ELECTRO-OPTIC ELEMENT

• US 20170068143A1
• Filed: 11/16/2016
• Published: 03/09/2017
• Est. Priority Date: 07/08/2010
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Bruizeman, Jeffrey T., Luten, Henry A., Anderson, John S., Neuman, George A.
• Granted Patent: US 10,345,672 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60R 1/025 comprising special mechanical means for correcting the field of view in relation to particular driving conditions, e.g. change of lane; scanning mirrors
• CPC Class Codes: B60R 1/04 mounted inside vehicle B60R1/025, B60R1/08 take precedence
• CPC Class Codes: B60R 1/06 mounted on vehicle exterior B60R1/025, B60R1/08 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: B60R 1/12 Mirror assemblies combined with other articles, e.g. clocks
• CPC Class Codes: B60R 2001/1223 with sensors or transducers
• CPC Class Codes: G02F 1/153 Constructional details
• CPC Class Codes: G02F 1/155 Electrodes
• 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
• CPC Class Codes: G02F 2203/09 transflective

Abstract

A vehicular rearview assembly with a mirror element having a curved or rounded edge on the first surface that is fully observable from the front of the assembly, a complex peripheral ring, and a user interface with switches and sensors that activate and configure pre-defined function(s) or device(s) of the assembly in response to the user input applied to the user interface. The mirror element is supported by a hybrid carrier co-molded of at least two materials, a portion of which is compressible between the housing shell and an edge of the mirror element. The peripheral ring may include multiple bands. Electrical communications between the electronic circuitry, the mirror element, and the user interface utilize connectors configured to exert a low contact force, onto the mirror element, limited in part by the strength of adhesive affixing the EC element to an element of the housing of the assembly.

Claims

1. An electro-optic element comprising:

a first substrate having first and second surfaces;

a second substrate having third and fourth surfaces, the second and third surfaces disposed in a parallel and spaced-apart relationship such to form a gap therebetween;

a sealing material circumferentially disposed along a perimeter of the third surface to sealingly affix the second and third surfaces together to form a chamber therebetween; and

an electro-optic medium in the chamber;

wherein at least one of the second and third surfaces carries a transparent conducting oxide (TCO);

wherein the at least one of the second and third surfaces carried a metal-containing layer;

wherein the metal-containing layer is substantially absent at at least a portion of a surface of the TCO to define an opening and the TCO layer is present in substantially all of the opening; and

wherein the metal-containing layer has a sharp or abruptly terminated edge.

2. The electro-optic element according to claim 1, wherein a distance of a transition of the sharp or abruptly terminated edge from about 90% of the maximum thickness of the metal-containing layer to about 10% of the maximum thickness of the metal containing layer is less than 1 mm.

3. The electro-optic element according to claim 1, wherein the metal-containing layer has a rate of change of a thickness per millimeter of distance, at the sharp or abruptly terminated edge, that is about four times a value of the maximum thickness of the metal-containing layer or less.

4. The electro-optic element according to claim 1, wherein the metal-containing layer has a rate of change of a thickness per millimeter of distance, at the sharp or abruptly terminated edge, that is about two orders of magnitude larger than a value of the maximum thickness of the metal-containing layer.

5. The electro-optic element according to claim 1, devoid of color shift in the metal-containing layer near the sharp or abruptly terminated edge at the opening.

6. The electro-optic element according to claim 1, wherein the electro-optic element is one of an electrochromic mirror and an electrochromic window.

7. The electro-optic element according to claim 1, wherein the sharp or abruptly terminated edge has a laser finished characteristic.

8. The electro-optic element according to claim 7, wherein the sharp or abruptly terminated edge has a scalloped characteristic.

9. The electro-optic element according to claim 7, wherein the metal-containing layer has been removed with laser ablation to form the opening.

10. The electro-optic element according to claim 9, wherein the TCO remains relatively undamaged.

11. The electro-optic element according to claim 9, wherein the metal-containing layer has been removed with light from a laser source directed at the metal-containing layer through a substrate containing the metal-containing layer.

12. The electro-optic element according to claim 7, wherein a haze value characterizing a substrate carrying the metal-containing layer defining the opening and measured in the opening is less than about 0.5%.

13. The electro-optic element according to claim 7, wherein a metallic residue in an area of the opening covers less than about 2% of the area of a surface of the opening.

14. An electro optic element according to claim 1, wherein the metal-containing layer is under the TCO.

15. An electro-optic element comprising:

a first substrate having first and second surfaces;

a second substrate having third and fourth surfaces, the second and third surfaces disposed in a parallel and spaced-apart relationship to form a gap therebetween;

a sealing material circumferentially disposed along a perimeter of the third surface to sealingly affix the second and third surfaces together to form a chamber therebetween; and

an electro-optic medium in the chamber;

wherein at least one of the second and third surfaces carries a transparent conducting oxide (TCO);

wherein the at least one of the second and third surfaces carried a metal-containing layer;

wherein the metal-containing layer is substantially absent at at least a portion of a surface of the TCO to define an opening and the TCO layer is present in substantially all of the opening; and

wherein the TCO remains relatively undamaged.

16. The electro-optic element according to claim 15, devoid of color shift in the metal-containing layer near the sharp or abruptly terminated edge at the opening.

17. The electro-optic element according to claim 15, wherein the electro-optic element is one of an electrochromic mirror and an electrochromic window.

18. The electro-optic element according to claim 15, wherein the metal-containing layer has been removed with laser ablation to form the opening.

19. The electro-optic element according to claim 15, wherein the metal-containing layer has been removed with light from a laser source directed at the metal-containing layer through a substrate containing the metal-containing layer.

20. The electro-optic element according to claim 15, wherein a haze value characterizing a substrate carrying the metal-containing layer defining the opening and measured in the opening is less than about 0.5%.

21. The electro-optic element according to claim 15, wherein a metallic residue in an area of the opening covers less than about 2% of the area of a surface of the opening.

22. An electro optic element according to claim 15, wherein the metal-containing layer is under the TCO.

23. A method for fabrication of an electro optic element, the method comprising:

depositing a first metal-containing layer onto a first transparent substrate;

laser ablating the first metal-containing layer from a portion of an area of the first transparent substrate to create an opening in the metal-containing layer in said portion;

depositing a transparent conductive oxide (TCO) layer onto the first substrate to cover a surface of the transparent substrate corresponding to said portion;

wherein the opening in the metal-containing layer comprises at least one of;

a sharp or abruptly terminated edge;

a haze value of less than 0.5%, the haze value of a substrate carrying the metal-containing layer defining the opening and measured in the opening;

an absorption value of less than 10%, the absorption value of a substrate carrying the metal-containing layer defining the opening and measured in the opening; and

a metallic residue that covers less than 2% of an area of a surface of the opening.

24. A method for fabrication of an electro optic element, the method comprising:

depositing a first transparent conductive oxide (TCO) layer onto a transparent substrate;

depositing a metal-containing layer onto the TCO layer; and

laser ablating a portion of an area of the transparent substrate covered by the metal-containing layer to create an opening in the metal-containing layer;

wherein the opening in the metal-containing layer is characterized by at least one of;

a sharp or abruptly terminated edge;

a haze value of less than 0.5%, the haze value of a substrate carrying the metal-containing layer defining the opening and measured in the opening;

an absorption value of less than 10%, the absorption of a substrate carrying the metal-containing layer defining the opening and measured in the opening; and

a metallic residue that covers less than 2% of an area of a surface of the opening.