U.S. patent application number 11/098163 was filed with the patent office on 2005-08-11 for rearview mirror with integrated frame.
Invention is credited to Bostwick, Daniel J., Carter, John W., Fogg, Jeremy A., Rumsey, Wayne, Ypma, Kenton J..
Application Number | 20050174663 11/098163 |
Document ID | / |
Family ID | 33097115 |
Filed Date | 2005-08-11 |
United States Patent
Application |
20050174663 |
Kind Code |
A1 |
Carter, John W. ; et
al. |
August 11, 2005 |
Rearview mirror with integrated frame
Abstract
An electrochromic mirror includes an integrated internal plate
frame with an electrochromic mirror subassembly adhered to its flat
front surface, electrical components supported on a rear with the
frame acting as a heat sink and EMI/RFI shield, and a back cover
supported on the plate frame. The subassembly is uniformly
supported across the front surface of the plate frame for good
mirror impact resistance. The mirror is supported by an angularly
adjustable ball-and-socket connection. In one embodiment, the ball
is formed integrally on the plate frame. The present mirror is
surprisingly thin, with at least 50% of the depth dimensions being
less than about 3.0 centimeters.
Inventors: |
Carter, John W.; (Holland,
MI) ; Rumsey, Wayne; (Zeeland, MI) ; Ypma,
Kenton J.; (Hudsonville, MI) ; Bostwick, Daniel
J.; (Grandville, MI) ; Fogg, Jeremy A.;
(Holland, MI) |
Correspondence
Address: |
PRICE, HENEVELD, COOPER, DEWITT, & LITTON,
LLP/GENTEX CORPORATION
695 KENMOOR, S.E.
P O BOX 2567
GRAND RAPIDS
MI
49501
US
|
Family ID: |
33097115 |
Appl. No.: |
11/098163 |
Filed: |
April 4, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11098163 |
Apr 4, 2005 |
|
|
|
10405526 |
Apr 2, 2003 |
|
|
|
Current U.S.
Class: |
359/879 ;
359/871 |
Current CPC
Class: |
B60R 1/088 20130101;
G02B 7/182 20130101 |
Class at
Publication: |
359/879 ;
359/871 |
International
Class: |
G02B 005/08; G02B
007/18; G02B 007/182 |
Claims
I claim:
1. A rearview mirror apparatus for vehicles comprising: a mirror
including an internal frame having a front surface, and an
electrochromic mirror subassembly supported on the front surface; a
mount adapted to support the mirror in a vehicle; and an
angularly-adjustable connector adjustably supporting the mirror on
the mount, the angularly-adjustable connector including a ball
section and a socket-defining section, with the ball section being
formed on one of the internal frame and the mount, and the
socket-defining section being formed on the other of the internal
frame and the mount; the socket-defining section receiving and
supporting the ball section for angular adjustment, but engaging
the ball section with sufficient force and friction to hold the
mirror in a selected angular position once the mirror is released
by a vehicle driver.
2. The apparatus defined in claim 1, wherein the socket-defining
section includes a casing connected to a plate frame and a bearing
positioned within the casing.
3. The apparatus defined in claim 2, wherein the casing is formed
of material that is contiguous and continuous with material of the
plate frame.
4. The apparatus defined in claim 3, wherein the plate frame
material is deep-draw material, and the casing is a tubular section
deep-drawn from the material of the plate frame.
5. A rearview mirror for vehicles comprising: an internal metal
plate; an electrochromic mirror subassembly supported in front of
the plate; and an electrical circuit supported by the metal plate
and operably connected to the electrochromic mirror subassembly,
the metal plate having heat conduction properties and acting as a
heat sink for the circuit.
6. A rearview mirror for vehicles comprising: an internal metal
plate; an electrochromic mirror subassembly supported in front of
the plate; and an electrical circuit supported by the metal plate
and operably connected to the electrochromic mirror subassembly,
the electrical circuit including electrical devices that generate
at least one of EMI emissions and RFI emissions, and the metal
plate having an integrally-formed section shaped to at least
partially cover and shield the electrical device to reduce EMI and
RFI emissions.
7. A rearview mirror for vehicles comprising: a mirror subassembly;
a frame supporting the mirror subassembly; a cover attached to the
frame and covering a back and edges of the mirror subassembly; and
the mirror subassembly forming a front surface and the cover
forming a rear surface of the mirror, the front and rear surfaces
including areas defining a plurality of different depth dimensions,
with at least 50% of the depth dimensions being less than about 3
centimeters.
8. The rearview mirror defined in claim 7, wherein each end section
is 25% of total width, and each end section is less than 3-cm
depth.
9. The rearview mirror defined in claim 7, wherein at least 50% of
the depth dimensions are less than about 2 centimeters.
10. A rearview mirror for vehicles comprising: an internal plate; a
back cover supported by the plate and covering a rear of the plate;
an electrochromic mirror element supported in front of the plate;
at least one button operably supported by the plate; and an
electrical circuit supported by the plate and operably connected to
the button for controlling an electrical feature of the
vehicle.
11. A plate frame adapted for use in a rearview mirror for vehicles
comprising: an internal plate frame including a smooth front
surface adapted for supporting a rearview mirror element; and an
integrally-formed protrusion extending rearwardly from the plate,
the protrusion including a stem and a ball section on an end of the
stem that is adapted to form a ball-and-socket connection for
angularly and adjustably supporting the internal plate and mirror
elements attached to and supported by the internal plate.
12. A mirror comprising the frame defined in claim 11, and
including an electrochromic mirror subassembly attached to the
smooth front surface and further including a mount having a socket
operably engaging the ball section for angular adjustment.
13. A plate frame adapted for use in a rearview mirror for vehicles
comprising: an internal plate frame including a smooth front
surface adapted for supporting a rearview mirror element; an
integrally-formed tubular section extending rearwardly from the
plate; and bearings forming a socket in an end of the tubular
section, the bearings being adapted to receive a ball section to
form a ball-and-socket connection for angularly and adjustably
supporting the internal plate frame and the rearview mirror element
on a mirror mount having the ball section.
14. A rearview mirror for vehicles comprising: an internal plate
frame having a smooth front surface; a reflector layer on the front
surface; an electrochromic material covering the reflector layer;
and a glass element on the electrochromic material that contains
the electrochromic material on the reflector layer against the
front surface.
15. The mirror defined in claim 14, including an electrical circuit
supported by the plate frame and operably connected to the
electrochromic material for controlling the electrochromic material
of the vehicle.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional of U.S. patent application
Ser. No. 10/405,526, entitled REARVIEW MIRROR WITH INTEGRATED
FRAME, which was filed on Apr. 4, 2003, now U.S. Pat. No.
______.
BACKGROUND
[0002] The present invention concerns vehicle mirrors, and more
particularly relates to rearview mirrors having an integrated
frame.
[0003] Interior and exterior rearview mirrors of modern passenger
vehicles have become heavier and heavier as more and more content
and features are added. For example, many modern vehicle mirrors
include several of the following options: electrochromic mirror
subassemblies and circuitry to reduce glare, keyless entry sensing
systems, microphone-speaker-antennae-- phone communication systems,
audio-control systems, compass and temperature devices and
displays, lighting, switches for control of electrical circuits,
and the like. Since most vehicle mirrors are supported from one
side (usually a back or topside), this added weight creates a
pendulum effect that causes the mirrors to shake, vibrate, and
resonate unacceptably. In order to reduce the shaking, vibration,
and resonation, the rear support area on most rearview mirrors is
beefed up to increase rigidity and stability, and/or reinforcement
ribs are added to the rear support area. However, any increase in
wall thickness and/or increase in the number of reinforcement ribs
adds to part weight, adds to sinks and blemishes and other quality
problems when molding the parts, and adds to part complexity.
Further, the added ribs take up substantial space, making a profile
of the mirrors much larger. It is desirable to provide a mirror
design where the number of reinforcement ribs and webs in a mirror
housing are minimized or eliminated, and where the mirror housing
is primarily designed as a cosmetic covering rather than a
structural member. It is noted that vehicle manufacturers have high
visual standards for the housings of interior rearview mirrors,
since vehicle passengers not only look at and touch the mirror
housings often, but also the mirrors are in a position where every
blemish and defect is easily seen.
[0004] Modern interior rearview mirrors are typically mounted from
their hidden backside by an elongated mount, and are made to be
angularly adjustable by a ball-and-socket connector that connects
the mirror to the mount. This allows each vehicle driver to
angularly adjust the mirror to an optimal position and preference.
The adjustable connector is made sufficiently rigid to hold the
mirror in a selected angular position, even when receiving
substantial vibrational stress. However, the adjustable connectors
include multiple separate parts and pieces that require assembly,
and further take up space. It would be desirable to provide a mount
where the ball and socket connection was better integrated into one
of the mirror components.
[0005] Still another concern is wire management. Modern vehicle
mirrors can have several wires connected to internal components
within the mirror head. These wires need to be managed so that they
do not become entangled or pinched during assembly or during
angular adjustment. Further, mis-positioning of wires can cause
substantial variation in electromagnetic interference and radio
frequency interference emitted from power-using electrical
components on the mirror, which is of increasing concern to vehicle
manufacturers. It is desirable to provide a mirror having an
integrated wire management system so that wires are well managed
and consistently located in the mirror, and so that the wires are
integrally shielded along with the electrical devices that they are
connected to.
[0006] Another concern is impact testing and vehicle safety. For
example, at least one vehicle manufacturer requires that the mirror
glass not break or result in separation of large glass pieces from
the mirror, particularly where the glass pieces are more than 2.5
mm from a crack line, since loose broken glass can be injurious to
a vehicle driver or passenger. Hence, it is important that glass
elements be supported in a manner that minimizes a tendency of the
glass to be sharply bent and broken upon impact, and that holds the
glass elements in a manner keeping broken pieces from coming loose
upon impact. This problem can be complicated in an electrochromic
(EC) mirror since an EC mirror has two glass elements with an EC
material therebetween.
[0007] In addition to the above problems, as mirrors have become
increasingly complex and sophisticated, the number of parts and
pieces necessary for assembly have increased. It is desirable to
provide an improvement where the many parts and pieces can be
assembled in a more open physical arrangement, rather than having
to be assembled into the cavity of a concave mirror housing. It is
also potentially preferable that the mirror housing be designed
more for "pure aesthetics", such that functional aspects are not as
much of a concern.
[0008] Accordingly, an apparatus is desired having the
aforementioned advantages and solving and/or making improvements on
the aforementioned disadvantages.
SUMMARY OF THE PRESENT INVENTION
[0009] In one aspect of the present invention, a rearview mirror
for vehicles includes an integrated plate frame, and an
electrochromic mirror subassembly including at least one glass
element and electrochromic material, with the subassembly being
supported by the plate frame. A circuit configured to operate the
electrochromic material is supported on a rear of the plate frame,
and a cover is supported by the plate frame that covers at least
one of the rear and edges of the plate frame.
[0010] In another aspect of the present invention, a rearview
mirror for vehicles includes an internal metal structural backing
plate having a flat front surface, and an electrochromic mirror
subassembly. The mirror subassembly includes front and rear glass
elements and electrochromic material therebetween, and is uniformly
supported on the front surface of the metal backing plate for good
impact resistance.
[0011] In another aspect of the present invention, a rearview
mirror apparatus for vehicles includes a mirror and a mount adapted
to support the mirror in a vehicle. The mirror includes an internal
frame having a front surface, and an electrochromic mirror
subassembly supported on the front surface. An angularly-adjustable
connector adjustably supports the mirror on the mount. The
angularly-adjustable connector includes a ball section and a
socket-defining section, where the ball section is formed on one of
the internal frame and the mount, and the socket-defining section
is formed on the other of the internal frame and the mount. The
socket-defining section receives and supports the ball section for
angular adjustment, but engages the ball section with sufficient
force and friction to hold the mirror in a selected angular
position once the mirror is released by a vehicle driver.
[0012] In another aspect of the present invention, a rearview
mirror for vehicles includes an internal metal plate, and an
electrochromic mirror subassembly supported in front of the plate.
An electrical circuit is supported on the metal plate and is
operably connected to the electrochromic mirror subassembly. The
metal plate has good heat conduction properties and acts as a heat
sink for the circuit.
[0013] In another aspect of the present invention, a rearview
mirror for vehicles includes an internal metal plate, and an
electrochromic mirror subassembly supported in front of the plate.
An electrical circuit is supported on the metal plate and is
operably connected to the electrochromic mirror subassembly. The
electrical circuit includes electrical devices that generate at
least one of EMI emissions and RFI emissions, and the metal plate
has an integrally-formed section shaped to at least partially cover
and shield the electrical device to reduce EMI and RFI
emissions.
[0014] In another aspect of the present invention, a rearview
mirror for vehicles includes a mirror subassembly, and a frame
supporting the mirror subassembly. A cover is attached to the frame
and covers a back and edges of the mirror subassembly. The mirror
subassembly forms a front surface and the cover forms a rear
surface of the mirror. The front and rear surfaces include areas
defining a plurality of different depth dimensions, with at least
50% of the depth dimensions being less than about 3
centimeters.
[0015] In another aspect of the present invention, a rearview
mirror for vehicles includes an internal plate. A back cover is
supported by the plate and covers a rear of the plate. An
electrochromic mirror element is supported in front of the plate.
At least one button is operably supported by the plate, and an
electrical circuit is supported by the plate and is operably
connected to the button for controlling an electrical feature of
the vehicle.
[0016] In still another aspect of the present invention, a plate
frame adapted for use in a rearview mirror for vehicles includes an
internal plate frame including a smooth front surface adapted for
supporting a rearview mirror element. An integrally-formed
protrusion extends rearwardly from the plate, the protrusion
including a stem and a ball section on an end of the stem that is
adapted to form a ball-and-socket connection for angularly and
adjustably supporting the internal plate and mirror elements
attached to and supported by the internal plate.
[0017] In yet another aspect of the present invention, a plate
frame adapted for use in a rearview mirror for vehicles includes an
internal plate frame including a smooth front surface adapted for
supporting a rearview mirror element. An integrally-formed tubular
section extends rearwardly from the plate. Bearings form a socket
in an end of the tubular section, the bearings being adapted to
receive a ball section to form a ball-and-socket connection for
angularly and adjustably supporting the internal plate frame and
the rearview mirror element on a mirror mount having the ball
section.
[0018] In another aspect of the present invention, a rearview
mirror for vehicles includes an internal plate frame having a
smooth front surface, a reflector layer on the front surface, an
electrochromic material covering the reflector layer, and a glass
element on the electrochromic material that contains the
electrochromic material on the reflector layer against the front
surface.
[0019] These and other aspects, objects, and features of the
present invention will be understood and appreciated by those
skilled in the art upon studying the following specification,
claims, and appended drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0020] FIGS. 1-2 are front and top views of a mirror assembly
embodying the present invention; FIG. 2A is similar to FIG. 2 but
showing a thinner mirror assembly;
[0021] FIGS. 3-4 are cross-sectional views taken along the lines
III-III and IV-IV in FIG. 1;
[0022] FIG. 5 is an enlargement of the circled area V in FIG.
3;
[0023] FIG. 6 is an exploded perspective view of the mirror in
FIGS. 1-4;
[0024] FIG. 7 is a fragmentary cross-sectional view taken
horizontally through a center of a first modified mirror
assembly;
[0025] FIG. 8 is a cross-sectional view taken along the line
VIII-VIII in FIG. 7;
[0026] FIG. 9 is a fragmentary cross-sectional view similar to FIG.
7 but of a second modified mirror assembly; and
[0027] FIG. 10 is a vertical cross-sectional view taken vertically
through a third modified mirror assembly, including a button and
switch operably positioned on the plate frame;
[0028] FIGS. 11-13 are a fragmentary side view, a cross section,
and a fragmentary side view of alternative plate frames, where the
plate frames include a tube, a ball and a socket to form a
ball-and-socket connection, FIG. 12 being a cross section taken
along line XII-XII in FIG. 11;
[0029] FIGS. 14-15 are top and front views of a mirror embodying
the present invention;
[0030] FIGS. 16-18 are cross sections, FIGS. 16 and 18 being taken
along the lines XVI-XVI and XVIII-XVIII in FIG. 14, FIG. 17 being
similar to FIG. 16 but with the back cover and bezel removed for
clarity;
[0031] FIG. 19 is an enlargement of the circled area XIX in FIG.
18;
[0032] FIGS. 20-21 are top and front views of a mirror embodying
the present invention;
[0033] FIGS. 22-23 are cross sections taken along the lines
XXII-XXII and XXIII-XXIII in FIG. 21;
[0034] FIGS. 24-25 are top and front views of another mirror
embodying the present invention;
[0035] FIGS. 26-29 are cross sections, FIGS. 26 and 28 being taken
along the lines XXVI-XXVI and XXVIII-XXVIII in FIG. 25, and FIGS.
27 and 29 being similar to FIGS. 26 and 28 but with the back cover
and bezel removed for clarity;
[0036] FIGS. 30-32 are front, cross section, and exploded
perspective views of additional mirrors embodying aspects of the
present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0037] An apparatus 18 includes a mount 33 supporting an EC mirror
20 for angular adjustment (FIGS. 1-4) on the front windshield 19 of
a vehicle. The electrochromic mirror 20 (FIG. 6) includes an
internal plate frame 21 (FIGS. 5-6) with an electrochromic (EC)
mirror subassembly 22 supported on a front surface 23 of the plate
frame 21. Electrical components 24 are supported by a circuit board
40 attached to a rear surface 25 (or to the front surface 23) of
the plate frame 21 with the plate frame 21 acting as a heat sink
and as an EMI and/or RFI shield, as discussed below. A back cover
26 and bezel 27 are supported on a perimeter edge 28 of the plate
frame 21 and cover the rear surface 25, the edge 28, and an outer
edge of the EC mirror subassembly 22. In the illustrated embodiment
of mirror 20, the EC mirror subassembly 22 is uniformly and
continuously supported across the front surface 23 of the plate
frame 21 (except at relatively small locations such as
display-receiving aperture 44) for good mirror impact resistance in
a vehicle crash. The mirror 20 is supported by an angularly
adjustable ball-and-socket connection 30 (FIG. 6) formed by a ball
section 31 on a glass-attached mount 33, and a mating socket 32 in
an attachment component 34 attached directly to the plate frame
21.
[0038] In the illustrated mirror 20 (FIG. 6), the socket 32 is
formed by an attachment component 34 attached directly to the plate
frame 21, and the ball section 31 is formed on a mount 33. Due to
the improvements associated with the plate frame 21, (and also
plate frame 21A, 21B and 21C described below) including its high
strength and wide reach while maintaining a minimal thickness, the
present mirror 20 (and mirrors 20A-20C) is surprisingly thin, with
at least 50% of the depth dimension D1 (FIG. 3) being less than
about 3 centimeters, and at least 50% of the depth dimensions being
less than 15% of the maximum width dimension W1. More preferably,
at least about 50% of the depth dimensions are less than about 3.0
cm, and also are less than about 12% of a maximum width dimension.
Further, it is estimated that a weight of the mirror head can be
reduced by 10%-20% (see FIG. 5, the mirror head including the
attachment component 34 but not including the ball section 31) and
can be reduced by as much as by 30%-40% (see FIGS. 7-10, the mirror
head including a metal plate with an integrally formed ball section
with wireway hole therethrough but not including the mount with
socket-forming bushings and coil spring). The present arrangement
takes maximum advantage of the high strength internal frame 21 and
the lightweight cover 26 (as opposed to a much heavier plastic rear
housing with stiffening ribs around the pivotal-adjusting
connection area) and further reduces a tendency of the mirror 20 to
vibrate since there is a lower pendulum effect. Specifically, the
mirror 20 has a center of gravity closer to the ball-and-socket
connection, due to the thinner total mirror thickness, and has a
reduced pendulum effect due to its lighter weight.
[0039] It is noted that the integrated plate frame 21 can be made
from a variety of different metals and also potentially can be made
from some composite materials that are capable of maintaining a
very flat front surface for supporting the glass. Thermal expansion
is important to maintaining flatness under the widely varying
temperatures often seen in vehicle passenger compartments. In
particular, plate frame materials having a thermal expansion close
to the thermal expansion of glass have less tendency to create
bowing and localized surface distortions, since there are less
stresses developed due to dissimilar thermal expansions. For
example, it has been found that steel will work well for plate
frame 21, since glass has a thermal expansion of about
4.5.times.10.sup.-6 in/in/oF (8.0 mm/mm/oK), while steel has a
thermal expansion of about 6.5.times.10.sup.-6 in/in/oF (11.5.0
mm/mm/oK). Alternatively, magnesium has a thermal expansion of
about 13.8.times.10.sup.-6 in/in/oF (24.5 mm/mm/oK), while aluminum
has a thermal expansion of about 13.0.times.10.sup.-6 in/in/oF
(23.9 mm/mm/oK), and ABS/PC plastic has a thermal expansion of
about 40.times.10.sup.-6 in/in/oF (71 mm/mm/oK), Nonetheless, it is
noted that each of these materials can be used in combination with
the present inventive concepts to produce a mirror having
beneficial aspects where the plate frame design is modified to
accommodate the dissimilar thermal expansion.
[0040] A brief discussion follows that is sufficient to provide an
understanding of the present invention to persons skilled in this
art. Nonetheless, it is noted that electrochromic mirror
subassemblies, such as EC subassembly 22, are generally well known
in the art. Thus, a detailed description is not necessary to
provide an understanding of the present invention to a person
skilled in this art. Further, though a particular EC mirror
subassembly is shown, it is specifically contemplated that the
present inventive concepts will work on many such EC mirror
subassemblies.
[0041] Briefly, the illustrated EC subassembly 22 (FIG. 5) includes
front and rear glass elements 35 and 36, with a layer of
electrochromic (EC) material 37 between. Top and bottom electrical
conductors 35' and 36' (FIG. 6) are connected to opposing sides of
the EC material 37 and are operably connected to a control circuit
41 on a circuit board 40, described below.
[0042] The reflective layer 38 is located either on the front
surface of the rear glass element 36 (called a third surface
reflector) or on the rear surface of the rear glass element 36
(called a fourth surface reflector). In the present arrangement,
there is a double-sided tape 39 adhering a rear of the EC mirror
subassembly 22 to the front surface 23 of plate frame 21. It is
contemplated that other attachment means could be used instead of
adhesive tape, such as a layer of adhesive. Alternatively,
mechanical edge connectors (such as tabs or resilient fingers) near
edges of the plate frame 21 could be used to retain the EC
subassembly 22 to the plate frame 21 in a multi-layer arrangement
permitting some lateral slippage of the EC subassembly 22 on the
plate frame 21. It is contemplated that the EC subassembly 22 could
also be retained to the plate frame 21 by the bezel 27.
Alternatively, it is conceived that the reflective layer 38 can be
formed directly on a front surface of the internal plate frame 21
as a third surface reflector, and the second glass element 36
eliminated.
[0043] The illustrated plate frame 21 is preferably made from a
stiff, strong material (such as steel or magnesium) having a high
strength-to-weight ratio, is dimensionally very stable, and further
has properties allowing it to be made with a very uniform and
consistently flat surface. The magnesium material has a thermal
expansion rate of about 13.8.times.10.sup.-6 in/in/oF (24.5
mm/mm/oK), which, based on testing, is similar enough to the
thermal expansion of glass to provide a stable arrangement
satisfactory for many automotive applications. However, it is noted
that other metals, such as steel, has thermal expansion properties
closer to glass. In particular, steel has a thermal expansion of
about 6.5.times.10.sup.-6 in/in/oF (11.5.0 mm/mm/oK), which is
relatively close to the thermal expansion of about
4.5.times.10.sup.-6 in/in/oF (8.0 mm/mm/oK) for glass.
[0044] Where the thermal expansion of such materials is not as well
matched to glass, care must be used in attaching the EC subassembly
21 to the plate frame to minimize stress during assembly and to
avoid unacceptable distortions and non-uniform stress in the glass
elements 35 and 36, since such distortions can result in buckling
or cracking of the glass and/or distortion of reflected images. The
fluidity and tackiness of the adhesive tape 39 can also be
important in reducing or distributing stress, including stress from
thermal expansion or contraction. Also, the thickness of the glass
elements is important in preventing distortion of reflected images.
For example, by using magnesium or steel, it has been found that a
thickness of the rear glass element 36 can be reduced from the more
normal glass thickness of about 2.2+mm, to a reduced glass
thickness as low as about 1.6 mm, and potentially even as low as
1.1 mm, and the front glass element 35 can be reduced in thickness
to about 1.6 mm or even lower, depending upon functional
considerations of the mirror design. When aluminum is used, it is
conceived that the thickness of plate frame 21 itself can be
reduced to a surprisingly thin dimension, such as about 1.0 to 1.5
mm thick. When die-cast grade magnesium is used, it is conceived
that the thickness of plate frame 21 can be reduced even more, such
as to about 1.0 mm or less. Also, apertures can be cut into the
plate frame to further reduce weight, with the apertures having a
size sufficiently small enough to allow the glass elements of the
mirror subassembly to span the apertures without distortion.
[0045] The electrical components 24 (FIG. 6) are mounted on a
circuit board(s) 40 and are interconnected to each other to form an
electrical circuit 41 operably connected to the EC material 37 for
darkening the EC material 37 to reduce a reflection of glaring
headlights of vehicles following the vehicle of mirror assembly 20.
The electrical control circuit 41 includes wires 42 that connect to
a vehicle wiring harness that extends from the mount 33 up and
along the vehicle roof and down the vehicle's "A" pillar to the
vehicle's electrical system.
[0046] The plate frame 21 (FIG. 6) (also called an internal,
integrated frame) is made of metal such as magnesium, which is
particularly strong and dimensionally accurate. The plate frame 21
is sufficiently strong to be the primary support for mirror 20. The
EC mirror subassembly 22 is attached to a front surface of the
plate frame by a double-sided adhesive tape 39 (FIG. 5). A compass
and temperature display 43 can be added, which fits into an
aperture/pocket 44 in a face of the plate frame 21. The illustrated
pocket 44 extends completely through the plate frame 21, but it is
contemplated that it could instead be a recess that extends only
partially into the plate frame 21. Circuit boards 40 include edges
or tabs that are frictionally attached or that are heat staked onto
the rear surface of the plate frame 21, and carry components such
as diodes, lights, displays, switches, and other components 24.
Alternatively, components such as diodes, lights, LEDs, displays,
displays, switches, and the like can also be mounted directly on
the plate frame 21, either on the front or rear surfaces 23 and 25,
or in recesses or apertures in the front or rear of the plate frame
21. Advantageously, the plate frame 21 is thermally conductive, and
acts as a very good heat sink for power-using components of the EC
control circuit 41 and for heat generating components such as
diodes, light sources, LED and the like. Also, the plate frame 21
is an excellent shield against electromagnetic interference (EMI)
and radio frequency interference (RFI). Thus, the plate frame 21
acts as an excellent shield where wire management channels and
apertures are provided and the wires are well managed tightly
against a rear surface of the mirror subassembly, or where tabs are
formed to partially encase the component. (See FIGS. 7-10.)
[0047] Since the plate frame 21 is the main structural member that
carries a load of the mirror 20, the cover 26 is merely an
aesthetic enclosure hung on the plate frame 21. Accordingly, the
cover 26 no longer requires the ribs and thickness required of
traditional mirror housings, especially around the mounting area
near the ball-and-socket connection 30. Instead, the cover 26 can
thus be nothing more than a cover. This has great advantages, since
the cover 26 can be made thinner, lighter, and from less expensive
plastic. Further, molding of the cover 26 is simplified and quality
improved over prior housings, since the stiffening ribs and webs
around the socket area are eliminated. (In prior art, the
stiffening ribs and webs were a quality problem, since they tend to
cause molding problems including sinks and visible marks on an
outside of the housing. Further, the ribs and webs made the mold
tooling much more expensive and difficult to maintain.)
[0048] Bezel 27 (FIG. 5) extends around a perimeter of the EC
mirror subassembly 22, and has a J-shaped cross section. The
J-shaped cross section includes a straight side section 50 spaced
from an edge of the glass elements 35 and 36, and a front arching
section 51 with an end that curls around and engages the front
surface of the front glass element 35 slightly inboard of an edge
of the glass element 35. The side section 50 includes a configured
trailing end with a notch 52 shaped to engage a tip 54 of the plate
frame 21, and a tapered end 53.
[0049] The outer perimeter edge of the plate frame 21 includes the
tip 54 that engages notch 52, and further includes a
rearward-extending perimeter lip 55 forming a recess on a rear side
of the plate frame 21 for receiving the circuit board 40. Bosses
55' and/or stand-offs and/or tabs are located on a rear of the
plate frame 21 for attachment of items to the plate frame 21. For
example, the bosses 55' receive screws to securely attach the
attachment component 34 to the plate frame 21. The plate frame 21
still further includes a rearward extending attachment flange 56.
The cover 26 includes an outboard flange 57 that overlaps the
tapered end 53 of the bezel 27. The illustrated outboard flange 57
of the cover 26 is spaced from and does not engage or press on the
bezel side section 50 (and notch 52). Instead, there is a gap
formed therebetween so that there is no risk of squeaking or
rattling. However, it is contemplated that the overlap could be
constructed so that the outboard flange 57 presses on the bezel
side section 50 to maintain engagement of the tip 54 of the plate
frame 21 with the notch 52. The outboard flange 57 on the cover 26
includes an inwardly extending protrusion 58 that engages an
aperture 59 on the attachment flange 56 of the plate frame 21. A
second attachment flange 60 on the cover 26, which lies parallel
and inboard of the flange 56, engages an inside surface of the
attachment flange 56 and helps keep the protrusion 58 in secure
attachment with the aperture 59.
[0050] The cover 26 includes a relatively thin rear wall 26' of
uniform thickness, with minimal reinforcement ribs and webs, since
they are not needed for structure. A perimeter wall 26' (FIG. 6)
extends forwardly from the rear wall 26' to define a concave shape.
A top portion of the perimeter wall 26' includes a forwardly open
slot 62 for receiving the ball-and-socket connection 30.
[0051] There are a variety of different mounts that can be used to
hold the present mirror 20, including single and double
ball-and-socket mounts. The illustrated mount 33 (FIG. 6) includes
an injection-molded or die-cast base 65 adapted for connection to a
window-adhered bracket 66 via a clip 67 on the base 65. The clip 67
engages opposing sides of the bracket 66. A tunnel cover 68
telescopingly attaches to a top flange 69 of the base 65 for
covering wires 42 extending from the mirror 20 up through
attachment component 34 and base 65 to a location above a vehicle
headliner. The base 65 includes reinforcement ribs and webs to
secure a down stem 70, which stem 70 supports the ball section 31.
A wireway is formed through the ball section 31 and stem 70 for
routing wires from the mirror 20 (or, alternatively, the wires can
be routed parallel and above the stem 70 in a semi-hidden
position).
[0052] The attachment component 34 (FIG. 6) includes a crown
section 72 and an attachment section 73. The attachment section 73
includes a triangularly-shaped flat side 74 shaped for stably
engaging a rear surface of the plate frame 21. Three apertured
bosses 75 on the attachment section 73 align with three apertured
bosses 76 in the plate frame 21, for receiving screws 77 to secure
the plate frame 21 to the attachment section 73. The attachment
section 73 is generally hollow to facilitate molding, but includes
one or more reinforcement ribs 78 that stiffen and strengthen the
attachment section 73. The illustrated component 34 includes a
wireway passage that extends laterally through the attachment
component 34 and upwardly through a center of the crown section 72.
The crown section 72 includes a plurality of resilient protrusions
79 that extend upwardly, and that have outer surfaces forming a
cylinder for receiving a hoop clamp 80, and that have inner
surfaces forming a socket 32 for receiving the ball section 31. As
the ball section 31 is extended downwardly into the socket 32, the
protrusions 79 flex outward and then return to their inward
positions. Thereafter, the clamp 80 is applied, holding the
protrusions 79 snugly against the ball section 31 for adequate
static friction to hold a selected position, but with sufficient
controlled force to permit angular adjustment. It is noted that the
ball section 31 and stem 70 could be designed to extend rearwardly,
instead of downwardly.
[0053] It is noted that the bezel 27 (FIG. 6) includes a rearwardly
extending tab 82 that closes a front portion of the slot 62 in a
top of the cover 26.
[0054] Mirror 20' (FIG. 2A) is similar to mirror 20 (FIG. 2),
except that mirror subassembly 20' includes a back cover 26' 30%
thinner in depth. (The front profile of the mirror subassembly 20'
and its internal components are basically the same as mirror 20.)
Also, the mount 33' of the apparatus 18' has a different shape.
[0055] The mirrors shown in FIGS. 7-29 are similar to but are
modified from the mirror 20. Features and characteristics on the
mirrors that are identical or similar to mirror 20 are identified
using identical numbers along with the letters "A", "B", etc.,
respectively, to reduce redundant discussion.
[0056] In the illustrated mirror 20, the socket 32 is formed by an
attachment component 34 that is attached directly to the plate
frame 21, and the socket 32 is formed on a mount 33. In a second
embodiment of FIGS. 7-8, the plate frame 21A of a mirror 20A
includes a ball section 31A and stem 70A formed integrally from the
material of the plate frame 21A (FIGS. 7-9). The ball section 31A
and stem 70A extend rearward from the plate frame 21. It is noted
that several different materials may be used to form the plate
frame 21A with integral ball section 31A and stem 70A, such as
magnesium, aluminum, and deep draw steels and even potentially a
strong, stiff plastic or composite.
[0057] The mirror 20A (FIGS. 7-8) includes a plate frame 21A
attached to a mount 33A. The illustrated plate frame 21A is a
die-cast magnesium part, with an integrally formed stem 70A and
ball section 31A integrally cast onto a back side of the plate
portion 89A of the plate frame 21A. The mount 33A includes a tube
90A with a formed end 91A holding socket-forming bearings 32A
against the ball section 31A. A coil spring 92A biases the bearings
32A against the end 91A. It is contemplated that mount 33A can be a
one-ball mount, with the ball-and-socket connection 30A being only
at a single end, or can be a two-ball mount, with a ball-and-socket
connection at each end. The illustrated stem 70A and ball section
31A have a wireway/passageway 94A formed therethrough for passing
wires 42A from the mirror 20A to the mount 33A. A lateral opening
95A is formed at a root of the stem 70A, slightly above the plate
portion 89A of the plate frame 21A. The opening permits wires 42A
to be passed out a side of the stem 70A to locations optimally
suited for attachment to electrical components 24 and circuit 41.
It is contemplated that the passageway 94A can be a hole requiring
feed-through of wires 42A, or can be an open channel with an
overhanging side flange permitting lay-in of wires 42A (with the
overhanging flange both helping to contain the wires and also
shield any EMI or RFI emissions).
[0058] Mirror 20B (FIG. 9) includes a plate frame 21B made from a
sheet of a deep-draw steel. The stem 70B and ball section 31B are
formed from the material of the plate portion 89B of the plate
frame 21B. A shielding tunnel or channel 97B is formed on a face of
the plate portion 89B for managing wires 42B as the wires 42B pass
from the passageway 94B along the channel 97B and through the
aperture 44B. The channel 97B can be formed under the second mirror
element 36, with the mirror element 36 bridging over the channel
97B. Alternatively, the channel 97B can be formed in a chin area of
the mirror 20B, below the EC mirror subassembly 22B, where the
electrical connector or device 98B does not interfere with the
glass elements of the EC mirror subassembly 22B. For example, the
device 98B could be a button on the "chin" area of a mirror
assembly 20B. Alternatively, a channel (not unlike channel 97B) can
be formed on a side of the plate portion 89B for communicating
wires 42B along a side of the plate portion 89B. Notably, the
channel 97B is large enough to carry the wires 42B without a tight
fit, but the access opening to the channel 97B is sufficiently
small such that the elements 36 of the EC mirror subassembly 22B
can span the access opening without distortion as they bridge the
access opening.
[0059] Mirror 20C (FIG. 10) includes a plate frame 21C and a
circuit board 40C, with buttons 100C and switches 101C operably
mounted directly onto and into the plate frame 21C and the circuit
board 40C. FIG. 10 is a vertical cross section taken through a
lower central "chin" area on the mirror 20C. The vertical cross
section passes through the button 100C and shows each of the plate
frame 21C, the circuit board 40C, the bezel 27C, the button 100C,
and the components of the switch 10C. The lower portion 89C' of the
plate portion 89C of the plate frame 21C includes an aperture 102C
for receiving the button 100C, and further includes a forward rib
103C. The rib 103C includes a tip that forms a top pivot/guide for
the button 100C and further includes a bottom tip that forms a stop
that engages the button 100C for limiting the maximum depth of
movement of the button 100C when the button 100C is depressed. The
rib 103C also promotes a better and more consistent gap and
appearance around the button 100C. Alternatively, it is
contemplated that the rib 103C and lower portion 89C' can be
components separate from the plate frame 21C. In such case, they
would be attached to and supported on the circuit board 40C or
attached to and supported on the bezel 27C.
[0060] Two electrical contacts 105C and 106C are positioned on the
circuit board 40C and connected to the electrical control circuit
41C on the circuit board 40C. A patch of resilient film 107C is
positioned over the electrical contacts 105C and 106C, and an
electrically conductive member 108C is attached under the patch
107C in a position where it will electrically connect the contacts
105C and 106C when the switch 101C is made. The button 100C is
positioned over the patch of film 107C. When the button 100C is
depressed, the button 100C depresses film 107C and moves the
conductive member 108C into operative contact with the contacts
105C and 106C, completing the circuit for operating whatever
electrical device is connected to the electrical contacts 105C and
106C. When the button 100C is released, the resilient patch of film
107C biasingly moves the button 100C back to an at-rest position,
where the conductive member 108C disconnects from the contacts 105C
and 106C and breaks the circuit.
[0061] Though mirrors 20-20C are flat mirrors, it is contemplated
that the present arrangement could be used in non-flat mirrors and
aspheric mirrors. Such mirrors are often used in Europe. Such
mirrors have glass elements that are bent or dished. Thus,
reflected images seen in the mirror are reduced in size, but a
larger viewing area is visible.
[0062] In the embodiment of FIG. 11, a mirror 20D includes an
internal plate frame 21D having a tubular section 109D integrally
formed thereon that extends rearwardly. The tubular section 109D
includes longitudinally extending grooves 110D, three such grooves
being illustrated. A crown-shaped bearing 72D defines a socket 32D
for receiving a ball section 31D. An annular spring 11D extends
around the tube section 109D and includes inwardly extending
sections 112D (FIG. 12) that extend into the grooves 110D in the
tube section and into grooves 113D in the crown bearing 72D, to
retain the crown bearing 72D in place. Thus, the ball section 31D
engages the socket 32D in the crown bearing 72D to form an
angularly adjustable ball and socket connection. A hole 94D extends
through the stem 70D and through the ball section 31D to allow wire
passage.
[0063] In the mirror arrangement 20E (FIG. 13), the plate frame 21E
includes a tube section 109E similar to tube section 109D (FIG.
11). However, an end of the tube section 109E includes an annular
ridge or a plurality of protrusions or detents 115E that extends
outwardly. The crown 72E includes an inner portion 116E that forms
the socket 32E. A spring 111E wraps around the crown and biases the
inner sections 116E inwardly against the ball section 31E. An
annular trailing flange 117E on the crown 72E extends from the
inner portion 116E around the end of the tube section 109E. The
annular reversed flange 117E includes a recess that mateably
snap-lockingly engages the detent 115E to retain the crown bearing
72E in position. The stem sections 70E extend from the ball section
31E and integrally connects to a mount for attachment to a vehicle
windshield.
[0064] Mirror 20F (FIGS. 14-19) discloses a complete mirror having
a construction similar to mirror 20A and 20B. In particular, we
note the plate frame 21F that incorporates an elongated tunnel 97F
forming a shield for wires 42F. Notably, the shield 97F further
includes an enlarged tab 97F' that partially shields a circuit
board 98F. Also, the button 100F (FIG. 19) includes a switch 101F
mounted on a circuit board 98F and that is operable by button 100F
under the mirror subassembly 22F and through a hole 21F' in the
integrated plate frame 21F. A bezel 50F extends around the
arrangement and includes a lip 50F' that snappingly engages an end
54F of the plate frame 21F to retain the bezel in position. The
back cover 26F also includes a front edge 26F' that engages the
edge of the plate frame 21F to retain the back cover in position,
such as by a similar snap-attach connection.
[0065] Mirror 20G (FIGS. 20-23) includes a mirror arrangement
similar to the integrally formed ball section and stem of the plate
frame 21A of mirror 20A (FIG. 7), however, the ball section 31G and
stem 70G are formed from a deep-draw material that is flowed and
formed into the tube section 70G and ball section 31G to have a
constant thin wall. Also, the tunnel shield 97G (FIG. 22) is formed
on a backside of the plate frame 21G and further an aperture or
hole 95G is formed in a base or root of the stem 70G for egress and
entrance of wiring. Still further, a button arrangement 100G (FIG.
23) is formed along a lower central edge of the mirror in a chin
area similar to mirror 20G (FIG. 23). The illustrated button 100G
is operably supported on the bezel 27G, and the switch 10G is
supported on the circuit board 40G.
[0066] The mirror 20H (FIGS. 24-29) includes a plate frame 21H
(FIG. 26), an electrochromic mirror subassembly 22H supported on
the plate frame 21H, and a bezel 27H and back cover 26H. The plate
frame 21H includes a cup-shaped mount 120H including a flat wall
121H formed from the material of plate portion 89H of plate frame
21H. A connection member 122H includes a flat base 1231H that
engage wall 121H, a stem 124H, and a ball section 31H. A washer
125H is positioned under the flat section 121H with the base 123H
opposite the washer 125H. A screw 126H includes a head 127H
positioned within the cup-shaped member 121H, and includes a
threaded shaft 127H' that extends through a hole in the washer
125H, through a hole in the flat wall 121H, and threadably into a
hole that extends up through stem 124H into ball section 31H. The
screw 126H includes a length that extends substantially into the
ball section 311H. However, it is contemplated that the shaft
length of the screw 126H can be significantly shorter. Further, the
hole can be extended through the ball section 31H and connected to
a passageway formed laterally out of a side of the stem 124H. Thus,
a wire passageway can be formed to communicate wires centrally
through the ball section 311H into the stem 124H and out a side of
the stem under the cover 26H into a backside of the plate frame
211H for connection to circuitry within the mirror.
[0067] It is contemplated that the present inventive concepts can
be used in combination with mirrors (interior and/or exterior)
having many different options to create synergistic and non-obvious
combinations that provide surprising and unexpected benefits not
previously possible. For example, turning now to FIG. 30, an
interior mirror assembly 502 includes a bezel 555 and a case 556
mounted on an internal frame 621 (FIG. 31). The bezel and the case
combine to define a mirror housing for incorporation of features in
addition to a reflective element and information display. Commonly
assigned U.S. Pat. No. 6,102,546; U.S. D Pat. No. 410,607; U.S.
Pat. Nos. 6,407,468; 6,420,800; and 6,471,362, the disclosures of
which are incorporated in their entireties herein by reference,
describe various bezels, cases, and associated button construction
for use with the present invention.
[0068] As depicted in FIG. 30, the mirror assembly may include top
and/or bottom microphones 559. Examples of microphones for use with
the present invention are described in commonly assigned U.S.
patent application Ser. Nos. 09/144,176 and 10/076,158, the
disclosures of which are incorporated in their entireties herein by
reference. As depicted in FIGS. 30-32, the microphone 561 or
microphones 560 may be mounted on the top of the mirror assembly,
on the bottom of the mirror assembly, on the backside of the mirror
case, or anywhere within the mirror case or bezel. Preferably, two
microphones are incorporated, one near each end, into the mirror
assembly on the backside of the mirror case within the recessed
portion as shown in FIGS. 30-32. These systems may be integrated,
at least in part, in a common control with information displays
and/or may share components with the information displays. In
addition, the status of these systems and/or the devices controlled
thereby may be displayed on the associated information
displays.
[0069] With further reference to FIG. 30, mirror assembly 502
includes first and second illumination assemblies 567, 571. Various
illumination assemblies and illuminators for use with the present
invention are described in commonly assigned U.S. Pat. Nos.
5,803,579; 6,335,548; and 6,521,916, the disclosures of which are
incorporated in their entireties herein by reference. As further
depicted in FIG. 32, each illumination assembly preferably
comprises a reflector, a lens, and an illuminator (not shown). Most
preferably, there are two illumination assemblies, with one
generally positioned to illuminate a driver seat area. There may be
only one or may be additional illuminator assemblies, such as one
to illuminate a center console area, overhead console area or an
area between the front seats.
[0070] With further reference to FIG. 30, mirror assembly 502
includes first and second switches 575, 577. Suitable switches for
use with the present invention are described in detail in commonly
assigned U.S. Pat. Nos. 6,407,468; 6,420,800; 6,471,362; and
6,614,579, the disclosures of which are incorporated in their
entireties herein by reference. These switches may be incorporated
to control the illumination assemblies, the displays, the mirror
reflectivity, a voice-activated system, a compass system, a
telephone system, a highway toll booth interface, a telemetry
system, a headlight controller, a rain sensor, etc. Any other
display or system described herein or within the references
incorporated by reference may be incorporated in any location
within the associated vehicle and may be controlled using the
switches.
[0071] With further reference to FIG. 30, mirror assembly 502
includes indicators 583. Various indicators for use with the
present invention are described in commonly assigned U.S. Pat. Nos.
5,803,579; 6,335,548; and 6,521,916, the disclosures of which are
incorporated in their entireties herein by reference. These
indicators may indicate the status of the displays, the mirror
reflectivity, a voice-activated system, a compass system, a
telephone system, a highway toll booth interface, a telemetry
system, a headlight controller, a rain sensor, etc. Any other
display or system described herein or within the references
incorporated by reference may be incorporated in any location
within the associated vehicle and may have a status depicted by the
indicators.
[0072] With further reference to FIG. 30, mirror assembly 502
includes first and second light sensors 586, 588 (glare and ambient
sensors in FIG. 7). Preferred light sensors for use within the
present invention are described in detail in commonly assigned U.S.
Pat. Nos. 5,923,027 and 6,313,457, the disclosures of which are
incorporated in their entireties herein by reference. The glare
sensor and/or ambient sensor automatically control the reflectivity
of a self-dimming reflective element as well as the intensity of
information displays and/or backlighting. The glare sensor is used
to sense headlights of trailing vehicles and the ambient sensor is
used to detect the ambient lighting conditions that the system is
operating within. In another embodiment, a sky sensor may be
incorporated positioned to detect light levels generally above and
in front of an associated vehicle, the sky sensor may be used to
automatically control the reflectivity of a self-dimming element,
the exterior lights of a controlled vehicle and/or the intensity of
information displays.
[0073] With further reference to FIG. 30, mirror assembly 502
includes first, second, third, and fourth operator interfaces 590,
591, 592, 593 located in mirror bezel 555. Each operator interface
is shown to comprise a backlit information display "A", "AB", "A1",
and "12". It should be understood that these operator interfaces
can be incorporated anywhere in the associated vehicle, for
example, in the mirror case, accessory module, instrument panel,
overhead console, dashboard, seats, center console, etc. Suitable
switch construction is described in detail in commonly assigned
U.S. Pat. Nos. 6,407,468; 6,420,800; 6,471,362; and 6,614,579, the
disclosures of which are incorporated in their entireties herein by
reference. These operator interfaces may control the illumination
assemblies, the displays, the mirror reflectivity, a
voice-activated system, a compass system, a telephone system, a
highway toll booth interface, a telemetry system, a headlight
controller, a rain sensor, etc. Any other display or system
described herein or within the references incorporated by reference
may be incorporated in any location within the associated vehicle
and may be controlled using an operator interface or interfaces.
For example, a user may program a display or displays to depict
predetermined information or may program a display or displays to
scroll through a series of information, or may enter set points
associated with certain operating equipment with associated sensor
inputs to display certain information upon the occurrence of a
given event. In one embodiment, for example, a given display may be
in a non-illuminated state until the engine temperature is above a
threshold, the display then automatically is set to display the
engine temperature. Another example is that proximity sensors
located on the rear of a vehicle may be connected to a controller
and combined with a display in a rearview mirror to indicate to a
driver the distance to an object; the display may be configured as
a bar that has a length proportional to the given distance.
[0074] Although specific locations and numbers of these additional
features are depicted in FIG. 30, it should be understood that
fewer or more individual devices may be incorporated in any
location within the associated vehicle and as described within the
references incorporated herein.
[0075] Turning now to FIG. 31, there is shown a section view of a
mirror assembly 602, with a reflective electrochromic subassembly
605 adhered to an internal plate frame 621 with double-sided
adhesive foam tape 622. Attachment component 634 is screwed to (or
integrally formed from) plate frame 621 and defines a crown 672
that engages a ball section 624. The depicted section of FIG. 31 is
taken along cut line 6-6 of FIG. 30, shows a preferred positional
relationship of third and fourth information displays 626, 641 with
respect to reflective EC element 605 along with third information
display backlighting 627 within a housing defined by case 656 and
bezel 655. Mirror assembly 602 is also shown to comprise a
microphone 659; first operator interface 690; along with circuit
board 695; mirror mount 657 and accessory module 658. The mirror
mount 657 and/or an accessory module 658 may comprise compass
sensors, a camera, a headlight control, an additional
microprocessor, a rain sensor, additional information displays,
additional operator interfaces, etc.
[0076] Turning now to FIG. 32, there is shown an exploded view of a
mirror assembly 702. FIG. 32 provides additional detail with regard
to one preferred positional relationship of individual components,
as well as providing additional structural detail of a mirror
assembly. Mirror assembly 702 comprises a reflective element 705
within a bezel 755 and a mirror case 756. A mirror mount 757 is
included for mounting the mirror assembly within a vehicle. It is
noted that a person skilled in the art of vehicle mirror design can
re-design the bezel 755, mirror case 756, and tube mount 757 to be
replaced with other bezel designs and/or mirror housing designs
previously described in this application. It should be understood
that a host of accessories may be incorporated into the mount 757
and/or onto the plate frame 621 in addition to a power pack
adjuster, such as a rain sensor, a camera, a headlight control, an
additional microprocessor, additional information displays, compass
sensors, etc. These systems may be integrated, at least in part, in
a common control with information displays and/or may share
components with the information displays. In addition, the status
of these systems and/or the devices controlled thereby may be
displayed on the associated information displays.
[0077] Mirror assembly 702 is shown in FIG. 32 to further comprise
third information display 726 with third information display
backlighting 737, 738, 739; first and second microphones 760, 761;
and including other known options such as a first reflector with a
first lens; a second reflector with a second lens; a glare sensor;
an ambient light sensor; first, second, third, and fourth operator
interfaces 790, 791, 792, 793, with first, second, third, and
fourth operator interface backlighting 790a, 791a, 792a, 793a; a
circuit board 795 having a compass sensor module 799; and a
daughter board 798 with an input/output bus interface 797.
[0078] Preferably, the illumination assemblies with associated
light source are constructed in accordance with the teachings of
commonly assigned U.S. Pat. Nos. 5,803,579; 6,335,548; and
6,521,916, the disclosures of which are incorporated in their
entireties herein by reference.
[0079] Preferably, the glare light sensor and the ambient light
sensor are active light sensors as described in commonly assigned
U.S. Pat. Nos. 6,359,274 and 6,402,328, the disclosures of which
are incorporated in their entireties herein by reference. The
electrical output signal from either, or both, of the sensors may
be used as inputs to a controller 796 on the circuit board 740 or
795 to control the reflectivity of reflective element 705 and/or
the intensity of third information display backlighting. The
details of various control circuits for use herewith are described
in commonly assigned U.S. Pat. Nos. 5,956,012; 6,084,700;
6,222,177; 6,224,716; 6,247,819; 6,249,369; 6,392,783; and
6,402,328, the disclosures of which are incorporated in their
entireties herein by reference. These systems may be integrated, at
least in part, in a common control with information displays and/or
may share components with the information displays. In addition,
the status of these systems and/or the devices controlled thereby
may be displayed on the associated information displays.
[0080] Although the compass sensor module 799 is shown to be
mounted circuit board 795 in FIG. 32, it should be understood that
the sensor module may be located within mount 757, an accessory
module 758 positioned proximate mirror assembly 702 or at any
location within an associated vehicle such as under a dashboard, in
an overhead console, a center console, a trunk, an engine
compartment, etc. Commonly assigned U.S. Pat. Nos. 6,023,229 and
6,140,933, as well as commonly assigned U.S. patent application
Ser. Nos. 10/210,910 and 60/360,723 and Attorney Docket GEN10
PP-443 entitled Electronic Compass System, the disclosures of which
are incorporated in their entireties herein by reference, describe
in detail various compass systems for use with the present
invention. These systems may be integrated, at least in part, in a
common control with information displays and/or may share
components with the information displays. In addition, the status
of these systems and/or the devices controlled thereby may be
displayed on the associated information displays.
[0081] Daughter board 798 is in operational communication with
circuit board 795. Circuit board 795 may comprise a controller 796,
such as a microprocessor, and daughter board 798 may comprise an
information display (not shown in FIG. 7). The microprocessor may,
for example, receive signal(s) from the compass sensor module 799
and process the signal(s) and transmit signal(s) to the daughter
board to control a display to indicate the corresponding vehicle
heading. As described herein and within the references incorporated
by reference herein, the controller may receive signal(s) from
light sensor(s), rains sensor(s) (not shown), automatic vehicle
exterior light controller(s) (not shown), microphone(s), global
positioning systems (not shown), telecommunication systems (not
shown), operator interface(s), and a host of other devices, and
control the information display(s) to provide appropriate visual
indications.
[0082] Controller 796 (or controllers) may, at least in part,
control the mirror reflectivity, exterior lights, rain sensor,
compass, information displays, windshield wipers, heater,
defroster, defogger, air conditioning, telemetry systems, voice
recognition systems such as digital signal processor-based
voice-actuation systems, and vehicle speed. The controller 796 (or
controllers) may receive signals from switches and/or sensors
associated with any of the devices described herein and in the
references incorporated by reference herein to automatically
manipulate any other device described herein or described in the
references included by reference. The controller 796 may be, at
least in part, located outside the mirror assembly or may comprise
a second controller elsewhere in the vehicle or additional
controllers throughout the vehicle. The individual processors may
be configured to communicate serially, in parallel, via Bluetooth
protocol, wireless communication, over the vehicle bus, over a CAN
bus or any other suitable communication.
[0083] Exterior light control systems as described in commonly
assigned U.S. Pat. Nos. 5,990,469; 6,008,486; 6,130,421; 6,130,448;
6,255,639; 6,049,171; 5,837,994; 6,403,942; 6,281,632; 6,291,812;
6,469,739; 6,465,963; 6,587,573; 6,429,594; 6,379,013; and
6,774,988 and U.S. patent application Ser. Nos. 09/538,389;
09/678,856; 09/847,197; 60/404,879; and 10/235,476, the disclosures
of which are incorporated in their entireties herein by reference,
may be incorporated in accordance with the present invention. These
systems may be integrated, at least in part, in a common control
with information displays and/or may share components with the
information displays. In addition, the status of these systems
and/or the devices controlled thereby may be displayed on the
associated information displays.
[0084] Moisture sensors and windshield fog detector systems are
described in commonly assigned U.S. Pat. Nos. 5,923,027 and
6,313,457, the disclosures of which are incorporated in their
entireties herein by reference. These systems may be integrated, at
least in part, in a common control with information displays and/or
may share components with the information displays. In addition,
the status of these systems and/or the devices controlled thereby
may be displayed on the associated information displays.
[0085] Commonly assigned U.S. Pat. No. 6,262,831, the disclosure of
which is incorporated herein by reference in its entirety,
describes power supplies for use with the present invention. These
systems may be integrated, at least in part, in a common control
with information displays and/or may share components with the
information displays. In addition, the status of these systems
and/or the devices controlled thereby may be displayed on the
associated information displays.
[0086] It is contemplated that the present invention would be
useful in inside or outside rearview mirrors having optical
electrochromic mirror elements, convex mirror elements, aspheric
mirror elements, planar mirror elements, non-planar mirror
elements, hydrophilic mirror elements, hydrophobic mirror elements,
and mirror elements having third surface and fourth surface
reflectors. It is further contemplated that the present invention
will be useful on mirrors that are transflective, or that have a
third or fourth surface mirror element with patterns of lines
thereon to optimize the effect of visible light (sometimes called
"jail bars"). Further, the present invention is useful with mirrors
having first surface or fourth surface heaters, anti-scratch
layers, and circuit boards including flexible circuit boards, and
circuit board and heater combinations, such as heaters having
embedded or integrated non-heater functions such as signal ellipses
and signal diffusants, locating holes or windows for light
pass-through. The present invention is also useful with potted or
snap-attached or elastomeric bezels, and useful with carriers
having an ultra-flat front surface. Also, additional options can be
integrated into the mirrors including signal lighting, key lights,
radar distance detectors, puddle lights, information displays,
light sensors and indicator and warning lighting, retainers with
living hinges, and integrated housings for receiving and supporting
said components. Still further, it is conceived that the present
mirror can include a manually folding or power folding mirrors,
extendable mirrors, and mirrors with a wide field of view, and with
information on the mirror such as "object in mirror is closer than
may appear" or other indicia, such as "heated" or "auto-dim". Still
further, the present invention is useful with a blue glass mirror
or "blue chemical" darkening mirror. Still further, efficiencies
can be had by incorporating the present concepts with mirrors
having an electrochromic mirror subassembly with front and rear
glass mirror elements with edges having a "zero offset" (i.e. less
than about 1-mm difference between perfect alignment edges of the
mirror elements), an edge seal, including clear reflective or
opaque edge seals, and/or second surface chrome or a chrome
bezel.
[0087] It is to be understood that variations and modifications can
be made on the aforementioned structure without departing from the
concepts of the present invention, 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.
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