Exterior mirror reflector sub-assembly with auxiliary reflector portion

  • US 9,102,279 B2
  • Filed: 01/26/2015
  • Issued: 08/11/2015
  • Est. Priority Date: 05/23/2007
  • Status: Active Grant
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First Claim
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1. A mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said mirror reflector sub-assembly comprising:

  • a mirror reflective element;

    said mirror reflective element comprising a glass substrate having a first surface and a second surface;

    wherein said mirror reflective element has a principal reflector portion and an auxiliary reflector portion;

    wherein said principal reflector portion of said mirror reflective element has a first radius of curvature;

    wherein said auxiliary reflector portion of said mirror reflective element comprises a curved recess established at said second surface of said glass substrate by physical removal of glass from a portion of said glass substrate so as to create a dish-shaped depression;

    wherein said curved recess of said auxiliary reflector portion of said mirror reflective element has a second radius of curvature;

    wherein said second radius of curvature is smaller than said first radius of curvature;

    wherein said curved recess has a cross-dimension size that is less than about 80 millimeters;

    wherein said curved recess has a maximum recess depth that is less than about 2.26 millimeters;

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

    wherein said second radius of curvature of said curved recess comprises a radius of curvature that is less than about 1,000 millimeters;

    wherein a reflector is established at said curved recess;

    wherein said reflector comprises at least one of (i) a metal and (ii) chromium;

    wherein a principal mirror reflector is established at said principal reflector portion;

    wherein said principal mirror reflector comprises at least one of (i) a metal and (ii) chromium;

    wherein said principal mirror reflector of said principal reflector portion is established at said second surface of said glass substrate via vacuum deposition and wherein said reflector is established at said curved recess via vacuum deposition;

    wherein said mirror reflective element is supported at a side of a mirror back plate and wherein an opposing side of said mirror back plate is adapted for attaching said mirror back plate to a mirror actuator of an exterior rearview mirror assembly equipped with said mirror reflector sub-assembly;

    wherein said mirror back plate comprises a plastic molding formed by at least one of (i) injection molding and (ii) co-injection molding;

    wherein a heater pad is disposed at said second surface of said glass substrate between said mirror reflective element and said mirror back plate;

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

    wherein said principal mirror reflector is established at said second surface of said glass substrate.

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