Rearview mirror assembly

Abstract

A rearview mirror assembly includes a housing and a printed circuit board (PCB) located in the housing. The rearview mirror assembly further includes a monitoring system including an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source. The optical element is configured to redirect illumination light from the illumination source toward an occupant location in the automobile.

Description

Technical Field

[0001] The present disclosure relates generally to a rearview mirror assembly, and more particularly to a rearview mirror assembly having a driver monitoring system that includes optical elements for redirecting and diffusing illumination light. Summary of the invention

[0002] According to one aspect of the present disclosure, a rearview mirror assembly includes a housing and a printed circuit board (PCB) located in the housing. The rearview mirror assembly further includes a monitoring system, the monitoring system including an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source. The optical element is configured to redirect and diffuse illumination light from the illumination source toward an occupant position in a car.

[0003] According to another aspect of the present disclosure, a rearview mirror assembly includes a housing and a printed circuit board (PCB) located in the housing. The rearview mirror assembly further includes a monitoring system, the monitoring system including an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source, the optical element including a plurality of wedges each extending to an apex. The plurality of wedges are configured to redirect and diffuse illumination light from the illumination source toward an occupant position in the vehicle.

[0004] According to another aspect of the present disclosure, a rearview mirror assembly includes a housing, a transmissive element at least partially located in the housing, and a printed circuit board (PCB) located in the housing. The rearview mirror assembly further includes a monitoring system, the monitoring system including an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source, the optical element including a plurality of wedges each extending to an apex. The plurality of wedges are configured to redirect and diffuse illumination light from the illumination source toward an occupant position in the vehicle.

[0005] These and other features, advantages and objects of the present disclosure will be further understood and appreciated by those skilled in the art with reference to the following description, claims and drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] In each diagram:

[0007] Figure 1 is a top perspective view of a vehicle incorporating a rearview mirror assembly according to one aspect of the present disclosure;

[0008] Figure 2 is a front view of a rearview mirror assembly according to one aspect of the present disclosure;

[0009] Figure 3Ais a cross-sectional side view of a rearview mirror assembly having an illumination source and an optical element in a first arrangement according to one aspect of the present disclosure;

[0010] Figure 3B is a cross-sectional side view of a rearview mirror assembly having an illumination source and an optical element in a second arrangement according to one aspect of the present disclosure;

[0011] Figure 3C is a cross-sectional side view of a rearview mirror assembly having an illumination source and an optical element in a third arrangement according to one aspect of the present disclosure;

[0012] Figure 3D is a cross-sectional side view of a rearview mirror assembly having an illumination source and an optical element in a fourth arrangement according to one aspect of the present disclosure;

[0013] Figure 3E is a cross-sectional side view of a rearview mirror assembly having an illumination source and an optical element in a fifth arrangement according to one aspect of the present disclosure;

[0014] Figure 4A is a side perspective view of an illumination source and an optical element having a first configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0015] Figure 4B is a rear view of an illumination source and an optical element having a first configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0016] Figure 5A is a side view of an illumination source and an optical element having a second configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0017] Figure 5B is a rear view of an illumination source and an optical element having a second configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0018] Fig. 6A is a side perspective view of an illumination source and an optical element having a third configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0019] Figure 6B is a rear view of an illumination source and an optical element having a third configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0020] Fig. 7Ais a rear view of an illumination source and an optical element having a fourth configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0021] Figure 7B is a front view of an illumination source and an optical element having a fourth configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0022] Fig. 8A is a side perspective view of an illumination source and an optical element having a fifth configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure;

[0023] Figure 8B is a rear view of an illumination source and an optical element having a fifth configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure; and

[0024] Fig. 9 is a side perspective view of an illumination source and an optical element having a sixth configuration that redirects and diffuses illumination light from the illumination source according to one aspect of the present disclosure. DETAILED DESCRIPTION

[0025] The embodiments shown in the present invention mainly consist in a combination of method steps and equipment components related to a rearview mirror assembly with a driver monitoring system, wherein the driver monitoring system includes optical elements for redirecting and diffusing illumination light. Therefore, equipment components and method steps have been represented by conventional symbols in the figures where appropriate, and only those specific details relevant to understanding the embodiments of the present disclosure are shown so as not to obscure the present disclosure, which has details that will be apparent to those skilled in the art and have the benefit of the description herein. In addition, the same numbers in the description and the figures represent the same elements.

[0026] For the purposes described herein, the terms "upper", "lower", "right", "left", "rear", "front", "vertical", "horizontal" and their derivatives shall be related to the present disclosure as oriented behind the rearview mirror assembly. Unless otherwise specified, the term "front" shall refer to the surface of the device that is closer to the intended viewer of the device, and the term "rear" shall refer to the surface of the device that is farther from the intended viewer of the device. However, it should be understood that the present disclosure may adopt various alternative orientations except where expressly specified to the contrary. It should also be understood that the specific devices and processes shown in the accompanying drawings and described in the following specification are merely exemplary embodiments of the inventive concepts defined in the appended claims. Therefore, unless the claims are otherwise expressly stated, the specific dimensions and other physical characteristics associated with the embodiments disclosed herein should not be considered restrictive.

[0027] The terms "including", "comprises", "comprising" or any other variations thereof are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by "comprising..." does not, without more constraints, exclude the presence of additional identical elements in the process, method, article, or apparatus that includes the element.

[0028] See also Figure 1-6B , reference numeral 10 generally refers to a rearview mirror assembly. The rearview mirror assembly 10 includes a housing 12 and a printed circuit board 14 (PCB) located in the housing. The rearview mirror assembly 10 further includes a monitoring system 16, which includes an image capture module 18 (e.g., a camera), an illumination source 20 connected to the PCB 14, and an optical element 22 coupled to the PCB 14 and aligned with the illumination source 20. The optical element 22 is configured to redirect and diffuse illumination light from the illumination source 20 toward an occupant position 24 (e.g., a driver position) in a car 26.

[0029] refer to Figure 1 , various embodiments of rearview mirror assembly 10 can be combined with one or more structures. For example, the traditional rearview mirror position in automobile 26 can adopt rearview mirror assembly 10. In other embodiments, the components of rearview mirror assembly 10 can be incorporated in emergency vehicles, family vehicles, aircraft, rail vehicles, etc. In certain embodiments, rearview mirror assembly 10 may not include reflective elements, but operate as a dimmable display. Generally speaking, rearview mirror assembly 10 can be incorporated into any environment where monitoring occupant position 24 may be beneficial.

[0030] refer to Figure 2 and 3A The housing 12 of the rearview mirror assembly 10 includes a frame 27 defining an opening 28, and a transmissive element 30 ( Figure 3A ) is located in the opening 28. The transmissive element 30 includes a front surface 32 facing the occupant position 24 and a rear surface 34 ( Figure 3A). The transmission element 30 may be configured and / or otherwise coupled to an electro-optical device containing an electro-optical medium 33. Thus, the transmission element 30 may switch between a reflective state and a darkened state, in which the electro-optical medium 33 is in a transmissive state and the rearview mirror assembly 10 operates as a reflector, and in which the electro-optical medium 33 has a reduced optical transmittance (e.g., to reduce glare). A reflective layer (not shown) may be located between the housing 12 and the transmission element 30 to reflect light in the reflective state. More specifically, the reflective layer may be located between the substrate defining the rear surface 34 and the electro-optical medium 33. A display device 35 may be located between the housing 12 and the electro-optical medium 33 for displaying information to the driver from the monitoring system 16. The reflectivity of the transmission element 30 may always be lower in front of the display device 35. The electro-optical device and electro-optical medium 33 as disclosed herein can be a single-layer single-phase component, a multi-layer component, or a multi-phase component, as described in the following documents: U.S. Patent No. 5,928,572 entitled "Electrochromic Layer And Devices Comprising Same", U.S. Patent No. 5,998,617 entitled "Electrochromic Compounds", U.S. Patent No. 6,020,987 entitled "Electrochromic Medium Capable of Producing a Pre-selected Color", U.S. Patent No. 6,037,471 entitled "Electrochromic Compounds", U.S. Patent No. 6,037,471 entitled "Electrochromic Media for Producing a Pre-selected Color", and U.S. Patent No. 6,041,971 entitled "Electrochromic Compounds". No. 6,141,137 entitled “Coupled Electrochromic Compounds With Photostable Dication Oxidation States”; No. 6,249,369 entitled “Electrochromic Media With Concentration Enhanced Stability, Process for Preparation and Use in Electrochromic Devices”;and U.S. Patent No. 6,137,620 entitled “Process for the Preparation Thereof and Use in Electrochromic Devices”, and U.S. Patent No. 6,519,072 entitled “Electrochromic Device”; and International Patent Application Publication No. WO 98 / 42796 entitled “Electrochromic Polymeric Solid Films, Manufacturing Electrochromic Devices Using Such Solid Films and Processes for Making Such Solid Films and Devices”, and WO 98 / 42796 entitled “Electrochromic Polymer System”. 99 / 02621, the entirety of which is incorporated herein by reference. The present disclosure may also be used with a display mirror system, such as the display mirror system described in U.S. Pat. Nos. 9,505,349 and 10,739,591, the entirety of which is incorporated herein by reference.

[0031] Continue to refer Figure 2 and 3A, PCB 14 may include multiple PCBs 14 or a single PCB 14. For example, the features of the transmission element 30 and the monitoring system 16 may run on PCB 14, and the image capture module 18 may run on a separate PCB (e.g., a second PCB 15). PCBs 14 and 15 may be located in the housing 12 and completely surrounded by the combination of the housing 12 and the transmission element 30. The housing 12 may include a connection hub 36, and the connection hub 36 may be connected to a mounting member 38. The mounting member 38 is configured to be connected to the automobile 26 (or other environment), and the housing 12 may be movable relative to the mounting member 38 so that the transmission element 30 is oriented at various angles relative to the occupant position 24 (or other environmental position), thereby obtaining different environmental views and / or orientations relative to the vehicle operator. PCBs 14 and 15 may be connected to the interior 40 of the housing 12 and move with the housing as the housing 12 is adjusted relative to the mounting member 38. In some embodiments, a carrier element 43 may connect one or both of the PCBs 14, 15 to the housing 12. In some embodiments, carrier element 43 may also connect transmissive element 30 to housing 12. Image capture module 18, illumination source 20, and optical element 22 may also move with housing 12 as housing 12 is adjusted relative to mounting member 38. In some embodiments, illumination element 20 and PCB 14 are located on a side (e.g., left or right) of connection hub 36 opposite image capture module 18 and second PCB 15. In some embodiments, image capture module 18 may be located outside housing 12. In still other embodiments, and as Figure 2 As shown, the illumination source 20 and the optical element 22 can be aligned with the central area of ​​the transmissive element 30 (e.g., aligned with the connection hub 36). In this way, the optical element 22 can be switched (e.g., rotated 180 degrees) during manufacturing to redirect light for left and right driver-side monitoring. In addition, the image capture module 18 can be positioned toward the right or left side of the optical element 22.

[0032] Reference now Figure 3A , the illumination source 20 can be directly connected to the PCB 14, and the optical element 22 can be maintained in a spaced relationship with the illumination source 20 using a connection body 42. For example, the connection body 42 can be configured as one or more of a pin (e.g., one or more), a clamp, and / or a carrier element 43 that connects the PCB 14 to the housing 12. The connection body 42 can be directly connected to the optical element 22 and extend to at least one of the PCB 14, the illumination source 20, the carrier element 43, the housing 12, or the transmissive element 30 and directly connected to the at least one ( Figure 3B). The optical element 22 may include an outer perimeter, and the connection body 42 may be connected to the outer perimeter or to an interior thereof. For example, in some embodiments, the optical element 22 may include an aperture adjacent to the outer perimeter for receiving the connection body 42. In some embodiments, the connection body 42 may be connected to the optical element 22 by other components such as adhesives, clamps, etc. The connection body 42 may be connected to the PCB 14 and / or the illumination source 20 using components similar to those used to connect it to the optical element 22.

[0033] Reference now Figure 3C-3E , the optical element 22 can be directly connected to the transmissive element 30, for example, via a wetting process and direct bonding with an adhesive (e.g., an optical adhesive). Figure 3C As shown, the optical element 22 can be located on one side of the front surface 32 of the transmissive element 30 (e.g., connected to the front surface 32). Figure 3D In other embodiments, such as the arrangement shown, the optical element 22 may be located on one side of the rear surface 34 of the transmissive element 30 (e.g., connected to the rear surface 34 and / or otherwise located between the rear surface 34 and the illumination source 20). Figure 3E In other embodiments such as the arrangement shown, the optical element 22 may extend through a portion of the housing 12, such as a bottom edge of the bezel 27. The illumination source 20 may include two or more illumination sources 20, and the optical element 22 may include two or more optical elements 22. In some embodiments, the two or more illumination sources 20 may be aligned with a single optical element 22. In some embodiments, each of the two or more illumination sources 20 may be aligned with a different optical element 22.

[0034] Reference now Figure 1-3E , the illumination source 20 can be configured to project light of multiple operating principles. For example, the light source 20 can be configured to project flood illumination light (e.g., in the visible and / or infrared spectrum). In this way, the optical element 22 can redirect and diffuse the flood illumination light to different locations around the car 26. In some embodiments, the light can be projected in a structured light pattern (e.g., redirected and / or diffused by the optical element 22, at least one of the two operations). The image capture module 18 can capture an image of the structured light pattern, and the control system (e.g., located on the first PCB 14 and / or the second PCB 15) can be configured to extrapolate the image of the structured light to obtain two-dimensional ("2D") and / or three-dimensional ("3D") information about, for example, the occupant position 24. In this way, the rearview mirror assembly 10 (e.g., the monitoring system 16) can be used for driver monitoring capabilities. In addition, it should be understood that the illumination source 20 can be configured to project light of other operating principles for driver monitoring in 2D or 3D space.

[0035] Reference now Figure 4A-4B , the optical element 22 and the illumination source 20 are isolated from the other components of the rearview mirror assembly 10. The optical element 22 is shown according to a first configuration. The optical element 22 includes a first major surface 48 facing the illumination source 20 and a second major surface 49 facing away from the illumination source 20. The first major surface 48 defines at least one refractive element 50. The at least one refractive element 50 may include a plurality of wedges 52 arranged vertically, the plurality of wedges being arranged as shown in FIG. Figure 4A 56 to redirect and evenly diffuse illumination light from the illumination source 20 in a horizontal direction as indicated by the arrows in . More specifically, each of the wedges 52 can include an inclined surface 54 that extends outwardly from the first major surface 48 to a vertex 56 in a horizontal direction, and a cliff portion 58 can extend from the vertex 56 to an adjacent wedge 52. In some embodiments, the inclined surface 54 of the wedge 52 is curved (e.g., concave or convex) to concentrate or diffuse the illumination light. The vertex 56 can also be curved (e.g., defined by a radius), and the cliff portion 58 can be angled toward or away from the inclined surface 54 from the vertex 56. Each wedge 52 extends across the first major surface 48 (e.g., linearly) from a top side 60 to a bottom side 62 of the optical element 22. The optical element 22 can be tapered so that one side 60, 62 is thicker ("T") than the other side 60, 62 to vertically bend light (i.e., illumination light from the illumination source 20) to redirect the light in a vertical direction, such as Figure 4B As shown by the arrow in . In some embodiments, the top side 60 is thinner than the bottom side 62. In this way, the direction of the taper can further bend the light in the vertical downward direction. In some embodiments, the taper can be on the first major surface 48, and the second major surface 49 can be substantially planar. In some embodiments, one of the major surfaces 48, 49 (e.g., the second major surface 49) can be curved (e.g., concave or convex) for concentrating or diffusing the illumination light. In some embodiments, the taper can be on the second major surface 49, and the vertex 56 of each wedge 52 can extend to a plane. In some embodiments, two or more wedges 52 can each include an inclined surface 54 that is inclined at different intervals or exhibits different curvatures for further redirection and diffusion of light.

[0036] Reference now Figure 5A and 5B , according to the second configuration, the optical element 122 is shown. Unless otherwise specified, the optical element 122 may be incorporated into at least Figure 1In the structures in and other structures described herein. In addition, the optical element 122 may include features, elements and materials similar to other configurations described herein. More specifically, the optical element 122 includes a first major surface 148 facing the illumination source 20 and a second major surface 149 facing away from the illumination source 20. The first major surface 148 defines at least one refractive element 150. The at least one refractive element 150 may include a plurality of wedges 152 arranged horizontally to Figure 5A 156 and 157. The wedges 152 may be configured to redirect and uniformly diffuse illumination light from the illumination source 20 in a vertical direction as indicated by the arrows in FIG. More specifically, each of the wedges 152 may include an inclined surface 154 extending outwardly from the first major surface 148 to a vertex 156 in a vertical direction, and a cliff portion 158 may extend from the vertex 156 to an adjacent wedge 152. In some embodiments, the inclined surface 154 of the wedge 152 is curved (e.g., concave or convex) for concentrating or diffusing illumination light. The vertex 156 may also be curved (e.g., defined by a radius), and the cliff portion 158 may be angled toward or away from the vertex 156 toward the inclined surface 154. Each wedge 152 extends across the first major surface 148 (e.g., linearly) from the right side 164 to the left side 166 of the optical element 122. The optical element 122 may be tapered so that one side 164, 166 is thicker ("T") than the other side 164, 166 to bend light horizontally. In some embodiments, the left side 166 is thinner than the right side 164. In this way, the direction of the taper can further bend the light in the horizontal rightward direction. In some embodiments, the taper can be on the first major surface 148, and the second major surface 149 can be substantially planar. In some embodiments, one of the major surfaces 148, 149 (e.g., the second major surface 149) can be curved (e.g., concave or convex) for concentrating or diffusing the illumination light. In some embodiments, the taper can be on the second major surface 149, and the vertex 156 of each wedge 152 can extend to a plane. In some embodiments, two or more wedges 152 can each include an inclined surface 154 that is inclined at different intervals or exhibits different curvatures.

[0037] Reference now Fig. 6A and 6B , according to the third configuration, the optical element 222 is shown. Unless otherwise specified, the optical element 222 may be incorporated into at least Figure 1In the structures in and other structures described herein. In addition, the optical element 222 may include features, elements and materials similar to other configurations described herein. More specifically, the optical element 222 includes a first major surface 248 facing the illumination source 20 and a second major surface 249 facing away from the illumination source 20. The first major surface 248 defines at least one refractive element 250. The at least one refractive element 250 may include a plurality of wedges 252, the plurality of wedges being arranged diagonally to be as Fig. 6A 256, and the like. The wedge-shaped member 252 can be used to redirect and evenly diffuse the illumination light from the illumination source 20 in a diagonal (i.e., both horizontally and vertically) direction indicated by the arrow in FIG. More specifically, each of the wedge-shaped members 252 can include an inclined surface 254 extending outwardly from the first major surface 248 in a diagonal direction to a vertex 256, and a cliff portion 258 can extend from the vertex 256 to an adjacent wedge-shaped member 252. In some embodiments, the inclined surface 254 of the wedge-shaped member 252 is curved (e.g., concave or convex) for concentrating or diffusing the illumination light. The vertex 256 can also be curved (e.g., defined by a radius), and the cliff portion 258 can be angled from the vertex 256 toward or away from the inclined surface 254. Each wedge-shaped member 252 extends across the first major surface 248 (e.g., linearly) in a direction between the top side 260 and the bottom side 262. The optical element 222 (e.g., the top side 260 and the bottom side 262) is positioned at a certain angle to the illumination source 20. In some embodiments, each wedge 252 extends across first major surface 248 (e.g., linearly) at an angle between top side 260 and bottom side 262, and top side 260 and bottom side 262 are parallel to the top and bottom edges of optical element 22. Optical element 222 can be tapered so that one side 260, 262 is thicker ("T") than the other side 260, 262 to further bend light in a diagonal direction. In some embodiments, top side 260 is thinner than bottom side 262. In this manner, the direction of the taper can further bend light in a diagonal downward and rightward direction, such as Figure 6B As shown by the arrows in . In some embodiments, the cone can be on the first major surface 248, and the second major surface 249 can be substantially planar. In some embodiments, one of the major surfaces 248, 249 (e.g., the second major surface 249) can be curved (e.g., concave or convex) to concentrate or diffuse the illumination light. In some embodiments, the cone can be on the second major surface 249, and the vertex 256 of each wedge 252 can extend to the plane. In some embodiments, two or more wedges 252 can each include an inclined surface 254 that is inclined at different intervals or exhibits different curvatures. In some embodiments, the cone can be in a diagonal direction.

[0038] Reference now Fig. 7A and 7B, according to the fourth configuration, the optical element 322 is shown. Unless otherwise specified, the optical element 322 may be incorporated into at least Figure 1 34 and other structures described herein. In addition, the optical element 322 may include features, elements, and materials similar to other configurations described herein. More specifically, the optical element 322 includes a first major surface 348 facing the illumination source 20 and a second major surface 349 facing away from the illumination source 20. The first major surface 348 and the second major surface 349 each define at least one refractive element 350. More specifically, the at least one refractive element 350 on the first major surface 348 includes a plurality of wedges 352 arranged vertically to redirect and evenly diffuse the illumination light from the illumination source 20 in the horizontal direction. The at least one refractive element 350 on the second major surface 349 includes a plurality of wedges 352 arranged horizontally to redirect the illumination light from the illumination source 20 in the vertical direction. Each of the wedges 352 may include an inclined surface 354 extending outward from the first major surface 348 to a vertex 356, and a cliff portion 358 may extend from the vertex 356 to an adjacent wedge 352. In some embodiments, the inclined surface 354 of the wedge 352 is curved (e.g., concave or convex) to focus or diffuse the illumination light. The vertex 356 can also be curved (e.g., defined by a radius), and the cliff portion 358 can be angled from the vertex 356 toward or away from the inclined surface 354. Each wedge 352 on the first major surface 348 extends across the first major surface 348 (e.g., linearly) from the top side 360 ​​to the bottom side 362 of the optical element 322. On the other hand, each wedge 352 on the second major surface 349 extends across the first major surface 348 (e.g., linearly) from the right side 364 to the left side 366 of the optical element 322. In this manner, as the illumination light passes through the first major surface 348, the illumination light is redirected and evenly diffused in the horizontal direction, and then as the illumination light passes through the second major surface 349, the illumination light is redirected and evenly diffused in the vertical direction, as shown in FIG. Fig. 7A and 7B As indicated by the arrows in FIG. 1 . It should be appreciated that, alternatively, the fourth configuration may be more generally described as having a first major surface 348 having refractive elements 350 and a second major surface 349 having refractive elements 350 perpendicular to the refractive elements 350 on the first major surface 348. In some embodiments, the wedges 352 on the first major surface 348 and / or the wedges 352 on the second major surface 349 may be angled relative to the sides 360, 362, 364, 366 such that light is bent in a diagonal direction, for example similar to Fig. 6A and 6B In some embodiments, two or more wedges 352 may include inclined surfaces 354 that are each inclined at different intervals or exhibit different curvatures.

[0039] Reference now Figures 4A-7B , the spacing, curvature, size, and extension (e.g., horizontally, vertically, and / or diagonally) of the wedges 52, 152, 252, and 352 affect the redirection of light from the illumination source 20. Likewise, the varying thickness T can be further used to affect the redirection of light from the illumination source 20. Additionally, the number of wedges 52, 152, 252, and 352 affects the spread of light from the illumination source 20. In this manner, the spread and redirection of light can be controlled to focus light onto areas of the vehicle 26 and / or other structures of interest (e.g., the occupant position 24).

[0040] Reference now Fig. 8A and 8B , according to the fifth configuration, the optical element 422 is shown. Unless otherwise specified, the optical element 422 may be incorporated into at least Figure 1 4 and other structures described herein. In addition, the optical element 422 may include features, elements, and materials similar to other configurations described herein. More specifically, the optical element 422 includes a first major surface 448 facing the illumination source 20 and a second major surface 449 facing away from the illumination source 20. The first major surface 448 defines at least one refractive element 450. The at least one refractive element 450 may include a plurality of wedges 452 arranged in a tower grid pattern to be arranged in a manner such as Figure 8B456 can be used to redirect and evenly diffuse the illumination light from the illumination source 20 in a diagonal (i.e., both horizontally and vertically) direction indicated by the arrows in . More specifically, each of the wedges 452 can include a diagonally inclined face 454 extending outwardly from the first major surface 448 to a vertex 456 in a diagonal direction, and a cliff portion 458 can extend from the vertex 456 to an adjacent wedge 452. Each wedge 452 extends only partially across the first major surface 448 in a tower grid pattern. In some embodiments, the inclined face 454 of the wedge 452 is curved (e.g., concave or convex) to concentrate or diffuse the illumination light. The vertex 456 can also be curved (e.g., defined by a radius), and the cliff portion 458 can be angled from the vertex 456 toward or away from the inclined face 454. The optical element 422 can be tapered such that one of the top side 460, bottom side 462, right side 464, or left side 466 is thicker ("T") than the opposing side 460, 462, 464, 466 to further bend light in one direction (e.g., diagonally, horizontally, or vertically). In some embodiments, the taper can be on the first major surface 448, and the second major surface 449 can be substantially planar. In some embodiments, one of the major surfaces 448, 449 (e.g., the second major surface 449) can be curved (e.g., concave or convex) to focus or diffuse the illumination light. In some embodiments, the taper can be on the second major surface 449, and the vertex 456 of each wedge 452 can extend to a plane. In some embodiments, at least two of the wedges 452 each include an inclined surface 454 extending in different directions, inclined at different intervals, and / or exhibit different curvatures.

[0041] Reference now Fig. 9 , according to the sixth configuration, the optical element 522 is shown. Unless otherwise specified, the optical element 522 may be incorporated into at least Figure 1548 and other structures described herein. In addition, the optical element 522 may include features, elements and materials similar to other configurations described herein. More specifically, the optical element 522 includes a first major surface 548 facing the illumination source 20 and a second major surface 549 facing away from the illumination source 20. The optical element 522 may be tapered so that one of the top side 560, the bottom side 562, the right side 564 or the left side 566 is thicker ("T") than the opposite side 560, 562, 564, 566 to redirect light in one direction (e.g., diagonally, horizontally or vertically). In some embodiments, the taper may be on the first major surface 548, and the second major surface 549 may be substantially planar. In some embodiments, one of the major surfaces 548, 549 (e.g., the second major surface 549) may be curved (e.g., concave or convex) for concentrating or diffusing the illumination light. In some embodiments, the taper can be on the second major surface 549 and can be generally planar or curved (eg, convex or concave). The fifth configuration can not include any wedges. In some embodiments, the taper can be in a diagonal direction.

[0042] Reference now Figure 1-9 In each of the configurations shown in , the optical element 22, 122, 222, 322, 422, 522 can be formed from a material configured to transmit infrared light. For example, the material can include at least one of polycarbonate, silicon, or acrylic. The material can further include an additive configured to absorb light outside the infrared spectrum. For example, the additive can include a dye, dye particles, and / or a film that absorbs wavelengths outside the infrared spectrum. In this way, the optical element 22, 122, 222, 322, 422, 522 can be substantially opaque outside the illumination spectrum (e.g., infrared or near infrared) to reduce and / or prevent a red glow from the illumination light. The monitoring system 16 and the transmissive element 30 (e.g., the electrically activated electro-optical medium 33) can operate on a single PCB (e.g., the first PCB 14 or the second PCB 15). Now referring to Figures 4A-8B , a wedge 52, 152, 252, 352, 452 may be provided to reduce the total thickness T requirement of the optical element 22, 122, 222, 322, 422 under the principle of a Fresnel lens. More specifically, the wedge 52, 152, 252, 352, 452 divides the optical element 22, 122, 222, 322, 422 into a plurality of sections. In some embodiments, the wedge 52, 152, 252, 352, 452 is uniform to simplify manufacturing.

[0043] It should also be understood that the present disclosure is not strictly limited to the various configurations of optical elements 22, 122, 222, 322, 422, 522 described herein. For example, in some embodiments, the wedge pattern ( Figures 4A-6B and 8A) can be located on the second major surface instead of the first major surface. Likewise, various additional configurations can be implemented, including a first major surface ( Figures 4A-6B and 8A) and a second major surface having the same or a different one of the wedge patterns ( Figures 4A-6B 8A). In addition, the taper of thickness T can be modified (e.g., diagonally, horizontally, or vertically) in any of the described configurations to redirect light in a diagonal (e.g., up and left, down and left, up and right, down and right), horizontal (e.g., left or right), or vertical (e.g., up or down) direction as desired. The taper can be located on the first major surface 48, 148, 248, 348, 448, and 548 or the second major surface 49, 149, 249, 349, 449, and 549. It should be understood that the light will be directed in the direction of the thicker portion of the taper and / or wedge 52, 152, 252, 352, and 448. Thus, various configurations may be defined as having a first wedge pattern on a first major surface, the first wedge pattern being configured to redirect and diffuse light uniformly in a diagonal (e.g., up and left, down and left, up and right, down and right), horizontal (e.g., left or right), or vertical (e.g., up or down) direction. Similarly, various configurations may be defined as having a second wedge pattern on a second major surface, the second wedge pattern being configured to redirect and diffuse light uniformly in a diagonal (e.g., up and left, down and left, up and right, down and right), horizontal (e.g., left or right), or vertical (e.g., up or down) direction. Generally speaking, the light will be directed in the direction of the apex of the wedge. In some embodiments, various configurations may include a first wedge pattern on a first major surface, a second wedge pattern on a second major surface, and a cone in a horizontal, vertical, or diagonal direction. In some embodiments, various configurations may include a wedge pattern on a first major surface, a flat second major surface, and a cone. In some embodiments, various configurations may include a flat first major surface, a wedge pattern on the second major surface, and a taper as described herein. In some embodiments, various configurations may include a taper on the first and / or second major surface.

[0044] The disclosure herein is further summarized in the following paragraphs and further characterized as any and all combinations of the various aspects described therein.

[0045] According to one aspect, a rearview mirror assembly comprises a housing and a printed circuit board (PCB) in the housing. The rearview mirror assembly further comprises a monitoring system, the monitoring system comprising an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source. The optical element is configured to redirect and diffuse the illumination light from the illumination source toward the occupant position in the automobile.

[0046] According to another aspect, the image capture module is located in the housing.

[0047] According to yet another aspect, a connection body connects the optical element to the PCB in spaced relationship to the illumination source.

[0048] According to another aspect, the connection body includes a pair of pins extending from the optical element to the PCB.

[0049] According to yet another aspect, the connection body includes a pair of clips extending from the optical element to the PCB.

[0050] According to another aspect, an optical element includes a first major surface facing toward an illumination source and a second major surface facing away from the illumination source.

[0051] According to yet another aspect, the first major surface of the optical element defines at least one refractive element.

[0052] According to another aspect, at least one refractive element includes a plurality of wedges arranged vertically to redirect and diffuse the illumination light in a horizontal direction.

[0053] According to yet another aspect, at least one refractive element includes a plurality of wedges arranged horizontally to redirect and diffuse the illumination light in a vertical direction.

[0054] According to another aspect, at least one refractive element includes a plurality of wedges arranged diagonally to redirect and diffuse the illumination light in horizontal and vertical directions.

[0055] According to yet another aspect, the transmissive element is located in the housing and transmits the illumination light therethrough and into the vehicle, and the second major surface of the optical element is directly bonded to the transmissive element.

[0056] According to another aspect, at least one refractive element comprises a first plurality of wedges arranged in at least one of a vertical or horizontal orientation, and the second major surface defines at least one second refractive element comprising a second plurality of wedges arranged perpendicular to the first plurality of wedges on the first major surface.

[0057] According to yet another aspect, the optical element is formed from at least one of polycarbonate, silicon, or acrylic.

[0058] According to another aspect, the optical element includes at least one additive configured to absorb light outside the infrared spectrum.

[0059] According to yet another aspect, the illumination source is configured to transmit infrared light.

[0060] According to another aspect of the present disclosure, a rearview mirror assembly includes a housing, a transmissive element at least partially located in the housing, and a printed circuit board (PCB) located in the housing. The rearview mirror assembly further includes a monitoring system, the monitoring system including an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source, the optical element including a plurality of wedges each extending to an apex. The plurality of wedges are configured to redirect and diffuse illumination light from the illumination source toward an occupant position in the vehicle.

[0061] According to another aspect, the plurality of wedges are arranged in a tower grid pattern.

[0062] According to yet another aspect, a connection body connects the optical element to the PCB in spaced relationship to the illumination source.

[0063] According to another aspect of the present disclosure, a rearview mirror assembly includes a housing and a printed circuit board (PCB) located in the housing. The rearview mirror assembly further includes a monitoring system, the monitoring system includes an image capture module, an illumination source connected to the PCB, and an optical element aligned with the illumination source. The optical element is configured to redirect and diffuse the illumination light from the illumination source toward the occupant position in the automobile. The connecting body is connected to the optical element in a spaced relationship with the illumination source.

[0064] According to another aspect, the connection body is configured to connect the optical element to one of a PCB, a housing, or a transmissive element.

[0065] Those skilled in the art will appreciate that the construction of the disclosed content and other components described are not limited to any particular material. Unless otherwise described herein, other exemplary embodiments of the disclosed content disclosed herein may be formed from a variety of materials.

[0066] For purposes of this disclosure, the term "coupled" (in all its forms, coupling, coupled, etc.) generally means the joining of two (electrical or mechanical) components to one another, directly or indirectly. Such joining may be stationary in nature or movable in nature. Such joining may be achieved using the two (electrical or mechanical) components and any additional intermediate members that are integrally formed as a single unitary body with one another or with the two components. Unless otherwise specified, such joining may be permanent in nature or removable or releasable in nature.

[0067] It is also worth noting that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments are merely illustrative. Although only a few embodiments of the present innovation have been described in detail in the present disclosure, it will be readily understood by those skilled in the art who consult the present disclosure that there may be many modifications (e.g., changes in the size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, colors, orientations, etc. of various elements) without substantially departing from the novel teachings and advantages of the subject matter. For example, an element shown as being integrally formed may be constructed from multiple parts, or an element shown as multiple parts may be integrally formed, the operation of the interface may be reversed or otherwise changed, the length or width of the structure and / or components or connectors or other elements of the system may be changed, and the nature or number of the adjustment positions set between the elements may be changed. It should be noted that the elements and / or assemblies of the system may be composed of any of a wide variety of materials that provide sufficient strength or durability, and may be in any of a wide variety of colors, textures, and combinations. Therefore, all such modifications are intended to be included within the scope of the present innovation. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangements of desired and other exemplary embodiments without departing from the spirit of the present innovation.

[0068] It should be understood that any described process or steps within a described process can be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be construed as limiting.

[0069] It will be further understood that changes and modifications may be made to the structures and methods described above without departing from the concepts of the present disclosure and it will be further understood that such concepts are intended to be covered by the appended claims unless the language of such claims expressly states otherwise.

Claims

1. A rearview mirror assembly, comprising: case; a printed circuit board (PCB) located in the housing; A monitoring system comprising: Image capture module; an illumination source connected to the PCB; and An optical element is aligned with the illumination source and is configured to redirect and diffuse illumination light from the illumination source toward an occupant position in the vehicle.

2. The rearview mirror assembly of claim 1, wherein the image capture module is located in the housing.

3. A rearview mirror assembly according to claim 1 or claim 2, further comprising a connecting body connecting the optical element to the PCB in a spaced relationship from the illumination source.

4. The rearview mirror assembly of claim 3, wherein the connecting body comprises a pair of pins extending from the optical element to the PCB.

5. The rearview mirror assembly of claim 3, wherein the connection body comprises a pair of clips extending from the optical element to the PCB.

6. A rearview mirror assembly according to claim 1 or claim 2, wherein the optical element comprises a first major surface facing the illumination source and a second major surface facing away from the illumination source.

7. The rearview mirror assembly of claim 6, wherein the first major surface of the optical element defines at least one refractive element. 8 . The rearview mirror assembly of claim 7 , wherein the at least one refractive element comprises a plurality of wedges arranged vertically to redirect and diffuse the illumination light in a horizontal direction.

9. The rearview mirror assembly of claim 7, wherein the at least one refractive element comprises a plurality of wedges arranged horizontally to redirect and diffuse the illumination light in a vertical direction.

10. The rearview mirror assembly of claim 7, wherein the at least one refractive element comprises a plurality of wedges arranged diagonally to redirect and diffuse the illumination light in horizontal and vertical directions.

11. The rearview mirror assembly according to claim 6, wherein a transmissive element is located in the housing and transmits the illumination light therethrough, and the second major surface is directly bonded to the transmissive element.

12. The rearview mirror assembly of claim 7, wherein the at least one refractive element comprises a first plurality of wedges arranged in at least one of a vertical or horizontal orientation, and the second major surface defines at least one second refractive element, the at least one second refractive element comprising a second plurality of wedges arranged perpendicular to the first plurality of wedges on the first major surface.

13. The rearview mirror assembly of claim 1 or claim 2, wherein the optical element is formed from at least one of polycarbonate, silicon, or acrylic.

14. The rearview mirror assembly of claim 13, wherein the optical element includes at least one additive configured to absorb light outside the infrared spectrum.

15. The rearview mirror assembly of claim 14, wherein the illumination source is configured to transmit infrared light.

16. A rearview mirror assembly comprising: case; a printed circuit board (PCB) located in the housing; A monitoring system comprising: Image capture module; an illumination source connected to the PCB; and An optical element is aligned with the illumination source, the optical element comprising a plurality of wedges, each wedge extending to an apex, the plurality of wedges being configured to redirect and diffuse illumination light from the illumination source toward an occupant position in the vehicle.

17. The rearview mirror assembly of claim 16, wherein the plurality of wedges are arranged in a tower grid pattern.

18. A rearview mirror assembly according to claim 16 or claim 17, further comprising a connecting body connecting the optical element to the PCB in spaced relation to the illumination source.

19. A rearview mirror assembly comprising: case; a transmissive element at least partially located within the housing; a printed circuit board (PCB) located in the housing; A monitoring system comprising: Image capture module; an illumination source connected to the PCB; an optical element aligned with the illumination source, the optical element comprising a tapered thickness configured to redirect illumination light from the illumination source toward an occupant position in a vehicle; and A connecting body connects the optical element in spaced relation to the illumination source.

20. The rearview mirror assembly of claim 19, wherein the connection body is configured to connect the optical element to one of the PCB, the housing, or the transmissive element.

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