Patent Application
20070229960
The present invention generally relates to dimmable mirrors, primarily for use with automobiles, trucks and other vehicles.
For some time, there has been a need for an inexpensive and reliable dimmable mirror that can be used with automobiles, trucks and other types of vehicles, to serve not only as the interior, rear-view mirror, but also as the vehicle's outside, rear-view mirror or mirrors. Early attempts included various prismatic constructions. Later attempts used electrochromic technology to replace the earlier prismatic dimmable mirror assemblies. In practice, however, the use of electrochromic technology for outside, dimmable mirror assemblies is not very widespread due to cost and reliability issues.
Other mirror technologies have been attempted over the years. Such technologies, however, have generally not produced a commercially viable product.
For example, one alternate mirror technology which has been proposed involves the placement of a fluid between a clear glass plate and a mirror that acts to attenuate light. The thickness of the fluid layer maintained between the clear glass plate and the light-reflecting mirror is then varied to adjust the amount of light attenuation achieved by the resulting system. This technique has, to date, not provided a commercially viable product primarily because of the mechanical or electromechanical complexity of the mechanism which is used to change the thickness of the fluid layer between the glass plate and the mirror.
For example, U.S. Pat. No. 4,726,656 discloses a relatively complex series of mechanical and electro-mechanical components to change the thickness of the fluid layer between the glass plates which comprise the dimmable mirror assembly. The various embodiments disclosed for this include a bellows unit, shape memory metal coils, mechanical latches and an electrically operated pump to achieve this basic operation.
U.S. Pat. No. 6,164,783 attempts to improve upon the electromechanical system described in U.S. Pat. No. 4,726,656, but continues to employ a relatively complex electro-mechanical system for changing the thickness of the fluid layer between the glass plates which comprise the dimmable mirror assembly. This includes the use of a flat electromagnetic solenoid, leaf springs, bi-directional motors, shape memory alloys, peristaltic pumps and piezoelectric actuators.
In general, such known devices for controlling the operation of a dimmable mirror assembly using an optical fluid either employ various electromechanical devices to move the respective elements of the mirror assembly to affect the dimming function, or to pump the optical fluid in and out of the mirror assembly to affect the dimming function.
It has generally been found that such systems do not result in a practical, commercially viable system for operating such dimmable mirrors, preventing the widespread use of dimmable mirrors based upon the use of an optical fluid.
In accordance with the present invention, a dimmable mirror assembly is provided which operates responsive to changes in the thickness of a light absorbing fluid contained between a transparent glass plate and a high reflectance, first surface mirror. The thickness of the light absorbing fluid layer is pneumatically or hydraulically controlled. To this end, variations in pressure are typically developed responsive to a compressible element which can be controlled manually, or responsive to an electrically operated solenoid, motor or pump, as desired, to control the pressures that are to create the desired actuation forces. The actuation forces produced by the resulting assembly can be controlled locally, to produce a dimmable mirror suitable for location within the interior of a vehicle, or can be controlled remotely by the driver to produce a dimmable mirror which is suitable for location outside of the vehicle.
For further discussion of the dimmable mirror of the present invention, reference is made to the detailed description which is provided below, taken together with the following illustrations.
As will be described more fully below, the dimmable mirror assembly of the present invention uses a pressure source to expand flexible tubing located in the mirror assembly, for altering the thickness of a fluid layer which is established between a transparent plate and a mirror associated with the mirror assembly. The need to locate electro-mechanical devices within the mirror assembly, and the need to manipulate optical fluids with electric pumps and valves, can in this way be eliminated.
Referring also to
The housing sections 5, 7 are preferably made from moldable plastic materials, such as ABS plastics, although other resilient materials, such as stamped sheet metals, could also be used, if desired. The face plate 6 is preferably transparent, and can be made from plate glass, clear acrylic or polycarbonate plastics, or other materials having similar properties.
The face plate 6 is attached to the front of the housing section 5, preferably using an adhesive which is appropriate for joining dissimilar materials such as the glass and plastic materials which are used in the manufacture of such components. A secondary, silicone-based adhesive, available from companies such as Dow Corning or GE, is preferably used in addition to the primary adhesive to ensure that the resulting cavity 8 is effectively sealed. The housing section 7 is attached, and preferably sealed to the housing section 5 using an adhesive which is appropriate for protecting the resulting cavity 9 from contaminants.
The housing section 5 includes a frame 10 which forms the periphery of the housing section 5, and a flexible seal 11 which is coupled with the frame 10. The face plate 6 is sealed to the frame 10 of the housing section 5 and, coupled with the flexible seal 11, forms a sealed cavity 8 for receiving a light absorbing optical fluid 12. The flexible seal 11 is preferably constructed as a rubber insert joined to the frame 10 of the housing section 5.
A mirrored plate 13 is attached to central portions 14 of the flexible seal 11, and includes a mirrored surface 15 which is positioned adjacent to the face plate 6. As an alternative, the mirrored plate 13 can be attached to plural positions on the flexible seal 11, if desired, to provide spaced supports for the mirrored plate 13. The mirrored plate 13 can be made from plate glass, an acrylic or polycarbonate plastic, a metal, or an equivalent material, which is preferably silver coated to form a reflective surface. The mirrored plate 13 and the flexible seal 11 are preferably attached using an adhesive which is appropriate for joining rubber to a glass or plastic material. A similar adhesive can be used to attach the flexible seal 11 to the frame 10 of the housing section 5. Suitable adhesives for accomplishing this are available from companies such as MasterBond, Epoxy Technologies, and others.
A backing plate 16 is also attached to the central portions 14 of the flexible seal 11, as shown in
Additionally referring to
In accordance with the present invention, the flexible tubing 18 is used to provide direct separation forces for causing the mirror assembly 2 to dim responsive to separation between the face plate 6 and the mirrored plate 13, as will be described more fully below. To this end, the flexible tubing 18 can be made of any of a variety of materials, including natural rubber latex, a thermoplastic elastomer or polyvinyl chloride. The thickness of the walls forming the flexible tubing 18 is preferably selected to minimize the amount of force required to distort the flexible tubing 18 from its natural (for example, circular) shape to the shape of the channel 19 which is developed between the frame 10 of the housing section 5 and the backing plate 16.
As an example, typical latex tubing useful for a mirror assembly 2 having a 50 square inch mirror area has a diameter of 5/32 in. and a wall thickness of 3/64 in. Such tubing develops a contact area between the frame 10 of the housing section 5 and the backing plate 16 of approximately 0.1 inch in width and 40 inches in length, yielding a contact area on the order of 4 square inches. Upon the application of a pressure of 4 PSI to the flexible tubing 18, a force of approximately 16 lbs. is exerted for separating the frame 10 of the housing section 5 and the backing plate 16, which is sufficient for typical operations of the dimmable mirror assembly 1 as will be described more fully below.
The size of the flexible tubing 18 which is selected for use, and the channel 19 which receives the flexible tubing 18, are preferably selected to provide the maximum separation force for the minimum amount of pressure applied to the system. As a secondary consideration, the flexible tubing 18 and the channel 19 are preferably selected to create a desired maximum separation of the plates 6, 13 when the maximum pressure is applied to the system.
Flexible tubing and tube-receiving channels having other shapes and sizes can also be used to achieve the foregoing operations. For example, square tubing, bellows tubing, and D-shaped tubing, among others, can be used together with any of a variety of suitable cavity configurations.
In the embodiment illustrated in
Other placements for the flexible tubing are also possible. For example, two separate sections of tubing can be placed along opposing horizontal edges of the mirror assembly 2, or along opposing vertical edges of the mirror assembly 2. As an alternative, four separate sections of tubing can be placed along the horizontal and vertical edges of the mirror assembly 2. As a further alternative, plural, discrete sections of flexible tubing can be positioned along the perimeter of the mirror assembly 2.
Different media can be used for conveying pressure to the flexible tubing 18 associated with the mirror assembly 2. Air can be used as the pressure-conveying medium, which can simplify installation of the flexible tubing and the connecting structures in a vehicle. Fluids can, in the alternative, be used as the pressure-conveying medium. Fluids are not compressible, and will tend to produce changes in volume which will be less significant over the anticipated range of operating temperatures to be encountered. Although the use of fluids provides a more efficient method of transferring pressure to the mirror assembly 2, the use of fluids can complicate installations in vehicles.
Selection of the pressure-conveying medium is related to the configuration of the mirror assembly 2 and the device 3 which is used to control the operation of the dimmable mirror assembly 1. For installations where the mirror assembly 2 and pressure-producing device 3 are in close proximity, a fluid medium (for example, a typical hydraulic fluid such as automotive transmission fluid) can appropriately be used. For installations where the mirror assembly 2 and pressure-producing device 3 are in separate areas, requiring the supply of pressure through one or more conduits, air can appropriately be used as the operating medium. In either case, the dimming controls for the dimmable mirror assembly are preferably optimized for the pressure medium which is selected for use.
In operation, a non-activated mode is assumed when the inner surface 23 of the face plate 6 is in close proximity to the surface 15 of the mirrored plate 13, as shown in
An activated mode is assumed by applying pressure to the mirror assembly 2 using the pneumatic device 3, as will be described more fully below, to in turn apply pressure to the flexible tubing 18 (via the pressure tube 4). This pressure causes the flexible tubing 18 to inflate, causing the flexible tubing 18 to assume a circular or near circular cross-section, as shown in
The distance separating the face plate 6 and the mirrored plate 13 will vary responsive to the pressure applied to the flexible tubing 18 and the return force of the spring 17. As increased pressures are applied, a greater separation will be developed between the face plate 6 and the mirrored plate 13, causing a greater amount of the light absorbing optical fluid 12 to be drawn into the space which is then created between the face plate 6 and the mirrored plate 13. The resulting increase in the thickness of the light absorbing fluid layer 12 will reduce the reflectance of the mirrored plate 13 proportionately. The characteristics of the light absorbing optical fluid 12 are selected so that, at a maximum separation between the face plate 6 and the mirrored plate 13, a nominal reflectance of 15% is achieved. In this way, the reflectance of the dimmable mirror assembly 1 can be controlled continuously between the maximum reflectance of the non-activated mode and the minimum reflectance of the activated mode.
As an alterative, the dye concentration in the optical fluid 12, which establishes the light absorbing characteristics of the optical fluid 12 as will be described more fully below, can be adjusted to attenuate light so the mirrored plate 13 cannot be seen by an observer. As a result, the face plate 6, having an inherently low reflectance of approximately 4%, will act as a low reflectance mirror.
Releasing the pressure applied by the pneumatic device 3 will return the mirror assembly 2 to the high reflectance state responsive to the force of the return spring 17. This provides the fail-safe mode which is required by federal regulations for dimmable mirror devices used on automotive vehicles.
The initial force required to separate the face plate 6 and the mirrored plate 13 is a function of elements including the contact area of the plates, the initial gap between the plates, the viscosity of the optical fluid and the return spring force. Separation of the face plate 6 and the mirrored plate 13 would tend to create a vacuum in the gap developed between the two plates. Instead of a vacuum being created, optical fluid is drawn into the resulting gap. Initially, the gap between the plates is small and the flow of optical fluid into the gap is restricted. This results in a force which acts against the separation of the plates. As the gap between the plates increases, the restriction to the flow of optical fluid decreases rapidly. The larger the initial gap between the plates, the less initial force is required to separate the plates. The larger the area of the plates, the larger the initial force which is required to separate the plates.
The viscosity of the optical fluid 12 determines the initial force required to separate the plates 6, 13. The higher the viscosity of the optical fluid, the larger the force required to separate the plates (to achieve the dimmed mirror state). The force applied to separate the plates 6, 13 must also overcome the return force of the spring 17.
As an example, for a typical application in conjunction with an automotive mirror, the areas for the face plate 6 and the mirrored plate 13 will typically range from about 25 sq. inches to 100 sq. inches. Assuming an initial gap between the face plate 6 and the mirrored plate 13 of 0.001 to 0.005 inches, a viscosity for the optical fluid of less than 500 centistokes, and a return force for the spring 17 of 2 lbs. to 5 lbs., a typical force applied to separate plates having a mirror area on the order of 50 sq. inches will range between 10 lbs. to 20 lbs.
As mentioned previously, the force of the spring 17 should be sufficient to force all but a thin layer of the light absorbing optical fluid 12 from between the face plate 6 and the mirrored plate 13. This can be accomplished by placing a single leaf spring, such as the leaf spring 17 shown in
As an alternative to use of the leaf springs 17 shown in
As a further alternative to use of the leaf springs 17 shown in
Another alternative to use of the leaf springs 17 shown in
The spacing between the face plate 6 and the mirrored plate 13, while maintained in close proximity to one another by the force of spring 17, 17′, is preferably controlled by placing a spacer between the plates 6, 13. Such a spacer is preferably implemented as a pattern of small dots formed on the inner surface 23 of the face plate 6 or on the surface 15 of the mirrored plate 13, for example, by screen printing. As an example, such a spacer can be developed using dots formed of a polyamide, having a thickness of from 0.001 in. to 0.005 in. and a diameter of from 0.005 in. to 0.01 in. The pattern selected for the dots is preferably biased to place the dots in areas at the periphery of the plates 6, 13 to increase the flow of optical fluid 12 into the gap which is developed between the plates 6, 13 as initial forces are applied to separate the plates.
The actuation of a dimmable mirror assembly cannot cause voids (for example, air pockets) to form between the face plate 6 and the mirrored plate 13 because this would then create non-uniformities in the reflectance observed by the driver. For this reason, as the face plate 6 and the mirrored plate 13 separate, only the optical fluid 12 must be drawn into the gap between the plates 6, 13, and not air. This is achieved by ensuring that the amount of the optical fluid 12 which is maintained in the sealed cavity 8 is more than sufficient to fill the maximum gap which can be developed between the face plate 6 and the mirrored plate 13. Further, the sealed cavity 8 must only be filled with the optical fluid 12, and cannot contain any air pockets. In addition, the sealed cavity 8 must maintain a constant volume during actuation of the mirror assembly 2, based upon the initial volume of the optical fluid 12.
Rearward movement of the backing plate 16, during dimming, would ordinarily act to increase the volume of the sealed cavity 8. The optical fluid 12 will maintain a constant volume. As a result, rearward movement of the mirrored plate 13 coupled with the backing plate 16 would act to increase the volume of the sealed cavity 8. Because the optical fluid 12 maintains a constant volume, a vacuum would then tend to be created. The forces required to create such a vacuum would typically act to prevent rearward movement of the mirrored plate 13.
Referring to
As an example, the flexible panels 24 can be formed as rubber inserts located in the apertures 25 and coupled with the housing section 5. Care must be taken to ensure that no leaks occur in the seals which are established between the face plate 6, the flexible seal 11, and the flexible panels 24, and the portions of the housing section 5 to which such structures are attached.
Selection of the optical fluid 12 is critical to the proper operation of the dimmable mirror assembly 1. The optical fluid 12 is typically a transparent host fluid incorporating a light absorbing dye dissolved into the host fluid.
Properties affecting the performance of the host fluid include the optical properties, the stability, the viscosity and the toxicity of the selected fluid, and the solubility of the dye in the host fluid.
The optical property of greatest importance is the index of refraction of the host fluid. The index of refraction of the host fluid, when combined with the dye, must closely match the index of refraction of the face plate 6. This is required to substantially reduce the reflection of light at the interface of the face plate 6 and the optical fluid 12. The reflection of light from this interface creates an observable secondary image when the mirrored plate 13 is positioned in the activated mode (plates 6, 13 separated). Such a secondary image will appear as a “ghost” image of the primary image produced from the mirrored plate 13. The severity of such ghosting is a function of the mismatch between the index of refraction of the host fluid and the index of refraction of the face plate 6.
Another optical property to consider is that the host fluid should have very minimal light scattering across the visible wavelengths. Light scattering by the optical fluid 12 will reduce the sharpness and contrast of the reflected image. It is also desirable that the optical fluid 12 have very minimal light attenuation in the visible spectrum. The light absorption of the optical fluid 12 will then only be a function of the dissolved dye.
The host fluid must also be stable over time. Exposure of the dimmable mirror assembly 1 to environmental conditions outside the vehicle with which it is used should not degrade the host fluid, including changes in fluid color or viscosity. This would include stability to ultraviolet exposure and extreme temperature ranges.
The viscosity of the host fluid is important to the operation of the dimmable mirror assembly 1 when activated. As previously described, the viscosity of the host fluid directly impacts upon the initial force required to separate the face plate 6 and the mirrored plate 13. The viscosity of the host fluid must be such that, over the intended operating temperature range, the force created by the pressure applied to the flexible tubing 18 is always sufficient to separate the plates 6, 13.
The host fluid must not be toxic. In the event the mirror assembly 2 is damaged, the optical fluid 12 could leak out. Human contact with the optical fluid 12 could then occur. This would be especially important for mirror application inside a vehicle.
The host fluid must allow a sufficient amount of a dye to be dissolved in the host fluid to provide sufficient light absorption to meet the low reflectance required when the plates 6, 13 are separated by a maximum gap. The dye must remain in solution over the operating temperature range for the mirror assembly, and should provide a useful product life.
The host fluid must also be compatible with the materials used to fabricate the dimmable mirror assembly 1. Specifically, the face plate 6, the mirrored plate 13, the flexible seal 11, the flexible panels 24, the housing section 5 and the adhesives used for assembly must all be compatible with one another.
A preferred host fluid that best meets the foregoing considerations is silicone oil, such as siloxane, which is often used as an optical fluid in laser optical technology. It is desirable for the silicone oil to have the capability of being formulated to match specific indices of refraction. For example, silicone oil with an index of refraction of 1.5 is specified when used with a transparent (colorless) glass plate, and an index of refraction of 1.6 is specified when used with a polycarbonate plate.
Silicone oils used in optical applications provide no measurable light attenuation or scattering over the range of visible wavelengths for the plate gap distances typically present in the dimmable mirror assembly 1. In addition, silicone oils have a transmissivity greater than 99% for the typical plate gap distances which are used. In addition, silicone oils used in optical applications have been shown to be stable over a ten year period of time. No yellowing or change in optical properties should be observed over this period of time. Silicone oils can be formulated to provide low viscosities consistent with the operating temperature range of the dimmable mirror assembly 1. For example, silicone oil specified for the dimmable mirror assembly 1 would have a viscosity less than 500 centistokes over the specified operating temperature range. Silicone oils are further compatible with the materials used in the dimmable mirror assembly.
Other optical fluids can be used in the dimmable mirror assembly 1, one such example being phthalate esters. While such optical fluids have appropriate optical properties, and a low viscosity, such fluids would require alternate materials to be used in the fabrication of the mirror assembly 2 to maintain compatibility.
Properties affecting the performance of the dye which is dissolved in the host fluid include the optical properties, the stability and the toxicity of the selected dye, and the solubility of the dye in the host fluid.
The optical property of greatest importance is that the dye perform as a neutral density filter (i.e., exhibiting equal light absorption across the visible spectrum). This minimizes any color shift in the reflected image.
The rate of color degradation of the dye, when subjected to ultraviolet exposure, must be sufficiently low to maintain an acceptable dimmed image over the useful life of the assembly. Ultraviolet exposure of the dye in the mirror assembly 2 is minimal. During daytime operation, the mirror assembly 2 is typically in the non-activated state. When in this mode, the majority of the optical fluid 12 containing the dye will not be exposed directly to sunlight. Activation of the mirror assembly 2 will typically occur from dusk to dawn, with a minimal amount of exposure to the sun (for example, when the mirror assembly is used to dim the sun, when low on the horizon behind the vehicle). Further mitigating degradation of the dye because of ultraviolet exposure is that only a small portion of the optical fluid 12 is exposed during activation, and any such exposed portions are then remixed with remaining optical fluid 12 in the cavity 8 when the mirror assembly 2 is returned to a non-activated state. The dye must also be soluble in the host fluid at a concentration that meets the necessary optical and environmental requirements. The addition of the dye to the host fluid must not make the resulting optical fluid toxic.
An example of a dye which is capable of meeting the above considerations is aniline dyes that are formulated to be soluble in oil. An optical fluid created by combining silicone oil and aniline dye exhibits the optical properties required for proper operation of the dimmable mirror assembly 1.
For plates 6, 13 formed of glass, the typical gap between the plates 6, 13, when in the fully activated mode is 0.040 inches. To achieve a reflectance of approximately 15%, the optical fluid 12 must attenuate the light by 60%. Aniline dye having a concentration of 0.25% (by volume) added to silicone oil provides a light absorption rate of approximately 1.5% per 0.001 inches of fluid thickness, achieving the required attenuation of 60%. This is well below the solubility limits of aniline dye in silicone oil for the proposed operating temperature range of the dimmable mirror assembly 1.
Other dyes can also be used to produce a satisfactory optical fluid for use in the dimmable mirror assembly 1. This would include azo dyes and anthraquinone dyes, for example.
The reflection of light from the outer surface of the face plate 6 can create a tertiary image if there is a mismatch of the index of refraction of the face plate 6 relative to the index of refraction of air. The tertiary image has a reflectance value of approximately 4% when the face plate 6 is made from glass. During daytime operation, the intensity of the resulting ghost image compared with the image reflected by the mirrored plate 13 does not tend to be distracting to the driver. When the mirror assembly 2 is fully activated, the tertiary image can be more apparent when compared to a reflectance of approximately 15% for a mirrored plate 13 formed of glass. This ghost image can be considered a distraction to some vehicle drivers.
An anti-reflective coating is preferably applied to the outer surface of the face plate 6, to significantly reduce the intensity of the tertiary (ghost) image. Suitable antireflective coatings can include multiple layers of silicon dioxide and titanium dioxide, and a single layer of MgF2.
As previously indicated, the mirror assembly 2 is operated to provide a dimming function by controlling the pressure which is applied to the flexible tubing 18. This, in turn, inflates the flexible tubing 18, from a compressed condition to its rounded shape, to cause separation of the mirrored plate 13 from the face plate 6 (for example, both formed of glass). This is accomplished using the pneumatic device 3, via the connecting tube 4.
The pressure-producing device 3 can take any of a variety of forms. Two preferred forms of the device 3 for use with the previously described mirror assembly 2 employ a bulb or a closed end bellows. As is shown in
Control of the dimming function is preferably achieved using one of two basic methods including direct manual control and electronic control.
A control mechanism for achieving direct manual control preferably allows the operator to make desired adjustments by taking simple actions such as the turning of a knob, the flipping of a lever, or other equivalent function that directly causes air to be forced from the pressure-producing device 3 to inflate the flexible tubing 18 in the mirror assembly 2. Such direct manual control allows the function of the mirror assembly to be remotely controlled, for example, from inside the vehicle (to control an outside mirror), without the need to derive any power from the vehicle.
One such embodiment, for direct manual control of the mirror assembly 2 using a bulb as the pressure device, is shown in
The control device 30 includes a knob 31, and a shaft 32 which is mated with the knob 31 and which terminates in a cam 33. A notched wheel 34 is further coupled with the shaft 32, and cooperates with a detent device 35 to maintain the position selected for the cam 33 responsive to rotations of the knob 31. A pressure bulb 36, similar to the pressure-producing device 3 shown in
The knob 31 is connected to the shaft 32 such that rotation of the knob 31 also causes the shaft 32 to rotate. The cam 33 is connected to the shaft 32 such that rotation of the shaft 32 also causes rotation of the cam 33. Rotation of the cam 33 from the non-activated position shown in
Another embodiment for direct manual control of the mirror assembly 2, which replaces the bulb 36 of the control device 30 shown in
In some applications, it is desirable to electronically control the previously described dimming functions. For example, if dimming of the mirror is to be automated, using light sensors to determine when dimming is to occur, electronic control of the dimmable mirror assembly 1 is required.
One such embodiment for electronic control of the mirror assembly 2 is shown in
The control device 40 includes a pressure bulb 41 and a connecting tube 4 connected to the pressure bulb 41. A solenoid 42 is positioned adjacent to the pressure bulb 41 and has a plunger 43 in contact with the pressure bulb 41. The solenoid 42 is electrically coupled with and receives operating signals from an electronic current control circuit 44. A potentiometer 45 is electrically coupled with and supplies operating signals to the electronic current control circuit 44.
Controlled energizing of the solenoid 42 causes the solenoid plunger 43 to compress the pressure bulb 41, creating a pressure for inflating the flexible tubing 18 in the mirror assembly 2 via the connecting tube 4. The force exerted by the plunger 43 is a function of the electric current flowing through the coil of the solenoid 42. The current supplied to the solenoid 42 by the electronic current control circuit 44 is proportional to the rotational position, and as a result, the resistance value of the potentiometer 45.
The electronic current control circuit 44 is preferably implemented using a voltage regulating integrated circuit which is configured to operate as a current regulating source. The electronic current control circuit 44 can, if desired, provide the additional function of generating a greater current value, yielding a relatively large solenoid plunger force, at the initiation of a dimming operation, before returning to a lower, nominal current value. Overall, the amount of force applied by the plunger 43 will be proportional to the selected position of the potentiometer 45. The additional function is accomplished by adding circuit components, such as a resistor coupled with a capacitor, for creating a turn-on time constant in the voltage regulating integrated circuit. The purpose of this additional function is to reduce the time required to achieve a selected dimming value when the mirror assembly 2 is first actuated.
As alternatives, a bellows can be substituted for the pressure bulb 41 of the electronic control device 40 shown in
The previously described, dimmable mirror assembly 1 could also be applied to interior automotive mirrors. The controls for an interior mirror would be integrated into the housing of the mirror assembly. As an example, the lever which is typically provided for the operator of the vehicle to control the state of a conventional mirror could operate to press against a pressure bulb or a bellows to activate the mirror assembly 2 as previously described to achieve the desired level of dimming.
The foregoing describes dimming functions which are capable of being operated by direct manual control and electronic control mechanisms which are not contained within the mirror assembly 2. It is also possible, if desired, to provide mechanisms for controlling operations of the dimmable mirror assembly 1 having components which are contained within the mirror assembly 2 or within a metal or plastic shell 52 (see
In practice, alternative locations for the control mechanism can lead to counterbalancing considerations. For example, the additional weight and/or size of a mirror assembly 2 which is positioned on the outside of a vehicle, resulting from the configuration of the mirror assembly 2 and/or a shell which surrounds the mirror assembly 2, can make the overall mirror assembly 2 more susceptible to vibration. Counterbalancing this is that running wires to the outside of the vehicle to communicate with such a mirror assembly 2 can, in practice, be more convenient than running the connecting tube 4 to the mirror assembly 2, as previously described, particularly in cases where the mirror assembly 2 is located at a relatively large distance from the control mechanism.
The previously described mechanisms for direct manual control of the mirror assembly 2 are located inside the vehicle, separate from the mirror assembly 2. Interior placement of the control mechanism is presently considered preferred to conveniently permit direct manual control of the dimmable mirror assembly 1 by an operator from inside the vehicle. However, other placements of mechanisms for the direct manual control of the mirror assembly 2 are also possible.
For example, as an alternative for interior mirror applications, a mechanism for direct manual control of the mirror assembly 2 can be integrated into the mirror assembly 2, or into the shell which surrounds the mirror assembly 2. This can be advantageous in reducing the complexity of the resulting installation.
As an alternative for outside mirror applications, a mechanism for the direct manual control of the mirror assembly 2 can similarly be integrated into the mirror assembly 2, or into the shell which surrounds the mirror assembly 2. However, such placements are presently considered less preferred because this would then require the operator of the vehicle to reach outside the vehicle to control the dimmable mirror assembly 1.
The previously described mechanisms for electronic control of the mirror assembly 2 are remote from the mirror assembly 2. Such remote placement is preferred in order to minimize the size and weight of the mirror assembly 2 when mounted in a suitable mirror shell. As an alternative, portions of an electronic control mechanism for the mirror assembly 2 can be located within the mirror assembly 2, or within the shell for the mirror assembly 2, if desired. In practice, any portions of the electronic control mechanism which are located within the mirror assembly 2 and/or the shell for the mirror assembly 2 should be selected to reduce the overall size and weight of the mirror assembly 2 to the extent possible.
The motor 47 and the air pump 48 can be implemented as separate components, or as a combined assembly to further minimize the size and weight of the electronic control mechanism and the mirror assembly 2 with which it is used. An example of a combined motor and pump assembly which can be used to develop such a function is the “CTS Series” single head micro-diaphragm pump and compressor which is manufactured by Hargraves Technology Corporation of N.C. The use of electronically controllable components having a minimum size and weight is preferred to reduce the susceptibility of the mirror assembly 2 to vibration.
The motor speed control 49 can be implemented using an appropriate electronic circuit for regulating the speed of the motor 47 responsive to the selective rotation of a potentiometer 50. Wires 51 connect the motor speed control 49 with the motor 47 and pump 48 which are located within the mirror assembly 2, or a shell for containing the mirror assembly 2, simplifying the connection between the mirror assembly 2 and the motor speed control 49 which is typically located within the vehicle.
Responsive to signals received from the motor speed control 49, via wires 51, the pressure developed by the pump 48 will be proportional to the speed of the motor 47. The amount of dimming of the mirror assembly 2 will be correspondingly proportional to the speed of the motor 47, with maximum dimming being achieved at full motor speed. The maximum pressure achieved at full motor speed is preferably limited to avoid overpressure and the potential for damage to the mirror assembly 2. Control of the maximum pressure which is developed can also be achieved by proper selection of the motor and pump which are used, or by providing an air bleed hole in the pressure line (for example, in the flexible tubing 18).
The previously described, miniaturized motor and pump combination could also be used inside the vehicle, if desired, as an alternative to the bulb 36 or the bellows 38. However, in such case, a certain amount of noise resulting from operations of the motor within the vehicle would be detectable.
Many external vehicle mirrors are convex in shape. For example, convex mirrors are often employed to provide wide angle views to an operator of a vehicle, primarily for right side view mirrors. Convex side mirrors are also required for most European commercial vehicles. The previously described dimmable mirror assembly 1, which is shown in conjunction with plates 6, 13 having flat surfaces, can also be applied to convex mirrors without encountering the otherwise typical difficulties of manufacturing laminated curved glass substrates.
In such a configuration, the face plate 6 and the mirrored plate 13 of the mirror assembly 2 would be manufactured in convex, dimensionally matched pairs. Glass plates can be manufactured in this way using a sag molding technique. For this, flat glass is placed on a curved mold and heated until it sags to match the mold shape. Molds having matching inner and outer diameters are used to create dimensionally matched pairs of glass plates, which would then serve as the face plate 6 and the mirrored plate 13. The housing section 5 and the backing plate 16 would then be appropriately modified to match the curved face plate 6 and the curved mirrored plate 13. Plastic plates could similarly be manufactured in convex, dimensionally matched pairs, in standard injection molds, to develop the face plate 6 and the mirrored plate 13 of the mirror assembly 2.
It is to be understood that while the foregoing structures are presently considered to be preferred, variations in such structures are also clearly possible.
In particular, while various parameters and ranges of parameters have been indicated for some of the components which have been described, these parameters are presently considered preferred, but can be varied to suite a particular application, as desired. For example, for a mirror assembly 2 having a face plate 6 or a mirrored plate 13 which is particularly large, or small, it is expected that the parameters which will be useful for such applications will lie outside of the ranges which have been specified.
Other variations will also occur to the skilled artisan. For example, the foregoing has been described in the context of developing pressures for moving the plates 6, 13 relative to each other. However, similar functionality can be achieved by using a vacuum in place of a pressurized element. Similarly, while the foregoing description positions flexible tubing 18 between structural components including the frame 10 and the backing plate 16, which is presently considered preferred for purposes of robustness, other arrangements would also be possible. For example, flexible tubing 18 could be positioned directly between the face plate 6 and the mirrored plate 13, or other intervening structures could be employed, if desired.
It will therefore be understood that various changes in the details, materials and arrangement of parts which have been herein described and illustrated in order to explain the nature of this invention may be made by those skilled in the art within the principle and scope of the invention as expressed in the following claims.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US05/16970 | 5/13/2005 | WO | 11/20/2006 |
| Number | Date | Country | |
|---|---|---|---|
| 60573094 | May 2004 | US |
