Patent Application
20180024401
The present disclosure generally relates to a rearview mirror assembly, and more particularly, electrical connections to an electro-optic element within the rearview mirror assembly.
In many mirror products today, a precise and uniform fit between an edge of a glass shape and a surrounding flush mounted bezel or housing is desirable to produce an aesthetically pleasing product. A uniform, yet minimal, gap produces a smooth, pleasing, seamless transition between the bezel or housing and the mirror element. In some instances where the bezel is flush to the mirror, it may be difficult to provide electrical connections to electrical components. Processes that form a bezel incorporated with a mirror element may benefit from unique electrical pathways between mirror element and its electrical drive circuit.
According to one aspect of this disclosure, a rearview mirror assembly is provided that includes a bezel, and an electro-optic element that includes a first substantially transparent substrate defining first and second surfaces. The second surface includes a first electrically conductive layer. A second substrate defines third and fourth surfaces and a hole extending between the third and fourth surfaces. The third surface includes a second electrically conductive layer. A primary seal is disposed between the first and second substrates. The seal and the first and second substrates define a cavity therebetween. A conductive bus is positioned proximate the hole of the second substrate and an electro-optic material is disposed within the cavity. The bezel extends onto at least one of the third and fourth surfaces of the second substrate.
According to another aspect of this disclosure, a rearview device is provided that includes a housing. An electro-optic element is positioned in the housing that includes a first substantially transparent substrate defining a first and a second surfaces and a first edge extending around at least a portion of a perimeter of the first substantially transparent substrate. The second surface has a first electrically conductive layer. A second substrate defines third and fourth surfaces. A second edge extends around at least a portion of a perimeter of the second substrate. The third surface has a second electrically conductive layer. The second substrate defines a hole disposed in the fourth surface. A primary seal is disposed between the first and second substrates. The seal and the first and second substrates define a cavity therebetween and an electro-optic material is disposed within the cavity. A conductive filler is disposed in the hole.
According to another aspect of this disclosure, an electro-optic element for a rearview device is provided that includes a first substantially transparent substrate defining first and second surfaces. The second surface has a first electrically conductive layer. A second substrate defines third and fourth surfaces. The second substrate defines a hole between the third and fourth surfaces. The third surface has a second electrically conductive layer. A primary seal is disposed between the first and second substrates. The seal and the first and second substrates define a cavity therebetween and an electro-optic material is disposed within the cavity. A conductive filler is disposed within the hole and defines a filler surface which is substantially planar with the fourth surface.
These and other aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. It will also be understood that features of each example disclosed herein may be used in conjunction with, or as a replacement for, features of the other examples.
In the drawings:
Additional features and advantages of the invention will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description or recognized by practicing the invention as described in the following description together with the claims and appended drawings.
As used herein, the term “and/or,” when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items, can be employed. For example, if a composition is described as containing components A, B, and/or C, the composition can contain A alone; B alone; C alone; A and B in combination; A and C in combination; B and C in combination; or A, B, and C in combination.
In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “comprises . . . a” does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.
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The rearview mirror assembly 10 also includes a circuit board 92 and a carrier plate 96. The carrier plate 96 can be located behind the electro-optic element 22 and have the circuit board 92 connected thereto. If the rearview mirror assembly 10 is an interior rearview assembly, the carrier plate 96 is typically fixed in position within the housing 14. The carrier plate 96 of the rearview mirror assembly 10 can be used to maintain the position of the electro-optic element 22 and/or carry the circuit board 92. An example of an interior rearview assembly including a carrier plate and a circuit board is disclosed in U.S. Pat. No. 6,239,899, entitled “MIRROR WITH INTERNAL SUPPORT PLATE,” assigned to Gentex Corporation, the entirety of which is hereby incorporated herein by reference. In the rearview mirror assembly 10, the carrier plate 96 assists in maintaining the electro-optic element 22 in position within the housing 14. An example of the housing 14, bezel 18, carrier plate 96, circuit board 92 and their interconnections may be found in U.S. Patent Application Publication No. 2005/0152054 entitled “REFLECTIVE ELEMENT HOLDER FOR REARVIEW MIRROR,” assigned to Gentex Corporation, the entirety of which is hereby incorporated herein by reference. However, it is contemplated that the rearview mirror assembly 10 may omit a bezel, circuit board and/or carrier plate from the rearview mirror assembly 10.
The illustrated electro-optic element 22 has the electro-optic material 70 positioned between the first substrate 26 and the second substrate 42. In some examples, the electro-optic material 70 may be an electrochromic material. In such examples, the electro-optic material 70 may be a solution phase as disclosed in U.S. Pat. No. 4,902,108 entitled “SINGLE-COMPARTMENT, SELF-ERASING, SOLUTION-PHASE ELECTROCHROMIC DEVICES, SOLUTIONS FOR USE THEREIN, AND USES THEREOF” and U.S. Pat. No. 5,278,693 entitled “TINTED SOLUTION-PHASE ELECTROCHROMIC MIRRORS,” commonly assigned to Gentex Corporation, both of which are hereby incorporated in their entirety herein. In other examples, the electro-optic material 70 may be in a solid-state. In addition, a hybrid system, where part of the electro-optic material 70 is solid-state and part is solution phase, is also contemplated. Solution-phase materials, because of their liquidic or flowable properties, do not rigidly bond the first and second substrates 26, 42 together like completely solid-state electro-optic material 70. The electro-optic material 70 may have a thickness between about 1 micron and about 1000 microns.
The flexibility of the electro-optic element 22 may be dependent on a variety of factors, including thickness of the first and second substrates 26, 42, type (e.g., solution-phase or solid-state) of electro-optic material 70, and overall thickness of the electro-optic element 22. For example, in examples of the rearview mirror assembly 10 having solid-state electro-optic material 70, the first and second substrates 26, 42 are bonded together in a manner that causes them to bend much like a piece having their total thickness. Contrastingly, electro-optic elements 22 having a solution-phase electro-optic material 70 bend in a complex manner wherein the first and second substrates 26, 42 bend simultaneously, but independently. Additionally, the solution phase electro-optic material 70 may ebb and flow somewhat in reaction to the stress. The net result is that the electro-optic element 22, in examples with solution phase electro-optic material 70, tends to be more flexible than electro-optic elements 22 with solid-state phase electro-optic material 70, even where the first and second substrates 26, 42 have the same thickness and other properties.
The first and second substrates 26, 42 may be cut to shape in a variety of processes. In one example, the first and second substrates 26, 42 are cut to shape with the use of a score and break technique. In another example, an abrasive wheel or a high pressure water jet may be used to cut the first and second substrates 26, 42. In yet another example, the first and second substrates 26, 42 may be cut using a laser. Examples of laser systems and laser cutting are described in U.S. Pat. No. 8,842,358, entitled “APPARATUS, METHOD, AND PROCESS WITH LASER INDUCED CHANNEL EDGE” and U.S. Patent Application Publication No. 2014/0034616, entitled “LASER SYSTEM AND METHOD THEREOF,” each of which is assigned to Gentex Corporation and is hereby incorporated herein by reference in its entirety.
Traditionally, design of the bezel 18 or housing 14 around the electro-optic element 22 takes into account the differences in the coefficient of thermal expansion (“CTE”) of the materials used in the electro-optic element 22, as well as the bezel 18 and housing 14. Polymeric materials typically have a greater CTE than glass, ceramic, or metal components. This means that as the temperature of the rearview mirror assembly 10 changes, the different materials of the rearview mirror assembly 10 expand and contract at different rates. The differential expansion of the components of the rearview mirror assembly 10 may result in the generation of stresses within the assembly 10 if not properly accounted for. In the case of automotive applications, typical temperature testing takes place in a range between about −40° C. to about 105° C. Conventional bezels are made out of strong and fairly rigid engineering plastics such as polypropylene, Acrylonitrile butadiene styrene/Polycarbonate, Acrylonitrile Styrene Acrylate, and have thermal expansion coefficients that are much larger than glasses, ceramics, and metals. This expansion difference can create hoop stress as conventional bezels shrink around glass and metal elements at cold temperatures. As a result, conventional bezels may have ribs or large gaps to accommodate the different thermal size changes between bezels/housings and mirrors.
The bezel 18 may include a polymeric material having a low enough CTE such that temperature changes in the bezel 18 do not cause undue contraction of the bezel 18 around the electro-optic element 22 and result in stress formation. In various examples, the CTE of the polymeric material of the bezel 18 and the housing 14 may be less than about 70 ppm, less than about 60 ppm, less than about 50 ppm, less than about 40 ppm, less than about 30 ppm, less than about 25 ppm, and less than about 20 ppm. Exemplary low CTE polymers may include polyetherimides, filled polyetherimides, liquid crystal polymer, filled liquid crystal polymer, nylon, filled nylon, filled polycarbonate, filled acrylonitrile butadiene styrene, polyamide-imide, filled polyamide-imide, filled polyphenylene sulfide, high density polyethylene, polystyrene and other polymers having a CTE below about 50 ppm. It should be noted that the bezel 18 may include combinations of low CTE polymers as well as combinations of low CTE polymers with regular CTE polymers. Additionally, the bezel 18 may include one or more fillers configured to further reduce the CTE of the bezel 18. Exemplary filler materials may include glasses, metals, minerals, organic materials or ceramics which may lower the overall CTE of the polymer. The filler materials may be in the form of powders, flakes, and fibers. Exemplary fibers may include glass fibers and/or carbon fibers. The bezel 18 may have a volume fraction of filler material greater than about 10%, greater than about 20%, greater than about 30%, greater than about 40%, and greater than about 50%. In a specific example, the bezel 18 may include nylon with an approximately 30% by volume glass filler. In some examples, the bezel 18 may have different local compositions of polymer or filler material in order to locally minimize the CTE of the bezel 18. For example, corners or long portions at the top and bottom of the bezel 18 may include a different polymer or higher volume fraction of filler material than other portions of the bezel 18. It should be understood that in examples of the rearview mirror assembly 10 not including the bezel 18, the housing 14 may alternatively include the aforementioned materials described in connection with the bezel 18.
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In some examples, the second edge 42A is positioned inboard, or in an inward direction, relative to the bezel 18 of the first edge 26A. Such an example may be accomplished by using a smaller dimensioned second substrate 42 relative to the first substrate 26, or through positioning of the first and second substrates 26, 42. In another example, the second edge 42A is positioned outboard, or in an outward direction relative to the first edge 26A. Such an example may be accomplished by using a smaller dimensioned first substrate 26 relative to the second substrate 42, or through positioning of the first and second substrates 26, 42. Exemplary advantages that may be achieved through such an example include a structural “lock” being formed due to the three dimensional aspect of the configuration (e.g., which may increase structural rigidity of the rearview assembly 10) and a reduced dimension bezel 18 (e.g., thinner, reduced and/or more compact) which may be aesthetically pleasing. In yet another example, the second edge 42A is positioned substantially flush, or in substantial alignment, with the first edge 26A. The first and second 26A, 42A can be flat and at a 90 degree angle relative to the first and fourth surfaces 30, 50 or at an angle other than 90 degrees relative to surfaces 30, 50. The first and second edges 26A, 42A can also be shaped such as a semicircle or pencil edge or contoured such as with a step, slot or notch. The texture of the first and second edges 26A, 42A can be smooth or rough depending on the edge appearance that is desired.
To facilitate adhesion between the bezel 18 and the first and/or second substrates 26, 42, one or more adhesion promoters may be included in the material of the bezel 18, in a resin base coating pre-applied to the first and second substrates 26, 42 and/or applied directly to the first and/or second substrates 26, 42. Exemplary adhesion promoters include silane coupling agents such as Dow Corning® Z-6121 and/or Dow Corning® Xiameter OF S-6032 and/or solvent based organic solutions that may etch the substrates 26, 42 such as LORD Chemlok® primers. It will be understood that although several examples are provided herein, other adhesion promoters, etchants or surface treatments and combinations of adhesion promoters and/or etchants or surface treatments may be used without departing from the spirit of the disclosure. The adhesion promoter used may be selected based at least in part on the material of the bezel 18 and the substrates 26, 42 in order to achieve a desired level of adhesion. The first and second edges 26A, 42A can also be coated with an elastomeric resin to help mitigate mechanical or thermal stresses that may develop in the rearview assembly 10.
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Disposed within the holes 54 may be a conductive filler 128. The filler 128 may include a metal tube (e.g., a via such as a multicore Copperset through hole plating system), conductive polymer, solder paste, a monolithic piece of metal, a thermal setting epoxy or combinations thereof. Any filler 128 may contain on its outer portion, an electrically insulating portion to isolate the electrical conductance from electrically conductive sections found on the third or fourth surfaces 46, 50. Optionally, a separate insulating member could be inserted into the hole 54 prior to the installation of the conductive filler. An insulator used in this method would be used to bring electrical conductance from the fourth surface 50 to the second surface 34. Further, any of the materials of the conductive bus 124 may be used as the filler 128 and any of the materials of the filler 128 may be used as the conductive bus 124. The filler 128 may be placed within the holes 54 at the time of assembling the electro-optic element 22 prior to formation of the bezel 18. The filler 128 may be flush with the third surface 46 or form a protruding connector. The filler 128 may be flush with the fourth surface 50 or form a protruding connector. In examples where the filler 128 is flush with the third and/or fourth surfaces 46, 50, the filler 128 may define a surface which is a distance of about 0.01 mm to about 0.2 mm from the third and/or fourth surfaces 46, 50. According to various examples, the filler 128 may define a surface (e.g., a filler surface) which is partially, substantially or completely parallel with the third and/or fourth surfaces 46, 50. According to various examples, the surface of the filler 128 is planar with the third and/or fourth surfaces 46, 50. The filler 128 may be partially or fully covered by the bezel 18. The filler material 128, depending on the example, may be held in place using an adhesive material (e.g., thermal or ultraviolet curing). The filler 128 is in electrical connection with the conductive bus 124 and the second electrically conductive layer 58 thereby providing electrical connection to both the first and second electrically conductive layers 38, 58. The filler 128 may cure with the conductive bus 124 to form a single continuous electrical connection. Use of the ablation areas 104 allows for the holes 54 to be in electrical connection with either the first and third portions 108, 116 or the second and fourth portions 112, 120 such that the electro-optic element 22 does not short out across the second electrically conductive layer 58. After lamination or formation of the bezel 18 to the electro-optic element 22, the circuit board 92 (
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It will be understood that although multiple separate examples have been described herein, combination of the examples are contemplated. For example, the holes 54 may be used with examples utilizing the notch 192, the conductive coating and member 136, 148, the conductive insert 156, the aperture 160, the conductive component 168 and the decorative film 176 without departing from the teachings provided herein. Similarly, any of the examples provided may be utilized with any other example provided.
According to various examples provided herein, the fourth surface 50 of the second substrate 42 may be substantially flush or flat (i.e., the filler 128, conductive bus 124, conductive coating 136, conductive member 148, conductive insert 156, flex circuit 180, and/or electrical connector 184 may be substantially flush or not extend onto the fourth surface 50). Such a flush example of the fourth surface 50 may be useful during the formation of the bezel 18. For example, in injection molded examples of the bezel 18, the fourth surface 50 may function as a surface for a mold of an injection molding machine to press against during formation of the bezel 18. Specifically, the pressure may be provided proximate the primary seal 62. In examples where the fourth surface 50 includes electrical contacts is otherwise is not flush, the molding equipment used to form the bezel 18 may apply unequal pressure which can result in damage to the electro-optic element 22. In such examples, the mold may need to be precisely machined to account for this variation such that uniform pressure may be applied. Accordingly, by creating a flush fourth surface 50 as disclosed herein, the bezel 50 may be formed in a cost effective manner.
Use of the present disclosure offers several advantages. First, the use of the present disclosure permits the formation of rearview mirror assemblies 10, and other structures having bezels 18, to include electrical components with low visibility electrical contacts. Second, use of the present disclosure allows for the formation of rearview mirror assemblies 10 which have a low profile and aesthetically pleasing design. Third, use of the present disclosure may allow for the reduction in the width of a concealment structure (e.g., a spectral filter, chrome ring, etc.) used to conceal the conductive bus 124, primary seal or other unsightly components located at edges of the electro-optic element 22. For example, by burying the electrical contacts (e.g., the conductive bus 124, conductive coating 136, conductive member 148, conductive insert 156, flex circuit 180, and/or electrical connector 184) within the bezel 18, the concealment structures may not need to be as wide. Thinner concealment structures may be advantageous in reducing the time and money required to manufacture them. Fourth, by positioning the electrical contacts within the bezel 18 and/or within the second substrate 42, the fourth surface 50 may be made flush (i.e., flat or substantially without changes in height). A flush fourth surface 50 may allow for uniform back pressure to be applied to the electro-optic element 22 during formation of the bezel 18. Further, a flush fourth surface 50 may allow for a more uniform formation of the bezel 18 onto the fourth surface 50.
Modifications of the disclosure will occur to those skilled in the art and to those who make or use the disclosure. Therefore, it is understood that the embodiments shown in the drawings and described above are merely for illustrative purposes and not intended to limit the scope of the disclosure, which is defined by the following claims as interpreted according to the principles of patent law, including the doctrine of equivalents.
It will be understood by one having ordinary skill in the art that construction of the described disclosure, and other components, is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.
For purposes of this disclosure, the term “coupled” (in all of its forms: couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature, or may be removable or releasable in nature, unless otherwise stated.
It is also important to note that the construction and arrangement of the elements of the disclosure, as shown in the exemplary embodiments, is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts, or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, and the nature or numeral of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.
It will be understood that any described processes, or steps within described processes, may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.
It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present disclosure, and further, it is to be understood that such concepts are intended to be covered by the following claims, unless these claims, by their language, expressly state otherwise. Further, the claims, as set forth below, are incorporated into and constitute part of this Detailed Description.
As used herein, the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term “about” is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites “about,” the numerical value or end-point of a range is intended to include two embodiments: one modified by “about,” and one not modified by “about.” It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.
The terms “substantial,” “substantially,” and variations thereof as used herein are intended to note that a described feature is equal or approximately equal to a value or description. For example, a “substantially planar” surface is intended to denote a surface that is planar or approximately planar. Moreover, “substantially” is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially” may denote values within about 10% of each other, such as within about 5% of each other, or within about 2% of each other.
This application claims the benefit of and priority to U.S. Provisional Patent Application Ser. No. 62/363,996, filed on Jul. 19, 2016, entitled ELECTRICAL CONNECTIONS FOR ELECTRO-OPTIC ELEMENTS, the entire disclosure of which is hereby incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 62363996 | Jul 2016 | US |
