Vehicular rearview mirror elements and assemblies incorporating these elements

• US 20060245026A1
• Filed: 06/29/2006
• Published: 11/02/2006
• Est. Priority Date: 09/30/2002
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Neuman, George A., Cammenga, David J., Tonar, William L., Poll, David L., Anderson, John S., Stray, Joel A., Ypma, Kenton J., Busscher, Bradley L.
• Granted Patent: US 7,379,225 B2
• Time in Patent Office: Days
• US Class Current: 359/265
• CPC Class Codes: B60R 1/08 involving special optical features, e.g. avoiding blind spots , e.g. convex mirrors; Side-by-side associations of rear-view and other mirrors B60R1/025, B60R1/10 take precedence
• CPC Class Codes: B60R 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: G02F 1/157 Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells

Abstract

The present invention relates to improved electro-optic rearview mirror elements and assemblies incorporating the same.

Claims

1. A variable reflectance mirror element, comprising:

a first substantially transparent substrate comprising a substantially transparent layer of material on at least a portion of a surface and an at least partially reflective layer of material proximate at least a portion of said substantially transparent layer of material, wherein said at least partially reflective layer of material is positioned such that said substantially transparent layer of material is at least partially between said substantially transparent substrate and said at least partially reflective layer of material;

a second substrate comprising at least one at least partially reflective layer on at least a portion of a surface, wherein a first b* value associated with at least a periphery portion of said first substantially transparent substrate is lower than a second b* value associated with said second substrate when the element is viewed looking at said first substantially transparent substrate when the mirror element is in a highly reflective state; and

an electrochromic material positioned between said first substantially transparent substrate and said second substrate.

2. A variable reflectance mirror element as in claim 1 wherein said substantially transparent layer of material is indium-tin-oxide.

3. A variable reflectance mirror element as in claim 1 wherein at least the portion of said substantially transparent layer of material positioned between said at least partially reflective material and said first substantially transparent substrate comprises an optical thickness of less than λ

/4, where λ

is the wavelength of light at which the coating is optimized and m is a positive, odd integer.

4. A variable reflectance mirror element as in claim 1 wherein at least the portion of said substantially transparent layer of material positioned between said at least partially reflective material and said first substantially transparent substrate comprises a more smooth surface compared with a portion of said substantially transparent layer of material not positioned between said at least partially reflective material and said first substantially transparent substrate.

5. A variable reflectance mirror element as in claim 4 wherein at least the portion of said substantially transparent layer of material positioned between said at least partially reflective material and said first substantially transparent substrate comprises an optical thickness of less than λ

/4, where λ

is the wavelength of light at which the coating is optimized and m is a positive, odd integer.

6. A variable reflectance mirror element as in claim 1 wherein said at least partially reflective material on said first substantially transparent substrate comprises chrome.

7. A variable reflectance mirror element as in claim 2 wherein said at least partially reflective material on said first substantially transparent substrate comprises chrome.

8. A variable reflectance mirror element as in claim 1 further comprising a curable plug material positioned between said first substantially transparent substrate and said second substantially transparent substrate such that radiation directed toward said plug material from said first substantially transparent substrate is attenuated more than radiation directed toward said plug material from said second substantially transparent substrate.

9. A variable reflectance mirror element as in claim 1 wherein a reflectance value associated with a periphery area is greater than a first mirror element reflectance value associated with a minimum mirror element reflectance state and less than a second mirror element reflectance value associated with a maximum mirror element reflectance state.

10. A variable reflectance mirror element as in claim 1 said first substantially transparent substrate comprising a periphery portion comprising a semi-transparent metallic glue layer proximate a second layer comprising a higher bulk reflectance than said semi-transparent metallic glue layer.

11. A variable reflectance mirror element as in claim 1 comprising a layer of ruthenium proximate at least a portion of at least one of said substrates.

12. A variable reflectance mirror element as in claim 1 configured within a rearview mirror assembly for a motor vehicle and further comprising a light source positioned to project light from said second substrate through said first substantially transparent substrate.

13. A variable reflectance mirror element as in claim 1 further comprising an epoxy proximate either said first substantially transparent substrate and, or, said second substrate, said epoxy comprising a plurality of silver flakes.

14. A variable reflectance mirror element as in claim 1 wherein said substantially transparent layer is thinner where said substantially transparent layer is between said substantially transparent substrate and said at least partially reflective layer of material compared to elsewhere.

15. A variable reflectance mirror element as in claim 14 wherein said substantially transparent layer is thinned via ion etching.

16. A variable reflectance mirror element as in claim 1 wherein said substantially transparent layer is more smooth where said substantially transparent layer is between said substantially transparent substrate and said at least partially reflective layer of material compared to elsewhere.

17. A variable reflectance mirror element as in claim 16 wherein said substantially transparent layer is thinned via ion etching.

18. A variable reflectance mirror element, comprising:

a first substantially transparent substrate comprising at least one at least partially reflective material proximate a periphery area; and

a second substrate comprising at least one at least partially reflective layer on at least a portion of a surface, wherein a reflectance value associated with said periphery area is greater than a first mirror element reflectance value associated with a minimum mirror element reflectance state and less than a second mirror element reflectance value associated with a maximum mirror element reflectance state and a first b* value associated with at least a periphery portion of said first substantially transparent substrate is lower than a second b* value associated with said second substrate when the element is viewed looking at said first substantially transparent substrate when the mirror element is in a highly reflective state.

19. A variable reflectance mirror element as in claim 18 further comprising a curable plug material positioned between said first substantially transparent substrate and said second substantially transparent substrate such that radiation directed toward said plug material from said first substantially transparent substrate is attenuated more than radiation directed toward said plug material from said second substantially transparent substrate.

20. A variable reflectance mirror element as in claim 18 said first substantially transparent substrate comprising a periphery portion comprising a semi-transparent metallic glue layer proximate a second layer comprising a higher bulk reflectance than said semi-transparent metallic glue layer.

21. A variable reflectance mirror element as in claim 18 comprising a layer of ruthenium proximate at least a portion of at least one of said substrates.

22. A variable reflectance mirror element as in claim 18 configured within a rearview mirror assembly for a motor vehicle and further comprising a light source positioned to project light from said second substrate through said first substantially transparent substrate.

23. A variable reflectance mirror element as in claim 18 further comprising an epoxy proximate either said first substantially transparent substrate and, or, said second substrate, said epoxy comprising a plurality of silver flakes.

24. A variable reflectance mirror element, comprising:

a first substantially transparent substrate comprising at least one at least partially reflective material proximate a periphery area; and

a second substrate comprising at least one at least partially reflective layer on at least a portion of a surface, wherein a reflectance value associated with said periphery area is greater than a first mirror element reflectance value associated with a minimum mirror element reflectance state and less than a second mirror element reflectance value associated with a maximum mirror element reflectance state.

25. A variable reflectance mirror element as in claim 24 further comprising a curable plug material positioned between said first substantially transparent substrate and said second substantially transparent substrate such that radiation directed toward said plug material from said first substantially transparent substrate is attenuated more than radiation directed toward said plug material from said second substantially transparent substrate.

26. A variable reflectance mirror element as in claim 24 said first substantially transparent substrate comprising a periphery portion comprising a semi-transparent metallic glue layer proximate a second layer comprising a higher bulk reflectance than said semi-transparent metallic glue layer.

27. A variable reflectance mirror element as in claim 24 comprising a layer of ruthenium proximate at least a portion of at least one of said substrates.

28. A variable reflectance mirror element as in claim 24 configured within a rearview mirror assembly for a motor vehicle and further comprising a light source positioned to project light from said second substrate through said first substantially transparent substrate.

29. A variable reflectance mirror element as in claim 24 further comprising an epoxy proximate either said first substantially transparent substrate and, or, said second substrate, said epoxy comprising a plurality of silver flakes.