Method of forming an exterior mirror reflector sub-assembly with auxiliary reflector portion

  • US 9,315,155 B2
  • Filed: 08/10/2015
  • Issued: 04/19/2016
  • Est. Priority Date: 05/23/2007
  • Status: Active Grant
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First Claim
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1. A method of forming a mirror reflector sub-assembly suitable for use in an exterior rearview mirror assembly of a vehicle, said method comprising the steps of:

  • providing a glass substrate, said glass substrate having a first surface and a second surface, said glass substrate having a thickness between said first surface and said second surface of less than 3 millimeters;

    physically removing glass from a portion of the second surface of said glass substrate to form a curved recess locally thereat, said curved recess having a maximum recess depth that is less than about 2.26 millimeters and a cross-dimension size that is less than about 80 millimeters, said curved recess comprising a radius of curvature that is less than about 1,000 millimeters;

    coating via a vacuum deposition process the second surface of said glass substrate with a mirror reflector to form a mirror reflective element suitable for use in an automotive exterior rearview mirror assembly, said mirror reflector comprising at least one mirror-reflecting metal thin film layer;

    wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, the first surface of said glass substrate is closer than said coated second surface to a side of a vehicle to which the automotive exterior rearview mirror assembly is attached;

    wherein, when said mirror reflective element is used in an automotive exterior rearview mirror assembly, said mirror reflective element provides a principal reflector portion and an auxiliary reflector portion to a driver of the vehicle who views said mirror reflective element when normally operating the vehicle;

    forming a mirror back plate in a plastic molding operation;

    said mirror plate having a first side and an opposing second side;

    wherein said plastic molding operation establishes at said second side of said mirror back plate structure for attaching said mirror back plate to a mirror actuator;

    said plastic molding operation comprising injection molding;

    providing a heater pad; and

    disposing said heater pad between said coated second surface of said glass substrate and said first side of said mirror back plate.

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