EXTERIOR MIRROR ELEMENT WITH WIDE ANGLE PORTION

• US 20100220407A1
• Filed: 05/10/2010
• Published: 09/02/2010
• 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 7,824,045 B2
• Time in Patent Office: Days
• US Class Current: 359/864
• 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

An electrochromic mirror reflective element includes a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween. A curved recess is established at a second surface of the front glass substrate or a fourth surface of the rear glass substrate. A first metallic reflector is coated at the curved recess, with the reflector-coated curved recess establishing an auxiliary wide angle reflector region of the electrochromic mirror reflective element. A second metallic reflector is coated at a surface of the rear glass substrate, with the reflector-coated surface establishing a principal reflector region of the electrochromic minor reflective element. The reflective element may include a hiding layer that hides at least a portion of a component of the electrochromic mirror reflective element that is behind the hiding layer from view by the driver of a vehicle equipped with the electrochromic mirror reflective element.

Claims

1. (canceled)

2. An electrochromic mirror reflective element for an exterior rearview mirror assembly of a vehicle, said electrochromic mirror reflective element comprising:

a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween, wherein said electrochromic medium is bounded by a seal;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein, when said electrochromic mirror reflective element is incorporated in an exterior rearview mirror assembly and said exterior rearview mirror assembly is normally mounted at the vehicle, said first surface generally faces a driver of a vehicle when the driver is normally operating the vehicle, and wherein said second surface faces said electrochromic medium;

wherein said rear glass substrate has a third surface facing said electrochromic medium and a fourth surface opposite said third surface;

a curved recess established at one of (a) said second surface of said front glass substrate and (b) said fourth surface of said rear glass substrate, wherein said curved recess is established by physical removal of a portion of a respective one of said front glass substrate and said rear glass substrate;

a first metallic reflector coated at said curved recess to establish an auxiliary wide angle reflector, said reflector-coated curved recess establishing an auxiliary wide angle reflector region of said electrochromic mirror reflective element;

a second metallic reflector coated at one of (a) said third surface of said rear glass substrate and (b) said fourth surface of said rear glass substrate, wherein said second metallic reflector establishes a principal reflector, said reflector-coated surface of said rear glass substrate establishing a principal reflector region of said electrochromic mirror reflective element; and

a hiding layer that hides at least a portion of a component of said electrochromic mirror reflective element that is behind said hiding layer from view by the driver of the vehicle when said exterior rearview mirror assembly is normally mounted at the vehicle and the driver is normally operating the vehicle.

3. The electrochromic mirror reflective element of claim 2, wherein said hiding layer at least in part demarcates said auxiliary wide angle reflector region from said principal reflector region when said exterior rearview mirror assembly is normally mounted at the vehicle and is normally viewed by the driver of the vehicle.

4. The electrochromic mirror reflective element of claim 2, wherein said component comprises at least a portion of said seal.

5. The electrochromic mirror reflective element of claim 4, wherein said portion of said seal at least partially circumscribes said auxiliary wide angle reflector region.

6. The electrochromic mirror reflective element of claim 2, wherein said auxiliary wide angle reflector region is inboard of a perimeter edge of said electrochromic mirror reflective element and wherein said principal reflector region of said electrochromic mirror reflective element surrounds said auxiliary wide angle reflector region of said electrochromic mirror reflective element and wherein said seal fully circumscribes said auxiliary wide angle reflector region.

7. The electrochromic mirror reflective element of claim 2, wherein said hiding layer is disposed at said second surface of said front glass substrate.

8. The electrochromic mirror reflective element of claim 2, wherein said component comprises a portion of said seal and wherein said seal circumscribes the perimeter of said front and rear glass substrates and at least partially circumscribes said auxiliary wide angle reflector region.

9. The electrochromic mirror reflective element of claim 2, wherein said component comprises a portion of said seal and wherein said seal circumscribes the perimeter of said front and rear glass substrates and fully circumscribes said auxiliary wide angle reflector region.

10. The electrochromic mirror reflective element of claim 2, wherein said electrochromic mirror reflective element is devoid of said electrochromic medium at said auxiliary wide angle reflector region.

11. The electrochromic mirror reflective element of claim 10, wherein, when a voltage is applied to said electrochromic mirror reflective element, (a) said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and (b) visible light reflectivity at said auxiliary wide angle reflector region is substantially unchanged.

12. The electrochromic mirror reflective element of claim 2, wherein said electrochromic medium is sandwiched between said front and rear glass substrates at said auxiliary wide angle reflector region.

13. The electrochromic mirror reflective element of claim 12, wherein, when a voltage is applied to said electrochromic mirror reflective element, said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and at said auxiliary wide angle reflector region.

14. The electrochromic mirror reflective element of claim 2, wherein said curved recess is established at said second surface of said front glass substrate.

15. The electrochromic mirror reflective element of claim 14, wherein said electrochromic mirror reflective element is devoid of said electrochromic medium at said auxiliary wide angle reflector region, and wherein said front and rear glass substrates are formed and assembled together so that said front glass substrate extends beyond an edge region of said rear glass substrate at said auxiliary wide angle reflector region.

16. The electrochromic mirror reflective element of claim 15, wherein said second metallic reflector is coated at said third surface of said rear glass substrate.

17. The electrochromic mirror reflective element of claim 2, wherein said curved recess is established at said fourth surface of said rear glass substrate.

18. The electrochromic mirror reflective element of claim 17, wherein said second metallic reflector is coated at said third surface of said rear glass substrate.

19. The electrochromic mirror reflective element of claim 18, wherein said second metallic reflector at said third surface of said rear glass substrate comprises a light-transmitting aperture, and wherein said light-transmitting aperture substantially corresponds to said auxiliary wide angle reflector region of said electrochromic mirror reflective element.

20. The electrochromic mirror reflective element of claim 2, wherein said front and rear glass substrates comprise generally planar glass substrates.

21. The electrochromic mirror reflective element of claim 2, wherein said curved recess is established by at least one of (a) grinding said portion of a respective one of said front glass substrate and said rear glass substrate and (b) ablating said portion of a respective one of said front glass substrate and said rear glass substrate.

22. The electrochromic mirror reflective element of claim 2, wherein said second metallic reflector is coated at said fourth surface of said rear glass substrate.

23. The electrochromic mirror reflective element of claim 22, wherein said curved recess is established at said fourth surface of said rear glass substrate, and wherein said first metallic reflector and said second metallic reflector are commonly coated at said fourth surface of said rear glass substrate.

24. The electrochromic mirror reflective element of claim 2, wherein said second metallic reflector is coated at said third surface of said rear glass substrate and wherein said second metallic reflector comprises a transflective metallic reflector.

25. The electrochromic mirror reflective element of claim 2, wherein said curved recess has a radius of curvature that is less than a radius of curvature of said principal reflector region.

26. The electrochromic mirror reflective element of claim 2, wherein said curved recess comprises a spherical curved surface.

27. The electrochromic mirror reflective element of claim 2, wherein said curved recess is generally circular-shaped.

28. The electrochromic mirror reflective element of claim 2, wherein said first metallic reflector comprises at least one of aluminum, silver, chromium, an aluminum alloy, a silver alloy and a chromium alloy.

29. The electrochromic mirror reflective element of claim 28, wherein said second metallic reflector comprises at least another of aluminum, silver, chromium, an aluminum alloy, a silver alloy and a chromium alloy.

30. The electrochromic mirror reflective element of claim 29, wherein said second metallic reflector is coated at said curved recess via sputter deposition.

31. An electrochromic mirror reflective element for an exterior rearview mirror assembly of a vehicle, said electrochromic mirror reflective element comprising:

a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween, wherein said electrochromic medium is bounded by a seal;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein, when said electrochromic mirror reflective element is incorporated in an exterior rearview mirror assembly and said exterior rearview mirror assembly is normally mounted at the vehicle, said first surface generally faces a driver of a vehicle when the driver is normally operating the vehicle, and wherein said second surface faces said electrochromic medium;

wherein said rear glass substrate has a third surface facing said electrochromic medium and a fourth surface opposite said third surface;

a curved recess established at one of (a) said second surface of said front glass substrate and (b) said fourth surface of said rear glass substrate, wherein said curved recess is established by physical removal of a portion of a respective one of said front glass substrate and said rear glass substrate;

a first metallic reflector coated at said curved recess to establish an auxiliary wide angle reflector, said reflector-coated curved recess establishing an auxiliary wide angle reflector region of said electrochromic mirror reflective element;

a second metallic reflector coated at one of (a) said third surface of said rear glass substrate and (b) said fourth surface of said rear glass substrate, wherein said second metallic reflector establishes a principal reflector, said reflector-coated surface of said rear glass substrate establishing a principal reflector region of said electrochromic mirror reflective element; and

wherein said electrochromic mirror reflective element is devoid of said electrochromic medium at said auxiliary wide angle reflector region, and wherein, when a voltage is applied to said electrochromic mirror reflective element, (a) said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and (b) visible light reflectivity at said auxiliary wide angle reflector region is substantially unchanged.

32. The electrochromic mirror reflective element of claim 31, wherein said seal circumscribes and bounds said electrochromic medium and at least partially circumscribes said auxiliary wide angle reflector region.

33. The electrochromic mirror reflective element of claim 32, further comprising a hiding layer that hides at least a portion of said seal from view by the driver of the vehicle when said exterior rearview mirror assembly is normally mounted at the vehicle and the driver is normally operating the vehicle.

34. The electrochromic mirror reflective element of claim 33, wherein said seal fully circumscribes said auxiliary wide angle reflector region.

35. The electrochromic mirror reflective element of claim 34, wherein said second metallic reflector at said third surface of said rear glass substrate comprises a light-transmitting aperture, and wherein said light transmitting-aperture substantially corresponds to said auxiliary wide angle reflector region of said electrochromic mirror reflective element.

36. The electrochromic mirror reflective element of claim 33, wherein said hiding layer at least in part demarcates said auxiliary wide angle reflector region from said principal reflector region when said exterior rearview mirror assembly is normally mounted at the vehicle and is normally viewed by the driver of the vehicle.

37. An electrochromic mirror reflective element for an exterior rearview mirror assembly of a vehicle, said electrochromic mirror reflective element comprising:

a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween, wherein said electrochromic medium is bounded by a seal;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein, when said electrochromic mirror reflective element is incorporated in an exterior rearview mirror assembly and said exterior rearview mirror assembly is normally mounted at the vehicle, said first surface generally faces a driver of a vehicle when the driver is normally operating the vehicle, and wherein said second surface faces said electrochromic medium;

wherein said rear glass substrate has a third surface facing said electrochromic medium and a fourth surface opposite said third surface;

a curved recess established at one of (a) said second surface of said front glass substrate and (b) said fourth surface of said rear glass substrate, wherein said curved recess is established by at least one of (a) grinding a portion of a respective one of said front glass substrate and said rear glass substrate and (b) ablating a portion of a respective one of said front glass substrate and said rear glass substrate;

a first metallic reflector coated at said curved recess to establish an auxiliary wide angle reflector, said reflector-coated curved recess establishing an auxiliary wide angle reflector region of said electrochromic mirror reflective element;

a second metallic reflector coated at said third surface of said rear glass substrate, wherein said second metallic reflector establishes a principal reflector, said reflector-coated surface of said rear glass substrate establishing a principal reflector region of said electrochromic mirror reflective element; and

wherein said second metallic reflector at said third surface of said rear glass substrate comprises a light-transmitting aperture, and wherein said light-transmitting aperture substantially corresponds to said auxiliary wide angle reflector region of said electrochromic mirror reflective element.

38. The electrochromic mirror reflective element of claim 37, wherein said electrochromic mirror reflective element is devoid of said electrochromic medium at said auxiliary wide angle reflector region, and wherein, when a voltage is applied to said electrochromic mirror reflective element, (a) said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and (b) visible light reflectivity at said auxiliary wide angle reflector region is substantially unchanged.

39. The electrochromic mirror reflective element of claim 37, wherein said electrochromic medium is sandwiched between said front and rear glass substrates at said auxiliary wide angle reflector region, and wherein, when a voltage is applied to said electrochromic mirror reflective element, said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and at said auxiliary wide angle reflector region.

40. The electrochromic mirror reflective element of claim 37, further comprising a hiding layer that hides at least a portion of said seal from view by the driver of the vehicle when said exterior rearview mirror assembly is normally mounted at the vehicle and the driver is normally operating the vehicle.

41. The electrochromic mirror reflective element of claim 40, wherein said hiding layer at least in part demarcates said auxiliary wide angle reflector region from said principal reflector region when said exterior rearview mirror assembly is normally mounted at the vehicle and is normally viewed by the driver of the vehicle.

42. An electrochromic mirror reflective element for an exterior rearview mirror assembly of a vehicle, said electrochromic mirror reflective element comprising:

a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween, wherein said electrochromic medium is bounded by a seal;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein, when said electrochromic mirror reflective element is incorporated in an exterior rearview mirror assembly and said exterior rearview mirror assembly is normally mounted at the vehicle, said first surface generally faces a driver of a vehicle when the driver is normally operating the vehicle, and wherein said second surface faces said electrochromic medium;

wherein said rear glass substrate has a third surface facing said electrochromic medium and a fourth surface opposite said third surface;

a curved recess established at said fourth surface of said rear glass substrate, wherein said curved recess is established by at least one of (a) grinding a portion of said rear glass substrate and (b) ablating a portion of said rear glass substrate;

a first metallic reflector coated at said curved recess to establish an auxiliary wide angle reflector, said reflector-coated curved recess establishing an auxiliary wide angle reflector region of said electrochromic mirror reflective element;

a second metallic reflector coated at said third surface of said rear glass substrate other than where said reflector-coated curved recess is established therebehind, wherein said second metallic reflector establishes a principal reflector, said reflector-coated third surface of said rear glass substrate establishing a principal reflector region of said electrochromic mirror reflective element, said principal reflector comprising a light-transmitting aperture coinciding with said auxiliary wide angle reflector region and allowing light incident at said third surface of said rear substrate at said auxiliary wide angle reflector region to pass through said rear glass substrate to be reflected off said reflector-coated curved recess; and

a hiding layer disposed at said second surface of said front substrate, wherein said hiding layer hides at least a portion of a component of said electrochromic mirror reflective element that is behind said hiding layer from view by the driver of the vehicle when said exterior rearview mirror assembly is normally mounted at the vehicle and the driver is normally operating the vehicle.

43. The electrochromic mirror reflective element of claim 42, wherein said component comprises at least a portion of said seal.

44. The electrochromic mirror reflective element of claim 43, wherein said portion of said seal at least partially circumscribes said auxiliary wide angle reflector region.

45. The electrochromic mirror reflective element of claim 44, wherein said auxiliary wide angle reflector region is inboard of a perimeter edge of said rear substrate and wherein said principal reflector region surrounds said auxiliary wide angle reflector region of said electrochromic mirror reflective element and wherein said portion of said seal fully circumscribes said auxiliary wide angle reflector region.

46. The electrochromic mirror reflective element of claim 45, wherein said electrochromic mirror reflective element is devoid of said electrochromic medium at said auxiliary wide angle reflector region, and wherein, when a voltage is applied to said electrochromic mirror reflective element, (a) said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and (b) visible light reflectivity at said auxiliary wide angle reflector region is substantially unchanged.

47. The electrochromic mirror reflective element of claim 42, wherein said electrochromic medium is sandwiched between said front and rear glass substrates at said auxiliary wide angle reflector region, and wherein, when a voltage is applied to said electrochromic mirror reflective element, said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and at said auxiliary wide angle reflector region.

48. The electrochromic mirror reflective element of claim 42, wherein said front and rear glass substrates comprise generally planar glass substrates.

49. The electrochromic mirror reflective element of claim 48, wherein said curved recess is generally circular-shaped.

50. The electrochromic mirror reflective element of claim 49, wherein said curved recess comprises a spherical curved surface.

51. An electrochromic mirror reflective element for an exterior rearview mirror assembly of a vehicle, said electrochromic mirror reflective element comprising:

a front glass substrate and a rear glass substrate having an electrochromic medium sandwiched therebetween, wherein said electrochromic medium is bounded by a seal;

wherein said front and rear glass substrates comprise generally planar glass substrates;

wherein said front glass substrate has a first surface and a second surface opposite said first surface, and wherein, when said electrochromic mirror reflective element is incorporated in an exterior rearview mirror assembly and said exterior rearview mirror assembly is normally mounted at the vehicle, said first surface generally faces a driver of a vehicle when the driver is normally operating the vehicle, and wherein said second surface faces said electrochromic medium;

wherein said rear glass substrate has a third surface facing said electrochromic medium and a fourth surface opposite said third surface;

a curved recess established at said fourth surface of said rear glass substrate, wherein said curved recess is generally circular-shaped, and wherein said curved recess is established by at least one of (a) grinding a portion of said rear glass substrate and (b) ablating a portion of said rear glass substrate;

a first metallic reflector coated at said curved recess to establish an auxiliary wide angle reflector, said reflector-coated curved recess establishing an auxiliary wide angle reflector region of said electrochromic mirror reflective element;

a second metallic reflector coated at said third surface of said rear glass substrate other than where said reflector-coated curved recess is established therebehind, wherein said second metallic reflector establishes a principal reflector, said reflector-coated third surface of said rear glass substrate establishing a principal reflector region of said electrochromic mirror reflective element, said principle reflector comprising a light-transmitting aperture coinciding with said auxiliary wide angle reflector region and allowing light incident at said third surface of said rear substrate at said auxiliary wide angle reflector region to pass through said rear glass substrate to be reflected off said reflector-coated curved recess;

a hiding layer disposed at said second surface of said front substrate, wherein said hiding layer hides at least a portion of said seal from view by the driver of the vehicle when said exterior rearview mirror assembly is normally mounted at the vehicle and the driver is normally operating the vehicle;

wherein said auxiliary wide angle reflector region is inboard of a perimeter edge of said rear substrate and wherein said principal reflector region surrounds said auxiliary wide angle reflector region of said electrochromic mirror reflective element and wherein said portion of said seal fully circumscribes said auxiliary wide angle reflector region; and

wherein said electrochromic mirror reflective element is devoid of said electrochromic medium at said auxiliary wide angle reflector region, and wherein, when a voltage is applied to said electrochromic mirror reflective element, (a) said electrochromic medium dims to reduce reflectivity of visible light at said principal reflector region and (b) visible light reflectivity at said auxiliary wide angle reflector region is substantially unchanged.