EXTERIOR MIRROR REFLECTIVE ELEMENT SUB-ASSEMBLY

• US 20150224934A1
• Filed: 04/20/2015
• Published: 08/13/2015
• Est. Priority Date: 10/24/2006
• Status: Active Grant

• Current Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Original Assignee: Magna Mirrors of America Incorporated (Magna International Incorporated)
• Inventors: Foote, Keith D., Lynam, Niall R.
• Granted Patent: US 9,162,624 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B60Q 1/0076 Switches therefor B60Q1/1446, B60Q1/343, B60Q1/40 take precedence
• CPC Class Codes: B60Q 1/0088 Details of electrical connections B60Q1/305 takes precedence; electrical connection of the light source itself F21S41/192, F21S43/195
• CPC Class Codes: B60Q 1/2607 comprising at least two indicating lamps
• CPC Class Codes: B60Q 1/2665 on rear-view mirrors lighting devices for vehicle interior on or for rear-view mirrors B60Q3/258
• CPC Class Codes: B60Q 1/2696 Mounting of devices using LEDs
• CPC Class Codes: B60Q 1/34 for indicating change of drive direction B60Q1/22 takes precedence
• CPC Class Codes: B60Q 1/503 using luminous text or symbol displays in or on the vehicle, e.g. static text
• CPC Class Codes: B60R 1/0602 comprising means for cleaning or deicing
• CPC Class Codes: B60R 1/072 for adjusting the mirror relative to its housing
• 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 1/081 avoiding blind spots, e.g. by using a side-by-side association of mirrors
• 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 1/1207 with lamps; with turn indicators
• CPC Class Codes: B60R 2001/1215 with information displays
• CPC Class Codes: B60R 2300/802 for monitoring and displaying vehicle exterior blind spot views
• CPC Class Codes: B60R 2300/8093 for obstacle warning
• CPC Class Codes: F21V 23/005 the substrate is supporting also the light source
• CPC Class Codes: F21V 23/0464 the sensor sensing the level of ambient illumination, e.g. dawn or dusk sensors
• CPC Class Codes: F21Y 2115/10 Light-emitting diodes [LED]
• CPC Class Codes: G08G 1/167 Driving aids for lane monitoring, lane changing, e.g. blind spot detection

Abstract

A mirror reflective element sub-assembly for an exterior rearview mirror assembly includes a mirror reflective element attached at a mirror back plate, which includes a mirror actuator attaching portion established at the back plate by a plastic injection molding operation. A heater pad is disposed between the mirror reflective element and the mirror back plate. An indicator associated with a blind spot detection system has a light source that is activatable to emit light. When the mirror assembly is mounted at a side of a vehicle and with the light source activated, light emitted by the light source passes through a light diffuser and through an aperture of the mirror back plate and through a light transmitting portion of the heater pad and through a light-transmitting window of the mirror reflector and exits the mirror reflective element to provide a visual icon visible to a driver of the vehicle.

Claims

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

a mirror reflective element;

said mirror reflective element comprising a transparent glass substrate with a mirror reflector disposed at a surface thereof;

a mirror back plate comprising a plastic molding formed in a plastic injection molding operation;

said mirror back plate comprising a first side and a second side;

said mirror reflective element attached at said second side of said mirror back plate;

said mirror back plate comprising a mirror actuator attaching portion that is established at said first side by said plastic injection molding operation;

wherein said mirror actuator attaching portion comprises structure for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly, and wherein said mirror actuator comprises an electrically operable mirror actuator;

wherein said mirror back plate comprises an aperture;

a heater pad disposed between said mirror reflective element and said second side of said mirror back plate;

wherein said heater pad has a light transmitting portion that is generally aligned with said aperture of said mirror back plate;

wherein said mirror reflector comprises a light-transmitting window at a portion thereof that is generally aligned with said light transmitting portion of said heater pad;

an indicator having a light source that is activatable to emit light;

wherein said light source comprise at least one light emitting diode;

wherein said indicator is associated with a blind spot detection system of a vehicle equipped with an exterior rearview mirror assembly equipped with said mirror reflective element sub-assembly; and

wherein, when the exterior rearview mirror assembly equipped with said mirror reflective element sub-assembly is mounted at a side of the equipped vehicle and with said light source activated, light emitted by said light source passes through a light diffuser and through said aperture of said mirror back plate and through said light transmitting portion of said heater pad and through said light-transmitting window of said mirror reflector and exits said mirror reflective element to provide a visual icon visible to a driver of the equipped vehicle who is driving the equipped vehicle and who is viewing said mirror reflective element.

2. The mirror reflective element sub-assembly of claim 1, wherein said aperture is established through said mirror back plate by said plastic injection molding operation.

3. The mirror reflective element sub-assembly of claim 1, wherein said indicator comprises a housing, and wherein a circuit board is disposed in said housing and wherein said circuit board comprises said at least one light emitting diode and wherein said circuit board is orientated in said housing so that at least one light emitting portion of said at least one light emitting diode generally faces towards said mirror reflective element.

4. The mirror reflective element sub-assembly of claim 1, wherein said aperture has a shape, and wherein said indicator comprises a housing, and wherein a circuit board is disposed in said housing and wherein said housing comprises wall structure, and wherein said wall structure of said housing has a cross-sectional shape that generally matches the shape of said aperture.

5. The mirror reflective element sub-assembly of claim 1, wherein said indicator is substantially water impervious.

6. The mirror reflective element sub-assembly of claim 1, wherein said indicator includes a passageway, and wherein light emitted by said light source, when said light source is activated, passes through said passageway.

7. The mirror reflective element sub-assembly of claim 1, wherein said light source comprises a plurality of light emitting diodes, and wherein said light transmitting portion of said heater pad comprises at least one of (i) an aperture through said heater pad, (ii) a transparent portion of said heater pad, (iii) a translucent portion of said heater pad and (iv) a diffuse portion of said heater pad.

8. The mirror reflective element sub-assembly of claim 1, wherein said indicator comprises a housing, and wherein said light source is disposed at a circuit board, and wherein said housing at least substantially encases said circuit board, and wherein said circuit board comprises an electrical connector for electrically connecting said circuit board to a power source of the equipped vehicle.

9. The mirror reflective element sub-assembly of claim 1, wherein circuitry is established at a circuit board of said indicator, and wherein said circuitry comprises at least one of (i) said light source, (ii) a DC converter with a voltage dropping resistor and (iii) an electrical connector for electrically connecting said indicator to a power source of the equipped vehicle.

10. The mirror reflective element sub-assembly of claim 1, wherein said visual icon comprises a triangular shape.

11. The mirror reflective element sub-assembly of claim 1, wherein said structure of said mirror actuator attaching portion for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly comprises at least one of (i) a raised annular ring, (ii) annular prongs and (iii) annular snaps.

12. The mirror reflective element sub-assembly of claim 1, wherein, during a daytime driving condition and with said light source activated, said visual icon has a luminance of at least about 5,000 candelas/square meter when viewed from the front along its axis of highest brightness when viewed from the front of said mirror reflective element and emitting light therethrough.

13. The mirror reflective element sub-assembly of claim 12, wherein, during a nighttime driving condition, luminance of said visual icon is significantly reduced responsive to an ambient light sensing photosensor of the vehicle detecting an ambient light level at or below a threshold light level.

14. The mirror reflective element sub-assembly of claim 1, wherein, during a daytime driving condition and with said light source activated, said visual icon has a luminance of at least about 30,000 candelas/square meter when viewed from the front along its axis of highest brightness when viewed from the front of said mirror reflective element and emitting light therethrough.

15. The mirror reflective element sub-assembly of claim 1, wherein said indicator is adhesively attached to a rear surface of said mirror reflective element.

16. The mirror reflective element sub-assembly of claim 15, wherein said indicator is adhesively attached to the rear surface of said mirror reflective element using at least one of an optical adhesive, an optical tape and an optical film.

17. The mirror reflective element sub-assembly of claim 1, wherein said indicator comprises a mask.

18. The mirror reflective element sub-assembly of claim 17, wherein said mask, at least in part, establishes the shape of said visual icon.

19. The mirror reflective element sub-assembly of claim 18, wherein said shape comprises a triangular shape.

20. A mirror reflective element sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

a mirror reflective element;

said mirror reflective element comprising a transparent glass substrate with a mirror reflector disposed at a surface thereof;

a mirror back plate comprising a plastic molding formed in a plastic injection molding operation;

said mirror back plate comprising a first side and a second side;

said mirror reflective element attached at said second side of said mirror back plate;

said mirror back plate comprising a mirror actuator attaching portion that is established at said first side by said plastic injection molding operation;

wherein said mirror actuator attaching portion comprises structure for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly, and wherein said mirror actuator comprises an electrically operable mirror actuator;

wherein said mirror back plate comprises an aperture;

a heater pad disposed between said mirror reflective element and said second side of said mirror back plate;

wherein said heater pad has a light transmitting portion that is generally aligned with said aperture of said mirror back plate;

wherein said mirror reflector comprises a light-transmitting window at a portion thereof that is generally aligned with said light transmitting portion of said heater pad;

an indicator having a light source that is activatable to emit light;

wherein said light source comprise a plurality of light emitting diodes;

wherein said indicator is associated with a blind spot detection system of a vehicle equipped with an exterior rearview mirror assembly equipped with said mirror reflective element sub-assembly;

wherein, when the exterior rearview mirror assembly equipped with said mirror reflective element sub-assembly is mounted at a side of the equipped vehicle and with said light source activated, light emitted by said light source passes through a light diffuser and through said aperture of said mirror back plate and through said light transmitting portion of said heater pad and through said light-transmitting window of said mirror reflector and exits said mirror reflective element to provide a visual icon visible to a driver of the equipped vehicle who is driving the equipped vehicle and who is viewing said mirror reflective element;

wherein said indicator is adhesively attached to a rear surface of said mirror reflective element and wherein said indicator is adhesively attached to the rear surface of said mirror reflective element using at least one of an optical adhesive, an optical tape and an optical film; and

wherein said indicator comprises a mask and wherein said mask, at least in part, establishes the shape of said visual icon and said shape comprises a triangular shape.

21. The mirror reflective element sub-assembly of claim 20, wherein, during a daytime driving condition and with said light source activated, said visual icon has a luminance of at least about 5,000 candelas/square meter when viewed from the front along its axis of highest brightness when viewed from the front of said mirror reflective element and emitting light therethrough, and wherein, during a nighttime driving condition, luminance of said visual icon is significantly reduced responsive to an ambient light sensing photosensor of the vehicle detecting an ambient light level at or below a threshold light level.

22. The mirror reflective element sub-assembly of claim 21, wherein said aperture is established through said mirror back plate by said plastic injection molding operation, and wherein said indicator is substantially water impervious, and wherein said light transmitting portion of said heater pad comprises at least one of (i) an aperture through said heater pad, (ii) a transparent portion of said heater pad, (iii) a translucent portion of said heater pad and (iv) a diffuse portion of said heater pad, and wherein said structure of said mirror actuator attaching portion for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly comprises at least one of (i) a raised annular ring, (ii) annular prongs and (iii) annular snaps.

23. The mirror reflective element sub-assembly of claim 21, wherein said indicator comprises a housing, and wherein a circuit board is disposed in said housing and wherein said circuit board comprises said plurality of light emitting diodes and wherein said circuit board is orientated in said housing so that light emitting portions of said plurality of light emitting diodes generally face towards said mirror reflective element.

24. The mirror reflective element sub-assembly of claim 23, wherein said indicator is substantially water impervious.

25. A mirror reflective element sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

a mirror reflective element;

said mirror reflective element comprising a transparent glass substrate with a mirror reflector disposed at a surface thereof;

a mirror back plate comprising a plastic molding formed in a plastic injection molding operation;

said mirror back plate comprising a first side and a second side;

said mirror reflective element attached at said second side of said mirror back plate;

said mirror back plate comprising a mirror actuator attaching portion that is established at said first side by said plastic injection molding operation;

wherein said mirror actuator attaching portion comprises structure for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly, and wherein said mirror actuator comprises an electrically operable mirror actuator;

wherein said mirror back plate comprises an aperture;

a heater pad disposed between said mirror reflective element and said second side of said mirror back plate;

wherein said heater pad has a light transmitting portion that is generally aligned with said aperture of said mirror back plate;

wherein said mirror reflector comprises a light-transmitting window at a portion thereof that is generally aligned with said light transmitting portion of said heater pad;

an indicator having a light source that is activatable to emit light;

wherein said light source comprise at least one light emitting diode;

wherein said indicator is associated with a blind spot detection system of a vehicle equipped with an exterior rearview mirror assembly equipped with said mirror reflective element sub-assembly;

wherein, when the exterior rearview mirror assembly equipped with said mirror reflective element sub-assembly is mounted at a side of the equipped vehicle and with said light source activated, light emitted by said light source passes through a light diffuser and through said aperture of said mirror back plate and through said light transmitting portion of said heater pad and through said light-transmitting window of said mirror reflector and exits said mirror reflective element to provide a visual icon visible to a driver of the equipped vehicle who is driving the equipped vehicle and who is viewing said mirror reflective element;

wherein said indicator is adhesively attached to a rear surface of said mirror reflective element; and

wherein said indicator comprises a housing.

26. The mirror reflective element sub-assembly of claim 25, wherein a circuit board is disposed in said housing and wherein said circuit board comprises said at least one light emitting diode.

27. The mirror reflective element sub-assembly of claim 26, wherein said indicator comprises a mask and wherein said mask, at least in part, establishes the shape of said visual icon.

28. The mirror reflective element sub-assembly of claim 27, wherein said structure of said mirror actuator attaching portion for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly comprises at least one of (i) a raised annular ring, (ii) annular prongs and (iii) annular snaps.

29. The mirror reflective element sub-assembly of claim 28, wherein said indicator is adhesively attached to the rear surface of said mirror reflective element using at least one of an optical adhesive, an optical tape and an optical film.

30. The mirror reflective element sub-assembly of claim 29, wherein said shape comprises a triangular shape.

31. The mirror reflective element sub-assembly of claim 26, wherein said circuit board is orientated in said housing so that at least one light emitting portion of said at least one light emitting diode generally faces towards said mirror reflective element.

32. The mirror reflective element sub-assembly of claim 25, wherein said aperture has a shape, and wherein a circuit board is disposed in said housing and wherein said housing comprises wall structure, and wherein said wall structure of said housing has a cross-sectional shape that generally matches the shape of said aperture.

33. The mirror reflective element sub-assembly of claim 25, wherein, during a daytime driving condition and with said light source activated, said visual icon has a luminance of at least about 5,000 candelas/square meter when viewed from the front along its axis of highest brightness when viewed from the front of said mirror reflective element and emitting light therethrough, and wherein, during a nighttime driving condition, luminance of said visual icon is significantly reduced responsive to an ambient light sensing photosensor of the vehicle detecting an ambient light level at or below a threshold light level.

34. The mirror reflective element sub-assembly of claim 25, wherein said aperture is established through said mirror back plate by said plastic injection molding operation, and wherein said indicator is substantially water impervious, and wherein said light transmitting portion of said heater pad comprises at least one of (i) an aperture through said heater pad, (ii) a transparent portion of said heater pad, (iii) a translucent portion of said heater pad and (iv) a diffuse portion of said heater pad.