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

  • US 9,499,102 B2
  • Filed: 04/18/2016
  • Issued: 11/22/2016
  • 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, 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 back 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;

    said heater pad having a first surface and an opposing second surface;

    said heater pad comprising a first adhesive layer disposed at said first surface of said heater pad;

    said first adhesive layer comprising a pressure sensitive adhesive;

    said heater pad comprising a second adhesive layer disposed at said second surface of said heater pad;

    said second adhesive layer comprising a pressure sensitive adhesive;

    disposing said heater pad between said coated second surface of said glass substrate and said first side of said mirror back plate, with said first surface of said heater pad facing said first side of said mirror back plate and with said second surface of said heater pad facing said coated second surface of said glass substrate;

    adhering said heater pad to said coated second surface of said glass substrate via said second adhesive layer; and

    adhering said heater pad to said first side of said mirror back plate via said first adhesive layer.

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