Interior rear view mirror mounting system utilizing one-package structural adhesive

Claim 2

A mirror mounting button, windshield arrangement, comprising: a windshield, said windshield including an interior surface; a cured non-elastomeric, thermosetting, one-package, structural adhesive in contact with and adhered to said interior windshield surface, said adhesive having a modulus of elasticity at 85° C. of at least about 10,000 psi, said structural adhesive being a latent curing adhesive system capable of substantial cure at a temperature below about 325° F. and requiring exposure to a temperature in excess of about 125° F. before substantial curing is achieved; and a mirror mounting button attached to said adhesive, whereby said cured adhesive forms a bond between said windshield and said mirror mounting button, wherein said adhesive bond can support a weight greater than or equal to about 100 grams.

Claim 3

The arrangement as set forth in claim 1 wherein said adhesive is a modified epoxy.

Claim 4

The arrangement as set forth in claim 2 wherein said adhesive is a blend of a polymeric epoxy reaction product of molecular weight greater than 700, epoxy resins, a dicyanodiamide, a non-volatile amide and n,n'-(methyl-1,3-phenylene) bis (n,n'-dimethylurea).

Claim 5

The arrangement as set forth in claim 3 wherein said adhesive is contacted with a latent accelerator selected from the group including tolyl bis(dimethyl urea), 2-ethyl-4-methyl-imidazole and 1-phenyl-3,3-dimethyl urea.

Claim 6

The arrangement as set forth in claim 1 wherein said mirror mounting button contains a perimetal groove located at the outer perimeter of said button, whereby excess adhesive applied to said button is contained within said groove during bonding of said button to said glass surface.

Claim 7

The arrangement as set forth in claim 5 wherein said adhesive is applied to a receptacle centrally located in said mirror mounting button.

Claim 8

The arrangement as set forth in claim 6 wherein said adhesive is a modified epoxy.

Claim 9

The arrangement as set forth in claim 7 wherein said adhesive is a blend of a polymeric epoxy reaction product of molecular weight greater than 700, epoxy resins, a dicyanodiamide, a non-volatile amide and n,n'-(methyl-1,3-phenylene) bis (n,n'-dimethylurea).

Claim 10

The arrangement as set forth in claim 8 wherein said adhesive is contacted with a latent accelerator selected from the group including tolyl bis(dimethyl urea), 2-ethyl-4-methyl-imidazole and 1-phenyl-3,3-dimethyl urea.

Claim 11

The arrangement as set forth in claim 1 further comprising an interior rearview mirror assembly attached to said mirror mounting button.

Claim 12

The arrangement as set forth in claim 10 wherein said adhesive bond can support a weight greater than or equal to about 200 grams.

Claim 13

The arrangement as set forth in claim 11 wherein said adhesive is a modified epoxy.

Claim 14

The arrangement as set forth in claim 12 wherein said adhesive is a blend of a polymeric epoxy reaction product of molecular weight greater than 700, epoxy resins, a dicyanodiamide, a non-volatile amide and n,n'-(methyl-1,3-phenylene) bis (n,n'-dimethylurea).

Claim 15

The arrangement as set forth in claim 13 wherein said adhesive is contacted with a latent accelerator selected from the group including tolyl bis(dimethyl urea), 2-ethyl-4-methyl-imidazole and 1-phenyl-3,3-dimethyl urea.

Claim 16

The arrangement as set forth in claim 10 wherein said mirror mounting button contains a perimetal groove located at the outer perimeter of said button, whereby excess adhesive applied to said button is contained within said groove during bonding of said button to said glass surface.

Claim 17

The arrangement as set forth in claim 15 wherein said adhesive is applied to a receptacle centrally located in said mirror mounting button.

Claim 18

The arrangement as set forth in claim 16 wherein said adhesive is a modified epoxy.

Claim 19

The arrangement as set forth in claim 17 wherein said adhesive is a blend of a polymeric epoxy reaction product of molecular weight greater than 700, epoxy resins, a dicyanodiamide, a non-volatile amide and n,n'-(methyl-1,3-phenylene) bis (n,n'-dimethylurea).

Claim 20

The arrangement as set forth in claim 18 wherein said adhesive is contacted with a latent accelerator selected from the group including tolyl bis(dimethyl urea), 2-ethyl-4-methyl-imidazole and 1-phenyl-3,3-dimethyl urea.

Claim 21

An interior rearview mirror mounting system for use on an automobile comprising: a laminated windshield; said windshield comprising a first bent glass panel having a front surface and a rear surface, and a second bent glass panel having a front surface and a rear surface; a sheet of polymeric interlayer disposed between the rear surface of said first panel and the front surface of said second panel wherein said polymeric interlayer laminates said first and second panel together, said lamination together of said first panel and said second panel being achieved by an autoclave process; a mirror mounting button adhered to said rear surface of said second panel by a layer of substantially cured adhesive and an interior rearview mirror assembly supported by said button; said layer of substantially cured adhesive being formed by disposing a film of a one-package, structural adhesive between said rear surface of said second panel and said mirror mounting button, and curing said film in an autoclave process to form a joint between said button and said windshield, said curing of said film and said lamination of said windshield being achieved in the same autoclave process; and said film of structural adhesive comprising an epoxy resin and a latent hardener.

Claim 22

An interior rearview mirror mounting system for use on an automobile comprising: a laminated windshield; said windshield comprising a first bent glass panel having a front surface and a rear surface, and a second bent glass panel having a front surface and a rear surface; a sheet of polymeric interlayer disposed between the rear surface of said first panel and the front surface of said second panel wherein said polymeric interlayer laminates said first and second panel together, said lamination together of said first panel and said second panel being achieved by an autoclave process; a mirror mounting button adhered to said rear surface of said second panel by a layer of substantially cured adhesive and an interior rearview mirror assembly supported by said button; said layer of substantially cured adhesive being formed by disposing a film of a one-package, structural adhesive between said rear surface of said second panel and said mirror mounting button, and curing said film in an autoclave process to form a joint between said button and said windshield, said curing of said film and said lamination of said windshield being achieved in the same autoclave process; and said film of structural adhesive comprising an epoxy resin and a latent hardener.

Claim 23

The mirror mounting system of claim 20 wherein said polymeric interlayer is plasticized polyvinylbutyral.

Claim 24

The mirror mounting system of claim 21 wherein said curing of said film occurs at a temperature greater than about 125° F. and less than about 325° F.

Claim 25

The mirror mounting system of claim 21 wherein said mirror mounting button comprises one of a sintered steel mounting button or a die cast zinc mounting button.

Claim 26

The mirror mounting system of claim 23 wherein said latent hardener comprises one of a dicyanodiamide or a hindered amine.

Claim 27

The mirror mounting system of claim 23 wherein said adhesive film has a thickness of about 0.005 inches.

Claim 28

The mirror mounting system of claim 20 wherein said adhesive film is one of a clear adhesive film or a transparent adhesive film.

Claim 29

The mirror mounting system of claim 20 wherein said adhesive film is one of a gray adhesive film or a black adhesive film.

Claim 30

The mirror mounting system of claim 20 wherein said adhesive film is die cut to the shape of said mounting button.

Claim 31

The mirror mounting system of claim 20 wherein said adhesive film is die cut to an area smaller than the area of said mounting button.

Claim 32

The mirror mounting system of claim 20 wherein said adhesive film is die cut to a shape and to an area smaller than the shape and area of said mounting button.

Claim 33

The mirror mounting system of claim 20 wherein said mirror mounting button comprises a sintered steel mounting button.

Claim 34

The mirror mounting system of claim 31 wherein said latent hardener comprises a diocyanodiamide.

Claim 35

The mirror mounting system of claim 20 wherein said interior rearview mirror assembly has a weight exceeding about 200 grams.

Claim 36

The mirror mounting system of claim 33 wherein said interior rearview mirror assembly has a weight exceeding about 400 grams.

Claim 37

An interior rearview mirror mounting system for use on an automobile comprising: a laminated windshield; said windshield comprising a first bent glass panel having a front surface and a rear surface, and a second bent glass panel having a front surface and a rear surface; a sheet of polymeric interlayer disposed between the rear surface of said first panel and the front surface of said second panel wherein said polymeric interlayer laminates said first and second panel together, said lamination together of said first panel and said second panel being achieved by an autoclave process; a mirror mounting button adhered to said rear surface of said second panel by a layer of substantially cured adhesive; said layer of substantially cured adhesive being formed by disposing a film of a one-package, structural adhesive between said rear surface of said second panel and said mirror mounting button, and curing said film in an autoclave process to form a joint between said button and said windshield suitable to support an interior rearview mirror assembly, said curing of said film and said lamination of said windshield being achieved in the same autoclave process; said film of structural adhesive comprising an epoxy resin and a latent hardener; and wherein said curing of said film occurs at a temperature greater than about 125° F. and less than about 325° F.

Claim 38

An interior rearview mirror mounting system for use on an automobile comprising: a laminated windshield; said windshield comprising a first bent glass panel having a front surface and a rear surface, and a second bent glass panel having a front surface and a rear surface; a sheet of polymeric interlayer disposed between the rear surface of said first panel and the front surface of said second panel wherein said polymeric interlayer laminates said first and second panel together, said lamination together of said first panel and said second panel being achieved by an autoclave process; a mirror mounting button adhered to said rear surface of said second panel by a layer of substantially cured adhesive; said layer of substantially cured adhesive being formed by disposing a film of a one-package, structural adhesive between said rear surface of said second panel and said mirror mounting button, and curing said film in an autoclave process to form a joint between said button and said windshield suitable to support an interior rearview mirror assembly, said curing of said film and said lamination of said windshield being achieved in the same autoclave process; said film of structural adhesive comprising an epoxy resin and a latent hardener; and wherein said curing of said film occurs at a temperature greater than about 125° F. and less than about 325° F.

Claim 39

The mirror mounting system of claim 35 wherein said latent hardener comprises one of a dicyanodiamide and a hindered amine.

Claim 40

The mirror mounting system of claim 35 wherein said adhesive film has a thickness of about 0.005 inches.

Claim 41

The mirror mounting system of claim 35 wherein said latent hardener comprises one of dicyanodiamide or a hindered amine.

Claim 42

The mirror mounting system of claim 35 wherein said adhesive film is one of a gray adhesive film or a black adhesive film.

Claim 43

The mirror mounting system of claim 35 wherein said mirror mounting button comprises one of a sintered steel mounting button or a die cast zinc mounting button.

Claim 44

The mirror mounting system of claim 40 wherein said mirror mounting button comprises a sintered steel mounting button.

Claim 45

The mirror mounting system of claim 40 wherein said adhesive film is die cut to a shape and to an area smaller than the shape and area of said mounting button.