Rearview mirror assembly for vehicle

• US 7,898,719 B2
• Filed: 10/16/2009
• Issued: 03/01/2011
• Est. Priority Date: 10/02/2003
• Status: Active Grant

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Wight, David C., Kramer, Mark E., Schofield, Kenneth
• Primary Examiner(s): Lavarias; Arnel C
• Assistant Examiner(s): Chapel; Derek S
• Application Number:
  US12/580,499
• Publication Number:
  US 20100033797A1
• Time in Patent Office: 501 Days
• Field of Search: None
• US Class Current: 359/267
• CPC Class Codes: B32B 37/1292 selectively, e.g. in stripes, in patterns B32B37/0076 takes 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: H05K 1/0274 Optical details, e.g. printed circuits comprising integral optical means H05K1/0269 takes precedence; coupling light guides with opto-electronic components G02B6/42
• CPC Class Codes: H05K 1/181 associated with surface mounted components
• CPC Class Codes: H05K 2201/2054 Light-reflecting surface, e.g. conductors, substrates, coatings, dielectrics

Abstract

A rearview mirror assembly includes an electrochromic reflective element having a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween. The reflective element includes (a) a transparent electrically conductive coating disposed at a second surface of a front glass substrate and (b) a mirror reflector disposed at a third surface of a rear glass substrate. A conductive trace is established on a fourth surface of the rear glass substrate. An electrical connector establishes electrical conductivity between the conductive trace and one of (i) the transparent electrically conductive coating disposed at the second surface of the front glass substrate and (ii) the mirror reflector disposed at the third surface of the rear glass substrate. The electrical connector connects to the conductive trace via a solderless connection.

Claims

1. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said second surface is opposite said first surface and faces said electrochromic medium;

wherein said third surface faces said electrochromic medium and said fourth surface is opposite said third surface;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises a trace of electrically conductive epoxy;

an electrical connector establishing electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate; and

wherein said electrical connector connects to said conductive trace via a solderless connection.

2. The rearview mirror assembly of claim 1, wherein said conductive trace comprises an electrically conductive rail disposed at least a portion of a perimeter region of said fourth surface of said rear glass substrate, and wherein said electrical connector is connected between said electrically conductive rail and one of (i) a perimeter portion of said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) a perimeter portion of said mirror reflector disposed at said third surface of said rear glass substrate.

3. The rearview mirror assembly of claim 2, wherein said electrical connector is connected between said electrically conductive rail and a perimeter portion of said transparent electrically conductive coating disposed at said second surface of said front glass substrate, and wherein a second electrical connector is connected between another electrically conductive rail disposed at another portion of said perimeter region of said fourth surface of said rear glass substrate and a perimeter portion of said mirror reflector disposed at said third surface of said rear glass substrate.

4. The rearview mirror assembly of claim 1, wherein said electrical connector comprises a clip that clips onto an edge portion of one of (a) said front substrate and (b) said rear substrate to establish electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate.

5. The rearview mirror assembly of claim 1, wherein an electrically conductive layer is disposed at a portion of said fourth surface of said rear glass substrate and a non-conductive layer is applied at said electrically conductive layer and covering at least a portion of said electrically conductive layer and leaving at least one portion of said electrically conductive layer exposed, and wherein said at least one exposed portion of said electrically conductive layer comprises said conductive trace at said fourth surface of said rear glass substrate.

6. The rearview mirror assembly of claim 1, wherein said conductive trace comprises an electrically conductive resin.

7. The rearview mirror assembly of claim 1, wherein said conductive trace comprises an electrically conductive silver epoxy.

8. The rearview mirror assembly of claim 1, wherein at least one electronic circuitry component is directly attached at said fourth surface of said rear glass substrate.

9. The rearview mirror assembly of claim 8, wherein said at least one electronic circuitry component comprises a carbon ink resistor.

10. The rearview mirror assembly of claim 8, wherein said at least one electronic circuitry component comprises at least one proximity sensor positioned along a portion of said rear surface of said rear glass substrate, said at least one proximity sensor being operable to detect a presence of a person'"'"'s finger at or near said mirror assembly.

11. The rearview mirror assembly of claim 1, wherein said conductive trace comprises a layer of resin material disposed at said fourth surface of said rear glass substrate, and wherein, when said resin material is in an uncured state at said fourth surface of said rear glass substrate, said electrical connector contacts said uncured resin material at said fourth surface of said rear glass substrate, and wherein said solderless electrical connection is established when said resin material cures to form said conductive trace.

12. The rearview mirror assembly of claim 11, wherein said resin material comprises a conductive silver epoxy.

13. The rearview mirror assembly of claim 1, wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly.

14. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said second surface is opposite said first surface and faces said electrochromic medium;

wherein said third surface faces said electrochromic medium and said fourth surface is opposite said third surface;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises an electrically conductive silver epoxy;

an electrical connector establishing electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate; and

wherein said electrical connector connects to said conductive trace via a solderless connection.

15. The rearview mirror assembly of claim 14, wherein said conductive trace comprises an electrically conductive rail disposed at least a portion of a perimeter region of said fourth surface of said rear glass substrate, and wherein said electrical connector is connected between said electrically conductive rail and one of (i) a perimeter portion of said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) a perimeter portion of said mirror reflector disposed at said third surface of said rear glass substrate.

16. The rearview mirror assembly of claim 14, wherein said conductive trace comprises a layer of resin material disposed at said fourth surface of said rear glass substrate, and wherein, when said resin material is in an uncured state at said fourth surface of said rear glass substrate, said electrical connector contacts said uncured resin material at said fourth surface of said rear glass substrate, and wherein said solderless electrical connection is established when said resin material cures to form said conductive trace.

17. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises an electrically conductive silver epoxy;

an electrical connector establishing electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrical connector connects to said conductive trace via a solderless connection, wherein said conductive trace comprises an electrically conductive rail disposed at least a portion of a perimeter region of said fourth surface of said rear glass substrate, and wherein said electrical connector is connected between said electrically conductive rail and one of (i) a perimeter portion of said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) a perimeter portion of said mirror reflector disposed at said third surface of said rear glass substrate; and

wherein said electrical connector is connected between said electrically conductive rail and a perimeter portion of said transparent electrically conductive coating disposed at said second surface of said front glass substrate, and wherein a second electrical connector is connected between another electrically conductive rail disposed at another portion of said perimeter region of said fourth surface of said rear glass substrate and a perimeter portion of said mirror reflector disposed at said third surface of said rear glass substrate.

18. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises an electrically conductive silver epoxy;

an electrical connector establishing electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate; and

wherein said electrical connector connects to said conductive trace via a solderless connection, and wherein said electrical connector comprises a clip that clips onto an edge portion of one of (a) said front substrate and (b) said rear substrate to establish electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate.

19. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises an electrically conductive silver epoxy;

an electrical connector establishing electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate; and

wherein said electrical connector connects to said conductive trace via a solderless connection, and wherein at least one electronic circuitry component is directly attached at said fourth surface of said rear glass substrate.

20. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said second surface is opposite said first surface and faces said electrochromic medium;

wherein said third surface faces said electrochromic medium and said fourth surface is opposite said third surface;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises a layer of resin material disposed at said fourth surface of said rear glass substrate, and wherein said resin material comprises an electrically conductive silver epoxy;

wherein said conductive trace comprises an electrically conductive rail disposed at least a portion of a perimeter region of said fourth surface of said rear glass substrate;

an electrical connector establishing electrical conductivity between said electrically conductive rail and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate; and

wherein said electrical connector connects to said conductive trace via a solderless connection, and wherein, when said resin material is in an uncured state at said fourth surface of said rear glass substrate, said electrical connector contacts said uncured resin material at said fourth surface of said rear glass substrate, and wherein said solderless electrical connection is established when said resin material cures to form said conductive trace.

21. A rearview mirror assembly for a vehicle, said rearview mirror assembly comprising:

an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween;

wherein said front glass substrate has a first surface and a second surface and said rear glass substrate has a third surface and a fourth surface;

wherein said rearview mirror assembly comprises an interior rearview mirror assembly mounted at an interior portion of a vehicle equipped with said rearview mirror assembly;

wherein said first surface of said front glass substrate faces generally towards a driver of a vehicle equipped with said rearview mirror assembly when said rearview mirror assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

wherein said reflective element comprises (a) a transparent electrically conductive coating disposed at said second surface of said front glass substrate and (b) a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating and said mirror reflector;

a conductive trace established on said fourth surface of said rear glass substrate, wherein said conductive trace comprises a layer of resin material disposed at said fourth surface of said rear glass substrate, and wherein said resin material comprises an electrically conductive silver epoxy;

wherein said conductive trace comprises an electrically conductive rail disposed at least a portion of a perimeter region of said fourth surface of said rear glass substrate;

an electrical connector establishing electrical conductivity between said electrically conductive rail and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrical connector connects to said conductive trace via a solderless connection, and wherein, when said resin material is in an uncured state at said fourth surface of said rear glass substrate, said electrical connector contacts said uncured resin material at said fourth surface of said rear glass substrate, and wherein said solderless electrical connection is established when said resin material cures to form said conductive trace; and

wherein said electrical connector comprises a clip that clips onto an edge portion of one of (a) said front substrate and (b) said rear substrate to establish electrical conductivity between said conductive trace and one of (i) said transparent electrically conductive coating disposed at said second surface of said front glass substrate and (ii) said mirror reflector disposed at said third surface of said rear glass substrate.