Vehicular rearview mirror elements and assemblies incorporating these elements

• US 9,346,402 B2
• Filed: 04/29/2015
• Issued: 05/24/2016
• Est. Priority Date: 09/30/2002
• Status: Expired due to Term

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Tonar, William L., Cammenga, David J., Anderson, John S., Poll, David L., Neuman, George A., Stray, Joel A., Busscher, Bradley L., Ypma, Kenton J.
• Primary Examiner(s): TRA, TUYEN Q
• Application Number:
  US14/699,402
• Publication Number:
  US 20150239399A1
• Time in Patent Office: 391 Days
• Field of Search: 359265-275, 359/105, 427/108, 427/164, 427/165, 427/596, 427/554
• US Class Current: 1/1
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: B32B 17/10321 Laminated safety glass or glazing containing liquid layers
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• CPC Class Codes: B32B 2255/205 Metallic coating
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 2307/40 having particular optical properties light or UV resistant B32B2307/71
• CPC Class Codes: B32B 2307/412 Transparent
• CPC Class Codes: B32B 2307/728 Hydrophilic
• CPC Class Codes: B32B 2307/73 Hydrophobic
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 2605/006 Transparent parts other than made from inorganic glass, e.g. polycarbonate glazings
• 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 2001/1215 with information displays
• CPC Class Codes: C23C 14/086 of zinc, germanium, cadmium, indium, tin, thallium or bismuth
• CPC Class Codes: C23C 14/34 Sputtering
• CPC Class Codes: G02F 1/153 : Constructional details
• CPC Class Codes: G02F 1/157 : Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: Y10T 29/49002 : Electrical device making

Abstract

The present invention relates to improved electro-optic rearview mirror elements and assemblies incorporating the same, including processes for making such elements and assemblies.

Claims

1. A vehicular rearview assembly prepared by a process comprising the steps:

providing a first substrate comprising a first surface and a second surface;

providing a second substrate comprising a third surface and a fourth surface;

applying an electrically conductive coating to at least a portion of the second surface;

applying an electrically conductive coating to at least a portion of the third surface;

ablating by a laser a portion of the electrically conductive coating on the second surface forming an isolation area that is substantially devoid of the electrically conductive coating and a plurality of non-ablated portions of the electrically conductive coating;

applying a perimeter seal to the second surface and the third surface to define a cavity;

filling the cavity with an electro-optic medium to form an electro-optic element; and

connecting the electro-optic element to a housing structure having an aperture corresponding to a front of the assembly, wherein the housing structure is configured to support the electro-optic element.

2. The vehicular rearview assembly prepared by a process according to claim 1, wherein the isolation area comprises an isolation line having a width of about 0.005 inches to about 0.010 inches.

3. The vehicular rearview assembly prepared by a process according to claim 1, wherein the isolation area comprises an isolation line having a width of about 0.002 inches to about 0.004 inches.

4. The vehicular rearview assembly prepared by a process according to claim 1, wherein the isolation area comprises an isolation line having a width of less than or equal to about 0.002 inches.

5. The vehicular rearview assembly prepared by a process according to claim 1, wherein the isolation area comprises an isolation line having a width of less than or equal to about 1 um.

6. The vehicular rearview assembly prepared by a process according to claim 1, wherein the isolation area comprises an isolation line configured such that the electrical resistance between the plurality of non-ablated portions of the electrically conductive coating is greater than 30 ohms.

7. The vehicular rearview assembly prepared by a process according to claim 1, wherein the isolation area comprises an isolation line configured such that the electrical resistance between the plurality of non-ablated portions of the electrically conductive coating is greater than 100 ohms.

8. The vehicular rearview assembly prepared by a process according to claim 1, wherein the electro-optic mirror element further comprises one or more of a textual feature, emblem, graphic, and artwork, and further wherein the isolation area is substantially incorporated into the one or more of the textual feature, emblem, graphic, and artwork.

9. The vehicular rearview assembly prepared by a process according to claim 1, further comprising the step:

providing a spectral filter between the second surface and the perimeter seal, the spectral filter comprises a first and a second spectral filter portion substantially isolated from one another by the isolation area.

10. The vehicular rearview assembly prepared by a process according to claim 9, wherein the isolation area is located over the perimeter seal.

11. The vehicular rearview assembly prepared by a process according to claim 10, wherein the step of applying an electrically conductive coating to at least a portion of the second surface comprises applying the electrically conductive coating directly on the second surface.

12. The vehicular rearview assembly prepared by a process according to claim 10, wherein the step of providing a spectral filter between the second surface and the perimeter seal comprises applying the spectral filter directly on the second surface.

13. The vehicular rearview assembly prepared by a process according to claim 10, wherein the spectral filter comprises an inboard edge and the isolation area is substantially aligned in close proximity to the inboard edge such that the isolation area is substantially hidden from view with respect to the front of the vehicular rearview assembly.

14. A vehicular rearview assembly prepared by a process comprising the steps:

providing a first substrate comprising a first surface and a second surface;

providing a second substrate comprising a third surface and a fourth surface;

applying an electrically conductive coating over at least a portion of the second surface;

applying an electrically conductive coating over at least a portion of the third surface;

applying a perimeter seal to the second surface and the third surface to define a cavity;

providing a spectral filter over at least a portion of the second surface and between the second surface and the perimeter seal;

ablating by a laser a viewable portion of the spectral filter;

filling the cavity with an electro-optic medium to form an electro-optic element; and

connecting the electro-optic element to a housing structure having an aperture corresponding to a front of the assembly, wherein the housing structure is configured to support the electro-optic element.

15. The vehicular rearview assembly prepared by a process according to claim 14, further comprising the step:

ablating by a laser a portion of the electrically conductive coating and the spectral filter over at least a portion of the second surface to form (a) an isolation area that is substantially devoid of the electrically conductive coating and the spectral filter, (b) a plurality of non-ablated portions of the electrically conductive coating, and (c) a plurality of non-ablated portions of the spectral filter.

16. The vehicular rearview assembly prepared by a process according to claim 15, wherein the step of applying the electrically conductive coating over at least a portion of the second surface is performed before the step of providing a spectral filter.

17. The vehicular rearview assembly prepared by a process according to claim 16, wherein the electrically conductive coating over at least a portion of the second surface comprises a transparent conductive oxide.

18. The vehicular rearview assembly prepared by a process according to claim 17, wherein the electrically conductive coating over at least a portion of the second surface comprises indium tin oxide.

19. The vehicular rearview assembly prepared by a process according to claim 15, wherein the step of applying the electrically conductive coating over at least a portion of the second surface is performed after the step of providing a spectral filter.

20. The vehicular rearview assembly prepared by a process according to claim 19, wherein the electrically conductive coating over at least a portion of the second surface comprises a transparent conductive oxide.

21. The vehicular rearview assembly prepared by a process according to claim 20, wherein the electrically conductive coating over at least a portion of the second surface comprises indium tin oxide.

22. The vehicular rearview assembly prepared by a process according to claim 14, wherein the spectral filter comprises chrome material.

23. The vehicular rearview assembly prepared by a process according to claim 14, wherein the spectral filter comprises a stack of materials.

24. The vehicular rearview assembly prepared by a process according to claim 14, wherein the electro-optic medium comprises an electrochromic material.