CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 61/546,281, filed on October 12, 2011, entitled "MOUNT SYSTEM," and U.S. Provisional Patent Application No. 61/549,815, filed on October 21, 2011, entitled "OPTICAL ELEMENT," the entire disclosures of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention generally relates to a rearview device, and more particularly, to a mount system and optical assembly for a rearview device in a vehicle.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, a rearview device for a vehicle includes a display portion that displays a view rearward of the vehicle. A rear housing is attached to the display portion. The rear housing includes a top surface, a bottom surface, a first side surface, a second side surface, and a rear surface. A light source is configured to project light from the bottom surface. An optical element is connected to the bottom surface and is in optical communication with the light source. At least two contact points are configured to contact the housing of the rearview device. The at least two contact points include a first contact point and a second contact point spaced from the first contact point. A non-planar optical element extends from the first contact point to the second contact point. The non-planar optical element and housing are configured to define a gap, and the non-planar optical element is configured to be in optical communication with the light source, such that light emitted from the light source propagates through the non-planar optical element. The gap provides a forward field of view when viewing the rearview device from an approximately frontal position. The non- planar optical element is configured so that the emitted light propagating therethrough is emitted in a substantially lateral planar 360 degree illumination pattern, such that the emitted light is viewable from the frontal position, a first side position, a second side position opposite the first side position, and a rearward position of the rearview device.

According to another aspect of the present invention, an optical assembly is configured for use with a bottom portion of a rearview device having at least one light source in optical communication with the optical assembly. The optical assembly includes at least one contact point configured to contact a housing of the rearview device. The at least one contact point includes at least one of a first contact point and a second contact point spaced from the first contact point. A non-planar optical element extends from the first contact point towards the second contact point. The non-planar optical element and housing are configured to define a gap. The non-planar optical element is configured to be in optical communication with the at least one light source, such that the light emitted from the at least one light source propagates through the non-planar optical element. The gap provides a forward field of view when viewing the rearview device from an approximately frontal position. The non-planar optical element is configured so that the emitted light propagating therethrough is emitted in a substantially lateral planar 360 degree illumination pattern, such that the emitted light is viewable when viewing the rearview device from the frontal position, a first side position, a second side position opposite the first side position, a rearward position, and laterally planar positions intermediate thereto.

According to yet another aspect of the present invention, a mount system for a rearview assembly in a vehicle includes a support and a ball connected to the support. The ball is configured to be formed separately from the support and is connected to the support after forming the support, such that the ball has a different torque characteristic than the support.

According to still another aspect of the present invention, a mount system for a rearview assembly in a vehicle includes a socket having at least one stabilizing finger and at least one torque finger.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

FIG. 1 is a front perspective view of a rearview device having a lighting optic, in accordance with one embodiment of the present invention;

FIG. 2 is a front elevational view of a rearview device having an optical element, in accordance with one embodiment of the present invention; FIG. 3 is a bottom elevational view of a rearview device having an optical element, in accordance with one embodiment of the present invention;

FIG. 4 is an enlarged bottom perspective view of area IV in FIG. 1;

FIG. 5 is a top perspective view of an optical element, in accordance with one embodiment of the present invention;

FIG. 6 is a side perspective view of an optical element, in accordance with one embodiment of the present invention;

FIG. 7 is a top perspective view of an optical element, in accordance with one embodiment of the present invention;

FIG. 8 is a top perspective view of a split mount system for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 9 is a top perspective view of a mount system for a rearview assembly having a split ball, in accordance with one embodiment of the present invention;

FIG. 10 is a side perspective view of a mount system for a rearview assembly having a one-piece ball, in accordance with one embodiment of the present invention;

FIG. 11 is a side perspective view of a split mount system for a rearview assembly having a one-piece ball, in accordance with one embodiment of the present invention;

FIG. 12 is a side perspective view of a mount system for a rearview assembly having a one-piece ball, in accordance with one embodiment of the present invention;

FIG. 13 is a side perspective view of a mount system for a rearview assembly having a split ball, in accordance with one embodiment of the present invention;

FIG. 14 is a side perspective view of a mount system for a rearview assembly having a one-piece ball, in accordance with one embodiment of the present invention;

FIG. 15 is a side perspective view of a mount system for a rearview assembly having a one-piece ball, in accordance with one embodiment of the present invention;

FIG. 16 is a side perspective view of a mount system for a rearview assembly having a one-piece ball, in accordance with one embodiment of the present invention;

FIG. 17 is an exploded top perspective view of one embodiment of a mount system for a rearview assembly, in accordance with one embodiment of the present invention; FIG. 17A is an exploded top perspective view of another embodiment of a mount system for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 18 is a cross-sectional top perspective view of one embodiment of a socket for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 18A is a cross-sectional top perspective view of another embodiment of a socket for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 19 is a cross-sectional top perspective view of one embodiment of a socket for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 19A is a cross-sectional top perspective view of another embodiment of a socket for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 20 is a top perspective view of a socket for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 21 is a side perspective view of one embodiment of one part of a split ball for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 21A is a side perspective view of another embodiment of one part of a split ball for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 22 is a top perspective view of one embodiment of a socket and band spring for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 22A is a top perspective view of another embodiment of a socket and band spring for a rearview assembly, in accordance with one embodiment of the present invention;

FIG. 23 is a top perspective view of another embodiment of a mount system for a rearview assembly, in accordance with another embodiment of the present invention;

FIG. 23A is a top exploded perspective view of the mount system of FIG. 23;

FIG. 24 is another top exploded perspective view of the mount system of FIG. 23; FIG. 25 is a top perspective cross-sectional view of a split mount system, in accordance with one embodiment of the present invention;

FIG. 26 is a top perspective view of a socket for the split mount system of FIG. 25; FIG. 27 is a top exploded perspective view of the socket prior to assembly; and FIG. 28 is another top exploded perspective view of the socket of FIG. 27.

DETAILED DESCRIPTION OF EMBODIMENTS

The present illustrated embodiments reside primarily in combinations of method steps and apparatus components related to a lighting optic. Accordingly, the apparatus components and method steps have been represented, where appropriate, by conventional symbols in the drawings, showing only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the disclosure with details that will be readily apparent to those of ordinary skill in the art having the benefit of the description herein. Further, like numerals in the description and drawings represent like elements.

In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements, but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by "comprises . . . a" does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

In one embodiment, a rearview device includes a display portion that displays a view rearward of a vehicle. A rear housing is attached to the display portion. The rear housing includes a top surface, a bottom surface, a first side surface, a second side surface, and a rear surface. A light source is configured to project light from the bottom surface. An optical element is connected to the bottom surface and is in optical communication with the light source. At least two contact points are configured to contact a housing of the rearview device. The at least two contact points include a first contact point and a second contact point spaced from the first contact point. A non- planar optical element extends from the first contact point to the second contact point. The non-planar optical element and the rear housing are configured to define a gap. The non-planar optical element is configured to be in optical communication with the at least one light source, such that light emitted from the at least one light source propagates through the non-planar optical element. The gap provides a forward field of view when viewing the rearview device from an approximately frontal position. The non-planar optical element is configured so that the emitted light propagating therethrough is emitted in a substantially lateral planar 360 degree illumination pattern, such that the emitted light is viewable when viewing the rearview device from all of the frontal position, a first side position, a second side position opposite the first side position, a rearward position, and laterally planar positions intermediate thereto. An engagement post is integral with the optical element and extends into the housing to secure the optical element with the housing. An intermediate rib extends from the first contact point to the second contact point.

An optical assembly is configured for use with a bottom portion of a rearview device having at least one light source in optical communication with the optical assembly. At least one contact point is configured to contact a housing of the rearview device. The at least one contact point includes a first contact point and a second contact point spaced from the first contact point. A non-planar optical element extends from the first contact point towards the second contact point. The non-planar optical element and the housing are configured to define a gap. The non-planar optical element is configured to be in optical communication with the at least one light source, such that light emitted from the at least one light source propagates through the non-planar optical element. The gap provides a forward field of view when viewing the rearview device from an approximately frontal position. The non-planar optical element is configured so that the emitted light propagating therethrough is emitted in a substantially lateral planar 360 degree illumination pattern, such that the emitted light is viewable when viewing the rearview device from all of the frontal position, a first side position, a second side position opposite the first side position, a rearward position, and laterally planar positions intermediate thereto. An engagement post is integral with the optical element and extends into the housing to secure the optical element with the housing. An intermediate rib extends from the first contact point to the second contact point.

Referring generally to the embodiment illustrated in FIGS. 1-6, a rearview device

10 for a vehicle includes a display portion 12 that displays a view rearward of the vehicle, a rear housing 14 attached to the display portion 12, the rear housing 14 having a top surface 16, a bottom surface 18, a first side surface 20, a second side surface 22, a rear surface 24, and a light source 26 configured to project light from the bottom surface 18. An optical element is connected to the bottom surface 18 and is in optical communication with the light source 26. At least two contact points are configured to contact the housing 14 of the rearview device 10. The at least two contact points include a first contact point 34 and a second contact point 36 spaced from the first contact point 34. A non-planar optical element 30 extends from the first contact point 34 to the second contact point 36. The non-planar optical element 30 and the housing 14 are configured to define a gap 42. The non-planar optical element 30 is configured to be in optical communication with the light source 26, such that light emitted from the light source 26 propagates through the non-planar optical element 30, wherein the gap 42 provides a forward field of view when viewing the rearview device 10 from an approximately frontal position. The non-planar optical element 30 is configured so that the emitted light propagating therethrough is emitted in a substantially lateral planar 360 degree illumination pattern, such that the emitted light is viewable from the frontal position, a first side position, a second side position opposite the first side position, and a rearward position of the rearview device 10.

The rearview device 10, as illustrated in FIGS. 1 and 2, is designed for support on an interior surface of a windshield of a vehicle. The optical element 30 is disposed on the bottom surface 18 of the housing 14 of the rearview device 10 proximate a plurality of buttons or switches. It is generally contemplated that the bottom surface 18 of the housing 14 could take on a variety of shapes and constructions and may or may not include buttons, map lamps, etc. The optical element 30 is generally positioned in a middle portion of the bottom surface 18 of the housing 14. However, it is also generally contemplated that the optical element 30 could be generally positioned proximate the top surface 16, the first side surface 20, second side surface 22, or at least partially on a bezel 31. In addition, as shown in FIG. 3, the optical element 30 is generally positioned in an intermediate position between a forward surface and a rearward surface of the housing 14.

As illustrated in FIG. 3, the optical element 30 includes a first base 50 proximate the first contact point 34 and a second base 52 proximate the second contact point 36. The first and second bases 50, 52 are generally wider than an intermediate portion 54 of the optical element 30, thereby providing additional stability to the optical element 30. As illustrated, the optical element 30 includes a non-planar configuration. More specifically, the first base 50 includes a slightly arcuate construction and connects with a first end of the intermediate portion 54, which also includes a slightly arcuate construction. A second end of the intermediate portion 54 connects with the second base 52, which also includes an arcuate construction. The first base 50, the second base 52, and the intermediate portion 54 may also include linear constructions and may be arranged at a variety of angles without deviating from the concept discussed herein.

Referring again to FIG. 2, the optical element 30 is generally positioned so that it is viewable on each of a front side, a first side, a second side, a rear side, and a bottom side of the rearview device 10. Although the illustrated embodiment shows the optical element 30 generally out of view from a top plan view, the optical element 30 may be viewable from a top plan view in other constructions where the first and second bases 50, 52 generally protrude forward relative to a front portion of the rearview device 10, or rearward relative to a back portion of the housing 14 of the rearview device 10.

Referring now to FIG. 4, the first contact point 34 includes engagement members 60 adapted to be received in complementary receiving apertures at a bottom portion of the housing 14. At the same time, the second contact point 36 includes engagement members 62 adapted to be received in complementary receiving apertures in the bottom surface 18 of the housing 14. The light source 26, which may be disposed inside or outside the housing 14, is generally configured to project light downward from the bottom surface 18 of the housing 14. It is generally contemplated that the light source 26 may project light onto the intermediate portion 54, which extends between the first and second bases 50, 52. However, it is also contemplated that the light source 26 may project light toward the first contact point 34, the second contact point 36, or both the first and second contact points 34, 36, thereby illuminating the optical element 30.

It should be appreciated by those skilled in the art that the optical element 30 can include only one of the first and second contact points 34, 36, such that the optical element 30 extends from the contact point 34 towards the second contact point 36, as illustrated in FIG. 4, but does not contact the housing 14 at the second contact point 36.

According to one embodiment, the light source 26 and/or the optical element 30 are configured for approximately uniform light distribution. The optical element 30 can include surface configurations (e.g., stippling) where the light source 26 is in direct optical communication with the optical element 30.

As shown in FIGS. 5 and 6, it is generally contemplated that the first contact point 34 and the second contact point 36 may be substantially planar in construction. More specifically, the first contact point 34 and the second contact point 36 may be planar so as to engage the housing 14, providing a smooth contoured appearance. In the event the bottom surface 18 of the housing 14 is arcuate, the first contact point 34 and the second contact point 36 of the optical element 30 may be arcuate to complement the bottom surface 18 of the housing 14. The optical element 30 may be constructed from a variety of materials that convey light. Further, the optical element 30 may be any of a variety of colors, including red, violet, blue, etc.

According to an embodiment illustrated in FIG. 7, the optical element 30 can include a second intermediate portion 64 that is configured to propagate light and project light as a portion of the substantially lateral planar 360 degree illumination pattern. The second intermediate portion 64 can be substantially transparent, so when the light source 26 is not emitting light, a user can view the scene forward of the vehicle through the second intermediate portion 64.

According to an alternate embodiment, the optical element can include a single contact point at a first end of the optical element that contacts a rear housing, and a second end of the optical element distant from the rear housing can be wider than the first end. The light source can be in optical communication with the optical element at the contact point, and propagate through an intermediate portion of the optical element to the second end. The second end can be configured so that the light is projected outwards in a substantially lateral planar 360 degree illumination pattern.

With respect to any of the embodiments described herein, the optical element 30 can include a clear or color filter (e.g., red, blue, etc.), the light source 26 can emit light having a wavelength of a particular color spectrum (e.g., a color filter, a light-emitting diode die, etc.), or a combination thereof.

The display portion 12 in any of the embodiments described herein can include a reflective element (e.g., an electrochromic mirror or a prism mirror), a display device (e.g., an LCD screen), or a combination thereof. Referring now to FIGS. 8-22A, a mount system is generally described that is configured so that a ball can have substantially constant torque characteristics, while a support connected to the ball can have various material characteristics. Thus, the changes of the torque characteristics are reduced even though the characteristics of the support are changed between embodiments. For example, if the support is painted tan and the ball is also painted tan, the ball will have different torque characteristics than the support and the ball painted black. It should also be noted that the painted ball surface varies in friction, which may affect torque, due to the application method, thickness, and other factors. This provides different surface characteristics than the rest of the mount system, and allows the torque surface to be installed mechanically. The mount system is optimized for structure and the ball is optimized for preferred torque. Any parting line/gating issue on the ball can be eliminated and the number and complexity of parts can be used.

Typically, the mount system described herein is used as a rearview device configured to image a view rearward of a driver in a vehicle. The rearview device can be connected to a windshield or a headliner of the vehicle by the support and the support can extend into a housing of the rearview device, such that a connection point between the support and the ball are substantially enclosed by the housing. The rearview device can be a reflective element (e.g., an electrochromic mirror or a prism mirror) or a display.

Referring now to FIG. 8, a split mount system 100 includes at least a first portion

102A and a second portion 102B. The first portion 102A can include a support portion 104A and a ball portion 106A, and the corresponding second portion 102B can include a support portion 104B and a ball portion 106B. Typically, the ball portion 106A is integrated with the first portion 102A, and the ball portion 106B is integrated with the second portion 102B. The split mount system 100 can be made of one or more suitable plastic materials. The first portion 102A and the second portion 102B can be connected by sonic weld or vibration weld. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the first and second portions 102A, 102B. When the first and second portions 102A, 102B are connected, the first and second portions 102A, 102B can define a cavity 108, wherein one or more wires 110 can pass through the cavity 108. Thus, the wire 110 can be inserted into the cavity 108, and the first and second portions 102A, 102B can be connected (e.g., welded) to one another.

As illustrated in FIG. 9, a mount system 200 includes a support 204 and a split ball having a first ball portion 206A and a second ball portion 206B. The mount system 200 can be made of one or more suitable plastic materials. The first ball portion 206A and the second ball portion 206B can be connected to one another and/or the support 204 by sonic welding or vibration welding. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the first and second ball portions 206A, 206B to the support 204. When the first and second ball portions 206A, 206B are connected to the support 204, the support 204 and the first and second ball portions 206A, 206B define a cavity 208, wherein one or more wires 210 pass through the cavity 208. The support 204 can be configured to have one or more protuberances 212 at one or more points of contact of the support 204 and the split ball, such that the one or more protuberances 212 contacting the first ball portion 206A and the second ball portion 206B can generally eliminate rotation of the split ball about a neck 214 of the support 204. Thus, the wire 210 can be inserted into the cavity 208, and the first and second ball portions 206A, 206B can be connected (e.g., welded) to one another to enclose the neck 214 so that the ball is substantially fixedly connected to the support 204.

Referring now to FIG. 10, a mount system 300 includes a support 304 and a ball

306. The mount system 300 can be made of one or more suitable plastic materials. The support 304 and the ball 306 can be connected by vibration weld, spin weld, or sonic weld. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the ball 306 to the support 304. The support 304 and the ball 306 can be configured to define a cavity 308, wherein one or more wires 310 pass through the cavity 308. Thus, the wire 310 can be inserted into the cavity 308, and the ball 306 can be connected (e.g., welded) to the support 304.

Referring now to FIG. 11, a mount system 400 includes a support 404 and a ball 406. The mount system 400 can be made of one or more suitable plastic materials. The support 404 and the ball 406 can be connected by vibration weld or sonic weld. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the ball 406 to the support 404. The ball 406 can be configured to define a cavity 408, wherein one or more wires 410 pass through the cavity 408. The ball 406 includes a ball portion 416, a neck portion 418, and an attachment portion 420, wherein the attachment portion 420 corresponds to the support 404, such that an attachment point of the support 404 and the attachment portion 420 are enclosed in a housing of a rearview device. Thus, the wire 410 can be inserted into the cavity 408, and the ball 406 can be connected (e.g., welded) to the support 404.

Referring now to FIG. 12, a mount system 500 includes a support 504 and a ball 506. The mount system 500 can be made of one or more suitable plastic materials. The ball 506 can be overmolded to the support 504. The support 504 and the ball 506 can be configured to define a cavity 508, wherein one or more wires 510 pass through the cavity 508. Thus, the wire 510 is inserted into the support 504 and the ball 506 is overmolded to the support 504 and encases a portion of the wire 510.

Referring now to FIG. 13, a mount system 600 includes a support 604 and a split ball having a first ball portion 606A and a second ball portion 606B. The support 604 can be made of a suitable metallic material, and the first and second ball portions 606A, 606B can be made of a suitable plastic material. The first and second ball portions 606A, 606B can be connected by sonic weld or vibration weld to enclose a neck 614 of the support 604, such that the first and second ball portions 606A, 606B are substantially fixedly connected to the support 604. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the first and second balls 606A, 606B to the support 604. When the first and second ball portions 606A, 606B are connected to the support 604, the support 604 and the first and second ball portions 606A, 606B define a cavity 608, wherein one or more wires 610 pass through the cavity 608. The support 604 can be configured to have one or more protuberances 612 at one or more points of contact of the support 604 and the spit ball, such that the one or more protuberances 612 contacting the first ball portion 606A and the second ball portion 606B can generally eliminate rotation of the split ball about the neck 614 of the support 604. Thus, the wire 610 can be inserted into the cavity 608, and the first and second ball portions 606A, 606B can be connected (e.g., welded) to one another to enclose the neck 614 so that the ball is substantially fixedly connected to the support 604. Referring now to FIG. 14, a mount system 700 includes a support 704 and a ball 706. The support 704 can be made of a suitable metallic material, and the ball 706 can be made of a suitable plastic material. The ball 706 can be connected to the support 704 by sonic weld or spin weld. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the ball 706 to the support 704. The support 704 and the ball 706 can define a cavity 708, wherein one or more wires 710 pass through the cavity 708. The support 704 can be configured to have one or more protuberances 712 at one or more points of contact of the support 704 and the ball 706, such that the one or more protuberances 712 contacting the ball 706 can generally eliminate rotation of the ball 706 about a neck 714 of the support 704. Thus, the wire 710 can be inserted into the cavity 708, and the ball 706 can be connected (e.g., welded) so that the ball 706 is substantially fixedly connected to the support 704.

Referring now to FIG. 15, a mount system 800 includes a support 804 and a ball 806. The support 804 can be made of a suitable metallic material, and the ball 806 can be made of a suitable plastic material. The ball 806 can be connected to the support 804 by being cold formed or screwed onto a neck 814 of the support 804. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the ball 806 to the support 804. The support 804 and the ball 806 can define a cavity 808, wherein one or more wires 810 pass through the cavity 808. The support 804 can be configured to have one or more protuberances 812 at one or more points of contact of the support 804 and the ball 806, such that the one or more protuberances 812 contacting the ball 806 can generally eliminate rotation of the ball 806 about a neck 814 of the support 804. Thus, the wire 810 can be inserted into the cavity 808, and the ball 806 can be connected (e.g., pushed or screwed) onto the neck 814 so that the ball 806 is substantially fixedly connected to the support 804.

Referring now to FIG. 16, a mount system 900 includes a support 904 and a ball 906. The support 904 can be made of a suitable metallic material, and the ball 906 can be made of a suitable plastic material. The ball 906 can be connected to the support 904 by overmolding the ball 906 onto a neck 914 of the support 904. However, it should be appreciated by those skilled in the art that additional or alternative methods of attachment can be used to connect the ball 906 to the support 904. The support 904 and the ball 906 can define a cavity 908, wherein one or more wires 910 pass through the cavity 908. Thus, the wire 910 can be inserted into the cavity 908, and the ball 906 can be connected (e.g., overmolded) onto the neck 914 of the support 904 so that the ball 906 is substantially fixedly connected to the support 904.

Referring now to FIGS. 17-22A, a mount system 1000 includes a support 1004, a split ball having a first ball portion 1006A and a second ball portion 1006B, a socket 1022, and a band or coil spring 1024. The support 1004 can include a neck 1014 that can be cylindrically-shaped and can define one or more holes or detents 1026. The one or more holes 1026 can correspond to one or more protrusions 1028 on an interior side 1030 of the split ball, which can be configured to be used when aligning the split ball on the neck 1014. Alternatively, the neck 1014 can include one or more engagement tabs 1031 adapted for engagement with tab receiving apertures 1033 disposed on the interior side 1030 of the split ball. The interior side 1030 of the split ball can include support ribs 1035 that provide increased structural rigidity to the split ball after assembly. The band spring 1024 can be a low stiffness band spring. The socket 1022 can include one or more stabilizing fingers 1032 (exemplary illustrated with four fingers) and one or more torque fingers 1034 (exemplary illustrated with four fingers). For purposes of explanation and not limitation, the split ball can be made of an acetal material and the socket 1022 can be made of a nylon material, or the socket 1022 can be made of an acetal material and the split ball can be made of a nylon material.

The socket 1022 can cause torque variation due to high finger stiffness. Torque is therefore sensitive to dimensional variations. However, the fingers 1032, 1034 cannot all be flexible or the mount system may result in poor vibration performance under dynamic loads. Thus, the socket 1022 can be configured to reduce the stiffness of one or more of the fingers 1032, 1034, while increasing a pre-deflection result in the same torque value with lower stiffness. A finger clamp can be introduced to reduce strain on the socket 1022, and therefore, creep of plastic material used to form the socket 1022. When the split ball is made of an acetal material, the material options for the socket 1022 can include, but are not limited to, glass bead filled nylon, which increases strength, rigidity, creep resistance, and temperature resistance, as compared to other materials.

In the embodiment illustrated in FIGS. 20, 22, and 22A, between four and eight fingers 1032 apply a normal force to the split ball and are contacted by the band spring 1024. The fingers 1032 act as torque or compression fingers on the ball or split ball. The fingers 1032 can have varying stiffnesses. According to one embodiment, alternating fingers 1034 generally have higher stiffness, which can be controlled by one or more ribs 1036 on the fingers 1034. The fingers 1034 serve as retention features that secure the ball or split ball in the socket 1022, but do not apply a compression or torsional force on the ball or split ball. The band spring 1024 may not contact the fingers 1032 that have the increased stiffness. As noted above, the fingers 1034 are generally configured to retain the ball or split ball in the socket 1022. Generally, there is reduced interference between the stiff fingers 1034 and the split ball. Large interferences can cause high strain and result in creep variation in clamp force over time. Any looseness is minimized by the compression fingers 1032. The fingers 1034 are generally configured to apply a force on the ball in a direction that is partially toward a base wall of the socket 1022, thereby retaining the ball in the socket 1022. However, the fingers 1032 have lesser stiffness than the fingers 1034. The band spring 1024 can be applied around the fingers 1032, such that the fingers 1032 apply a force on the ball or split ball. The compressive force, together with the friction between the socket 1022 and the ball, provide a torque-resisting motion between the ball and the socket 1022. The torsional force can increase or decrease the effort required to rotate a rearview device secured with the base wall of the mount. Generally, the force applied by the retention fingers 1034 is less than the force applied by the torque fingers 1032. Stated differently, the torque fingers 1032 apply greater force on the ball than the retention fingers 1034.

Referring now to FIGS. 21 and 21A, the second ball portion 1006B is illustrated, and it should be appreciated that the first ball portion 1006A can be a replica of this illustration. Typically, the first and second ball portions 1006A, 1006B snap-fit into the holes 1026 of the neck 1014 of the support 1004, such that the first and second ball portions 1006A, 1006B are adjacent and form a single ball. The compression of the split ball by the socket 1022 can also press the first and second ball portions 1006A, 1006B together. The split ball can be configured to provide a substantially consistent coefficient of friction. Also, the substantially consistent coefficient of friction can be achieved regardless of a paint color applied to the support 1004. Acceptable compressive creep resistance can be achieved by balancing strain with the one or more ribs 1036, backing up with die casting, using glass bead filled creep resistance acetal formulation, or a combination thereof. Referring again to FIGS. 22 and 22A, the band spring 1024 can contact four fingers 1032, 1034 to create a static determinate system, according to one embodiment. Stress can be reduced during assembly of the support 1004 and the ball into the socket 1022 because the flexible fingers have little or no deflection. The flexible fingers 1032 can include a positive stop that can be used to locate the band spring 1024. Having the one or more ribs 1036 on one of the stiff fingers 1034 can be adapted to provide a positive location feature. Low stiffness and increased high pre-deflection can enhance robustness to tolerance variations. Typically, stiff fingers 1034 are configured to provide enhanced rigidity and vibration performance. Generally, in a system where the band spring 1024 contacts eight fingers 1032, 1034, it is very difficult to determine how much force is on each finger 1032, 1034. The force can be distributed on any of between four to eight fingers 1032, 1034, depending on tolerance variation of the band spring 1024 and the socket 1022. Over time, the fingers 1032, 1034 experiencing higher force will creep more, changing the shape of the fingers 1032, 1034. At the same time, force is lost from the band spring 1024. Since the amount of force on each individual finger 1032, 1034 determines the mirror adjustment torque normal to that finger 1032, 1034, redistribution of these normal forces will change the adjustment torque differently in all eight directions.

Referring now to FIGS. 23-28, another embodiment is depicted, which includes a mount system 1200 having a support 1202, a ball 1204, and a split socket 1206. The split socket 1206 includes a first distinct socket portion 1208 and a second distinct socket portion 1210. The first distinct socket portion 1208 and the second distinct socket portion 1210 form a ball receiving wall 1211 that generally defines a cavity 1212 having predetermined torque characteristics for use with the ball 1204, which includes different predefined torque characteristics than the cavity 1212. The first distinct socket portion 1208 and the second distinct socket portion 1210 are mirror images of each other and can be connected by other methods than mechanical fasteners (e.g., vibration weld, spin weld, or sonic weld). It is also contemplated that the first and second distinct socket portions 1208, 1210 can be held together by the band spring 1024. The first distinct socket portion 1208 and the second distinct socket portion 1210 are then positioned around the ball 1204 and connected at first and second fastener locations. In the illustrated embodiment, an interference fit is provided between a male protrusion 1220 and a female receiver 1222 at each of the first and second fastener locations. A band spring 1230 is then positioned around the ball receiving wall 1211, and more specifically around a plurality of fingers 1232 that are disposed around the ball receiving wall 1211. The band spring 1230 is generally configured to extend about the periphery of the ball receiving wall 1211 in abutting contact with the plurality of fingers 1232 and force the ball receiving wall 1211 inward into frictional contact with the ball 1204. The ball 1204 is then operably coupled with a neck 1216 of the support 1202. The cavity 1212 generally defines an internal wire aperture 1234 for routing power and data lines through both the split socket 1206 and the ball 1204, and into the mount system 1200. The split socket 1206 generally includes first and second retention members 1240, 1242 designed to retain the ball 1204 in the split socket 1206. The ball receiving wall 1211 and the plurality of fingers 1232 are generally configured to flex under pressure or force applied by the band spring 1230, thereby providing a selective force on the ball 1204, which affects the torsional properties between the ball 1204 and the split socket 1206. Accordingly, the retention and adjustment torque on a rearview device connected with the mount system 1200 can be modified by using different band springs 1230.

It will be understood by one having ordinary skill in the art that construction of the described invention and other components is not limited to any specific material. Other exemplary embodiments of the invention disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term "coupled" (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the invention as shown in the exemplary embodiments is illustrative only.

Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present invention. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.