Elemental semiconductor mirror

• US 6,065,840 A
• Filed: 05/17/1999
• Issued: 05/23/2000
• Est. Priority Date: 05/15/1991
• Status: Expired due to Fees

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Lynam, Niall R., Hichwa, Bryant P., Caskey, Gregory T.
• Primary Examiner(s): Spyrou, Cassandra
• Assistant Examiner(s): SIKDER, MOHAMMAD YUNUS
• Application Number:
  US09/313,152
• Time in Patent Office: 372 Days
• Field of Search: 359/603, 359/604, 359/608, 359/584, 359/585, 359/586, 359/587, 359/588, 359/589
• US Class Current: 359/603
• CPC Class Codes: B60R 1/082 using a single wide field mirror or an association of rigidly connected mirrors
• CPC Class Codes: B60R 1/083 Anti-glare mirrors, e.g. "day-night" mirrors
• CPC Class Codes: G02B 5/0833 comprising inorganic materials only

Abstract

An elemental mirror having a high luminous reflectance of at least about 60% of incident light at the wavelength region of about 550 nanometers and being acromatic includes a substrate coated with a reflector comprising a multilayer thin film stack. The thin film stack comprises a first thin film layer of an elemental semiconductor which is closest to the first surface of the glass substrate and has a refractive index of greater than 3.0, a second thin film layer which is farthest from the first surface of the glass substrate, and a third thin film layer disposed between the first thin film layer and the second thin film layer, the third thin film layer having a refractive index between about 1.3 and 2.7, the second thin film layer having a refractive index greater than the third thin film layer. A light absorbing coating is included on at least one surface of the substrate and a layer of the reflector, the light absorbing coating absorbing light transmitted by the reflector coated substrate. Alternately, the multilayer thin film stack may be coated on the second surface of the glass substrate with the light absorbing coating disposed on the reflector coated second surface of the glass substrate. The elemental semiconductor may comprise silicon or germanium. The light absorbing coating may comprise one of a paint, a lacquer, a tape, a ceramic, a hot melt plastic, a resinous plastic, a plastisol, or an epoxy material.

Claims

1. A high luminous reflectance mirrored substrate comprising:

a glass substrate having first and second surfaces;

a reflector coated upon said second surface of said glass substrate, said second surface adapted to face away from a source of light to be reflected;

said reflector comprising a multilayer thin film stack comprising a first thin film layer of an elemental semiconductor which is farthest from said second surface of said glass substrate and has a refractive index of greater than 3.0, a second thin film layer which is closest to said second surface of said glass substrate, a third thin film layer disposed between said first thin film layer and said second thin film layer, said third thin film layer having a refractive index between about 1.3 and 2.7, said second thin film layer having a refractive index greater than said third thin film layer;

said reflector having a light reflectance of at least about 60% of light incident thereon at the wavelength region of about 550 nanometers and being achromatic; and

a light absorbing coating disposed on said reflector coated second surface of said glass substrate.

2. The mirrored substrate of claim 1 wherein said elemental semiconductor thin layer comprises one of silicon and germanium.

3. The mirrored substrate of claim 1 wherein said elemental semiconductor thin film layer comprises silicon.

4. The mirrored substrate of claim 3 wherein said light absorbing coating is disposed on said third thin film layer.

5. The mirrored substrate of claim 3 wherein said light absorbing coating is disposed on said second surface of said glass substrate.

6. The mirrored substrate of claim 1 wherein said light absorbing coating comprises one of a paint, a lacquer, a tape, a ceramic, a hot melt plastic, a resinous plastic, a plastisol or an epoxy material.

7. The mirrored substrate of claim 6 wherein said light absorbing coating provides antiscatter protection for said glass substrate should it be broken.

8. The mirrored substrate of claim 3 wherein the luminous transmittance of said light absorbing coated mirrored substrate is less than about 4%.

9. The mirrored substrate of claim 1 wherein said light absorbing coating comprises one of a paint and a lacquer.

10. The mirrored substrate of claim 1 wherein said light absorbing coating comprises a tape.

11. The mirrored substrate of claim 1 wherein said third thin film layer comprises one of an oxide, fluoride, nitride, and sulfide.

12. The mirrored substrate of claim 1 wherein said third thin film layer comprises a silicon compound.

13. The mirrored substrate of claim 12 wherein said silicon compound comprises silicon nitride.

14. The mirrored substrate of claim 12 wherein said silicon compound comprises silicon oxide.

15. The mirrored substrate of claim 1 wherein at least one of said first thin film layer and said second thin film layer comprises doped silicon.

16. The mirrored substrate of claim 15 wherein said doped silicon is doped with a material selected from the group consisting of phosphorous, aluminum, gallium, boron and arsenic.

17. The mirrored substrate of claim 1 wherein at least one of said first thin film layer, said second thin film layer, and said third thin film layer is a non-vacuum coated layer.

18. The mirrored substrate of claim 17 wherein said non-vacuum coated layer is one of a dip-coated layer and a spin-coated layer.

19. The mirrored substrate of claim 1 wherein said glass substrate is a bent glass substrate having a curvature.

20. The mirrored substrate of claim 19 wherein said bent glass substrate has a generally convex surface and a generally concave surface.

21. The mirrored substrate of claim 20 wherein said reflector is coated on said convex surface.

22. The mirrored substrate of claim 20 wherein said reflector is coated on said concave surface.

23. The mirrored substrate of claim 19 wherein said bent glass substrate has a radius of curvature of at least about forty (40) inches.

24. The mirrored substrate of claim 19 wherein said bent glass substrate is heated to at least about 450°

C. following coating of said reflector and bent to said curvature after heating.

25. The mirrored substrate of claim 1 wherein said glass substrate is heated and bent following coating of said reflector on said second surface of said glass substrate.

26. The mirrored substrate of claim 1 wherein said mirrored substrate is a reflector suitable for use in a rearview mirror for a vehicle.

27. The mirrored substrate of claim 26 wherein said mirrored substrate is a reflector of an exterior rearview mirror on a vehicle.

28. The mirrored substrate of claim 27 wherein the vehicle is an automobile.

29. The mirrored substrate of claim 27 wherein the vehicle is a truck.