Exterior sideview mirror system

• US 8,128,243 B2
• Filed: 10/25/2010
• Issued: 03/06/2012
• Est. Priority Date: 05/20/2003
• Status: Active Grant

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Lynam, Niall R.
• Primary Examiner(s): AMARI, ALESSANDRO V
• Application Number:
  US12/911,274
• Publication Number:
  US 20110051270A1
• Time in Patent Office: 498 Days
• Field of Search: 359/866, 359/868, 359/872, 359/877, 359/883
• US Class Current: 359/866
• 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 1/082 using a single wide field mirror or an association of rigidly connected 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: G02B 27/0006 with means to keep optical surfaces clean, e.g. by preventing or removing dirt, stains, contamination, condensation G02B1/18 takes precedence; cleaning in general B08B
• CPC Class Codes: G02B 7/182 for mirrors
• CPC Class Codes: G02F 1/157 Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells

Abstract

An exterior sideview mirror assembly includes a single mirror backing plate element within a mirror housing. A main plano mirror element and an auxiliary non-plano curved mirror element are supported by the backing plate element. The backing plate element has a generally flat portion for supporting the main plano mirror element and a curved portion for supporting the auxiliary non-plano curved mirror element. The curved portion may be angled relative to the generally flat portion in a manner such that, when a driver of the vehicle aligns the rearward field of view of the main plano mirror element, the rearward field of view of the main plano mirror element may be aligned downwardly relative to the vehicle body side. The main plano mirror element includes a generally flat reflector-coated glass substrate or a generally flat polymeric substrate having a thin glass element applied to a surface thereof.

Claims

1. An exterior sideview minor assembly suitable for vehicular use, said exterior sideview mirror assembly comprising:

a mirror housing defining a primary opening;

a single mirror backing plate element within said mirror housing and disposed adjacent to said primary opening;

said single mirror backing plate element movable by an electrically-operable actuator;

a main plano mirror element fixedly secured to and supported by said single mirror backing plate element and disposed within said primary opening for providing a view rearward of a vehicle equipped with said exterior sideview mirror assembly through a first primary field of view;

an auxiliary non-plano curved mirror element fixedly secured to and supported by said single mirror backing plate element and disposed adjacent to said main plano minor element, said auxiliary non-piano curved mirror element defined by a single radius of curvature differing from said main piano mirror element such that said auxiliary non-plano curved minor element provides a second auxiliary field of view rearward of the vehicle equipped with said exterior sideview minor assembly;

wherein said first primary field of view of said main plano mirror element overlaps said second auxiliary field of view of said auxiliary non-plano curved mirror element;

wherein said single mirror backing plate element comprises a generally rigid polymeric molding able to support said main piano mirror element and said auxiliary non-piano curved mirror element;

wherein said single mirror backing plate element comprises a generally flat portion for supporting said main piano mirror element and a curved portion for supporting said auxiliary non-piano curved mirror element;

wherein said curved portion of said single mirror backing plate element for supporting said auxiliary non-piano curved mirror element is angled relative to said generally flat portion of said single mirror backing plate element for supporting said main piano mirror element in a manner such that, when a driver of a vehicle equipped with said exterior side view mirror assembly aligns the rearward field of view of said main plano mirror element, the rearward field of view of said main piano mirror element is aligned downwardly relative to a vehicle body side to which said exterior side view mirror assembly is attached;

wherein said main piano mirror element comprises one of (a) a generally flat glass substrate having a surface coated with a metallic reflector coating and (b) a generally flat polymeric substrate having a thin glass element applied to a surface thereof and with an opposing surface thereof having a reflecting layer applied thereto; and

wherein said curved portion of said single mirror backing plate element defines an auxiliary non-piano curved mirror element backing plate element radius of curvature substantially equal to said single radius of curvature.

2. The exterior sideview mirror assembly of claim 1, including a divider between said main piano mirror element and said auxiliary non-plano curved mirror element that demarcates said auxiliary non-piano curved minor element from said main plano mirror element visually.

3. The exterior sideview mirror assembly of claim 2, wherein said main piano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating.

4. The exterior sideview mirror assembly of claim 3, wherein said single mirror backing plate element includes a molded wall extending from a surface thereof and wherein said divider comprises at least a portion of said molded wall.

5. The exterior sideview mirror assembly of claim 4, wherein said wall generally circumscribes the circumferential edge of said auxiliary non-plano curved mirror element when said auxiliary non-plano curved mirror element is supported by said single mirror backing plate element.

6. The exterior sideview mirror assembly of claim 1, wherein said main piano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating and including a bracket configured for fixedly securing said exterior sideview mirror assembly to the vehicle body side.

7. The exterior sideview mirror assembly of claim 1, wherein said main plano mirror element comprises a generally flat polymeric substrate having a thin glass element applied to a surface thereof and with an opposing surface thereof having a reflecting layer applied thereto, and wherein said generally flat polymeric substrate is formed from an elongated sheet of substrate material comprising a polymeric resin material, and wherein said elongated sheet has a substantially transparent functional film applied at a surface thereof, and wherein said substantially transparent functional film provides at least one of (a) an anti-abrasion function, (b) a hydrophobic function and (c) a hydrophilic function, and wherein said functional film comprises an ultrathin glass material which is sufficiently flexible to be provided in a reel or roll, and wherein said functional film is sufficiently flexible to conform to said generally flat polymeric substrate of said main piano mirror element, and said main piano mirror element comprises a reflective film disposed at a surface of said generally flat polymeric substrate opposite said substantially transparent functional film.

8. The exterior sideview mirror assembly of claim 7, wherein said thin glass element comprises a thin flexible glass sheet, said thin flexible glass sheet existing as a pre-formed glass sheet that is separate from said generally flat polymeric substrate, said thin flexible glass sheet having an attaching surface, said attaching surface being opposed to and adhered to said surface of said generally flat polymeric substrate when said thin flexible glass sheet is adhered to said exterior surface of said generally flat polymeric substrate, said thin flexible glass sheet providing an anti-abrasion function at said surface of said generally flat polymeric substrate when adhered thereto, said thin flexible glass sheet substantially conforming to said exterior surface of said generally flat polymeric substrate when adhered thereto, said thin flexible glass sheet having a thickness of less than approximately 0.8 mm and greater than approximately 0.3 mm.

9. The exterior sideview mirror assembly of claim 8, wherein said generally flat polymeric substrate is cut from a molded or extruded or cast elongated sheet, said thin flexible glass sheet being laminated to said elongated sheet and wherein said plano reflective element comprises a reflective film applied to an inner surface of said generally flat polymeric substrate opposite said exterior surface, and wherein said reflective film comprises a polymeric reflective film at least one of laminated, adhered and applied to said inner surface of said generally flat polymeric substrate.

21. The exterior sideview mirror assembly of claim 1, wherein said generally flat portion of said single mirror backing plate element defines a primary plane that is substantially flat and wherein said curved portion of said single minor backing plate element is substantially convex-curved.

22. The exterior sideview mirror assembly of claim 21, wherein a part of said curved portion of said single mirror backing plate element is one of (a) substantially coplanar with said primary plane and (b) substantially rearward of said primary plane.

23. The exterior sideview mirror assembly of claim 21, wherein a first part of said curved portion of said single mirror backing plate element is substantially coplanar with said primary plane and a second part of said curved portion of said single mirror backing plate element is substantially rearward of said primary plane.

10. An exterior sideview mirror assembly suitable for vehicular use, said exterior sideview mirror assembly comprising:

a mirror housing defining a primary opening;

a single mirror backing plate element within said minor housing and disposed adjacent to said primary opening;

said single mirror backing plate element movable by an electrically-operable actuator;

a main piano mirror element fixedly secured to and supported by said single mirror backing plate element and disposed within said primary opening for providing a view rearward of a vehicle equipped with said exterior sideview mirror assembly through a first primary field of view;

an auxiliary non-plano curved mirror element fixedly secured to and supported by said single mirror backing plate element and disposed adjacent to said main piano mirror element, said auxiliary non-piano curved mirror element defined by a curvature differing from said main plano mirror element such that said auxiliary non-piano curved mirror element provides a second auxiliary field of view rearward of the vehicle equipped with said exterior sideview mirror assembly;

wherein said first primary field of view of said main piano mirror element overlaps said second auxiliary field of view of said auxiliary non-piano curved mirror element;

wherein said single minor backing plate element comprises a generally rigid polymeric molding able to support said main plano mirror element and said auxiliary non-piano curved mirror element;

wherein said single mirror backing plate element comprises a generally flat portion for supporting said main plano mirror element and a curved portion for supporting said auxiliary non-piano curved mirror element;

wherein said curved portion of said single mirror backing plate element for supporting said auxiliary non-piano curved mirror element is angled relative to said generally flat portion of said single mirror backing plate element for supporting said main plano mirror element in a manner such that, when a driver of a vehicle equipped with said exterior side view mirror assembly aligns the rearward field of view of said main piano mirror element, the rearward field of view of said main piano mirror element is aligned downwardly relative to a vehicle body side to which said exterior side view mirror assembly is attached;

wherein said main piano mirror element comprises one of (a) a generally flat glass substrate having a surface coated with a metallic reflector coating and (b) a generally flat polymeric substrate having a thin glass element applied to a surface thereof and with an opposing surface thereof having a reflecting layer applied thereto; and

wherein said curved portion of said single mirror backing plate element defines an auxiliary non-piano curved mirror element backing plate element radius of curvature substantially equal to said curvature of said auxiliary non-plano curved mirror element.

11. The exterior sideview mirror assembly of claim 10, including a divider between said main piano mirror element and said auxiliary non-piano curved mirror element that demarcates said auxiliary non-piano curved mirror element from said main plano mirror element visually.

12. The exterior sideview mirror assembly of claim 11, wherein said single mirror backing plate element includes a molded wall extending from a surface thereof and wherein said divider comprises at least a portion of said molded wall and wherein said wall generally circumscribes the circumferential edge of said auxiliary non-plano curved mirror element when said auxiliary non-piano curved mirror element is supported by said single mirror backing plate element.

13. The exterior sideview mirror assembly of claim 12, wherein said main piano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating and including a bracket configured for fixedly securing said exterior sideview mirror assembly to the vehicle body side.

14. The exterior sideview mirror assembly of claim 10, wherein said auxiliary non-plano curved mirror element comprises a reflector-coated multiradius curved substrate.

15. The exterior sideview mirror assembly of claim 10, wherein said generally flat portion of said single mirror backing plate element defines a primary plane that is substantially flat and wherein said curved portion of said single mirror backing plate element is substantially convex-curved.

16. The exterior sideview mirror assembly of claim 15, wherein a part of said curved portion of said single mirror backing plate element is one of (a) substantially coplanar with said primary plane and (b) substantially rearward of said primary plane.

17. The exterior sideview mirror assembly of claim 15, wherein a first part of said curved portion of said single mirror backing plate element is substantially coplanar with said primary plane and a second part of said curved portion of said single mirror backing plate element is substantially rearward of said primary plane.

18. The exterior sideview mirror assembly of claim 10, wherein said main piano mirror element comprises a generally flat polymeric substrate having a thin glass element applied to a surface thereof and with an opposing surface thereof having a reflecting layer applied thereto, and wherein said generally flat polymeric substrate is formed from an elongated sheet of substrate material comprising a polymeric resin material, and wherein said elongated sheet has a substantially transparent functional film applied at a surface thereof, and wherein said substantially transparent functional film provides at least one of (a) an anti-abrasion function, (b) a hydrophobic function and (c) a hydrophilic function, and wherein said functional film comprises an ultrathin glass material which is sufficiently flexible to be provided in a reel or roll, and wherein said functional film is sufficiently flexible to conform to said generally flat polymeric substrate of said main piano mirror element, and said main piano mirror element comprises a reflective film disposed at a surface of said generally flat polymeric substrate opposite said substantially transparent functional film.

19. The exterior sideview mirror assembly of claim 18, wherein said thin glass element comprises a thin flexible glass sheet, said thin flexible glass sheet existing as a pre-formed glass sheet that is separate from said generally flat polymeric substrate, said thin flexible glass sheet having an attaching surface, said attaching surface being opposed to and adhered to said surface of said generally flat polymeric substrate when said thin flexible glass sheet is adhered to said exterior surface of said generally flat polymeric substrate, said thin flexible glass sheet providing an anti-abrasion function at said surface of said generally flat polymeric substrate when adhered thereto, said thin flexible glass sheet substantially conforming to said exterior surface of said generally flat polymeric substrate when adhered thereto, said thin flexible glass sheet having a thickness of less than approximately 0.8 mm and greater than approximately 0.3 mm.

20. The exterior sideview mirror assembly of claim 19, wherein said generally flat polymeric substrate is cut from a molded or extruded or cast elongated sheet, said thin flexible glass sheet being laminated to said elongated sheet and wherein said plano reflective element comprises a reflective film applied to an inner surface of said generally flat polymeric substrate opposite said exterior surface, and wherein said reflective film comprises a polymeric reflective film at least one of laminated, adhered and applied to said inner surface of said generally flat polymeric substrate.

24. An exterior sideview mirror assembly suitable for vehicular use, said exterior sideview minor assembly comprising:

a minor housing defining a primary opening;

a single mirror backing plate element within said mirror housing and disposed adjacent to said primary opening;

said single mirror backing plate element movable by an electrically-operable actuator;

a main piano minor element fixedly secured to and supported by said single mirror backing plate element and disposed within said primary opening for providing a view rearward of a vehicle equipped with said exterior sideview minor assembly through a first primary field of view;

an auxiliary non-piano curved mirror element fixedly secured to and supported by said single mirror backing plate element and disposed adjacent to said main piano mirror element, wherein said auxiliary non-piano curved mirror element comprises a reflector-coated spherically curved substrate and has a spherical radius of curvature with substantially a single radius of curvature differing from said main piano mirror element such that said auxiliary non-piano curved mirror element provides a second auxiliary field of view rearward of the vehicle equipped with said exterior sideview mirror assembly;

wherein said first primary field of view of said main piano mirror element overlaps said second auxiliary field of view of said auxiliary non-piano curved mirror element;

wherein said single mirror backing plate element comprises a generally rigid polymeric molding able to support said main piano mirror element and said auxiliary non-piano curved mirror element;

wherein said single mirror backing plate element comprises a generally flat portion for supporting said main piano mirror element and a curved portion for supporting said auxiliary non-piano curved mirror element;

wherein said main plano mirror element is fixedly secured to said generally flat portion of said single mirror backing plate element and said auxiliary non-piano curved mirror element is fixedly secured to said curved portion of said single mirror backing plate;

wherein said curved portion of said single mirror backing plate element for supporting said auxiliary non-piano curved mirror element is angled relative to said generally flat portion of said single mirror backing plate element for supporting said main piano mirror element in a manner such that, when a driver of a vehicle equipped with said exterior side view mirror assembly aligns the rearward field of view of said main piano mirror element, the rearward field of view of said main piano mirror element is aligned downwardly relative to a vehicle body side to which said exterior side view mirror assembly is attached;

wherein said main piano mirror element comprises one of (a) a generally flat glass substrate having a surface coated with a metallic reflector coating and (b) a generally flat polymeric substrate having a thin glass element applied to a surface thereof and with an opposing surface thereof having a reflecting layer applied thereto; and

wherein said curved portion of said single mirror backing plate element defines an auxiliary non-piano curved mirror element backing plate element radius of curvature substantially equal to said single radius of curvature.

25. The exterior sideview mirror assembly of claim 24, wherein said single mirror backing plate element includes a molded wall extending from a surface thereof;

and wherein said wall generally circumscribes the circumferential edge of said auxiliary non-plano curved mirror element when said auxiliary non-piano curved mirror element is supported by said single mirror backing plate element.

26. The exterior sideview mirror assembly of claim 24, wherein said main plano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating.

27. The exterior sideview mirror assembly of claim 24, wherein said main piano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating and including a bracket configured for fixedly securing said exterior sideview mirror assembly to the vehicle body side.

28. The exterior sideview mirror assembly of claim 24, wherein said generally flat portion of said single mirror backing plate element defines a primary plane that is substantially flat and wherein said curved portion of said single mirror backing plate element is substantially convex-curved.

29. The exterior sideview mirror assembly of claim 28, wherein a part of said curved portion of said single mirror backing plate element is one of (a) substantially coplanar with said primary plane and (b) substantially rearward of said primary plane.

30. The exterior sideview mirror assembly of claim 28, wherein a first part of said curved portion of said single mirror backing plate element is substantially coplanar with said primary plane and a second part of said curved portion of said single minor backing plate element is substantially rearward of said primary plane.

31. An exterior sideview mirror assembly suitable for vehicular use, said exterior sideview mirror assembly comprising:

a mirror housing defining a primary opening;

a single mirror backing plate element within said minor housing and disposed adjacent to said primary opening;

said single mirror backing plate element movable by an electrically-operable actuator;

a main piano mirror element fixedly secured to and supported by said single mirror backing plate element and disposed within said primary opening for providing a view rearward of a vehicle equipped with said exterior sideview minor assembly through a first primary field of view;

an auxiliary non-plano curved mirror element fixedly secured to and supported by said single minor backing plate element and disposed adjacent to said main piano minor element, said auxiliary non-plano curved minor element defined by a curvature differing from said main plano mirror element such that said auxiliary non-plano curved minor element provides a second auxiliary field of view rearward of the vehicle equipped with said exterior sideview minor assembly;

wherein said auxiliary non-piano curved mirror element comprises a reflector-coated spherically curved substrate and has a spherical radius of curvature with substantially only one radius of curvature;

wherein said first primary field of view of said main piano mirror element overlaps said second auxiliary field of view of said auxiliary non-plano curved mirror element;

wherein said single mirror backing plate element comprises a generally rigid polymeric molding able to support said main piano mirror element and said auxiliary non-plano curved mirror element;

wherein said single mirror backing plate element comprises a generally flat portion for supporting said main piano mirror element and a curved portion for supporting said auxiliary non-piano curved mirror element;

wherein said main piano mirror element is fixedly secured to said generally flat portion of said single mirror backing plate element and said auxiliary non-piano curved mirror element is fixedly secured to said curved portion of said single mirror backing plate;

wherein said curved portion of said single mirror backing plate element for supporting said auxiliary non-piano curved mirror element is angled relative to said generally flat portion of said single mirror backing plate element for supporting said main piano mirror element in a manner such that, when a driver of a vehicle equipped with said exterior side view mirror assembly aligns the rearward field of view of said main piano mirror element, the rearward field of view of said main plano mirror element is aligned downwardly relative to a vehicle body side to which said exterior side view mirror assembly is attached;

wherein said main piano mirror element comprises one of (a) a generally flat glass substrate having a surface coated with a metallic reflector coating and (b) a generally flat polymeric substrate having a thin glass element applied to a surface thereof and with an opposing surface thereof having a reflecting layer applied thereto; and

wherein said curved portion of said single mirror backing plate element defines an auxiliary non-piano curved mirror element backing plate element radius of curvature substantially equal to said substantially only one radius of curvature of said auxiliary non-plano curved mirror element.

32. The exterior sideview mirror assembly of claim 31, wherein said single mirror backing plate element includes a molded wall extending from a surface thereof and wherein said wall generally circumscribes the circumferential edge of said auxiliary non-piano curved mirror element when said auxiliary non-piano curved mirror element is supported by said single mirror backing plate element.

33. The exterior sideview mirror assembly of claim 31, wherein said main piano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating.

34. The exterior sideview mirror assembly of claim 31, wherein said main piano mirror element comprises a generally flat glass substrate having a surface coated with a metallic reflector coating and including a bracket configured for fixedly securing said exterior sideview mirror assembly to the vehicle body side.

35. The exterior sideview mirror assembly of claim 31, wherein said generally flat portion of said single mirror backing plate element defines a primary plane that is substantially flat and wherein said curved portion of said single mirror backing plate element is substantially convex-curved.

36. The exterior sideview mirror assembly of claim 35, wherein a part of said curved portion of said single mirror backing plate element is one of (a) substantially coplanar with said primary plane and (b) substantially rearward of said primary plane.

37. The exterior sideview mirror assembly of claim 35, wherein a first part of said curved portion of said single mirror backing plate element is substantially coplanar with said primary plane and a second part of said curved portion of said single mirror backing plate element is substantially rearward of said primary plane.