Exterior mirror element with wide angle portion

• US 8,267,535 B2
• Filed: 11/07/2011
• Issued: 09/18/2012
• Est. Priority Date: 05/23/2007
• Status: Expired due to Fees

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Zhao, Mingtang
• Primary Examiner(s): Cherry, Euncha
• Application Number:
  US13/290,640
• Publication Number:
  US 20120050899A1
• Time in Patent Office: 316 Days
• Field of Search: 359/841, 359/850, 359/864, 359/866, 359/868, 359/869, 359/871, 359/872
• US Class Current: 359/868
• 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 mirror reflective element suitable for use in an exterior rearview mirror assembly of a vehicle includes a glass substrate and a principal reflector portion and an auxiliary wide angle curved portion. The auxiliary wide angle curved portion has a curved recess established at a region of the rear surface of the glass substrate by at least one of grinding and ablating. The curved recess may have a cross-dimension size that is in the range from about 30 millimeters to about 80 millimeters, and may have a radius of curvature that is in the range from about 200 millimeters to about 1,000 millimeters, and may have a maximum recess depth that is in the range from about 0.11 millimeters to about 4.04 millimeters.

Claims

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

a glass substrate having a front surface and a rear surface;

a principal reflector portion and an auxiliary wide angle curved portion;

wherein said principal reflector portion comprises a principal mirror reflector established at said rear surface of said glass substrate;

wherein said auxiliary wide angle curved portion comprises a curved recess established at a region of said rear surface of said glass substrate by at least one of grinding and ablating;

wherein said auxiliary wide angle curved portion comprises an auxiliary mirror reflector established at said curved recess;

wherein said curved recess has a cross-dimension size that is in the range from about 30 millimeters to about 80 millimeters;

wherein said curved recess comprises a radius of curvature that is in the range from about 200 millimeters to about 1,000 millimeters;

wherein said curved recess has a maximum recess depth that is in the range from about 0.11 millimeters to about 4.04 millimeters;

wherein said auxiliary wide angle curved portion is inboard of a perimeter edge of said mirror reflective element;

wherein said principal reflector portion of said mirror reflective element surrounds said auxiliary wide angle curved portion of said mirror reflective element; and

wherein said curved recess is generally circular-shaped.

2. The mirror reflective element of claim 1, wherein said curved recess comprises a spherical convex-curved surface and wherein said spherically curved and generally circular-shaped recess has a maximum recess depth H that is a function of its radius of curvature R and its cross-dimension size D.

3. The mirror reflective element of claim 2, wherein:

H=R−

(R^2−

(D/2)^2)^0.5.

4. The mirror reflective element of claim 1, wherein said curved recess is established at a region of said rear surface of said glass substrate by grinding.

5. The mirror reflective element of claim 1, wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating, and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating.

6. The mirror reflective element of claim 5, wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion is established at said curved recess via sputter deposition.

7. The mirror reflective element of claim 6, wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material.

8. The mirror reflective element of claim 7, wherein said same material substantially coats the entire rear surface of said glass substrate.

9. The mirror reflective element of claim 8, wherein said same material comprises at least one of (i) a metal and (ii) chromium.

10. The mirror reflective element of claim 9, wherein said glass substrate comprises a curved glass substrate and where the radius of curvature of said curved glass substrate is larger than the radius of curvature of said curved recess.

11. The mirror reflective element of claim 1, wherein said curved recess is established at a region of said rear surface of said glass substrate by grinding, and wherein said curved recess has a maximum recess depth that is less than about 2.26 millimeters.

12. The mirror reflective element of claim 11, wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters.

13. The mirror reflective element of claim 1, wherein said cross-dimension size of said curved recess is less than about 60 millimeters.

14. The mirror reflective element of claim 1, wherein said curved recess has a maximum recess depth that is less than about 2.26 millimeters.

15. The mirror reflective element of claim 14, wherein said cross-dimension size of said curved recess is less than about 60 millimeters.

16. The mirror reflective element of claim 1, wherein said principal mirror reflector of said principal reflector portion is established at said rear surface of said glass substrate via sputter deposition.

17. The mirror reflective element of claim 1, wherein said principal mirror reflector of said principal reflector portion comprises a metallic reflector and wherein said metallic reflector is established at said rear surface of said glass substrate via sputter deposition.

18. The mirror reflective element of claim 17, wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating, and wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material.

19. The mirror reflective element of claim 1, wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating, and wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material and wherein said same material substantially coats the entire rear surface of said glass substrate.

20. The mirror reflective element of claim 19, wherein said same material comprises chromium.

21. The mirror reflective element of claim 20, wherein said glass substrate comprises a curved glass substrate and where the radius of curvature of said curved glass substrate is larger than the radius of curvature of said curved recess, and wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element.

22. The mirror reflective element of claim 1, wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters, and wherein said curved recess has a maximum recess depth that is greater than about 0.2 millimeters, and wherein said cross-dimension size of said curved recess is greater than 40 millimeters.

23. The mirror reflective element of claim 22, wherein said curved recess has a maximum recess depth that is less than about 2.26 millimeters, and wherein said cross-dimension size of said curved recess is less than about 60 millimeters.

24. The mirror reflective element of claim 23, wherein a heater pad is disposed at said rear surface of said glass substrate.

25. The mirror reflective element of claim 24, wherein said heater pad conforms to said rear surface of said glass substrate.

26. The mirror reflective element of claim 24, wherein said heater pad heats the reflecting area of said mirror reflective element, including said auxiliary wide angle curved portion.

27. The mirror reflective element of claim 24, wherein said heater pad provides heating over substantially the entire reflecting area of said mirror reflective element, including said auxiliary wide angle curved portion.

28. The mirror reflective element of claim 24, wherein said heater pad is fixedly secured by an adhesive at said rear surface of said glass substrate.

29. The mirror reflective element of claim 28, wherein said heater pad is fixedly secured by an adhesive at both of (i) said auxiliary wide angle curved portion and (ii) said principal reflector portion.

30. The mirror reflective element of claim 24, wherein electrical power for heating the reflecting area of said mirror reflective element, including said auxiliary wide angle curved portion, is provided via at least one electrically conductive trace of said heater pad that generates heat when passing an electrical current, and wherein said electrical power is applied via at least one electrical connector of said heater pad that is adapted for connection to a wiring harness of an exterior mirror assembly for powering of said heater pad by a power source of a vehicle equipped with said exterior mirror assembly.

31. The mirror reflective element of claim 30, wherein said heater pad comprises a flexible heater pad and wherein said at least one electrically conductive trace of said heater pad traverses a flexible strip of said flexible heater pad.

32. The mirror reflective element of claim 31, wherein said heater pad heats the reflecting area of said mirror reflective element, including said auxiliary wide angle curved portion.

33. The mirror reflective element of claim 1, wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element.

34. The mirror reflective element of claim 1, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at the side of a vehicle, said auxiliary wide angle curved portion is generally disposed at an outboard upper region of said mirror reflective element relative to the side of the vehicle.

35. The mirror reflective element of claim 1, wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters, and wherein said curved recess has a maximum recess depth that is greater than about 0.5 millimeters and less than about 0.78 millimeters, and wherein said cross-dimension size of said curved recess is greater than 40 millimeters and less than 50 millimeters.

36. The mirror reflective element of claim 35, wherein said glass substrate comprises a curved glass substrate and where the radius of curvature of said curved glass substrate is larger than the radius of curvature of said curved recess.

37. The mirror reflective element, of claim 36, wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating, and wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material and wherein said same material substantially coats the entire rear surface of said glass substrate.

38. The mirror reflective element of claim 37, wherein said curved recess comprises a radius of curvature of about 400 millimeters.

39. The mirror reflective element of claim 37, wherein said same material comprises a metal.

40. The mirror reflective element of claim 39, wherein said same material comprises chromium.

41. The mirror reflective element of claim 39, wherein said same material is deposited via sputtering.

42. The mirror reflective element of claim 39, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at the side of a vehicle, said auxiliary wide angle curved portion is generally disposed at an outboard upper region of said mirror reflective element relative to the side of the vehicle.

43. The mirror reflective element of claim 42, wherein said exterior rearview mirror assembly comprises a passenger-side exterior rearview mirror assembly.

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

a glass substrate having a front surface and a rear surface;

a principal reflector portion and an auxiliary wide angle curved portion;

wherein said principal reflector portion comprises a principal mirror reflector established at said rear surface of said glass substrate;

wherein said auxiliary wide angle curved portion comprises a curved recess established at a region of said rear surface of said glass substrate by at least one of grinding and ablating;

wherein said auxiliary wide angle curved portion comprises an auxiliary mirror reflector established at said curved recess;

wherein said curved recess has a cross-dimension size that is in the range from about 30 millimeters to about 60 millimeters;

wherein said curved recess comprises a radius of curvature that is in the range from about 200 millimeters to about 800 millimeters;

wherein said curved recess has a maximum recess depth that is in the range from about 0.11 millimeters to about 2.26 millimeters;

wherein said auxiliary wide angle curved portion is inboard of a perimeter edge of said mirror reflective element;

wherein said principal reflector portion of said mirror reflective element surrounds said auxiliary wide angle curved portion of said mirror reflective element;

wherein said glass substrate comprises a curved glass substrate and where the radius of curvature of said curved glass substrate is larger than the radius of curvature of said curved recess; and

wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating, and wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material and wherein said same material substantially coats the entire rear surface of said glass substrate.

45. The mirror reflective element of claim 44, wherein said same material comprises a metal and wherein said same material is deposited via sputtering.

46. The mirror reflective element of claim 44, wherein said same material comprises chromium and wherein said same material is deposited via sputtering.

47. The mirror reflective element of claim 44, wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters and wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at the side of a vehicle, said auxiliary wide angle curved portion is generally disposed at an outboard upper region of said mirror reflective element relative to the side of the vehicle.

48. The mirror reflective element of claim 47, wherein said exterior rearview mirror assembly comprises a passenger-side exterior rearview mirror assembly.

49. The mirror reflective element of claim 44, wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters, and wherein said curved recess has a maximum recess depth that is greater than about 0.5 millimeters and less than about 0.78 millimeters, and wherein said cross-dimension size of said curved recess is greater than 40 millimeters and less than 50 millimeters.

50. The mirror reflective element of claim 49, wherein said curved recess comprises a radius of curvature of about 400 millimeters.

51. The mirror reflective element of claim 49, wherein said curved recess is established at said rear surface of said glass substrate prior to substantially coating the entire rear surface of said glass substrate with said same material.

52. The mirror reflective element of claim 51, wherein said same material comprises a metal.

53. The mirror reflective element of claim 52, wherein said metal is deposited via sputtering.

54. The mirror reflective element of claim 52, wherein said metal comprises chromium.

55. The mirror reflective element of claim 44, wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at the side of a vehicle, said auxiliary wide angle curved portion is generally disposed at an outboard upper region of said mirror reflective element relative to the side of the vehicle.

56. The mirror reflective element of claim 55, wherein said exterior rearview mirror assembly comprises a passenger-side exterior rearview mirror assembly and wherein said curved recess is generally circular-shaped.

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

a glass substrate having a front surface and a rear surface;

a principal reflector portion and an auxiliary wide angle curved portion;

wherein said principal reflector portion comprises a principal mirror reflector established at said rear surface of said glass substrate;

wherein said auxiliary wide angle curved portion comprises a curved recess established at a region of said rear surface of said glass substrate by at least one of grinding and ablating;

wherein said auxiliary wide angle curved portion comprises an auxiliary mirror reflector established at said curved recess;

wherein said curved recess has a cross-dimension size that is in the range from about 40 millimeters to about 50 millimeters;

wherein said curved recess comprises a radius of curvature that is in the range from about 200 millimeters to about 600 millimeters;

wherein said curved recess has a maximum recess depth that is in the range from about 0.5 millimeters to about 0.78 millimeters;

wherein said auxiliary wide angle curved portion is inboard of a perimeter edge of said mirror reflective element;

wherein said principal reflector portion of said mirror reflective element surrounds said auxiliary wide angle curved portion of said mirror reflective element;

wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters;

wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at the side of a vehicle, said auxiliary wide angle curved portion is generally disposed at an outboard upper region of said mirror reflective element relative to the side of the vehicle;

wherein said exterior rearview mirror assembly comprises a passenger-side exterior rearview mirror assembly;

wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element;

wherein said glass substrate comprises a curved glass substrate and where the radius of curvature of said curved glass substrate is larger than the radius of curvature of said curved recess;

wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating, and wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material and wherein said same material substantially coats the entire rear surface of said glass substrate; and

wherein said same material comprises a metal and wherein said metal is deposited via sputtering.

58. The mirror reflective element of claim 57, wherein said curved recess comprises a radius of curvature of about 400 millimeters and wherein said curved recess is generally circular-shaped.

59. The mirror reflective element of claim 58, wherein said metal comprises chromium.

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

a glass substrate having a front surface and a rear surface;

a principal reflector portion and an auxiliary wide angle curved portion;

wherein said principal reflector portion comprises a principal mirror reflector established at said rear surface of said glass substrate;

wherein said auxiliary wide angle curved portion comprises a curved recess established at a region of said rear surface of said glass substrate by at least one of grinding and ablating;

wherein said auxiliary wide angle curved portion comprises an auxiliary mirror reflector established at said curved recess;

wherein said curved recess has a cross-dimension size that is in the range from about 40 millimeters to about 50 millimeters;

wherein said curved recess comprises a radius of curvature that is in the range from about 200 millimeters to about 700 millimeters;

wherein said curved recess has a maximum recess depth that is less than about 1.63 millimeters;

wherein said glass substrate has a thickness between said front surface and said rear surface of less than 3 millimeters;

wherein, when an exterior rearview mirror assembly equipped with said mirror reflective element is normally mounted at the side of a vehicle, said auxiliary wide angle curved portion is generally disposed at an outboard upper region of said mirror reflective element relative to the side of the vehicle;

wherein said mirror reflective element comprises a fixed reflectance non-electro-optic mirror reflective element; and

wherein said principal mirror reflector of said principal reflector portion comprises a principal reflecting coating and wherein said auxiliary mirror reflector of said auxiliary wide angle curved portion comprises a wide angle reflector coating, and wherein said wide angle reflector coating of said auxiliary mirror reflector of said auxiliary wide angle curved portion and said principal reflecting coating of said principal reflector portion comprise the same material and wherein said same material substantially coats the entire rear surface of said glass substrate.

61. The mirror reflective element of claim 60, wherein said exterior rearview mirror assembly comprises a passenger-side exterior rearview mirror assembly and wherein said glass substrate comprises a curved glass substrate and where the radius of curvature of said curved glass substrate is larger than the radius of curvature of said curved recess and wherein said same material comprises a metal.

62. The mirror reflective element of claim 61, wherein said curved recess is generally circular-shaped and wherein said auxiliary wide angle curved portion is inboard of a perimeter edge of said mirror reflective element.

63. The mirror reflective element of claim 62, wherein said principal reflector portion of said mirror reflective element surrounds said auxiliary wide angle curved portion of said mirror reflective element.

64. The mirror reflective element of claim 60, wherein said curved recess has a maximum recess depth that is greater than about 0.5 millimeters and less than about 0.78 millimeters.

65. The mirror reflective element of claim 64, wherein said curved recess comprises a radius of curvature of about 400 millimeters.

66. The mirror reflective element of claim 65, wherein said curved recess is established at said rear surface of said glass substrate prior to substantially coating the entire rear surface of said glass substrate with said same material.

67. The mirror reflective element of claim 66, wherein said same material comprises chromium.

68. The mirror reflective element of claim 66, wherein said same material is established at said rear surface of said glass substrate via sputtering.

69. The mirror reflective element of claim 60, wherein said front surface of said glass substrate comprises a generally planar surface and wherein, other than at said curved recess, said rear surface of said glass substrate comprises a generally planar surface.

70. The mirror reflective element of claim 69, wherein said curved recess has a maximum recess depth that is greater than about 0.5 millimeters and less than about 0.78 millimeters.

71. The mirror reflective element of claim 70, wherein said curved recess comprises a radius of curvature of about 400 millimeters.

72. The mirror reflective element of claim 70, wherein said curved recess is established at said rear surface of said glass substrate prior to substantially coating the entire rear surface of said glass substrate with said same material.

73. The mirror reflective element of claim 72, wherein said same material comprises chromium.

74. The mirror reflective element of claim 72, wherein said same material is established at said rear surface of said glass substrate via sputtering.