Exterior mirrors with partially translucent cover film

Abstract

The present invention relates to a method for manufacturing an exterior mirror (1) for a motor vehicle (2). According to the method, a translucent mirror base (6) of the exterior mirror (1) is manufactured with a cover film (3) arranged thereon, wherein the cover film (3) has an opaque area (4) and a translucent area (5). The invention further relates to an exterior mirror (1) for a motor vehicle (2) and a motor vehicle (2).

Description

[0001] The present invention relates to a method for manufacturing an exterior mirror for a motor vehicle. The invention further relates to an exterior mirror for a motor vehicle and to a motor vehicle with an exterior mirror.

[0002] Exterior mirrors for motor vehicles are known in which a signaling device, such as a flashing light or a warning light for a blind spot assist system, is integrated into the mirror housing. For this purpose, the mirror housing has a recess into which the signaling device can be inserted.

[0003] Furthermore, illuminated displays are known in which a light source, such as an LED, is surrounded by a translucent housing. The housing can also be covered with a film that is partially translucent and partially opaque. In this way, a predefined light signature can be provided. Document DE 10 2021 006 465 A1 discloses a generic light source designed as an illuminated vehicle emblem.

[0004] Conventional exterior mirrors with integrated warning devices have the disadvantage of a gap between the mirror housing and the warning device's lens. This gap may not be flush, creating air turbulence while driving, which can lead to disruptive wind noise. Furthermore, mounting the lens to the recess in the mirror housing requires an additional step, increasing the manufacturing costs of exterior mirrors with integrated warning devices. Finally, the mirror caps of conventional exterior mirrors are often painted, for example, to match the vehicle's color, adding further labor and increasing production costs.

[0005] It is therefore an object of the present invention to eliminate, or at least partially eliminate, the disadvantages described above in an exterior mirror with an integrated signaling device. In particular, it is an object of the present invention to provide a method for manufacturing an exterior mirror for a motor vehicle, an exterior mirror for a motor vehicle, and a motor vehicle with an exterior mirror, which avoid increased assembly effort and / or reduce air turbulence at the mirror housing in a simple and cost-effective manner.

[0006] The aforementioned problem is solved by the claims. Accordingly, the problem is solved by a method for manufacturing an exterior mirror for a motor vehicle with the features of independent claim 1, by an exterior mirror for a motor vehicle with the features of dependent claim 8, and by a motor vehicle with an exterior mirror with the features of dependent claim 10. Further features and details of the invention will become apparent from the dependent claims, the description, and the drawings. Features and details described in connection with the method for manufacturing an exterior mirror for a motor vehicle according to the invention naturally also apply in connection with the exterior mirror and the motor vehicle according to the invention, and vice versa, so that the disclosure of the individual aspects of the invention always makes, or can make, reciprocal references.

[0007] According to a first aspect of the invention, the problem is solved by a method for manufacturing an exterior mirror for a motor vehicle. The method comprises: - Providing a cover film with an opaque area and a translucent area, - Creating a mirror base cap for the exterior mirror, wherein the mirror base cap is designed to be translucent, - Arranging the cover film on the mirror base cap to form a mirror cap, - Providing a mirror core assembly of the external mirror, wherein the mirror core assembly comprises a signaling device with a lighting device, and - Combining the mirror cap with the mirror core assembly in such a way that the mirror cap surrounds the mirror core assembly from several sides and the lighting device faces the light-transmitting area of ​​the cover film.

[0008] The protective film can, for example, be provided as an adhesive film that is applied to the mirror base cap by sticking it on. The protective film is preferably a single piece. Alternatively, the protective film can also be made of two or more parts. Preferably, the protective film has a thickness of less than 0.5 mm, particularly preferably less than 0.25 mm. More preferably, the protective film has a thickness of more than 0.05 mm, particularly preferably more than 0.1 mm. The protective film is preferably designed to lie flat against the mirror base cap without creases. Preferably, the protective film is elastically or plastically deformable, for example, above a plasticizing temperature of more than 90 °C. The protective film has a translucent area and an opaque area.According to the invention, the cover film can also have several translucent areas, which are preferably separated from one another by opaque areas of the cover film. A translucent area is understood to be an area that is permeable to the light from the lighting device. The translucent area can, for example, be clear or frosted. With a clear translucent area, the lighting device is clearly visible from the outside. With a frosted translucent area, the light from the lighting device is diffused. According to the invention, the translucent area can be colored, for example, yellow, orange, or red. The cover film is preferably arranged on an outward-facing outer surface of the mirror base cap.

[0009] The mirror base cap is preferably curved. Preferably, the shape of the mirror base cap corresponds to the shape of an ordinary mirror cap of a conventional exterior mirror without a signal device.

[0010] The mirror core assembly includes the signaling device and the lighting device. Preferably, the mirror core assembly includes a mirror bracket for holding a mirror of the exterior mirror, a mirror of the exterior mirror arranged on the mirror bracket, an adjustment mechanism for adjusting the mirror's alignment, and connecting cables. The connecting cables are designed to supply power to the signaling device. Preferably, the adjustment mechanism includes one or more electric motors for electrically adjusting the mirror's alignment. In this case, the connecting cables are also designed to supply power to the electric motors. More preferably, the mirror includes a mirror heater. In this case, the connecting cables are also designed to supply power to the mirror heater. The connecting cables can be connected to the vehicle's on-board electronics, preferably via a plug connection.

[0011] The mirror cap is coupled to the mirror core assembly of the exterior mirror in such a way that the mirror core assembly is surrounded by the mirror cap on several sides and the mirror is visible from the outside. Furthermore, the mirror core assembly is arranged in the mirror cap such that the light source of the signaling device faces the translucent area of ​​the cover film, allowing light emitted by the light source of the signaling device to pass through the translucent area of ​​the cover film to the outside. Areas of the mirror cap through which no light should pass are preferably covered by the opaque area of ​​the cover film.

[0012] An inventive method for manufacturing an exterior mirror for a motor vehicle has the advantage over conventional methods that an exterior mirror with an integrated signaling device is provided using simple means and in a cost-effective manner. This mirror features a continuous mirror cap without seams, thus effectively preventing disruptive wind noise. Furthermore, no additional viewing windows for the signaling device are required, eliminating the complex processes involved in attaching the viewing window to the mirror cap. Additionally, the use of the masking film eliminates the need for a separate painting process, further reducing the labor involved in manufacturing the exterior mirror. The masking film also allows for a high degree of product variety in a particularly cost-effective and sustainable way.

[0013] According to a preferred embodiment of the invention, a method for manufacturing an exterior mirror for a motor vehicle may include the provision of a cover film designed to cover the entire mirror base or a predominant portion thereof. Preferably, a cover film is provided that is designed to completely cover an area of ​​the mirror base visible when the exterior mirror is assembled. Preferably, the cover film covers all externally visible areas of the mirror base. More preferably, the cover film has a light-transmitting area only in the region of the light source of the signaling device.This has the advantage that an exterior mirror with an integrated signaling device can be produced using simple means and in a cost-effective manner, which has a continuous mirror cap without seams and produces particularly low noise levels while driving.

[0014] According to the invention, it is preferred that the mirror cap is manufactured using an in-mold labeling process such that the cover film is applied to the mirror base cap during its production. In the in-mold labeling process, the cover film is preferably provided in a mold in which the mirror base cap is subsequently produced, for example, by an injection molding process, such that the material of the mirror base cap adheres to the cover film, thus bonding the cover film to the mirror base cap. Alternatively, the mirror cap can also be manufactured using a multi-component injection molding process. In this process, the mirror base cap is preferably produced from a first component, the opaque area of ​​the cover film from a second component, and the transparent area of ​​the cover film from a third component, all in the injection molding process.Alternatively, the mirror base cap and the translucent area of ​​the cover film can be produced from the first component, and the opaque area of ​​the cover film from the second component, using injection molding. This has the advantage that a secure and precise arrangement and bonding of the cover film to the mirror base cap can be achieved simply and cost-effectively. Additional adhesives for fixing the cover film to the mirror base cap are not required. Furthermore, the in-mold labeling process is flexible and ensures a high degree of product variety with minimal effort.

[0015] Preferably, the cover film is arranged on the mirror base cap such that a light-transmitting area of ​​the cover film faces the driver of the vehicle both when the exterior mirror is installed and when the vehicle is in operation. The signaling device is therefore preferably designed as a blind spot assist system, with the light device also facing the driver of the vehicle both when the exterior mirror is installed and when the vehicle is in operation. Preferably, the light device and the light-transmitting area are aligned with each other, so that light emitted by the light device can be radiated outwards through the light-transmitting area, particularly in the direction of the driver.This has the advantage that an exterior mirror can be produced using simple means and in a cost-effective manner, which is particularly suitable for a signal device designed as a blind spot assistant and does not have any additional air turbulence due to the covering of the light device of the signal device.

[0016] In a particularly preferred embodiment of the invention, a method may provide that the cover film is arranged on the mirror base cap such that a light-transmitting area of ​​the cover film faces away from the driver of the motor vehicle both when the exterior mirror is installed and when the vehicle is in operation. The signaling device is therefore preferably designed as a flashing device, with the light device also facing away from the driver of the motor vehicle both when the exterior mirror is installed and when the vehicle is in operation. Preferably, the light device and the light-transmitting area are aligned with each other, so that light emitted by the light device can be radiated outwards through the light-transmitting area, particularly away from the driver.This has the advantage that an exterior mirror can be produced using simple means and in a cost-effective manner, which is particularly suitable for a signaling device designed as a flashing device and does not have any additional air turbulence due to the covering of the light device of the signaling device.

[0017] Preferably, a cover film is provided in which the translucent area has the shape of a symbol. For the purposes of this invention, a symbol is understood to be, for example, a shape that is more complex than a circle, triangle, or rectangle. According to the invention, the symbol can be designed as a positive or negative symbol, i.e., inverted. Preferably, the translucent area has a shape with at least two differently shaped sections. The translucent area can, for example, have the shape of a brand logo, arrow, warning triangle, letters, word, image, or the like. According to the invention, it may be provided that one or more opaque sections are arranged within the translucent area.Thus, the cover film in the translucent area allows for the display of complex designs, which are particularly clearly visible when illuminated by the light device. This has the advantage that the effect of the signaling device can be enhanced by displaying the sign in a simple and cost-effective manner, thereby further improving the safety of the vehicle through the exterior mirror.

[0018] According to a preferred embodiment of the invention, a protective film is provided which is designed as a lacquered film. Within the scope of the invention, a lacquered film is understood to be a film that has the appearance of a painted surface, such as a vehicle door. This has the advantage that an exterior mirror can be provided simply and cost-effectively, which can be precisely matched to the color of the vehicle, without requiring an additional painting process. Thus, several steps in the manufacturing of the exterior mirror can be saved.

[0019] According to a second aspect of the invention, the problem is solved by an exterior mirror for a motor vehicle. The exterior mirror comprises a mirror core assembly with a signaling device and a mirror cap that partially surrounds the mirror core assembly. The signaling device includes a lighting device. According to the invention, the mirror cap comprises a mirror base cap made of a translucent material and a cover film arranged on the mirror base cap. The cover film has an opaque area and a translucent area, the translucent area being located adjacent to the lighting device.

[0020] The cover film can, for example, be designed as an adhesive film or bonded to the mirror base cap using an in-mold labeling process. The cover film is preferably a single piece. Alternatively, the cover film can also be made of two or more parts. Preferably, the cover film has a thickness of less than 0.5 mm, particularly preferably less than 0.25 mm. More preferably, the cover film has a thickness of more than 0.05 mm, particularly preferably more than 0.1 mm. The cover film preferably lies flat against the mirror base cap without creases. Preferably, the cover film exhibits elastic or plastic deformability above a plasticizing temperature of 90 °C. The cover film has a translucent area and an opaque area.According to the invention, the cover film can also have several translucent areas, which are preferably separated from each other by opaque areas of the cover film. The translucent area can, for example, be clear or frosted. It can also be provided according to the invention that the translucent area is colored, for example, yellow, orange, or red. The cover film is preferably arranged on an outward-facing outer surface of the mirror base cap.

[0021] The mirror base cap is preferably curved. Preferably, the shape of the mirror base cap corresponds to the shape of an ordinary mirror cap of a conventional exterior mirror without a signal device.

[0022] The mirror core assembly includes the signaling device and the lighting device. Preferably, the mirror core assembly includes a mirror bracket on which a mirror of the exterior mirror is mounted. More preferably, the mirror core assembly includes an adjustment mechanism for adjusting the mirror's alignment and connecting cables. The connecting cables are designed to supply power to the signaling device. Preferably, the adjustment mechanism includes one or more electric motors for electrically adjusting the mirror's alignment. In this case, the connecting cables are also designed to supply power to the electric motors. More preferably, the mirror includes a mirror heater. In this case, the connecting cables are also designed to supply power to the mirror heater. The connecting cables can be connected to the vehicle's on-board electronics, preferably via a plug connection.

[0023] The mirror cap is coupled to the mirror core assembly of the exterior mirror in such a way that the mirror core assembly is surrounded by the mirror cap on several sides, and the mirror is visible from the outside. Furthermore, the mirror core assembly is arranged in the mirror cap such that the light source of the signaling device faces the translucent area of ​​the cover film, allowing light emitted by the light source of the signaling device to pass through the translucent area of ​​the cover film to the outside. Areas of the mirror cap through which no light should pass are preferably covered by the opaque area of ​​the cover film.

[0024] The exterior mirror according to the invention for a motor vehicle offers all the advantages already described in relation to a method for manufacturing an exterior mirror for a motor vehicle according to the first aspect of the invention. Accordingly, the exterior mirror according to the invention has the advantage over conventional exterior mirrors that, using simple means and in a cost-effective manner, an exterior mirror with an integrated signaling device is provided, which has a continuous mirror cap without seams, thus effectively preventing disruptive wind noise. Furthermore, no additional viewing windows for the signaling device are required, eliminating the complex processes for attaching the viewing window to the mirror cap. Moreover, the use of the protective film eliminates the need for an additional painting process, further reducing the labor involved in manufacturing the exterior mirror.The cover film allows for a high degree of variety in a particularly cost-effective and sustainable way.

[0025] According to the invention, it is preferred that the exterior mirror is manufactured using a method according to the invention. Particularly preferred is the bonding of the cover film to the mirror base cap using an in-mold labeling process. In the in-mold labeling process, the cover film is preferably provided in a mold in which the mirror base cap is subsequently produced, for example, by an injection molding process, such that the material of the mirror base cap adheres to the cover film, thus bonding the cover film to the mirror base cap. This has the advantage that a secure and precise arrangement and bonding of the cover film to the mirror base cap can be achieved using simple and cost-effective means. Additional adhesives for fixing the cover film to the mirror base cap are not required.The in-mold labeling process is also flexible and ensures a high variety of options with minimal effort.

[0026] According to a third aspect of the invention, the problem is solved by a motor vehicle. According to the invention, the motor vehicle has an exterior mirror according to the invention. Particularly preferably, the motor vehicle has two exterior mirrors according to the invention, which are arranged on opposite sides of the motor vehicle.

[0027] The motor vehicle according to the invention offers all the advantages already described for a method for manufacturing an exterior mirror for a motor vehicle according to the first aspect of the invention and for an exterior mirror for a motor vehicle according to the second aspect of the invention. Accordingly, the motor vehicle according to the invention has the advantage over conventional motor vehicles that an exterior mirror with an integrated signaling device is provided using simple and cost-effective means. This mirror has a continuous mirror cap without seams, thus effectively preventing disruptive wind noise. Furthermore, no additional viewing windows for the signaling device are required, eliminating the complex processes involved in attaching the viewing window to the mirror cap.Furthermore, the use of the masking film eliminates the need for an additional painting process, thus further reducing the labor involved in manufacturing the exterior mirror. The masking film also allows for a high degree of design variety in a particularly cost-effective and sustainable way.

[0028] A method according to the invention for manufacturing an exterior mirror for a motor vehicle, an exterior mirror according to the invention for a motor vehicle, and a motor vehicle according to the invention are explained in more detail below with reference to the drawings. The drawings schematically show: Fig. 1. In a perspective view, an external mirror in accordance with the state of the art, Fig. 2 in a sectional view the exterior mirror Fig. 1, Fig. 3 in a sectional view an external mirror according to a preferred first embodiment of the invention, Fig. 4 in a perspective view the exterior mirror Fig. 3, Fig. 5 in a perspective view an external mirror according to a preferred second embodiment of the invention, Fig. 6 in a side view a preferred embodiment of a motor vehicle according to the invention, and Fig. 7 in a flowchart a preferred embodiment of a method according to the invention.

[0029] Elements with the same function and mode of operation are in the Fig. 1, Fig. 2, Fig. 3, Fig. 4, Fig. 5, Fig. 6 to Fig. 7 each with the same reference numerals.

[0030] In Fig. Figure 1 is an exterior mirror 1 shown schematically in a perspective view according to the state of the art. Fig. 2 shows the exterior mirror 1 from Fig. Figure 1 shows a schematic cross-sectional view. The exterior mirror 1 has a mirror core assembly 8, which is surrounded on several sides by a mirror cap 7. The mirror core assembly 8 has a signal device 9 with a light device 10 and a mirror 11, which is arranged on a mirror bracket (not shown) with an adjustment mechanism for the exterior mirror 1. In this example, the signal device 9 is configured as a blind spot assist system.

[0031] The mirror cap 7 has an opaque mirror base 6, the outer surface of which is covered with a layer of lacquer 12. A translucent viewing window 13 is arranged in a recess in the mirror base 6. The lighting device 10 is arranged adjacent to the viewing window 13, so that light emitted by the lighting device 10 can shine outwards through the viewing window 13. Due to the manufacturing process, a gap 14 is formed between the mirror base 6 and the viewing window 13, through which air turbulence and associated noise emissions can occur during driving.

[0032] In Fig. Figure 3 shows a schematically sectional view of an exterior mirror 1 according to a preferred first embodiment of the invention. Fig. 4 shows the exterior mirror 1 from Fig. Figure 3 is shown schematically in a sectional view. The exterior mirror 1 has a mirror core assembly 8, which is surrounded on several sides by a mirror cap 7. The mirror core assembly 8 has a signal device 9 with a light device 10 and a mirror 11, which is arranged on a mirror bracket (not shown) with an adjustment mechanism for the exterior mirror 1. In this example, the signal device 9 is configured as a blind spot assist system.

[0033] The mirror cap 7 has a translucent mirror base cap 6, the outer surface of which is completely covered with a cover film 3. The cover film 3 has an opaque area 4 and a translucent area 5. The lighting device 10 is arranged adjacent to the translucent area 5, so that light emission generated by the lighting device 10 can radiate outwards through the translucent mirror base cap 6 and the translucent area 5. Due to the cover film 3, the mirror cap 7 has a continuous smooth surface without any joints 14 (see figure). Fig. 2) so that air turbulence and noise emissions during driving are reduced compared to the state of the art.

[0034] In Fig. Figure 5 shows a schematic cross-sectional view of an exterior mirror 1 according to a preferred second embodiment of the invention. The exterior mirror 1 according to the preferred second embodiment of the invention differs from the exterior mirror 1 according to the preferred first embodiment of the invention in the design of the light-transmitting area 5 of the cover film 3. According to the preferred second embodiment of the invention, several opaque areas 4 are arranged in the light-transmitting area 5, such that a symbol, in this case a warning triangle with an exclamation mark, is formed by the light-transmitting area 5 and the opaque areas 4.

[0035] Fig. Figure 6 schematically shows a preferred embodiment of a motor vehicle 2 according to the invention in a side view. The motor vehicle 2 has an exterior mirror 1 according to the invention. The exterior mirror 1 has a mirror cap 7 with a cover film 3. The cover film 3 has an opaque area 4 and a translucent area 5, the translucent area 5 facing away from the driver of the motor vehicle 2. Behind the translucent area 5, a signal device 9 designed as a flashing device with a light device 10 is arranged.

[0036] In Fig.Figure 7 schematically illustrates a preferred embodiment of a method according to the invention for manufacturing an exterior mirror 1 for a motor vehicle 2 in a flowchart. In a first process step 100, a cover film 3 with an opaque area 4 and a translucent area 5 is provided. Preferably, the cover film 3 is provided in a mold for an in-mold labeling process. In a second process step 200, a translucent mirror base 6 of the exterior mirror 1 is produced in the mold. In a third process step 300, the cover film 3 is arranged on the mirror base 6. The second process step 200 and the third process step 300 are preferably carried out within the framework of an in-mold labeling process. By producing the mirror base 6 in the mold, the mirror base 6 is thus directly bonded to the cover film 3.This creates a mirror cap 7 for the exterior mirror 1. The cover film 3 gives the mirror cap 7 a smooth outer surface with an opaque area 4 and a translucent area 5.

[0037] In a fourth process step 400, a mirror core assembly 8 of the exterior mirror 1 is provided. The mirror core assembly 8 has a signal device 9 with a lighting device 10 and a mirror 11 arranged on a mirror bracket, which can be pivoted about two axes via an adjustment mechanism of the mirror core assembly 8. In a fifth process step 500, the mirror cap 7 is combined with the mirror core assembly 8 such that the mirror cap 7 surrounds the mirror core assembly 8 from several sides and the lighting device 10 faces the light-transmitting area 5 of the cover film 3. Reference symbol list 1 exterior mirror 2 motor vehicles 3 Cover film 4 opaque area 5 translucent area 6 Mirror base cap 7 Mirror cap 8 Mirror core assembly 9 Signal device 10 Lighting device 11 mirrors 12 coats of lacquer 13 viewing windows 14 Separation joint 100 first procedural action 200 second procedural action 300 third procedural action 400 fourth procedural action 500 fifth procedural action QUOTES INCLUDED IN THE DESCRIPTION

[0000] This list of documents cited by the applicant was automatically generated and is included solely for the reader's convenience. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2021 006 465 A1

[0003]

Claims

Method for manufacturing an external mirror (1) for a motor vehicle (2), comprising: - providing a cover film (3) with an opaque area (4) and a translucent area (5), - producing a mirror base cap (6) of the external mirror (1), wherein the mirror base cap (6) is translucent, - arranging the cover film (3) on the mirror base cap (6) to form a mirror cap (7), - providing a mirror core assembly (8) of the external mirror (1), wherein the mirror core assembly (8) has a signaling device (9) with a lighting device (10), - combining the mirror cap (7) with the mirror core assembly (8) such that the mirror cap (7) surrounds the mirror core assembly (8) from several sides and the lighting device (10) faces the translucent area (5) of the cover film (3). Method according to claim 1, characterized in that a cover film (3) is provided which is designed to cover the entire mirror base cap (6) or a predominant part of the mirror base cap (6). Method according to claim 1 or 2, characterized in that the mirror cap (7) is manufactured in an in-mold labelling process such that the cover film (3) is arranged on the mirror base cap (6) when producing the mirror base cap (6). Method according to one of the preceding claims, characterized in that the cover film (3) is arranged on the mirror base cap (6) such that a light-transmitting area (5) of the cover film (3) is directed towards a driver of the motor vehicle (2) in the installed state of the exterior mirror (1) and during driving operation. Method according to one of the preceding claims, characterized in that the cover film (3) is arranged on the mirror base cap (6) such that a light-transmitting area (5) of the cover film (3) is turned away from a driver of the motor vehicle (2) in the installed state of the exterior mirror (1) and during driving operation. Method according to one of the preceding claims, characterized in that a cover film (3) is provided in which the light-transmitting area (5) has the form of a sign. Method according to one of the preceding claims, characterized in that a cover film (3) is provided which is designed as a paint film. Exterior mirror (1) for a motor vehicle (2), comprising a mirror core assembly (8) with a signal device (9) having a light device (10) and a mirror cap (7) partially surrounding the mirror core assembly (8), characterized in that the mirror cap (7) has a mirror base cap (6) made of a translucent material and a cover film (3) arranged on the mirror base cap (6), wherein the cover film (3) has an opaque area (4) and a translucent area (5), and wherein the translucent area (5) is arranged adjacent to the light device (10). Exterior mirror (1) according to claim 8, characterized in that the exterior mirror (1) is manufactured by a method according to one of claims 1 to 7. Motor vehicle (2), characterized in that the motor vehicle (2) has an external mirror (1) according to claim 8 or 9.

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