Lighted mirror frame

Abstract

A rearview device (100) for a vehicle includes a housing, a bezel (130), and a rearview element (120). In one embodiment, the bezel includes a clear or chrome-based coating to allow one or more lighting components positioned within or below the bezel to illuminate the surrounding environment and provide different functionality to the driver or other personnel. For example, different indicator functions can be provided. Different electronic devices can be placed within or below the bezel to optimize the use of space inside the rearview device.

Description

[0001] Related applications

[0002] This application claims a divisional application of the invention application filed on March 13, 2018, with a priority date of March 13, 2017, application number 201880030091.X, entitled "Light-emitting Mirror Frame".

[0003] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 470,658, filed March 13, 2017, the entire contents of which are incorporated herein by reference for all purposes; and this application is a continuation-in-part of U.S. Patent Application No. 15 / 256,532, which claims a foreign priority of European Patent Application No. 15183748.1, filed September 3, 2015, the entire contents of which are incorporated herein by reference for all purposes; and this application is a continuation-in-part of U.S. Patent Application No. 15 / 256,540, filed September 3, 2016, which claims a foreign priority of European Patent Application No. 15183758.0, filed September 3, 2015, the entire contents of which are incorporated herein by reference for all purposes; and this application was filed on September 7, 2016. This application is a continuation-in-part of U.S. Patent Application No. 15 / 124,310, which is a national phase entry application for International Patent Application No. PCT / AU2015 / 000093, filed February 20, 2015, which claims a foreign priority interest in Australian Patent Application No. 2014900781, filed March 7, 2014, both of which are incorporated herein by reference in their entirety for all purposes; and this application is a continuation-in-part of U.S. Patent Application No. 15 / 800,413, filed November 1, 2017, which is a continuation-in-part of U.S. Patent Application No. 15 / 603,751, filed May 24, 2017, which claims a claim in European Patent Application No. 16198759, filed November 14, 2016.The foreign priority rights of 9 are incorporated herein by reference in their entirety for all purposes; and this application is a continuation-in-part of U.S. Patent Application No. 2017327167, filed June 5, 2017, which is a national phase entry application of International Patent Application No. PCT / IB2015 / 059419, filed June 9, 2016, which claims foreign priority rights to European Patent Application No. 14196582, filed December 5, 2014, and European Patent Application No. 15162850, filed April 8, 2015. Benefits, which are incorporated herein by reference in their entirety for all purposes; and this application is a continuation-in-part of U.S. Patent Application No. 15 / 607,894, filed May 30, 2017, which is a continuation-in-part of U.S. Patent Application No. 15 / 000,754, filed January 19, 2016 and now published as U.S. Patent Application No. 9,796,333, which is a continuation-in-part of U.S. Patent Application No. 14 / 022,896, filed September 10, 2013, which is a continuation-in-part of U.S. Patent Application No. 14 / 022,896 claims a foreign priority interest in German Patent Application No. 102012108480.7, filed September 11, 2012, the entire contents of which are incorporated herein by reference for all purposes; and this application is a continuation-in-part of U.S. Patent Application No. 15 / 439,188, filed February 22, 2017, which is a continuation-in-part of U.S. Patent Application No. 14 / 936,024, filed November 9, 2015 and now published as U.S. Patent No. 9,656,601. Application No. 14 / 374,376, filed July 24, 2014, and now published as U.S. Patent No. 9,181,616, is a continuation-in-part of U.S. Patent Application No. 14 / 374,376, filed January 24, 2013, which is a national phase application for International Patent Application No. PCT / AU2013 / 000047, filed January 24, 2013, which claims a foreign priority interest in Australian Patent Application No. 2012900267, filed January 24, 2012. Both are incorporated herein by reference in their entirety for all purposes. Technical Field

[0004] The following description relates to a vehicle rearview device, which, for example, may include a bezel that can be illuminated to provide different functions to the driver or other persons viewing the bezel. Background Technology

[0005] The integration of external rearview devices with light sources into vehicles is well known in the prior art. Typically, flashing direction indicators are installed to improve safety and enhance the design, as described, for example, in U.S. Patent No. 7,600,905 or European Patent No. 2,340,967.

[0006] Furthermore, warning indicators and other light sources have been integrated into the housing, bezel, and behind the rearview elements to serve as turn signals, circuit breakers, or blind spot indicators. Such light sources are described in EP Patent Nos. 2,151,350, 2,463,152, 2,463,153, U.S. Patent Nos. 7,674,025, and 8,164,482. In U.S. Patent No. 7,954,985, warning indicators using fiber optics have also been used in external rearview devices. Additionally, external rearview devices can be equipped with video displays and display devices, and have also been used as indicators, for example, in U.S. Patent Nos. 7,777,611 and 7,581,859.

[0007] Lighting systems that illuminate the ground and the area around doors to increase vehicle occupant safety have been incorporated into exterior rearview devices and are well known, for example, as described in U.S. Patent No. 6,149,287.

[0008] An interior rearview device is known from EP patent number 2 106 970, which provides ambient light originating from behind a reflective portion of the rearview element. This configuration provides a frameless design to minimize the required space and meet certain design criteria to enhance the appearance from the driver's perspective.

[0009] For all these purposes, different types of light sources and guides have been identified to meet the requirements for high brightness, low power consumption, and ease and flexibility of installation, some of which are described in EP patent number 3 138 734 and EP patent number 3 061587.

[0010] Furthermore, U.S. Patent Application Publication No. 2016 / 0221505 describes a specular reflective element having a heating pad including conductive traces. U.S. Patent Application Publication No. 2016 / 0221505 describes a specular reflective element assembly for an exterior rearview mirror assembly for a vehicle, comprising a reflective element and a heating pad. The heating pad includes a heating pad substrate having a plurality of conductive traces established thereon. The heating pad substrate is disposed on the rear surface of the reflective element. The conductive traces may include (i) heating traces, (ii) a first electro-optic control trace and a second electro-optic control trace, and / or (iii) auxiliary control traces.

[0011] U.S. Patent Application No. 2017327167 describes a method for manufacturing an automotive mirror, particularly a side mirror, comprising forming a printed circuit board as a flexible printed circuit board having n+1 branches nεN, providing n modules, each module including at least one electronic component, and connecting up to n branches to a module respectively, and connecting a branch to a cable or cable bundle that will be connected to a power supply and / or control unit external to the mirror.

[0012] The rearview device is positioned at a highly visible level relative to the vehicle driver. State-of-the-art external rearview devices typically have a black or colored bezel around the rearview element. Usually, the rearview element is not attached to the bezel, but rather to an attachment plate to allow adjustment of the rearview element according to the driver's needs. When the rearview element is adjusted to the driver's needs, the actuator only moves the rearview element. Therefore, additional space is required between the bezel / housing and the rearview element, and nothing can be placed there, otherwise it would result in a loss of installation space. Typically, the actuator can adjust the rearview element within an angle of at least 8 to 12 degrees. Furthermore, this exposes the electronics and other components located behind the rearview element to environmental conditions.

[0013] Furthermore, rearview mirror systems typically incorporate multiple independent individual modules to provide different functions, such as lighting modules, heating pads, and others. This results in mirror assemblies having many parts and being very expensive to manufacture.

[0014] As a result, there is a need for a rearview mirror assembly that has improved space utilization to allow for the integration of additional functions and components and to provide additional functionality for the vehicle’s driver and other occupants.

[0015] Therefore, it is advantageous to utilize the highly visible position of the rearview device to provide the driver with additional important information. In particular, when using a sealed rearview device whose components are integrally formed and when moving the entire rearview device during the process of adapting it to the driver, the extra space required for adjusting the rearview elements no longer needs to be kept free and can be used to install additional components and functions within the rearview device by directly mounting them behind the rearview elements and / or attaching them to the frame. Summary of the Invention

[0016] A multi-functional rearview device for use with a vehicle includes: a rearview element including at least one of a reflective element, a camera, and a display element; a frame formed on the exterior of the multi-functional rearview device surrounding the rearview element; and an interior space formed within the frame, and at least one of one or more lamp assemblies located at least partially within the interior space of the frame, wherein the rearview element is attached to at least one of the frame and a housing configured to be attached to the vehicle and movable relative to the vehicle.

[0017] The frame may be made of a plastic substrate, which is at least one of colored, surface-finished, transparent, and coated.

[0018] The coating on the frame substrate can be at least one of a decorative coating, an advanced surface technology (AST) surface coating, and a spectral control system.

[0019] The border can be formed or molded from a polymer substrate.

[0020] The frame may be transparent and may include a chrome-based coating, thereby concealing the one or more light components beneath the frame before they are turned on.

[0021] The chromium-based coating may be an alloy of chromium and a dopant material selected from hexagonal close-packed transition metals, wherein the alloy has a crystal structure of a primary body-centered cubic phase coexisting with a secondary Ω hexagonal close-packed phase.

[0022] The one or more light assemblies may provide at least one or more light function indications, including turn indicators, approach lights, forced braking signals, emergency braking signals, warning lights, puddle lights, human-machine interface (HMI), blind spot indicator (BSI), charging indicator status, vehicle mode, sport mode, economy mode, autopilot mode, sleep mode, vehicle lock, vehicle theft, warning signals, temperature or weather indicators, traffic light signals, fuel status, emergency indications for emergency vehicles (including police cars, medical vehicles, ambulances, or traffic maintenance vehicles), vehicle communication, handshake, connection indicators, and warning lights.

[0023] The one or more lamp components may each include at least one of the following: a printed circuit board, a light-emitting diode, an integrated lens, a self-charging lighting material; a flexible circuit board; a light bulb; and at least one of the following: a lamp.

[0024] The light assembly can be configured to direct light to different locations on the frame.

[0025] The light assembly can be configured to direct light with different characteristics to different locations on the frame to provide different light function indications.

[0026] The plurality of light assemblies can be configured to direct light with different characteristics to different locations on the frame to provide different light function indications.

[0027] Different optical properties can be determined by at least one of light color, light intensity, and light pulse length.

[0028] The different positions of the frame may include at least: a position on the frame above the rearview element, a position on the frame below the rearview element, a position on the frame facing the vehicle, and a position on the frame not facing the vehicle.

[0029] The plurality of light assemblies may include four light assemblies: a first light assembly located in the interior space of the frame above the rearview device, a second light assembly located in the interior space of the frame below the rearview device, a third light assembly located in the interior space of the frame at a position on the frame facing the vehicle, and a fourth light assembly located in the interior space of the frame at a position not facing the vehicle.

[0030] The one or more lamp components can be placed directly on the plastic part of the frame, or by using surface mount, over mold, conductive material or printed material, without the use of a printed circuit board.

[0031] The conductor track, electronic device, and at least one of the one or more lamp assemblies can be directly applied to the frame by at least one of injection molding (MID), conductive foil (IML), and laser direct forming (LDS).

[0032] The one or more lamp assemblies may include an LED retainer having an integrated connector that can be clipped into the interior space of the frame.

[0033] The one or more lamp assemblies may include at least one light source unit having at least one wire but not a printed circuit board; a housing unit supporting the light source unit and provided with means suitable for holding and connecting at least one of them; and a sealing device.

[0034] The one or more lamp components may include a light source, which includes at least one of LED lamps, light strips, printed lighting, optical light guides, lamps, lighting charging materials, rechargeable batteries, solar cells, or batteries.

[0035] The multi-functional device may include the one or more light assemblies, wherein the one or more light assemblies are configured to direct multiple different colors of light onto the entire surface of the frame, such that the entire frame can have one color at a time, and are configured to provide multiple different colors of light to different areas of the frame, such that different areas of the frame can have different colors at a time.

[0036] The housing, the reflective element, and the frame can be integrally formed, thereby sealing the multifunctional device away from the external environment to prevent dust, water, or moisture.

[0037] The multifunctional device may further include a light diffuser located within the interior space of the frame.

[0038] The multi-functional rearview device can be functionally connected to an actuator, and the actuator can be located outside the housing.

[0039] The multi-functional rearview device can be functionally connected to the actuator through automatic docking or direct contact.

[0040] The actuator can move the entire multi-functional device, including the housing, and not just the rearview element.

[0041] The actuator can be configured for at least one of rotational and translational motion.

[0042] The multifunctional device may further include a foot adapted to be fixed to the vehicle, and the housing having the frame is movable relative to the foot.

[0043] The foot can provide at least one spherical seat for the housing.

[0044] The housing may include an upper part and a lower part, and the frame may be attached to these two parts.

[0045] The frame can be fixed, glued, movably attached to, or clipped onto the housing.

[0046] The frame can be attached to the housing together with at least one of the one or more lamp assemblies and the electronic device.

[0047] The actuator can determine the light output of the one or more lamp assemblies.

[0048] The actuator can use a LIN or CAN connection to determine the light output of the one or more lamp assemblies.

[0049] The multi-functional device may further include a connector to a control unit of the vehicle, the control unit being used to control at least one of the one or more lamp assemblies, the display element, the actuator, the camera controller, or the cleaning equipment.

[0050] The multifunctional device may further include at least one sensor, wherein the output of the sensor controls at least one of the one or more lamp assemblies, the display, and the actuator.

[0051] The sensor can be a camera.

[0052] The multi-functional device may further include at least one of a heater and a wiper for the rearview element.

[0053] The electronic device may be connected to at least one of the one or more lamp assemblies, the display element, the actuator, the sensor, the camera, the heater, and the wiper.

[0054] The electronic device and the frame can form a unit.

[0055] The multifunctional device may further include an automatic dimming element.

[0056] The multifunctional device may further include optical sensors for controlling multiple light intensities or brightness.

[0057] The one or more light assemblies can provide at least one or more light function indications, including side sign indications or parking light indications.

[0058] The multifunctional device may further include a flexible circuit, the flexible circuit including one or more lamp elements, the one or more lamp elements being directly attached to the flexible circuit.

[0059] The flexible circuit may further include a single connector control unit configured to control the one or more lamp elements and receive an external connector.

[0060] The flexible circuit may further include an integrated heating pad configured to heat the rearview element.

[0061] The flexible circuit may further include an integrated temperature sensor.

[0062] The flexible circuit may further include at least one of an integrated Wi-Fi or Bluetooth communication unit and an antenna.

[0063] The flexible circuit may further include an integrated heating pad configured to heat the rearview element and bending around a slot formed in the frame.

[0064] The frame may include a light receiving portion configured to receive light used as an indicator, specifically a side turn indicator.

[0065] The one or more lamp elements may be at least two lamp elements configured to project different colors of light to provide different functions.

[0066] The one or more lamp elements can be at least four lamp elements configured to project different colors of light to provide different functions.

[0067] The various functions provided may include turn signals, approach lights, forced entry signals, emergency braking signals, emblem lights, puddle lights, human-machine interface (HMI), blind spot indicator (BSI), charging indicator status, vehicle modes, sport mode, economy mode, autopilot mode, sleep mode, vehicle locking, vehicle theft, warning signals, temperature or weather indicators, traffic light signals, fuel status, emergency indications for emergency vehicles (including police cars, medical vehicles, ambulances, or traffic maintenance vehicles), vehicle communication, handshake, connection indicators, warning lights, side sign indicators, and / or stop light indicators.

[0068] In the original application of this divisional application, the original claims contained the following:

[0069] 1. A multi-functional rearview device (100, 700, 900) for use with a vehicle, said multi-functional rearview device comprising:

[0070] Rearview element (120, 750, 950), comprising at least one of a reflective element, a camera, and a display element;

[0071] A frame (130, 720, 920), formed on the exterior of the multi-functional rearview device (100, 700, 900) surrounding the rearview elements (120, 750, 950), has the following characteristics:

[0072] • The internal spaces (130, 720, 920) formed within the frame; and

[0073] • At least one of one or more lamp assemblies (200, 610, 810) and one or more electronic devices, at least partially positioned within the interior space of the frame (130).

[0074] The rearview elements (120, 750, 950) are attached to at least one of the frame (130, 720, 920) and the housing (110), the housing being configured to be attached to the vehicle and movable relative to the vehicle.

[0075] 2. The multifunctional device (100) as described in claim 1, wherein...

[0076] The frame (130) is made of a plastic substrate, which is at least one of colored, polished, transparent, and coated; and / or

[0077] The border (130) is coated, and the coating of the border (130) is at least one of a decorative coating, an advanced surface technology (AST) surface coating, and a spectral control system; and / or

[0078] The border (130) is formed or molded from a polymer substrate.

[0079] 3. The multifunctional device (100) as described in claim 1 or 2, wherein...

[0080] The frame (130) is transparent and includes a chromium-based coating, such that the one or more lamp assemblies (200) below the frame (130) are hidden before being illuminated.

[0081] Preferably, the chromium-based coating is an alloy of chromium and a dopant material selected from hexagonal close-packed transition metals, and the alloy has a crystal structure of a primary body-centered cubic phase coexisting with a secondary Ω hexagonal close-packed phase.

[0082] 4. The multifunctional device (100) as described in any of the preceding claims, wherein

[0083] The one or more lamp components provide at least one or more lighting function indicators, preferably including turn indicators, approach lights, forced start signals, emergency braking signals, warning lights, puddle lights, human-machine interface (HMI), blind spot indicator (BSI), charging indicator status, vehicle mode, sport mode, economy mode, autopilot mode, sleep mode, vehicle lock, vehicle theft, warning signals, temperature or weather indicators, traffic light signals, fuel status, emergency indication for emergency vehicles, vehicle communication, handshake, connection indicator, hazard lights, side marking indicators, and / or stop light indicators, wherein the emergency vehicle includes a police car, medical vehicle, ambulance, or traffic maintenance vehicle; and / or

[0084] Each of the one or more lamp assemblies (200) includes at least one of the following:

[0085] Printed circuit boards;

[0086] Light-emitting diode;

[0087] Integrated lens;

[0088] Self-charging lighting materials;

[0089] Flexible circuit board;

[0090] Light bulb; and

[0091] lamp.

[0092] 5. The multifunctional device (100) as described in any of the preceding claims, comprising:

[0093] Only one of the one or more lamp assemblies (200), wherein

[0094] • The lamp assembly (200) is configured to direct light to different locations on the frame (130), and / or

[0095] The lamp assembly (200) is configured to direct light with different characteristics to different positions on the frame (130) to provide different lamp function indications.

[0096] 6. The multifunctional (100) device as claimed in any one of claims 1 to 4, comprising:

[0097] A plurality of the one or more lamp assemblies (200) are configured to direct light with different characteristics to different locations on the frame (130) to provide different lighting function indications, wherein

[0098] The different properties of light are determined by at least one of light color, light intensity, and light pulse length and / or

[0099] The different positions of the frame (130) include at least the position on the frame (130) above the rearview element (120), the position on the frame (130) below the rearview element (120), the position (130) facing the vehicle, and the position (130) not facing the vehicle, and / or

[0100] The plurality of light assemblies (200) includes four light assemblies (200): a first light assembly (200) located in the interior space of the frame (130A) above the rearview device, a second light assembly (200) located in the interior space of the frame (130B) below the rearview device, a third light assembly (200) located in the interior space of the frame (130C) at a position facing the vehicle, and a fourth light assembly (200) located in the interior space of the frame (130D) at a position not facing the vehicle.

[0101] 7. The multifunctional device (100) as described in any of the preceding claims, wherein

[0102] Each lamp assembly (200) is placed directly on the plastic part of the frame (130), or by using surface mount, overmolding, conductive material or printed material, without the use of a printed circuit board.

[0103] 8. The multifunctional device (100) as described in any of the preceding claims, wherein

[0104] The conductor trace, the electronic device, and at least one of the one or more lamp assemblies (200) are directly applied to the frame (130) by at least one of injection molding (MID), conductive foil (IML), and laser direct forming (LDS).

[0105] 9. The multifunctional device (100) as claimed in any of the preceding claims, comprising the one or more lamp assemblies (200), wherein

[0106] The one or more lamp assemblies (200) include LED holders having an integrated connector (210) that can be clipped into the interior space of the frame (130); and / or

[0107] The one or more lamp assemblies (200) include

[0108] • At least one light source unit (230) having at least one wire, but excluding a printed circuit board.

[0109] • A housing unit that supports the light source unit (230) and is provided with means suitable for holding and connecting at least one of the following; and

[0110] • Sealing device; and / or

[0111] The one or more lamp assemblies include a light source (230), which includes at least one of LED lamps, light strips, printed lighting, optical light guides, lamps, lighting charging materials, rechargeable batteries, solar cells, or batteries.

[0112] 10. The multifunctional device (100) as claimed in any of the preceding claims, comprising the one or more lamp assemblies (200), wherein

[0113] The one or more lamp assemblies (200) are configured to direct multiple different colors of light onto the entire surface of the frame (130), such that the entire frame (130) can have one color at a time, and are configured to provide multiple different colors of light to different areas (130A, 130B, 130C, 130D) of the frame (130), such that the different areas (130A, 130B, 130C, 130D) of the frame (130) can have different colors at a time.

[0114] 11. The multifunctional device (100) as described in any of the preceding claims, wherein

[0115] The housing (110), the reflective element (120), and the frame (130) are integrally formed, thereby sealing the multifunctional device (100) from the external environment to prevent dust, water, or moisture.

[0116] 12. The multifunctional device (100) as described in any of the preceding claims, further comprising:

[0117] A light diffuser (150) located within the interior space of the frame (130).

[0118] 13. The multifunctional device (100) as described in any of the preceding claims, wherein

[0119] The multifunctional device (100) is functionally connected to an actuator, and the actuator is located outside the housing (110).

[0120] Preferably, the multifunctional device (100) is functionally connected to the actuator via automatic docking or direct contact.

[0121] 14. The multifunctional device (100) as claimed in claim 13, wherein

[0122] The actuator moves the entire multifunction device (100), including the housing (110), and not just the rearview element (120); and / or

[0123] The actuator is configured for at least one of rotational and translational motion; and / or

[0124] The actuator determines the light output of the one or more lamp assemblies (200), and in particular, the actuator uses a LIN or CAN connection to determine the light output.

[0125] 15. The multifunctional device (100) as described in any of the preceding claims, further comprising:

[0126] The foot portion is adapted to be fixed to the vehicle, and the housing (110) having the frame (130) is movable relative to the foot portion.

[0127] Preferably, the foot provides at least one spherical seat for the housing (110).

[0128] 16. The multifunctional device (100) as described in any of the preceding claims, wherein

[0129] The housing (110) includes an upper part and a lower part, and the frame (130) is attached to these two parts.

[0130] 17. The multifunctional device (100) as described in any of the preceding claims, wherein

[0131] The frame (130) is fixed, glued, removably attached to, or clipped to the housing; and / or

[0132] The frame (130) is attached to the housing together with at least one of the one or more lamp assemblies (200) and the electronic device.

[0133] 18. The multifunctional device (100) as described in any of the preceding claims, further comprising:

[0134] A connector to a control unit of the vehicle, the control unit being used to control at least one of the one or more lamp assemblies (200), the display element, the actuator, the camera controller, or the cleaning equipment.

[0135] 19. The multifunctional device (100) as described in any of the preceding claims, further comprising:

[0136] At least one sensor, wherein the output of said sensor controls at least one of the one or more lamp assemblies (200), the display, and the actuator.

[0137] Preferably, the sensor is a camera; and / or

[0138] Preferably, the sensor is a light sensor used to control multiple light intensities or brightness.

[0139] 20. The multifunctional device (100) as described in any of the preceding claims, further comprising:

[0140] At least one of the heater and wiper of the rearview element (120); and / or

[0141] Automatic dimming element.

[0142] 21. The multifunctional device (100) as described in any of the preceding claims, wherein

[0143] The electronic device is connected to at least one of the one or more lamp assemblies (200), the display element, the actuator, the sensor, the camera, the heater, and the wiper.

[0144] Preferably, the electronic device and the frame (130) form a unit.

[0145] 22. The multifunctional device (700, 900) as described in claim 1, further comprising:

[0146] Flexible circuits (600, 800) including one or more lamp elements (610, 810) directly attached to the flexible circuits (600, 800).

[0147] 23. The multifunctional device (700, 900) as described in claim 22, wherein...

[0148] The flexible circuits (600, 800) further include a single connector control unit (620, 820), the single connector control unit (620, 820) configured to control the one or more lamp elements (610, 810) and receive an external connector (910); and / or

[0149] The flexible circuits (600, 800) further include integrated heating pads (630, 830) configured to heat the rearview elements (750, 950); and / or

[0150] The flexible circuits (600, 800) further include integrated temperature sensors (640, 840); and / or

[0151] The flexible circuit (600, 800) further includes at least one of an integrated Wi-Fi or Bluetooth communication unit (850) and an antenna (860); and / or

[0152] The flexible circuit (800) further includes an integrated heating pad (830) configured to heat the rearview element (950) and bend around a slot (960) formed in the frame (920).

[0153] 24. The multifunctional device (700, 900) as described in claim 22 or 23, wherein...

[0154] The frame (720, 920) includes a light receiving portion (940) configured to receive light used as an indicator, specifically a side turn indicator.

[0155] 25. The multi-functional rearview device (700, 900) as claimed in any one of claims 22 to 24, wherein...

[0156] The one or more lamp elements (610, 810) are at least two lamp elements (610, 810) configured to project different colors of light to provide different functions; and / or

[0157] The one or more lamp elements (610, 810) are at least four lamp elements (610, 810) configured to project different colors of light to provide different functions.

[0158] 26. The multifunctional device (700, 900) as described in claim 25, wherein...

[0159] The various functions provided include direction indicators, approach lights, forced entry signals, emergency braking signals, warning lights, puddle lights, human-machine interface (HMI), blind spot indicator (BSI), charging indicator status, vehicle modes, sport mode, economy mode, autopilot mode, sleep mode, vehicle locking, vehicle theft, warning signals, temperature or weather indicators, traffic light signals, fuel status, emergency indication for emergency vehicles, vehicle communication, handshake, connection indicator, warning lights, side sign indication and / or stop light indication, wherein the emergency vehicle includes police cars, medical vehicles, ambulances or traffic maintenance vehicles. Attached Figure Description

[0160] The foregoing summary of the invention and the following detailed description will be better understood when read in conjunction with the accompanying drawings. For illustrative purposes, certain embodiments of this disclosure are shown in the drawings. However, it should be understood that the invention is not limited to the precise arrangements and means shown. The drawings, which are incorporated in and constitute a part of this specification, depict implementations of systems and apparatus consistent with the invention and, together with the description, serve to explain the advantages and principles consistent with the invention.

[0161] Figure 1 This is a perspective view depicting an example of a rear-view device.

[0162] Figure 2 This is another perspective view depicting a rear-view device with line AA.

[0163] Figure 3 It is a description along Figure 2 The figure depicts a sectional view of the rear-view device of line AA.

[0164] Figure 4 This is a diagram depicting an example of a lamp assembly.

[0165] Figure 5 These are two examples of diagrams depicting a stereoscopic view of the rearview device and details of the rearview device.

[0166] Figure 6 This is a diagram depicting an example of an integrated flexible circuit that includes one or more lighting elements.

[0167] Figure 7 It is a description including Figure 6 A perspective view of an example of a rearview device with integrated flexible circuitry.

[0168] Figure 8 This is a perspective view depicting another example of a rearview device that includes another integrated flexible circuit. Detailed Implementation

[0169] Before explaining at least one example of the invention in detail, it should be understood that the application of the invention is not limited to the construction details and arrangement of components set forth in the following description or shown in the drawings. The drawings and written description are provided to teach any person skilled in the art to make and use the invention for which patent protection is sought. The invention can have other embodiments and can be practiced and performed in various ways. Those skilled in the art will understand that not all features of commercial implementations are shown for clarity and understanding. Those skilled in the art will also understand that the development of actual commercial implementations incorporating various aspects of the invention will require numerous implementation-specific decisions to achieve the developer's ultimate goals for the commercial implementation. While these efforts may be complex and time-consuming, they will remain routine work for those skilled in the art who benefit from this disclosure.

[0170] Furthermore, it should be understood that the wording and terminology used herein are for descriptive purposes and should not be considered restrictive. For example, the use of singular terms (e.g., "a") is not intended to limit the number of items. For clarity, relational terms, such as but not limited to "top," "bottom," "left side," "right side," "upper part," "lower part," "downward," "upward," "side," and "corner," are also used in descriptions specifically relating to the drawings and are not intended to limit the scope of the invention or the appended claims. Moreover, it should be understood that any feature of the invention may be used alone or in combination with other features. Other systems, methods, features, and advantages of the invention will be apparent to those skilled in the art upon review of the drawings and detailed description. All such additional systems, methods, features, and advantages are intended to be included in this specification, within the scope of the invention, and protected by the appended claims.

[0171] Figure 1 This is a perspective view depicting an example of a rearview device 100. (See reference...) Figure 1 The rearview device 100 includes a housing 110, a rearview element 120, and a bezel 130. The bezel 130 may be subdivided into multiple different areas 130A, 130B, 130C, and 130D. As an example, four (4) different positions or areas 130A, 130B, 130C, and 130D are shown. These different positions 130A, 130B, 130C, and 130D provide different functions or combinations of different functions to the driver and other personnel, such as indicators.

[0172] The multi-functional rearview device bezel 130 has four or any number of individual zones 130A, 130B, 130C, 130D, each zone having one or more of the following functions (monochrome or multicolor light source) or combinations thereof: clear coating; AST coating; charging indicator; marker light; approach light side turn indicator; HMI / BLIS; vehicle mode (sport / economy); autopilot mode; sleep mode; vehicle lock; vehicle theft; warning signal; temperature / weather indicator; traffic lights; hard / emergency braking signal; fuel status; and other functions.

[0173] The light in different positions 130A, 130B, 130C, and 130D can have different characteristics, such as color, intensity, and pulse length, but can also be used to simultaneously provide the same light as illuminating all or part of the frame 130. The foot can be connected to the rearview device 100.

[0174] Figure 2 Showing highlights for Figure 3 Example of a rear-view device 100 with line AA in a cross-sectional view.

[0175] Figure 3 It is a description along Figure 2 The diagram shows a cross-sectional view of the rearview device 100 depicted by line AA. The rearview element 120 in this example is a glass substrate with a reflective coating on its inner surface. An illumination assembly in the form of an LED light strip 140 is attached to a diffuser 150. The diffuser 150 is attached to a bezel 130. The bezel 130 is a multi-functional outer glass bezel 130 with an integrated clear and chrome-based coating for use as a molding trim for a cosmetic mirror bezel. A painted portion 115 of the housing 110 is shown, which can be scalp-painted.

[0176] Figure 4 This is a diagram depicting an example of a lighting assembly 200. This example lighting assembly 200 includes a connector 210, a PCB board 220, an LED 230, one or more lenses 240, and at least one filter 250. The lamp assembly can be housed in a housing 260.

[0177] Figure 5 These are two example diagrams depicting a perspective view of the rearview device 100 and details of the rearview device 100.

[0178] Reference Figure 5 Details of the rearview device 100, according to Figure 4The lighting assembly 200 can be housed inside the rearview device 100. An external connector 210A controls and supplies power to the lighting assembly 200. The rearview device 100 includes a multi-function exterior mirror glass bezel 130, and displays both without and with the integrated lens 240.

[0179] Based on the foregoing example, this description provides a multi-functional rearview device 100 for use with a vehicle, comprising a multi-functional rearview element 120, a housing 110, and a bezel 130. The housing 110 is configurable to be attached to a vehicle and is movable relative to the vehicle when attached. The rearview element 120 may include at least one of a reflective element and a display element, and is attached to at least one of the housing 110 and the bezel 130.

[0180] The housing 110 may be made of a single part, or it may include an upper part and a lower part, with the frame 130 attached to both parts.

[0181] The bezel 130 may be formed on the exterior of the housing 110 surrounding the rearview element 120, and may include an interior space formed within the bezel 130 and at least one of one or more lamp assemblies 200 and one or more electronic devices located within the interior space of the bezel 130. The bezel 130 may be formed as a single integral part, or may be formed from a plurality of segments 130A, 130B, 130C, 130D (e.g., including two segments at the top and bottom, four segments 130A, 130B, 130C, 130D on the four sides, or any number of segments).

[0182] The frame 130 can be formed or molded from any type of glass. The glass used herein refers to an amorphous solid that exhibits a glass transition toward a liquid state upon heating. Polymer substrates are particularly suitable, not only because they are lightweight, but also because they are cost-effective and durable. The frame is interchangeable with and can be removed from standard non-illuminated frames, allowing the non-illuminated frame to be removed and replaced in place with a frame that provides illumination and indication. Non-illuminated frames can be opaque, clear, transparent, or translucent. Similarly, illuminated frames can be opaque, clear, transparent, or translucent.

[0183] The frame 130 may be molded to include recesses on its inner surface to accommodate at least one or more lamp assemblies 200, one or more electronic devices, and other internal structures of the rearview device 100.

[0184] The bezel 130 may include a colored, polished, transparent, or coated surface, and the space below the bezel may be used to accommodate at least one optoelectronic device and at least some other functional components, such as a heater or wiper integrated into the rearview device.

[0185] The frame 130 can also be configured to be fixed, glued, clamped or removably attached to the housing 110 in any way.

[0186] Transparent materials or surface coatings can be used to transmit light from one or more lamp assemblies 200 within the rearview device 100 to the outside, for example, to the driver of the vehicle or any other person or sensor observing the rearview device 100. For example, a transparent bezel 130 including a chrome-based coating can be used, such that the lamp assembly 200 beneath the bezel 130 is hidden from an external observer before being illuminated.

[0187] The chromium-based coating can be an alloy of chromium and a dopant material selected from hexagonal close-packed transition metals, the alloy having a crystal structure of a primary body-centered cubic phase coexisting with a secondary Ω hexagonal close-packed phase.

[0188] The multi-functional device or bezel 130 may include only one lamp assembly 200 or multiple lamp assemblies 200. The lamp assembly 200 or multiple lamp assemblies 200 may be configured to direct light to different locations on the bezel 130 and may provide different light characteristics for different locations on the bezel 130 to provide different light function indications. These different characteristics may include at least one of light color, light intensity, and light pulse length.

[0189] The coating can impede different light applications. To allow for light shaping according to different needs, a portion of the frame surface can be left out of the coating, or the coating can be removed later to form a specific shape. Lens 240 can be molded directly into this or other portions, or added later. This allows, for example, a company logo to be projected onto the ground without a coating or when the coating is removed from the lower part of the frame 130.

[0190] Different positions of the frame 130 may include at least: position 130A on the frame 130 above the rearview element 120, position 130C on the frame 130 below the rearview element 120, position 130B on the vehicle-facing frame 130, and position 130D on the vehicle-free frame 130. In each position, a single lamp assembly 200 may be located within the interior space of the frame 130. For example, a first lamp sub-assembly 200 may be located within the interior space of the frame above the rearview device 120, a second lamp assembly 200 within the interior space of the frame 130 below the rearview device 120, a third lamp assembly 200 within the interior space of the frame 130 at the vehicle-facing position, and a fourth lamp assembly 200 within the interior space of the frame 130 at the vehicle-free position.

[0191] Alternatively, the frame 130 can be subdivided into multiple locations to provide a variety of different lighting functions, and multiple different lamp sub-assemblies 200 can be located in the interior space of the frame at multiple locations.

[0192] One or more lighting components 200 may include a light source 230, which has at least one of an LED lamp, a light strip, printed lighting, an optical light guide, or a lamp.

[0193] One or more lamp assemblies 200 or electronic devices can be placed directly on the plastic component or frame 130 without the use of a printed circuit board 220. One or more conductor traces can connect different components of the one or more lamp assemblies and electronic devices, and also connect to other electrical systems inside and outside the rearview device 100. Alternatively, the plastic component or frame 130 can be molded around the conductor traces, one or more lamp assemblies 200 or electronic devices. At least one conductor trace, electronic device, and one or more lamp assemblies 200 can be directly applied to the plastic component or frame 130 by one or more of injection molding (MID), conductive foil (IML), and laser direct molding (LDS).

[0194] One or more lamp assemblies 200 may also include an LED holder having an integrated connector 210 that can be clipped into the interior space of the frame 130.

[0195] One or more lamp assemblies 200 may include at least one light source unit 230 having at least one wire and no printed circuit board; a housing unit that supports the light source unit and is designed with means suitable for holding and connecting at least one of them; and a sealing device for protecting the LED and sealing it away from the environment.

[0196] One or more light components 200 can be configured to direct multiple different colors of light to the entire surface of the frame 130, so that the entire frame can have one color at a time, and can be configured to provide multiple different colored lights to different areas of the frame, so that different areas of the frame can have different colors at a time.

[0197] In one example, the lamp assembly may include a printed circuit board (PCB) 220, a light-emitting diode (LED) 230, and an integrated lens 240.

[0198] Light from one or more lamp components 200 in different implementations can be used to provide at least one or more lighting function indications at different locations, including direction indicators, blind spot indicators, approach lights, forced entry signals, emergency braking signals, logo lights, puddle lights, human-machine interfaces, charging indicator status, vehicle modes, sport mode, economy mode, autopilot mode, sleep mode, vehicle lock, vehicle theft, warning signals, temperature or weather indicators, traffic light signals, and fuel status.

[0199] In some examples, at least some of the light can be directed toward the ground or toward other people or sensors outside the vehicle to convey information. The rearview device may further include a light diffuser located within the interior space of the bezel. The housing 110, reflective element 120, and bezel 130 of the rearview device 100 may be integrally formed, thereby sealing the multi-functional device 100 away from the external environment.

[0200] The multi-function rearview device 100 can be functionally connected to an actuator, whereby the actuator is located outside the housing. This allows the actuator to move the entire multi-function device 100, including the housing 110, and not just the rearview element 120. The actuator can be configured to perform one or more different types of motion, including rotational and translational motion.

[0201] The actuator may also be configured to determine the light output of one or more lamp assemblies 200. The rearview device 100 may include a foot adapted to be fixed to the vehicle, and a housing 110 having a frame 130 is movable relative to the foot.

[0202] In one example, the foot provides at least one spherical seat for the housing 110.

[0203] In another example, the frame 130 is attached to the housing 110 together with one or more lamp assemblies 200 and at least one electronic device.

[0204] The rearview device 100 may include a connector to a control unit for controlling at least one of one or more light assemblies 200, rearview elements 120, and actuators.

[0205] Additionally, the rearview device 100 may include at least one sensor. The output of the sensor can be used to control at least one of one or more lamp assemblies 200, reflective elements 120, actuators, or any other functions and systems (such as heaters and wipers).

[0206] The rearview device 100 may include a connector to a control unit of the vehicle for controlling at least one of one or more light assemblies 200, rearview elements 120, and actuators. The sensor may be, for example, a camera.

[0207] The rearview device 100 may further include additional functions and systems, such as a heater or wipers. Electronics may be configured to control and connect to one or more of the following: light assemblies 200, display elements 120, actuators, sensors, cameras, heaters, and wipers. Electronics may also form a unit together with the bezel 130.

[0208] Figure 6 This is a diagram depicting an example of an integrated flexible circuit 600 including one or more lighting elements 610.

[0209] Reference Figure 6 The light and signal modules and sensors housed in the exterior mirrors are typically configured as separate modular components and connected to a separate rigid PCB using conventional wiring harnesses. In a preferred example, the rearview device may include lighting, sensor, and heating functions all integrated into a single flexible printed circuit / ribbon circuit 600, which is adhesively attached to the surface of the rearview device (e.g., a glass surface) to function as a heat sink. The flexible circuit 600 provides single-point electrical connections and self-mapping connections to the mounting surfaces of all exterior mirror functions, as well as LED lights and electronic components, while also providing flexibility to position the lights and sensors correctly. Therefore, these exterior electronic functions can be integrated into a fixed glass housing frame and can be disassembled, assembled, or repaired with a simple operation using the rotational assembly movement of the glass support frame.

[0210] In this example, the flexible circuit 600 may include a connector control unit 620 and a flexible heating pad or ribbon circuit 630 directly attached to one or more lighting elements 610.

[0211] Figure 7 It is a description including Figure 6 A perspective view of an example of a rearview device with integrated flexible circuitry.

[0212] Reference Figure 7 The rear-view device 700 may include an integrated flexible circuit 600. (As already referred to...) Figure 6The flexible circuit 600, as described, includes a connector control unit 620 and a flexible heating pad or ribbon circuit 630 directly attached to one or more lighting elements 610. In this example, five lighting units are attached and face separate directions, and can project different colors of light, as described throughout this application. For example, the first lamp 610a can project blue light, the second lamp 610b and the third lamp 610c can project red light, the fourth lamp 610d can project green light, and the fifth lamp 610e can project yellow light; all lamps are capable of changing color and can be used for different functions. A connector control unit 620 can control all functions on the frame, including all lighting elements 610a to 610e, the heating pad, and the temperature sensor 640. The connector control unit 620 can be configured to accommodate a wiring harness with connectors 710, and is preferably described as a single control unit 620, but more than one control unit 620 may be provided.

[0213] Therefore, the housing frame 720 of the rearview device 700 can be provided as part of a single-piece fixed glass frame assembly with integrated lighting and other modules. The frame 720 may include a light-receiving portion 740 forming a built-in lateral turn indicator module, in this case receiving light projected by the fifth lamp 610e. A glass reflector 750 may be provided on the opposite side of the frame 720; however, it should be understood that the described frame 720 and flexible circuitry 600 are equally applicable to camera monitoring systems (CMS).

[0214] When providing a single-piece fixed glass bezel assembly 700 with integrated flexible circuitry / ribbon 600, an assembly is provided that integrates all peripheral electronic mirror functions into a single, easily serviceable component, allowing customers to easily upgrade and reduce maintenance costs. The electronic components fixed to the flexible ribbon 600 can also provide a mirror glass defrosting heater element, and the mirror glass can also be used as a heat sink. A single-point electrical connector 620 integrated into the flexible circuitry 600 provides electrical connection to the vehicle, and when used in conjunction with a rotating bezel concept, connection can be made using conventional electrical connectors or self-mapping connectors. This also provides reduced packaging space and repeatable placement / routing for multiple functional components.

[0215] Figure 8 This is a perspective view depicting another example of a rearview device that includes another integrated flexible circuit.

[0216] and Figure 7 The rearview camera is very similar to the 700. Figure 8The rearview device 900 includes a flexible circuit 800 having an integrated lighting element 810, an electrical connector 820, and a temperature sensor 840. The flexible circuit 800 may include an attached heating pad 830, which is formed as an accessory to the body of the flexible circuit 800; for example, it is attached to the body of the flexible circuit 800 via a narrow neck. This allows the heating pad 830 to be received in a slot 960 formed in a frame 920 to position the heating pad 830 in an ideal location, for example, around the slot 960 and curved behind a glass reflector 950. Furthermore, the flexible circuit 800 may also include a communication module 850, such as a Bluetooth or Wi-Fi module, and an integrated antenna 860.

[0217] Similar to rearview device 700, rearview device 900 can be configured to receive a wiring harness with connector 910. The housing frame 920 of rearview device 900 can be provided as part of a single-piece fixed glass frame assembly with integrated lighting and other modules. Frame 920 may include a light-receiving section 940 forming a built-in lateral turn indicator module, in this case receiving light projected by a fifth lamp 810. A glass reflector 950 can be provided on the opposite side of frame 920; however, it should be understood that the described frame 920 and flexible circuitry 800 are equally applicable to camera monitoring systems (CMS).

[0218] This application also relates to a lamp assembly, a rearview device, and a lamp module for a lamp assembly of an external rearview device for a vehicle, as described in U.S. Patent Application No. 15 / 256,540, the entire contents of which are incorporated herein by reference for all purposes.

[0219] A lamp module for a lamp assembly of an external rearview device may include a light source unit having at least one wire, adapted for electrical connection to a printed circuit board of the rearview device (particularly the lamp assembly). The lamp module further includes a housing unit supporting the light source unit and is provided with connection and / or retention means adapted to attach to at least a portion of the rearview device, particularly the housing portion. The lamp module further includes a sealing device adapted to provide a waterproof and dustproof connection between the lamp module and at least a portion thereof.

[0220] Preferably, the light source unit includes a photoelectric component electrically connected to a wire; a radiating surface, preferably provided by a transparent and / or translucent resin in which the photoelectric component is embedded; and a light source housing, which is included in or attached to the housing unit.

[0221] Furthermore, a preferred example may be characterized in that the housing unit can be formed together with the light source housing and / or sealing device, for example by hot embossing or 2-K injection molding.

[0222] The housing unit may have through holes for each wire, and / or the housing unit may have a receiving structure for the light source unit, and / or the housing unit may have connection and / or retention devices, such as plugs or snap-fit ​​connectors.

[0223] The connection and / or retaining device may include at least two latches, each latch being provided with a stop element. In another example, one latch may be used; in another example, three latches may be used; and in yet another example, four latches may be used; and any number of latches may be used.

[0224] Furthermore, the sealing device can be placed around the periphery of the housing unit, or the periphery of the housing unit can be formed in the area supporting the light source unit. An additional example may feature that one or more light source units can be supported by the housing unit, and / or each light source unit includes an LED unit having one or more LEDs. In another example, at least two light source units are used. In yet another example, at least three light source units are used, and any number of light source units can be used.

[0225] Additionally, the lighting components of the external rearview device may include a side turn indicator, blind spot detection, sign light, door handle light, and / or approach light having at least one of the lighting modules described herein.

[0226] The lamp assembly may include at least one printed circuit board located away from the lighting module to which one or more wires are soldered and provides a solder pad pattern.

[0227] For each lamp module, the solder pad pattern may include at least one pad, preferably two pads, wherein each pad has a diameter of 3 to 5 mm. 2 The area and / or two pads having a distance of at least 0.5 mm or an extension of at least 0.5 mm in length and / or width, and / or on the outside of the pads, provide solder resist on the printed circuit board.

[0228] An electronic circuit board unit can be connected to each lighting module and power supply, and / or one electronic circuit board unit can be connected to two or more light source units, particularly to light source units connected in series or parallel.

[0229] The electronic circuit board unit may include at least one driver circuit for direct or indirect connection to a power source; and at least one printed circuit board, preferably one printed circuit board for all lamp modules in a plurality of lighting modules, or one printed circuit board for each lamp module.

[0230] At least one plug connector may be provided for electrical and physical connection of printed circuit boards and / or driver circuits.

[0231] Additionally, the present invention may provide an external rearview device for a vehicle, comprising at least one lamp module as described herein and / or at least one lamp assembly as described herein.

[0232] The radiating surface of the lamp module may be flush with the outer surface of at least one housing portion, to which the lamp module is attached via its connection and / or holding means. In another example, the radiating surface of the light module may overlap or underlap the outer surface of at least one housing portion to which the light module is attached, and a variety of different arrangements of overlapping, flush, or underlap may be used.

[0233] By using three components—a light source unit, a housing unit, and a sealing device—several advantages can be provided for the optical module. First, it's important to note that the light source unit, which can be an LED unit, does not need a printed circuit board, thus providing a solderless light source bracket, which reduces production costs. Secondly, the housing unit not only holds or supports the light source unit but also incorporates connection and / or holding devices to facilitate the attachment of the optical module to the rearview device, which also reduces production costs. Furthermore, the fact that the sealing device is designed to be waterproof and dustproof extends the lifespan of the optical module within the external rearview device.

[0234] It may be advantageous to form the housing unit together with the light source housing and / or sealing device of the light source unit, for example, using a 2-K injection molding process, to further save costs.

[0235] The lamp module can be connected to a remote printed circuit board because it may not have its own printed circuit board, thus providing a high degree of flexibility regarding its installation location within the external rearview device. Therefore, a lamp assembly comprising a single printed circuit board connected to multiple electronically consuming units, including the lamp module as described herein, can have a very simple system architecture with a reduced number of parts.

[0236] The printed circuit board of the lamp assembly can have improved heat dissipation and enhanced performance due to a special solder pad pattern. For example, an optical module of the present invention can be connected to two pads of the pattern with two wires, wherein the minimum distance between the two pads is at least 0.5 mm, and / or each pad has an extension having a dimension of at least 0.5 mm. Furthermore, the printed circuit board can be covered with solder resist on the outside of the solder pads.

[0237] When the optical module has multiple light source units connected in parallel, the number of wires that need to be connected to the solder pad pattern can be reduced compared to arranging each light source unit individually.

[0238] The external rearview device of the present invention may include one or more light modules, particularly for providing side turn indicators, blind spot detection, sign lights, door handle lights, and / or approach lights. Each of these functions can be implemented by a light module, wherein all light modules are connected to a single circuit board arranged remotely from the light modules, thereby providing a high degree of flexibility regarding the arrangement of the light modules within the external rearview device.

[0239] Because each light module is equipped with a sealing device, virtually no water or dust can enter the interior of the external rearview device, which is essential for ensuring a long lifespan.

[0240] This application also relates to an electronic device configured for use in a rearview device for a motor vehicle, and a rearview device including such an electronic device, as described in U.S. Patent Application No. 15 / 256,532, the entire contents of which are incorporated herein by reference for all purposes.

[0241] An improved rearview device for a motor vehicle, configured for use in a motor vehicle, the improved rearview device comprising at least one housing device having at least one base plate and a cover disposed on or potentially disposed on the base plate, the cover defining, in an engaged state, at least a nearly completely closed cavity; the improved rearview device having at least one first retaining device for retaining a retaining unit, by which the housing device is secured or can be secured in or on the rearview device; the improved rearview device having at least one electronic module comprising at least one conductor unit and at least one contact device connected to the conductor unit, wherein the conductor unit is disposed on the surface of a steering cavity of the base plate and / or the cover, the conductor unit having at least one carrier and at least one conductor trace directly applied to the carrier, the contact device extending through the cover and / or through the base plate via at least one protruding contact section being externally accessible, the at least one carrier of the at least one conductor unit being at least segmented (at least in The sections are formed by the functional surfaces of the base plate and / or cover that are adjacent to and turn toward the cavity, and the cover and / or base plate are formed or shaped together with at least one first retaining device of the retaining unit as a common component.

[0242] Other preferred examples of electronic devices are also described.

[0243] Because at least one carrier of the conductor unit is formed, at least segmentally, from the functional surfaces of the base plate and / or cover, the electronic device has fewer parts and can be designed compactly. This also reduces assembly work.

[0244] In addition to conductor traces, conductor units may also include other electronic components, such as integrated circuits (ICs), capacitors, resistors, etc. They can also be arranged on a carrier, particularly on the functional surfaces of the base plate and / or cover.

[0245] The conductor unit can have a plate-like design without individual components. In this case, the conductor unit can be formed entirely from the functional surface. It is conceivable that the components of the conductor unit can be attached to the functional surface as individual components, rather than the conductor unit as a whole being formed from individual components.

[0246] In another improvement, at least one of the carriers can be formed entirely from the functional surfaces of the base plate and / or the cover. In this case, if the functional surfaces of the base plate or the cover perform the functions of a carrier that is already formed as a separate component, the carrier of the electronic module formed as a separate component can be completely eliminated.

[0247] Conductor traces applied to a carrier (e.g., a functional surface) can essentially be achieved based on conductor units formed as individual components. However, electronic devices can have a compact design when conductor traces are applied directly to the carrier, such as through injection molding (molded interconnect devices [MID]), through conductive foil (in-mold labeling [IML]), and / or through laser direct forming [LDS].

[0248] Furthermore, if the electronic module includes multiple conductor units and / or if the electronic module forms a common control unit for multiple electrical loads of the rearview device, the number of housing devices and electronic modules arranged therein can be reduced, wherein each electrical load is functionally assigned to or may be functionally assigned to at least one conductor unit, and wherein in particular at least one dominant unit includes a driver circuit via which the conductor units functionally assigned to the electrical loads can be individually and / or collectively controlled.

[0249] This allows existing separate and independently operating electronic modules to be combined into a common electronic module. In this way, the number of housing devices can also be reduced to a single housing device in which the common electronic module is arranged. Because less space is allowed to accommodate the electronics, this enables rear-view devices to have a compact design with fewer components.

[0250] At least one retaining unit may include at least one first retaining device, which together with the cover and / or base plate forms a common component, such as an injection-molded part.

[0251] If the first holding device of the holding unit with a cover or base plate forms a common component, especially an injection-molded part, the electronic device can be designed with fewer parts and further improve the ease of assembly.

[0252] It has further proven advantageous that the housing device is detachably secured or can be secured to the rearview device or the rearview device by means of a retaining unit, particularly by means of a first retaining device, especially by means of a rear gripper; and / or the first retaining device includes an externally threaded section on the cover or the base plate, a latching element, such as a clip or bayonet fitting, and / or a screw or bolt element.

[0253] In further research results of the above exemplary embodiments, it has proven advantageous that the retaining unit includes a second retaining device fixed in or on the rearview device, particularly to a retaining plate of the rearview device. The second retaining device includes an internally threaded section capable of interacting with a first retaining device designed as an externally threaded section, and includes a rear grip receiving device and / or a receiving portion of the first retaining device designed as a screw or bolt element that interacts with the first retaining device designed as a latching element.

[0254] In the manufacture of electronic devices, the various components of an electronic module are mechanically arranged on the functional surfaces of a cover and / or a base plate. Here, a tool for assembling the components of the electronic module travels parallel to the plane of the functional surface of the cover and / or base plate, said plane being traversed by vectors in the x and y directions, wherein the tool travels in the z direction when connecting the components transversely to this plane. To maintain low movement in the z direction, it has proven advantageous that a first end of a first retaining device is fixed to the end of the cover or base plate opposite to the functional surface of the cover or base plate, and a second end is arranged extending in the direction of the functional surface, wherein the first retaining device is designed to extend without overlapping the plane of the functional surface, and the second end is spaced a certain distance from the plane of the functional surface.

[0255] For example, the first retaining device can be designed as a clamp. In this case, the retaining device designed as a clamp can extend in the z-direction without protruding beyond the functional surface. This means that wide assembly paths for the assembly tool (which are necessary for the retaining device to protrude beyond the functional surface) can be prevented so as not to damage the retaining device.

[0256] If the first retaining device includes, for example, an externally threaded section on the cover plate or base plate of the housing device and the second retaining device includes an internally threaded section, the electronic device can be easily screwed into the rearview device without tools.

[0257] If the first retaining device includes a latching element and the second retaining device includes a receiving device that interacts with the latching device, the electronic device can be easily assembled by clamping it into the rearview device. Furthermore, maintenance of the electronic device is simplified in this case, as it can be installed on the rearview device without tools, or removed without tools by releasing the clamp connection.

[0258] If at least one externally accessible protruding contact section of at least one contact device includes at least one pin, in particular multiple pins, and the electronic module is connected or can be connected to at least one power source and / or at least one electrical load via said pins, then the electronic module can be connected to a power source.

[0259] Furthermore, in one example of an electronic device, the electronic device may include at least one energy storage device arranged in a cavity of the housing device and functionally allocated in an electronic module for storing and releasing electrical energy.

[0260] In such cases, it may be possible to maintain energy reserves independent of the power source, for example, to balance peak loads, or to maintain available energy reserves in the event of a power failure, such as keeping the warning light function active for at least a limited time.

[0261] To simplify the connection between the cover and the base plate and reduce the risk of tilting when connecting the cover to the base plate, the cover and the base plate may include cylindrical sections through which they can slide into each other when connected. They can slide concentrically or telescopically, and the cover may include edge sections that project radially relative to the cylindrical sections and extend completely around the outer surface of the cover, forming end stops when the cover and the base plate are connected.

[0262] Because it is circular, it is possible to maintain a uniform distribution of clamping force on the unit, and a good sealing surface can be obtained by providing a uniform circular contact area.

[0263] In another improvement, the cover and / or base plate may have a basin-shaped design, wherein at least the cover includes a wide base plate adjacent to the cylindrical section, the base plate traveling transversely or inclined to the axis of the cylindrical section, and having a functional surface arranged on its side facing the base plate, while a contact section of a contact device is arranged on its side facing away from the base plate and surrounded by the cylindrical section.

[0264] Because the base plate and the cover are each designed with cylindrical sections, they can slide concentrically and extensibly into each other when connected, thus achieving a uniform contact area. In this way, the gap between the base plate and the cover can be kept small. The electronic device may include at least one sealant disposed between the cover and the base plate, particularly between the edge sections of the base plate and the cover, thereby sealing the cavity of the housing device relative to the gap present between the cover and the base plate.

[0265] In this way, moisture and dirt are prevented from entering the cavity, thereby reducing the risk of contaminating or damaging the electronic modules.

[0266] If the base plate of the housing device includes a one-piece element of the rearview device components, particularly a one-piece injection-molded part, such as a retaining plate, then the electronic equipment can be assembled and disassembled particularly easily for maintenance purposes. In this case, the various components of the electronic equipment can be pre-assembled so that, during final assembly, only the cover containing the electronic module, the first retaining unit, and the sealant is screwed or glued onto the base plate. In this way, the existing multiple individual electronic modules of existing housing devices, which in various cases are formed by multiple separate components, can be assembled and disassembled with a single movement.

[0267] If the base plate, cover, first retaining device, and / or second retaining device are made of plastic, the electronic device can also be manufactured in a lighter and more economical manner.

[0268] Electronic devices can be designed as lighting modules, especially for peripheral lights used in rear-view devices.

[0269] The rear-view device may include at least one electronic device as described herein. The rear-view device may include at least one reflective element and / or at least one camera. Electronic devices and rear-view devices have proven advantageous in many respects:

[0270] Because the base plate and / or cover include functional surfaces facing the cavity, which at least partially form the carrier of the conductor unit, the electronic device can be designed to have a reduced number of components.

[0271] Because multiple conductor units forming a common electronic module can be arranged within the housing device, multiple existing electronic devices can be arranged in a common electronic device, for example, within a common housing device. In this way, the space that must be accommodated in the rearview device is reduced.

[0272] The device also describes a head section and a rear-view device that can be designed in a compact manner as described in U.S. Patent Application No. 15 / 000,754, the entire contents of which are incorporated herein by reference for all purposes.

[0273] This objective is achieved by means of the fact that the head section and the cover section tightly seal the hollow region outwards at least almost the entire circumference.

[0274] Because the hollow area is surrounded at least almost its entire circumference facing outwards, it is protected from the penetration of dust and moisture. This makes it possible to arrange at least one electronic unit within the hollow area without requiring its own sealing. This also makes it possible to create a compact design for the head section.

[0275] Typically, it is feasible to provide the electronic unit with its own housing, which allows it to be arranged in the hollow region between the housing section and the cover section. However, it has been shown to be advantageous to arrange, or at least arrange, at least one electronic unit without requiring a housing in the hollow region.

[0276] The housing section and the cover section can typically be connected to each other in any desired manner. In one embodiment of the head section according to the invention, the housing section and the cover section are specified to be locked relative to each other at the joint by overlapping each other, particularly by forming an undercut. When the cover section and the housing section form an undercut, it is possible to easily achieve a secure connection between the two components. In particular, in this case, the housing section and the cover section can be locked to each other without the use of tools (e.g., by means of clamps).

[0277] Typically, it is feasible to form only a partial connecting portion. Preferably, the connecting portion is designed to surround a circle.

[0278] It is feasible to make the rearview device relatively movable relative to the housing section. This may be the case, for example, when the cover section and / or housing section are at least segmented and made of a flexible, bendable material such as a plastic film. However, the rearview device can be locked relative to the housing section. In this case, the rearview device can be positioned by adjusting the head section.

[0279] The rearview device may include components that are separate from or separable from the cover section. In this case, the cover section may be adhered or locked, for example, by spraying a reflective coating onto the cover section. However, in one embodiment of the head section according to the invention, the cover section and the rearview device are provided as single-piece components.

[0280] This makes it possible to reduce the number of components in the head section.

[0281] Typically, it is feasible to make the cover section into a disc shape. However, the cover section can be designed as a clamp type and includes a flat portion and at least one edge portion, specifically, the flat portion including a rear-view device, while the edge portion extends laterally or diagonally relative to the flat portion. In this case, the cover section can be locked to the housing section like a clamp using at least one edge section. Here, the edge section can grip the housing section from the inside or from the outside.

[0282] The housing section and the cover section can be made of any desired material. When the cover section and the rearview device comprise combined single-piece components, i.e. when the rearview device is part of the cover section, it has been shown to be advantageous when the cover section comprises a multi-component assembly, wherein the flat portion comprises a first cover component, particularly a plastic component, and the edge portion comprises a second cover component, particularly a plastic component.

[0283] Typically, it is feasible for a multi-part assembly to consist of two plastic sections. However, when the cover section has multiple functions, other plastic parts may be provided.

[0284] Because the edge section may include another plastic component, such as a flat portion, it can be designed to form a tight seal. The electronic unit may include, for example, a lighting unit. Light generated by the lamp from the head section can be transmitted outwards through a light window. In this case, the electronic unit may include repetitive flashing light or illumination for an area immediately surrounding the vehicle.

[0285] On one hand, it is specified that the housing section includes a first housing component, particularly a plastic component, which is located directly on the hollow area and has a certain coloring. Specifically, the coloring is substantially opaque and / or non-transparent, wherein the first housing component includes an opening in the area of ​​the light window. Because the first housing component is opaque and non-transparent, an attractive appearance can be achieved. Because an opening is provided in the first housing component, light from the electronic unit can be transmitted outwards.

[0286] To prevent the penetration of dust or moisture, another improvement in a later embodiment of the invention specifies that an optical element, such as an optical fiber and / or an optical disc, may be arranged in and / or on an opening in the first housing component of the housing section, and a housing seal is arranged or may be arranged between the first housing component of the housing section and the optical element. Because a housing seal is provided between the optical element and the opening of the housing section, the hollow area is tightly sealed outwards. As a result, again, the electronic unit does not require a separate housing.

[0287] As a supplement or alternative to providing housing seals, it has been shown to be advantageous for a second housing component, particularly a plastic component, to be arranged such that it is located on the surface of the first housing component away from the hollow region and is substantially translucent and / or transparent, at least in the region of the light window, particularly in the region of the light window, and is designed as an optical element, such as an optical fiber and / or optical disc.

[0288] Because the second housing component is adjacent to the first housing component, and specifically covers the outward-facing opening in the first housing component, a housing seal is not required. Because the second housing portion is translucent and / or transparent, light from the electronic unit, designed as an illumination unit, can penetrate outward from the hollow area of ​​the head section.

[0289] The rear-view device may include a reflective device and / or a display device, such as a screen, particularly an LED or LCD screen. When the display device includes a screen, the screen may be arranged on a flat portion of the cover section. Alternatively, it is possible for the cover section, on which at least a portion of the LED or LCD screen is arranged, to be transparent and / or translucent, and for the screen to be arranged on the side of the flat portion of the cover section facing the hollow area.

[0290] The electronic unit may include mounting facilities for a rearview device. This makes it possible to mount the rearview device in a simple manner. The mounting facilities may be arranged on the upper surface of the flat portion of the cover section facing the hollow area.

[0291] The setup may include a setup unit having at least one lighting device that is locked relative to a rearview device or can be locked in such a way, and by means of the lighting device, can emit a directional or directed beam of light that is at least substantially uniquely perceptible to the driver and / or control unit of the motor vehicle in a designated operating position. The lighting device may include a coiled wire bulb, an LED, or a laser.

[0292] Because the beam of light can be detected at least almost exclusively by the driver and / or control unit of a motor vehicle in a designated operating position, the rearview device can be easily adjusted to a compliant position.

[0293] In order to allow light to escape, the housing sections and / or cover sections, especially the edge sections, may include transparent and / or translucent areas through which the light beam emitted by the lighting device can penetrate outward at least almost unimpeded.

[0294] This allows light emitted by the lighting device to penetrate from the inside of the rearview device outwards and be perceived from the outside, while in the hollow area of ​​the housing, it is protected from environmental influences.

[0295] Transparent and / or translucent areas can generally be designed in any desired manner. Transparent and / or translucent areas may include recesses, particularly through-holes, and / or translucent and / or transparent materials, such as glass (especially smoked glass) or plastic.

[0296] Typically, it is feasible to sufficiently focus the light beam emitted from the lighting device so that it is virtually exclusively perceptible to the driver and / or control unit of the motor vehicle in a designated operating position. Furthermore, the setting unit may include at least one optical element that may be assigned or functionally allocated to the lighting device, thereby at least focusing the light beam emitted by the lighting device.

[0297] Furthermore, this objective is achieved by means of a rearview device (e.g., an interior or exterior mirror) for a motor vehicle, the rearview device having at least one head section, particularly a head section having at least one of the aforementioned features.

[0298] Finally, this objective is achieved by means of a motor vehicle having at least one rear-view device having at least one of the above-mentioned features and / or having at least one head section, particularly a head section having at least one of the above-mentioned features.

[0299] Because the cover section and housing section surround the hollow area in a nearly completely sealed manner, electronic devices that do not require a housing can be placed in the hollow area. As a result, the head section and rear-view equipment can be designed to be compact.

[0300] The present invention also provides a plastic substrate coated with a decorative coating, as described in U.S. Patent Application No. 15 / 124,310 (the entire contents of which are incorporated herein by reference for all purposes), wherein the decorative coating includes a spectral control system and a stress control system, the spectral control system being multilayered and optionally including a protective layer, and the stress control system being at least a single layer between the spectral control system and the substrate.

[0301] The multilayer of the spectral control system can be an absorption layer alternating with a transparent layer, the optical thickness of the spectral control system is selected such that the decorative coating achieves the desired optical effect, and at least one layer of the stress control system has a compressive stress such that when measured in the absence of an optional protective layer, the total residual stress of the decorative coating is compressible.

[0302] To understand the following description, it is important to understand what the phrase "desired optical effect" refers to in this document, and the impact of determining the desired optical effect on how the decorative coating is spectrally tuned to provide the said desired optical effect to the coated substrate.

[0303] The desired optical effect will be the desired appearance (when viewed from the front) of the surface or part of the surface of the product comprising the substrate coated according to the invention. Taking into account the combined effects of the decorative coating, the plastic substrate, and the presence and absence of backlighting, the desired optical effect will consist of a combination of the desired transmitted color, the desired specular color, and the desired diffuse color. In this regard, the plastic substrate needs to be considered because the substrate itself may be stained or clear, or may include embedded particles to provide a hazy appearance to the uncoated substrate, or one or both of its (uncoated) surfaces may be textured, for example, a texture that can be adopted to provide a "brushed metal" appearance. While all these properties will contribute to the overall appearance of the finished product, it should be understood that in the present invention, the decorative coating, in particular the spectral control system, can be tuned to allow the desired optical effect to be achieved.

[0304] Regarding the desired transmitted color, desired specular color, and desired diffuse color, throughout the specification, references to "color" refer to the color defined by L*, a*, and b* as measured according to the 1976 CIE L*a*b*Space (or CIELAB) color model (which is an approximately uniform color scale organized in a cubic form). On orthogonal a* and b* color axes, positive a* values ​​are red, negative a* values ​​are green, positive b* values ​​are yellow, and negative b* values ​​are blue, while the vertical scale L* of brightness (or grayscale) ranges from 0 (black) to 100 (white), thus allowing the total color E to be located at three points. The chromaticity (C*) of a color is defined as (a*.sup.2 + b*.sup.2) and is used to quantify the magnitude of the color, independent of its brightness.

[0305] It should also be understood that the references to "transmitted" color and "reflected" color refer to the color of light that has been transmitted through an object ("transmitted color") or the color of light that has been reflected by the surface of an object ("reflected color"). Furthermore, for reflected color, "specular reflection" refers to the mirror-like reflection of light from the surface of an object, where light from a single incident direction is reflected to a single outgoing direction, while "diffuse reflection" naturally refers to incident light being reflected in a wide range of directions.

[0306] Therefore, a spectral control system is ideally used to modify spectral reflection and transmission, thereby achieving the desired optical effect for the coated substrate. Specifically, the optical thickness of the spectral control system is selected to enable the decorative coating to achieve the desired optical effect. In one form, the amplitude of spectral transmission is primarily controlled by the total optical thickness of the absorption layers within the spectral control system. However, both reflected and transmitted colors are controlled by the interference effect between the absorption and transparent layers within the spectral control system. By controlling the optical thickness of all layers in the spectral control system (including, where necessary, both absorption and transparent layers), this interference effect can be "tuned" to achieve the desired reflected and transmitted colors.

[0307] In a preferred embodiment, the optical thickness is first selected to achieve the desired transmittance, which is controlled by the combined optical thickness of the absorption layers. Once this objective is determined, the optical thickness of the transparent layer and the thickness ratio of each absorption layer are further refined using thin-film modeling software (e.g., Tfcalc.TM.) to achieve the desired reflected color through interference effects.

[0308] For example, the desired product might require a glossy black appearance in front of a lighting display. This can be achieved via a decorative coating with low, neutral reflectance and negligible diffuse reflectance. This would result in a desired transmissive color L* = 44, a* = 0, b* = 0 and a desired specular color L* = 25, a* = 0, b* = 0.

[0309] Taking this example further, using a CrZr alloy as the absorption layer, the combined thickness of the absorption layer achieving approximately 14% %T can be approximately 16.4 nm. To obtain the desired interference rate, a four-layer stack can be used, such that the combined thickness of the absorption layer is divided into two layers: 9.7 nm and 6.7 nm, with the thicker layer deposited first. The two absorption layers can then be separated using a SiO2 (SiO.sub.2) transparent layer, on which a final SiO2 layer is deposited. In this example, a spectral control system comprising CrZr / SiO2 / CrZr / SiO2 is used, where the combined thickness of the SiO2 layer and the CrZr layer is then optimized using a thin-film modeling procedure to achieve the desired reflected color.

[0310] In this regard, it will be understood that "optical thickness" is a size-free measure of how much a given material impedes the passage of light through it, derived from the product of its complex refractive index and the distance the beam travels through the material. It is also called the optical path length. The complex refractive index is a number consisting of a real part (defined as the refractive index) and an imaginary part (defined as the extinction coefficient). It will then be understood that for any given layer of material, the optical thickness (t) is defined as the refractive index (n) of the material multiplied by the physical thickness (d) of the layer, normalized to the refractive index at the wavelength being processed. Therefore, for example, the optical thickness can be calculated using the refractive index at a wavelength of 550 nm. For example, chrome:n with a physical thickness of 50 nm. 550 =3.17, which corresponds to an optical thickness of 0.288 and a physical thickness of 100 nm for SiO2:n. 550 =1.455, which corresponds to an optical thickness of 0.265.

[0311] It should also be understood that, throughout the specification, references to "absorbing layer" refer to a layer comprising a material or mixture of materials having a measured extinction coefficient greater than 1 in the spectral range of 400 to 1000 nm. Furthermore, it will be understood that, throughout the specification, references to "transparent layer" refer to a layer comprising a material or mixture of materials having a measured extinction coefficient less than 1 in the spectral range of 400 to 1000 nm.

[0312] If used in the decorative coating of this invention, the protective layer will be applied on top of the spectral control system (and thus the outermost layer) to provide enhanced abrasion resistance, fingerprint resistance, and "easy-clean" properties. Suitable materials for such a protective layer may be coatings based on plasma-polymerized hexamethyldisiloxane (HMDSO) or fluoropolymers deposited via evaporation or liquid transfer techniques, or liquid hard coatings applied via spin coating, dip coating, spray coating, or flow coating techniques, with or without particulate additives (matte additives) for haze control.

[0313] If a protective layer is used, it forms part of the spectral control system (and thus part of the decorative coating), and therefore its impact on the desired optical effect needs to be considered in the same manner as described above. In fact, in the form of the invention employing a protective layer, the combined optical thickness of the protective layer plus the absorption and transparent layers is thus selected to achieve the desired optical effect of the decorative coating.

[0314] For the absorption layer of the spectral control system, as described above, these layers are layers of materials or mixtures of materials having a measured extinction coefficient greater than 1 in the spectral range of metals from 400 to 1000 nm. Preferably, these materials are metals, quasi-metals, metal alloys, or mixtures thereof, having a refractive index such that the sum of the refractive index and the extinction coefficient is greater than 2, while maintaining an extinction coefficient greater than 1. For the transparent layer of the spectral control system, again as described above, these layers are layers of materials or mixtures of materials having a measured extinction coefficient less than 1 in the spectral range of metals from 400 to 1000 nm. Preferably, these materials are metals, quasi-metals, metal alloys (or mixtures thereof), having a refractive index such that the sum of the refractive index and the extinction coefficient is less than 3, while maintaining an extinction coefficient less than 1.

[0315] In this form, the spectral control system is an interferometric system composed of alternating layers of materials with different refractive indices, ideally possessing a relatively high refractive index contrast between adjacent layers. In this respect, such refractive index contrast can be achieved by selecting a transparent layer of material with a suitable low refractive index and an absorbing layer of material with a suitable high refractive index. In this regard, the difference in refractive index should be as large as possible to reduce the total film thickness required to produce the desired reflected color. It is desirable to use materials with the lowest possible refractive index.

[0316] With this in mind, suitable materials for the absorber layer can be selected from metals, metalloids, and metal alloys, including: chromium, aluminum, titanium, nickel, molybdenum, zirconium, tungsten, silicon, niobium, tantalum, vanadium, cobalt, manganese, silver, zinc, indium, germanium, tin, and mixtures thereof; as well as their oxides, nitrides, borides, fluorides, or carbides and mixtures thereof. Most preferably, at least one layer is chromium, or a mixture of chromium (e.g., Cr-Zr, Cr-Ni, or Cr-Mo), or a carbide or nitride thereof (e.g., Cr-N).

[0317] Suitable materials for the transparent layer can be selected from metals, metalloids, and metal alloys, including: boron, silicon, germanium, antimony, tellurium, polonium, niobium, zirconium, magnesium, tin, tantalum, aluminum, chromium, titanium, and mixtures thereof; as well as oxides, nitrides, borides, fluorides, or carbides thereof, and mixtures thereof. Most preferably, at least one layer is formed of an oxide (e.g., SiO2).

[0318] Preferred deposition methods for applying multilayers of the spectral control system to the stress control system can be selected from any suitable vacuum phase deposition system, such as thermal evaporation, electron beam evaporation (with or without ion beam assistance), or sputtering deposition. Sputtering deposition is the preferred method. Additionally, the surface of the plastic substrate can be pre-treated to improve adhesion between the stress control system and the spectral control system. Surface treatments can be selected from any of plasma discharge, corona discharge, glow discharge, and UV radiation.

[0319] The preferred optical thickness of each individual layer in the spectral control system will, of course, depend on the desired optical effect. Therefore, for each different product, a different set of "preferred optical thicknesses" is expected. Noting this, in a spectral control system as a four-layer stack (as in the example provided above), it is envisioned that the first CrZr layer might have a preferred physical thickness in the range of 2 to 40 nm. The second layer could have a preferred physical thickness in the range of 20 to 200 nm. The second layer could have a more preferred physical thickness in the range of 48 to 101 nm. The third layer could have a preferred physical thickness in the range of 2 to 40 nm. The third layer could have a more preferred physical thickness in the range of 6.7 to 25 nm. The fourth layer could have a preferred physical thickness in the range of 15 to 200 nm. The fourth layer could have a more preferred physical thickness in the range of 15 to 40 nm.

[0320] Turning now to the description of the stress control system, as described above, the stress control system ideally consists of one or more material layers that ensure the total residual stress of the decorative coating will be compressible (measured in the absence of an optional protective layer) but will also be compatible with the plastic substrate. In this respect, the "compatible" layer will be the layer that exhibits good adhesion to the plastic substrate.

[0321] In this regard, it has been found that substrates coated within this stress range will exhibit good performance throughout durability tests (e.g., salt spray, thermal shock, dry heat, immersion, and humidity tests). Throughout this specification, this range will be referred to as the “desired stress window.” That said, alternative ranges for the desired stress window are less than -6 MPa, or less than -63 MPa, or less than -76 MPa, or less than -100 MPa, or less than -110 MPa, or less than -112 MPa, or less than 160 MPa. Furthermore, the lower limit of the stress window can be -360 MPa or greater, -359 MPa or greater, -300 MPa or greater, -250 MPa or greater, or -200 MPa or greater. Further combinations of these ranges are also contemplated in this invention. For example, the stress window can be between 0 MPa and -300 MPa; between -63 MPa and -300 MPa, -75 MPa and -300 MPa, -110 MPa and -300 MPa, or between 0 MPa and -250 MPa, etc.

[0322] As described above, a stress control system is ideally used to balance the total residual stress of the decorative coating, keeping it within a desired stress window. In this regard, when the combined optical thickness of the absorbing layer and the transparent layer (and the protective layer, if present) is selected such that the spectral control system provides the desired optical effect, the stress control system needs to include a compressive stress layer of appropriate quantity to keep the total residual stress of the decorative coating within the desired stress window.

[0323] The deposition method used to apply one or more layers of a stress control system to a plastic substrate can be selected from any vacuum phase deposition system, such as thermal evaporation, electron beam evaporation (with or without ion beam assistance), or sputtering deposition. Sputtering deposition is a preferred method. Additionally, the surface of the substrate can be pre-treated to improve adhesion between the stress control system and the substrate. Surface treatment can be selected from any of plasma discharge, corona discharge, glow discharge, and UV radiation.

[0324] In one approach, the stress control system can be tuned to achieve a desired stress window by optimizing the deposition parameters of one or more layers. These parameters include sputtering power, gas pressure, nitrogen doping, and coating thickness. Stress can also be tuned to have higher compressive forces (or lower tensile forces) by introducing thermal stress components through substrate heating, or by performing a pretreatment process directly prior to stress control system deposition. The interaction between the stress control system and the spectral control system is complex, and tuning the total residual stress is ideally performed by treating the entire decorative coating as a complete coating “stack.”

[0325] In this respect, total residual stress is the measured stress distribution of the entire stack of stress control and spectral control systems deposited on the glass microscope coverslip (without a protective layer, even when such a protective layer is used). Stress measurements are obtained by placing the slide in a stress measuring device (e.g., Sigma Physik SIG-500SP) before and after coating deposition.

[0326] Typically, the stress tuning space in a spectral control system is small because the layers need to maintain near-perfect (and consistent) composition to achieve the desired optical effects. This means that the stress generated in the spectral control system is often uncontrollable and will be tensile or sometimes only slightly compressible. Therefore, the stress control system is tuned to bring the total residual stress of the decorative coating into the desired stress window. For example, if the spectral control system is highly tensile, the stress control system will need to be compressible in stress and on a higher order of magnitude to achieve the desired stress window.

[0327] Preferably, the stress control system will be a single material layer that generates a high level of compressive stress during deposition. The material with known compressive stress is SiO₂. x SiO x N y CrN x NbO x TaO x and ZrO x Preferably, both x and y are between 0.1 and 2.0.

[0328] The stress control system can be a multilayer system, which may be necessary when the preferred stress control layer is incompatible with the substrate (exhibiting poor adhesion). In this case, a compressible or slightly stretchable compatible layer is deposited on the substrate, followed by a high-compressibility layer on top. An example of a multilayer system could be CrN / Nb2O5. It is envisioned that such a multilayer stress control system would achieve high compressive stress compatible with the substrate.

[0329] Therefore, it will be obvious that when it is required to change the desired optical effect to another desired optical effect (e.g., by making different optical thickness choices for one or both of the absorption and transparent layers of the spectral control system to produce different colors), the stress control system will also likely need to be changed accordingly to ensure that the total residual stress of the decorative coating remains within the desired residual stress window.

[0330] Therefore, this application also provides a method for applying a decorative coating to a plastic substrate, the decorative coating providing a desired optical effect to the coated substrate, the decorative coating including a spectral control system and a stress control system, the spectral control system being multilayered and optionally including a protective layer, and the stress control system being at least a single layer, wherein the multilayers of the spectral control system are absorption layers alternating with transparent layers, the method comprising:

[0331] a) Determine the desired optical effect;

[0332] b) Determine a suitable spectral control system that will provide the desired optical effect, referring to the optical thickness required by the spectral control system.

[0333] c) Determine a suitable stress control system, wherein the amount of compressive stress in the stress control system is such that the total residual stress of the decorative coating is compressible when measured in the absence of an optional protective layer;

[0334] d) Coating the suitable stress control system onto the plastic substrate;

[0335] e) Coating the suitable spectral control system onto the stress control system; and

[0336] f) thereby forming a coated plastic substrate having the desired optical effect.

[0337] The plastic substrate of the present invention can be formed from any suitable plastic material. For example, the plastic substrate can be formed from materials selected from: polyacrylate, polyester, polystyrene, polyethylene, polypropylene, polyamide, polyamide, polycarbonate, epoxy resin, phenolic resin, acrylonitrile-butadiene-styrene, acrylonitrile-styrene-acrylate, acetal, and mixtures thereof. Preferred plastic substrate materials include polycarbonate, poly(2,2'-dihydroxyphenylpropane)carbonate, polyethylene glycol bis(allyl carbonate), polymethyl methacrylate, and polystyrene, or mixtures thereof. In a preferred form, the substrate will generally have a physical thickness in the range of 0.1 mm to 20 mm, more preferably in the range of 1 mm to 5 mm, and most preferably in the range of 2 mm to 3 mm.

[0338] Products with decorative coatings as described herein may also include other coatings, such as those between the decorative coating and the substrate, within the decorative coating, or, for example, the protective layer described above that may optionally be part of the spectral control system of the decorative coating, or on the decorative coating. In particular, it is contemplated that, in some embodiments, including a hard coating between the decorative coating and the substrate would be advantageous. In this form, the hard coating is a protective layer that does not contribute to the generally desired optical effect, while in other embodiments, the outer protective layer on the decorative coating itself would be a hard coating.

[0339] In this regard, a coating known as a "hard coating" is a coating that is harder and stiffer than the substrate, thereby increasing the substrate's abrasion resistance. This abrasion-resistant hard coating reduces damage caused by impact and scratching. Abrasion resistance can be measured using a Taber Abrader via tests such as ASTM F735 "Standard Test Method for Abrasion Resistance of Transparent Plastics and Coatings Using the Oscillating Sand Method" and ASTM D4060 "Standard Test Method for Abrasion Resistance of Organic Coatings," or by using the well-known Steelwool test.

[0340] Furthermore, some plastic substrates may be damaged by certain solvents; for example, polycarbonate can be damaged by acetone. For many products to which the decorative coatings of this invention may be suitable, they are required to possess "chemical resistance," which refers to the ability to withstand exposure to common solvents such as diesel fuel, petroleum, battery acids, brake fluid, antifreeze, acetone, alcohol, automatic transmission fluids, hydraulic oil, and ammonia-based window cleaners. In this regard, it will be understood that hard coatings ideally provide this chemical resistance to products bearing the decorative coatings of this invention.

[0341] The hard coating preferably consists of one or more abrasion-resistant layers and may include a primer layer that bonds well to the plastic substrate and forms a preferred material for the subsequent abrasion-resistant layer. The primer layer can be provided by any suitable material and may be, for example, an organic resin, such as an acrylic polymer, a copolymer of acrylic monomer and methacryloxysilane, or a copolymer of methacrylic monomer and acrylic monomer having benzotriazole or benzophenone groups. These organic resins may be used alone or in combination of two or more.

[0342] The wear-resistant layer is preferably formed from one or more materials selected from the following: silicone, acrylic acid, urethane, melamine, or amorphous SiO2. x C yH2. Most preferably, the wear-resistant layer is an organosilicon layer due to its excellent wear resistance and compatibility with physical vapor deposition films. For example, a wear-resistant layer comprising an organosilicon polymer can be formed by methods such as dip coating to form a compound layer selected from the following compounds, and then curing the layer: trialkoxysilanes or triacyloxysilanes, such as methyltrimethoxysilane, methyltriethoxysilane, methyltrimethoxyethoxysilane, methyltriacetoxysilane, methyltripropoxysilane, methyltributoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltriacetoxysilane, vinyltrimethoxyethoxysilane, phenyltrimethoxysilane, etc. Silane, phenyltriethoxysilane, phenyltriacetoxysilane, γ-chloropropyltrimethoxysilane, γ-chloropropyltriethoxysilane, γ-chloropropyltripropoxysilane, 3,3,3-trifluoropropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-(β-glycidoxyethoxy)propyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltriethoxysilane, γ-methacryloyloxypropyltrimethoxysilane, γ-amino γ-aminopropyltrimethoxysilane, γ-mercaptopropyltrimethoxysilane, γ-mercaptopropyltriethoxysilane, γ-mercaptopropyltriethoxysilane, N-β-(aminoethyl)-γ-aminopropyltrimethoxysilane, β-cyanoethyltriethoxysilane, and the like; and dialkoxysilanes or diacyloxysilanes, such as dimethyldimethoxysilane, phenylmethyldimethoxysilane, dimethyldiethoxysilane, phenylmethyldiethoxysilane, γ-epoxypropoxypropylmethyldimethoxysilane, γ-epoxypropoxypropylmethyldiethoxysilane, γ-epoxypropoxypropylbenzene γ-dimethoxysilane, γ-glycidoxypropylphenyldiethoxysilane, γ-chloropropylmethyldimethoxysilane, γ-chloropropylmethyldiethoxysilane, dimethyldiacetoxysilane, γ-methacryloyloxypropylmethyldimethoxysilane, γ-methacryloyloxypropylmethyldiethoxysilane, γ-mercaptopropylmethyldimethoxysilane, γ-mercaptopropylmethyldiethoxysilane, γ-aminopropylmethyldimethoxysilane, γ-aminopropylmethyldiethoxysilane, methylvinyldimethoxysilane, methylvinyldiethoxysilane, and the like.

[0343] The wear-resistant layer can be coated onto a plastic substrate by dip coating in a liquid followed by solvent evaporation, or by plasma-enhanced chemical vapor deposition (PECVD) via a suitable monomer. Alternative deposition techniques such as flow coating and spray coating are also suitable. To improve the wear resistance of the hard coating, a subsequent coating can be added to the wear-resistant layer, preferably within 48 hours, to avoid premature aging and contamination of the coating.

[0344] The thickness of the abrasion-resistant layer is preferably selected to help provide sufficient abrasion resistance. In this regard, sufficient abrasion resistance is considered to be a Bayer abrasion ratio of 5 relative to an uncoated plastic substrate (e.g., polycarbonate), or alternatively, a δ haze of less than 15% (haze % as measured according to ASTM D1003) after testing with a CS10F wheel under a 500g load and for 500 cycles, as determined by the Taber abrasion resistance test. When silicone is used as the abrasion-resistant layer, the thickness of the hard coating is preferably in the range of about 1 to about 15 micrometers, most preferably between 3 and 7 micrometers, provided these requirements are met.

[0345] Visual improvements can be achieved by patterning the substrate. For example, patterns can be formed on the front surface of the substrate using a patterned injection mold. An example of an ideal optical effect is the imitation of brushed stainless steel, and it has been found that parallel lines of random lengths (between 1 and 5 cm) closely adjacent to each other can achieve this appearance when the present invention is subsequently applied.

[0346] A further improvement to enhance the visual contrast with brushed stainless steel is the incorporation of a matte additive into a hard coating protective layer applied to a patterned substrate. In this regard, a matte effect is known to be achieved due to the uneven surface created by the small (typically about 5 μm) particles of the matte additive. A “satin” appearance can also be achieved by modifying the protective layer by adding a matte additive to the hard coating. It is characterized by a significant diffuse reflectance component (diffuse reflectance between about 10% and 30%, preferably 16%, and specular reflectance of about 8%).

[0347] In another form of the invention, the decorative coating may be overlaid with a protective layer to further enhance abrasion resistance or aid in the cleanliness of the coated product. For example, the protective layer may be formed of a material exhibiting properties including hydrophobic, hydrophilic, oleophobic, lipophilic, and oleophobic properties or combinations thereof, and may include a hard coating [with or without matte additives (particles)], such as as described above.

[0348] Regarding the possible uses of the decoratively coated plastic substrate according to the invention, as previously described, the coated plastic substrate can be used as a design surface on a variety of consumer products, including premium automotive interior and exterior trim parts, consumer and household products, and stylish home electronics, as well as some or all of the surfaces of these products.

[0349] Furthermore, the coated plastic substrate can provide an illuminated pattern for the product under suitable conditions, sometimes referred to as "hidden 'til lit" (hidden before illumination), and typically provides backlighting. In this regard, the desired optical effect can be achieved by selecting the correct %R and %T so that light can pass through the coating to produce an illuminated pattern. However, when there is no backlighting, the product's visual appearance makes it appear uniform, thus eliminating the possibility of a visible pattern.

[0350] Another object of the present invention is to further develop known external rearview devices to enhance functionality and efficiency while reducing size and cost, as described in European Patent Application No. 16198759.9, which is incorporated herein by reference for all purposes.

[0351] This objective is achieved by the feet of the base assembly and the frame assembly, the feet providing spherical seats for the housing (particularly the lower housing element) of the head assembly, and the frame assembly providing at least one spherical seat for the housing, wherein the frame assembly is rigidly attached to or contained within the fixing member.

[0352] According to this application, the base assembly may include an attachment portion for attachment to a motor vehicle, wherein the attachment portion carries a control system for the articulation assembly or a control system for the articulation assembly, and / or the attachment portion guides a cable from the interior of the motor vehicle to the interior of the foot, and / or the attachment portion closes the foot at one end opposite its ball seat.

[0353] It is also proposed that the base assembly includes a support portion for attaching a fixed portion of the hinge assembly and / or a support portion of the attachment frame device, wherein the support portion extends from the ball seat of the base assembly and / or the support portion guides the cable from inside the foot through the cable outlet into the head assembly.

[0354] Furthermore, according to the present invention, the supporting portion is at least partially arranged within the fixed portion, and / or the supporting portion is attached to the fixed portion by screws or clips and / or by bayonet attachment.

[0355] The frame assembly may include a support portion that supports a fixed portion of the hinge assembly, preferably by at least partially surrounding the fixed portion (wherein, in particular, the support portion has an annular shape), and / or by a clip or snap connection.

[0356] The preferred embodiment is characterized in that the frame device includes a first spherical seat for a lower housing element of the housing and a second spherical seat for an upper housing element of the housing, wherein preferably, the first and second spherical seats of the frame device are provided by extensions arranged at opposite ends of the fixed portion and / or on a side of the support portion away from the fixed portion of the hinge device.

[0357] According to the present invention, the first spherical seat is provided by a first extension away from the fixed portion of the hinge and a second extension away from the movable portion of the hinge, wherein preferably, the support portion and the first and second extensions form part of a ring with a cutout, thereby providing an edge facing the movable portion of the hinge.

[0358] Preferably, the fixing device is provided with a cable outlet, wherein the cable outlet of the fixing device is aligned with the cable outlet of the bearing portion, and / or the cable outlet of the fixing device is arranged on the side of the fixing device opposite to the fixing portion of the hinge device, and / or the cable exiting from the cable outlet of the fixing device is connected to at least one camera and / or at least one lamp unit arranged at least partially within the head assembly.

[0359] According to the invention, the lower housing element has a first spherical seat that mates with a spherical seat of a foot and / or a second spherical seat that mates with a first spherical seat of a frame assembly, wherein preferably, the first and second spherical seats of the lower housing element are provided by the base of the lower housing element.

[0360] Preferably, the lower housing element has an attachment portion fixed to a movable portion of the hinge assembly, wherein preferably, the attachment portion extends substantially perpendicular to the base of the lower housing element, and / or preferably, the attachment portion and the frame assembly are arranged on opposite sides of the unit provided by the fixed portion and the movable portion of the hinge assembly, and / or preferably, the attachment portion at least partially surrounds the movable portion, and / or preferably, the attachment portion and the movable portion are connected via a clip connection, a plug, and / or a snap connection.

[0361] Additionally, it is proposed that the attachment portion be provided with a component ring for partially surrounding the movable portion of the hinge assembly, wherein preferably, the component ring is provided by a cutout defined by the component ring provided by the support component and the first and second extensions.

[0362] The unit may be an actuator for a reflective element (particularly in the form of a mirror element), which is attached to the attachment portion.

[0363] Additionally, it is proposed that a lower housing element carries an upper housing element and / or a camera, and / or a frame is attached to the lower housing element and the upper housing element, wherein preferably, the frame surrounds the reflective element.

[0364] The head assembly of external rearview devices, particularly the lens section of external rearview mirrors, can utilize hinge mechanisms, especially glass actuators, hinged around a ball joint on the inside / outside and vertically, with the ball seat positioned between the relatively movable parts, allowing them to rotate about two mutually perpendicular hinge axes with a common engagement point. This ensures maintenance of current end-user functionality while providing a significantly smaller mirror size, with a size reduction of up to 30%. Furthermore, the unique layout of the internal mechanism of its ball seat improves packaging and performance.

[0365] The articulated assembly is also supported and protected from impacts by the use of a ball joint, particularly due to the frame arrangement between the housing of the articulated assembly and the head assembly. The housing is assembled from several housing elements, one of which is fixed to the movable portion of the articulated assembly, thereby improving weight distribution and reducing the overall frontal area of ​​the housing on the vehicle, which in turn improves aerodynamics and thus provides greater fuel efficiency.

[0366] The pivot system of the rearview device of the present invention, having a single pivot point for two hinge axes, allows for mirror adjustment movement while providing dynamic mirror performance and mirror impact support.

[0367] Furthermore, as discussed in U.S. Patent Application No. 15 / 439,188 (the entire contents of which are incorporated herein by reference for all purposes), in another aspect, the mirror assembly includes a mirror housing; a reflective element having a first field of view; a reflective coating having a second field of view wider than the first field of view; and a multifunctional backplate supported by the mirror housing, and including a reflective element support region, wherein the reflective element is supported by the multifunctional backplate and the reflective coating support region, wherein the reflective coating is applied to the backplate.

[0368] The reflective coating support area can be convex, making the reflective coating convex and providing a wider field of view.

[0369] The reflective element support area may include a hole for accommodating the reflective element, and the reflective coating support area may be thicker than the reflective element support area.

[0370] The reflective coating can be a chromium-based reflective coating.

[0371] In another aspect, the present invention relates to a backsheet or polymer substrate, wherein the backsheet or polymer substrate is coated with a reflective coating, such as a chromium-based reflective coating.

[0372] This specification also provides chromium-based reflective coatings for backplates or polymer substrates, wherein the coating is an alloy of chromium and a dopant material selected from hexagonal close-packed transition metals, the alloy having a crystal structure of a primary body-centered cubic phase coexisting with a secondary Ω-hexagonal close-packed phase. In a preferred embodiment of the invention, the alloy is a binary alloy of chromium and the dopant material.

[0373] This specification also provides a method for forming a chromium-based reflective coating on a backplate or polymer substrate, the method comprising applying chromium and a dopant material to the polymer substrate by physical vapor deposition, the dopant material being selected from hexagonal close-packed transition metals to form an alloy coating, and applying the alloy coating to have a crystal structure of a primary body-centered cubic phase coexisting with a secondary Ω-hexagonal close-packed phase. In a preferred embodiment of the invention, the alloy is applied as a binary alloy of chromium and the dopant material.

[0374] In one embodiment, at least one lamp element is disposed on one side of a polymer substrate, and wherein the polymer substrate and the chromium-based reflective coating are at least partially permeable to light from at least one lamp element.

[0375] Polymer substrates can be used in various technical fields, such as the automotive industry, the advertising industry, or any industry that provides products with protective coatings (which also provide light reflectivity and light transmittance).

[0376] Chromium-based reflective coatings can be based on alloys including chromium. Chromium is a group 6 element of the transition metals and has a body-centered cubic (bcc) crystal structure. As a major dopant in the preferred binary alloys (which are alloys of two main metallic components) of this invention, chromium is used primarily because it contributes to the formation of a corrosion-resistant, glossy, hard surface, thereby giving the alloy ideal optical reflectivity, preferably with an R% greater than 50%, for acceptable use in mirror formation. Its high melting point, stable crystal structure, and moderate thermal expansion make it an ideal major component for use under the aforementioned harsh environmental conditions.

[0377] The secondary component of the preferred binary alloy is the aforementioned dopant material, commonly referred to here as M, and selected from hexagonal close-packed (hcp) transition metals. The hcp structure is the most common among transition metals, including zirconium (Zr), titanium (Ti), cobalt (Co), hafnium (Hf), rubidium (Ru), yttrium (Y), and osmium (Os). In this respect, some of these hcp transition metals, such as Zr, Ti, and Co, are actually easier to process and are therefore preferred dopant materials for the purposes of this invention.

[0378] Although Zr is envisioned as the most preferred hcp dopant material, the present invention will be described primarily with reference to Zr as an hcp dopant material, but this should not be considered as a limitation on the scope of the invention.

[0379] In a preferred embodiment of the invention, the alloy will be a binary alloy, and the atomic percentage of the dopant material in the binary alloy will be in the range of about 1.9 at.% to about 5.8 at.%. However, within this wide range, there may be narrower ranges associated with specific dopant materials, as will be further described below.

[0380] It has been found that introducing small amounts of HCP dopant material into chromium (a BCC transition metal) can yield a range of alloy compositions with intermetallic crystal structures exhibiting coexisting BCC and ω-HCP phases. This has been found to provide these alloys with additional advantageous properties (properties other than those of chromium). In fact, it has been found that careful selection of the amount of HCP dopant material relative to the amount of chromium can bring the alloy composition into a particularly preferred range, where desired properties (e.g., wear resistance) are maximized and undesirable properties (e.g., non-neutral color) are minimized.

[0381] Through interpretation, it has been found that the coating according to the invention changes in phase composition as the elemental composition of the dopant material increases from only bcc to bcc plus ω-hcp, to bcc plus an amorphous phase. The observed optical and mechanical properties of the coating show changes commensurate with these compositional changes, with preferred optical and mechanical properties occurring when the phase composition is bcc plus ω-hcp. Without wishing to be bound by theory, it is believed that the observed changes are due to variations in the electronic structure of the atoms and their crystallographic conformations relative to each other.

[0382] Specifically, when the phase composition is bcc plus ω-hcp, the coating's crystal structure exhibits a d-orbital transition, resulting in neutral color and relatively low reflectivity, with the ordered crystal structure acquiring higher relative abrasion resistance. In contrast, when an amorphous phase is present, the d-orbital transition is no longer observed, indicating that orbital hybridization between adjacent atoms partially fills the d orbitals, which is associated with the suboptimal lower reflectivity. Furthermore, the lower atomic packing density found in this amorphous phase yields a coating with reduced abrasion resistance, which is certainly less desirable.

[0383] Taking this into account, and in the general formula CrM x The dopant material is referred to as M. This phase transition from the bcc plus ω-hcp phase to the bcc plus amorphous phase was found to occur at a value of x approximately 0.06 (correlated with approximately 5.8 t.%) when the dopant material is Zr. For Ti and Co, the same transition is expected to occur at approximately the same x value.

[0384] Unlike reflectance, the color of the coating of the present invention did not show a trend change during the transition from the bcc plus ω-hcp phase to the bcc plus amorphous phase. Instead, a color change in the coating of the present invention was observed during the phase transition from bcc to bcc plus ω-hcp [found to occur for Zr at a value of x (in the above formula) of approximately 0.05 (corresponding to a lower limit of approximately 4.5 at.%)]. This indicates that orbital hybridization of the electronic structure begins at various concentrations of Zr when the dopant material approaches approximately 4.5 at.%. However, the transition point for Co, with the same dopant material, was found to be approximately 1.9 at.%.

[0385] As an explanation, and again using Zr as an exemplary hcp dopant material, at low concentrations, wear resistance increases with increasing Zr elemental composition. The greatest wear resistance was observed during the transition from bcc to bcc plus ω-hcp, after which further increases in Zr concentration led to a steady decrease in the measured wear resistance. Indeed, according to CrZr... x Electron diffraction analysis of the coating defined two transition concentrations that represent the change from one phase composition to another. For Zr as a dopant, these transitions are approximately x = 0.05 (from bcc to bcc+Ω-hcp) and approximately 0.06 (from bcc+Ω-hcp to bcc+ amorphous). In this respect, the ω-hcp phase is understood as a substitutional phase transition from the bcc structure.

[0386] Therefore, in one example, the alloy will be a binary alloy, and the dopant material will be Zr, wherein the atomic percentage of the dopant material in the binary alloy will be in the range of about 4.5 at.% to about 5.8 at.%.

[0387] In yet another form, the alloy will be a binary alloy, and the dopant material will be Co, wherein the atomic percentage of the dopant material in the binary alloy will be in the range of about 1.9 at.% to about 5.7 at.%. Regarding the predictive conclusions that the inventors (based on the similarity of the physical properties of all hcp transition metals) were able to draw from experimental work (described below) on Zr and Co, and to some extent on Ti, those skilled in the art will understand that the behavior of other hcp transition metals as dopant materials in this invention can reasonably be expected to be the same as or similar to that seen with respect to Zr, Co, and Ti. Indeed, comparative experimental work on the bcc transition metal molybdenum (Mo) (see again below) [where no similar behavior was expected (or seen) due to the different physical properties of this transition metal] also tends to confirm these predictive conclusions regarding hcp transition metals.

[0388] In fact, given that the physical properties of other hcp transition metals are similar to those of both Zr and Co, it is expected that when the concentrations of Ti, Hf, Ru, Y, and Os are in the range of about 1.9 at.% to about 5.8 at.%, they will exhibit the same structure-forming ability in the Cr-based alloys of the present invention.

[0389] The coating can preferably be an ultrathin coating, wherein the thickness is selected to achieve desired optical properties, such as transmittance and / or reflectance. For example, in this specification, a coating is defined as a coating with a thickness of 200 nm or less. In one embodiment, the coating has a thickness of 100 nm. It is contemplated that the preferred thickness will be in the range of 100 nm or less, or more preferably in the range of 40 nm to 80 nm, or more preferably in a narrower range of 50 nm to 70 nm. Ideally, the thickness will be about 60 nm.

[0390] Preferably, the polymer substrate of the present invention is formed by injection compression molding, but any other methods known in the art (e.g., compression molding, blow molding, reaction molding and sheet casting) may also be used and therefore fall within the scope of the present invention.

[0391] The polymer substrate can be any known type of polymer substrate material, such as a substrate formed from materials selected from: polyacrylate, polyester, polystyrene, polyethylene, polypropylene, polyamide, polyamide, polycarbonate, epoxy resin, phenolic resin, acrylonitrile-butadiene-styrene, acrylonitrile-styrene-aryl compounds, acetal, and mixtures thereof. Preferred substrate materials include polycarbonate, poly(2,2'-dihydroxyphenylpropane)carbonate, polyethylene glycol bis(allyl carbonate), polymethyl methacrylate, and polystyrene, or mixtures thereof.

[0392] The polymer substrate or backing plate carrying the coating of the present invention may also include other coatings (pre-coatings) between the coating and the substrate, within the coating, or as an outer layer. In particular, it is contemplated that in some embodiments, a hard coating included between the coating and the substrate or as an outer coating is advantageous. In this form, the hard coating is a protective layer that does not contribute to the overall desired optical effect, while in other embodiments, the outer protective layer on the decorative coating will itself be a hard coating.

[0393] In this regard, a coating referred to as a "hard coating" is one that is harder and stiffer than the substrate, thereby increasing the substrate's wear resistance. Examples of hard coatings are, but are not limited to, silicone, acrylic, urethane, melamine, or amorphous SiO2. x C y H zThis abrasion-resistant hard coating reduces damage caused by impacts and scratches. Abrasion resistance can be measured using a Taber abrasion tester through tests such as ASTM F735 "Standard Test Method for Abrasion Resistance of Transparent Plastics and Coatings Using the Oscillating Sand Method" and ASTM D4060 "Standard Test Method for Abrasion Resistance of Organic Coatings," or by using the well-known Steelwool test.

[0394] The wear-resistant layer is preferably formed from one or more materials selected from the following: silicone, acrylic acid, urethane, melamine, or amorphous SiO2. x C y H zMost preferably, the wear-resistant layer is an organosilicon layer due to its excellent wear resistance and compatibility with physical vapor deposition films. For example, a wear-resistant layer comprising an organosilicon polymer can be formed by methods such as dip coating to form a compound layer selected from the following compounds, followed by curing: trialkoxysilanes or triacyloxysilanes, such as methyltrimethoxysilane, methyltriethoxysilane, methyltrimethoxyethoxysilane, methyltriacetoxysilane, methyltripropoxysilane, methyltributoxysilane, ethyltrimethoxysilane, ethyltriethoxysilane, vinyltrimethoxysilane, vinyltriethoxysilane, vinyltriacetoxysilane, vinyltrimethoxyethoxysilane, phenyltrimethoxysilane, etc. γ-Oxypropylsilane, phenyltriethoxysilane, phenyltriacetoxysilane, γ-chloropropyltrimethoxysilane, γ-chloropropyltriethoxysilane, γ-chloropropyltripropoxysilane, 3,3,3-trifluoropropyltrimethoxysilane, γ-glycidoxypropyltrimethoxysilane, γ-glycidoxypropyltriethoxysilane, γ-(β-glycidoxyethoxy)propyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltriethoxysilane, γ-methacryloyloxypropyltrimethoxysilane γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, γ-mercaptopropyltrimethoxysilane, γ-mercaptopropyltriethoxysilane, Nβ(aminoethyl)-γ-aminopropyltrimethoxysilane, β-cyanoethyltriethoxysilane, and the like; and dialkoxysilanes or diacyloxysilanes, such as dimethyldimethoxysilane, phenylmethyldimethoxysilane, dimethyldiethoxysilane, phenylmethyldiethoxysilane, γ-glycidoxypropylmethyldimethoxysilane, γ-glycidoxypropylmethyldiethoxysilane, γ-glycidoxypropylmethyldiethoxysilane, γ-glycidoxypropylmethyldieth ... Propylphenyl dimethoxysilane, γ-glycidoxypropylphenyl diethoxysilane, γ-chloropropylmethyl dimethoxysilane, γ-chloropropylmethyl diethoxysilane, dimethyldiacetoxysilane, γ-methacryloyloxypropylmethyl dimethoxysilane, γ-methacryloyloxypropylmethyl diethoxysilane, γ-mercaptopropylmethyl dimethoxysilane, γ-mercaptopropylmethyl diethoxysilane, γ-aminopropylmethyl dimethoxysilane, γ-aminopropylmethyl diethoxysilane, methylvinyldimethoxysilane, methylvinyldiethoxysilane, and the like.

[0395] The pre-coated film may also include inorganic oxides (silicon dioxide, titanium dioxide, aluminum oxide), metal films (Cr, etc.), wherein the pre-coated substrate has been prepared to have the desired surface energy, residual stress, coefficient of thermal expansion, electrical conductivity, chemical functionality, etc. required for the specific application of such Cr-based alloy coatings.

[0396] Similarly, those skilled in the art will understand that a topcoat can be applied to the coating of the present invention, the topcoat including a transparent coating for purposes such as mechanical strength, wettability, optical interference filtering, improved coefficient of friction, etc. The topcoat can be a hard coating as described above or any other protective layer. Such a protective layer provides enhanced abrasion resistance, fingerprint resistance, and "easy-to-clean" functionality. Suitable materials for such a protective layer can be plasma-polymerized hexamethyldisiloxane (HMDSO), fluoropolymer-based coatings deposited via evaporation or liquid transfer techniques, or liquid hard coatings applied via spin coating, dip coating, spray coating, or flow coating techniques, with or without particulate additives (matte additives) for haze control. In one embodiment, where the polymer substrate is used as the housing of the rearview device, the topcoat is permeable to light from the lamp element and can have the same color as the rearview device and the rest of the vehicle. In one embodiment, the color can be different from the rest of the vehicle.

[0397] In a preferred form, the physical vapor deposition technique employed in the method of the present invention will be based on magnetron sputtering, sputtering from a primary alloy target or using a co-sputtering process (involving two targets made of corresponding components of the alloy). Alternatively, it will be understood that preferred alloys can be deposited using thermal evaporation or electron beam evaporation of the corresponding alloy components.

[0398] It should be understood that, due to the nature of the polymer substrate, conventional temperature treatments (during or after deposition) cannot typically alter the properties of alloy coatings of the type of this invention, although this ultimately depends on the polymeric material of the polymer substrate. In the coatings of this invention, the inventors have determined that, with increasing elemental composition of the dopant material (e.g., Zr, Ti, or Co), preferred alloys exhibit variations in phase composition; from bcc only to bcc plus Ω-hcp, to bcc plus an amorphous phase. The optical and mechanical properties of these preferred alloys (as ultrathin coatings) show variations commensurate with the composition, and the observed variations relate to changes in the electronic structure of the atoms and their crystallographic conformations relative to each other.

[0399] In fact, these crystalline ultrathin coatings exhibit d-orbital transitions, which result in neutral colors and relatively low reflectivity, with the ordered crystal structure acquiring high relative abrasion resistance. When amorphous material is present in the coating, the d-orbital transition is no longer observed, indicating partial filling of d-orbitals. It is believed that orbital hybridization between adjacent atoms partially fills the d-orbitals, which is associated with the yellow color and higher reflectivity. Furthermore, the lower atomic packing density in the amorphous phase yields coatings with reduced abrasion resistance.

[0400] It should be understood that many different coating compounds are described throughout this specification, and the invention is not limited to such coatings. For example, a backplate coated according to this specification can be coated with any type of reflective coating, not limited to those described herein.

Claims

1. A multifunctional rearview device (100, 700, 900) for use with a vehicle, the multifunctional rearview device comprising: a rearview element (120, 750, 950) comprising at least one of a reflective element, a camera and a display element; a bezel (130, 720, 920) formed on an exterior of the multifunctional rearview device (100, 700, 900) surrounding the rearview element (120, 750, 950) having: • an interior space formed within the bezel (130, 720, 920), wherein a recess is included on an interior face of the bezel to form the interior space therein; and • at least one of one or more light assemblies (200, 610, 810) and one or more electronic devices positioned at least partially within the interior space of the bezel (130), wherein the rearview element (120, 750, 950) is attached to at least one of the bezel (130, 720, 920) and a housing (110) configured to be attached to the vehicle and movable relative to the vehicle, wherein each light assembly (200) is placed on a plastic component of the bezel (130) directly, or by using surface mount, overmold, conductive material or printed material without the use of a printed circuit board, wherein the bezel (130) is coated, and the coating of the bezel (130) is a spectral control system.

2. A multifunctional rearview device (100, 700, 900) adapted for use with a vehicle, the multifunctional rearview device comprising: a rearview element (120, 750, 950); a bezel (130, 720, 920) formed on an exterior of the multifunctional rearview device (100, 700, 900) surrounding the rearview element (120, 750, 950); one or more light assemblies providing at least one or more light function indications; and at least one sensor; wherein the rearview element (120, 750, 950) is attached to at least one of the bezel (130, 720, 920) and a housing (110) configured to be attached to the vehicle and movable relative to the vehicle, characterized in that the rearview element (120, 750, 950) comprises a reflective element, a camera and a display element, wherein the bezel (130) is made of a plastic substrate, the plastic substrate is transparent and coated, an interior space is formed within the bezel (130, 720, 920), and one or more light assemblies (200, 610, 810) and one or more electronic devices are at least partially located within the interior space of the bezel (130), wherein the at least one or more light function indications comprise a human machine interface (HMI), and an output of the sensor controls at least one of the one or more light assemblies (200) and the display element.

3. The multifunctional rearview device of claim 1 or 2, wherein ​ ​ The bezel (130) is made of a plastic substrate that is at least one of colored, surface finished, transparent, and coated with a spectral control system; and / or The coating of the bezel (130) is further at least one of a decorative coating and / or an advanced surface technology (AST) surface coating; and / or The bezel (130) is formed or molded from a polymeric substrate.

4. The multifunctional rearview device of any of claims 1-3, wherein The bezel (130) is transparent and includes a chrome-based coating such that the one or more light assemblies (200) underneath the bezel (130) are hidden prior to being illuminated.

5. The multifunctional rearview device of claim 4, wherein The chrome-based coating is an alloy of chromium and a dopant material selected from a hexagonally close-packed transition metal, the alloy having a crystal structure of a primary body-centered cubic phase coexisting with a secondary omega hexagonally close-packed phase.

6. The multifunctional rearview device of claim 3, wherein The bezel (130) with the decorative coating is provided with a protective layer applied on top of the spectral control system as the outermost layer.

7. The multifunctional rearview device of claim 6, wherein The material of the protective layer is a coating based on plasma-polymerized hexamethyldisiloxane (HMDSO), a fluoropolymer deposited via evaporation or liquid transfer techniques, or a liquid hardcoat applied via spin, dip, spray, or flow coating techniques, with or without particulate additives for haze control.

8. The multifunctional rearview device of any of claims 3-5, wherein The coating includes a protective layer that forms part of the spectral control system.

9. The multifunctional rearview device of any of claims 1, 3, 6-8, wherein The spectral control system includes an absorbing layer, wherein The absorbing layer includes a material or mixture of materials having a measured extinction coefficient greater than 1 in the spectral range of 400 to 1000 nm.

10. The multifunctional rearview device of claim 9, wherein The materials are metals, metalloids, metal alloys, or mixtures thereof, having a refractive index such that the sum of the refractive index and the extinction coefficient is greater than 2 while maintaining an extinction coefficient greater than 1.

11. The multifunctional rearview device of any of claims 1, 3, 6-8, wherein the spectral control system includes a transparent layer, wherein The transparent layer includes a material or mixture of materials having a measured extinction coefficient less than 1 in the spectral range of 400 to 1000 nm.

12. The multifunctional rearview device of claim 11, wherein The materials are metals, metalloids, metal alloys, or mixtures thereof, having a refractive index such that the sum of the refractive index and the extinction coefficient is less than 3 while maintaining an extinction coefficient less than 1.

13. The multifunctional rearview device of claim 11, wherein The spectral control system is an interference system composed of alternating layers of materials having different refractive indices.

14. The multifunctional rearview device of claim 13, wherein The spectral control system has a relatively high refractive index contrast between adjacent layers.

15. The multifunction rearview device of claim 13 or 14, wherein The refractive index contrast is achieved by selecting a transparent layer of material with a low refractive index and an absorbing layer of material with a high refractive index.

16. The multifunction rearview device of any one of claims 3, 6-7, wherein The decorative coating includes a spectral control system and a stress control system.

17. The multifunction rearview device of claim 16, wherein The spectral control system is multi-layered and the stress control system is at least a single layer between the spectral control system and the substrate.

18. The multifunction rearview device of claim 17, wherein The multi-layers of the spectral control system are absorbing layers alternating with transparent layers.

19. The multifunction rearview device of any one of the preceding claims, comprising only one light assembly (200) of the one or more light assemblies (200), wherein • the light assembly (200) is configured to direct light to different locations of the bezel (130), and / or • the light assembly (200) is configured to direct light with different characteristics to different locations of the bezel (130) to provide different light function indications.

20. The multifunction rearview device of any one of the preceding claims, wherein The multifunction rearview device further comprises a flexible circuit comprising an integrated heating pad (830) configured to heat the rearview element and flex around a slot (960) formed in the bezel.

21. The multifunction rearview device of any one of the preceding claims, wherein At least one of a conductor track, the electronic device, and the one or more light assemblies (200) are applied directly to the bezel (130) by at least one of injection molding (MID), conductive foil (IML), and laser direct structuring (LDS).

22. The multifunction rearview device of any one of the preceding claims, further comprising a connection to a control unit of the vehicle to control at least one of the one or more light assemblies (200).

23. The multifunction rearview device of any one of the preceding claims, further comprising at least one sensor, wherein an output of the sensor controls at least one of the one or more light assemblies (200).

24. The multifunction rearview device of claim 23, wherein The sensor is a camera; and / or The sensor is a light sensor to control a plurality of light intensities or luminances.

Images