Patent Application
20230251406
The present application claims priority to U.S. Provisional Pat. Application US 63/039,426 filed Jul. 15, 2020, herein incorporated by reference in its entirety.
The present disclosure relates generally to mirrors used in transportation, such as a side-view mirror or a rear-view mirror for a vehicle. The article is more specifically designed to lighten or darken using photochromic or hybrid photochromic/electrochromic or thermal reversion technology.
A key safety aspect in the operation of automotive vehicles is the capability of the rear- and side-view mirrors to enhance the field of view of the vehicle’s operator. This capability can be significantly impaired upon the introduction of glare, a term used herein as a property caused by either sunshine in the daytime or a headlight of another vehicle at nighttime. Glare can result in difficulty in seeing clearly in the mirror due to the bright light of direct or reflected sunlight, or headlights of other vehicles, and is caused by a significant difference in light coming from what is being looked at (e.g., other vehicles) and the source of the glare.
Many automotive mirrors employ some type of anti-glare technology in order to improve visibility. Older mirrors employ a mechanical technology that adjusts the angle of the mirror such that the amount of reflected light is much reduced. Materials that can dynamically adjust the amount of light passing through them can also be used to make rear-view mirrors. Electrochromic mirrors, for example those made by Gentex Corporation of Zeeland, Ml, are well known in the art (e.g., patent no. US4443057).
Another example of using dynamic optical filters to deal with glare is the utilization of photochromic materials. US5373392 describes a “Photochromic Light Control Mirror” in which a photochromic material similar to those used in eyeglasses (e.g., US5274132 and US5369158) is darkened using a fluorescent UV light source. Like the eyewear technology, these photochromic switching materials rely on a thermal back reaction to drive the transition back to the light state. The thermal back reaction occurs naturally during normal operating temperatures of the mirror. However, the rate of the thermal back reaction and the extent of the reaction is affected by the temperature experienced by the mirror. As a result, the dark state achieved and the rate of switching of such existing photochromic technologies is significantly dependent on temperature. In colder temperatures, the photostationary state of the photochromic media will shift such that the mirror will become much darker due to a slower thermal back reaction, possibly too dark for effective use. Conversely, in warmer temperatures, the photostationary state of the photochromic media will shift such that the mirror will become less dark due to a faster thermal back reaction, possibly too light for effective use, a disadvantage that would be apparent in the low reflectivity state or night mode.
Another issue that arises is that some of these technologies are controlled by a continuous light source, as in US20050270614A1. In other words, a light source emitting a specific wavelength needs to be on continuously to darken the photochromic material and to keep it dark, increasing the overall power consumption. A resulting problem then also arises of dissipating the heat generated from this continuous light source, as this heat will increase the degradation rate and further alter the photostationary state of the photochromic material.
In another aspect, the invention relates to dynamic mirror assemblies that can vary the amount of light reflected. According to the invention, the dynamic mirrors include a mirror, and a switching material, placed between the mirror and a viewer, having a dark state and a light state, that switches state in at least one direction due to a photochromic reaction, and that switches in the other direction due to one or more of a photochromic reaction or an electrochromic reaction or a thermal reversion above a threshold temperature.
Further aspects of the invention are as disclosed and claimed herein.
These and other features will become more apparent from the following description in which reference is made to the appended drawings. The figures are for illustrative purposes, and unless indicated otherwise, may not show relative proportion or scale.
The current invention relates in various aspects to dynamic mirrors such as rear-view and side view mirrors for vehicles, and in particular automobiles, that have variable reflectivity. That is, the amount of light that the mirrors reflect can be varied depending on the situation, for example to reduce glare from headlights on following cars at nighttime. The mirror may comprise a switching material comprising for example a photochromic or photochromic/electrochromic material that can be selectively lightened or darkened, thereby causing the mirror to reflect more or less light either through user control or through an automatic system based on time and/or geographic position and/or sensor input.
In one aspect, then, the invention relates to dynamic mirror assemblies that can vary the amount of light reflected, that include a mirror and a switching material. The switching material is placed between the mirror and a viewer, has a dark state and a light state, and switches state in at least one direction due to a photochromic reaction, and switches in the other direction due to one or more of a photochromic reaction or an electrochromic reaction.
In one aspect, the mirror is highly reflective in the visible light region and highly transmissive in the ultraviolet region. In one aspect the mirror may be a reciprocal mirror that appears reflective on one side and transparent on the other.
In an aspect, the switching material comprises a chromophore that switches state in at least one direction due to a photochromic reaction, and that switches in the other direction due to one or more of a photochromic reaction or an electrochromic reaction.
In another aspect, the switching material may further comprise a polymer such as polyvinyl butyral. In yet another aspect, the mirror may comprise one or more of gold, chromium, aluminum, or silver, sputtered onto a transparent substrate.
In a further aspect, the mirror may comprise a multilayered dielectric material having alternating layers of high and low refractive index materials.
In yet another aspect, the chromophore used may switch via a photochromic reaction to the dark state when excited by light of one wavelength range, and switch via a photochromic reaction to the light state when excited by light of a different wavelength range.
In a further aspect, the dynamic mirror assemblies of the invention may further comprise light-emitting diodes, on a side of the mirror opposite the switching material, that emit at a fixed wavelength range to drive one of the state changes. In yet another aspect, the light-emitting diodes may drive the switching material from the light state to the dark state. In a further aspect, light-emitting diodes may be used that have a fixed wavelength that is from about 350 nm to about 410 nm and serves to darken the switching material. In yet another aspect, the dynamic mirror assemblies may include additional light-emitting diodes that emit light within a wavelength range from 450 nm to 800 nm to lighten the switching material.
According to the invention, the dynamic mirror assemblies may further comprise a filter, between the switching material and sunlight, such that filtered sunlight transitions the switching material from the dark state to the light state.
In another aspect, the switching material may comprise a photochromic-electrochromic material, and the switching material may darken in response to light and lighten in response to electricity. In yet another aspect, the switching material may comprise a photochromic-electrochromic material, and the switching material darken in response to light and lighten in response to electricity. According to aspects of the invention, the photochromic-electrochromic material may comprise one or more chromophores.
In other aspects, the switching material may be either a photochromic or a photochromic-electrochromic switching material, and may comprise a P-Type photochromic material.
In one aspect of the dynamic mirror assemblies of the invention, the dark state of the switching material does not spontaneously revert to the light state upon removal of a light source over a temperature range from -20° C. to 50° C., or over a temperature range from -30° C. to 60° C., or over a temperature range from -40° C. to 70° C. In another aspect, the dynamic mirror assembly has a day mode and a night mode, and the mirror assembly is in a high reflectance state during the day mode and in a low reflectance state during the night mode.
In one aspect, the dynamic mirror assemblies of the invention may comprise a controller that controls whether the mirror should be in day mode or night mode based on one or more of a clock, a light sensor, or a GPS signal. In another aspect, the dynamic mirror assemblies of the invention may further include a controller that can place the mirror in intermediate states between the dark state and the light state according to manual input, or automatically based on one or more of a clock, a light sensor, or a GPS signal.
In another aspect, the invention relates to a dynamic mirror assembly that can vary the amount of light reflected, that includes a mirror, and a switching material. The switching material is placed between the mirror and a viewer, has a dark state and a light state, and switches state in at least one direction due to a photochromic reaction, and that switches in the other direction due to one or more of a photochromic reaction, or an electrochromic reaction, or a thermal reversion above a threshold temperature.
In aspects, the switching material switches in the other direction due only to a photochromic reaction, due only to an electrochromic reaction, or due to both a photochromic reaction and an electrochromic reaction.
In another aspect, the switching material switches in the other direction due only to thermal reversion above the threshold temperature.
In an aspect, the mirror is highly reflective in the visible light region and highly transmissive in the ultraviolet region.
In another aspect, the mirror is a reciprocal mirror that appears reflective on one side and transparent on the other.
In a further aspect, the switching material comprises a chromophore that switches state in at least one direction due to a photochromic reaction, and that switches in the other direction due to one or more of a photochromic reaction or an electrochromic reaction or a thermal reversion above a threshold temperature.
In one aspect, the switching material further comprises polyvinyl butyral.
In an aspect, the mirror may comprise one or more of gold, chromium, aluminum, or silver sputtered onto a transparent substrate. In another aspect, the mirror may comprise a multilayered dielectric material having alternating layers of high and low refractive index materials.
In an aspect, the chromophore switches via a photochromic reaction to the dark state when excited by light of one wavelength range, and switches via a photochromic reaction to the light state when excited by light of a different wavelength range.
According to the invention, the dynamic mirror assembly may further comprise light-emitting diodes, on a side of the mirror opposite the switching material, that emit at a fixed wavelength range to drive one of the state changes. In an aspect, the light-emitting diodes may drive the switching material from the light state to the dark state. In another aspect, the fixed wavelength is from about 350 nm to about 410 nm and serves to darken the switching material.
In one aspect, the dynamic mirror assembly of the invention may further comprise additional light-emitting diodes that emit light within a wavelength range from 450 nm to 800 nm to lighten the switching material. In another aspect, the dynamic mirror assemblies of the invention may further comprise a filter, between the switching material and sunlight, such that filtered sunlight transitions the switching material from the dark state to the light state.
In one aspect, the switching material comprises a photochromic-electrochromic material, and the switching material darkens in response to sunlight and lightens in response to electricity. In another aspect, the switching material comprises a photochromic-electrochromic material, and the switching material darkens in response to light and lightens in response to electricity. In yet another aspect, the switching material comprises a P-Type photochromic material.
In yet another aspect, the switching material may comprise a photochromic material that switches to the light state photochromically and switches to the dark state due to thermal reversion above the threshold temperature. In a further aspect, the switching material comprises a photochromic material that switches to the dark state photochromically and switches to the light state due to thermal reversion above the threshold temperature.
In various aspects the threshold temperature useful according to the invention is at least 50° C., or at least 60° C., or at least 70° C.
In an aspect, the dark state of the switching material does not spontaneously revert to the light state upon removal of a light source over a temperature range from -20° C. to 50° C., or over a temperature range from -30° C. to 60° C., or over a temperature range from -40° C. to 70° C.
In an aspect, the dynamic mirror assembly of the invention has a day mode and a night mode, and the dynamic mirror assembly is in a high reflectance state during the day mode and in a low reflectance state during the night mode.
In one aspect, the dynamic mirror assembly of the invention comprises a controller that controls whether the dynamic mirror assembly should be in day mode or night mode based on one or more of a clock, a light sensor, or a GPS signal. In another aspect, the dynamic mirror assembly of the invention comprises a controller that can place the dynamic mirror assembly in intermediate states between the dark state and the light state according to manual input, or automatically based on one or more of a clock, a light sensor, or a GPS signal.
In one aspect, the switching material switches state in at least one direction due to a photochromic reaction, and switches in the other direction due to thermal reversion, and the threshold temperature is higher than the regular operational temperature range of the dynamic mirror. In another aspect, the dynamic mirror assembly of the invention may further comprise a heating element that drives the switching material in the other direction due to the thermal reaction that occurs.
In yet another aspect, the switching material comprises a chromophore that darkens due to a photochromic reaction and lightens due to thermal reversion that occurs above the threshold temperature. In further aspects, the threshold temperature is greater than 60° C., or greater than 70° C., or greater than 80° C., or greater than 90° C.
When we say that the dynamic mirror assemblies of the invention have a switching material that has a dark state and a light state, we refer to two relative states, the dark state being one in which the amount of light transmitted is lower than the amount of light transmitted in the light state. Relative intermediate states between the light state and the dark state are possible and desirable, and each intermediate state will be understood to be lighter or darker than another state. Because the switching material is placed between the mirror and a viewer, the dark state will cause the assembly to reflect less light from the mirror than will the light state.
When we refer to a photochromic reaction, we mean one that lightens or darkens a material when exposed to light, thus affecting the dark or light state of the material. When we refer to an electrochromic reaction, we mean one that lightens or darkens a material when exposed to an electrical current, thus affecting the dark or light state of the material. When we refer to a thermal reversion above a threshold temperature, we mean a reversion to a more thermodynamically-stable state above a threshold temperature that serves to lighten or darken a material when exposed to temperatures above the threshold temperature, thus affecting the dark or light state of the material. When we say that the switching material, having a dark state and a light state, switches state in one direction or another, we mean that it changes from a light state to a dark state, or from a dark state to a light state, in relative terms, as already described.
The switching material will be understood to typically comprise at least one chromophore, and may comprise more than one chromophore. The chromophore may, for example, be a P-type chromophore that is bistable, meaning that once the chromophore is in the dark state, it will stay in that state until subjected to a stimulus to transition them away from that state. Examples of possible stimuli that can be used to transition the chromophore from one state to another include light of an appropriate wavelength, electricity of an appropriate voltage, or, for thermal reversion an amount of heat required to raise the temperature of the system above a threshold temperature.
The present invention provides, in part, a vehicle mirror that comprises photochromic switching materials which, upon subjection to a light source, will darken in response to said light source, minimizing the transmission of light to the operator of the vehicle.
The mirror may function in two modes: the first, “night mode”, will ensure the mirror reflects a lower percentage of incident light, to reduce any glare to the vehicle operator that may be associated with any following vehicles. The second, “day mode”, will allow the mirror to reflect a higher percentage of incident light.
An optional third mode will encompass aspects of the first and second modes, in that it is able to rapidly dim or lighten in response to changing environments (e.g. introduction of a need for low transmission, such as entering a tunnel while driving during the day).
In another aspect, the vehicle mirror may be self-dimming or self-lightening, in that a control mechanism will automatically respond to changes in ambient light conditions.
In another aspect, the self-dimming mirror is capable of achieving intermediate states in between the day and night modes. Intermediate states may be set by the user, or based on light sensors and on time of day.
In another aspect, the self-dimming mirror may include an auto reset from “night mode” to “day mode” when the vehicle is parked at night or when a driver enters the vehicle during the day.
In another aspect, the self-dimming mechanism of the mirror may be achieved by the use of a light-emitting diode (LED) light source. This light source may include LEDs that emit a range of wavelengths, for example, of less than 300 nm, between 300 - 700 nm, or greater than 700 nm, or a combination of the aforementioned ranges. In a related aspect, one range of wavelengths may be used to drive the photochromic material of the mirror to a darkened state, while another range of wavelengths may be used to lighten the material.
In another related aspect, the photochromic material may also be electrochromic, and one reaction (for example, the photochromic mechanism) may be used to darken the material while the other reaction (for example, the electrochromic mechanism) may be used to lighten the material. The photochromic mechanism may be achieved by subjecting the material to an LED light source, while the electrochromic mechanism may be induced by the application of an electric voltage.
In another aspect, the photochromic material may transition from the dark state / low reflectance state to the light state / high reflectance state above a certain temperature threshold, wherein the photochromic mechanism may be used to darken the material while the thermal lightening mechanism may be used to lighten the material. The thermal lightening reaction would occur above a threshold temperature that is above the normal operating temperature range of the mirror. Referring to
This light-emitting diode (“LED”) light array 103 may be a light guide panel with edge-lit LEDs. It may have a reflective backing to direct more light from the LED towards adhesive layer 105. It may be glass, for example, or plastic or silicone, specifically liquid-injection-molded silicone. It is ideally highly transmissive in the UV range. It may have a light diffuser on the side closer to the adhesive layer 105. It should ideally withstand exposure to UV light. There may be optional filters provided, that block visible light configured between the LEDs and the light guide panel, to filter out low levels of visible light emitted (bleed into the visible region) by the UV LEDs. Also, the filter may optionally be configured between the LED array 103 and the mirror 104.
A mirror 104, is attached to the LED array 103. Mirror 104 should have high reflectivity in the visible light region of the electromagnetic spectrum and high transmission in the UV region of the electromagnetic spectrum. Mirror 104 may be a half-silvered mirror formed by either sputtering gold, chromium, aluminum or silver onto a glass or transparent surface, or a laminated polyethylene terephthalate (“PET”) film. Mirror 104 may also be a multilayered dielectric coating with alternating layers of high and low refractive index materials of specified layer thicknesses so as to achieve the indicated reflection and transmission properties. Other mirrors as known in the art are possible. Mirror 104 may be curved to form a concave or convex surface. An optional resistive heating element 102 may be adhered between the backing plate 101 and the LED light array 103, or between the LED light array 103 and the glass 104. Adhesive layer 105 comprises a switching material that may contain one or more photochromic dyes and be bonded to outer layer 106.
Layer 105 may comprise one or more layers of polyvinyl butyral (“PVB”), poly(ethylene-vinyl acetate) (“PEVA” or “EVA”), pressure-sensitive adhesive (“PSA”) or any combination of the aforementioned. In one example, this adhesive layer is separated into two parts, the first inner part containing the photochromic dye(s) and the second outer part containing UV-absorbing materials or UV absorber (“UVA”). Layer 105 may also be an adhesive stack formed by laminating a PET film containing the dye, between two layers of adhesive. The outer layer of this adhesive stack may contain a UVA. An outer layer 106 is bonded to layer 105 and may be comprised of either glass or plastic. Outer layer 106 may be labeled or etched with text, or may have patterns to mask functional elements of the embodiment such as edge seals. In another example, outer layer 106 is preferentially comprised of glass, which may be curved, to form a concave or convex mirror, or not curved. Outer layer 106 may also include coatings on either the inside or outside surfaces. Coatings may include UV absorbers that will block 99.5% or more of a UV light source. These coatings may be adhered to either surface of outer layer 106 by sputtering, or they may be flow coated in an organic matrix. Any UV absorber in layer 105 or 106 would adsorb UV light (and/or high energy visible light) that causes a photochromic darkening reaction in some photochromic dyes.
In an embodiment, the layer 105 may comprise a layer-by-layer coating, such as disclosed and claimed in U.S. Pat. No. 9,453,949, the disclosure of which is incorporated herein by reference, containing a dye-containing layer coated onto a polymer substrate such as PET. In this aspect, a layer-by-layer coating may be used that comprises a polymeric substrate and a composite coating including a first layer and a second layer. Typically, the first layer is immediately adjacent the polymeric substrate at its first face and the second layer is immediately adjacent to the first layer at its opposite face. This first layer includes a polyionic binder while the second layer includes the dye. Each layer includes a binding group component with the binding group component of the first layer and the binding group component of the second layer constituting a complimentary binding group pair.
As used herein, the phrase “complementary binding group pair” means that binding interactions, such as electrostatic binding, hydrogen bonding, Van der Waals interactions, hydrophobic interactions, and/or chemically induced covalent bonds are present between the binding group component of the first layer and the binding group component of the second layer of the composite coating. A “binding group component” is a chemical functionality that, in concert with a complimentary binding group component, establishes one or more of the binding interactions described above. The components are complimentary in the sense that binding interactions are created through their respective charges.
Typically, these layer-by-layer coatings comprise a plurality of these composite coatings. The number of layers of composite coatings is not intended to be limiting in any way on the possible number of composite coatings and one of ordinary skill will appreciate that this description is simply exemplary and illustrative of an embodiment with multiple or a plurality of composite coatings.
In one example, the side-view mirror uses sunlight to transition to the lighter (higher reflectance) state for a “day mode”, and UV light from the LED light array 103 for transitioning to the darker (lower reflectance) state for a “night mode”. Under daylight conditions filtered sunlight will drive a photochromic reaction in layer 105 that causes the photochromic layer to transition to the light state. In this scenario the UV component of sunlight is filtered, and the photochromic layer is exposed only to lower energy visible light, which results in the photochromic lightening of the active layer. Day mode can be triggered simply by the presence of sunlight. Under low light or high glare conditions the UV LEDs in LED array 103 can be switched on to activate or darken the photochromic layer, transitioning the mirror to the low reflection state for night mode operation.
Mirror 104 allows transmission of the UV backlight from the LED array 103 to the photochromic switching material in layer 105. This enables darkening of the photochromic layer and reflects the visible component of light transmitted through the outer layer 106, therefore acting as a mirror. The speed of switching of the photochromic material can be fast; for example, it may have a switching half-life within a few minutes, or even within seconds. The outer layer 106 with UV cut-off protects the user from the exposure to the UV from LED array 103, and also serves the dual purpose of preventing darkening of the mirror during the day. One of skill in the art will understand that many commercial UV LEDs have a light emission profile such that there may be low levels of visible light emitted (bleed into the visible region). To prevent the consumer from seeing this light, mirror 104 may be backed with a filter that blocks transmission of visible light. One commercially available example of such a filter is UG11 from Schott. Night mode can be triggered automatically by a clock either alone or combined with a GPS to indicate vehicle location, it can be triggered by the user, or it can be triggered by sensor readings. Once the UV backlight is switched off, the low reflection state in this example persists until daytime, when exposure to sunlight causes a photochromic lightening reaction that restores the mirror to a high reflection state. The photochromic layer may contain one or multiple chromophores. Elements 106, 105 and 104 may be laminated together providing a mirror laminate with high structural integrity allowing the use of thinner, for example chemical-treated glass, for example Gorilla® Glassfrom Corning® or Dragontrail™ glass from AGC, or plastic layers for reducing weight of the mirror assembly and providing NVH benefits. Chemical-treated glass is known in the art to be stronger and lighter, allowing thinner panes or panels to be used.
Referring to
Array 203 is either bonded to backing plate 101 or mechanically attached. A mirror 204, is attached or adjacent to LED array 203. Mirror 204 should have high transmission in the UV region of the electromagnetic spectrum, high reflectivity in the majority of the visible light region of the electromagnetic spectrum, but also high transmission of visible light at the specific wavelength corresponding to the visible LEDs on LED array 203. The mirror 204 may be curved to form a concave or convex surface. In addition, the mirror 204 may have a polarized coating or a polarized film that may be attached using transparent PSA. An outer layer 206 is bonded to layer 205 and is comprised of either glass or plastic. Outer layer 206 may be labeled or etched with text or may be patterned to mask functional elements of the example such as edge seals. In another example, outer layer 206 is comprised of glass, which is curved to form a concave or convex mirror. Outer layer 206 may include coatings on either the inside or outside surfaces. Coatings may include UVAs that will block 99.5% or more of a UV light source. These coatings may be adhered to either surface of outer layer 206 by sputtering, flow coating an organic matrix, or other deposition technologies known in the art. Outer layer 206 may also comprise a polarized filter, either coated or attached to one face of layer 206 using a plastic film and PSA. The polarized filter of layer 206 must be perpendicularly aligned to the polarized coating or film of mirror 204.
The example described with reference to
In an example of automatic operation, detection of bright ambient lighting conditions (eg. daylight) can cause the visible LEDs in the LED array 203 to be switched on, which lightens the photochromic layer 205 and achieves the high reflectance state. Using visible LEDs, the lightening of the photochromic layer occurs when light from the visible LED passes through the mirror 204 and its associated linear polarizer to reach the photochromic layer 205, triggering the photochemical lightening reaction to achieve the high reflectance state. Any remaining polarized visible light that is transmitted through the photochromic layer is blocked by the linear polarizer on or attached to outer layer 206. Since the linear polarizer on or attached to outer layer 206 is a crossed polarizer with respect to the linear polarizer on 204, no UV light escapes from the front face of the mirror, thereby protecting the user from the LED light. In an aspect, the layer 205 may comprise a layer-by-layer coating, as described above, containing a dye-containing layer coated onto a polymer substrate such as PET.
Similarly, when the onboard light sensors detect low ambient light conditions (e.g., nighttime or tunnel), the UV LED is activated, darkening the photochromic layer to achieve the low reflectance state. The crossed polarizers and/or the optional UV absorber in layer 205 prevent light from the UV LEDs in LED array 203 from escaping the side view mirror assembly in the same way as described above for the visible LEDs. Thus, element 203 can be a light guide panel with edge-lit LEDs, as already described. None of the light from LED array 203 (UV or visible), or minimal amounts of it, is able to exit the side view mirror assembly. The UV filter on the outer glass layer 206 also ensures that inadvertent darkening of the photochromic layer 205 due to sunlight does not occur. The mirror 204 reflects incident sunlight providing the mirror functionality for both the high and low reflectance states. Additional light filtering strategies to ensure no light is able to exit the mirror assembly are possible. For example, the pair of crossed polarizers may be replaced by two circular polarizers, where a first polarizer is a right circular polarizer and the second is a left circular polarizer. In a second example, the pair of crossed polarizers may be replaced by a single notch filter on the outer glass, which is selected such that the wavelength of light generated by the visible LED backlight is centered in the reflectance band of the notch filter. In a third example, the crossed polarizers may be replaced with a light guide layer between the LED array 203 and the mirror 204 to minimize light exiting the mirror assembly in the direction of the driver or vehicle occupants, One commercially available example of such a light guide layer is ALCF-A2+ from 3M™. Elements 206, 205 and 204 may be laminated together providing a mirror laminate with high structural integrity allowing the use of thinner glass, for example chemical-treated glass, for example Gorilla® Glass from Corning® or Dragontrail™ glass from AGC, or plastic layers for reducing weight of the mirror assembly and providing NVH benefits. Chemical-treated glass is known in the art to be stronger and lighter, allowing thinner panes or panels to be used.
Referring to
Referring to
The photochromic-electrochromic example of
Heating elements may be included in the rear-view mirror to prevent fogging and icing of the mirror. Heating element 102 may be located between backing plate 101 shown in
Referring to
Array 503 is either bonded to the assembly or mechanically attached. A mirror 504, is attached to LED array 503. In an example, mirror 504 has a high transmission in the UV region of the electromagnetic spectrum, high reflectivity in the majority of the visible light region of the electromagnetic spectrum, but may also have high transmission of visible light at the specific wavelength corresponding to the visible LEDs on LED array 503. The mirror 504 may be curved to form a concave or convex surface. In addition, the mirror 504 may have a polarized coating or a polarized film that may be attached using transparent PSA. An outer layer 506 is bonded to layer 505 and is comprised of either glass or plastic. Outer layer 506 may be labeled or etched with text or may be patterned to mask functional elements of the example such as edge seals. In another example, outer layer 506 is comprised of glass, which is curved to form a concave or convex mirror. Outer layer 506 may include coatings on either the inside or outside surfaces. Coatings may include UVAs that will block 99.5% or more of a UV light source. These coatings may be adhered to either surface of outer layer 506 by sputtering, flow coating in an organic matrix, or other deposition technologies known in the art. Outer layer 506 may also comprise a polarized filter, either coated or attached to one face of layer 506 using a plastic film and PSA. The polarized filter of layer 506 must be perpendicularly aligned to the polarized coating or film of mirror 504.
In an alternative example, the mirror comprises an LED array 507 at the side of the stack emitting light with wavelengths in the range of 450 - 800 nm for lightening the photochromic layer 505. This can be in place of LED assembly 503 or in addition to LED assembly 503. The entire mirror assembly is encapsulated in a casing 508. In another alternative example, LED or other light sources 509 emitting light with wavelengths in the range of 450 - 800 nm for lightening the photochromic layer 505 are adhered to this casing. In the case of a sideview mirror, light sources 509 may be directionally pointed in such a manner that the reflected light is not visible to the driver.
The example described herein with reference to
In an example of automatic operation, detection of bright ambient lighting conditions (eg. daylight) may cause the visible LEDs in the LED arrays 503 and/or LED array 507 and/or light array 509 to be switched on, which lightens the photochromic layer 505 and achieves the high reflectance state. Using visible LEDs, the lightening of the photochromic layer occurs when light from the visible LED passes through the mirror 504 and its associated linear polarizer to reach the photochromic layer 505, triggering the photochemical lightening reaction to achieve the high reflectance state. Any remaining polarized visible light that is transmitted through the photochromic layer is blocked by the linear polarizer on or attached to outer layer 506. Since the linear polarizer on or attached to outer layer 506 is a crossed polarizer with respect to the linear polarizer on mirror 504, little or no UV light escapes from the front face of the mirror, thereby protecting the user from the LED light.
Similarly, when the onboard light sensors detect low ambient light conditions (e.g., nighttime or tunnel), the UV LED is activated, darkening the photochromic layer to achieve the low reflectance state. The crossed polarizers and/or the optional UV absorber in layer 505 prevent light from the UV LEDs in LED array 503 from escaping the side view mirror assembly in the same way as described above for the visible LEDs. None of the light from LED array 503 (UV or visible), or minimal amounts of it, is able to exit the side view mirror assembly. The UV filter on the outer glass layer 506 also ensures that inadvertent darkening of the photochromic layer 505 due to sunlight does not occur. The mirror 504 reflects incident sunlight providing the mirror functionality for both the high and low reflectance states. Additional light filtering strategies to ensure no light is able to exit the mirror assembly are possible. For example, the pair of crossed polarizers may be replaced by two circular polarizers, where a first polarizer is, for example, a right circular polarizer and a second is a left circular polarizer. In a second example the pair of crossed polarizers may be replaced by a single notch filter on the outer glass, which is selected such that the wavelength of light generated by the visible LED backlight is centered in the reflectance band of the notch filter. In a third example the crossed polarizers may be replaced with a light guide layer between the LED array 503 and the mirror 504 to minimize light exiting the mirror assembly in the direction of the driver or vehicle occupants. One commercially available example of such a light guide layer is ALCF-A2+ from 3M™. In another example only the directional LEDs 509 are used to transition from “night mode” to “day mode” and no polarizers are used in layer 505 and no polarizers or light guide layers are employed between LED array 503 and mirror 504. This is possible because this light is not directional and since it is reflected away from the driver it is not seen during the lightening.
In another example of automatic operation like in the example in
In all of the examples described above, it is also possible to control the mirror to an intermediate state in between the dark state and the low state. This control can be achieved either manually by the user selecting a desired amount of reflectance, or it can be controlled automatically based on sensor input to set the mirror at an optimum state of reflectivity in between the fully dark and fully light states. The control system can also include algorithms to ensure that during daytime operation the minimum reflectance level required by law is achieved.
In an alternate example, the photochromic layer comprises a chromophore that switches from light to dark based on a photochromic reaction, and can also switch from dark to light due to a thermal lightening reaction that occurs above a threshold temperature that is higher than the temperature that would be reached during regular normal operation and higher than the temperature achieved when the mirror defroster is switched on. In an example, the chromophore could fade back to the light state when it is heated above a threshold temperature of 60° C., or above the threshold temperature of 70° C., or above the threshold temperature of 80° C., or above the threshold temperature of 90° C. In this example, the resistive heating element 102 can also be used to transition the photochromic layer back to the light state through a thermal lightening reaction. This can have advantages by not requiring LEDs for one of the switching directions, and also for simplifying the optical filters required. Within the normal operating temperature range of the mirror (e.g., -20° C. to 50° C., or -30° C. to 60° C., or -40° C. to 70° C.), the chromophore remains thermally stable such that the chromophore will stay in the dark state without the need to continually apply UV light, as in some of the prior art examples. In addition the dark and light states only change minimally or not at all within the range of regular operating temperatures; that is, the light and dark states are not temperature dependent over the regular operational temperature range of the mirror.
In another example a photochromic mirror was built and tested according to the current invention.
One of skill in the art will understand that the percent reflectivity of the mirror stack 604 will be a function of the reflectivity of the mirror 605 utilized and the transmission of the PVB adhesive layers (607 and 608), float glass 609, chromophore type (for example, that shown in
Photochromic and photochromic-electrochromic materials can be used to provide the switching function in the rear-view and side-view mirrors according to this invention. Photochromic and photochromic-electrochromic chromophores or dyes absorb visible light in one state (dark state) and allow visible light to pass in another state (light state). The term “chromophore” or “dye” refer to these light absorbing materials and the terms are used interchangeably. Examples of photochromic chromophores suitable for this invention darken (i.e., change to light absorbing mode) in response to light of one wavelength range, and lighten (i.e., change to light transmitting mode) in response to light of a different wavelength range.
For example, suitable chromophores could darken in response to light in the range of 350 - 410 nm, and lighten in response to light in the 450 - 800 nm range. The example chromophores described below for use according to the invention are P-Type photochromic materials, meaning that they are bistable. P-Type photochromic materials are discussed in Pure Appl. Chem, Vol. 73, No. 4, pp. 639-665, 2001; they are familiar to one skilled in the art of photochromic technologies. Once the photochromic chromophore is in the dark state, it will stay in that state until subjected to a stimulus to transition them away from that state. Examples of possible stimuli that can be used to transition the chromophores from one state to another include light of an appropriate wavelength, electricity of an appropriate voltage, or an amount of heat required to raise the temperature of the system above a threshold temperature. This feature has the potential advantage of requiring less power to maintain the rear-view mirror in a certain state (light state or dark state) over a much wider operational temperature range. For example, the photochromic materials described below will persist in the dark or light state over an operational temperature range of -20° C. to 50° C., or over a range from -30° C. to 60° C., or over a range from -40° C. to 70° C., or at least -40° C., or at least -30° C., or at least -20° C., up to about 90° C., or up to 85° C., or up to 80° C., or up to 75° C.
In contrast, T-Type photochromic materials, such as those referenced in prior art US5373392, will thermally revert from the dark state to the light state at lower temperatures. For example, they will switch at temperatures below 70° C., or less than 60° C., or less than 50° C., or less than 40° C., or less than 30° C. in the absence of continuous exposure to UV light. For a photochromic material incorporating a T-Type photochromic compound, the UV LED must remain switched on for the entire time night mode is required, which results in substantially higher power consumption, increased generation of heat that must be dissipated from the mirror assembly, as well a higher requirement for resistance to photochemical degradation.
In other examples, suitable chromophores are photochromic and electrochromic, meaning that one of the transitions (either from the dark state to the light state or vice versa) is driven by light, and the reverse transition is driven by electricity. For example, a photochromic-electrochromic chromophore darkens in response to UV and visible light in the range of 350 - 410 nm and lightens when an electrical voltage is applied across the switching material by way of transparent conductive electrodes that are in contact with the switching material. These photochromic-electrochromic chromophores are also P-Type photochromic materials and will also provide a significant improvement over the T-Type photochromic chromophores used in eyewear and in prior art examples of rear-view mirrors that rely on a thermal back reaction to drive the chromophores into the light state.
Chromophore(s) suitable for use with examples shown in
An example of such a chromophore is outlined in US7777055. This material may darken (e.g. reach a ‘dark state’, or “photodarken”) when exposed to ultraviolet (UV) light or light comprising wavelengths from about 350 nm to about 450 nm, and it may lighten (“fade”, “photofade”, “photobleach”, or achieve a ‘light state’) when exposed to light comprising wavelengths from about 450 to about 800 nm. Preferably the chromophore photofades when exposed to sunlight that has passed through a cut-off filter, which filters off light comprising wavelengths shorter than 450 nm (“450 nm cut-off filter”) or shorter than 420 nm (“420 nm cut-off filter”) or shorter than 410 nm (“410 nm cut-off filter”) or shorter than 400 nm (“400 nm cut-off filter”). These chromophores may have an additional structural feature that they undergo a thermal ring-opening reaction above a threshold temperature. These chromophores are categorized as P-Type photochromic materials as this property is different from T-Type photochromic behaviour as defined above in that the P-Type chromophore does not undergo a thermal ring-opening reaction below the threshold temperature. At a temperature equal to or higher than the threshold temperature the P-Type chromophore undergoes a rapid thermal ring-opening reaction. The switching material may be optically clear, or substantially transparent, or not opaque.
Photochromic-electrochromic switching materials are used in the example described with reference to
An example of a photochromic/electrochromic “switching material” is outlined in US10054835. This material may darken (e.g. reach a ‘dark state’) when exposed to ultraviolet (UV) light or blue light from a light source, and may lighten (“fade”, achieve a ‘light state’) when exposed to an electric voltage. In some examples, the switching material may also fade upon exposure to selected wavelengths of visible light (“photofade”, “photobleach”), in addition to fading when electricity is applied. In some examples, the switching material may darken when exposed to light comprising wavelengths from about 350 nm to about 450 nm, or any amount or range therebetween, and may lighten when a voltage is applied, or when exposed to light comprising wavelengths from about 450 to about 800 nm. The switching material may be optically clear, or substantially transparent, or not opaque.
A voltage source 701 provides an appropriate voltage for powering the LEDs. In this case, the voltage source is depicted as a DC voltage, but in other examples AC voltage could potentially be used. In an example, the DC voltage could be the 12 Volts supplied by a standard vehicle battery, or it could be any other voltage. With both UV and visible LEDs present, a switch 702 controls whether current flows to one of two possible circuit paths. In one circuit path 705, the voltage is applied across UV LEDs 703 used for darkening the photochromic film within the mirror. UV LEDs 703 in this case are connected in series such that the voltage being applied is sufficient to light both LEDs. Different LEDs may have different voltage drops and further voltage conditioning circuitry can be provided in order to provide the right voltage across each of the LEDs.
In a second circuit path 706 the voltage is applied across visible LEDs 704. LEDs 704 emit light of a wavelength appropriate for lightening the photochromic layer, for example 405 in
Switch 702 can be controlled manually or controlled through an automated process. In one example, the switch could be controlled based on a clock and/or a GPS signal to determine whether the mirror should be operating in “day mode” or in “night mode”. In another example of an automated system, light sensors could be used to automatically detect light levels and to decide whether the mirror should be lightened or darkened, and then activate switch 702 accordingly to either turn on the UV LEDs 703 or the visible LEDs 704. Note that switch 702 could also have a third “off” position such that no LEDs are connected. This is for the situation when the mirror comprises a switching material that is bi-stable, meaning that once in a certain state (e.g., dark or light) it does not change further without some outside stimulus. So if the mirror is already in the correct transmission level then no LEDs are required to be on to maintain it in that transmission level absent some other external stimulus.
As shown in
Darkening LEDs and/or lightening LEDs can also be arranged to create an LED edge-lit configuration by using LEDs in combination with a light guide film or filter, for example ACRYLITE® LED light guiding edge lit. In this configuration the LED is configured at the edge of the light guide layer and the light is fed in through the edge of the film or filter and emitted uniformly across the surface of the layer. Light diffusing particles embedded in the light guide layer suppress the total internal reflection allowing light to exit the sheet via the surfaces in a controlled and uniform manner. LEDs may be configured on one side of the light guide layer or on two sides of the light guide layer or on any number of sides up to and including each individual side of the light guide layer. The light guide layer may be configured with only darkening LEDs or it may be configured with both darkening and lightening LEDs. Darkening LEDs may be arranged together on the same side of the light guide layer or they may be distributed between two or more sides of the light guide layer. Similarly, lightening LEDs may be arranged together on the same side of the light guide layer or they may be distributed between two or more sides of the light guide layer. Darkening and lightening LEDs may be arranged together on the same side of the light guide layer, alternating between lightening and darkening LEDs, or as a pattern determined by the relative ratio of darkening LEDs to lightening LEDs required for the particular application, for example the repeating pattern of one darkening LED followed by two lightening LEDs. The light guide layer and associated LEDs may be configured behind the mirror or configured in front of the mirror. If the light guide layer is configured in front of the mirror there may be additional design considerations for selecting the light guide layer such as low haze and high optical clarity. Those skilled in the art will understand that the type of light guide layer may be selected based on the size of the area to be illuminated and other design considerations. Other LED configurations are also possible.
It is contemplated that any embodiment discussed in this specification can be implemented or combined with respect to any other embodiment, method, composition or aspect, and vice versa.
The present invention has been described with regard to one or more embodiments. However, it will be apparent to persons skilled in the art that a number of variations and modifications can be made without departing from the scope of the invention as defined in the claims. Therefore, although various embodiments of the invention are disclosed herein, many adaptations and modifications may be made within the scope of the invention in accordance with the common general knowledge of those skilled in this art. Such modifications include the substitution of known equivalents for any aspect of the invention in order to achieve the same result in substantially the same way. Numeric ranges are inclusive of the numbers defining the range. The terms “approximately” and “about” when used in conjunction with a value mean +/- 10% of that value. In the specification, the word “comprising” is used as an open-ended term, substantially equivalent to the phrase “including, but not limited to,” and the word “comprises” has a corresponding meaning. As used herein, the singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Citation of references herein shall not be construed as an admission that such references are prior art to the present invention, nor as any admission as to the contents or date of the references. All publications are incorporated herein by reference as if each individual publication was specifically and individually indicated to be incorporated by reference herein and as though fully set forth herein. The invention includes all embodiments and variations substantially as hereinbefore described and with reference to the examples and drawings.
Directional terms such as “top”. “bottom”, “upwards”, “downwards”, “vertically”, “laterally”, “inner”, “outer”, are used in this disclosure for the purpose of providing relative reference only, and are not intended to suggest any limitations on how any article is to be positioned during use, or to be mounted in an assembly or relative to an environment.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as is commonly understood by one of ordinary skill in the art to which this invention belongs. If a definition set forth in this section is contrary to or otherwise inconsistent with a definition set forth in the documents that are herein incorporated by reference, the definition set forth herein prevails over the definition that is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CA2021/050962 | 7/13/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63039426 | Jun 2020 | US |
