METHOD OF FORMING AN EXTERIOR MIRROR REFLECTOR SUB-ASSEMBLY WITH AUXILIARY REFLECTOR PORTION

• US 20150343952A1
• Filed: 08/10/2015
• Published: 12/03/2015
• 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 9,315,155 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• 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

A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle includes providing a glass substrate having a first surface and a second surface. Glass is physically removed from a portion of the second surface of the glass substrate to form a curved recess locally thereat. The second surface of the glass substrate is coated with a mirror reflector via a vacuum deposition process. When used in an automotive exterior rearview mirror assembly, the mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views the mirror reflective element when normally operating the vehicle. A mirror back plate is formed in a plastic molding operation and a heater pad is disposed between the coated second surface of the glass substrate and a first side of the mirror back plate.

Claims

1. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

providing a glass substrate, said glass substrate having a first surface and a second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, the first surface of said glass substrate is closer than said coated second surface to a side of a vehicle to which the automotive exterior rearview mirror assembly is attached;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

forming a mirror back plate in a plastic molding operation;

said mirror plate having a first side and an opposing second side;

wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

said plastic molding operation comprising injection molding;

providing a heater pad; and

disposing said heater pad between said coated second surface of said glass substrate and said first side of said mirror back plate.

2. The method of claim 1, wherein physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat comprises at least one of (i) physically removing glass via a glass grinding operation and (ii) physically removing glass via a glass ablation operation.

3. The method of claim 2, wherein said portion of the second surface of said glass substrate where said curved recess is formed is inboard of a perimeter edge of said glass substrate, and wherein said curved recess is generally circular-shaped.

4. The method of claim 1, wherein coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector comprises coating via sputter deposition.

5. The method of claim 1, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle.

6. The method of claim 5, wherein said glass substrate comprises (i) a generally planar second surface other than where said curved recess is formed and (ii) a generally planar first surface, and wherein said mirror reflector sub-assembly comprises a driver-side mirror reflector sub-assembly for use in a driver-side exterior rearview mirror assembly.

7. The method of claim 1, wherein, with said heater pad disposed between said coated second surface of said glass substrate and said first side of said mirror back plate, a portion of said mirror back plate extends around a perimeter edge of said glass substrate.

8. The method of claim 1, wherein, with said heater pad disposed between said coated second surface of said glass substrate and said first side of said mirror back plate, said mirror reflector sub-assembly comprises a frameless mirror reflector sub-assembly.

9. The method of claim 1, wherein said structure established at said second side of said mirror back plate for attaching said mirror back plate to a mirror actuator comprises at least one of (i) an annular ring, (ii) annular prongs and (iii) annular snaps.

10. The method of claim 1, wherein said curved recess comprises a spherically curved recess.

11. The method of claim 1, comprising adhesively securing said heater pad at said coated second surface of said glass substrate.

12. The method of claim 1, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said coated glass substrate comprises a spherically curved glass substrate having a first radius of curvature and wherein said curved recess comprises a spherically curved recess having a second radius of curvature and wherein said second radius of curvature of said spherically curved recess is smaller than said first radius of curvature of said spherically curved glass substrate, and wherein said mirror reflector sub-assembly comprises a passenger-side mirror reflector sub-assembly for use in a passenger-side exterior rearview mirror assembly.

13. The method of claim 1, wherein said at least one mirror-reflecting metal thin film layer comprises chromium.

14. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

providing a glass substrate, said glass substrate having a generally planer first surface and a generally planar second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

physically removing glass from a portion of the second surface of said glass substrate to form a generally circular-shaped curved recess inboard of a perimeter edge of said glass substrate, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

coating via a sputter deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in a driver-side automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

wherein, when said mirror reflective element is used in a driver-side automotive exterior rearview mirror assembly, the first surface of said glass substrate is closer than said coated second surface to a side of a vehicle to which the driver-side automotive exterior rearview mirror assembly is attached;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

forming a mirror back plate in a plastic molding operation;

said mirror plate having a first side and an opposing second side;

wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

said plastic molding operation comprising injection molding;

providing a heater pad; and

disposing said heater pad between said coated second surface of said glass substrate and said first side of said mirror back plate.

15. The method of claim 14, wherein physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat comprises at least one of (i) physically removing glass via a glass grinding operation and (ii) physically removing glass via a glass ablation operation.

16. The method of claim 15, comprising adhesively securing said heater pad at said coated second surface of said glass substrate.

17. The method of claim 16, wherein said at least one mirror-reflecting metal thin film layer comprises chromium.

18. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

providing a glass substrate, said glass substrate having a first surface and a second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

physically removing glass from a portion of the second surface of said glass substrate to form a generally circular-shaped curved recess inboard of a perimeter edge of said glass substrate, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

coating via a sputter deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, the first surface of said glass substrate is closer than said coated second surface to a side of a vehicle to which the automotive exterior rearview mirror assembly is attached;

wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at a side of a vehicle, said curved recess is generally disposed at an outboard region of said glass substrate relative to the side of the vehicle, and wherein said coated glass substrate comprises a spherically curved glass substrate having a first radius of curvature and wherein said curved recess comprises a spherically curved recess having a second radius of curvature and wherein said second radius of curvature of said spherically curved recess is smaller than said first radius of curvature of said spherically curved glass substrate, and wherein said mirror reflector sub-assembly comprises a passenger-side mirror reflector sub-assembly for use in a passenger-side exterior rearview mirror assembly;

forming a mirror back plate in a plastic molding operation;

said mirror plate having a first side and an opposing second side;

wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

said plastic molding operation comprising injection molding;

providing a heater pad;

adhesively securing said heater pad at said coated second surface of said glass substrate; and

disposing said heater pad between said coated second surface of said glass substrate and said first side of said mirror back plate.

19. The method of claim 18, wherein physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat comprises at least one of (i) physically removing glass via a glass grinding operation and (ii) physically removing glass via a glass ablation operation.

20. The method of claim 18, wherein said at least one mirror-reflecting metal thin film layer comprises chromium.