REARVIEW MIRROR ASSEMBLY FOR VEHICLE

• US 20140192520A1
• Filed: 02/17/2014
• Published: 07/10/2014
• Est. Priority Date: 05/16/2005
• Status: Active Grant

• Current Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Baur, Michael J., McCabe, Ian A., Habibi, Hamid, Lynam, Niall R.
• Granted Patent: US 9,469,252 B2
• Time in Patent Office: Days
• US Class Current: 362/135
• 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 17/1022 Metallic coatings
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• CPC Class Codes: B32B 17/10541 comprising a light source or a light guide
• CPC Class Codes: B32B 17/10733 containing epoxy
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10798 containing silicone
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2551/08 Mirrors
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 7/14 applied in spaced arrangements, e.g. in stripes
• 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: G02F 1/157 Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: G02F 2001/1536 additional, e.g. protective, layer inside the cell

Abstract

A mirror element sub-assembly for a vehicular exterior rearview mirror assembly includes a mirror reflective element, a mirror back plate and an indicator. The front side of the mirror back plate includes a reflective element attaching portion and the rear side of the mirror back plate includes (i) an actuator attaching portion and (ii) an indicator attaching portion, all of which are integrally formed during injection molding of the mirror back plate. The indicator attaching portion includes structure extending from the rear side of the mirror back plate and having a passageway therethrough. The indicator is attached at the structure, and light emitted by the indicator passes through the passageway and through an opening of the mirror back plate and through the mirror reflective element so as to exit from the mirror reflective element at an angle relative to the reflective element attaching portion.

Claims

1. A mirror element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror element sub-assembly comprising:

a mirror reflective element;

a mirror back plate, wherein said mirror back plate is formed by injection molding of a polymeric material;

wherein said mirror back plate has a front side and a rear side and wherein said rear side is opposite said front side;

wherein said front side of said mirror back plate comprises a reflective element attaching portion and wherein said rear side of said mirror back plate comprises (i) an actuator attaching portion and (ii) an indicator attaching portion;

wherein said reflective element attaching portion, said actuator attaching portion and said indicator attaching portion are integrally formed as parts of said mirror back plate during injection molding of said mirror back plate;

wherein said mirror reflective element is fixedly attached at said reflective element attaching portion of said front side of said mirror back plate;

an indicator having a light source that is electrically activatable to emit light, and wherein said light source comprises at least one light emitting diode;

wherein said indicator attaching portion comprises structure extending outward from said rear side of said mirror back plate and wherein said structure has a passageway therethrough;

wherein said indicator is attached at said structure, and wherein light emitted by said light source of said indicator passes through said passageway and through an opening of said mirror back plate and through said mirror reflective element so as to exit from said mirror reflective element;

wherein said structure is configured to orient said indicator at an angle relative to said reflective element attaching portion of said mirror back plate and wherein said angle is less than 90 degrees and greater than zero degrees relative to said reflective element attaching portion of said mirror back plate; and

wherein, when said light source is activated, light exiting from said mirror reflective element is one of (a) principally viewed by a driver of the equipped vehicle and (b) principally viewed by drivers of other vehicles.

2. The mirror element sub-assembly of claim 1, wherein said structure supports said indicator at said angle relative to said reflective element attaching portion of said mirror back plate such that when said mirror element sub-assembly is mounted and used at a side of the equipped vehicle and when said light source is electrically activated, light exiting from said mirror reflective element is directly principally away from the side of the equipped vehicle at which said mirror element sub-assembly is mounted and wherein said exiting light is principally viewed by drivers of other vehicles.

3. The mirror element sub-assembly of claim 1, wherein said structure supports said indicator at said angle relative to said reflective element attaching portion of said mirror back plate such that when said mirror element sub-assembly is mounted and used at a side of the equipped vehicle and when said light source is electrically activated, light exiting from said mirror reflective element is directly principally towards the side of the equipped vehicle at which said mirror element sub-assembly is mounted and wherein said exiting light is principally viewed by a driver of the equipped vehicle.

4. The mirror element sub-assembly of claim 1, wherein said indicator comprises a circuit board having said light source disposed thereat, and wherein said circuit board attaches at said structure at said angle relative to said reflective element attaching portion of said mirror back plate.

5. The mirror element sub-assembly of claim 1, wherein at least one of (i) an optical element is disposed in said passageway and light emitted by said light source passes through said optical element and (ii) light emitted by said light source, when electrically activated, passes through a light directing film.

6. The mirror element sub-assembly of claim 1, wherein said mirror reflective element comprises an electrochromic mirror reflective element having electrically variable reflectivity between a high reflectance state and a dimmed reflectance state, and wherein said electrochromic mirror reflective element comprises (i) a front substrate having a first surface and a second surface and (ii) a rear substrate having a third surface and a fourth surface, and wherein said second surface of said front substrate and said third surface of said rear substrate oppose each other with an electrochromic medium disposed therebetween, and wherein a specularly reflecting mirror reflector is established at said third surface of said rear substrate and wherein said specularly reflecting mirror reflector comprises a mirror-reflective metallic thin film established at a viewing region of said electrochromic mirror reflective element, and wherein a specularly reflecting indicia reflector is locally established at said second surface of said front substrate to form indicia at said electrochromic mirror reflective element, said specularly reflecting indicia reflector comprising a mirror-reflective metallic thin film established at a portion of said viewing region of said electrochromic mirror reflective element.

7. The mirror element sub-assembly of claim 1, wherein a heater pad is disposed at a rear surface of said mirror reflective element, and wherein said heater pad comprises a light transmitting portion that coincides with said opening of said mirror back plate.

8. The mirror element sub-assembly of claim 1, wherein said indicator comprises a blind spot alert indicator of the equipped vehicle and wherein, when said light source is activated, light passing through said passageway and exiting from said mirror reflective element is principally viewed by a driver of the equipped vehicle.

9. The mirror element sub-assembly of claim 1, wherein said indicator comprises a turn signal indicator of the equipped vehicle and wherein, when said light source is activated, light passing through said passageway and exiting from said mirror reflective element is principally viewed by drivers of other vehicles.

10. A mirror element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror element sub-assembly comprising:

a mirror reflective element;

a mirror back plate, wherein said mirror back plate is formed by injection molding of a polymeric material;

wherein said mirror back plate has a front side and a rear side and wherein said rear side is opposite said front side;

wherein said front side of said mirror back plate comprises a reflective element attaching portion and wherein said rear side of said mirror back plate comprises (i) an actuator attaching portion and (ii) an indicator attaching portion;

wherein said reflective element attaching portion, said actuator attaching portion and said indicator attaching portion are integrally formed as parts of said mirror back plate during injection molding of said mirror back plate;

wherein said mirror reflective element is fixedly attached at said reflective element attaching portion of said front side of said mirror back plate;

an indicator having a light source that is electrically activatable to emit light, and wherein said light source comprises at least one light emitting diode;

wherein said indicator attaching portion comprises structure extending outward from said rear side of said mirror back plate and wherein said structure has a passageway therethrough;

wherein said indicator is attached at said structure, and wherein light emitted by said light source of said indicator passes through said passageway and through an opening of said mirror back plate and through said mirror reflective element so as to exit from said mirror reflective element;

wherein said indicator comprises a turn signal indicator of the equipped vehicle;

wherein said structure is configured to orient said indicator at an angle relative to said reflective element attaching portion of said mirror back plate and wherein said angle is less than 90 degrees and greater than zero degrees relative to said reflective element attaching portion of said mirror back plate; and

wherein said structure supports said indicator at said angle relative to said reflective element attaching portion of said mirror back plate such that when said mirror element sub-assembly is mounted and used at a side of the equipped vehicle and when said light source is electrically activated, light exiting from said mirror reflective element is directly principally away from the side of the equipped vehicle at which said mirror element sub-assembly is mounted and wherein said exiting light is principally viewed by drivers of other vehicles.

11. The mirror element sub-assembly of claim 10, wherein said indicator comprises a circuit board having said light source disposed thereat, and wherein said circuit board attaches at said structure at said angle relative to said reflective element attaching portion of said mirror back plate.

12. The mirror element sub-assembly of claim 10, wherein an optical element is disposed in said passageway and light emitted by said light source passes through said optical element.

13. The mirror element sub-assembly of claim 10, wherein said mirror reflective element comprises an electrochromic mirror reflective element having electrically variable reflectivity between a high reflectance state and a dimmed reflectance state, and wherein said electrochromic mirror reflective element comprises (i) a front substrate having a first surface and a second surface and (ii) a rear substrate having a third surface and a fourth surface, and wherein said second surface of said front substrate and said third surface of said rear substrate oppose each other with an electrochromic medium disposed therebetween, and wherein a specularly reflecting mirror reflector is established at said third surface of said rear substrate and wherein said specularly reflecting mirror reflector comprises a mirror-reflective metallic thin film established at a viewing region of said electrochromic mirror reflective element, and wherein a specularly reflecting indicia reflector is locally established at said second surface of said front substrate to form indicia at said electrochromic mirror reflective element, said specularly reflecting indicia reflector comprising a mirror-reflective metallic thin film established at a portion of said viewing region of said electrochromic mirror reflective element, and wherein the specular reflectivity of said specularly reflecting indicia reflector is within about five percent of the specular reflectivity of said specularly reflecting mirror reflector when said electrochromic mirror reflective element is at said high reflectance state, and wherein the indicia is discernible due to at least one of (a) a contrast in color between said specularly reflecting indicia reflector and said specularly reflecting mirror reflector, (b) a contrast in reflectance between said specularly reflecting indicia reflector and said specularly reflecting mirror reflector and (c) an interference effect of said specularly reflecting indicia reflector with an undercoating transparent conductor layer.

14. The mirror element sub-assembly of claim 10, wherein a heater pad is disposed at a rear surface of said mirror reflective element, and wherein said heater pad comprises a light transmitting portion that coincides with said opening of said mirror back plate.

15. A mirror element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror element sub-assembly comprising:

a mirror reflective element;

a mirror back plate, wherein said mirror back plate is formed by injection molding of a polymeric material;

wherein said mirror back plate has a front side and a rear side and wherein said rear side is opposite said front side;

wherein said front side of said mirror back plate comprises a reflective element attaching portion and wherein said rear side of said mirror back plate comprises (i) an actuator attaching portion and (ii) an indicator attaching portion;

wherein said reflective element attaching portion, said actuator attaching portion and said indicator attaching portion are integrally formed as parts of said mirror back plate during injection molding of said mirror back plate;

wherein said mirror reflective element is fixedly attached at said reflective element attaching portion of said front side of said mirror back plate;

an indicator having a light source that is electrically activatable to emit light, and wherein said light source comprises at least one light emitting diode;

wherein said indicator attaching portion comprises structure extending outward from said rear side of said mirror back plate and wherein said structure has a passageway therethrough;

wherein said indicator is attached at said structure, and wherein light emitted by said light source of said indicator passes through said passageway and through an opening of said mirror back plate and through said mirror reflective element so as to exit from said mirror reflective element;

wherein said indicator comprises a blind spot alert indicator of the equipped vehicle;

wherein said structure is configured to orient said indicator at an angle relative to said reflective element attaching portion of said mirror back plate and wherein said angle is less than 90 degrees and greater than zero degrees relative to said reflective element attaching portion of said mirror back plate; and

wherein said structure supports said indicator at said angle relative to said reflective element attaching portion of said mirror back plate such that when said mirror element sub-assembly is mounted and used at a side of the equipped vehicle and when said light source is electrically activated, light exiting from said mirror reflective element is directly principally towards the side of the equipped vehicle at which said mirror element sub-assembly is mounted and wherein said exiting light is principally viewed by a driver of the equipped vehicle.

16. The mirror element sub-assembly of claim 15, wherein said indicator comprises a circuit board having said light source disposed thereat, and wherein said circuit board attaches at said structure at said angle relative to said reflective element attaching portion of said mirror back plate.

17. The mirror element sub-assembly of claim 15, wherein an optical element is disposed in said passageway and light emitted by said light source passes through said optical element.

18. The mirror element sub-assembly of claim 15, wherein said polymeric material comprises at least one of ABS and polycarbonate.

19. The mirror element sub-assembly of claim 15, wherein a heater pad is disposed at a rear surface of said mirror reflective element, and wherein said heater pad comprises a light transmitting portion that coincides with said opening of said mirror back plate.

20. The mirror element sub-assembly of claim 19, wherein said light transmitting portion of said heater pad comprises one of an aperture, a window and a hole.