Vehicle door mirror and manufacturing method thereof

Abstract

The present invention relates to a door mirror and / or a method for manufacturing the same, and provides a technique that allows different types of lamps to be assembled in a manner that suppresses an increase in cost. A door mirror (1) for a vehicle is provided with: a lamp mounting section (8); a first lamp (6B) attached to the lamp attachment part (8) via a bracket (15); and a housing cover (31) provided with an optical opening (46) through which light emitted from the first lamp (6B) passes. The lamp mounting part (8) is configured so that a second lamp (6A) having different illumination characteristics from the first lamp (6B) can be mounted as an alternative to the first lamp (6B). The bracket (15) is configured such that the optical axis of the first lamp (6B) in a state in which the first lamp (6B) is attached to the lamp attachment part (8) is inclined in a direction different from the optical axis of the second lamp (6A) in a case where the second lamp (6A) is attached to the lamp attachment part (8) as an alternative.

Description

Technical Field

[0001] This disclosure relates to a vehicle door rearview mirror and a method of manufacturing the same, and more specifically, to a vehicle door rearview mirror assembled with at least one lamp and a method of manufacturing the same. Background Technology

[0002] Patent document 1 discloses the assembly of a camera and a light within the housing of a vehicle side rearview mirror. As described in that document... Figure 2 As shown, the camera 50 and the light 60 are fixed by a common screw B.

[0003] Patent document 2 discloses the assembly of lights in the rearview mirror of a car door to provide foot lighting when passengers get in and out of the vehicle.

[0004] Patent document 3 discloses a projection device that projects decorative light designs onto the outer surface of a vehicle and assembles it into the vehicle.

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent Application Publication No. 2016-78559

[0008] Patent Document 2: Japanese Patent Application Publication No. 11-198717

[0009] Patent Document 3: US Patent No. 7,175,321 Summary of the Invention

[0010] The problem that the invention aims to solve

[0011] To house a light within the housing of a car door rearview mirror, the light mounting portion is sometimes located within a component of the rearview mirror (e.g., the mirror housing, housing cover, or other housing parts). However, there may be more than one type of light. For example, even in rearview mirrors for the same car model, there may be cases where a projection light for markings is installed instead of a footwell light. In such cases, shaping or molding the components of the rearview mirror according to each different type of light inevitably increases manufacturing costs (e.g., increased mold costs).

[0012] As can be understood from the above non-limiting illustrative description, the inventors of this application have discovered a new subject of study regarding the manufacturing method of car door rearview mirrors and / or their manufacturing methods: providing a technology that allows for the assembly of different types of lights in a way that minimizes cost increases.

[0013] Solution for solving the problem

[0014] The first aspect of this disclosure is a vehicle door rearview mirror comprising: a lamp mounting portion; a first lamp mounted on the lamp mounting portion via a bracket; and a housing having an optical opening for transmitting radiated light from the first lamp. The lamp mounting portion is configured to mount a second lamp with different lighting characteristics as a replacement for the first lamp. The bracket is configured such that the optical axis of the first lamp mounted on the lamp mounting portion is tilted in a direction different from the optical axis of the second lamp when the second lamp is mounted on the lamp mounting portion as a replacement.

[0015] The second aspect of this disclosure is a door rearview mirror of the first aspect described above, wherein the housing cover has a periphery or peripheral wall defining an opening as the optical opening, and the bracket has at least one closing rib protruding toward the periphery or peripheral wall.

[0016] The third aspect of this disclosure is the rearview mirror of the door of the second aspect described above, wherein the at least one closing rib has a height that varies continuously or intermittently in the circumferential direction of the opening.

[0017] The fourth aspect of this disclosure is the door rearview mirror of the third aspect mentioned above, wherein the height of the at least one closing rib is set to be higher on the inner side in the vehicle width direction than on the outer side in the vehicle width direction.

[0018] The fifth aspect of this disclosure is a rearview mirror for a car door of any one of the second to fourth aspects described above, wherein the first light includes a light source, a housing, and at least one lens supported by the housing and through which radiated light emitted from the light source is transmitted, and the at least one sealing rib is disposed on the outer periphery of the at least one lens.

[0019] The sixth aspect of this disclosure is a door rearview mirror of the fifth aspect described above, wherein the at least one closure rib extends around the entire circumference of the at least one lens about the optical axis.

[0020] The seventh aspect of this disclosure is a door rearview mirror of the fifth or sixth aspect described above, wherein a convex lens portion on the outer side of at least one lens can be visually confirmed from the outside through the opening.

[0021] The eighth aspect of this disclosure is a door rearview mirror of any one of the second to seventh aspects described above, wherein the housing has the peripheral wall, the peripheral wall having a height that varies continuously or discontinuously in the circumferential direction of the opening, and the at least one closing rib having a height that varies complementary to the height variation of the peripheral wall.

[0022] The ninth aspect of this disclosure is a door rearview mirror of any one of the second to eighth aspects described above, wherein the bracket includes a cylindrical housing that accommodates the first lamp, the cylindrical housing having an open inner end and an outer end opposite to the inner end, the outer end having at least one flange, the at least one flange having the at least one closing rib.

[0023] The tenth aspect of this disclosure is a door rearview mirror of any one of the first to ninth aspects described above, wherein the bracket is configured such that, when the door rearview mirror is installed in the vehicle, and the optical axis of the first lamp installed in the lamp mounting part is replaced by the second lamp installed in the lamp mounting part, the optical axis of the second lamp is tilted inward in the vehicle width direction.

[0024] The 11th aspect of this disclosure is a door rearview mirror of any one of the 1st to 10th aspects mentioned above, wherein the first light is a projection device for projecting a predetermined pattern or mark.

[0025] The 12th embodiment of this disclosure is a door rearview mirror of any one of the 1st to 11th embodiments described above, wherein the light mounting part is disposed in the rearview mirror housing that defines a storage space together with the housing cover.

[0026] The 13th aspect of this disclosure is a vehicle door rearview mirror comprising: a lamp mounting portion; a first lamp mounted on the lamp mounting portion via a bracket; and a housing having an opening through which radiated light from the first lamp is transmitted, the bracket having at least one closing rib protruding toward the housing around the opening, the at least one closing rib having a height varying circumferentially in the opening.

[0027] The 14th aspect of this disclosure is a rearview mirror for a car door according to the 13th aspect described above, wherein the housing cover has a peripheral wall formed in a manner that defines the opening, the peripheral wall having a height that varies continuously or discontinuously in the circumferential direction of the opening, and the height variation of the closing rib is complementary to the height variation of the peripheral wall.

[0028] The 15th embodiment of this disclosure is the door rearview mirror of the 13th or 14th embodiment described above, wherein the height of the at least one closing rib is set to be higher on the inner side in the vehicle width direction than on the outer side in the vehicle width direction.

[0029] The 16th aspect of this disclosure is a method for manufacturing a vehicle door rearview mirror, comprising: a step of continuously forming a housing part having a lamp mounting portion using a predetermined mold device; a step of assembling a lamp unit by mounting a first lamp on a bracket; a step of mounting the bracket of the lamp unit to the lamp mounting portion of the first housing part included in the continuously formed housing part assembly; and a step of mounting a second lamp to the lamp mounting portion of the second housing part included in the continuously formed housing part assembly.

[0030] The 17th aspect of this disclosure is a method for manufacturing a vehicle door rearview mirror according to the 16th aspect described above, wherein the bracket is configured such that the optical axis of the first lamp, when mounted on the lamp mounting portion via the bracket, is tilted in a different direction than the optical axis of the second lamp when the second lamp is mounted on the lamp mounting portion instead.

[0031] The 18th aspect of this disclosure is a method for manufacturing a vehicle door rearview mirror according to the 16th or 17th aspect described above, which further includes a step of continuously forming a housing cover using a predetermined mold device, the housing cover having an opening configured to be shared with respect to the first and second lamps.

[0032] Invention Effects

[0033] According to one aspect of this disclosure, a technique is available that allows for the assembly of different types of lamps in a manner that minimizes cost increases. Attached Figure Description

[0034] Figure 1 This is a front view of a door rearview mirror as described in one aspect of this disclosure, with the built-in camera and lights indicated by dashed lines.

[0035] Figure 2 This is a rear view of the car door's rearview mirror, with the built-in camera and lights represented by dashed lines.

[0036] Figure 3 It is a bottom view of the car door rearview mirror, with openings for the camera and lights formed on its lower cover.

[0037] Figure 4 This is a rough rear view of the lower cover that defines the storage space together with the rearview mirror housing.

[0038] Figure 5 This is a rough three-dimensional drawing of the lower part of the cover.

[0039] Figure 6 This is a schematic 3D view of the lower cover, showing the camera's installation status.

[0040] Figure 7 This is a front view showing the installation status of the lighting fixture on the rearview mirror housing.

[0041] Figure 8 This is a front view showing the installation status of the projection lamp on the lamp mounting part of the rearview mirror housing.

[0042] Figure 9 This is a schematic diagram that mainly shows the position of the lighting lamp relative to the opening of the lower cover.

[0043] Figure 10 It is a rough three-dimensional diagram of a lighting fixture.

[0044] Figure 11 This is a schematic diagram that mainly shows the position of the projection lamp relative to the opening of the lower cover.

[0045] Figure 12 This is a rough side view of the projector lamp.

[0046] Figure 13 This is a rough bottom view of the projector.

[0047] Figure 14 It is a simplified diagram of the manufacturing process for car door rearview mirrors. Detailed Implementation

[0048] Hereinafter, non-limiting embodiments and features of the present invention will be described with reference to the accompanying drawings. Those skilled in the art will be able to combine the various embodiments and / or features without extensive explanation, and will understand the synergistic effects of such combinations. Repeated descriptions between embodiments are omitted in principle. The accompanying drawings are primarily for the purpose of describing the invention and have been simplified for ease of drawing. The features should be understood as general features applicable not only to the rearview mirror and its manufacturing method disclosed in this specification, but also to various other rearview mirrors and their manufacturing methods not disclosed in this specification.

[0049] Reference Figures 1 to 3 Please provide an explanation. Figure 1 This is the front view of the rearview mirror 1, with the camera 5 and light 6 built into it represented by dashed lines. Figure 2 This is a rear view of the car door rearview mirror, with the built-in camera 5 and light 6 represented by dashed lines. Figure 3This is a bottom view of the rearview mirror, with openings for the camera 5 and the light 6 formed on its lower cover 31. Regarding the rearview mirror 1, concerning a straight line connecting any first position on the outside of the rearview mirror 1 and any second position on the inside of the rearview mirror 1, the position closer to the first position than the second position or the direction towards the first position is called the outer side, and the position closer to the second position than the first position or the direction towards the second position is called the inner side. The up / down / left / right / forward / backward directions are used assuming the rearview mirror 1 is installed in the vehicle. The up / down / left / right / forward / backward directions are based on the driver of the vehicle. The vehicle width direction, vertical direction, and direction of travel are as follows... Figures 1 to 3 The coordinates are shown in the diagram.

[0050] The door rearview mirror 1 is fastened to the vehicle's door panel by fasteners, providing the driver of the vehicle (not shown) with a rear view (so-called rear view or back view). Typically, the door rearview mirror 1 has a base 11 and a rearview mirror assembly 12, which is configured to be rotatable about a rotation axis AX3 relative to the base 11, either manually or electrically. The base 11 is fastened to the vehicle's door panel by fasteners. The base 11 can be composed of a combination of multiple parts such as a base housing, a bearing, and wiring harness guides.

[0051] The rearview mirror assembly 12 is typically rotatably connected to the base 11 via an axis not shown. When the rearview mirror assembly 12 is in the deployed position (see reference...), Figure 1 and Figure 2 The rearview mirror 35 is positioned facing rearward. When the rearview mirror assembly 12 is in the retracted position (not shown), the rearview mirror 35 is positioned opposite the side of the vehicle. Based on the axis structure, the rearview mirror assembly 12 can be electrically controlled between the extended and retracted positions. Additionally, the rearview mirror 35 can swing according to the movement of a rearview mirror drive unit (not shown). These drive mechanisms are well known in the art and are omitted from description.

[0052] The rearview mirror assembly 12 can be assembled from multiple housing parts. These housing parts are made of metal or resin and are formed by die casting or injection molding, but other molding methods are also possible. In some cases, the rearview mirror assembly 12, as housing parts, includes: a rearview mirror housing 3; a lower cover 31, which, together with the rearview mirror housing 3, defines the storage space for the door rearview mirror 1; and an upper cover 32, which, together with the rearview mirror housing 3 and the lower cover 31, defines the storage space for the door rearview mirror 1. The rearview mirror housing 3 functions as the housing for the rearview mirror 35 and can also function as a support for various parts, actuators, wiring harnesses, etc. The lower cover 31 and the upper cover 32 can be lighter than the rearview mirror housing 3. The external shape of these parts can be changed according to various requirements such as design requirements. The lower and upper covers are also simply referred to as housing covers without distinction.

[0053] A camera 5 and a light 6 are installed in the storage space of the rearview mirror assembly 12, for example, in the storage space defined by the rearview mirror housing 3 and the lower cover 31. An opening 45 is formed in the lower cover 31 to optically communicate the camera 5 with the external space, and an opening 46 is formed to optically communicate the light 6 with the external space. When the rearview mirror 1 is installed in the vehicle, openings 45 and 46 face downwards in the vertical direction, i.e., towards the driving surface (e.g., the road surface) for vehicle travel. Openings 45 and 46 refer to empty spaces not occupied by any object, but they can also be configured as optical openings with transparent window material (e.g., glass plate, transparent plastic plate) that allows light to pass through. The opening 46 for the light is formed to be larger than the opening 45 for the camera, but is not necessarily limited to this.

[0054] Camera 5 is used as a monitor to capture images of the vehicle's surroundings to assist safe driving, but it can also be used for other purposes (object detection around the vehicle). Light 6 is a device for illuminating the road surface and / or the sides of the vehicle; typically, it can be either a headlight (e.g., footwell lights) or a projection light. The headlight can illuminate in sync with the opening of the vehicle's doors or the operation of camera 5. The projection light can illuminate in sync with the opening or unlocking of the vehicle's doors or other events. The headlight has a larger illumination range than the projection light, thus possessing different illumination characteristics. The projection light, unlike the headlight, sometimes has a convex lens, also possessing different illumination characteristics. Various other types of lights can be used as light 6. The projection light can project logos or patterns related to or unrelated to the vehicle's manufacturer or model.

[0055] like Figure 1As shown, the acute angle θ1 formed by the optical axis AX5 of camera 5 with respect to axis L1, which is parallel to the rotation axis AX3 of rearview mirror assembly 12, is greater than the acute angle θ2 formed by the optical axis AX6 of lamp 6 with respect to axis L2, which is parallel to the rotation axis AX3 of rearview mirror assembly 12. This allows images to be acquired at a distance sufficiently far from the vehicle. The same applies if axes L1 and L2 are replaced with axes parallel to the vertical direction.

[0056] Reference Figure 4 The lower cover 31 has a peripheral portion 41 defining an opening 45, and also has a peripheral wall 42 defining an opening 46. The peripheral wall may also be provided for defining the opening 45. The peripheral edge may also be provided for defining the opening 46. The peripheral wall 42 extends toward the inside of the door rearview mirror 1 (rearview mirror assembly 12), and preferably extends in a narrowing manner (see also...). Figure 5 , 6 That is, the opening width of the opening 46 can increase as the opening 46 extends outward along the optical axis of the lamp 6. Advantageously, the height of the peripheral wall 42 varies continuously (see the example with reference to the figure) or discontinuously (not shown) in the circumferential direction of the opening 46. Thus, the shape of the peripheral wall 42 can be optimized for the lamp 6A described later. Advantageously, the peripheral wall 42 is set to be higher on the outer side in the vehicle width direction than on the inner side in the vehicle width direction. It should be noted that the inner side in the vehicle width direction refers to a position closer to or towards the centerline of the vehicle extending along the vehicle's direction of travel at the center of the vehicle's width, while the outer side in the vehicle width direction refers to a position further away from or away from the centerline.

[0057] like Figures 4 to 6 As shown, the lower cover 31 has a camera mounting section 7 for mounting the camera 5. The camera 5 is mounted via a bracket 9 (see reference). Figure 6 It is installed in the camera mounting part 7. The camera mounting part 7 is composed of the retaining part 71 of the foot 91 of the retaining bracket 9 and the boss 72 of the seat plate 92 of the threaded fixing bracket 9. For reference, in Figure 5 and Figure 6 The image shows a perspective view of the lower cover 31 before and after the camera 5 is installed. The camera 5 can be omitted, as can the camera mounting part 7.

[0058] Reference Figure 7 and Figure 8 Further explanation is needed. Figure 7 This is a front view showing the installation state of the lighting lamp 6A (hereinafter, sometimes simply referred to as lamp 6A) toward the lamp mounting part 8 of the rearview mirror housing 3. Figure 8This is a front view showing the installation state of the projection lamp 6B (hereinafter, sometimes simply referred to as lamp 6B) onto the lamp mounting portion 8 of the rearview mirror housing 3. Either the headlight 6A or the projection lamp 6B can be selectively used depending on the vehicle model or class of the vehicle on which the door rearview mirror 1 is installed. Regardless of whether the headlight 6A or the projection lamp 6B is used, both the headlight 6A and the projection lamp 6B are mounted on the same lamp mounting portion 8 of the same structure in the rearview mirror housing 3. That is, a common rearview mirror housing 3 can be used regardless of the type of lamp 6. Therefore, an increase in manufacturing costs (e.g., an increase in mold costs) can be suppressed or avoided, thereby preventing or suppressing an increase in the cost of the door rearview mirror 1.

[0059] The rearview mirror housing 3 is larger and / or has higher mechanical strength than the lower cover 31. Therefore, by placing the lamp mounting part 8 on the rearview mirror housing 3 instead of the lower cover 31, the lamp 6 can be mounted and fixed more stably. Of course, the lamp mounting part 8 can be placed on any part of the door rearview mirror 1, or it can be placed on the lower cover 31.

[0060] like Figure 7 and Figure 8 As shown, a lamp mounting portion 8 is provided on the front surface 34 of the rearview mirror housing 3. While not limited to this, the lamp mounting portion 8 consists of two bosses 81 and 82, rising forward from the front surface 34 of the rearview mirror housing 3. Each boss has an insertion hole for inserting a fastener (e.g., the shaft of a screw). Structures other than bosses may also be used. The position and / or structure of the lamp mounting portion 8 are not particularly limited. The lamp mounting portion 8 may also be provided on a component mounted on a different part from the rearview mirror housing 3.

[0061] exist Figure 7 In the case shown, the lighting lamp 6A is directly mounted to the lamp mounting part 8 by fasteners (for example, by two fasteners fastening to the two bosses 81 and 82 respectively). On the other hand, in Figure 8 In the illustrated case, the projection lamp 6B is mounted to the lamp mounting portion 8 via the bracket 15 using fasteners (for example, secured to the two bosses 81 and 82 by two fasteners respectively). By using the bracket 15, the lamp mounting portion 8 can be configured with the same structure for both lamps 6A and 6B. Advantageously, by mounting the lamp 6B to the lamp mounting portion 8 via the bracket 15, optimal setting of the optical axis of the lamp 6B can be achieved.

[0062] The bracket 15 is configured such that the optical axis AX6b of the projection lamp 6B (first lamp) when mounted on the lamp mounting section 8 is tilted in a different direction than the optical axis AX6a of the lighting lamp 6A (second lamp) when it is mounted on the lamp mounting section 8 instead (see reference). Figure 8 ). Figure 8The intersection of the optical axes AX6a and AX6b shown can be observed from the front or rear when the rearview mirror 1 is installed in the vehicle. Optical axis AX6b extends from the projection lamp 6B toward the illuminated target (e.g., the road surface), and optical axis AX6a extends from the lamp 6A toward the illuminated target (e.g., the road surface). The angle (acute angle) formed by optical axes AX6a and AX6b can be less than 30°, less than 20°, less than 10°, or less than 5°.

[0063] In one example design, a lamp mounting section 8 is designed for mounting a lighting lamp 6A without a bracket. A bracket 15 is designed for mounting a projection lamp 6B to this lamp mounting section 8. Here, the orientation of the projection lamp 6B with the bracket 15 mounted on the lamp mounting section 8 can be adjusted based on the orientation of the bracket 15 relative to the lamp mounting section 8. Specifically, by adjusting the position of the fastening parts 27' and 28' relative to the cylindrical housing 16 of the bracket 15, as described later, the orientation of the lamp 6B (its optical axis) can be adjusted. The lamp 6B is mounted on the lamp mounting section 8 via the bracket 15, and at the same time, the optimal setting of the optical axis of the lamp 6B can be achieved without additional work for optical axis adjustment. In this way, the standardization of the parts provided with the lamp mounting section 8 (the housing parts in the example) and the optimal setting of the optical axes of each lamp 6A and 6B can be achieved simultaneously.

[0064] Furthermore, by mounting the lighting lamp 6A to the lamp mounting section 8 without a bracket, the number of components can be reduced. It should be noted that a bracket could also be designed for lamp 6A instead of lamp 6B. However, when using both the lighting lamp 6A and the projection lamp 6B as alternative lamps, it is advantageous to design a bracket for the anticipated smaller number of projection lamps 6B. Even more advantageously, the bracket 15 is configured such that the optical axis AX6b is inclined inward in the vehicle width direction than the optical axis AX6a (see reference). Figure 8 This allows signs or patterns to be projected closer to the vehicle, thus enhancing the sense of unity or connection with the vehicle. On the other hand, the lamp 6A can illuminate the road surface from a distance further from the vehicle, thereby providing more effective illumination for vehicle occupants or the camera 5.

[0065] Reference Figure 9 and Figure 10 Explanation (and also refer to) Figure 7Lamp 6A is a lighting device with a larger illumination range than lamp 6B, and has a substrate 22 on which a light source 21 is mounted and a housing 23 for housing the substrate 22. The light source 21 is a semiconductor light-emitting element such as an LED (Light Emitting Diode) or LD (Laser Diode), which emits light according to the current supplied via a wiring harness. Not only can the light source 21 be mounted on the substrate 22, but its driving circuit can also be mounted on it. The housing 23 includes an inner part 24 and an outer part 25. At least the outer part 25 is made of a transparent material (e.g., a transparent resin that allows visible light to pass through). The substrate 22 is fixed to the inner part 24. The outer part 25 is combined with the inner part 24, and the lens portion 26 of the outer part 25 is aligned on the optical axis of the light source 21. The lens portion 26 has, for example, an inclined surface 26a that refracts the light beam emitted from the light source 21. The inclined surface 26a can be visually observed from the outside through the opening 46. The inclined surface 26a is located at a height offset upward from the peripheral wall 42 relative to the outer surface of the lower cover 31. In addition, the optical axis AX6a of lamp 6A is aligned with the optical axis of light source 21 or lens 26. As an addition or alternative, it can be understood as corresponding to the point of maximum brightness in the brightness distribution of the radiated beam.

[0066] The outer part 25 (e.g., lens portion 26) is provided to block the opening 46 from the inside of the rearview mirror assembly 12. The outer surface of the outer part 25 (the inclined surface 26a of the lens portion 26) is adjacent to the top or top surface (also referred to as the inner end of the peripheral wall 42 that defines the opening 46 of the lower cover 31), preferably adjacent with a small gap, or abutting without a gap. This suppresses the generation of wind noise during vehicle operation.

[0067] The housing 23 of lamp 6A has integrally provided flat, fastening portions 27 and 28 extending away from the opening 46. This allows lamp 6A to be mounted on lamp mounting portion 8 without a bracket. In other words, the housing 23 of lamp 6A also functions as a bracket. By avoiding the use of a dedicated bracket for lamp 6A, the number of parts can be reduced, thus promoting cost reduction. For this purpose, lamp 6A is cheaper than lamp 6B, and unlike lamp 6B, it does not need to have a lens separate from the housing.

[0068] The fastened portion 27 extends upward from the inner part 24 (the side opposite to the mounting surface of the light source 21). The fastened portion 28 is located inside the fastened portion 27 in the vehicle width direction and extends diagonally upward and to the right in the vehicle width direction. The fastened portions 27 and 28 each have a hole through which the shaft portion of a fastener (e.g., the shaft portion of a screw or bolt) is inserted and a seat surface around the hole for the head of the fastener (the head of a screw or bolt) to sit on. There are no limitations on the number, position, or shape of the fastened portions, and they can be varied arbitrarily.

[0069] Reference Figures 11 to 13 Explanation (and also refer to) Figure 8 Lamp 6B is a projection device for projecting a predetermined pattern or mark. Lamp 6B has a substrate 22' on which a light source 21' is mounted, a housing 23', and at least one lens 29 supported by the housing 23' and through which radiated light emitted from the light source 21' is transmitted. To form a bright or dark image of the mark or pattern, a light-shielding plate with a light-transmitting pattern corresponding to the mark or pattern can be installed inside the housing 23'. Other structures may also be used for this purpose.

[0070] The housing 23' is a cylindrical part with an inner end (upper end in the illustrated case) 23a and an outer end (lower end in the illustrated case) 23b. The inner end 23a is configured to accommodate the substrate 22'. The outer end 23b is shaped to hold the lens 29. The lens 29 has a convex lens portion (lens surface) 29a on its inner side and a convex lens portion (lens surface) 29b with greater optical power on its outer side. The lens portion 29b can be visually inspected from the outside through the opening 46, which is advantageous because the entire part can be visually inspected. This may be because the opening 46 was not optimized for the lens 29, but for the lens portion 26 of the lamp 6A. In addition, the housing 23' does not have a fastening part for mounting to the lamp mounting part 8.

[0071] The bracket 15 has a cylindrical housing 16 for accommodating the lamp 6B and fastening portions 27' and 28'. The fastening portion 27' extends upward from the cylindrical housing 16. The fastening portion 28' is located inside the cylindrical housing 16 in the vehicle width direction, in short, inside and connected to the cylindrical housing 16 in the vehicle width direction. The fastening portions 27' and 28' each have a hole through which the shaft portion of a fastener (e.g., the shaft portion of a screw or bolt) is inserted, and a seat surface around the hole for the head of the fastener (screw or bolt head) to rest. There are no limitations on the number, position, or shape of the fastening portions; they can be varied arbitrarily.

[0072] The cylindrical housing 16 has an open inner end (upper end in the illustrated case) 16a and an outer end (lower end in the illustrated case) 16b opposite to the inner end 16a. The lamp 6B can be inserted into the bracket 15 through the opening of the inner end 16a of the cylindrical housing 16. A flange 17 extending radially inward relative to the optical axis AX6b is provided at the outer end 16b of the bracket 15. The flange 17 determines the stopping position of the lamp 6B inserted into the bracket 15 (the outer end 23b can abut against the inner surface of the flange 17). Any method such as pressing, fitting, bonding, or welding can be used to connect the lamp 6B and the bracket 15. In this sense, the specific shape of the bracket 15 is arbitrary.

[0073] The bracket 15 has at least one closing rib 18 projecting toward the lower cover 31 around the opening 46. Preferably, the closing rib 18 protrudes from the flange 17 of the bracket 15. Alternatively, the closing rib 18 extends continuously along the circumference of the opening 46, i.e., it is formed in a ring shape. In the illustrated example, the closing rib 18 protrudes toward the peripheral wall 42 defining the opening 46. In the absence of a peripheral wall, the closing rib 18 protrudes toward the periphery defining the opening 46. Thus, the gap between the bracket 15 and the lower cover 31 that would exist without the closing rib 18 is closed.

[0074] Without the sealing rib 18, a gap would exist between the bracket 15 and the lower cover 31, potentially causing wind noise when the vehicle is in motion. However, by providing the sealing rib 18 to the bracket 15, this problem can be avoided or suppressed. The aforementioned gap is easily generated when ensuring the optimal orientation of the light axis of lamp 6B and making the shape of the bracket 15 reasonable.

[0075] The closing rib 18 can have a height that varies continuously or intermittently in the circumferential direction of the opening 46 (in other words, it can have a height that varies continuously or intermittently around the optical axis AX6b of the lens 29). As described above, by changing the height of the closing rib 18 in the circumferential direction of the opening 46, it is possible to achieve a good balance between optimizing the optical axis of the lamp 6B and closing the gap. In the relationship between the lighting lamp 6A and the projection lamp 6B, it is advantageous that the height of the closing rib 18 is set to be higher on the inner side in the vehicle width direction than on the outer side in the vehicle width direction.

[0076] The height variation of the closing rib 18 can complement the height variation of the peripheral wall 42. This allows the peripheral wall 42 to be shaped optimally for lamp 6A and also promotes wind noise reduction for lamp 6B. Furthermore, the cross-sectional shape of the closing rib 18 in a plane orthogonal to its extension direction is not limited to a rectangle or a chamfered rectangle; it can also be triangular or other shapes. The top surface of the closing rib 18 (the outermost surface of the closing rib in the inward and outward directions of the rearview mirror assembly 12) does not necessarily have to be a flat, sloping surface.

[0077] A sealing rib 18 is provided on the outer periphery of the lens 29 (particularly the lens portion 29b). The sealing rib 18 facilitates the protection of the lens 29. Alternatively, the sealing rib 18 may be lower than the height of the lens 29. This prevents or inhibits the lens 29 from being positioned excessively inward.

[0078] The functions of lamps 6A and 6B are further explained. The light beam emitted from the light source 21 of lamp 6A propagates within the internal space of housing 23, undergoes optical effects (e.g., refraction) at the lens portion 26 of the outer part 25, and is transmitted as diverging light through opening 46, propagating in the external space of the rearview mirror 1, and finally reaching the illuminated target (e.g., the road surface). Afterward, the light beam is reflected by the road surface and propagates towards a person's eye or a camera.

[0079] The light beam emitted from the light source 21' of lamp 6B is patterned by passing through the light-transmitting pattern of the light shield. At lens 29, it is acted upon by a convex lens, passing as converging light through opening 46 and propagating in the external space of the rearview mirror 1, eventually reaching the illuminated target (e.g., the road surface). Afterward, the beam is reflected by the road surface and propagates towards the viewer's eye. The convex lens action may reduce the divergence angle of the beam, but it may also propagate as diverging light instead of converging light.

[0080] The installation method of lamps 6A and 6B to lamp mounting part 8 is clear from the above description. For the sake of caution, the following explanation is provided: The fastening parts 27 and 28 of the housing 23 of lamp 6A are aligned with the bosses 81 and 82 and fastened with fasteners. Lamp 6B is first housed in bracket 15 to obtain the unit of both lamps. Next, the fastening parts 27' and 28' of bracket 15 are aligned with the bosses 81 and 82 and fastened with fasteners. By installing the lower cover 31 onto the rearview mirror housing 3, the opening 46 can be properly aligned with lamps 6A and 6B.

[0081] Reference Figure 14 A method for manufacturing a vehicle door rearview mirror is described. This method includes a step (S1) of continuously forming a housing part having a lamp mounting portion using a predetermined mold assembly. The housing part is, for example, the rearview mirror housing 3 described above, but is not limited to it. Die casting or injection molding can be used. The structure of the housing part is complex. Therefore, the structure of the mold assembly is also complex and very expensive.

[0082] The manufacturing method also includes a step (S2) of assembling the lamp unit by combining the lamp 6B (first lamp) with the bracket 15. The lamp 6B is inserted into the cylindrical housing 16 of the bracket 15, and the two are combined to form a unit. In order to combine the two by fitting, the locking part and the locked part can be provided separately. Other means such as bonding or welding can also be used. The order of S1 and S2 can also be reversed.

[0083] The manufacturing method also includes a step (S3) of mounting the lamp unit bracket 15 onto the lamp mounting portion of the first housing part included in the continuously formed housing part assembly. This yields a semi-finished product of a door rearview mirror with a built-in lamp 6B.

[0084] The manufacturing method also includes a step (S4) of mounting lamp 6A (second lamp) to the lamp mounting portion of the second housing part included in the continuously formed housing part group. This yields a semi-finished product of a door rearview mirror with lamp 6A built-in. It should be noted that the second housing part described here is obtained in the same manner as the first housing part via step S1.

[0085] As described above, the semi-finished products obtained in S3 and S4 undergo additional processes such as assembly of other parts to ultimately become the door rearview mirror 1. This is well known in the art, and detailed description is omitted. In this way, common housing parts (e.g., rearview mirror housing 3) can be used for different types of lights 6. As a result, it is possible to suppress or avoid increases in mold costs, thereby preventing or suppressing increases in the cost of the door rearview mirror 1.

[0086] Alternatively, the manufacturing method may also include the step of continuously forming a housing cover (e.g., lower cover 31) using a predetermined mold device, the housing cover having an opening 46 configured to be shared with respect to lamps 6A and 6B. This feature relates to the manner in which the lamp mounting portion is located in a housing part other than the rearview mirror housing 3.

[0087] Regarding the bracket 15, one or more of the features described above can also be applied to the manufacturing method. For example, the bracket 15 tilts the optical axis of lamp 6B in a direction different from that of lamp 6A. By mounting the bracket 15 to the lamp mounting part, the optical axis of lamp 6B can be automatically set. By providing the bracket 15 with the closing rib 18, a wind noise reduction effect can be achieved. Further redundant descriptions are unnecessary for those skilled in the art and are therefore omitted.

[0088] Symbol Explanation

[0089] 1—Rearview mirror; 3—Rearview mirror housing; 6—Lamp; 6A—Lighting lamp; 6B—Projection lamp; 8—Lamp mounting part; 15—Bracket; 16—Cylindrical housing; 16a—Inner end; 16b—Outer end; 17—Flange; 18—Closed rib; 21—Light source; 21'—Light source; 23—Housing; 23'—Housing; 23a—Inner end; 23b—Outer end; 26—Lens part; 29—Lens; 29b—Lens part; 35—Rearview mirror; 42—Peripheral wall; 45—Opening; 46—Opening; 60—Lamp.

Claims

1. A rearview mirror for a vehicle door, characterized in that, have: Lighting installation section; The first lamp is mounted on the lamp mounting part via a bracket; as well as The housing cover has an optical opening for the transmission of radiated light from the first lamp. The lamp mounting section is configured to install a second lamp with different lighting characteristics as a replacement for the first lamp. The bracket is configured such that the optical axis of the first lamp, when mounted on the lamp mounting part, is tilted in a different direction than the optical axis of the second lamp when the second lamp is mounted on the lamp mounting part instead.

2. The rearview mirror for a car door according to claim 1, characterized in that, The housing cover has a periphery or peripheral wall that defines the opening as the optical opening, and the bracket has at least one closing rib that protrudes toward the periphery or peripheral wall.

3. The rearview mirror for a car door according to claim 2, characterized in that, The at least one closing rib has a height that varies continuously or intermittently in the circumferential direction of the opening.

4. The rearview mirror for a car door according to claim 3, characterized in that, The height of the at least one closed rib is set to be higher on the inside of the vehicle width direction than on the outside of the vehicle width direction.

5. The rearview mirror for a car door according to claim 2, characterized in that, The first lamp includes a light source, a housing, and at least one lens supported by the housing and through which radiated light emitted from the light source is transmitted. The at least one closing rib is disposed on the outer periphery of the at least one lens.

6. The rearview mirror for a car door according to claim 5, characterized in that, The at least one closure rib extends around the optical axis of the at least one lens.

7. The rearview mirror for a car door according to claim 5, characterized in that, The convex lens portion on the outer side of the at least one lens can be visually confirmed from the outside through the opening.

8. The rearview mirror for a car door according to claim 2, characterized in that, The housing cover has the peripheral wall. The peripheral wall has a height that varies continuously or intermittently in the circumferential direction of the opening, and the at least one closing rib has a height that varies complementary to the height variation of the peripheral wall.

9. The rearview mirror for a car door according to claim 1, characterized in that, The bracket includes a cylindrical housing that houses the first lamp, the cylindrical housing having an open inner end and an outer end opposite to the inner end, the outer end having at least one flange having the at least one closing rib.

10. The rearview mirror for a car door according to claim 1, characterized in that, The bracket is configured such that, when the rearview mirror is mounted on the vehicle door, and the optical axis of the first lamp mounted on the lamp mounting part is tilted inward in the vehicle width direction instead of the second lamp mounted on the lamp mounting part.

11. The rearview mirror for a car door according to claim 1, characterized in that, The first lamp is a projection device that projects a predetermined pattern or symbol.

12. The rearview mirror for a car door according to claim 1, characterized in that, The light mounting part is disposed in the rearview mirror housing, which together with the housing cover defines the storage space.

13. A rearview mirror for a vehicle door, characterized in that, have: Lighting installation section; The first lamp is mounted on the lamp mounting part via a bracket; as well as The housing cover has an opening for the transmission of radiated light from the first lamp. The bracket has at least one closing rib protruding toward the housing around the opening, the at least one closing rib having a height that varies circumferentially around the opening.

14. The rearview mirror for a car door according to claim 13, characterized in that, The housing cover has a peripheral wall formed in a manner that defines the opening, the peripheral wall having a height that varies continuously or discontinuously in the circumferential direction of the opening, the height variation of the closing rib being complementary to the height variation of the peripheral wall.

15. The rearview mirror for a car door according to claim 13, characterized in that, The height of the at least one closed rib is set to be higher on the inside of the vehicle width direction than on the outside of the vehicle width direction.

16. A method for manufacturing a vehicle door rearview mirror, characterized in that, include: The step of continuously forming a housing part with a lamp mounting part using a predetermined mold device; The steps of assembling the lamp unit by mounting the first lamp onto the bracket; The step of mounting the bracket of the lamp unit to the lamp mounting portion of the first housing part included in the continuously formed housing part group; as well as The step of mounting a second lamp to the lamp mounting portion of the second housing part included in the continuously formed housing part assembly.

17. The method for manufacturing a vehicle door rearview mirror according to claim 16, characterized in that, The bracket is configured such that the optical axis of the first lamp, when mounted on the lamp mounting part via the bracket, is tilted in a different direction than the optical axis of the second lamp when the second lamp is mounted on the lamp mounting part instead.

18. The method for manufacturing a vehicle door rearview mirror according to claim 16, characterized in that, It also includes the step of continuously forming a housing cover using a predetermined mold device, the housing cover having an opening configured to be shared with respect to the first lamp and the second lamp.

Images