Automotive rearview mirror with capacitive switches

• US 9,134,585 B2
• Filed: 07/07/2011
• Issued: 09/15/2015
• Est. Priority Date: 09/30/2002
• Status: Active Grant

• Current Assignee: Gentex Corporation
• Original Assignee: Gentex Corporation
• Inventors: Tonar, William L., Bugno, Mark D., Roth, Mark R., Cammenga, David J., Minikey, Danny L. Jr., Stray, Joel A., Neuman, George A.
• Primary Examiner(s): TRA, TUYEN Q
• Application Number:
  US13/395,069
• Publication Number:
  US 20130170013A1
• Time in Patent Office: 1,531 Days
• Field of Search: 359265-275, 359/843, 359/862, 359/871, 345/105, 362/135, 362/494
• US Class Current: 1/1
• CPC Class Codes: B23K 2103/00 Materials to be soldered, welded or cut
• CPC Class Codes: B23K 2103/50 Inorganic material, e.g. metals, not provided for in B23K2103/02 – B23K2103/26
• CPC Class Codes: B23K 26/362 Laser etching
• CPC Class Codes: B23K 26/402 involving non-metallic material, e.g. isolators
• 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 1/157 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

A vehicular rearview assembly that has a rounded outer perimeter edge to satisfy safety standards and contains an EC element having a complex peripheral ring, a front surface that is fully observable from the front of the assembly, and a user interface with switches and sensors that activate and configure, in cooperation with electronic circuitry of the assembly, pre-defined function(s) or device(s) of the assembly in response to the user input applied to the user interface. A complex peripheral ring may include multiple bands the structures of which is adapted to provide for specified optical characteristics of light, reflected off of the ring. Electrical communications between the electronic circuitry, the mirror element, and the user interface utilize connectors configured to exert a low contact force, onto the mirror element, limited in part by the strength of adhesive affixing the EC element to an element of the housing of the assembly.

Claims

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

an electrochromic (EC) element including

a first glass substrate having first and second surfaces, the first surface configured as an outer surface of the EC element and corresponding to the front of the assembly, wherein the first substrate includes an annular peripheral region having a radius of at least 2.5mm, the second surface carrying a transparent electrically-conductive layer thereon;

a second glass substrate having third and fourth surfaces, the third surface carrying a reflective-and-electrically-conductive layer thereon, and wherein the first and second substrates are disposed in a spaced-apart and parallel relationship with the second and third surfaces facing each other and an EC medium disposed therebetween and bounded by the perimeter seal;

at least one electrical contact portion in electrical communication with one of the transparent electrically-conductive layer and the reflective-and-electrically-conductive layer,

a mounting element adapted to support the EC element, the mounting element having an extended portion that is juxtaposed with the EC element and a passageway allowing an electrical link therethrough;

an adhesive element disposed between the EC element and the mounting element to adhere the EC element to the mounting element with a bond strength;

a housing shell configured to mechanically engage the mounting element;

electronic circuitry disposed behind the mounting element and inside the housing shell, the electric circuitry at least in part providing power to operate the EC element; and

a first electrical connector having first and second electrical contact portions, wherein the first electrical contact portion is in contact with the at least one electrical contact portion of the EC element and the second electrical contact portion is in contact with a contact portion on the electronic circuitry, wherein the electrical connector is at least partially disposed in the mounting element opening, wherein the electrical portion of the first electrical connector that is in contact with the at least one electrical contact portion of the EC element provides a force that (1) is sufficient to maintain said contact between the electrical portion of the first electrical connector and the at least one electrical contact portion of the EC element and (2) is less than the bond strength adhering the EC element to the mounting element.

2. An assembly according to claim 1, wherein the second surface carries a peripheral ring established around a perimeter thereof and configured to conceal a perimeter seal.

3. An assembly according to claim 1, wherein said first electrical connector is pre-molded into the mounting element.

4. An assembly according to claim 1, wherein the contact between the first electrical connector and one of the at least one electrical contact of the EC element and the electrical contact of the electronic circuitry comprises a solderless interfacial contact.

5. An assembly according to claim 3, wherein said electrical connector is an elastically-deformable electrical connector is configured to generate, in response to a deflection of said elastically-deformable electrical connector, a mechanical stress that is below the yield point of a material of said elastically-deformable electrical connector.

6. An assembly according to claim 5, wherein said elastically-deformable electrical connector includes a two-sided cantilever having spring leaves and configured to establish opposite contact force vectors when deflected, and wherein the width of spring leaves linearly varies between upper and lower values.

7. An assembly according to claim 1, wherein said EC element further comprises an additional electrical contact that is in electrical communication with the other of the transparent electrically-conductive layer and the reflective-and-electrically-conductive layer;

the electronic circuitry further comprises an additional contact portion; and

wherein said vehicular rearview assembly comprises a second electrical connector having two contact portions, wherein the second electrical connector is in contact with the additional contact of the EC element and the additional contact portion of the electronic circuitry.

8. An assembly according to claim 7, wherein the combined force of both of said first and second electrical connectors is less than 5 N.

9. An assembly according to claim 8, wherein the combined force of both of said first and second electrical connectors is less than 2 N.

10. An assembly according to claim 7, wherein the combined force of both of said first and second electrical connectors is less than 150 grams per square inch.

11. An assembly according to claim 10, wherein the force provided by the first electrical connector is greater than 0.2 N.

12. An assembly according to claim 11, wherein the force provided by the first electrical connector is greater than 0.5 N.

13. An assembly according to claim 12, wherein the force provided by the first electrical connector is greater than 1N.

14. An assembly according to claim 1, wherein said mounting element further includes a perimeter lip extending from the extended portion from behind the second substrate towards the first substrate so as to conceal an edge surface of the second substrate from view.

15. A vehicular rearview assembly having a front, the assembly comprising:

an electrochromic (EC) element including

a first glass substrate having first and second surfaces, the first surface configured as an outer surface of the EC element and corresponding to the front of the assembly, the second surface carrying a transparent electrically-conductive layer thereon;

a second glass substrate having third and fourth surfaces, the third surface carrying a reflective-and-electrically-conductive layer thereon, and wherein the first and second substrates are disposed in a spaced-apart and parallel relationship with the second and third surfaces facing each other and an EC medium disposed therebetween and bounded by the perimeter seal;

at least one electrical contact in electrical communication with one of the transparent electrically-conductive layer and the reflective-and-electrically-conductive layer,

a mounting element adapted to support the EC element, the mounting element having an extended portion that is juxtaposed with the EC element and a passageway allowing an electrical link therethrough, and wherein the mounting element further includes a side portion cooperating with the extended portion along a periphery thereof and protruding from behind the second substrate towards the first substrate when the EC element is supported by the mounting element, and wherein a front peripheral region of the side portion does not engage the first surface of the EC element and has a radius of curvature of at least 2.5 mm;

an adhesive element disposed between the EC element and the mounting element to adhere the EC element to the mounting element with a bond strength;

a housing shell configured to mechanically engage the mounting element;

electronic circuitry disposed behind the mounting element and inside the housing shell, the electric circuitry at least in part providing power to operate the EC element; and

a first electrical connector having first and second electrical contact portions, wherein the first electrical contact portion is in contact with the at least one electrical contact of the EC element and the second electrical contact portion is in contact with a contact portion on the electronic circuitry, wherein the portion of the first electrical connector that is in contact with the at least one electrical contact of the EC element provides a force that (1) is sufficient to maintain said contact between the electrical portion of the first electrical connector and the at least one electrical contact portion of the EC element and (2) is less than the bond strength adhering the EC element to the mounting element.

16. An assembly according to claim 15, wherein the second surface carries a peripheral ring established around a perimeter thereof and configured to conceal a perimeter seal.

17. An assembly according to claim 15, wherein said first electrical connector is pre-molded into the mounting element.

18. An assembly according to claim 15, wherein the contact between the first electrical connector and one of the at least one electrical contact of the EC element and the electrical contact of the electronic circuitry comprises a solderless interfacial contact.

19. An assembly according to claim 18, wherein said first electrical connector is an elastically-deformable electrical connector configured to generate, in response to a deflection of said elastically-deformable electrical connector, a mechanical stress that is below the yield point of a material of said elastically-deformable electrical connector.

20. An assembly according to claim 19, wherein said elastically-deformable electrical connector includes a two-sided cantilever having spring leaves and configured to establish opposite contact force vectors when deflected, and wherein the width of spring leaves linearly varies between upper and lower values.

21. An assembly according to claim 15, wherein said EC element further comprises an additional electrical contact that is in electrical communication with the other of the transparent electrically-conductive layer and the reflective-and-electrically-conductive layer;

the electronic circuitry further comprises an additional contact portion; and

wherein said vehicular rearview assembly comprises a second electrical connector having two contact portions, wherein the second electrical connector is in contact with the additional contact of the EC element and the additional contact portion of the electronic circuitry.

22. An assembly according to claim 21, wherein the combined force of both of said first and second electrical connectors is less than 5 N.

23. An assembly according to claim 22, wherein the combined force of both of said first and second electrical connectors is less than 2 N.

24. An assembly according to claim 23, wherein the combined force of both of said first and second electrical connectors is less than 150 grams per square inch.

25. An assembly according to claim 23, wherein the force provided by the first electrical connector is greater than 1 N.

26. An assembly according to claim 22, wherein the force provided by the first electrical connector is greater than 0.5 N.

27. An assembly according to claim 21, wherein the force provided by the first electrical connector is greater than 0.2 N.

28. An assembly according to claim 15, wherein said side portion of said mounting element conceals an edge surface of the second substrate from view.

29. A vehicular rearview assembly having a front and, the assembly comprising:

an electrochromic (EC) element including

a first glass substrate having first and second surfaces, the first surface configured as an outer surface of the EC element and corresponding to the front of the assembly, the second surface carrying a transparent electrically-conductive layer thereon;

a second glass substrate having third and fourth surfaces, the third surface carrying a reflective-and-electrically-conductive layer thereon, and wherein the first and second substrates are disposed in a spaced-apart and parallel relationship with the second and third surfaces facing each other and an EC medium disposed therebetween and bounded by the perimeter seal;

wherein the peripheral edges of first and second glass substrates define a curved profile with a radius of curvature of at least 2.5 mm; and

at least one electrical contact in electrical communication with one of the transparent electrically-conductive layer and the reflective-and-electrically-conductive layer,

a mounting element adapted to support the EC element, the mounting element having an extended portion that is juxtaposed with the EC element and a passageway allowing an electrical link therethrough;

an adhesive element disposed between the EC element and the mounting element to adhere the EC element to the mounting element with a bond strength;

a housing shell configured to mechanically engage the mounting element;

electronic circuitry disposed behind the mounting element and inside the housing shell, the electric circuitry at least in part providing power to operate the EC element; and

a first electrical connector having first and second electrical contact portions, wherein the first electrical contact portion is in contact with the at least one electrical contact of the EC element and the second contact portion is in contact with a contact portion on the electronic circuitry, wherein the first electrical connector is at least partially disposed in the opening of the mounting element, wherein the portion of the electrical connector that is in contact with the EC element provides a force that (1) is sufficient to maintain said contact between the electrical portion of the first electrical connector and the at least one electrical contact portion of the EC element and (2) is less than the bond strength adhering the EC element to the mounting element.

30. An assembly according to claim 29, wherein the second surface carries a peripheral ring established around a perimeter thereof and configured to conceal a perimeter seal.

31. An assembly according to claim 29, wherein said electrical connector is pre-molded into the mounting element.

32. An assembly according to claim 29, wherein the contact between the first electrical connector and one of the at least one electrical contact of the EC element and the electrical contact of the electronic circuitry comprises a solderless interfacial contact.

33. An assembly according to claim 32, wherein said first electrical connector is an elastically-deformable electrical connector configured to generate, in response to a deflection of said elastically-deformable electrical connector, a mechanical stress that is below the yield point of a material of said elastically-deformable electrical connector.

34. An assembly according to claim 33, wherein said elastically-deformable electrical connector includes a two-sided cantilever having spring leaves and configured to establish opposite contact force vectors when deflected, and wherein the width of spring leaves linearly varies between upper and lower values.

35. An assembly according to claim 29, wherein said EC element further comprises an additional electrical contact that is in electrical communication with the other of the transparent electrically-conductive layer and the reflective-and-electrically-conductive layer;

the electronic circuitry further comprises an additional contact portion; and

wherein said vehicular rearview assembly comprises a second electrical connector having two contact portions, wherein the second electrical connector is in contact with the additional contact of the EC element and the additional contact portion of the electronic circuitry.

36. An assembly according to claim 35, wherein the combined force of both of said first and second electrical connectors is less than 5 N.

37. An assembly according to claim 36, wherein the combined force of both of said first and second electrical connectors is less than 2 N.

38. An assembly according to claim 37, wherein the combined force of both of said first and second electrical connectors is less than 150 grams per square inch.

39. An assembly according to claim 37, wherein the force provided by the first electrical connector is greater than 1N.

40. An assembly according to claim 36, wherein the force provided by the first electrical connector is greater than 0.5 N.

41. An assembly according to claim 35, wherein the force provided by the first electrical connector is greater than 0.2 N.