Vehicular rearview mirror elements and assemblies incorporating these elements

• US 8,638,488 B2
• Filed: 07/21/2011
• Issued: 01/28/2014
• Est. Priority Date: 09/30/2002
• Status: Expired due to Term

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Tonar, William L, Cammenga, David J, Anderson, John S, Poll, David L, Neuman, George A, Stray, Joel A, Busscher, Bradley L, Ypma, Kenton J
• Primary Examiner(s): TRA, TUYEN Q
• Application Number:
  US13/188,042
• Publication Number:
  US 20110317242A1
• Time in Patent Office: 922 Days
• Field of Search: 359265-275, 359/245, 359/248, 345/105
• US Class Current: 359/267
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/10174 Coatings of a metallic or dielectric material on a constituent layer of glass or polymer
• CPC Class Codes: B32B 17/10321 Laminated safety glass or glazing containing liquid layers
• CPC Class Codes: B32B 17/10513 Electrochromic layer
• 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 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: G02F 1/1533 structural features not otherwise provided for
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells
• CPC Class Codes: G02F 1/163 Operation of electrochromic cells, e.g. electrodeposition cells; Circuit arrangements therefor

Abstract

The present invention relates to improved electro-optic rearview mirror elements and assemblies incorporating the same.

Claims

1. A vehicular rearview assembly having a front and a front peripheral portion, the assembly comprising:

an electrochromic (EC) mirror element defined by first and second substrates that contain electrodes of the EC mirror element and an EC-medium disposed therebetween and bounded by a perimeter seal, a perimeter of the second substrate being concealed behind the first substrate with respect to the front of the assembly;

a housing structure having an aperture corresponding to the front of the assembly and a portion of which is configured to support the EC mirror element;

wherein a first surface of the first substrate that is an outer surface of the EC element corresponds to the front of the assembly;

wherein a second surface of the first substrate that is internal to the EC mirror element contains a ring of spectral filter material established around a perimeter thereof that conceals the perimeter seal from the front of the assembly,

wherein said second surface contains a plurality of electrically-conductive coatings disposed thereon and substantially electrically isolated from one another by at least one area, of the said second surface, that is substantially devoid of electrically-conductive material, and

wherein the front peripheral portion of the assembly has a radius of greater than 2.5 mm.

2. An assembly according to claim 1, wherein said front peripheral portion of the assembly having a radius of greater than 2.5 mm includes a portion of the housing structure having a radius of greater than 2.5 mm.

3. An assembly according to claim 2, wherein a portion of the housing structure is configured to extend towards the front of the assembly from the second substrate beyond the second surface and to keep the first surface unobstructingly observable from the front of the assembly.

4. An assembly according to claim 1, wherein the second substrate has a third surface that is internal to the EC mirror element, and wherein said third substrate carries a transflective stack of thin-film coatings disposed thereon.

5. An assembly according to claim 4, wherein an electrically-conductive layer of said transflective stack is electrically extended over an edge of the second substrate to the fourth surface through a conductive section.

6. An assembly according to claim 1, wherein the second surface includes an electrically-conductive coating comprising a sequence of a first transparent oxide layer, at least one metal layer, and a second transparent oxide layer.

7. An assembly according to claim 1, further comprising at least one auxiliary device and an operator interface element disposed at the front of the assembly and configured to coordinate operation of the at least one auxiliary device.

8. An assembly according to claim 1,

wherein the EC element contains a curable plug material positioned between the first and second substrates,

wherein the second substrate has a third surface that is internal to the EC element and a fourth surface opposite to the third surface, the third surface having a reflecting thin-film stack disposed thereon under the perimeter seal and extending outboard from the center of the third surface, and

wherein at least one of said perimeter seal and said curable plug material is observable when viewed from the fourth surface.

9. An assembly according to claim 1, further comprising at least one device selected from the group consisting of a light source positioned to project light from the second substrate through the first substrate, an interior illumination assembly, a digital voice processing system, a power supply, a global positioning system, an exterior light control, a moisture sensor, an information display, a light sensor, a blind spot indicator, a turning signal indicator, an approach warning, an operator interface, a compass, a temperature indicator, a voice actuated device, a microphone, a dimming circuitry, a GPS device, a telecommunication system, a navigation aid, a lane departure warning system, an adaptive cruise control, a vision system, a rear vision system and a tunnel detection system.

10. A vehicular rearview mirror assembly having a front and comprising:

an electrochromic (EC) mirror element including

a first substantially transparent substrate having first and second surfaces;

a second substrate having third and fourth surfaces and an edge surface adjoining the third and fourth surfaces, the first and second substrates being sealed together in a spaced-apart relationship by a primary seal material circumferentially disposed between the second and third surfaces such as to form a chamber therebetween;

a first thin-film stack deposited on the second surface and containing an opaque optical thin-film ring disposed around a perimeter of the second surface;

a second thin-film stack covering at least a central portion of the third surface, the second thin-film stack being transflective and including a least one electrically conductive layer that is electrically extended over the edge surface to the fourth surface through a conductive section;

an EC medium in said chamber, and

wherein the first surface corresponds to the front of the assembly,

wherein the first and second substrate are disposed such that a perimeter of the second substrate is concealed behind the first substrate with respect to the front of the assembly,

wherein said optical thin-film ring conceals the primary seal from being observable from the front;

wherein an edge of the front of the assembly has a radius of greater than 2.5 mm, and

wherein reflectance of the EC-mirror element varies between a minimum value and a maximum value as a function of voltage applied to the EC medium.

11. An assembly according to claim 10, further comprising at least one device selected from the group consisting of a light source positioned to project light from the second substrate through the first substrate, an interior illumination assembly, a digital voice processing system, a power supply, a global positioning system, an exterior light control, a moisture sensor, an information display, a light sensor, a blind spot indicator, a turning signal indicator, an approach warning, an operator interface, a compass, a temperature indicator, a voice actuated device, a microphone, a dimming circuitry, a GPS device, a telecommunication system, a navigation aid, a lane departure warning system, an adaptive cruise control, a vision system, a rear vision system and a tunnel detection system.

12. An assembly according to claim 10, wherein the first thin-film stack includes first and second electrically-conductive coatings disposed adjacent to one another and separated by an area that is devoid of electrically-conductive material and that electrically isolates the first and second electrically-conductive coatings from one another.

13. An assembly according to claim 10, wherein a difference between intensity of ambient light reflected from a portion of the EC-mirror element defined by said optical thin-film ring and intensity of ambient light reflected from inside said portion of the EC-mirror element is less than 10 percent.