly. This allows the lens assembly (including the mirror reflector) to be adjusted relative to the mounting arm by operation of the actuator, thereby adjusting the driver's rearward view and / or folding (towards a folded or stored position) or unfolding (towards an unfolded, driven, or used position) relative to the mounting arm and the vehicle side. The opening at the lens assembly allows adjustment or movement of the lens assembly relative to the outer end of the mounting arm. In this configuration, the mirror reflector can move together with and sequentially from the lens assembly (the lens assembly may include a mirror housing, cover, or shell that moves together with and sequentially from the mirror reflector).

[0059] An exterior rearview mirror assembly can refer to any suitable exterior rearview mirror assembly with any suitable structure, such as a frameless mirror. A conventional interior (or exterior) rearview mirror assembly uses a plastic edging that covers and penetrates above / on top of the outermost surface of the plane of the foremost / outermost glass substrate used in conventional rearview mirror assemblies, framing the foremost / outermost glass substrate within the plastic, such as protecting the driver from contact with the sharp outer cut edges of the foremost / outermost glass substrate. Frameless rearview mirror assemblies do not have such edging or framing. For example, Infinity... TM and EVO TM The interior rearview mirror assembly is a frameless (also called a bezel-less) interior rearview mirror assembly and does not use such bezels or borders.

[0060] An Infinity TM Infinity electrochromic rearview mirror assembly TM(This is a trademark of Magna Mirrors of America, a company based in Holland, Michigan, USA) comprises a plastic mirror housing or shell formed by a plastic injection molding process [preferably by injection molding PC / ASA, a thermoplastic amorphous alloy of polycarbonate (PC) and ASA (acrylic-styrene-acrylate terpolymer) to provide enhanced heat resistance and enhanced mechanical properties]. The electrochromic / electro-optic mirror reflective element includes a front glass substrate and a rear glass substrate separated from the front glass substrate by a peripheral seal. An electrochromic medium (which is electrically dimmable) is sandwiched between the front and rear glass substrates and constrained by the peripheral seal. The front glass substrate has a planar first glass surface (which is the planar front surface of the mirror reflective element) and a planar second glass surface separated from the planar first glass surface by a thickness dimension of the front glass substrate. The front glass substrate includes an outer peripheral surface extending between the planar first glass surface and the planar second glass surface and spanning the thickness dimension of the front glass substrate. When the rearview mirror assembly is mounted on the windshield or front of the vehicle (e.g., via a mounting structure), the first planar surface faces the driver. A transparent conductive coating is disposed on the second planar glass surface and is in contact with an electro-optic (i.e., electrochromic) medium. The front glass substrate has a specularly reflective and conductive peripheral band established along the peripheral boundary region of the second planar surface of the front glass substrate, which is circumscribed to the outer peripheral boundary region of the second glass surface of the front glass substrate, so that when the rearview mirror assembly is mounted on the vehicle, a concealed peripheral seal is provided for the driver in the vehicle who is viewing the rearview mirror assembly. The rear glass substrate has a planar third glass surface and a planar fourth glass surface (which is the rear surface of the planar specular reflective element), and the planar third glass surface of the rear glass substrate is coated with a visible light transmissive / visible light reflective / near-infrared light transmissive (preferably with a dominant wavelength center of 940 nm) multilayer transmissive reflector. The outermost layer of the multilayer stack constituting the transmissive reflector includes a transparent conductive coating (preferably indium tin oxide, and preferably having a sheet resistance of less than 30 ohms per square, more preferably less than 25 ohms per square, and most preferably less than 20 ohms per square) in contact with an electro-optic (typically electrochromic) medium.

[0061] The circumferential outer periphery of the front glass substrate of the rearview mirror assembly includes a rounded, curved outer glass surface that provides a rounded transition between the planar first glass surface of the front glass substrate and the smaller curvature outer surface of the sidewall of the mirror housing or attachment plate. The circumferentially curved / rounded outer glass surface of the front glass substrate has a radius of curvature of at least 2.5 mm and is exposed to, accessible to, and visible to the driver of the vehicle when the rearview mirror assembly is mounted on it. No part of the mirror housing (or the front plastic bracket / attachment on which the electrochromic / electro-optic mirror reflector is mounted) intrudes above or on the planar first glass surface of the front glass substrate (i.e., the front surface of the planar mirror reflector). The cross-sectional dimension of the front glass substrate is larger than that of the rear glass substrate, such that the front glass substrate extends beyond the corresponding edge of the rear glass substrate. The rear glass substrate is received and externally attached to the sidewall of the front plastic bracket / attachment on which the electrochromic / electro-optic mirror reflector is mounted. The rear glass substrate is preferably attached to the front plastic bracket / attachment element on which the electrochromic / electro-optic mirror reflector is mounted by double-sided adhesive tape (arranged between the fourth glass surfaces of the rear glass substrate; i.e., the rear surface of the plane of the mirror reflector).

[0062] Therefore, in Infinity TM In the rearview mirror assembly, the mirror reflective element disposed at the mirror housing (and pivotable with respect to the mounting portion of the assembly together with the mirror housing) includes the outermost glass substrate (which may be equipped with an Infinity-O-Touch glass substrate). TM The rearview mirror assembly (in driver contact of the vehicle) has a flat front glass surface, a flat rear glass surface, and a circumferential outer peripheral edge. The outer peripheral edge surrounds the periphery of a glass substrate and extends across the thickness dimension separating the flat front and rear glass surfaces. The front outer peripheral edge includes a rounded glass surface that circumferentially surrounds and circumferentially borders the outer periphery of the glass substrate, and the rounded glass surface at least partially spans the thickness dimension of the glass substrate. The rounded glass surface has a radius of curvature of at least 2.5 mm. No part of the mirror housing covers or intrudes upon the rounded glass surface of the glass substrate. The rounded glass surface of the glass substrate is exposed to and accessible to the driver of the vehicle via a mounting portion installed on the interior side of the windshield of the vehicle. Preferably, the radius of curvature of the rounded glass surface is uniform around the outer periphery of the glass substrate. The mirror assembly includes an attachment surface, and preferably, a mirror reflector is attached to the attachment surface to secure the mirror reflector within the mirror assembly.

[0063] The internal prism rearview mirror assembly (or non-electrochromic external rearview mirror assembly) has a single glass substrate and can similarly include a rounded glass surface at the front outer peripheral edge of the circumferential outer edge, which circumferentially surrounds the outer periphery of the external glass substrate, wherein the rounded glass surface at least partially spans the thickness dimension of the glass substrate and has a radius of curvature of at least 2.5 mm.

[0064] In an EVO TM Electrochromic rearview mirror assembly (EVO) TM The electrochromic / electro-optical mirror reflective element (a trademark of Magna Mirrors of America, a company based in Holland, Michigan, USA) includes a front glass substrate and a rear glass substrate separated from the front glass substrate by a peripheral seal. An electrochromic medium (which is electrically dimmable) is sandwiched between the front and rear glass substrates and constrained by the peripheral seal. The front glass substrate has a planar first glass surface (which is the planar front surface of the mirror reflective element) and a planar second glass surface separated from the planar first glass surface by a thickness dimension of the front glass substrate. The front glass substrate includes an outer peripheral surface that extends between the planar first glass surface and the planar second glass surface and spans the thickness dimension of the front glass substrate. When EVO TM After the rearview mirror assembly is mounted on the windshield or front of the vehicle (e.g., via a mounting structure), the planar first glass surface faces the driver. A transparent conductive coating is disposed on the planar second glass surface and is in contact with an electro-optic (i.e., electrochromic) medium. The front glass substrate has a specular reflective and conductive peripheral band established along the peripheral boundary region of the planar second glass surface of the front glass substrate, which circumferentially borders the outer peripheral boundary region of the second surface of the front glass substrate, so that when the rearview mirror assembly is mounted on the vehicle (i.e., the vehicle equipped with the rearview mirror assembly), a concealed peripheral seal is provided for a person viewing the rearview mirror assembly. The rear glass substrate has a planar third glass surface and a planar fourth glass surface (which is the rear surface of the planar specular reflective element), and the planar third glass surface of the rear glass substrate is coated with a visible light transmissive / visible light reflective / near-infrared light transmissive (preferably with a dominant wavelength center of 940 nm) multilayer transmissive reflector. The outermost layer of the multilayer stack constituting the transmissive reflector includes a transparent conductive coating (preferably indium tin oxide, and preferably having a sheet resistance of less than 30 ohms per square, more preferably less than 25 ohms per square, and most preferably less than 20 ohms per square) in contact with the electro-optic medium.

[0065] In an EVO TMIn a rearview mirror assembly, the mirror reflector element includes an outermost glass substrate having a planar first glass surface and a planar second glass surface, with an outer peripheral edge disposed along the outer periphery of the foremost / outermost glass substrate. The outer peripheral edge spans the thickness dimension of the glass substrate between the first and second glass surfaces. The first glass surface of the glass substrate includes the front or outermost surface of the mirror reflector element, which is closest to the driver of the vehicle equipped with the rearview mirror assembly after the rearview mirror assembly is conventionally mounted on the vehicle. The mirror reflector element includes a mirror transmission reflector established on the surface of the mirror reflector element other than the first glass surface of the glass substrate. A plastic molded insert is circumferentially arranged around and external to the outer peripheral edge of the glass substrate, without covering or intruding on or above the first glass surface of the glass substrate. The plastic molded insert includes a portion that: (a) abuts against the outer peripheral edge of a foremost / outermost glass substrate and (b) has an outwardly curved surface extending from a first glass surface substantially adjacent to the foremost / outermost glass substrate and without sharp edges. The plane containing the first glass surface of the foremost / outermost glass substrate is substantially flush with the outermost portion of the plastic molded insert. The outwardly curved surface of the plastic molded insert provides a curved transition between the plane containing the first glass surface of the glass substrate and the plane containing the generally less curvature portion of the plastic molded insert. The generally less curvature portion is located rearward, adjacent to, and continuous with the outwardly curved surface of the plastic molded insert. The plastic molded insert includes at least a portion of a mirror housing of a rearview mirror assembly. The mirror housing and the mirror reflector move sequentially when the mirror reflector is moved to set the field of vision to a setting desired by the driver of the vehicle. The plastic molded insert includes a recess in which a mirror-reflecting element is received, and when the mirror-reflecting element is received in the recess, at least a portion of the plastic molded insert is located behind a glass substrate. The plastic molded insert includes a structure for attaching a rear mirror housing cover thereto. The rear mirror housing cover is configured to be attached to the structure of the plastic molded insert.

[0066] Therefore, in an EVO TMIn the rearview mirror assembly, a mirror-reflecting element is nested within an attachment element or a molded plastic strip or bracket, and an electrochromic / electro-optic mirror-reflecting element is nested within / supported by the attachment element or molded plastic strip or bracket. The rear glass substrate is preferably attached to the front plastic bracket / attachment element on which the electrochromic / electro-optic mirror-reflecting element is mounted via double-sided adhesive tape (arranged between the fourth glass surfaces of the rear glass substrate; i.e., the rear surface of the plane of the mirror-reflecting element). A circumferential wall structure extends from the mirror-element attachment side of the attachment element or molded plastic strip or bracket. The circumferential wall structure spans the rear glass substrate, spans the electrochromic medium, and spans the thickness dimension of the front glass substrate. However, the circumferential wall structure does not cover or intrude above / on top of the first (front) glass surface of the plane of the front glass substrate (i.e., the front surface of the plane of the mirror-reflecting element). When the mirror assembly is used in a vehicle, the circumferential wall structure prevents the driver from contacting any cut edges of the front and rear glass substrates, and in particular protects against contact with the circumferentially outer cut edges of the front glass substrate.

[0067] An internal prism EVO TM Rearview mirror assembly (or non-electrochromic exterior EVO) TM The rearview mirror assembly has a single glass substrate (external EVO). TM The rearview mirror assembly may have a flat glass substrate (such as a single magnified or bent / flexed glass substrate for the driver's side mirror, or a widened rearward field of view for the passenger side mirror), and may similarly have a circumferential wall structure extending from the mirror-element attachment side of the attachment element or plastic molded strip or bracket. The circumferential wall structure spans the glass substrate and extends across the thickness dimension of the glass substrate. However, the circumferential wall structure does not cover or intrude above / on top of the flat first (front) glass surface of the glass substrate (i.e., the front surface of the plane of the mirror reflector element).

[0068] The mirror assembly may include any suitable structure, such as, as an example, in which the reflective element is nested within a mirror housing, and the mirror housing has a curved or rounded outer peripheral edge that surrounds the reflective element and does not cover the front surface of the reflective element (such as the features of aspects of the mirror assembly described in U.S. Patent Nos. 7,255,451; 7,289,037; 7,360,932; 8,049,640; 8,277,059 and / or 8,529,108, the entire contents of all of which are incorporated herein by reference), or such as a mirror assembly having a rear substrate with an electro-optic or electrochromic reflective element nested within a mirror housing, and a front substrate with a curved or rounded peripheral edge, or such as a mirror assembly having a single glass substrate reflective element arranged within the mirror housing. At the outer peripheral edge of the body, and wherein the glass substrate has a curved or rounded peripheral edge, or such as a mirror assembly having a reflective element glass substrate, which is externally attached to the peripheral wall of an attachment plate, wherein no part of the peripheral wall of the attachment plate intrudes into or covers the outermost surface of the glass substrate, such as by adopting aspects of the mirror assembly described in U.S. Patent Nos. 10,099,618; 9,827,913; 9,598,016; 9,346,403; 9,174,578; 8,915,601; 8,730,553 and / or 8,508,831, all of which are incorporated herein by reference in their entirety (and wherein the electrochromic and prism lenses in these structures are available from the assignee of this application under the trade name INFINITY). TM(Mirrors are commercially available). In such applications, the mirror reflective element can be adhesively attached to the bracket or attachment plate of the lens section and can move together with and sequentially relative to the mounting arm. The mirror assembly may include actuators located at the mounting arm or lens section, operable to pivot or adjust the lens section (and reflective element) relative to the mounting arm and the vehicle side to which the mounting arm is attached, as described in various aspects of the mirror assembly as described in the following documents: U.S. Patent Publications US-2021-0331625; US-2021-0316664; US-2021-0213880 and / or US-2020-0353867, and / or U.S. Patents 11,173,843; 10,099,618; 9,827,913; 9,487,142; 9,346,403; 9,067,541; 8,915,601; 8,764,256; 7,887. The entire contents of all these references are incorporated herein by reference.

[0069] Therefore, the vehicle exterior rearview mirror assembly includes: (i) a mounting arm having a first end configured to be attached to a side of the vehicle and a second end remote from the first end; (ii) a lens portion disposed at the second end of the mounting arm, wherein the lens portion includes a mirror-reflecting element; and (iii) an electrically folding actuator, wherein the electrically folding actuator includes an electrically operated motor. When the electrically operated motor is electrically operated, the electrically folding actuator pivots the lens portion relative to the mounting arm between at least: (i) a driving position, wherein the lens portion extends outward relative to the side of the mounted vehicle; and (ii) a folded position, wherein the lens portion is folded toward the side of the mounted vehicle. The electrically operated folding actuator includes: (i) a pivot column including a first end and a second end away from the first end; (ii) a base fixed relative to the first end of the pivot column and fixed relative to a mounting arm; (iii) a first gear; (iv) a housing portion attached to the lens portion; (v) a lifting element non-rotatably arranged at the pivot column; and (vi) a spring element arranged between the first gear and the second end of the pivot column, the spring element pressing the first gear toward the base. The electrically operated motor, when electrically operated, rotatably drives the second gear meshing with the first gear to pivot the housing portion relative to the first gear and the pivot column. In the driven position of the lens portion, the lifting element does not engage with the first gear. During electrically pivoting of the housing portion relative to the pivot column, the lifting element engages with the first gear to limit the rotation of the first gear relative to the pivot column. In the driven position of the lens portion, the spring element acts on the base through the first gear and the housing portion. During the electric pivoting of the housing portion relative to the pivot column, the spring element acts on the base through the first gear, not through the housing portion or the lifting element.

[0070] Optionally, when the lens section is in the drive position, the lower cam surface of the first gear engages with the upper cam surface of the housing section. When the lens section is in the drive position, the lower surface of the housing section can nest with the stop surface of the base. When the electric folding actuator operates to pivot the lens section from the drive position to the folding position, the first gear rotates relative to the pivot column, and the lower cam surface of the first gear can disengage from the upper cam surface of the housing section and engage with the upper cam surface of the base. When the first gear disengages from the upper cam surface of the housing section and engages with the upper cam surface of the base, the spring element switches from acting on the housing section via the first gear to acting on the base via the first gear. As the first gear rotates relative to the pivot column, the lower cam surface of the first gear travels along the upper cam surface of the base. As the first gear rotates relative to the pivot column and the lower cam surface of the first gear travels along the upper cam surface of the base, the lower cam surface of the first gear separates from the upper cam surface of the lower housing and the lifting element. As the lower cam surface of the first gear travels along the upper cam surface of the base, the rotation of the first gear relative to the pivot is stopped when the lower cam surface of the first gear engages with the uppermost protrusion of the upper cam surface of the base. The rotation of the first gear relative to the pivot can also be stopped by a cam on the upper cam surface of the base. With the rotation of the first gear stopped, further operation of the electrically operated motor rotates the housing portion relative to the pivot and the base, causing the housing portion and the lifting element to rise upwards toward the first gear. As the housing portion rotates relative to the pivot and the base and the housing portion and the lifting element rise upwards toward the first gear, the spring element acts on the base through the first gear, not through the housing portion or the lifting element. With the lower surface of the housing portion traveling along the stop surface of the base, the housing portion can be guided upwards along the pivot as it rotates relative to the pivot and the base. As the housing portion and lifting element rise toward the first gear, the receiving portion of the lifting element at least partially receives a lower cam on the lower cam surface of the first gear to limit the rotation of the first gear relative to the lifting element and the pivot column. With the lower cam on the lower cam surface at least partially received in the receiving portion of the lifting element, a first portion of each lower cam is received in the receiving portion, and a second portion of each lower cam engages with the upper cam surface of the base. The receiving portion of the lifting element only partially receives the lower cam on the lower cam surface, such that with the lower cam on the lower cam surface of the first gear partially received in the receiving portion of the lifting element, the spring element acts on the base without lifting the element.

[0071] Optionally, as the lens portion moves from the drive position toward the folded position, the housing portion can move upward relative to the base to lift the lens portion relative to the mounting arm. As the housing portion moves upward relative to the base, the lifting element moves to engage with the first gear to limit the rotation of the first gear relative to the pivot column.

[0072] Optionally, during manual pivoting of the housing portion relative to the pivot post, the first gear and the housing portion may pivot together and sequentially relative to the pivot post.

[0073] Alternatively, during manual pivoting of the housing portion relative to the pivot column, the housing portion may move upward relative to the base as the lower surface of the housing portion travels along the stop surface of the base.

[0074] Optionally, the electrically operated folding actuator may include a resilient element disposed on the upper end of the first gear, having radially projecting flaps for engaging with corresponding flaps at the housing portion to restrict rotation of the housing portion relative to the first gear, thereby residing the electrically operated motor in a stop position. The resilient element flexes radially inward to allow movement of the radially projecting flaps of the resilient element to prevent the electrically operated motor from residing in other positions separated from the stop position.

[0075] Optionally, the lifting element can be longitudinally movable along the base and pivot column.

[0076] Optionally, the lifting element is externally connected to the pivot column and arranged radially inward of the upper cam surface of the housing portion. The lifting element may include a portion of the housing portion. The housing portion may be rotatable relative to the lifting element, and the lifting element may be longitudinally movable along the base and pivot column, thereby moving longitudinally together with the housing portion. The lower cam surface of the first gear may include one or more cams radially disposed along the lower cam surface of the first gear. Each of the one or more cams on the lower cam surface of the first gear includes: (i) an inner portion configured to engage a receiving portion of the lifting element, and (ii) an outer portion located radially outward of the inner portion and configured to engage the upper cam surface of the housing portion. The inner portions of the one or more cams on the lower cam surface of the first gear are further configured to engage a base cam surface of the base.

[0077] Optionally, the lifting element may include a lower cam surface configured to engage with a corresponding cam surface of the housing portion. The corresponding cam surface of the housing portion is located on the inner surface of the housing portion and is radially inward of the upper cam surface of the housing portion.

[0078] Alternatively, the lens can be pivotally mounted at the second end of the mounting arm.

[0079] Optionally, when the lens section is in the drive position, the spring load of the spring element is transmitted to the base via the first gear and the housing section. During the electric pivoting of the housing section relative to the pivot column, the spring load is transmitted directly to the base via the first gear. During the electric pivoting of the housing section relative to the pivot column, the spring load is not transmitted through the housing section. During the electric pivoting of the housing section relative to the pivot column, the spring load is not transmitted through the lifting element.

[0080] Optionally, the lens portion includes a frameless mirror reflector. The frameless mirror reflector includes a glass substrate having a first glass surface and a second glass surface, with an outer peripheral edge along the outer periphery of the glass substrate and spanning the thickness dimension of the glass substrate between the first and second glass surfaces. The first glass surface of the planar glass substrate is closest to the driver of the vehicle equipped with the exterior rearview mirror assembly when the vehicle exterior rearview mirror assembly is conventionally installed in the vehicle. The frameless mirror reflector includes a mirror reflector formed on a surface of the frameless mirror reflector other than the first glass surface of the glass substrate. The lens portion includes a plastic molded insert circumferentially arranged around and external to the outer peripheral edge of the glass substrate without covering or encroaching upon the first glass surface of the glass substrate. The plastic molded insert may be a portion of an attachment plate attached to the rear side of the frameless mirror reflector opposite the first glass surface of the glass substrate. The plastic molding insert includes an outer curved surface that extends from a first glass surface adjacent to the glass substrate and provides a curved transition between the plane containing the first glass surface of the glass substrate and the plane containing the less curved portion of the plastic molding insert.

[0081] Changes and modifications may be made to the specific embodiments described without departing from the principles of the invention, the principles of which are limited only by the scope of the appended claims as interpreted in accordance with the principles of patent law.

Claims

1. A vehicle exterior rearview mirror assembly, the vehicle exterior rearview mirror assembly comprising: The mounting arm has a first end configured to be attached to the side of the vehicle and a second end located away from the first end; A lens portion disposed at the second end of the mounting arm, wherein the lens portion includes a mirror-reflecting element; An electric folding actuator, wherein the electric folding actuator includes an electrically operated motor; When the electrically operated motor is electrically operated, the electric folding actuator pivots the lens portion relative to the mounting arm between at least the following positions: (i) a driving position, wherein the lens portion extends outward relative to the side of the vehicle being mounted, and (ii) a folding position, wherein the lens portion is folded toward the side of the vehicle being mounted. The electric folding actuator includes: (i) a pivot column having a first end and a second end away from the first end; (ii) a base fixed relative to the first end of the pivot column and fixed relative to the mounting arm; (iii) a first gear; (iv) a housing portion attached to the lens portion; (v) a lifting element non-rotatably arranged at the pivot column; and (vi) a spring element arranged between the first gear and the second end of the pivot column, the spring element pushing the first gear toward the base. The electrically operated motor, when electrically operated, can rotatably drive a second gear meshing with a first gear to pivot the housing portion relative to the first gear and the pivot column. In the case where the lens is in the driving position, the lifting element does not engage with the first gear; During the electric pivoting of the housing portion relative to the pivot column, the lifting element engages with the first gear to limit the rotation of the first gear relative to the pivot column; In the driving position, the spring element acts on the base through the first gear and the housing portion; and During the electric pivoting of the housing portion relative to the pivot column, the spring element acts on the base through the first gear, not through the housing portion or the lifting element.

2. The vehicle exterior rearview mirror assembly as claimed in claim 1, wherein, With the lens in the driving position, the lower cam surface of the first gear engages with the upper cam surface of the housing.

3. The vehicle exterior rearview mirror assembly as claimed in claim 2, wherein, With the lens in the driving position, the lower surface of the housing is nested with the stop surface of the base.

4. The vehicle exterior rearview mirror assembly as claimed in claim 3, wherein, When the electric folding actuator is operated to pivot the lens section from the drive position toward the folding position, the first gear rotates relative to the pivot column, and the lower cam surface of the first gear disengages from the upper cam surface of the housing section and engages with the upper cam surface of the base.

5. The vehicle exterior rearview mirror assembly as claimed in claim 4, wherein, When the first gear disengages from the upper cam surface of the housing portion and engages with the upper cam surface of the base portion, the spring element switches from acting on the housing portion through the first gear to acting on the base portion through the first gear.

6. The vehicle exterior rearview mirror assembly as claimed in claim 5, wherein, As the first gear rotates relative to the pivot column, the lower cam surface of the first gear travels along the upper cam surface of the base.

7. The vehicle exterior rearview mirror assembly as claimed in claim 6, wherein, As the first gear rotates relative to the pivot column and the lower cam surface of the first gear travels along the upper cam surface of the base, the lower cam surface of the first gear is separated from the upper cam surface of the lower housing and the lifting element.

8. The vehicle exterior rearview mirror assembly as claimed in claim 4, wherein, As the lower cam surface of the first gear travels along the upper cam surface of the base, the rotation of the first gear relative to the pivot column stops when the lower cam surface of the first gear engages with the uppermost protrusion of the upper cam surface of the base.

9. The vehicle exterior rearview mirror assembly as claimed in claim 4, wherein, The rotation of the first gear relative to the pivot column is stopped by a cam on the upper cam surface of the base.

10. The vehicle exterior rearview mirror assembly as claimed in claim 9, wherein, With the rotation of the first gear stopped, further operation of the electrically operated motor causes the housing portion to rotate relative to the pivot and base, and as the housing portion rotates relative to the pivot and base, the housing portion and the lifting element are lifted upward toward the first gear.

11. The vehicle exterior rearview mirror assembly as claimed in claim 10, wherein, As the housing portion rotates relative to the pivot and the base, and the housing portion and the lifting element are lifted upward toward the first gear, the spring element acts on the base through the first gear, but not through the housing portion or the lifting element.

12. The vehicle exterior rearview mirror assembly as claimed in claim 10, wherein, As the housing portion rotates relative to the pivot and the base, it is guided upward along the pivot as it travels along the stop surface of the base on its lower surface.

13. The vehicle exterior rearview mirror assembly as claimed in claim 10, wherein, As the housing portion and the lifting element are lifted upward toward the first gear, the receiving portion of the lifting element at least partially receives the lower cam on the lower cam surface of the first gear to limit the rotation of the first gear relative to the lifting element and the pivot column.

14. The vehicle exterior rearview mirror assembly as claimed in claim 13, wherein, With the lower cam on the lower cam surface at least partially received in the receiving portion of the lifting element, the first portion of each lower cam is received in the receiving portion, and the second portion of each lower cam engages with the upper cam surface of the base.

15. The vehicle exterior rearview mirror assembly as claimed in claim 13, wherein, The receiving part of the lifting element only partially receives the lower cam on the lower cam surface, so that when the lower cam on the lower cam surface of the first gear is partially received in the receiving part of the lifting element, the spring element acts on the base and not on the lifting element.

16. The vehicle exterior rearview mirror assembly as claimed in any of the preceding claims, wherein, As the lens moves from the driving position toward the folded position, the housing portion moves upward relative to the base to lift the lens relative to the mounting arm.

17. The vehicle exterior rearview mirror assembly as claimed in claim 16, wherein, As the housing portion moves upward relative to the base, the lifting element moves to engage with the first gear to limit the rotation of the first gear relative to the pivot column.

18. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, During manual pivoting of the housing portion relative to the pivot post, the first gear and the housing portion pivot together and sequentially relative to the pivot post.

19. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, During manual pivoting of the housing portion relative to the pivot column, the housing portion moves upward relative to the base as the lower surface of the housing portion travels along the stop surface of the base.

20. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, The electric folding actuator includes a resilient element disposed on the upper end of the first gear, having radially protruding winglets that engage with corresponding winglets at the housing portion to limit rotation of the housing portion relative to the first gear, thereby keeping the electrically operated motor in a stopped position.

21. The vehicle exterior rearview mirror assembly as claimed in claim 20, wherein, The resilient element flexes radially inward to allow the radially protruding flaps of the resilient element to move, thereby preventing the electrically operated motor from dwelling in positions other than the respective stop positions.

22. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, The lifting element can move longitudinally along the base and pivot column.

23. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, The lifting element is externally connected to the pivot column and is arranged radially inside the upper cam surface of the housing portion.

24. The vehicle exterior rearview mirror assembly as claimed in claim 23, wherein, The lifting element includes a portion of the housing.

25. The vehicle exterior rearview mirror assembly as claimed in claim 23, wherein, The housing portion is rotatable relative to the lifting element.

26. The vehicle exterior rearview mirror assembly as claimed in claim 25, wherein, The lifting element can move longitudinally along the base and pivot column, and moves longitudinally together with the housing portion.

27. The vehicle exterior rearview mirror assembly as claimed in claim 23, wherein, The lower cam surface of the first gear includes one or more cams arranged radially along the lower cam surface of the first gear.

28. The vehicle exterior rearview mirror assembly as claimed in claim 27, wherein, Each of one or more cams on the lower cam surface of the first gear includes: (i) an inner portion configured to engage with a receiving portion of the lifting element, and (ii) an outer portion located radially outside the inner portion and configured to engage with the upper cam surface of the housing portion.

29. The vehicle exterior rearview mirror assembly as claimed in claim 28, wherein, The inner side of one or more cams on the lower cam surface of the first gear is further configured to engage with the base cam surface of the base.

30. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, The lifting element includes a lower cam surface configured to engage with a corresponding cam surface of the housing portion.

31. The vehicle exterior rearview mirror assembly as claimed in claim 30, wherein, The corresponding cam surface of the housing portion is arranged on the inner surface of the housing portion and is located radially inside the upper cam surface of the housing portion.

32. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, The lens is pivotally mounted at the second end of the mounting arm.

33. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, When the lens is in the driving position, the spring load of the spring element is transmitted to the base through the first gear and the housing part.

34. The vehicle exterior rearview mirror assembly as claimed in claim 33, wherein, During the electric pivoting of the housing portion relative to the pivot column, the spring load is transmitted directly to the base via the first gear.

35. The vehicle exterior rearview mirror assembly as claimed in claim 34, wherein, During the electric pivoting of the housing portion relative to the pivot column, the spring load is not transmitted through the housing portion.

36. The vehicle exterior rearview mirror assembly as claimed in claim 35, wherein, During the electric pivoting of the housing portion relative to the pivot column, the spring load is not transmitted through the lifting element.

37. The vehicle exterior rearview mirror assembly as claimed in any one of claims 1-15, wherein, The lens section includes a frameless mirror reflector.

38. The vehicle exterior rearview mirror assembly as claimed in claim 37, wherein, The frameless mirror reflective element includes a glass substrate having a first glass surface and a second glass surface, wherein an outer peripheral edge spans the thickness dimension of the glass substrate between the first and second glass surfaces along the outer periphery of the glass substrate, and wherein, when the vehicle exterior rearview mirror assembly is conventionally mounted on a vehicle, the first glass surface of the plane of the glass substrate is closest to the driver of the vehicle equipped with the vehicle exterior rearview mirror assembly, and wherein the frameless mirror reflective element includes a mirror reflector formed on the surface of the frameless mirror reflective element in addition to the first glass surface of the glass substrate.

39. The vehicle exterior rearview mirror assembly as claimed in claim 38, wherein, The lens portion includes a plastic molded strip that is arranged around and external to the outer peripheral edge of the glass substrate without covering or penetrating the first glass surface of the glass substrate.

40. The vehicle exterior rearview mirror assembly as claimed in claim 39, wherein, The plastic molded insert is part of the attachment plate, which is attached to the rear side of the frameless mirror reflective element opposite to the first glass surface of the glass substrate.

41. The vehicle exterior rearview mirror assembly as claimed in claim 39, wherein, The plastic molding insert includes an outer curved surface that extends from a location adjacent to a first glass surface of the glass substrate and provides a curved transition between the plane containing the first glass surface of the glass substrate and the plane containing the less curved portion of the plastic molding insert.

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