Electrochromic Devices With Thin Bezel-Covered Edge

• US 20080049295A1
• Filed: 10/30/2007
• Published: 02/28/2008
• Est. Priority Date: 07/09/1999
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Carter, John, Arnold, John, Busscher, Bradley, Fogg, Jeremy, Bauer, Frederick, Cammenga, David, Tonar, William
• Granted Patent: US 7,612,929 B2
• Time in Patent Office: Days
• US Class Current: 359/267
• CPC Class Codes: C09K 9/02 Organic tenebrescent materials
• CPC Class Codes: G02F 1/1503 caused by oxidation-reduction reactions in organic liquid solutions, e.g. viologen solutions
• CPC Class Codes: G02F 1/153 Constructional details
• CPC Class Codes: G02F 2001/1502 complementary cell
• CPC Class Codes: G02F 2001/15145 the electrochromic layer comprises a mixture of anodic and cathodic compounds

Abstract

A mirror includes an electro-optic mirror subassembly, and a thin-profiled bezel attached around a perimeter of the electrochromic mirror subassembly. The electro-optic mirror subassembly is supported on a carrier by an adheringly bonded heater and foam tape in a laminar arrangement. The bezel may be bonded to an edge of the front surface of the front element of the electro-optic mirror subassembly, and/or may be bonded and/or interlockingly mechanically attached to an edge of the carrier. Alternatively, the bezel can be a strip of paint or thin coating material. The bezel can be molded in place, or can be pre-molded and elastically stretched to permit assembly. In one form, the bezel includes a laterally-extending fin that prevents seeing past the bezel into the inside of a mirror housing. In at least one embodiment, the assembly has no bezel or only a bezel on one edge.

Claims

1. An electrochromic rearview mirror for a vehicle, comprising:

an electrochromic mirror subassembly including front and rear elements defining a chamber therebetween and having electrochromic material disposed in the chamber;

a carrier supporting the electrochromic mirror subassembly; and

a bezel disposed around a periphery of the electrochromic mirror subassembly and having a front lip extending over part of a front surface of the front element, and having a rear lip extending onto an edge of the carrier, the rear lip being secured to the edge of the carrier.

2. The rearview mirror of claim 1, wherein the rear lip includes at least one key interlockingly engaging at least one recess in the edge of the carrier.

3. The rearview mirror of claim 1, wherein the bezel is elastomeric.

4. The rearview device of claim 3, wherein the perimeter of said bezel, when in an unstressed state, is smaller than the periphery of said front element.

5. The rearview mirror of claim 1, wherein the bezel includes a laterally outwardly extending flexible fin.

6. The rearview mirror of claim 5, wherein the fin is made of elastomeric material.

7. The rearview device of claim 1, wherein said bezel is made of a material having a tensile modulus of less than about 72,000 psi.

8. A rearview mirror for a vehicle, comprising:

an electrochromic mirror subassembly including front and rear elements defining a chamber therebetween and having electrochromic material disposed in the chamber;

a carrier supporting the electrochromic mirror subassembly; and

a bezel disposed around a periphery of the electrochromic mirror subassembly and having a front lip extending over and bonded to an edge section of a front surface of the front element and further having a side flange that extends from the front lip at least partially along a side of the electrochromic mirror subassembly.

9. The mirror defined in claim 8, wherein the bezel includes a plastic co-extruded onto and bonded to the front element.

10. The mirror defined in claim 8, wherein the bezel comprises a painted-on coating applied to the edge section.

11. A rearview mirror for a vehicle, comprising:

a mirror housing defining an interior and a front opening and having an adjustment device mounted therein;

a mirror element;

a carrier supporting the mirror element positioned in the front opening and that is operably attached to the adjustment device for angular adjustment; and

a bezel disposed around a periphery of the mirror element, the bezel having a laterally extending fin that slidingly engages an inside surface of the mirror housing for closing the interior to prevent visibility into the interior of the mirror housing.

12. The mirror defined in claim 11, wherein the mirror element includes front and rear elements defining a chamber therebetween and having electrochromic material disposed in the chamber.

13. A variable reflectance mirror for a vehicle, comprising:

a mirror subassembly; and

a bezel disposed around and attached to a periphery of the mirror subassembly, the bezel having a laterally extending flexible fin that extends in an outboard lateral direction, the fin being adapted to flexibly engage an inside surface of a mirror housing for closing an interior space to prevent visibility into the interior of the mirror housing.

14. The mirror defined in claim 13, wherein the mirror element includes front and rear elements defining a chamber therebetween and having electrochromic material disposed in the chamber.

15. An electrochromic variable reflectance mirror for a vehicle, comprising:

a front element having a front surface and a rear surface having a first layer of electrically conductive material disposed thereon;

a rear element having a front surface and a rear surface, said front surface of said rear element having a second layer of electrically conductive material disposed thereon;

a seal provided to sealably bond said elements together in a spaced-apart relationship to define a chamber;

an electrochromic material disposed in said chamber; and

a strip of non-light-transmitting material disposed on the rear surface of the front element along an edge thereof and extending around the periphery thereof.

16. The mirror defined in claim 15, wherein the strip is entirely located inboard of the edge of the front element.

17. The mirror defined in claim 15, wherein the non-light-transmitting material is opaque.

18. The mirror defined in claim 15, wherein the non-light-transmitting material is reflective.

19. An electrochromic rearview mirror for vehicles comprising:

a housing;

an electrochromic mirror subassembly including front and rear elements defining a chamber therebetween and having electrochromic material disposed in the chamber;

the front element having a front surface and an edge defining the front surface; and

a bezel covering the edge of the front element but extending less than 1 mm onto the front surface.

20. The mirror defined in claim 19, wherein the bezel does not extend onto and does not cover or touch the front surface, such that 100% of the front surface is exposed and usable as a viewing area.

21. The mirror defined in claim 19, wherein the front surface includes a strip that extends around a perimeter of the front surface adjacent the edge, and at least 50 percent of a length of the strip is not covered by the bezel.

22. The mirror defined in claim 19, wherein the front surface includes a strip that extends around a perimeter of the front surface adjacent the edge, and at least a portion of the strip is not entirely covered by the bezel.

23. A mirror element, comprising:

a first substantially transparent substrate comprising a substantially transparent conductor on at least one surface thereof and having a first electrical contact; and

a second substrate comprising an at least partially reflective conductor on at least one surface thereof and having a second electrical contact, wherein said first and second contact define a substantially continuous portion on an edge of the mirror element.

24. A mirror element as in claim 23 wherein said first substantially transparent substrate and said second substrate are secured in a spaced apart relationship with one another via a seal to define a chamber.

25. A mirror element as in claim 24 wherein said chamber contains at least one electro-optic medium.

26. A mirror element as in claim 25 wherein said at least one electro-optic medium is selected from the group comprising:

a gel, a solution phase and a solid.

27. A mirror element as in claim 23 wherein said substantially transparent conductor comprises a sheet resistance of between approximately 1.0 Ω

/□ and

approximately 10 Ω

/□

.

28. A mirror element as in claim 27 wherein said substantially transparent conductor comprises a sheet resistance of approximately 2 Ω

/□

.

29. A mirror element as in claim 23 wherein said substantially transparent conductor comprises at least one layer selected from the group comprising:

zinc oxide, doped-zinc oxide, IMI, and ITO.

30. A mirror element as in claim 23 wherein said at least partially reflective conductor comprises a sheet resistance of less than 0.5 Ω

/□

.

31. A mirror element as in claim 23 wherein said substantially transparent conductor is placed on said at least one surface of said first substantially transparent substrate by either sputtering, evaporation, chemical vapor deposition or plating.

32. A mirror element as in claim 23 wherein said at least partially reflective conductor comprises a sheet resistance of between approximately 0.05 Ω

/□ and

approximately 0.5 Ω

/□

.

33. A mirror element as in claim 32 wherein said at least partially reflective conductor comprises a sheet resistance of approximately 0.1 Ω

/□

.

34. A mirror element as in claim 23 wherein said at least partially reflective conductor comprises at least one layer selected from the group comprising:

silver or silver-gold.

35. A mirror element as in claim 23 wherein said at least partially reflective conductor is placed on said at least one surface of said second substantially transparent substrate by either sputtering, evaporation, chemical vapor deposition or plating.

36. A mirror element as in claim 23 wherein said first electrical contact is between approximately 0.6 and approximately 0.8 times a total length of said first and second electrical contacts combined.

37. A mirror element as in claim 23 wherein said second electrical contact is between approximately 0.2 and approximately 0.4 times a total length of said first and second electrical contacts combined.

38. A mirror element as in claim 23 further comprising an at least partially reflective ring around a perimeter of at least one surface of said first substantially transparent substrate.

39. A mirror element as in claim 38 wherein a reflectivity of said at least partially reflective conductor and a reflectivity of said at least partially reflective ring is substantially the same.

40. A mirror element as in claim 24 wherein said seal comprises a material that is substantially transparent.

41. A mirror element as in claim 40 further comprising a spectral filter material around a perimeter of at least one surface of said first substantially transparent substrate.

42. A mirror element as in claim 41 wherein said spectral filter material comprises an ultra-violet spectral filtering property.

43. A mirror element as in claim 41 wherein said spectral filter material comprises an infrared spectral filtering property.

44. A mirror element as in claim 23 wherein said first and second electrical contacts are located on an inboard edge of the mirror element.

45. A mirror element as in claim 23 further comprising a bezel, said bezel is between approximately 1.5 mm and approximately 4.0 mm.

46. A mirror element as in claim 45 wherein said bezel is integral with a carrier plate.

47. A mirror element as in claim 46 wherein said bezel is only proximate the inboard edge.

48. A mirror element as in claim 23 wherein said first substantially transparent substrate has a thickness of less than 2.0 mm.

49. A mirror element as in claim 23 wherein said second substrate has a thickness of less than 2.0 mm.

65. A mirror assembly, comprising:

the mirror element of claim 23.

66. A mirror assembly as in claim 65 further comprising at least one additional device selected from the group comprising an interior illumination assembly, an illuminated operator interface, an information display, a voice activated system, a trainable transceiver, a microphone, a compass sensor, a compass system, a digital sound processing system, a digital voice processing system, a telephone system, a highway toll booth interface, a telemetry system, an exterior light controller, a moisture sensor, a loran system, a global positioning system, a variable reflectance reflector, a vehicle vision system, an accessory module, a remote keyless entry system, a wireless communication interface, a CAN bus interface, a serial bus interface, a parallel bus interface, a light sensor, a camera, a climate control system, a power supply, a controller, a transflective reflector, a tire pressure monitoring system, a navigation system, a lane departure warning system, a turn signal, a keyhole illuminator, a door area illuminator, a security light, and an adaptive cruise control system.

67. A mirror assembly as in claim 66 where said information display is selected from the group comprising a vacuum fluorescent display, a segmented light emitting diode display, a matrix light emitting diode display, an organic light emitting diode display, a liquid crystal display, a backlit indicia display, a plasma display, and a gas discharge display.

68. A mirror assembly as in claim 66 wherein said at least one illuminated operator interface is selected from the group comprising a pushbutton, a slide bar switch, a toggle switch, a “

thumb-wheel”

switch (such as a variable potentiometer), a rotary switch, a “

rocker”

switch and a “

latching”

pushbutton.

50. A mirror element, comprising:

a first substantially transparent substrate comprising an at least partially reflective ring around a perimeter of at least one surface of said first substantially transparent substrate; and

a second substrate comprising an at least partially reflective conductor on at least one surface, wherein a reflectivity of said at least partially reflective conductor and a reflectivity of said at least partially reflective ring is substantially the same.

51. A mirror element as in claim 50 wherein said reflectivity of said reflective ring is less than 10 percent different than said reflectivity of said at least partially reflective conductor.

52. A mirror element as in claim 50 wherein said at least partially reflective ring comprises chromium.

53. A mirror element as in claim 50 wherein said at least partially reflective conductor comprises silver.

54. A mirror element as in claim 50 wherein said first and second substantially transparent substrates are secured in a spaced apart relationship with respect to one another via a seal to define a chamber.

55. A mirror element as in claim 50 wherein said chamber contains at least one electro-optic medium.

56. A mirror element as in claim 55 wherein said at least one electro-optic medium is selected from the group comprising:

a gel, a solution phase and a solid.

57. A mirror element as in claim 50 wherein said first substantially transparent substrate has a thickness of less than 2.0 mm.

58. A mirror element as in claim 50 wherein said second substrate has a thickness of less than 2.0 mm.

59. A mirror element, comprising:

a first substantially transparent substrate and a second substrate secured in a spaced apart relationship with respect to one another via a seal to define a chamber, wherein said seal is substantially clear and said first substantially transparent substrate comprises a spectral filter material near a perimeter portion thereof.

60. A mirror element as in claim 59 wherein said first substantially transparent substrate has a thickness of less than 2.0 mm.

61. A mirror element as in claim 59 wherein said second substrate has a thickness of less than 2.0 mm.

62. A mirror element as in claim 59 wherein said spectral filter material substantially blocks light rays from impinging upon said seal.

63. A mirror element as in claim 59 wherein said spectral filter material substantially prevents ultra-violet light rays from impinging upon said seal.

64. A mirror element as in claim 59 wherein said spectral filter material substantially prevents infrared light rays from impinging upon said seal.

69. A mirror element, comprising:

a first substantially transparent substrate comprising a substantially transparent conductor on at least one surface thereof and having a first electrical contact; and

a second substrate comprising an at least partially reflective conductor on at least one surface thereof and having a second electrical contact, wherein said first and second electrical contacts combined occupy less than approximately 0.5 times a total length defined by a perimeter of the mirror element.

70. A mirror element as in claim 69 wherein said first substantially transparent substrate has a thickness of less than 2.0 mm.

71. A mirror element as in claim 69 wherein said second substrate has a thickness of less than 2.0 mm.

72. A mirror element as in claim 69 wherein said first and second electrical contacts combined occupy less than approximately 0.4 times a total length defined by a perimeter of the mirror element.

73. A mirror element as in claim 69 wherein said first and second electrical contacts are substantially contiguous with one another.

74. A mirror element as in claim 69 wherein said first and second electrical contacts are linearly extending along a common edge of the mirror element.

75. A mirror element as in claim 69 wherein said first and second electrical contacts are tangentially extending along an edge of the mirror element.

76. A mirror element as in claim 69 wherein said first and second electrical contacts combined occupy less than approximately 0.25 times a total length defined by a perimeter of the mirror assembly.

77. A mirror element, comprising:

a first substantially transparent substrate comprising a low sheet resistance conductor on a second surface thereof, wherein said low sheet resistance conductor comprises a sheet resistance of between approximately 1.0 Ω

/□ and

approximately 10 Ω

/□

.

78. A mirror element as in claim 77 wherein said low sheet resistance conductor comprises a sheet resistance of less than 8 Ω

/□

.

79. A mirror element as in claim 77 wherein said substantially transparent conductor comprises a sheet resistance of between approximately 2.0 Ω

/□ and

approximately 4 Ω

/□

.

80. A mirror element as in claim 77 wherein said first substantially transparent substrate has a thickness of less than 2.0 mm.

81. A mirror element as in claim 77 wherein said second substrate has a thickness of less than 2.0 mm.

82. A mirror element as in claim 77 wherein said substantially transparent conductor comprises at least one layer selected from the group comprising:

zinc oxide, doped-zinc oxide, IMI, and ITO.

83. A mirror element as in claim 77 wherein said substantially transparent conductor is placed on said at least one surface of said first substantially transparent substrate by either sputtering, evaporation, chemical vapor deposition or plating.

84. A mirror element as in claim 77 further comprising a second substrate comprising an at least partially reflective conductor, wherein said at least partially reflective conductor comprises a sheet resistance of between approximately 0.05 Ω

/□ and

approximately 0.5 Ω

/□

.

85. A mirror element as in claim 84 wherein said at least partially reflective conductor comprises a sheet resistance of approximately 0.1 Ω

/□

.

86. A mirror element as in claim 84 wherein said at least partially reflective conductor comprises at least one layer selected from the group comprising:

silver or silver-gold.

87. A mirror element as in claim 84 wherein said at least partially reflective conductor is placed on said at least one surface of said second substantially transparent substrate by either sputtering, evaporation, chemical vapor deposition or plating.

88. A mirror element, comprising:

a substantially transparent substrate comprising an electrical conductor comprising variable sheet resistance, wherein said sheet resistance is lower near an associated electrical contact and becomes higher in proportion to the distance from said contact.

89. A mirror element as in claim 88 wherein said first substantially transparent substrate has a thickness of less than 2.0 mm.

90. A mirror element as in claim 88 further comprising a second substrate wherein said second substrate has a thickness of less than 2.0 mm.

91. A mirror element as in claim 88 further comprising a second substrate comprising an at least partially reflective conductor comprising a low sheet resistance, wherein said sheet resistance is lower near an associated electrical contact and becomes higher in proportion to the distance from said contact.

92. A mirror element, comprising:

a first substantially transparent substrate comprising a substantially transparent conductor on a second surface thereof and further comprising a first perimeter length; and

a second substrate comprising a second perimeter length and further comprising an electrical conductor comprising a sheet resistance of between approximately 0.05 Ω

/□ and

approximately 8.0 Ω

/□

, wherein said first perimeter length is larger than said second perimeter length.

93. A mirror element as in claim 92 further comprising a Z clip connector in contact with said substantially transparent conductor.

94. A mirror element as in claim 92 further comprising a J clip connector in contact with said electrical conductor of said second substrate.

95. A mirror element as in claim 92 further comprising a C clip connector in contact with said electrical conductor of said second substrate.

96. A mirror element as in claim 92 further comprising a substantially transparent seal disposed between said first substantially transparent substrate and said second substrate to define a chamber therebetween.

97. A mirror element as in claim 96 further comprising a spectral filter material disposed proximate a perimeter portion of said first substantially transparent substrate such that selected light rays are prevented from impinging upon said seal.

98. A mirror element, comprising:

a first substantially transparent substrate comprising a substantially transparent conductor on a second surface thereof and further comprising a first perimeter length, said first substantially transparent substrate further comprises a thickness of less than 2.0 mm; and

a second substrate comprising a second perimeter length and further comprising an electrical conductor.

99. A mirror element as in claim 98, said electrical conductor comprising a sheet resistance of between approximately 0.05 Ω

/□ and

approximately 8.0 Ω

/□

.

100. A mirror element as in claim 98 further comprising a second substrate wherein said second substrate has a thickness of less than 2.0 mm.

101. A mirror element as in claim 98 wherein said first perimeter length is larger than said second perimeter length.

102. A mirror element as in claim 98 wherein said first perimeter length is less than said second perimeter length.

103. A mirror element, comprising:

a first substantially transparent substrate comprising a thickness of less than 2.0 mm, said first substantially transparent substrate comprises a substantially opaque material near a perimeter portion thereof.

104. A variable reflectance mirror for a vehicle, comprising:

a substantially transparent substrate comprising a thickness of less than 2.0 mm, said first substantially transparent substrate comprises a substantially opaque material near a perimeter portion thereof along substantially an entire periphery;

a mirror subassembly comprising said substantially transparent substrate; and

a bezel disposed around and attached to a periphery of the mirror subassembly, the bezel having a laterally extending flexible fin that extends in an outboard lateral direction, the fin being adapted to flexibly engage an inside surface of a mirror housing for closing an interior space to prevent visibility into the interior of the mirror housing.

105. The mirror defined in claim 104, wherein the mirror element includes front and rear elements defining a chamber therebetween and having electrochromic material disposed in the chamber.

106. An electrochromic variable reflectance mirror for a vehicle, comprising:

a substantially transparent substrate comprising a thickness of less than 2.0 mm, said first substantially transparent substrate comprises a substantially opaque material near a perimeter portion thereof along substantially an entire periphery;

a front element having a front surface and a rear surface having a first layer of electrically conductive material disposed thereon;

a rear element having a front surface and a rear surface, said front surface of said rear element having a second layer of electrically conductive material disposed thereon;

a seal provided to sealably bond said elements together in a spaced-apart relationship to define a chamber;

an electrochromic material disposed in said chamber; and

a strip of non-light-transmitting material disposed on the rear surface of the front element along an edge thereof and extending around the periphery thereof.

107. The mirror defined in claim 106, wherein the strip is entirely located inboard of the edge of the front element.

108. The mirror defined in claim 106, wherein the non-light-transmitting material is opaque.

109. The mirror defined in claim 106, wherein the non-light-transmitting material is reflective.