# US 10,766,421 B2 · Rearview mirror assembly for vehicle

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- Number: US 10,766,421 B2
- Document ID: US10766421B2
- Status: Granted
- Kind: B2
- Application number: 16/188,142
- Filed: 2018-11-12
- Published: 2019-03-07
- Granted: 2020-09-08
- Earliest claimed: 2005-05-16
- Assignees: Donnelly Corporation
- Applicants: Donnelly Corporation
- Inventors: Michael J. Baur; Ian A. McCabe; Hamid Habibi; Niall R. Lynam
- Web page: https://patentgrep.com/patent/US10766421B2

## CPC

- B60R 1/088: {using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors}
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 17/10174: {Coatings of a metallic or dielectric material on a constituent layer of glass or polymer}
- B32B 17/1022: {Metallic coatings}
- B32B 17/10513: {Electrochromic layer}
- B32B 17/10541: {comprising a light source or a light guide}
- B32B 17/10733: {containing epoxy}
- B32B 17/10761: {containing vinyl acetal}
- B32B 17/10798: {containing silicone}
- B60R 1/12: Mirror assemblies combined with other articles, e.g. clocks
- B60R 1/1207: {with lamps; with turn indicators}
- G02F 1/157: Structural association of cells with optical devices, e.g. reflectors or illuminating devices
- B32B 2307/416: Reflective
- B32B 2551/08: Mirrors
- B32B 2605/08: Cars
- B60R 2001/1215: {with information displays}
- G02F 2001/1536: {additional, e.g. protective, layer inside the cell}
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- G02F: OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS

## Abstract

An electro-optic mirror reflective element for a rearview mirror assembly for a vehicle includes a front substrate and a rear substrate. A surface of the front substrate and a surface of the rear substrate oppose one another and are spaced apart by a perimeter seal, with an electro-optic medium disposed between the surfaces and bounded by the perimeter seal. A transparent electrically conductive coating is established at the surface of the front substrate, and a specularly reflective mirror reflector is established at the surface of the rear substrate. The specularly reflective mirror reflector includes a stack of thin film layers having (i) an environmentally stable electrically conductive metallic reflecting thin film layer including chromium, (ii) an environmentally vulnerable electrically conductive metallic reflecting thin film layer and (iii) a transparent electrically conductive thin film layer including aluminum doped zinc oxide.

## Claims

### Claim 1

An electro-optic mirror reflective element for a rearview mirror assembly for a vehicle, said electro-optic mirror reflective element operable to exhibit electrically variable reflectivity between a high reflectance state and a dimmed reflectance state when an electrical voltage is applied thereto, said electro-optic mirror reflective element comprising:
a front substrate having a first surface and a second surface;
a rear substrate having a third surface and a fourth surface;
wherein said second surface of said front substrate and said third surface of said rear substrate oppose each other and are spaced apart by a perimeter seal, and wherein an electro-optic medium is disposed between said second surface of said front substrate and said third surface of said rear substrate and is bounded by said perimeter seal;
wherein no part of said rear substrate extends beyond said front substrate;
a transparent electrically conductive coating established at said second surface of said front substrate;
a specularly reflective mirror reflector established at said third surface of said rear substrate;
wherein said specularly reflective mirror reflector comprises a stack of thin film layers;
wherein said stack of thin film layers comprises (i) an environmentally stable electrically conductive metallic reflecting thin film layer, (ii) an environmentally vulnerable electrically conductive metallic reflecting thin film layer and (iii) a transparent electrically conductive thin film layer;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer comprises a layer of chromium;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer comprises a layer of a metallic material selected from the group consisting of (i) silver, (ii) silver alloy, (iii) aluminum and (iv) aluminum alloy;
wherein said transparent electrically conductive thin film layer comprises a layer of aluminum doped zinc oxide;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer is closer to said third surface of said rear substrate than is said environmentally vulnerable electrically conductive metallic reflecting thin film layer;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer is closer to said third surface of said rear substrate than is said transparent electrically conductive thin film layer; and
wherein said environmentally stable electrically conductive metallic reflecting thin film layer extends outward beyond said perimeter seal at a perimeter region of said rear substrate toward a perimeter edge of said rear substrate.

### Claim 2 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer deteriorates when exposed to an environment of 85 degrees Celsius and 85 percent relative humidity.

### Claim 3 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said environmentally stable electrically conductive metallic reflecting thin film layer is stable when exposed to an environment of 85 degrees Celsius and 85 percent relative humidity.

### Claim 4 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer overcoats said layer of chromium.

### Claim 5 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer comprises a layer of aluminum or aluminum alloy.

### Claim 6 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said specularly reflective mirror reflector is contacted by an environmentally stable material at a perimeter region of said rear substrate.

### Claim 7 (depends on 6)

The electro-optic mirror reflective element of claim 6, wherein said environmentally stable material comprises an electrically conductive epoxy.

### Claim 8 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said transparent electrically conductive coating established at said second surface of said front substrate comprises indium tin oxide.

### Claim 9 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said transparent electrically conductive coating established at said second surface of said front substrate comprises aluminum doped zinc oxide.

### Claim 10 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said electro-optic medium comprises an electrochromic medium.

### Claim 11 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein said specularly reflective mirror reflector established at said third surface of said rear substrate comprises a transflective specularly reflective mirror reflector.

### Claim 12 (depends on 1)

The electro-optic mirror reflective element of claim 1, comprising a specularly reflective perimeter layer established at least partially around a perimeter border region of said second surface of said front substrate, wherein said specularly reflective perimeter layer is, at least in part, visible through said front substrate to a viewer when viewing said first surface of said front substrate of said electro-optic mirror reflective element.

### Claim 13 (depends on 12)

The electro-optic mirror reflective element of claim 12, wherein a light source is disposed behind said specularly reflective perimeter layer and emits light that is visible to a viewer viewing said first surface of said front substrate of said electro-optic mirror reflective element at said specularly reflective perimeter layer.

### Claim 14 (depends on 12)

The electro-optic mirror reflective element of claim 12, wherein a light sensor is disposed behind said specularly reflective perimeter layer and senses light that passes through said front substrate at said specularly reflective perimeter layer.

### Claim 15 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein a specularly reflecting indicia reflector is locally established at said second surface of said front substrate to form indicia at said electro-optic mirror reflective element and wherein said indicia is significantly more discernible by a person viewing said electro-optic mirror reflective element when said electro-optic mirror reflective element is at a dimmed reflectance state than when said electro-optic mirror reflective element is at a high reflectance state, and wherein said specularly reflecting indicia reflector comprises a reflective metal coating, and wherein said specularly reflecting indicia reflector is overcoated by said transparent electrically conductive coating at said second surface so as to be disposed between said second surface and said transparent electrically conductive coating.

### Claim 16 (depends on 1)

The electro-optic mirror reflective element of claim 1, wherein a dimension of said front substrate is larger than a corresponding dimension of said rear substrate so as to provide an overhang region.

### Claim 17

An electro-optic mirror reflective element for a rearview mirror assembly for a vehicle, said electro-optic mirror reflective element operable to exhibit electrically variable reflectivity between a high reflectance state and a dimmed reflectance state when an electrical voltage is applied thereto, said electro-optic mirror reflective element comprising:
a front substrate having a first surface and a second surface;
a rear substrate having a third surface and a fourth surface;
wherein said second surface of said front substrate and said third surface of said rear substrate oppose each other and are spaced apart by a perimeter seal, and wherein an electro-optic medium is disposed between said second surface of said front substrate and said third surface of said rear substrate and is bounded by said perimeter seal;
wherein said electro-optic mirror reflective element comprises an electrochromic mirror reflective element, and wherein said electro-optic medium comprises an electrochromic medium;
wherein no part of said rear substrate extends beyond said front substrate;
a transparent electrically conductive coating established at said second surface of said front substrate;
a specularly reflective mirror reflector established at said third surface of said rear substrate;
wherein said specularly reflective mirror reflector comprises a stack of thin film layers;
wherein said stack of thin film layers comprises (i) an environmentally stable electrically conductive metallic reflecting thin film layer, (ii) an environmentally vulnerable electrically conductive metallic reflecting thin film layer and (iii) a transparent electrically conductive thin film layer;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer comprises a layer of chromium;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer overcoats said layer of chromium;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer comprises a layer of a metallic material selected from the group consisting of (i) aluminum and (ii) aluminum alloy;
wherein said transparent electrically conductive thin film layer comprises a layer of aluminum doped zinc oxide;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer is closer to said third surface of said rear substrate than is said environmentally vulnerable electrically conductive metallic reflecting thin film layer;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer is closer to said third surface of said rear substrate than is said transparent electrically conductive thin film layer;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer extends outward beyond said perimeter seal at a perimeter region of said rear substrate toward a perimeter edge of said rear substrate; and
wherein said specularly reflective mirror reflector is contacted by an environmentally stable material at the perimeter region of said rear substrate.

### Claim 18 (depends on 17)

The electro-optic mirror reflective element of claim 17, wherein said environmentally stable material comprises an electrically conductive epoxy.

### Claim 19 (depends on 17)

The electro-optic mirror reflective element of claim 17, wherein said specularly reflective mirror reflector established at said third surface of said rear substrate comprises a transflective specularly reflective mirror reflector.

### Claim 20 (depends on 17)

The electro-optic mirror reflective element of claim 17, comprising a specularly reflective perimeter layer established at least partially around a perimeter border region of said second surface of said front substrate, wherein said specularly reflective perimeter layer is, at least in part, visible through said front substrate to a viewer when viewing said first surface of said front substrate of said electro-optic mirror reflective element.

### Claim 21

An electro-optic mirror reflective element for a rearview mirror assembly for a vehicle, said electro-optic mirror reflective element operable to exhibit electrically variable reflectivity between a high reflectance state and a dimmed reflectance state when an electrical voltage is applied thereto, said electro-optic mirror reflective element comprising:
a front substrate having a first surface and a second surface;
a rear substrate having a third surface and a fourth surface;
wherein said second surface of said front substrate and said third surface of said rear substrate oppose each other and are spaced apart by a perimeter seal, and wherein an electro-optic medium is disposed between said second surface of said front substrate and said third surface of said rear substrate and is bounded by said perimeter seal;
wherein said electro-optic mirror reflective element comprises an electrochromic mirror reflective element, and wherein said electro-optic medium comprises an electrochromic medium;
wherein no part of said rear substrate extends beyond said front substrate;
a transparent electrically conductive coating established at said second surface of said front substrate;
a specularly reflective mirror reflector established at said third surface of said rear substrate;
wherein said specularly reflective mirror reflector comprises a stack of thin film layers;
wherein said stack of thin film layers comprises (i) an environmentally stable electrically conductive metallic reflecting thin film layer, (ii) an environmentally vulnerable electrically conductive metallic reflecting thin film layer and (iii) a transparent electrically conductive thin film layer;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer comprises a layer of chromium;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer comprises a layer of a metallic material selected from the group consisting of (i) silver, (ii) silver alloy, (iii) aluminum and (iv) aluminum alloy;
wherein said transparent electrically conductive thin film layer comprises a layer of aluminum doped zinc oxide;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer is closer to said third surface of said rear substrate than is said environmentally vulnerable electrically conductive metallic reflecting thin film layer;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer is closer to said third surface of said rear substrate than is said transparent electrically conductive thin film layer;
wherein said environmentally stable electrically conductive metallic reflecting thin film layer extends outward beyond said perimeter seal at a perimeter region of said rear substrate toward a perimeter edge of said rear substrate;
wherein said environmentally vulnerable electrically conductive metallic reflecting thin film layer deteriorates when exposed to an environment of 85 degrees Celsius and 85 percent relative humidity; and
wherein said environmentally stable electrically conductive metallic reflecting thin film layer is stable when exposed to the environment of 85 degrees Celsius and 85 percent relative humidity.

### Claim 22 (depends on 21)

The electro-optic mirror reflective element of claim 21, wherein said specularly reflective mirror reflector established at said third surface of said rear substrate comprises a transflective specularly reflective mirror reflector.

### Claim 23 (depends on 21)

The electro-optic mirror reflective element of claim 21, comprising a specularly reflective perimeter layer established at least partially around a perimeter border region of said second surface of said front substrate, wherein said specularly reflective perimeter layer is, at least in part, visible through said front substrate to a viewer when viewing said first surface of said front substrate of said electro-optic mirror reflective element.