MULTI-ZONE MIRRORS

• US 20120026570A1
• Filed: 10/07/2011
• Published: 02/02/2012
• Est. Priority Date: 03/05/2007
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Luten, Henry A., Anderson, John S., Neuman, George A., Forgette, Jeffrey A., Williams, Jeffrey N., Perron, Lansen M.
• Granted Patent: US 8,649,083 B2
• Time in Patent Office: Days
• 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 2001/1253 with cameras, video cameras or video screens
• CPC Class Codes: C03C 17/36 at least one coating being a metal
• CPC Class Codes: C03C 17/3618 Coatings of type glass/inorganic compound/other inorganic layers, at least one layer being metallic
• CPC Class Codes: C03C 17/3639 Multilayers containing at least two functional metal layers
• CPC Class Codes: C03C 17/3663 specially adapted for use as mirrors
• CPC Class Codes: G02B 27/14 operating by reflection only
• CPC Class Codes: G02F 1/15 based on an electrochromic effect

Abstract

A multi-zone reflector having an opaque zone and a transflective zone. The reflector includes a supporting base, a lower reflecting layer disposed adjacent the supporting base, and an upper reflecting layer extending over the opacifying layer and the transflective zone of the reflector. The lower reflecting layer substantially completely covers the transflective zone, and the opacifying layer is disposed substantially outside the transflective zone adjacent to the lower reflecting layer. Over at least a portion of the transflective zone, the upper and lower reflecting layers have a common surface.

Claims

1. A multi-zone mirror element having a transflective zone and an opaque zone, the mirror element comprising

a supporting base;

at least one of a prismatic element and an electrochromic (EC) element having a surface and distanced from the supporting base, the surface being parallel to the supporting base;

an opacifying layer proximate to the supporting base substantially outside the transflective zone, the opacifying layer having a lower surface facing the supporting base and an upper surface, the opacifying layer having thickness that varies with displacement in a first direction from the transflective zone to the opaque zone, the thickness of the opacifying layer varying at a first rate;

an upper continuous reflecting layer extending substantially completely over the transflective zone, the upper continuous reflecting layer having thickness that varies with displacement in a second direction from the transflective zone to the opaque zone, the thickness of the upper continuous reflecting layer varying at a second rate.

2. A mirror element according to claim 1, further comprising a lower continuous reflecting layer between the supporting base and the lower surface of the opacifying layer.

3. A mirror element according to claim 1, further comprising a quarter-wave thin-film stack between the opacifying layer and the supporting base.

4. A mirror element according to claim 1, wherein the second rate remains constant across at least a portion of a region between the transflective and opaque zones.

5. A mirror element according to claim 1, wherein the first and second rates are different.

6. A mirror element according to claim 1, wherein a region of changing thickness of the upper continuous reflecting layer connects the opaque and transflective zones.

7. A mirror element according to claim 1, wherein the difference between spectral content of light reflected from the opaque zone and that of light reflected from the transflective zone is no greater than 5 units of Δ

E* per centimeter.

8. A mirror element according to claim 1, wherein the difference between spectral content of light reflected from the opaque zone and that of light reflected from the transflective zone is no greater than 2.5 units of Δ

E* per centimeter.

9. A mirror element according to claim 1, wherein the difference between spectral content of light reflected from the opaque zone and that of light reflected from the transflective zone is no greater than 1 unit of Δ

E* per centimeter.

10. A mirror element according to claim 1, wherein the difference between a reflectance value of the mirror element at the opaque zone and a reflectance value of the mirror element at the transflective zone does not exceed 10 percent.

11. A mirror element according to claim 1, wherein the opacifying layer includes at least one of chromium, stainless steel, silicon, titanium, nickel, molybdenum, Inconel, indium, palladium, osmium, tungsten, rhenium, iridium, rhodium, ruthenium, tantalum, copper, gold, platinum, and alloys thereof.

12. A mirror element according to claim 1, wherein a transmittance of the mirror element at the opaque zone does not exceed 5%.

13. A mirror element according to claim 1, wherein a transmittance of the mirror element at the opaque zone does not exceed 2.5%.

14. A mirror element according to claim 1, wherein a transmittance of the mirror element at the opaque area does not exceed 0.5% and a transmittance of the mirror element at the transflective area does not exceed 25%.

15. A mirror element according to claim 1, configured as part of a vehicular rearview assembly that comprises at least one of 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 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.

16. A multi-zone mirror element comprising:

a first substantially transparent supporting base having a thin-film stack with a quarter-wave optical thickness thereon;

a lower continuous reflecting layer disposed adjacent the supporting base, the lower reflecting layer substantially completely covering a first transflective zone of the mirror element;

an opacifying layer having a lower surface facing the supporting base and an upper surface, the opacifying layer disposed substantially outside the first transflective zone adjacent to the lower reflecting layer of the mirror element;

an upper continuous reflecting layer extending substantially completely over the opacifying layer and the first transflective zone of the mirror element;

the upper continuous reflecting layer and the lower continuous reflecting layer having a common surface over at least a portion of the first transflective zone; and

a second supporting base in optical communication with said first supporting base through said lower continuous reflecting layer, said opacifying layer, and said upper continuous reflecting layer.

17. A mirror element according to claim 16, wherein a portion of the upper surface of the opacifying layer is inclined with respect to the lower surface of the opacifying layer.

18. A mirror element according to claim 16, wherein a portion of the upper surface of the opacifying layer is inclined with respect to the lower surface of the opacifying layer and said portion connects the opaque and first transflective zones of the mirror element.

19. A mirror element according to claim 16, wherein the opacifying layer includes a material from the group consisting of chromium, stainless steel, silicon, titanium, nickel, molybdenum, Inconel, indium, palladium, osmium, tungsten, rhenium, iridium, rhodium, ruthenium, tantalum, copper, gold, platinum, and alloys thereof.

20. A mirror element according to claim 16 having a reflectance spectrum that is substantially unvarying across the mirror element.

21. A mirror element according to claim 16, wherein the opacifying layer has an aperture at the first transflective zone of the mirror element.

22. A mirror element according to claim 16, wherein the mirror element further comprises a second transflective zone, and wherein the upper continuous reflecting layer extends substantially completely over the second transflective zone, the second transflective zone being joined with the first transflective zone.

23. A mirror element according to claim 16, wherein the upper continuous reflecting layer has substantially uniform thickness.

24. A mirror element according to claim 16, wherein the upper and lower continuous reflecting layers have a common surface over at least a portion of the first transflective zone.

25. A mirror element according to claim 16, further comprising

a flash layer of material interposed at the opaque zone between the upper continuous reflecting layer and the upper surface of the opacifying layer, the flash layer substantially completely covering the opacifying layer.

26. A mirror element according to claim 25, wherein the flash layer has thickness changing in a direction from the first transflective zone to the opaque zone.

27. A mirror element according to claim 25 having a substantially spectrally-uniform reflectance, said substantially spectrally-uniform reflectance exceeding at least 50 percent.

28. A mirror element according to claim 27, wherein the opaque zone has transmittance below 0.5% and the first transflective zone has transmittance below 25%.

29. A mirror element according to claim 16, wherein a transmittance of the mirror element at the opaque area does not exceed 5%.

30. A mirror element according to claim 16, wherein a transmittance of the mirror element at the opaque area does not exceed 2.5%.

31. A mirror element according to claim 16, wherein the second supporting base includes a prismatic element.

32. A vehicular rearview assembly that comprises a mirror element according to claim 16, and that further comprises at least one of 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 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.

33. A multi-zone mirror element comprising:

a substantially transparent supporting base;

a thin-film stack carried on said supporting base, the thin-film stack including

a first opacifying layer having a lateral bound defining a first zone of the thin-film stack that is free of the first opacifying layer, the first opacifying layer having thickness changing in a direction towards the first zone; and

a second opacifying layer deposited adjacent the first opacifying layer so as to extend over the first opacifying layer and beyond the lateral bound of the first opacifying layer, the second opacifying layer defining a second zone of the thin-film stack that is free of the second opacifying layer, the second zone characterized by a lateral extent that is smaller than a lateral extent of the first zone, the second zone being at least partially aligned with the first zone along a direction perpendicular to the stack; and

an upper reflective layer deposited on the second opacifying layer, the upper reflective layer substantially continuously covering the first zone.

34. A mirror element according to claim 33, further comprising:

a lower reflective layer between said supporting base and said thin-film stack, the lower reflective layer being at least coextensive with the upper reflective layer.

35. A mirror element according to claim 33, wherein the second opacifying layer has uniform thickness.

36. A mirror element according to claim 33, wherein the second zone is defined by a hard-edge in the second opacifying layer.

37. A multi-zone mirror element according to claim 33, wherein the first opacifying layer has thickness decreasing in a direction towards the first zone.

38. A mirror element according to claim 33, wherein the difference between a reflectance value of the mirror element at the opaque zone and a reflectance value of the mirror element at the transflective zone does not exceed 10 percent.

39. A mirror element according to claim 33, wherein the first opacifying layer includes at least one of chromium, stainless steel, silicon, titanium, nickel, molybdenum, Inconel, indium, palladium, osmium, tungsten, rhenium, iridium, rhodium, ruthenium, tantalum, copper, gold, platinum, and alloys thereof.

40. A mirror element according to claim 33, wherein a transmittance of the mirror element at the opaque zone does not exceed 5%.

41. A mirror element according to claim 33, wherein a transmittance of the mirror element at the opaque zone does not exceed 2.5%.

42. A mirror element according to claim 33, wherein a transmittance of the mirror element at the opaque zone does not exceed 0.5% and a transmittance of the mirror element at the transflective zone does not exceed 25%.

43. A mirror element according to claim 33, wherein the difference in color between ambient light reflected by the mirror element at the opaque zone and light reflected by the mirror element at the transflective zone is less than 10 C* units.

44. A mirror element according to claim 33, wherein the difference in color between ambient light reflected by the mirror element at the opaque zone and light reflected by the mirror element at the transflective zone is less than 5 C* units.

45. A multi-zone mirror element according to claim 33, further comprising at least one of a prismatic element and an electrochromic (EC) medium in optical communication with said supporting base.

46. A mirror element according to claim 33, further comprising a quarter-wave thin-film stack between the first opacifying layer and the first supporting base, said quarter-wave thin-film stack substantially completely covering the first supporting base.

47. A vehicular rearview assembly that comprises a mirror element according to claim 33, and that further comprises at least one of 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 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.

48. A multi-zone mirror element comprising:

a first substantially transparent supporting base;

a thin-film stack carried on the supporting base, the thin-film stack including

a first opacifying layer on the supporting base and a second opacifying layer adjacent to the first opacifying layer, the first opacifying layer having a first opening therein and the second opacifying layer having a second opening therein, the first opacifying layer having a graded portion characterized by thickness increasing in a direction away from the first opening, the second opacifying layer extending over at least part of the first opening; and

an upper reflective layer substantially completely covering the thin-film stack and the first and second openings.

49. A mirror element according to claim 48, further comprising a quarter-wave thin-film stack between the first opacifying layer and the first supporting base, said quarter-wave thin-film stack substantially completely covering the first supporting base.

50. A mirror element according to claim 48, further comprising a lower reflective layer between said first supporting base and said thin-film stack, said lower and upper reflective layers having a common surface at the first opening.

51. A mirror element according to claim 48, wherein the graded portion of the first opacifying layer defines a transition region of the mirror element, the transition region having spatially monotonic distribution of at least one optical characteristic of the mirror element.

52. A mirror element according to claim 51, wherein the at least one optical characteristic includes a reflectance spectrum.

53. A mirror element according to claim 48, further comprising at least one of a prismatic element and an electrochromic (EC) element adjacent the upper reflective layer.

54. A mirror element according to claim 48, wherein the first opacifying layer includes at least one of chromium, stainless steel, silicon, titanium, nickel, molybdenum, Inconel, indium, palladium, osmium, tungsten, rhenium, iridium, rhodium, ruthenium, tantalum, copper, gold, platinum, and alloys thereof.

55. A mirror element according to claim 48, wherein the first and second opening at least partially overlap, and wherein the transmission of the mirror element outside the first opening does not exceed 5%.

56. A vehicular rearview assembly that comprises a mirror element according to claim 48, and that further comprises at least one of 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 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.

57. A multi-zone mirror element having a transflective zone and an opaque zone, the mirror element comprising

a supporting base;

at least one of a prismatic element and an electrochromic (EC) element having a surface and distanced from the supporting base, the surface being parallel to the supporting base;

an opacifying layer proximate to the supporting base substantially outside the transflective zone, the opacifying layer having a lower surface facing the supporting base and an upper surface, the opacifying layer having thickness that varies with displacement in a first direction from the transflective zone to the opaque zone, said thickness of the opacifying layer varying at a first rate;

an upper reflecting layer substantially completely covering the transflective zone, wherein the upper reflecting layer includes a reflective polarizer containing an anisotropic film, and wherein the upper reflecting layer disposed between the at least one of a prismatic element and an EC element and the supporting base.

58. A mirror element according to claim 57, wherein the anisotropic film is birefringent, and wherein the reflective polarizer transmits light having a first state of polarization and reflects light having a second state of polarization, the first and second states of polarization being orthogonal to one another.

59. A mirror element according to claim 57, wherein the opacifying layer has thickness that varies with displacement in a second direction from the transflective zone to the opaque zone, said thickness of the opacifying layer varying at a second rate.

60. A mirror element according to claim 57, wherein the upper reflecting layer extends substantially completely over the opacifying layer between said opacifying layer and the at least one of a prismatic element and an EC element.

61. A mirror element according to claim 57, wherein the supporting based includes a substantially transparent substrate having a thin-film stack with a quarter-wave optical thickness disposed thereon in the transflective zone.

62. A mirror element according to claim 57, wherein the first opacifying layer includes at least one of chromium, stainless steel, silicon, titanium, nickel, molybdenum, Inconel, indium, palladium, osmium, tungsten, rhenium, iridium, rhodium, ruthenium, tantalum, copper, gold, platinum, and alloys thereof.

63. A vehicular rearview assembly that comprises a mirror element according to claim 57, and that further comprises a source of light separated from the opacifying layer by the supporting base and transmitting light through the transflective zone of the mirror element towards a field-of-view (FOV) corresponding to a front of the mirror element.

64. A vehicular rearview assembly that comprises a mirror element according to claim 57, and that further comprises at least one of 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 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.