Vehicular rearview mirror elements and assemblies incorporating these elements

• US 7,978,393 B2
• Filed: 09/21/2009
• Issued: 07/12/2011
• Est. Priority Date: 02/27/2004
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Neuman, George A., Cammenga, David J., Tonar, William L., Poll, David L., Anderson, John S., Stray, Joel A.
• Primary Examiner(s): Mack; Ricky L
• Assistant Examiner(s): JONES, JAMES
• Application Number:
  US12/563,917
• Publication Number:
  US 20100020380A1
• Time in Patent Office: 659 Days
• Field of Search: 359/265
• US Class Current: 359/265
• 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 1/1207 with lamps; with turn indicators
• CPC Class Codes: B60R 2001/1215 with information displays
• CPC Class Codes: B60R 2001/1223 with sensors or transducers
• CPC Class Codes: B60R 2001/123 with thermometers
• CPC Class Codes: B60R 2001/1284 with communication systems other than radio-receivers, e.g. keyless entry systems, navigation systems; with anti-collision systems
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• 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

Abstract

The present invention relates to improved electro-optic rearview mirror elements and assemblies incorporating the same. Area of the effective field of view of the electro-optic mirror element substantially equals to that defined by the outermost perimeter of the element.

Claims

1. A variable reflectance mirror element having a periphery area, the minor element comprising:

a first optically transparent substrate including first and second surfaces;

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band, that is circumferentially disposed at a peripheral area of the second surface, and an optically transparent layer adjoining and overlaying said optical thin-film band;

a second thin-film stack covering at least a central portion of the third surface; and

an electrochromic medium disposed in the gap,

wherein the second thin-film stack includes at least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section.

2. A mirror element according to claim 1, wherein the first and second substrates are disposed so as to have at least one edge surface of the first substrate misaligned with respect to at least one edge surface of the second substrate.

3. A mirror element according to claim 1, wherein the conductive section includes a thin-film coating.

4. A mirror element according to claim 3, wherein the thin-film coating is deposited onto the third surface, the edge surface, and the fourth surface of the second substrate.

5. A mirror element according to claim 3, wherein the thin-film coating includes at least a portion of the second thin-film stack.

6. A mirror element according to claim 3, wherein the first thin-film stack is electrically extended to the fourth surface through an electrically conductive member.

7. A mirror element according to claim 6, wherein the electrically conductive member includes a first clip.

8. A mirror element according to claim 6, further including an electrically conductive element is adhered to the fourth surface, the electrically conductive element being in electrical communication with the thin-film coating.

9. A mirror element according to claim 8, wherein a portion of at least one of the electrically conductive element and the electrically conductive member is encapsulated in at least one of a potting material and a sealant.

10. A mirror element according to claim 8, wherein a portion of at least one of the electrically conductive element and the electrically conductive member is coated with a conformal coating.

11. A mirror element according to claim 1, wherein the intensity of ambient light reflected from the periphery area differs from the intensity of light reflected from inside the periphery area by no more than 10 percent.

12. A mirror element according to claim 11, wherein the intensity of ambient light reflected from the periphery area differs from the intensity of light reflected from inside the periphery area by no more than 6 percent.

13. A mirror element according to claim 11, wherein the intensity of ambient light reflected from the periphery area differs from the intensity of light reflected from inside the periphery area by no more than 3 percent.

14. A mirror element according to claim 1, wherein a difference in color of ambient light reflected from a periphery area and ambient light reflected from inside the periphery area is less than 30 C* units.

15. A mirror element according to claim 14, wherein the difference in color is less than 15 C* units.

16. A mirror element according to claim 14, wherein the difference in color is less than 10 C* units.

17. A mirror element according to claim 1, wherein the reflectance of ambient light from the periphery area exceeds 60 percent.

26. A mirror element according to claim 1 configured as a rearview mirror element for a motor vehicle and further comprising at least one device selected from the group consisting 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 sensor, 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 GPS device, 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.

27. A mirror element according to claim 1, wherein the second thin-film stack includes a layer of chromium adjacent to a layer of a platinum group metal.

18. A variable reflectance mirror element having a periphery area, the mirror element comprising:

a first optically transparent substrate including first and second surfaces,

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band circumferentially disposed at a peripheral area of the second surface;

a second thin-film stack covering at least a central portion of the third surface, at least one of the first and second thin-film stacks including a sequence of a first transparent oxide layer, at least one metal layer, and a second transparent oxide layer; and

an electrochromic medium disposed in the gap,

wherein the second thin-film stack includes a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section, the conductive section including a thin-film coating.

19. A mirror element according to claim 18, wherein the thin film coating includes at least a portion of the second thin-film stack.

20. A mirror element according to claim 18, further including an electrically conductive element adhered to the fourth surface, the electrically conductive element being in electrical communication with the thin-film coating.

21. A mirror element according to claim 18, wherein at least one of the first and second oxide layers includes a transparent conductive oxide.

22. A variable reflectance mirror element having a periphery area, the mirror element comprising:

a first optically transparent substrate including first and second surfaces,

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band circumferentially disposed at a peripheral area of the second surface, the first thin-film stack being electrically extended to the fourth surface through an electrically conductive member;

a second thin-film stack covering at least a central portion of the third surface, wherein the second thin-film stack includes a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section;

an electrochromic medium disposed in the gap; and

a conformal coating configured to cover at least a portion of at least one of the conductive section and the electrically conductive member, the at least a portion being adjacent the fourth surface.

23. A mirror element according to claim 22, wherein the conductive section includes a metal plating.

24. A mirror element according to claim 22, further comprising an electrical bus extending along at least a portion of the fourth surface, the electrical bus being in electrical contact with the conductive section.

25. A mirror element according to claim 22, wherein the conformal coating includes at least one of the sealant and potting material.

28. A variable reflectance mirror element having a periphery area, the mirror element comprising:

a first optically transparent substrate including first and second surfaces;

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band circumferentially disposed at a peripheral area of the second surface;

a second thin-film stack covering at least a central portion of the third surface; and

an electrochromic medium disposed in the gap,

wherein the second thin-film stack includes a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section that includes a thin-film coating.

29. A variable reflectance mirror element having a periphery area, the mirror element comprising:

a first optically transparent substrate including first and second surfaces;

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band, that is circumferentially disposed at a peripheral area of the second surface, and an optically transparent layer adjoining said optical thin-film band;

a second thin-film stack covering at least a central portion of the third surface; and

an electrochromic medium disposed in the gap,

wherein the second thin-film stack includes a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section, and

wherein the intensity of ambient light reflected from the periphery area differs from the intensity of light reflected from inside the periphery area by no more than 10 percent.

30. A variable reflectance mirror element having a periphery area, the mirror element comprising:

a first optically transparent substrate including first and second surfaces;

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band, that is circumferentially disposed at a peripheral area of the second surface, and an optically transparent layer adjoining said optical thin-film band;

a second thin-film stack covering at least a central portion of the third surface; and

an electrochromic medium disposed in the gap,

wherein the second thin-film stack includes a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section, and

wherein a difference in color of ambient light reflected from a periphery area and ambient light reflected from inside the periphery area is less than 30 C* units.

31. A variable reflectance mirror element having a periphery area, the mirror element comprising:

a first optically transparent substrate including first and second surfaces;

a second substrate including third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates disposed in a parallel and spaced-apart relationship with the second and third surfaces facing one another so as to define a gap therebetween;

a first thin-film stack deposited on the second surface, the first thin-film stack containing an optical thin-film band, that is circumferentially disposed at a peripheral area of the second surface, and an optically transparent layer adjoining said optical thin-film band;

a second thin-film stack covering at least a central portion of the third surface; and

an electrochromic medium disposed in the gap,

wherein the second thin-film stack includes a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section, and

wherein the reflectance of ambient light from the periphery area exceeds 60 percent.