Rearview mirror assembly for vehicle

• US 8,179,586 B2
• Filed: 02/24/2011
• Issued: 05/15/2012
• Est. Priority Date: 10/02/2003
• Status: Active Grant

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Schofield, Kenneth, Wight, David C., Kramer, Mark E.
• Primary Examiner(s): Chapel, Derek S
• Application Number:
  US13/033,951
• Publication Number:
  US 20110141542A1
• Time in Patent Office: 446 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 substrate and a rear substrate and an electrochromic medium sandwiched therebetween. The reflective element includes a resin material disposed at least at a portion of a fourth surface of the rear substrate. While the resin material is in its uncured state at the rear substrate, an electrical connector is engaged with the uncured resin material. The electrical connector is electrically conductively connected with the resin material and is substantially affixed at the fourth surface of the rear substrate via curing of the resin material while the electrical connector is engaged with the resin material. The electrical connector may establish electrical conductivity between the cured resin material and one of (i) a transparent electrically conductive coating at the second surface of the front substrate and (ii) a mirror reflector at the third surface of the rear substrate.

Claims

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

providing an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween and bounded by a perimeter seal;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein said rear glass substrate has a third surface and a fourth surface opposite said third 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 minor assembly is normally mounted and is viewed by the driver when normally operating the vehicle;

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

wherein said electrochromic medium contacts said transparent electrically conductive coating at said second surface of said front glass substrate and said mirror reflector at said third surface of said rear glass substrate;

disposing an uncured resin layer at least at said fourth surface of said rear glass substrate;

while said uncured resin layer is in its uncured state at said fourth surface of said rear glass substrate, engaging an electrical connector with said uncured resin layer at said fourth surface of said rear glass substrate; and

while said electrical connector is engaged with said uncured resin layer, curing said uncured resin layer to a cured resin layer, and wherein, after said uncured resin layer is cured to said cured resin layer, said electrical connector is electrically conductively connected with said cured resin layer and said electrical connector is substantially affixed at said fourth surface of said rear glass substrate via said cured resin layer.

2. The method of claim 1, wherein said electrical connector comprises at least a portion of at least one of (a) an electrical component, (b) a wire, (c) an electrical accessory and (d) a clip.

3. The method of claim 2, wherein said electrical connector establishes, at least in part, electrical conductivity between said cured resin layer and one of (i) said transparent electrically conductive coating at said second surface of said front glass substrate and (ii) said mirror reflector at said third surface of said rear glass substrate.

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

5. The method of claim 1, wherein said cured resin layer comprises an electrically conductive silver epoxy.

6. The method of claim 1, wherein disposing an uncured resin layer at least at said fourth surface of said rear glass substrate comprises screen printing an uncured resin layer onto said fourth surface of said rear glass substrate.

7. The method of claim 1, wherein curing said uncured resin layer comprises curing said uncured resin layer and said perimeter seal via a common curing process.

8. The method of claim 1, wherein curing said uncured resin layer comprises curing said uncured resin layer via an air curing process.

9. The method of claim 1, wherein curing said uncured resin layer comprises curing said uncured resin layer via an oven curing process.

10. The method of claim 1, comprising electrically connecting at least one electronic circuitry component to said cured resin layer via curing of said uncured resin layer to said cured resin layer when said at least one electronic circuitry component is in contact with said uncured resin layer, and wherein said at least one electronic circuitry component is substantially affixed at said fourth surface of said rear glass substrate after said uncured resin layer is cured to said cured resin layer.

11. The method of claim 1, comprising attaching at least one electronic circuitry component at said fourth surface of said rear glass substrate and wherein, after said uncured resin layer is cured to said cured resin layer, said at least one electronic circuitry component is electrically connected with a portion of said cured resin layer.

12. The method of claim 11, wherein said at least one electronic circuitry component comprises a carbon ink resistor.

13. The method of claim 11, wherein said at least one electronic circuitry component comprises at least one proximity sensor positioned along a portion of said fourth 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 rearview mirror assembly.

14. The method of claim 1, wherein said electrical connector comprises at least a portion of at least one of (a) electrical circuitry, (b) an electrical component, (c) a resistor, (d) a capacitor, (e) an electrical jumper, (f) a clip, (g) an electrical accessory, (h) a sensor, (i) a display element, (j) a light emitting diode and (k) an antenna.

15. The method of claim 1, wherein said cured resin layer establishes a conductive trace at least at said fourth surface of said rear glass substrate.

16. The method of claim 15, wherein disposing an uncured resin layer comprises disposing an uncured resin layer at a portion of said fourth surface of said rear glass substrate and wherein said method comprises applying a non-conductive layer at said uncured resin layer that covers at least a portion of said uncured resin layer and leaves at least one portion of said uncured resin layer exposed, and wherein said at least one exposed portion of said uncured resin layer, when said uncured resin layer is cured to said cured resin layer, comprises said conductive trace at said fourth surface of said rear glass substrate.

17. The method of claim 15, 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 at said second surface of said front glass substrate and (ii) a perimeter portion of said mirror reflector at said third surface of said rear glass substrate.

18. The method of claim 17, wherein said electrical connector is connected between said electrically conductive rail and a perimeter portion of said transparent electrically conductive coating at said second surface of said front glass substrate, and wherein said method comprises connecting a second electrical connector 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 at said third surface of said rear glass substrate.

19. The method 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.

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

providing an electrochromic reflective element comprising a front substrate and a rear substrate having an electrochromic medium sandwiched therebetween and bounded by a perimeter seal;

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

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

wherein said electrochromic medium contacts said transparent electrically conductive coating at said second surface of said front substrate and said mirror reflector at said third surface of said rear substrate;

disposing an uncured resin layer at least at said fourth surface of said rear substrate;

while said uncured resin layer is in its uncured state at said fourth surface of said rear substrate, engaging an electrical connector with said uncured resin layer at said fourth surface of said rear substrate;

while said electrical connector is engaged with said uncured resin layer, curing said uncured resin layer to a cured resin layer, and wherein, after said uncured resin layer is cured to said cured resin layer, said electrical connector is electrically conductively connected with said cured resin layer and said electrical connector is substantially affixed at said fourth surface of said rear substrate via cured resin layer, and wherein said cured resin layer comprises an electrically conductive silver epoxy; and

wherein said electrical connector establishes, at least in part, electrical conductivity between said cured resin layer and one of (i) said transparent electrically conductive coating at said second surface of said front substrate and (ii) said mirror reflector at said third surface of said rear substrate.

21. The method of claim 20, wherein said electrical connector comprises a clip that clips onto an edge portion of a respective one of said front and rear substrates.

22. The method of claim 20, wherein disposing an uncured resin layer comprises screen printing an uncured resin layer onto said fourth surface of said rear substrate.

23. The method of claim 20, wherein curing said uncured resin layer comprises curing said uncured resin layer and said perimeter seal via a common curing process.

24. The method of claim 20, wherein curing said uncured resin layer comprises curing said uncured resin layer via at least one of (a) an air curing process and (b) an oven curing process.

25. A method for manufacturing a rearview mirror assembly for a vehicle, said method comprising:

providing an electrochromic reflective element comprising a front substrate and a rear substrate having an electrochromic medium sandwiched therebetween and bounded by a perimeter seal;

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

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

wherein said electrochromic medium contacts said transparent electrically conductive coating at said second surface of said front substrate and said mirror reflector at said third surface of said rear substrate;

disposing an uncured resin layer at least at said fourth surface of said rear substrate;

while said uncured resin layer is in its uncured state at said fourth surface of said rear substrate, engaging an electrical connector with said uncured resin layer at said fourth surface of said rear substrate;

while said electrical connector is engaged with said uncured resin layer, curing said uncured resin layer to a cured resin layer, and wherein, after said uncured resin layer is cured to said cured resin layer, said electrical connector is electrically conductively connected with said cured resin layer and said electrical connector is substantially affixed at said fourth surface of said rear substrate said cured resin layer; and

wherein curing said uncured resin layer comprises curing said uncured resin layer and said perimeter seal via a common curing process.

26. The method of claim 25, wherein curing said uncured resin layer and said perimeter seal comprises curing said uncured resin layer and said perimeter seal via at least one of (a) an air curing process and (b) an oven curing process.

27. The method of claim 25, wherein said electrical connector comprises at least a portion of at least one of (a) an electrical component, (b) a wire, (c) an electrical accessory and (d) a clip.

28. The method of claim 25, wherein said electrical connector establishes, at least in part, electrical conductivity between said cured resin layer and one of (i) said transparent electrically conductive coating at said second surface of said front substrate and (ii) said mirror reflector at said third surface of said rear substrate.

29. The method of claim 25, wherein said electrical connector comprises a clip that one of (a) clips onto an edge portion of said front substrate to establish electrical conductivity between said cured resin layer and said transparent electrically conductive coating at said second surface of said front substrate, and (b) clips onto an edge portion of said rear substrate to establish electrical conductivity between said cured resin layer and said mirror reflector at said third surface of said rear substrate.

30. The method of claim 25, wherein said cured resin layer comprises an electrically conductive silver epoxy.

31. A method for manufacturing a rearview mirror assembly for a vehicle, said method comprising:

providing an electrochromic reflective element comprising a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween and bounded by a perimeter seal;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein said rear glass substrate has a third surface and a fourth surface opposite said third 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 reflective element comprises a transparent electrically conductive coating disposed at said second surface of said front glass substrate and wherein said reflective element comprises a mirror reflector disposed at said third surface of said rear glass substrate;

wherein said electrochromic medium contacts said transparent electrically conductive coating at said second surface of said front glass substrate and said mirror reflector at said third surface of said rear glass substrate;

disposing an uncured resin layer least at a perimeter region of said fourth surface of said rear glass substrate;

while said uncured resin layer is in its uncured state at said fourth surface of said rear glass substrate, engaging an electrical connector with said uncured resin layer at said fourth surface of said rear glass substrate; and

while said electrical connector is engaged with said uncured resin layer, curing said uncured resin layer to a cured resin layer, and wherein, after said uncured resin layer is cured to said cured resin layer, said electrical connector is electrically conductively connected with said cured resin layer and said electrical connector is substantially affixed at said fourth surface of said rear glass substrate via said cured resin layer.

32. The method of claim 31, wherein said electrical connector connects to one of (i) a perimeter portion of said transparent electrically conductive coating at said second surface of said front glass substrate and (ii) a perimeter portion of said mirror reflector at said third surface of said rear glass substrate.

33. The method of claim 32, wherein said electrical connector comprises at least a portion of at least one of (a) an electrical component, (h) a wire, (c) an electrical accessory and (d) a clip.

34. The method of claim 33, wherein said cured resin layer comprises an electrically conductive silver epoxy.

35. The method of claim 34, wherein curing said uncured resin layer comprises curing said uncured resin layer and said perimeter seal via a common curing process.