Method for manufacturing blind zone indicator module for exterior rearview mirror assembly

A method for manufacturing an indicator module for an exterior rearview mirror assembly for a vehicle, said method comprising:

• providing a hollow housing formed by injection molding of plastic material;
• wherein the hollow housing comprises (i) a front end adapted for attaching the indicator module at the rear of a mirror reflective element for an exterior rearview mirror assembly, (ii) a rear end opposite the front end, and (iii) an intermediate portion between the front end and the rear end;
• providing a circuit board having a first side and a second side opposite the first side, wherein three light emitting diodes are disposed at the first side of the circuit board;
• wherein the three light emitting diodes are disposed at the first side of the circuit board in a triangular relationship one to the other;
• disposing the circuit board between the rear end of the hollow housing and the front end of the hollow housing such that the first side of the circuit board faces the front end of the hollow housing and the second side of the circuit board faces away from the front end of the hollow housing;
• with the circuit board disposed between the rear end of the hollow housing and the front end of the hollow housing, disposing potting material at and over the second side of the circuit board to seal the rear side of the circuit board;
• attaching a diffuser element at the front end of the hollow housing, wherein the diffuser element closes the front end of the hollow housing;
• wherein, when the at least one light emitting diode is activated, light emitted by the three emitting diodes passes through the diffuser element to exit the indicator module;
• wherein the front end of the hollow housing, with the diffuser element attached thereat, comprises an attaching surface configured to attach the indicator module at the mirror reflective element for an exterior rearview mirror assembly;
• wherein the circuit board is parallel to the attaching surface of the front end of the hollow housing;
• adhesively attaching a pressure sensitive adhesive tape at the attaching surface of the hollow housing for attaching the indicator module at the mirror reflective element;
• wherein the pressure sensitive adhesive tape comprises an aperture therethrough that corresponds to the shape of an opening at the first end of the hollow housing;
• and
• wherein the indicator module comprises a blind zone indication module.

A method for manufacturing an indicator module for an exterior rearview mirror assembly for a vehicle, said method comprising:

• providing a hollow housing formed by injection molding of plastic material;
• wherein the hollow housing comprises (i) a front end adapted for attaching the indicator module at the rear of a mirror reflective element for an exterior rearview mirror assembly, (ii) a rear end opposite the front end, and (iii) an intermediate portion between the front end and the rear end;
• wherein the hollow housing comprises an inner surface that reflects light incident thereon;
• providing a circuit board having a first side and a second side opposite the first side, wherein at least one light emitting diode is disposed at the first side of the circuit board;
• disposing the circuit board between the rear end of the hollow housing and the front end of the hollow housing such that the first side of the circuit board faces the front end of the hollow housing and the second side of the circuit board faces away from the front end of the hollow housing;
• with the circuit board disposed between the rear end of the hollow housing and the front end of the hollow housing, disposing potting material at and over the second side of the circuit board to seal the rear side of the circuit board;
• attaching a diffuser element at the front end of the hollow housing, wherein the diffuser element closes the front end of the hollow housing;
• wherein the circuit board comprises circuitry and electrically conductive terminals in electrical connection with circuitry of the circuit board;
• wherein disposing the circuit board within the hollow housing comprises inserting the electrical conductive terminals into a connector portion of the hollow housing;
• wherein the connector portion, with the electrically conductive terminals therein, is configured to connect to a connector of a wire harness of an exterior rearview mirror assembly;
• wherein, when the at least one light emitting diode is activated, light emitted by the at least one light emitting diode reflects off the inner surface of the hollow housing and passes through the diffuser element to exit the indicator module;
• wherein the indicator module is configured to be disposed at an aperture formed through a mirror back plate of a mirror reflective element for an exterior rearview mirror assembly;
• wherein, with the indicator module disposed at the aperture formed through the mirror back plate of the mirror reflective element, light emitted by the at least one light emitting diodes that passes through the diffuser element passes through the mirror reflective element;
• and
• wherein the indicator module comprises a blind zone indication module.