Patent Application
20130077165
1. Field of the Invention
The instant disclosure relates to a vehicle display mirror and a method of manufacturing the same, and more particularly, to a vehicle display mirror as a rear-view mirror and a method of manufacturing the same.
2. Description of Related Art
Glare is one of the troublesome factors when driving a vehicle. Many efforts have been made to solve the glaring problem. One of the most effective ways is to provide an electrochromic unit for the rearview mirror of the vehicle. The electrochromic unit deepens the color and thus reduces the reflectance of the mirror according to the degree of the glare, thereby minimizing the glaring effect.
A conventional anti-glare rearview mirror includes a photo-detector mounted on an electrochromic rearview mirror, and oriented to detect rearward light. The photo-detector outputs a control signal to the electrochromic rearview mirror to adjust the reflectance of the mirror according to the intensity of the rearward light. For example, for an intense rearward light, the reflectance of the mirror is required to be lowered. That is, the color of the mirror is deepened in order to avoid irritating to the driver's eyes.
One aspect of the instant disclosure relates to a vehicle display mirror and a method of manufacturing the same. The vehicle display mirror can be used as a rear-view mirror of the vehicle and provide a clear displayed screen for user in the vehicle.
One of the embodiments of the instant disclosure provides a vehicle display mirror, comprising: a light-polarizing reflection unit and an image display unit. The light-polarizing reflection unit includes at least one multilayer reflector composed of a plurality of inter-stacked polymer films, wherein at least one of the inter-stacked polymer films is a birefringence material layer that conforms to the condition of NX≠NY≠NZ, wherein NX is the index of refraction of light at X direction, NY is the index of refraction of light at Y direction, and NZ is the index of refraction of light at Z direction. The image display unit includes at least one image display screen, wherein the at least one multilayer reflector is disposed on the at least one image display screen.
Furthermore, the light-polarizing reflection unit includes a first substrate, a second substrate, a first functional layer, and a second functional layer. For example, the instant disclosure has at least four embodiment, as follows: (1) the first functional layer and the second functional layer may be respectively disposed on a first surface and a second surface of the at least one multilayer reflector; (2) the first functional layer and the second functional layer may be respectively disposed on a first surface and a second surface of the at least one multilayer reflector, and the first substrate and the second substrate may be respectively disposed on the first functional layer and the second functional layer; (3) the first substrate and the first functional layer may be respectively disposed on a first surface and a second surface of the at least one multilayer reflector, and the second substrate and the second functional layer may be respectively disposed on the first functional layer and the first substrate; (4) the first substrate and the second substrate may be respectively disposed on a first surface and a second surface of the at least one multilayer reflector, and the first functional layer and the second functional layer may be respectively disposed on the first substrate and the second substrate.
Moreover, the first functional layer and the second functional layer are one of a metal oxide layer or an ultraviolet absorbing layer, and the first substrate and the second substrate are selected from the group consisting of polyethylene terephthalate (PET), poly carbonate (PC), polyethylene (PE), poly vinyl chloride (PVC), poly propylene (PP), poly styrene (PS), and polymethylmethacrylate (PMMA).
Another one of the embodiments of the instant disclosure provides a method of manufacturing a vehicle display mirror, comprising the steps of: (A) forming at least one multilayer reflector composed of a plurality of inter-stacked polymer films by a co-extruding process, wherein at least one of the inter-stacked polymer films is a birefringence material layer that conforms to the condition of NX≠NY≠NZ, wherein NX is the index of refraction of light at X direction, NY is the index of refraction of light at Y direction, and NZ is the index of refraction of light at Z direction; (B) extending the at least one multilayer reflector; (C) respectively placing a first functional layer and a second functional layer on a first surface and a second surface of the at least one multilayer reflector to form a light-polarizing reflection unit; (D) adjusting the size of the light-polarizing reflection unit to conform to the size of an image display screen by cutting; and (E) adhesively placing the light-polarizing reflection unit on the image display screen.
Another one of the embodiments of the instant disclosure provides a method of manufacturing a vehicle display mirror, comprising the steps of: (A) forming at least one multilayer reflector composed of a plurality of inter-stacked polymer films by a co-extruding process, wherein at least one of the inter-stacked polymer films is a birefringence material layer that conforms to the condition of NX≠NY≠NZ, wherein NX is the index of refraction of light at X direction, NY is the index of refraction of light at Y direction, and NZ is the index of refraction of light at Z direction; (B) extending the at least one multilayer reflector; (C) respectively placing a first substrate and a first functional layer on a first surface and a second surface of the at least one multilayer reflector, and then respectively placing a second substrate and a second functional layer on the first functional layer and the first substrate, in order to form a light-polarizing reflection unit; (D) adjusting the size of the light-polarizing reflection unit to conform to the size of an image display screen by cutting; and (E) adhesively placing the light-polarizing reflection unit on the image display screen.
Another one of the embodiments of the instant disclosure provides a method of manufacturing a vehicle display mirror, comprising the steps of: (A) forming at least one multilayer reflector composed of a plurality of inter-stacked polymer films by a co-extruding process, wherein at least one of the inter-stacked polymer films is a birefringence material layer that conforms to the condition of NX≠NY≠NZ, wherein NX is the index of refraction of light at X direction, NY is the index of refraction of light at Y direction, and NZ is the index of refraction of light at Z direction; (B) extending the at least one multilayer reflector; (C) respectively placing a first substrate and a second substrate on a first surface and a second surface of the at least one multilayer reflector, and then respectively placing a first functional layer and a second functional layer on the first substrate and the second substrate, in order to form a light-polarizing reflection unit; (D) adjusting the size of the light-polarizing reflection unit to conform to the size of an image display screen by cutting; and (E) adhesively placing the light-polarizing reflection unit on the image display screen.
In conclusion, the at least one multilayer reflector composed of the inter-stacked polymer films can be disposed on the image display screen, thus the vehicle display mirror of the instant disclosure can be used as a rear-view mirror of the vehicle and provide a clear displayed screen for user in the vehicle.
To further understand the techniques, means and effects of the instant disclosure applied for achieving the prescribed objectives, the following detailed descriptions and appended drawings are hereby referred, such that, through which, the purposes, features and aspects of the instant disclosure can be thoroughly and concretely appreciated. However, the appended drawings are provided solely for reference and illustration, without any intention to limit the instant disclosure.
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Furthermore, according to different operating needs, the plurality of inter-stacked polymer films 100 can be manufactured with thicker protection layer at its top or bottom surface, so as to protect the internal layers of the polymer films 100. At least one of the inter-stacked polymer films 100 is a ultra-violet reflector for reflecting ultra-violet lights, and can furthermore include a layer of infrared reflector for reflecting infrared lights. The ultra-violet reflector or infrared reflector can be composed of single-layer optical film or multi-layer optical films; which can be manufactured with multi-layer polymer films, and there can also be additions of metal oxide particles or ultra-violet absorbent; and can be placed via lamination on any surface of the inter-stacked polymer films 100 through coating, extrusion or ultra-violet paste curing. Other function layers can be added for the inter-stacked polymer films 100, such as locating a structure layer for increasing the strength and resilience, a protection layer for increasing resistance to scratch, a Nano-layer with self-cleansing effect, or locating a micro structure layer with convergence, diffraction, or diffusion capability on any surface of the inter-stacked polymer films 100. The optical microstructure layer with specific optical effect can be prism shaped, pyramid shaped, hemisphere shaped, aspheric shaped, Frensel lens shaped, lenticular, or grating structured. Furthermore, the multilayer reflector 10 can be formed through single-axial or bi-axial stretching, so that the average transmittance rate of the multilayer reflector for light spectrum 380˜780 nm is selectively between 30% and 90%, thereby effectively controls the intensity of light. Also, when the multilayer reflector 10 is formed through bi-axial stretching, then according to differences in usage needs, the multilayer reflector 10 can selectively be polarized or non-polarized.
For example, the structure of the multilayer reflector 10 is formed through many layers of material stacked in sequence of refraction rate, such as shown in
Furthermore, the multilayer reflector 10 can utilize single-axial or bi-axial stretching formation, so as to effectively adjust P and S polarization pattern ratio; or utilize just the bi-axial stretching formation to generate lights that have no polarization pattern. Furthermore a surface structure can be located on any surface of the inter-stacked polymer films 100 that forms the internal part of the multilayer reflector 10. The surface structure not only provides physical structure characteristics of additional functionality such as anti-sticking and anti-scratching, but may also include a photo-catalyst layer or a self-cleansing layer that provides corresponding functionalities, such that when light beams enter the photo-catalyst layer then harmful environmental substances can be broken down. Besides specialized functionality, another function provided by locating a surface structure is to provide optical utility, such as providing structures that is prism shaped, pyramid shaped, hemisphere shaped, aspheric shaped, Fresnel lens shaped, or grating structured, or a combination thereof. Simply stated, by locating a surface structure on the surface of inter-stacked polymer films 100, the optical effects of convergence, blending, diffraction, and scattering can be generated.
During manufacturing process, especially while the multilayer reflector 10 is forming, the molecular chain and molecular orientation of the polymer internal structure can be varied through a stretching machine in a single-axial or bi-axial formation, so that its physical characteristic changes, and the parameter affecting the stretch formation includes stretching temperature, speed, scaling factor, contraction, formation path, and heat setting temperature and time.
If single-axial or bi-axial stretching formation is utilized, generally the scaling ratio of single-axial stretching is from 1.5 to 6 times, and possibly greater, which is dependent upon needs and film material. Therein the film material of the inter-stacked polymer films 100 includes polyethylene terephthalate (PET), polycarbonate (PC), tri-acetyl cellulose (TAC), polymethylmethacrylate (PMMA) particle, methylmethacrylate styrene (MS), polypropylene (PP), polystyrene (PS), polymethylmethacrylate (PMMA), cyclic olefin copolymer (COC), polyethylene naphthalate (PEN), ethylene-tetrafluoroethylene (ETFE), polylactide (PLA), or a mix or polymerization of these materials thereof. Those optical elements formed via single-axial stretching formation can have specific directional polarization effect, thereby be used to adjust polarized wavelength range for light.
If bi-axial stretching formation is utilized, the scaling factor for each axial can be different, and the stretching formation can be according to sequence or both axial simultaneously, so that besides able to adjust for wavelength range, P and S polarization pattern ratio of light passing through multilayer reflector 10 can also be managed, such that adjustment can be made to near non-polarized condition.
Referring to
Furthermore,
According to one of the embodiments of the instant disclosure, the multilayer reflector 10 is formed by a plurality of composite materials after repeatedly stacking in the co-extrusion procedure. The variant refractive indexes and thicknesses of the multilayer reflector 10 formed by multiple types of high-polymer meet the condition of optical interference that cause the light polarized and reflected. Since the interference condition is seriously defined, the coating technology used for the general optical lens often require multiple layers with high and low refractive indexes, such as dozen or hundred layers. In the instant disclosure, the multilayer reflector 10 can increase the reflectivity of polarized light by producing multiple times of interfered reflection through the multiple layers with high and low refractive indexes. That will be like the mentioned interference made by plural films. The multilayer reflector 10 will have better reflectivity to a certain wavelength when the multilayer reflector 10 has more layers stacked and better evenness control for higher variations of the refractive indexes. For example, the current embodiment repeatedly stacks the PET and PEN materials to form an (AB)n structure in the co-extrusion process. In which, n is an integer which is ranged within 10 to 500 based on the design, and the preferred value is within 120 through 180. When the temperature in the stretch procedure is controlled just as the anisotropy of the birefringence of the material happens, that is to make the refractive indexes of anisotropic and isotropic films change, and meanwhile the thickness with one-quarter wavelength is also employed, it is to accomplish the interference of multi-layer.
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In conclusion, the at least one multilayer reflector composed of the inter-stacked polymer films can be disposed on the image display screen, thus the vehicle display mirror of the instant disclosure can be used as a rear-view mirror of the vehicle and provide a clear displayed screen for user in the vehicle. Furthermore, at least one of the inter-stacked polymer films is a birefringence material layer that conforms to the condition of NX≠NY≠NZ, wherein NX is the index of refraction of light at X direction, NY is the index of refraction of light at Y direction, and NZ is the index of refraction of light at Z direction.
The above-mentioned descriptions merely represent the preferred embodiments of the instant disclosure, without any intention or ability to limit the scope of the instant disclosure which is fully described only within the following claims. Various equivalent changes, alterations or modifications based on the claims of instant disclosure are all, consequently, viewed as being embraced by the scope of the instant disclosure.
