EXTERIOR MIRROR REFLECTIVE ELEMENT WITH AUXILIARY REFLECTOR

• US 20180118114A1
• Filed: 12/31/2017
• Published: 05/03/2018
• 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 10,023,122 B2
• Time in Patent Office: Days
• 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 mirror reflective element suitable for use in an exterior rearview mirror assembly of a vehicle includes a glass substrate having a first side and an opposing second side. The mirror reflective element has a principal reflector portion and an auxiliary reflector portion. The auxiliary reflector portion includes a curved recess established at the second side of the glass substrate. An auxiliary mirror metallic reflector is coated at the curved recess at the second side of the glass substrate and a principal mirror metallic reflector is coated at the principal reflector portion. The mirror reflective element is configured so that, when an exterior rearview mirror assembly equipped with the mirror reflective element is normally mounted at a side of a vehicle, the curved recess is disposed at an outboard upper region of the mirror reflective element relative to the side of the equipped vehicle.

Claims

1. A mirror reflective element suitable for use in an exterior rearview mirror assembly of a vehicle, said mirror reflective element comprising:

a glass substrate having a first side and an opposing second side;

wherein said glass substrate has a thickness between said first side and said second side of less than 3 millimeters;

wherein said mirror reflective element has a principal reflector portion and an auxiliary reflector portion;

wherein said auxiliary reflector portion comprises a curved recess established at said second side of said glass substrate;

wherein said curved recess comprises a radius of curvature less than 1,000 millimeters;

wherein said curved recess has a recess depth less than 2.26 millimeters;

an auxiliary mirror metallic reflector coated at said curved recess at said second side of said glass substrate;

a principal mirror metallic reflector coated at said principal reflector portion;

wherein said principal mirror metallic reflector coated at said principal reflector portion is disposed at said second side of said glass substrate;

wherein said auxiliary mirror metallic reflector coated at said curved recess and said principal mirror metallic reflector coated at said principal reflector portion comprise the same material;

wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element;

wherein said mirror reflective element is configured so that, 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 disposed at an outboard upper region of said mirror reflective element relative to the side of the equipped vehicle;

wherein a heater pad is disposed at said second side of said glass substrate;

wherein said heater pad, when electrically powered, heats both of (i) said curved recess and (ii) said principal reflector portion;

wherein electrical power for heating said mirror reflective element is provided via at least one electrically conductive trace of said heater pad that generates heat when passing an electrical current;

wherein said electrical power is applied via at least one electrical connector of said heater pad that is adapted for connection to a wiring harness of an exterior mirror assembly for powering of said heater pad by a power source of a vehicle equipped with the exterior mirror assembly; and

wherein said heater pad comprises a flexible heater pad.

2. The mirror reflective element of claim 1, wherein said same material coats the entire second side of said glass substrate.

3. The mirror reflective element of claim 2, wherein said glass substrate comprises a bent glass substrate having a radius of curvature, and wherein said radius of curvature of said bent glass substrate is larger than said radius of curvature of said curved recess.

4. The mirror reflective element of claim 2, wherein said same material comprises chromium.

5. The mirror reflective element of claim 1, wherein said first side of said glass substrate is flat, and wherein said second side of said glass substrate is flat other than at said curved recess.

6. The mirror reflective element of claim 1, wherein said first side of said glass substrate has a radius of curvature, and wherein said radius of curvature of said first side of said glass substrate is greater than said radius of curvature of said curved recess.

7. The mirror reflective element of claim 1, wherein said curved recess is inboard of a perimeter edge of said glass substrate.

8. The mirror reflective element of claim 7, wherein said principal reflector portion of said mirror reflective element surrounds said curved recess of said mirror reflective element.

9. The mirror reflective element of claim 8, wherein said curved recess is circular-shaped.

10. The mirror reflective element of claim 9, wherein said curved recess comprises a spherical convex-curved surface, and wherein said spherically curved and circular-shaped recess has a maximum recess depth H that is a function of its radius of curvature R and its cross-dimension size D, and wherein:

H=R−

(R²−

(D/2)²)^0.5.

11. The mirror reflective element of claim 10, wherein said curved recess has a cross-dimension size D less than 80 millimeters.

12. The mirror reflective element of claim 11, wherein said curved recess has a cross-dimension size D that is greater than 30 millimeters.

13. The mirror reflective element of claim 12, wherein said curved recess has a maximum recess depth H that is greater than 0.11 millimeters.

14. The mirror reflective element of claim 13, wherein said curved recess comprises a radius of curvature R greater than 200 millimeters.

15. The mirror reflective element of claim 10, wherein said curved recess is established at said second side of said glass substrate by grinding and wherein said at least one electrically conductive trace of said flexible heater pad traverses a flexible strip of said flexible heater pad.

16. A mirror reflective element suitable for use in a driver-side exterior rearview mirror assembly of a vehicle, said mirror reflective element comprising:

a glass substrate having a first side and an opposing second side;

wherein said glass substrate has a thickness between said first side and said second side of less than 3 millimeters;

wherein said mirror reflective element has a principal reflector portion and an auxiliary reflector portion;

wherein said auxiliary reflector portion comprises a curved recess established at said second side of said glass substrate;

wherein said first side of said glass substrate is flat;

wherein said second side of said glass substrate is flat other than at said curved recess;

wherein said curved recess comprises a radius of curvature less than 1,000 millimeters;

wherein said curved recess has a recess depth less than 2.26 millimeters;

an auxiliary mirror metallic reflector coated at said curved recess at said second side of said glass substrate;

a principal mirror metallic reflector coated at said principal reflector portion;

wherein said principal mirror metallic reflector coated at said principal reflector portion is disposed at said second side of said glass substrate;

wherein said auxiliary mirror metallic reflector coated at said curved recess and said principal mirror metallic reflector coated at said principal reflector portion comprise the same material;

wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element;

wherein said curved recess is inboard of a perimeter edge of said glass substrate;

wherein said principal reflector portion of said mirror reflective element surrounds said curved recess of said mirror reflective element;

wherein said curved recess is circular-shaped;

wherein said curved recess comprises a spherical convex-curved surface;

wherein said mirror reflective element is configured so that, when a driver-side exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a driver side of a vehicle, said curved recess is disposed at an outboard upper region of said mirror reflective element relative to the driver side of the equipped vehicle;

wherein a heater pad is disposed at said second side of said glass substrate;

wherein said heater pad, when electrically powered, heats both of (i) said curved recess and (ii) said principal reflector portion;

wherein electrical power for heating said mirror reflective element is provided via at least one electrically conductive trace of said heater pad that generates heat when passing an electrical current;

wherein said electrical power is applied via at least one electrical connector of said heater pad that is adapted for connection to a wiring harness of a driver-side exterior mirror assembly for powering of said heater pad by a power source of a vehicle equipped with the driver-side exterior mirror assembly; and

wherein said heater pad comprises a flexible heater pad.

17. The mirror reflective element of claim 16, wherein said curved recess has a cross-dimension size less than 80 millimeters, and wherein said curved recess has a cross-dimension size that is greater than 30 millimeters, and wherein said curved recess has a maximum recess depth that is greater than 0.11 millimeters.

18. The mirror reflective element of claim 17, wherein said curved recess is established at said second side of said glass substrate by grinding, and wherein said at least one electrically conductive trace of said flexible heater pad traverses a flexible strip of said flexible heater pad, and wherein said curved recess comprises a radius of curvature greater than 200 millimeters.

19. A mirror reflective element suitable for use in a passenger-side exterior rearview mirror assembly of a vehicle, said mirror reflective element comprising:

a glass substrate having a first side and an opposing second side;

wherein said glass substrate has a thickness between said first side and said second side of less than 3 millimeters;

wherein said mirror reflective element has a principal reflector portion and an auxiliary reflector portion;

wherein said auxiliary reflector portion comprises a curved recess established at said second side of said glass substrate;

wherein said glass substrate comprises a bent glass substrate having a radius of curvature;

wherein said radius of curvature of said bent glass substrate is larger than said radius of curvature of said curved recess;

wherein said curved recess comprises a radius of curvature less than 1,000 millimeters;

wherein said curved recess has a recess depth less than 2.26 millimeters;

an auxiliary mirror metallic reflector coated at said curved recess at said second side of said glass substrate;

a principal mirror metallic reflector coated at said principal reflector portion;

wherein said principal mirror metallic reflector coated at said principal reflector portion is disposed at said second side of said glass substrate;

wherein said auxiliary mirror metallic reflector coated at said curved recess and said principal mirror metallic reflector coated at said principal reflector portion comprise the same material;

wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element;

wherein said curved recess is inboard of a perimeter edge of said glass substrate;

wherein said principal reflector portion of said mirror reflective element surrounds said curved recess of said mirror reflective element;

wherein said curved recess is circular-shaped;

wherein said curved recess comprises a spherical convex-curved surface;

wherein said mirror reflective element is configured so that, when a passenger-side exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a passenger side of a vehicle, said curved recess is disposed at an outboard upper region of said mirror reflective element relative to the passenger side of the equipped vehicle;

wherein a heater pad is disposed at said second side of said glass substrate;

wherein said heater pad, when electrically powered, heats both of (i) said curved recess and (ii) said principal reflector portion;

wherein electrical power for heating said mirror reflective element is provided via at least one electrically conductive trace of said heater pad that generates heat when passing an electrical current;

wherein said electrical power is applied via at least one electrical connector of said heater pad that is adapted for connection to a wiring harness of a passenger-side exterior mirror assembly for powering of said heater pad by a power source of a vehicle equipped with the passenger-side exterior mirror assembly; and

wherein said heater pad comprises a flexible heater pad.

20. The mirror reflective element of claim 19, wherein said curved recess has a cross-dimension size less than 80 millimeters, and wherein said curved recess has a cross-dimension size that is greater than 30 millimeters, and wherein said curved recess has a maximum recess depth that is greater than 0.11 millimeters, and wherein said at least one electrically conductive trace of said flexible heater pad traverses a flexible strip of said flexible heater pad.