METHOD FOR MANUFACTURING AN AUTOMOTIVE MIRROR

Abstract

A method for manufacturing an automotive mirror, in particular a side mirror, includes forming a printed circuit board as flexible printed circuit board with n+1 branches, nεN, providing n modules each including at least one electronic element housed within a plastic casting and connected to conducting paths on at least one of the surfaces of the plastic casting, and at least one standard gripping point, guiding structure, snap connection element and/or sealing member provided by the plastic casting, connecting up to n of said branches to one module each and connecting one branch to cables or a cable harness to be connected to a power supply and/or a control unit outside the mirror, providing mirror parts free of electronic elements, and assembling the mirror parts and the modules.

Claims

1-22. (canceled)

23. A method for manufacturing an automotive mirror, comprising the following steps: forming a printed circuit board as a flexible printed circuit board comprising n+1 branches, nN; providing n modules each comprising at least one electronic element housed within a plastic casting and connected to conducting paths on at least one of the surfaces of the plastic casting; and at least one of a standard gripping point, guiding structure, snap connection element and sealing member provided by the plastic casting; connecting up to n of said branches to one module each and connecting one branch to cables or a cable harness to be connected to at least one of a power supply and a control unit outside the mirror; providing mirror parts free of electronic elements; and assembling the mirror parts and the modules.

24. The method according to claim 1, wherein the printed circuit board and the modules are connected to form a pre-assembled unit, and/or either the mirror parts and the modules or the pre-assembled unit are assembled by snap connections together with the mirror parts.

25. The method according to claim 1, wherein each module is formed as a molded interconnect device providing the plastic casting with the conducting paths, with the MID being a metalized two component injection molding, an injection molding with an impressed metal foil or a laser structured injection molding.

26. The method according to claim 1, wherein the plastic casting of each module is molded with the standard gripping point provided in an edge region, the guiding structure provided by a tapering, the snap connection element provided by a hook or recess, and/or the sealing member provided by a deformable projection.

27. The method according to claim 1, wherein at last one of the modules is connected to a mirror part provided with a structure mating the guiding structure, the snap connection element and/or the sealing member of the module, respectively.

28. The method according to claim 1, wherein at least one of the modules comprises a lightning unit, to function as a turn signal module, a blind spot warning module, a logo lamp unit, an environment illuminating unit or the like; a motor for mirror glass adjustment; or a sensor in form of a camera or radar sensor.

29. The method according to claim 1, further comprising providing at least one of some of the mirror parts and the flexible printed circuit board with at least one standard gripping point.

30. The method according to claim 1, further comprising providing a gripping device with at least one gripping unit designed for gripping the mirror parts, the modules and/or the flexible printed circuit board at the standard gripping points; and assembling the parts by controlling the gripping device.

31. The method according to claim 1, wherein the standard gripping points are provided by slots, cut outs, recesses, clips, straps, edges and/or projections, and/or the standard gripping points are introduced within the mirror parts, the modules, and/or the flexible printed circuit board during manufacture thereof, and/or the standard gripping points are formed with a shape and/or dimension depending from the gripping unit design.

32. The method according to claim 1, wherein a gripping unit design defines the standard gripping points, and the mirror parts, the modules and/or the flexible printed circuit board mirror are formed with the defined standard gripping points.

33. The method according to claim 1, wherein at least one structural feature of at least one of the modules, the flexible printed circuit board and/or the mirror parts fulfilling a separate function is selected to provide at least one standard gripping point, and the gripping unit design and/or control is defined by the structural feature.

34. The method according to claim 33, wherein the separate function is defined by a snap connection element for a mechanical connection or a terminal for an electrical connection.

35. The method according to claim 30, wherein the gripping device is introduced into a production line, and/or the gripping device is integrated into an industrial robot as an end effector tool or is connected to an industrial robot via an automatic tool changer system.

36. The method according to claim 30, wherein the gripping device is formed with a plurality of gripping units which are moved in different directions during the assembling, and/or the gripping device is operated by controlling motors, pneumatic systems and/or hydraulic systems, preferably in reaction to sensor output signals.

37. The method according to claim 30, wherein the gripping units are moveable relative to each other or all together, each gripping unit comprising a pair of two fingers for gripping one mirror part, one module or the flexible printed circuit board; and an arm for moving the pair of two fingers.

38. The method according to claim 37, wherein the fingers of each pair are moveable and/or cooperate with an ejection means for ejecting the part, the module or the flexible printed circuit board gripped by the respective pair of fingers.

39. The method according to claim 30, wherein the gripping units are attached to a center spine, and the spine can be controlled to conduct a rotary and/or translatory movement via a center spine placing means.

40. The method according to claim 37, wherein each gripping arm comprises an upper arm and a lower arm, with the upper arm being moveable relative to the lower arm, and/or the upper arm being pivotable or rotatable relative to the lower arm with at least one axis of rotation via arm bending means.

41. The method according to claim 37, wherein each pair of fingers is designed to grip a branch of a flexible circuit board.

42. The method according to claim 30, wherein a control unit cooperates with the gripping device, the tool connecting means, the center spine placing means, the arm bending means and/or the ejecting means during an assembly of the automotive mirror.

43. The method according to claim 42, wherein the control unit receives signals from at least one sensor provided by the gripping device and/or at least one stopper.

44. The method according to claim 30, wherein the gripping device electrically connects the flexible printed circuit board with the modules by crimping.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] The invention, together with further objects and advantages, may be best understood, by example, with reference to the following description of embodiments taken together with the accompanying schematic drawings:

[0043] FIG. 1A shows a perspective view of a flexible circuit board without an electrical module of the invention being connected.

[0044] FIG. 1B shows an enlargement of one of the branches of the flexible circuit board of FIG. 1a with a connected electrical module.

[0045] FIG. 2A shows a perspective view of a housing part and a second mirror part in form of a light guide unit prior to assembly.

[0046] FIG. 2B shows an enlargement of the first mirror part in form of a housing part and the light guide unit of FIG. 2A after assembly and a turn signal module during assembly.

[0047] FIG. 3A shows a perspective view of a first mirror part in form of a housing ring with first gripping points provided by straps.

[0048] FIG. 3B shows the third mirror part of FIG. 3A gripped by a gripping unit at third gripping points.

[0049] FIG. 4A shows a perspective view of a fourth mirror part in form of a top cap with fourth gripping points provided by clips.

[0050] FIG. 4B shows an enlargement of one of the clips of FIG. 4A with recesses.

[0051] FIG. 4C shows the fourth mirror part of FIGS. 4A and 4B gripped by the gripping unit at fourth gripping points.

[0052] FIG. 5A shows a perspective view of a fifth mirror part in form of a mirror foot with fifth gripping points provided by cut outs.

[0053] FIG. 5B shows the fifth mirror part of FIG. 5A gripped by the gripping unit at the fifth gripping points.

[0054] FIG. 6A shows a perspective view of an alternative gripping device.

[0055] FIG. 6B shows an enlargement of one of the gripping units of the gripping device of FIG. 6A.

DETAILED DESCRIPTION

[0056] An automotive side mirror includes a plurality of parts, like a flexible printed circuit board (FPC) shown in FIGS. 1A and 1B and to be installed within a housing to connect electrical modules, e.g. a turn signal module, with a power supply and a control unit outside the automotive side mirror during assembly thereof, with said assembly being described with respect to FIGS. 2A and 2B below.

[0057] The FPC 40 of FIG. 1A has 7 arms or branches, 6 of said branches being provided with terminals 41 to 46 to be connected to electrical modules, with FIG. 1B showing one of said 6 branches connected to one module 50, whereas the 7th branch is connected to cables 47 for connecting the electrical module 50 to a not shown power supply and a not shown control unit.

[0058] In a pre-assembly step the FPC 40 is connected with 6 modules 50 and the cables 47 by crimping, soldering or the like, to provide one unit. Said unit of the FPC 40, the 6 electrical modules 50 and the cables 47 looks like a spider (not shown) and, therefore, is called spider in the following.

[0059] In order to connect said pre-assembled spider to the remaining parts of the automotive side mirror in an automated production line with a spider gripper described with respect to FIGS. 6A and 6B below, each of said modules 50 is provided with standard gripping points. The electrical module 50 of FIG. 1B is formed with opposing recesses 52 providing said gripping points.

[0060] The gripping points providing recesses 52 of each of the 6 modules 50 allow for said spider gripper having 6 arms and, thus, 6 pairs of fingers to grip each of the modules 50 between 2 fingers of one arm for assembly. Each free end of an arm of the spider gripper has a small pneumatic or hydraulic cylinder or electrically operated motor based system for gripping one electric module 50 between 2 fingers engaging the module 50 within its recess 52 at two opposite sides, introducing the module 50 into a corresponding mirror part and ejecting the module 50 between said 2 fingers at the end of the assembly.

[0061] The modules 50 can be provided as MIDs with a plastic molding housing electrical components comprising e.g. a lightning unit to form in particular a turn signal module and providing conducting paths obtained by Laser Direct Structuring (LDS). The plastic molding can be provided with further structural features facilitating the assembly of the modules 50 of the spider to the remaining automotive mirror parts.

[0062] In case the module is to function as a turn signal module 500 connected to a flexible printed circuit board 400, it is to be assembled with a light guide unit 20 during the assembly thereof to a housing part 10 as will be explained with respect to FIGS. 2A and 2B in the following.

[0063] The light guide unit 20 is provided with a plurality of clip connection elements 21, 22 formed together with a housing 23 which is also provided with an opening 24 for inserting the turn signal module 500 between the housing 23 and a light guide 25.

[0064] The clip connection elements 21 are suited for engaging mating clip connection elements 11 provided by the housing part 10. The housing part 10 is formed in addition with further clip connection elements 12 for the connection of a mirror foot 30 extending through an opening 14 provided within the housing 10. The direction of assembly of the mirror parts 10, 20 and 30 is indicated by the arrow A in FIG. 2A.

[0065] The light guide unit 20 does not include any electronic element, in particular no lighting unit. All electronic elements required for providing a turn signal are arranged within the turn signal module 500 to be introduced into the opening 24 during assembly.

[0066] In an aspect, the two pre-assembled parts, namely a spider comprising the flexible printed circuit board 400, the turn signal module 500 and a cable harness 470, and a unit with the light guide 20, the housing part 10 and the mirror foot 30, are connected to each other via snap connections, with the assembly direction being indicated by the arrows B in FIG. 2B.

[0067] The turn signal module 500 is provided with opposing gripping edges 520 at its upper end facing away from the light guide unit 20 in FIG. 2B. Said gripping edges 520 can be gripped by said spider gripper, which can move the module 500 in assembly direction B to enter the opening 24.

[0068] The turn signal module 500 is provided with a opposing guiding faces 510, 511 providing a tapering facilitating the insertion of the turn signal module 500 into the opening 24. The turn signal module 500 is slided into the opening 24 by the spider gripper until an abutment of the guiding faces 510, 511 against corresponding surfaces of the housing 23, with a final locking by a snap connection. For that purpose the module 500 is provided with a snap connection element 513 in form of a hole into which a hook (not shown) provided within the light guide units 20 can enter.

[0069] In the assembled position of the turn signal module 500 within the light guide unit 20 a connection 532 of conducting paths 530 of the module 500 to the flexible printed circuit board 400 is arranged within the region of the opening 24. Still further, a sealing member 540 provided in form of a projection of the module 500 seals the connection between the light guide unit 20 and the exterior of the automotive mirror 1 to be assembled.

[0070] The spider gripper is detached from the module 500 as soon as the same has been placed into its final position within the opening 24.

[0071] Further mirror parts of an automotive side mirror will be described in the following, namely in form of a housing ring as shown in FIG. 3A, a top cap as shown in FIG. 4A and a mirror foot as shown in FIG. 5A. In order to assemble said mirror parts in an automated production line with a standard or rather common gripper each part is provided with standard gripping points.

[0072] The housing ring 111 shown in FIG. 3A includes a plurality of straps 112 each providing standard gripping points. This is further illustrated by FIG. 3B showing a standard gripping unit 100 with two gripping fingers 102 each having an inner surface 104 with a recess 106 and an outer surface 108 with a recess 110. Each strap 112 can be gripped between the inner surfaces 104 of the gripping fingers 102 of the gripping unit 100 in a standard manner.

[0073] The top cap 120 of FIG. 4Aa includes two different kinds of standard gripping points in form of clips 122 and 124. The clips 122 correspond substantially to the straps 112 shown in FIG. 3A and can be gripped between the inner surfaces 104 of the gripping fingers 102 of the gripping unit 100, whereas the clip 124 is gripped by the outer surfaces 108 of the gripping fingers 102 of the gripping unit 100 by entering the gripping fingers 102 into recesses 126a, 126b as best seen in FIGS. 4B and 4C.

[0074] The clips 122 can also serve to enable a snap connection with another housing part of the automotive side mirror.

[0075] The mirror foot 130 of FIG. 5A is provided with two cut outs 132 forming standard gripping points with can be gripped between the inner surfaces 104 of the gripping fingers 102 of the gripping device 100 as shown in FIG. 5B.

[0076] In order to handle a plurality of mirror parts, in particular in form of the spider provided by the flexible circuit board 40 having modules 50 attached to its plurality of branches as discussed with respect to FIGS. 1A and 1B; a gripping device 1000 may also be used as shown in FIG. 6A. Such a gripping device 1000 is provided with a center spine 1002 which is connected at its upper end in FIG. 6A to a tool connection means 1004 for the attachment to a not shown robot and at its lower end to six gripping units 1100. Via a center spine placing means 1006 operated by supplying air to air nipples 1008 the center spine 1002 can be moved upwards and downwards whereas a rotation of the center spine 1002 can be achieved manually.

[0077] Each gripping unit 1100 includes an arm having two parts, in form of an upper gripping arm 1102 and a lower gripping arm 1104, which can be pivoted with respect to each other via an arm bending means 1200 provided with an air nipple 1202 pneumatically moving a piston 1204. At the free end of the arm of each gripping unit 1100 a pair of gripping fingers 1106 is provided, as best seen in FIG. 6B. The fingers 1106 of each pair cooperate with ejecting means 1300 each provided with an air nipple 1302 in order to pneumatically move a piston 1304 to eject an article gripped between the two gripping fingers 1106.

[0078] The gripping device 1000 can be controlled to move its gripping units 1100 like the legs of a spider with the additional advantage of fingers of a human palm. With this particular design it is possible to grip each of the 6 branches of the flexible circuit board 40 shown in FIG. 1A between a pair of gripping fingers 1106 and move said branches in different directions relative to each other allowing a high degree of freedom with respect to the arrangement of the electrical modules 50 within the automotive side mirror 1 and still have them all connected to the power supply via the electrical circuit board 40.

[0079] Thus, the gripping device 1000 is not restricted to handling articles to be assembled in a single production direction, but provides a high degree of freedom enabling an optimal usage of flexible circuit boards. This also speeds up the manufacturing of automotive mirrors.

[0080] Although modifications and changes may be suggested by those skilled in the art, it is the intention of the application to embody within the patent warranted hereon all changes and modifications as reasonably and probably come within the scope of this contribution to the art. The features of the present invention which are believed to be novel are set forth in detail in the appended claims. The features disclosed in the description, the figures as well as the claims could be essential alone or in every combination for the realization of the invention in its different embodiments.

REFERENCE SIGN LISTING

[0081] 1 automotive mirror [0082] 10 housing part [0083] 11, 12 clip connection element [0084] 14 opening [0085] 20 light guide unit [0086] 21, 22 clip connection element [0087] 23 housing [0088] 24 opening [0089] 25 light guide [0090] 30 mirror foot [0091] 40 flexible printed circuit board [0092] 41-46 terminals [0093] 47 cables [0094] 50 electrical module [0095] 52 recess [0096] 60 mirror plate adjustment unit [0097] 100 gripping unit [0098] 102 gripping finger [0099] 104 inner surface [0100] 106 recess [0101] 108 outer surface [0102] 110 recess [0103] 111 housing ring [0104] 112 strap [0105] 120 top cap [0106] 122 clip [0107] 124 clip [0108] 126a, 26b recess [0109] 130 mirror foot [0110] 132 cut out [0111] 400 flexible printed circuit board [0112] 470 cable harness [0113] 500 turn signal module [0114] 510, 511 guiding face [0115] 513 snap connection element [0116] 520 gripping edge [0117] 530 conducting paths [0118] 532 connection to flexible printed circuit board [0119] 540 sealing member [0120] 1000 gripping device [0121] 1002 center spine [0122] 1004 tool connection means [0123] 1006 center spine placing means [0124] 1008 air nipple [0125] 1100 gripping unit [0126] 1102 upper gripping arm [0127] 1104 lower gripping arm [0128] 1106 gripping finger [0129] 1200 arm bending means [0130] 1202 air nipple [0131] 1204 piston [0132] 1300 ejecting means [0133] 1302 air nipple [0134] 1304 piston [0135] A, B assembly direction