Fillable and stiffened rearview mirror assembly
View Patent ↗A fillable rearview mirror assembly and method of molding a carrier for the assembly are provided. The mirror assembly has a hollow carrier that can be at least partially filled with a material having a density different than that of the carrier. A mirror can be attached to the carrier and the carrier attached to the vehicle.
1. A method of manufacturing a carrier for a rearview mirror assembly, comprising the steps of:
providing a blank to be melted;
heating the blank to form a molten blank;
forcing air into the molten blank to form a blowmolded carrier having a hollow space therein;
inserting a stiffening structure in the blowmolded carrier;
cooling the blowmolded carrier to achieve form stability; and
inserting a foam element in the hollow space.
2. The method as in claim 1 , further comprising the step of providing the blank with varying thicknesses to achieve varying thicknesses in the carrier.
3. The method as in claim 1 , wherein the hollow space is a plurality of hollow bubbles.
4. The method as in claim 1 , wherein the stiffening structure is one of grid-like ribs, tubes, or combinations thereof.
5. The method as in claim 1 , wherein the foam element is shaped complementary to the stiffening structure, the hollow space, and combinations thereof.
6. A method of manufacturing a stiffened, extrusion blowmolded carrier for a rearview mirror assembly, the carrier having a hollow space therein, comprising the steps of:
providing a plastic blank to be melted;
heating the blank to form a molten blank;
forcing the molten blank to form a continuous hollow carrier;
inserting a stiffening rib in the hollow space;
affixing the stiffening rib in the hollow space to the carrier;
cooling the carrier to achieve form stability;
injecting a plastic foam in the hollow space; and
encapsulating the rib with the plastic foam.
7. A method of manufacturing an injection molded carrier for a rearview mirror assembly, comprising the steps of:
providing a plastic blank to be melted;
heating the blank to form a molten blank;
forming by injection the molten blank into the form of a carrier having a hollow space therein, the hollow space having a first part and a second part;
inserting stiffening tubes and ribs in the hollow space;
affixing the tubes and ribs in the hollow space to the carrier;
cooling the carrier to achieve form stability;
injecting a plastic foam in at least the first part of the hollow space;
encapsulating the tubes and ribs at least partially with the foam; and
injecting a granulate in at least the second part of the hollow space.
8. The method as in claim 7 , further comprising the step of forming one of the first and second parts to have a plurality of hollow bubbles suspended in a portion of the hollow space and stabilized carrier.