The present disclosure relates to a housing for a mirror. More specifically, the present disclosure relates to a housing for a mirror that is extruded, cut to size, assembled, and then installed to an illuminated mirror.
Housings for an illuminated mirror are generally known in the art. These known housings are formed of metal and include a top component, a bottom component, and two side components that form a square or rectangular housing. The top and bottom components are generally different in shape and design than the side components. The top and bottom components are customized to a mirror width and etch design, which facilitates illumination (e.g., task lighting, ambient lighting, accent lighting, etc.). The side components are customized to a mirror height. Unfortunately, these metal components that form a housing have certain limitations. For example, since the metal components are custom fabricated for different sized mirrors, and further utilized in illuminated mirrors, the components must go through a plurality of manufacturing steps to form and finish each component. Manufacturing includes custom lengths and sizes based on mirror size, along with providing suitable mounting systems for attaching and positioning a light source and associated electronics for operation. Finishing includes application of a coating that assists with reflecting and/or directing light to achieve a desired illuminance (measured in lux). The custom fabrication requires substantial lead time, which can delay manufacturing of the mirror. In addition, since the top components, bottom component, and side components are all different in design (along with size), there is additional supply chain and production complexities to manufacture a housing. Accordingly, there is a need to improve components of an illuminated mirror housing to reduce manufacturing lead time, reduce customized inventory, and standardize components, while also providing a desired strength, ability to attach a light source and associated electronics at a variety of positions based on a desired etch design, and illuminance.
In one example of an embodiment, a housing assembly for an illuminated mirror includes a side member including a base wall, a first sidewall, and a second sidewall defining a channel, the base wall including an inner base wall spaced from an outer base wall and defining a first slot, and a corner member including a corner member base wall, an interior sidewall, and an exterior sidewall defining a corner member channel, a first mounting tab projecting from a first end of the corner member base wall, wherein the first mounting tab is configured to be received by the first slot of the side member to interlock the corner member to the side member.
In another example of an embodiment, a housing assembly for an illuminated mirror includes alternating interlocking side members and corner members, each side member including a base wall, a first sidewall, and a second sidewall defining a side member channel, the base wall including an inner base wall spaced from an outer base wall and defining a first slot. Each corner member includes a corner member base wall, an interior sidewall, and an exterior sidewall defining a first corner member channel, a first mounting tab projecting from a first end of the corner member base wall, and a second mounting tab projecting from a second end of the corner member base wall, wherein the first mounting tab is configured to be received by the first slot of one adjacent side member, and the second mounting tab is configured to be received by the first slot of the other adjacent side member.
Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
Before embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways.
The present disclosure is directed to a housing assembly 100 for a mirror assembly 10, and more specifically an illuminated mirror assembly 10. The housing assembly 100 includes a plurality of side members 104 and a plurality of corner members 108. The side members 104 can be extruded and cut to any suitable size to form a customized housing assembly 100 in response to an associated size of a mirror. The side members 104 have a geometry that provides a plurality of mounting positions for an illumination source and efficient assembly with corner member 108. Since the side members 104 are cut to size to form a customized housing assembly 100 size for a desired sized mirror, the side members 104 advantageously reduce the need for customized metal components, simplifying inventory and supply chain complexity.
With reference now to the figures,
With reference to
With reference now to
The first, second, and third portions 120, 124, 128 of the side member 104 are formed by a double wall construction. More specifically, the first portion 120 (or base wall 120) includes an inner wall 120a (or interior base wall 120a or inner base wall 120a) spaced from an outer wall 120b (or exterior base wall 120b or outer base wall 120b) (shown in
With continued reference to
The third portion 128 (or second sidewall 128) includes an inner wall 128a (or second interior wall 128a or second inner sidewall 128a) (shown in
The passages 136, 144, 148 allow for a reduction in material, decreasing the weight of the side member 104 while providing a suitable structural rigidity to support the housing assembly 100. The passages 136, 144, 148 also facilitate engagement with the corner member 108, which is discussed in additional detail below.
The channel 132 of the side member 104 provides a plurality of mounting surfaces for mounting a light source 200 (shown in
The passages 136, 144, 148 each define slots that are configured to receive a portion of the corner member 108. With reference now to
In the illustrated embodiment, the channel 164 has an approximate U-shaped (or C-shaped) cross-section. The channel 164 is generally the same size as the channel 132 of each side member 104. This allows the channels 132, 164 to cooperate to form a continuous channel around the housing assembly 100. The channel 164 of the corner member 108 generally forms an L-shape. More specifically, the channel 164 includes a first channel portion 164a that is oriented orthogonal to a second channel portion 164b.
Each end of the corner member 108 includes a plurality of mounting tabs 168a, b, c. More specifically, each end of the channel 164 includes a plurality of mounting tabs 168a, b, c. For example, the first channel portion 164a includes a first mounting tab 168a that extends from (or projects from) the first portion 152, a second mounting tab 168b that extends from (or projects from) the second portion 156, and a third mounting tab 168c that extends from (or projects from) the third portion 160. Similarly, the second channel portion 164b includes a plurality of mounting tabs 168a, b, c. The first mounting tab 168a extends from (or projects from) the first portion 152, the second mounting tab 168b extends from (or projects from) the second portion 156, and the third mounting tab 168c extends from (or projects from) the third portion 160. While the illustrated embodiment illustrates the plurality of mounting tabs 168 as three total mounting tabs, in other examples of embodiments, there can be two or more mounting tabs 168 or at least one mounting tab 168. It should also be appreciated that each mounting tab 168a, b, c is oriented to be parallel to the associated portion 152, 156, 160 of the corner member 108.
Each mounting tabs 168a, b, c is configured to be received by one of the associated passages 136, 144, 148 defined by the side member 104 to couple one side member 104 to each end of the corner member 108. Stated another way, each mounting tab 168a, b, c is received by an associated passage 136, 144, 148. It should be appreciated that the passages 136, 144, 148 define slots that are configured to receive a portion of the corner member 108. In the illustrated embodiment, the first passage 136 is configured to receive the first tab 168a. The second passage 144 is configured to receive the second tab 168b. The third passage 148 is configured to receive the third tab 168c. By having each of the plurality of mounting tabs 168a, b, c of the corner member 108 being received by a respective slot (or passage) 136, 144, 148 of the side member 104, the engagement between the corner member 108 and the side member 104 minimizes light leakage through the assembled housing assembly 100. It should also be appreciated that one or more fasteners (e.g., a screw, a bolt, adhesive, etc.) can be used to further fasten the corner member 108 to each side member 104 following insertion of the mounting tabs 168a, b, c into respective slots 136, 144, 148 of the side member 104.
As shown in
It should be appreciated that the exterior wall 160 of the corner member partially defines the first channel 164 and partially defines the second channel 180. As illustrated, the exterior wall 160 defines a side wall of the first channel 164. The exterior wall 160 also defines a base wall (or bottom wall) of the second channel 180. As such, the second channel 180 is oriented orthogonal (or perpendicular) to the first channel 164.
The corner member 108 provides a plurality of mounting surfaces for mounting the light source 200 (see
In the first light configuration, shown in
In the second light configuration, shown in
The side members 104 can be made of a highly reflective white polyvinyl chloride (PVC) material. The reflective material can assist with enhancing a desired illumination from the light source. The side members 104 are also pigmented to a level to provide sufficient opacity to minimize light leakage from the light source 200 through the side members 104. The side members 104 are also configured to be formed by extrusion. In other examples of embodiments, the side members 104 can be formed of any plastic, synthetic polymer, or other suitable material to provide the combination of weight, strength, and light reflectivity desired by the housing assembly 100. The side members 104 can be injection molded, or formed of any other suitable process for forming the side member 104.
The corner members 108 can also be made of a highly reflective white polyvinyl chloride (PVC) material. The reflective material can assist with enhancing a desired illumination from the light source. The corner members 108 are also pigmented to a level to provide sufficient opacity to minimize light leakage from the light source 200 through the corner members 108. For example, the corner members 108 can include up to 20% colorant to achieve sufficient opacity to minimize light leakage. In other embodiments, the corner members 108 can be formed of a different color of material than the side members 104. The corner members 108 are configured to be formed by injection molding. In other examples of embodiments, the corner members 108 can be formed of any plastic, synthetic polymer, or other suitable material to provide the combination of weight, strength, and light reflectivity desired by the housing assembly 100. In addition, the corner members 108 can be extruded, or formed of any other suitable process for forming the corner members 108.
With reference now to
When assembling the customized housing assembly 100, each parent member 188 is cut into a plurality of side members 104. This allows for custom manufacturing to desired lengths of side members 104 based on the size of the custom mirror assembly 10. In the illustrated embodiment, the parent member 188 is cut into four side members 104—two sides of the housing assembly 100, a top of the housing assembly 100, and a bottom of the housing assembly 100. Accordingly, parent member 188 is cut four times to the desired lengths of side members 104. In the illustrated embodiment, after cutting of the parent member 188 to acquire the four side members 104, a portion of the parent member 188 remains as scrap. This scrap can be recycled for reuse as another parent member 188 by the extruder (or other process for forming the parent members 188). In other examples of embodiments, fewer than four side members 104 or more than four side members 104 can be cut from a single parent member 188. In addition, in other examples of embodiments, there may not be any scrap after cutting of the parent member 188 into desired length side members 104.
Once all side members 104 are cut to size, they are assembled to form the housing assembly 100. The housing assembly 100 includes four corner members 108. Each corner members 108 engages two adjacent side members 104 such that the finished housing assembly 100 includes four corner members 108 and four side members 104 (i.e., a top member, a bottom member, and two sides). Each corner member 108 slidably engages two adjacent side members 104 by mounting tabs 188 of the corner member 108 being received by a respective slot (or passage) 136, 144, 148 of the side member 104, as discussed above. Accordingly, the housing assembly 100 alternates between side member 104 and corner member 108 around the assembly 100. Once assembled, the mounting brackets 112a, 112b can be fastened to the corner members 108, and/or side members 104 by one or more fastener(s) (e.g., a screw, a bolt, adhesive, etc.). The light source is then attached to the housing assembly 100. More specifically, the light source is attached to a suitable surface of the side members 104 and corner members 108 to acquire a desired light output for a desired mirror etch design (e.g., task lighting, ambient lighting, accent lighting, etc.).
One or more aspects of the housing assembly 100 of the mirror assembly 10 provides certain advantages. The side members 104 can be cut to customized lengths from an extruded parent member 188, eliminating the need for prefabricated housing members that are customized for each mirror size. The side members 104 also include an advantageous double wall design that facilitates improved engagement with the corner members 108 to minimize light leakage, while also providing structural rigidity with a reduction in overall weight. The side members 104 and corner members 108 further include a unique geometry to provide a plurality of different mounting surfaces for fastening a light source in order to optimize light output based on a type of illuminated mirror. In addition, the second channel 180 defined by the exterior wall 160 of the corner member 108 is configured to both guide and protect the illumination source 200. More specifically, the second channel 180 is configured to guide the illumination source 200 around an outer perimeter of the housing assembly 100. In addition, since the second channel 180 includes a recessed surface, as the second side 176 is recessed relative to the projections 184, the illumination source 200 is fastened to the second side 176. Thus, the projections 184 protect the illumination source 200 from damage caused by contact with a surface (e.g., the ground, etc.), as the projections 184 absorb any force, deflecting such force (or impact) from contact with the illumination source 200. These and other advantages are realized by the disclosure provided herein.
This application claims priority to U.S. Provisional Patent Application No. 63/397,291, which was filed on Aug. 11, 2022 and titled “Extruded Housing for a Mirror,” the contents of which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63397291 | Aug 2022 | US |