Donnelly Corporation

Tun-Jen Chu

Leo W Pavao

Desmond J O'Farrell

A method of forming a composite shell member for a vehicular sideview exterior mirror assembly includes providing a decorative film substrate and a polymer resin. A shell is formed the decorative film substrate and the polymer resin to form the shell member. A discontinuity is formed in the polymer resin, with the film substrate conformed to the polymer resin to generally follow the edge definition of the discontinuity to form a surface discontinuity in an outer surface of the shell member having substantially the same edge definition of the discontinuity of the polymer resin.

Outside sideview mirror assembly with reduced wind noise

A method of forming a mirror housing according to the present invention includes providing a molding apparatus having a molding cavity, placing a film appliqu&eacute; in the mold cavity and injecting a polymer into the mold cavity over at least a portion of a side of the film appliqu&eacute; to form a housing wall of the mirror housing wherein the film appliqu&eacute; adheres to the substrate forming the housing wall. Preferably, the mold apparatus comprises an injection molding apparatus which injects a heated polymer into the mold cavity for forming the housing wall of the mirror housing. The film appliqu&eacute; preferably matches the color of the vehicle or provides a color accent, wood grain finish, or a metallic finish or the like to provide a decorative appearance to the mirror assembly but without the noise associated with the conventional detachable skull cap designs. The present invention also provides a vehicular exterior sideview mirror assembly which includes a mirror housing that is adapted for mounting to a vehicle. The mirror housing is formed by molding and has a housing wall that defines a cavity and an opening for facing rearward of the vehicle when the mirror assembly is mounted to the vehicle. A reflective element is provided in the cavity for rearward viewing of the vehicle. In addition, the mirror housing has a forward facing side when the mirror assembly is mounted to the vehicle with at least a portion of the forward facing side including a decorative film appliqu&eacute; molded therewith to provide a decorative function for the mirror assembly.

Consolidated exterior sideview mirror assembly incorporating an in-mold film process

A vehicular sideview exterior mirror assembly includes a body, which is adapted for mounting to a vehicle, and a reflective element supported in the body' cavity and positioned in an opening of the body which faces rearward of a vehicle when the mirror assembly is mounted to a vehicle. The body has a forward facing side, with at least a portion of the forward facing side including decorative film molded therewith. The portion of the forward facing side includes a surface discontinuity formed therein to reduce the wind noise of the sideview exterior mirror assembly when mounted to a vehicle.

A method of forming a mirror housing according to the present invention includes providing a molding apparatus having a molding cavity, placing a film appliqu&eacute; in the mold cavity and injecting a polymer into the mold cavity over at least a portion of a side of the film appliqu&eacute; to form a housing wall of the mirror housing wherein the film applique adheres to the substrate forming the housing wall. Preferably, the mold apparatus comprises an injection molding apparatus which injects a heated polymer into the mold cavity for forming the housing wall of the mirror housing. The film appliqu&eacute; preferably matches the color of the vehicle or provides a color accent, wood grain finish, or a metallic finish or the like to provide a decorative appearance to the mirror assembly but without the noise associated with the conventional detachable skull cap designs. The present invention also provides a vehicular exterior sideview mirror assembly which includes a mirror housing that is adapted for mounting to a vehicle. The mirror housing is formed by molding and has a housing wall that defines a cavity and an opening for facing rearward of the vehicle when the mirror assembly is mounted to the vehicle. A reflective element is provided in the cavity for rearward viewing of the vehicle. In addition, the mirror housing has a forward facing side when the mirror assembly is mounted to the vehicle with at least a portion of the forward facing side including a decorative film appliqu&eacute; molded therewith to provide a decorative function for the mirror assembly.

A coated housing for exterior rearview mirrors for vehicles provides increased gloss and depth of color in appearance, and enhanced resistance to scratching, surface crazing and ultraviolet radiation degradation. The housing is preferably molded from a resinous plastic material in a predetermined color and has a generally transparent polymeric material such as clear urethane or acrylic applied in a thin coating to the unpainted housing. The generally transparent coating may include a tint or particles of metal or mica to enhance the molded housing color and/or appearance. Optionally, adhesion of the coating to the housing may be increased by mixing an adhesion promoting agent in said resinous plastic material prior to molding, or by treating the housing surface after molding and prior to application of the coating. An ultraviolet radiation absorbing, blocking, screening material may be included in the generally transparent polymeric material. A method for making the coated exterior rearview mirror housing is also disclosed.

Growing community of inventors

Holland, MI, United States of America

Tun-Jen Chu