VEHICULAR REARVIEW MIRROR ELEMENTS AND ASSEMBLIES INCORPORATING THESE ELEMENTS

• US 20120092744A1
• Filed: 12/20/2011
• Published: 04/19/2012
• Est. Priority Date: 09/30/2002
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: TONAR, WILLIAM L., CAMMENGA, DAVID J., ANDERSON, JOHN S., POLL, DAVID L., NEUMAN, GEORGE A., STRAY, JOEL A., BUSSCHER, BRADLEY L., YPMA, KENTON J.
• Granted Patent: US 8,614,845 B2
• Time in Patent Office: Days
• US Class Current: 359/267
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: B32B 17/10321 Laminated safety glass or glazing containing liquid layers
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• 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 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells
• CPC Class Codes: G02F 1/163 Operation of electrochromic cells, e.g. electrodeposition cells; Circuit arrangements therefor

Abstract

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

Claims

1. A rearview assembly having a front and comprising:

an electrochromic (EC) mirror element, the EC mirror element including;

a first substrate having a first surface corresponding to the front, a second surface opposite to the first surface, and a rounded edge configured to improve durability of the first substrate, the second surface having a ring of spectral filter material disposed circumferentially around a perimeter of the second surface;

a second substrate having third and fourth surfaces and an edge surface, the second substrate being smaller than the first substrate and disposed in a parallel and spaced-apart relationship with respect to the first substrate such that a perimeter of the second substrate is concealed behind the first substrate the second and third surfaces defining a gap therebetween; and

an EC medium in said gap; and

a moveable mirror-element-supporting assembly mechanically cooperated with the mirror element and configured to support the mirror-element, said assembly including

a substantially rigid portion extending along a back of the mirror element, and

a peripheral portion integrated with the substantially rigid portion, configured to extend from the substantially rigid portion towards the front such as to keep the rounded edge observable and to conceal the edge surface of the second substrate.

2. A rearview assembly according to claim 1, wherein said rounded edge of the first substrate is polished.

3. A rearview assembly according to claim 1, further comprising a user interface (UI) in a lower portion of the assembly P2, and at least one indicator associated with said UI.

4. A rearview assembly according to claim 1, further comprising first and second conductive layers on the second surface , said first and second conductive layers being substantially electrically separated from each other by a separation area.

5. A rearview assembly according to claim 1, further comprising

a transflective thin-film stack disposed across the third surface;

and

a perimeter seal sealingly affixing the first and second substrates to one another around a perimeter of the EC mirror element, said perimeter seal disposed on top of said transflective thin-film stack.

6. A rearview assembly according to claim 5,

wherein the transflective thin-film stack includes at least one electrically-conductive layer that is electrically extended over the edge surface to a back of the EC mirror element through an electrically-conductive section, and

wherein a portion of the electrically-conductive section is encapsulated in at least one of a potting material and a sealant.

7. A rearview assembly according to claim 6, wherein the electrically-conductive section includes a thin-film coating.

8. A rearview assembly according to claim 5, further comprising at least one light sensor behind the transflective thin-film stack.

9. A rearview assembly according to claim 1,

wherein the substantially rigid portion is cooperated with the EC mirror element through an adhesive such as to support the EC mirror element,

wherein the peripheral portion circumscribes the edge surface of the second substrate, and

wherein the rounded edge of the first substrate is unobstructingly observable from the front.

10. A rearview assembly according to claim 1, wherein said ring of spectral filter material has a width of less than 4 mm.

11. A rearview assembly according to claim 1, wherein said ring of spectral filter material has a width of less than 1 mm.

12. A rearview assembly according to claim 1, wherein difference in color characteristics of ambient light reflected from a first portion of the EC mirror element associated with the ring of spectral material and of ambient light reflected by a second portion of the EC mirror element located inside the first portion is less than 10 C* units.

13. A rearview assembly according to claim 1, wherein reflectance of ambient light from a portion of the EC mirror element associated with the ring of spectral filter material exceeds 60 percent.

14. A rearview assembly according to claim 1, further comprising

a user interface (UI) in the lower portion of the assembly;

at least one auxiliary device associated with the rearview assembly; and

an electronic circuitry disposed behind the EC mirror element inside the moveable mirror element supporting assembly and operable to trigger, in response to an input applied to the UI, the at least one auxiliary device.

15. A rearview assembly according to claim 14, further comprising first and second conductive layers on the second surface , said first and second conductive layers being substantially electrically separated from each other by a separation area, wherein at least one of said first and second conductive layers is electrically extended to the electronic circuitry through an electrically conductive member.

16. A rearview assembly according to claim 15, wherein the electrically conductive member includes a thin-film coating.

17. A rearview assembly according to claim 1, wherein the first substrate has a beveled edge.

18. A rearview assembly according to claim 1, further comprising at least one of a light source positioned to project light from the second substrate through the first substrate, an interior illumination assembly, a digital voice processing system, a power supply, a global positioning system, an exterior light control, a moisture detection system, an information display, a light sensor, a blind spot indicator, a turning signal indicator, an approach warning, an operator interface, a compass, a temperature indicator, a voice actuated device, a microphone, a dimming circuitry, a telecommunication system, a navigation aid, a lane departure warning system, an adaptive cruise control, a vision system, a rear vision system and a tunnel detection system.

19. A rearview assembly comprising:

an electrochromic (EC) mirror element, the EC mirror element including;

a first substrate having a first surface corresponding to the front, a second surface opposite to the first surface, and a rounded edge configured to improve durability of the first substrate, the second surface having a ring of spectral filter material disposed circumferentially around the perimeter of the second surface;

a second substrate having third and fourth surfaces and an edge surface, the second substrate being smaller than the first substrate and disposed in a parallel and spaced-apart relationship behind the first substrate such that a perimeter of the second substrate is unobservable from the first surface, the second and third surfaces defining a gap therebetween; and

an EC medium in said gap; and

a carrier assembly mechanically cooperated with the EC mirror element through an adhesive to support the EC mirror element and configured to circumscribe the edge surface.

20. A rearview assembly according to claim 19, further comprising

a user interface (UI) in the lower portion of the assembly;

at least one auxiliary device associated with the rearview assembly; and

an electronic circuitry disposed behind the EC mirror element inside the moveable mirror element supporting assembly in operable communication with the UI, the electronic circuitry adapted to trigger, in response to an input applied to the UI, the at least one auxiliary device.

21. A rearview assembly according to claim 19, further comprising

a reflective thin-film stack disposed across the third surface to form a reflective layer of the EC mirror element;

and

a perimeter seal sealingly affixing the first and second substrates to one another around a perimeter of the EC mirror element, said perimeter seal disposed on top of said transflective thin-film stack,

wherein said reflective thin-film stack is configured to cause the perimeter seal to be visible through the second substrate.

22. A rearview assembly according to claim 21,

wherein the reflective thin-film stack includes at least one electrically-conductive layer that is electrically extended over the edge surface to a back of the EC mirror element through an electrically- conductive section, and

wherein a portion of the electrically-conductive section is encapsulated in at least one of a potting material and a sealant.

23. A rearview assembly according to claim 19, wherein a reflectance of the EC mirror element is greater than 55 percent.

24. A rearview assembly according to claim 19, wherein a difference between intensity of ambient light reflected from a first portion of the EC mirror element, which is associated with the ring of spectral filter material, and intensity of ambient light reflected from a second portion of the EC mirror element, which is located inside the first portion, is less than 10 percentage points.

25. A rearview assembly according to claim 19, wherein a difference between intensity of ambient light reflected from a first portion of the EC mirror element, which is associated with the ring of spectral filter material, and intensity of ambient light reflected from a second portion of the EC mirror element, which is located inside the first portion, is less than 6 percentage points.

26. A rearview assembly according to claim 19, wherein a difference between a color characteristic of ambient light reflected from a first portion of the EC mirror element, which is associated with the ring of spectral filter material, and a color characteristic of ambient light reflected from a second portion of the EC mirror element, which is located inside the first portion, is less than 15 C* units.

27. A rearview assembly according to claim 19, wherein a difference between a color characteristic of ambient light reflected from a first portion of the EC mirror element, which is associated with the ring of spectral filter material, and a color characteristic of ambient light reflected from a second portion of the EC mirror element, which is located inside the first portion, is less than 10 C* units.

28. A rearview assembly according to claim 19 further comprising first and second conductive layers on the second surface, said first and second conductive layers being substantially electrically separated from each other by a separation area, wherein at least one of said first and second conductive layers is electrically extended to the electronic circuitry through an electrically conductive member.

29. A rearview assembly according to claim 19, further comprising at least one of a light source positioned to project light from the second substrate through the first substrate, an interior illumination assembly, a digital voice processing system, a power supply, a global positioning system, an exterior light control, a moisture detection system, an information display, a light sensor, a blind spot indicator, a turning signal indicator, an approach warning, an operator interface, a compass, a temperature indicator, a voice actuated device, a microphone, a dimming circuitry, a telecommunication system, a navigation aid, a lane departure warning system, an adaptive cruise control, a vision system, a rear vision system and a tunnel detection system.

30. A vehicular rearview assembly having a front and a front peripheral portion, the assembly comprising:

an EC mirror element including

a front substrate, the front substrate having a first surface that is unobstructingly observable from the front, a rounded edge, and a second surface carrying the first and second electrically-conductive coatings in a peripheral region thereof, the first and second electrically-conductive coatings being electrically separated from one another with a separation area, the first electrically-conductive coating including a ring of opaque material disposed around a perimeter of the second substrate; and

a rear substrate behind the first substrate as viewed from the front, the rear substrate having a third surface, an edge surface, and a fourth surface opposite the third surface, and further having a reflective thin-film stack deposited on a surface thereof;

a mounting element adapted to support the EC mirror element;

a housing shell defining an inner volume and an aperture corresponding to the front, the housing shell being configured to mechanically engage the mounting element;

an electronic circuitry disposed behind the mirror element inside the housing shell; and

a user interface (UI) in operable communication with said electronic circuitry, the UI containing triggering elements configured to be observable and reachable from the front, the triggering elements corresponding to at least one auxiliary device associated with the rearview assembly,

wherein the electronic circuitry is operable to trigger, in response to an input applied to the UI, the at least one auxiliary device, and

wherein said reflecting thin-film stack includes an electrically-conductive layer that is extended over the edge surface of the EC mirror element through an electrically-conductive member to said electronic circuitry.

31. A rearview assembly according to claim 30, wherein the front peripheral portion has an annular region that is defined around a perimeter thereof and that has a radius of curvature of greater than about 2.5 mm.

32. A rearview assembly according to claim 30, wherein a portion of the electrically-conductive member is encapsulated in at least one of a potting material and a sealant.

33. A rearview assembly according to claim 30, wherein a difference between a first intensity of ambient light reflected from a first portion of the EC mirror element that is associated with the ring of spectral filter material and a second intensity of ambient light reflected from a second portion of the EC mirror element that is located inside the first portion, is less than 10 percentage points.

34. A rearview assembly according to claim 30, wherein a difference between a color characteristic of light reflected from a first portion of the EC mirror element that is associated with the ring of spectral filter material, and a color characteristic of light reflected from a second portion of the EC mirror element that located inside the first portion, is less than 10 C* units.

35. A rearview assembly according to claim 30, further comprising

a perimeter seal sealingly affixing the first and second substrates to one another around a perimeter of the EC mirror element, said perimeter seal disposed on top of said reflective thin-film stack,

wherein said reflective thin-film stack is configured to make the perimeter seal to be visible through the second substrate.

36. A rearview assembly according to claim 35, wherein said perimeter seal includes a port filled with a plug material, and wherein said reflective thin-film stack is configured to make the plug material curable through the second substrate.

37. A rearview assembly according to claim 30, wherein reflectance of ambient light from a portion of the EC mirror element associated with the ring of spectral filter material exceeds 60 percent.

38. A rearview assembly according to claim 30, wherein the front substrate contains a beveled edge.

39. A rearview assembly according to claim 30, further comprising at least one of a light source positioned to project light from the second substrate through the first substrate, an interior illumination assembly, a digital voice processing system, a power supply, a global positioning system, an exterior light control, a moisture detection system, an information display, a light sensor, a blind spot indicator, a turning signal indicator, an approach warning, an operator interface, a compass, a temperature indicator, a voice actuated device, a microphone, a dimming circuitry, a telecommunication system, a navigation aid, a lane departure warning system, an adaptive cruise control, a vision system, a rear vision system and a tunnel detection system.