METHOD OF FORMING AN EXTERIOR MIRROR REFLECTOR SUB-ASSEMBLY WITH AUXILIARY REFLECTOR PORTION

• US 20160229345A1
• Filed: 04/18/2016
• Published: 08/11/2016
• Est. Priority Date: 05/23/2007
• Status: Active Grant

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Zhao, Mingtang
• Granted Patent: US 9,499,102 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B24B 7/241 Methods
• CPC Class Codes: B29C 45/0053 combined with a final operation, e.g. shaping injection-compression moulding B29C45/561
• CPC Class Codes: B29C 65/48 using adhesives , i.e. using supplementary joining material; solvent bonding
• CPC Class Codes: B29C 66/7465 Glass
• CPC Class Codes: B29D 11/00596 Mirrors
• CPC Class Codes: B29L 2031/3055 Cars
• CPC Class Codes: B60R 1/0602 comprising means for cleaning or deicing
• 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 1/082 using a single wide field mirror or an association of rigidly connected mirrors
• CPC Class Codes: C03C 17/09 by deposition from the vapour phase
• CPC Class Codes: C03C 2217/26 Cr, Mo, W
• CPC Class Codes: C03C 2217/70 Properties of coatings
• CPC Class Codes: C03C 2218/154 by sputtering
• CPC Class Codes: C03C 2218/31 Pre-treatment
• CPC Class Codes: C23C 14/028 Physical treatment to alter the texture of the substrate surface, e.g. grinding, polishing
• CPC Class Codes: C23C 14/185 by cathodic sputtering
• CPC Class Codes: C23C 14/34 Sputtering
• CPC Class Codes: G02B 5/0808 having a single reflecting layer G02B5/0883, G02B5/0891 take precedence
• CPC Class Codes: G02B 5/10 with curved faces
• CPC Class Codes: G02F 1/15165 Polymers
• CPC Class Codes: G02F 1/157 : Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: G02F 2201/34 : reflector

Abstract

A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle includes providing a glass substrate and physically removing glass from a portion of a second surface of the glass substrate to form a curved recess locally thereat, and coating via a vacuum deposition process the second surface of the glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly. The method includes forming a mirror back plate in a plastic molding operation and providing a heater pad and disposing the heater pad between the coated second surface of the glass substrate and the first side of the mirror back plate. The heater pad is adhered to the coated second surface of glass substrate and to the first side of the mirror back plate.

Claims

1. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

providing a glass substrate, said glass substrate having a first surface and a second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

forming a mirror back plate in a plastic molding operation;

said mirror back plate having a first side and an opposing second side;

wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

said plastic molding operation comprising injection molding;

providing a heater pad;

said heater pad having a first surface and an opposing second surface;

said heater pad comprising a first adhesive layer disposed at said first surface of said heater pad;

said first adhesive layer comprising a pressure sensitive adhesive;

said heater pad comprising a second adhesive layer disposed at said second surface of said heater pad;

said second adhesive layer comprising a pressure sensitive adhesive;

disposing said heater pad between said coated second surface of said glass substrate and said first side of said mirror back plate, with said first surface of said heater pad facing said first side of said mirror back plate and with said second surface of said heater pad facing said coated second surface of said glass substrate;

adhering said heater pad to said coated second surface of said glass substrate via said second adhesive layer; and

adhering said heater pad to said first side of said mirror back plate via said first adhesive layer.

2. The method of claim 1, wherein physically removing glass from a portion of the second surface of said glass substrate to form said curved recess locally thereat comprises at least one of (i) physically removing glass via a glass grinding operation and (ii) physically removing glass via a glass ablation operation.

3. The method of claim 2, wherein said portion of the second surface of said glass substrate where said curved recess is formed is inboard of a perimeter edge of said glass substrate, and wherein said curved recess is generally circular-shaped.

4. The method of claim 1, wherein coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector comprises coating via sputter deposition.

5. The method of claim 1, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle.

6. The method of claim 5, wherein said glass substrate comprises (i) a generally planar second surface other than where said curved recess is formed and (ii) a generally planar first surface, and wherein said mirror reflector sub-assembly comprises a driver-side mirror reflector sub-assembly for use in a driver-side exterior rearview mirror assembly.

7. The method of claim 1, wherein, with said heater pad disposed between said coated second surface of said glass substrate and said first side of said mirror back plate, a portion of said mirror back plate extends around a perimeter edge of said glass substrate.

8. The method of claim 1, wherein, with said heater pad disposed between said coated second surface of said glass substrate and said first side of said mirror back plate, said mirror reflector sub-assembly comprises a frameless mirror reflector sub-assembly.

9. The method of claim 1, wherein said structure established at said second side of said mirror back plate for attaching said mirror back plate to a mirror actuator comprises at least one of (i) an annular ring, (ii) annular prongs and (iii) annular snaps.

10. The method of claim 1, wherein said curved recess comprises a spherically curved recess.

11. The method of claim 1, comprising peeling away a first peel away film to expose said first adhesive layer and comprising peeling away a second peel away film to expose said second adhesive layer.

12. The method of claim 1, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said coated glass substrate comprises a spherically curved glass substrate having a first radius of curvature, and wherein said curved recess comprises a spherically curved recess having a second radius of curvature, and wherein said second radius of curvature of said spherically curved recess is smaller than said first radius of curvature of said spherically curved glass substrate, and wherein said mirror reflector sub-assembly comprises a passenger-side mirror reflector sub-assembly for use in a passenger-side exterior rearview mirror assembly.

13. The method of claim 1, wherein said at least one mirror-reflecting metal thin film layer comprises chromium.

14. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

providing a glass substrate, said glass substrate having a first surface and a second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

forming a mirror back plate in a plastic molding operation;

said mirror back plate having a first side and an opposing second side;

wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

said plastic molding operation comprising injection molding;

providing a heater pad;

said heater pad having a first surface and an opposing second surface;

said heater pad comprising a first adhesive layer disposed at said first surface of said heater pad;

said first adhesive layer comprising a pressure sensitive adhesive covered by a first peel away film;

said heater pad comprising a second adhesive layer disposed at said second surface of said heater pad;

said second adhesive layer comprising a pressure sensitive adhesive covered by a second peel away film;

peeling away said first peel away film to uncover said pressure sensitive adhesive;

peeling away said second peel away film to uncover said pressure sensitive adhesive;

disposing said heater pad between said coated second surface of said glass substrate said first side of said mirror back plate, with said first surface of said heater pad facing said first side of said mirror back plate and with said second surface of said heater pad facing said coated second surface of said glass substrate;

adhering said heater pad to said coated second surface of said glass substrate via said second adhesive layer; and

adhering said heater pad to said first side of said mirror back plate via said first adhesive layer.

15. The method of claim 14, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said glass substrate comprises (i) a generally planar second surface other than where said curved recess is formed and (ii) a generally planar first surface, and wherein said mirror reflector sub-assembly comprises a driver-side mirror reflector sub-assembly for use in a driver-side exterior rearview mirror assembly.

16. The method of claim 14, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said coated glass substrate comprises a spherically curved glass substrate having a first radius of curvature, and wherein said curved recess comprises a spherically curved recess having a second radius of curvature, and wherein said second radius of curvature of said spherically curved recess is smaller than said first radius of curvature of said spherically curved glass substrate, and wherein said mirror reflector sub-assembly comprises a passenger-side mirror reflector sub-assembly for use in a passenger-side exterior rearview mirror assembly.

17. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

providing a glass substrate, said glass substrate having a first surface and a second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

forming a mirror back plate in a plastic molding operation;

said mirror back plate having a first side and an opposing second side;

wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

said plastic molding operation comprising injection molding;

providing a heater pad;

said heater pad having a first surface and an opposing second surface;

said heater pad comprising a first adhesive layer disposed at said first surface of said heater pad;

said first adhesive layer comprising a pressure sensitive adhesive;

said heater pad comprising a second adhesive layer disposed at said second surface of said heater pad;

said second adhesive layer comprising a pressure sensitive adhesive;

disposing said heater pad between said coated second surface of said glass substrate said first side of said mirror back plate, with said first surface of said heater pad facing said first side of said mirror back plate and with said second surface of said heater pad facing said coated second surface of said glass substrate;

adhering said heater pad to said coated second surface of said glass substrate via said second adhesive layer;

adhering said heater pad to said first side of said mirror back plate via said first adhesive layer;

wherein physically removing glass from a portion of the second surface of said glass substrate to form said curved recess locally thereat comprises physically removing glass via a glass grinding operation;

wherein said portion of the second surface of said glass substrate where said curved recess is formed is inboard of a perimeter edge of said glass substrate, and wherein said curved recess is generally circular-shaped; and

wherein coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector comprises coating via sputter deposition.

18. The method of claim 17, wherein said structure established at said second side of said mirror back plate for attaching said mirror back plate to a mirror actuator comprises at least one of (i) an annular ring, (ii) annular prongs and (iii) annular snaps.

19. The method of claim 18, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said glass substrate comprises (i) a generally planar second surface other than where said curved recess is formed and (ii) a generally planar first surface, and wherein said mirror reflector sub-assembly comprises a driver-side mirror reflector sub-assembly for use in a driver-side exterior rearview mirror assembly.

20. The method of claim 18, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said coated glass substrate comprises a spherically curved glass substrate having a first radius of curvature, and wherein said curved recess comprises a spherically curved recess having a second radius of curvature, and wherein said second radius of curvature of said spherically curved recess is smaller than said first radius of curvature of said spherically curved glass substrate, and wherein said mirror reflector sub-assembly comprises a passenger-side mirror reflector sub-assembly for use in a passenger-side exterior rearview mirror assembly.