Mirror assembly for a vehicle

Abstract

A mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite the first surface. The electro-optic assembly has a second element substrate having a third surface and a fourth surface opposite the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is between the first and second electrodes. The mirror assembly further includes a heating assembly having a heating trace to distribute heat along a region of the heating assembly, a first conductive trace, and a second conductive trace. A first conductive interposer electrically couples the first conductive trace to the first electrode, and a second conductive interposer electrically couples the second conductive trace to the second electrode.

Description

Technical Field

[0001] This disclosure generally relates to a connection system for a heater and an electro-optical assembly, and more specifically, to a connection system comprising a pair of traces extending along the heating assembly and electrically coupled to the electro-optical assembly. Background Technology

[0002] Mirror assemblies for vehicles are known in the prior art. However, providing an improved mirror assembly for vehicles has always been a goal of the art. Utility Model Content

[0003] According to one aspect of this disclosure, a mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite the first surface. The electro-optic assembly also has a second element substrate having a third surface and a fourth surface opposite the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is located between the first and second electrodes. The mirror assembly further includes a heating assembly defining an outer periphery comprising a pair of conductive paths, each conductive path including either a through-hole or a notch defined by the outer periphery located within the outer periphery and extending completely through the heating assembly. Heating traces distribute heat along a region of the heating assembly. The first and second conductive traces each extend to one of the conductive paths. A first conductive intermediate is located in one of the conductive paths and electrically couples the first conductive trace to the first electrode, and a second conductive intermediate is located in the other conductive path and electrically couples the second conductive trace to the second electrode.

[0004] According to another aspect of this disclosure, a mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite the first surface. The electro-optic assembly also has a second element substrate having a third surface and a fourth surface opposite the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is located between the first and second electrodes. The mirror assembly further includes a heating assembly defining an outer periphery comprising a pair of conductive paths, each of the conductive paths including a through-hole or an opening. Heating traces distribute heat along a region of the heating assembly. The first and second conductive traces each extend to one of the conductive paths. A first conductive intermediate is located in one of the conductive paths and electrically couples the first conductive trace to the first electrode, and a second conductive intermediate is located in the other conductive path and electrically couples the second conductive trace to the second electrode.

[0005] According to another aspect of this disclosure, a mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite to the first surface. The electro-optic assembly also has a second element substrate having a third surface and a fourth surface opposite to the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is located between the first and second electrodes. The mirror assembly further includes a heating assembly defining an outer periphery comprising a pair of conductive paths. Heating traces distribute heat along a region of the heating assembly. The first and second conductive traces each extend to one of the conductive paths. A first conductive intermediate is located in one of the conductive paths and electrically couples the first conductive trace to the first electrode, and a second conductive intermediate is located in the other conductive path and electrically couples the second conductive trace to the second electrode.

[0006] These and other features, advantages and objectives of this disclosure will be further understood and appreciated by those skilled in the art by referring to the following specification, claims and drawings. Attached Figure Description

[0007] In the attached diagram: Figure 1 It is a top view of a vehicle having a mirror assembly with a first construction according to aspects of this disclosure; Figure 2A This is an exploded view of a mirror assembly constructed according to an aspect of this disclosure; Figure 2B This is a cross-sectional view of a mirror assembly constructed according to an aspect of this disclosure; Figure 2C This is a cross-sectional view of a mirror assembly with a first construction and improved arrangement according to aspects of this disclosure; Figure 3A This is an exploded view of a mirror assembly constructed according to a second aspect of this disclosure; Figure 3B This is a cross-sectional view of a mirror assembly constructed according to a second aspect of this disclosure; Figure 4A This is an exploded view of a mirror assembly constructed according to a third aspect of this disclosure; Figure 4B This is a cross-sectional view of a mirror assembly constructed according to a third aspect of this disclosure; Figure 5A This is an exploded view of a mirror assembly constructed according to a fourth aspect of this disclosure; Figure 5B This is a cross-sectional view of a mirror assembly constructed according to a fourth aspect of this disclosure; Figure 6A This is an exploded view of a mirror assembly constructed according to a fifth aspect of this disclosure; Figure 6B This is a cross-sectional view of a mirror assembly constructed according to a fifth aspect of this disclosure; Figure 7A This is a cross-sectional view of a mirror assembly having an improved arrangement of components according to aspects of this disclosure; Figure 7B This is a cross-sectional view of a mirror assembly having an improved arrangement of components according to aspects of this disclosure; Figure 8A This is an exploded view of a mirror assembly constructed according to a sixth aspect of this disclosure; Figure 8B This is a cross-sectional view of a mirror assembly having an improved arrangement of components according to aspects of this disclosure; and Figure 8C This is an exploded and partially fragmented view of the conductive clip according to aspects of this disclosure. Detailed Implementation

[0008] The embodiments shown here primarily concern a combination of method steps and device components associated with a connection system comprising a pair of traces extending along a heating assembly and electrically coupled to an electro-optic assembly. Therefore, device components and method steps have been indicated where appropriate by conventional symbols in the figures, with only those specific details relevant to understanding embodiments of this disclosure shown to avoid obscuring the disclosure, which has details that are obvious to those skilled in the art and have the benefit of the description herein. Further, the same numbers in the description and figures denote the same elements.

[0009] For the purposes of description in this article, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and their derivatives should be used interchangeably with those used in this article. Figure 1 The orientation of the device is relevant to this disclosure. Unless otherwise stated, the term "front" refers to the surface of the device closer to the intended observer of the device, and the term "rear" refers to the surface of the device farther from the intended observer of the device. However, it should be understood that various alternative orientations may be adopted in this disclosure, except where explicitly specified otherwise. It should also be understood that the specific devices and processes shown in the drawings and described in the following description are merely exemplary embodiments of the inventive concepts as defined in the appended claims. Therefore, unless otherwise expressly stated in the claims, the specific dimensions and other physical characteristics relating to the embodiments disclosed herein should not be considered limiting.

[0010] The terms “comprising,” “including,” or any other variations thereof are intended to cover non-exclusive inclusions, such that a process, method, article of manufacture, or apparatus that comprises a list of elements may include not only those elements but also other elements not expressly listed or not inherent to such process, method, article of manufacture, or apparatus. Without further constraints, an element preceded by “comprising…” does not exclude the presence of other identical elements in the process, method, article of manufacture, or apparatus that includes said element.

[0011] refer to Figure 1-2BReference numeral 10A generally indicates a mirror assembly 10A for a first configuration of vehicle 12. Mirror assembly 10A includes an electro-optic assembly 14 having a front element substrate 16 having a first surface 18 and a second surface 20 opposite to the first surface 18. Electro-optic assembly 14 also has a second element substrate 22 having a third surface 24 and a fourth surface 26 opposite to the third surface 24, the second surface 20 and the third surface 24 facing each other to define a gap 28. A first electrode 30 is coupled to the second surface 20, and a second electrode 32 is coupled to the third surface 24. An electro-optic medium 34 is located between the first electrode 30 and the second electrode 32. Mirror assembly 10A also includes a heating assembly 36 having a heating trace 38, a first conductive trace 40, and a second conductive trace 42 distributing heat along a region of the heating assembly 36. The first conductive intermediate 44 electrically couples the first conductive trace 40 to the first electrode 30, and the second conductive intermediate 46 electrically couples the second conductive trace 42 to the second electrode 32.

[0012] Now for reference Figure 1 The mirror assembly 10A can be incorporated into various structures. For example, the mirror assembly 10A can be incorporated into a side mirror 48 (e.g., a pair of side mirrors 48) for attachment to one or more sides of the vehicle 12. For example, the side mirror 48 can include a housing 50 and a mounting member 52 for attaching the housing 50 to the exterior 53 (e.g., side) of the vehicle 12. However, the mirror assembly 10A can be incorporated into any other structure (e.g., an aircraft, a boat, an architecture) that includes a mirror or window with a heating system, or an electro-optical component. The electro-optical component 14 can be switched between various transmittance and / or reflectance.

[0013] Now for reference Figure 2A and 2B The heating assembly 36 includes an outer periphery 54, and a heating trace 38 extends along a path within the outer periphery 54, the path covering a significant portion (e.g., 35% or more, 40% or more, 50% or more, 75% or more, or 75% or less) of the area defined by the outer periphery 54. The heating trace 38 extends between a first heating conduction terminal 56 and a second heating conduction terminal 58. Power (e.g., a PCB having inputs (e.g., traces) to both the heater assembly 36 and the electro-optic assembly 14, and one or more wire bundles) distributes power to the heating conduction terminals 56, 58 via direct contact or intermediate components. Intermediate components may include connecting clips, different types of conductors (e.g., wires, ink, bus, paste, solder, conductive spring 55) Figures 8A-8COne or more of the following: heating trace 38 or a power source. In this way, a fully conductive circuit (e.g., a heating circuit) is formed by the heating trace 38 and the power source. The heating assembly 36 also includes a first heater substrate 60 covering the front surface 62 of the heating trace 38 and the conductive traces 40, 42, and a second heater substrate 64 covering the rear surface 66 of the heating trace 38 and the conductive traces 40, 42. Each of the heater substrates 60, 64 and the heating trace 38 may extend substantially to the outer periphery 54.

[0014] Continue to refer to Figure 2A and 2B The first conductive trace 40 and the second conductive trace 42 may each extend between the electro-optical connection input terminal 68 and the electro-optical output terminal 70. In some embodiments, the electro-optical input terminal 68 and the electro-optical output terminal 70 may be formed of copper. Each of the electro-optical connection input terminals 68 may be positioned adjacent to the heating conductive terminals 56, 58, such that power can be distributed to both the heating assembly 36 and the electro-optical assembly 14 (e.g., through different wires within the wiring harness). Each of the electro-optical output terminals 70 may be positioned adjacent to the outer periphery 54 of the heating assembly 36. The first conductive intermediate 44 and the second conductive intermediate 46 electrically couple the electro-optical output terminal 70 to the first electrode 30 and the second electrode 32 directly or through one or more conductive structures that may extend around or adjacent to the edge of the second element substrate. For example, the conductive structure may include a conductive clip 72, other metal structures, conductive coatings, conductive inks, solder, conductive epoxy resins, conductive pastes, conductive adhesives, conductive tapes, bus 74 ( Figure 2B ), conductive spring 55 ( Figures 8A-8C One or more of the following: and / or combinations thereof. In this manner, the first conductive intermediate 44 and the second conductive intermediate 46 may extend between the electro-optical output terminals 70 to the conductive structure, and the conductive structure may be directly connected between the electro-optical output terminals 70 and the electrodes 30, 32. For example, the electro-optical output terminals 70 may extend directly above the conductive clip 72, and the conductive intermediates 44, 46 may include solder that directly electrically couples the electro-optical output terminals 70 to the conductive clip 72.

[0015] Continue to refer to Figure 2A and 2B The second heater substrate 64 may define an aperture 76 ( Figure 2AThe aperture exposes the electro-optic connection input terminal 68 and the heating conduction terminals 56, 58 for connecting power to the electro-optic connection input terminal and the heating conduction terminal. The heating assembly 36 may also include an adhesive layer 78 located between each of the heater substrates 60, 64, and may also be located in the space between the heating trace 38 and the conductive traces 40, 42. The heating assembly 36 defines a pair of conductive paths, which may include a first via 80 and a second via 82. More specifically, each of the vias 80, 82 may extend through the heater substrates 60, 64 and the conductive traces 40, 42 (e.g., aligned with the electro-optic output terminal 70). A first conductive intermediate 44 and a second conductive intermediate 46 extend through a corresponding one of the vias 80, 82 to electrically couple the electro-optic output terminal 70 to the first electrode 30 and the second electrode 32, either directly or through one or more conductive structures. The vias 80 and 82 may each include a larger profile in the second heater substrate 64 than that surrounding the electro-optic output terminal 70, such that the conductive intermediates 44 and 46 contact the rear surface 84 of the electro-optic output terminal 70. The electro-optic output terminal 70 may be wider than the conductive traces 40 and 42 to surround the vias 80 and 82 and to facilitate adequate electrical coupling between the conductive intermediates 44 and 46 and the rear surface 84 of the electro-optic output terminal 70.

[0016] Now for reference Figure 2B In some embodiments, conductive intermediates 44, 46 extend through through-holes 80, 82 to contact corresponding surfaces of conductive clips 72. Conductive clips 72 may extend around a fourth surface 26 of the electro-optic assembly 14 and wrap around an outer edge to a third surface 24 for electrical coupling to electrodes 30, 32 (e.g., bus 74). Bus 74 may be constructed of epoxy resin (e.g., silver epoxy resin) extending between and in direct contact with the two electrodes 30, 32. Bus 74 may include a pair of buses 74, each extending along at least 40% (e.g., at least 50%, at least 60%, at least 70%, at least 80%, at least 90%) of the periphery of the outer electrode. Seals 86 may be positioned at least partially inside the buses 74 to confine the electro-optic medium 34 within gap 28. A first isolation line 88 may be defined adjacent to one of the buses 74 in the first electrode 30, and a second isolation line 90 may be defined adjacent to the other bus 74 in the second electrode 32. In this way, each bus 74 can distribute power to only one of the electrodes 30, 32. In some embodiments, at least one of the conductive clip 72 and the bus 74 can be configured as a conductive spring 55, which is biased outward to contact the electrodes 30, 32. A hidden layer (not shown), such as an opaque ring or a chrome ring, may be located between the seal 86 and the front element substrate 16.

[0017] Now for reference Figure 2CThe vias 80 and 82 may exist only in the first heater substrate 60 (or notches 92 and 94), and the first conductive intermediate 44 (as shown) and / or the second conductive intermediate (e.g., conductive ink, conductive epoxy resin, conductive paste, solder, conductive adhesive, conductive tape) extend through the vias 80 and 82 and are directly electrically coupled to the electrodes 30 and 32 via a conductive structure such as clip 72. In this way, the first conductive intermediate 44 and / or the second conductive intermediate can be deposited prior to assembly.

[0018] Now for reference Figure 2A-2C The conductive intermediates 44 and 46 may include various constructions. For example, each conductive intermediate 44 or 46 may be formed from paste, epoxy resin, foam, tape, adhesive, ink, solder, conductive spring 55, mechanical conductor (e.g., rivet, bolt, pin, or clip), etc. The conductive intermediates may be isotropic, anisotropic, curable, or non-curable, exhibiting high or low hardness characteristics before or after curing. Although Figure 2B and 2C The clip 72 is shown to be in the same plane as the first heater substrate 60, but it should be understood that the first heater substrate 60 may cover the top of the clip 72 and extend above the clip 72, such that through-holes 80, 82 extend through the first heater substrate 60 to directly contact the clip 72 (or other conductive structures), as shown. Figure 2A As shown in the image.

[0019] Now for reference Figure 3A and 3BThe image shows a mirror assembly 10B according to a second configuration. Unless otherwise explicitly indicated, the mirror assembly 10B of the second configuration may share all the same features, elements, materials, and functions, and may be included in the same structure as other configurations described herein. However, the conductive paths include notches 92, 94 defined by an outer periphery 54, rather than including through holes 80, 82. It should be understood that, unless otherwise indicated, the outer periphery 54 may include only the first heater substrate 60, only the second heater substrate 64, or both heater substrates 60, 64. In this way, when notches 92, 94 are defined by the outer periphery 54, notches 92, 94 may be defined only by the first heater substrate 60, only by the second heater substrate 64, or by both heater substrates 60, 64. In some embodiments, notches 92, 94 may also be defined by a pattern of heating traces 38. More specifically, the first notch 92 may be aligned with one of the electro-optical output terminals 70, and the second notch 94 may be aligned with the other of the electro-optical output terminals 70. Each of the electro-optic output terminals 70 may extend within recesses 92, 94 along at least a portion of the outer periphery 54. In some embodiments, the electro-optic output terminals 70 may be branched and extend in opposite directions within recesses 92, 94 along at least a portion of the outer periphery 54. Conductive intermediates 44, 46 electrically couple the electro-optic output terminals 70 to the first electrode 30 and the second electrode 32 directly or via one or more conductive structures (e.g., conductive clip 72, bus 74, conductive spring 55). The first conductive intermediate 44 and the second conductive intermediate 46 may extend between the electro-optic output terminals 70 into the conductive structure, and the conductive structure may be directly connected between the electro-optic output terminals 70 and the electrodes 30, 32. In some embodiments, recesses 92, 94 may each include a larger profile in the second heater substrate 64 than surrounding the electro-optic output terminal 70, such that the conductive intermediates 44, 46 contact the rear surface 84 of the electro-optic output terminal 70 to further facilitate sufficient electrical coupling between the conductive intermediates 44, 46 and the rear surface 84 of the electro-optic output terminal 70.

[0020] Now for reference Figure 4A and 4B The image shows a mirror assembly 10C according to a third configuration. Unless otherwise explicitly indicated, the mirror assembly 10C of the third configuration may share all the same features, elements, materials, and functions, and may be included in the same structure as the other configurations described herein. However, notches 92, 94 may each include a larger profile in the first heater substrate 60 than surrounding the electro-optic output terminal 70, such that conductive intermediates 44, 46 contact the front surface 96 of the electro-optic output terminal 70 to facilitate adequate electrical coupling between the conductive intermediates 44, 46 and the front surface 96 of the electro-optic output terminal 70.

[0021] Now for reference Figure 5A and5B The image shows a mirror assembly 10D according to a fourth configuration. Unless otherwise explicitly indicated, the mirror assembly 10D of the fourth configuration may share all the same features, elements, materials, and functions, and may be included in the same structure as other configurations described herein. However, notches 92, 94 may be extended along heater assembly 36, and electro-optic output terminals 70 may extend along notches 92, 94 to act as bus 74 (e.g., by wrapping electrodes 30, 32 and / or using conductive intermediates), so an additional bus may not be necessary. More specifically, electro-optic output terminals 70 and / or conductive intermediates 44, 46 may extend along at least 40% (e.g., at least 50%, at least 60%, at least 70%, at least 80%, at least 90%) of the periphery of the outer electrodes. Conductive intermediate components 44 and 46 directly or via one or more conductive structures (e.g., conductive clips 72 (e.g., a plurality of clips 72 in sequence, or elongated clips 72), bus 74 (e.g., epoxy resin), conductive spring 55, electrodes 30, 32, etc.) electrically couple the electro-optical output terminal 70 to the first electrode 30 and the second electrode 32. The first conductive intermediate component 44 and the second conductive intermediate component 46 may extend between the electro-optical output terminals 70 to the conductive structures, and the conductive structures may be directly connected between the electro-optical output terminals 70 and the electrodes 30, 32.

[0022] Continue to refer to Figure 5A and 5B The notches 92 and 94 may each include a larger contour in the second heater substrate 64 than that surrounding the electro-optic output terminal 70, such that the conductive intermediates 44 and 46 contact the rear surface 84 of the electro-optic output terminal 70 to promote sufficient electrical coupling between the conductive intermediates 44 and 46 and the rear surface 84 of the electro-optic output terminal 70. Similarly, the notches 92 and 94 may each include a larger contour in the second heater substrate 64 than that surrounding the electro-optic output terminal 70, such that the conductive intermediates 44 and 46 contact the rear surface 84 of the electro-optic output terminal 70 to further promote sufficient electrical coupling between the conductive intermediates 44 and 46 and the rear surface 84 of the electro-optic output terminal 70.

[0023] Now for reference Figure 6A and 6B The image shows a mirror assembly 10E according to a fifth configuration. Unless otherwise explicitly indicated, the mirror assembly 10E of the fifth configuration may share all the same features, elements, materials, and functions, and may be included in the same structure as the other configurations described herein. However, notches 92, 94 may each include a larger profile in the first heater substrate 60 than surrounding the electro-optic output terminal 70, such that conductive intermediates 44, 46 contact the front surface 96 of the electro-optic output terminal 70 to facilitate adequate electrical coupling between the conductive intermediates 44, 46 and the front surface 96 of the electro-optic output terminal 70.

[0024] Now for reference Figure 7A and 7B In some embodiments, other configurations of mirror assemblies 10A-10F (e.g., mirror assemblies 10D, 10E) have electrodes 30, 32 that surround the outer periphery of element substrates 16, 22 and are directly or electrically coupled to output terminals 70 via conductive intermediates 44, 46. The materials used for electrodes 30, 32 may vary along the electrode path. For example, the material used for electrodes 30, 32 outside the seal 86 may differ from the material used inside the seal 86. Referring now... Figure 5A-7B It should be understood that additional conductive structures may be omitted or otherwise modified. For example, the electro-optical output terminal 70 may be directly connected to the electrodes 30, 32 or connected to the electrodes via conductive intermediates 44, 46. In some embodiments, the conductive intermediates 44, 46 may have a resistance of 2 ohms or less, such as about 1 ohm or less. In embodiments where the conductive intermediates 44, 46 have the described resistance range, the bus 74 (if present) may be formed of a material other than silver epoxy resin. For example, a less expensive material with a resistance of 5 ohms or greater, about 10 ohms, or 10 ohms or greater. In other embodiments, the bus 74 may be omitted, and the conductive intermediates 44, 46 provide power directly to the electrodes 30, 32.

[0025] Although the various configurations and arrangements of the mirror assemblies 10A-10E may include conductive intermediates 44, 46, each configured as a conductive spring 55, Figures 8A-8C A sixth configuration of the mirror assembly 10F is depicted. Unless otherwise explicitly indicated, the sixth configuration of the mirror assembly 10F may share all the same features, elements, materials, and functions, and may be incorporated into the same structure as the other configurations described herein. A conductive spring 55 may be clamped between (e.g., outwardly biased therebetween) the electro-optical input terminal 68 and the electro-optical output terminal 70 and at least one of the conductive clips 72, electrodes 30, 32, bus 74, or other conductive structures. In operation, the conductive spring 55 ultimately relieves stress between the electro-optical input terminal 68, the electro-optical output terminal 70, and the conductive clips 72 (e.g., other conductive structures) while ensuring contact for the transfer of power therebetween. The conductive clips 72 may be located in openings 98, 100, which may be similar to or substantially the same as one of the through holes 80, 82, and recesses 92, 94 as previously described. Figure 8A In the mirror assembly 10F depicted, openings 98 and 100 are typically larger than the previously described through-holes 80 and 82 to accommodate the size of the conductive clip 72. Openings 98 and 100 may be defined by a first heater substrate 60, a second heater substrate 64, and / or a second element substrate 22. Figure 8A and 8B In the embodiment depicted, the second heater substrate 64 defines openings 98, 100.

[0026] Now for reference Figure 8B and 8C The conductive spring 55 includes a rear rivet plate 102 coupled to a rear surface 84 and a front rivet plate 104 coupled to a front surface 96. At least one connector 106 extends through an electro-optical input terminal 68 and an electro-optical output terminal 70, respectively. In the depicted embodiment, at least one connector 106 includes two pairs of connectors 106, each pair of connectors associated with a different one of the electro-optical input terminal 68 and the electro-optical output terminal 70. More specifically, the rear rivet plate 102 and the front rivet plate 104 may define a pair of holes 108 for receiving the connector 106. The holes 108 may further extend through both the electro-optical input terminal 68 and the electro-optical output terminal 70. In this way, the electro-optical input terminal 68 and the electro-optical output terminal 70 can be effectively clamped between the two rivet plates 102, 104. The connector 106 is depicted as a rivet, which may be formed of a conductive material. The front rivet plate 104 is coupled to, connected to, and / or integral with the spring member 110. In the depicted embodiment, the spring element 110 is configured as a leaf spring integral with the front rivet plate 104. However, the spring element 110 may have other configurations, such as a coil spring, a spring pin, etc. In some embodiments, power supplied to the electro-optical input terminal 68 and the electro-optical output terminal 70 can be transmitted to the spring element 110 via the connector 106 between the rear rivet plate 102 and the front rivet plate 104. In some embodiments, the front rivet plate 104 is coupled directly or indirectly (e.g., with a conductive member or intermediate) to the front surface 96, and power supplied to the electro-optical input terminal 68 and the electro-optical output terminal 70 is transmitted from the front rivet plate 104 to the spring element 110.

[0027] Now for specific reference Figure 8C The image depicts an exploded and partially fragmented view of the conductive spring 55. The conductive spring 55 may also include a bonding element 112 (e.g., adhesive, tape, foam) that bonds between the front rivet plate 104 and at least one of the conductive clips 72, electrodes 30, 32, bus 74, or other conductive structures. The carrier foam 114 may substantially cover and / or isolate the rear rivet plate 102. The electro-optical input terminal 68 and electro-optical output terminal 70 in the mirror assembly 10F are each branched, thereby defining openings 98, 100 of the receiving connector 106.

[0028] Now for reference Figure 1-8CIt should be understood that, in some embodiments, conventional wires may be absent in the conductive loop between the electro-optic component 14 and the conductive traces 40, 42. This simplifies packaging and assembly. It should also be understood that the conductive traces 40, 42 may extend to an outer periphery 54, such as recesses 92, 94 (which may be located in one or both heater substrates 60, 64). Additionally, it should be understood that, unless otherwise stated, the conductive traces 40, 42 may extend to the outer periphery 54, and the outer periphery 54 may not include any recesses 92, 94. The conductive traces 40, 42 may extend from the central region of the heater assembly 36 to the outer periphery 54, such as… Figure 1-8C As shown in the image.

[0029] Continue to refer to Figure 1-8C It is envisioned that heating component 36 can be configured as a positive temperature coefficient (“PTC”) heater. In such embodiments, heating trace 38 is configured as one or more electrical buses, wherein the trace is divided into multiple interdigitated paths (e.g., positive and negative buses with positive and negative branches). For example, heating trace 38 can appear as a pair of combs, with the teeth parallel to each other but not in contact. The trace is applied on top of a PTC material (e.g., a substrate), which has low resistance at low temperatures and room temperature, but its resistance increases significantly at higher temperatures. As a result, current flows from, for example, a 13V trace through the PTC material to another trace grounded. Most of the heat is generated in the resistive PTC material. Once the PTC material heats up, the current decreases, and the power of the heater decreases accordingly. In embodiments utilizing a PTC heater configuration, it should be understood that the same connection scheme described in reference mirror assemblies 10A-10F can be used. However, in such embodiments, the PTC material is conductive, and the higher voltage on the heating traces could damage the electro-optic assembly 14 because it is electrically coupled to a high-voltage heater (e.g., a heating assembly 36 with PTC material). One solution to this problem is to electrically isolate the conductive traces 40, 42 of the electro-optic assembly 14 from the heater traces. Electrical isolation will prevent unwanted communication between the heater traces and the conductive traces 40, 42. The disadvantage of electrical isolation is that the area surrounding the conductive traces 40, 42 will not be heated.

[0030] The disclosures herein are further summarized in the following paragraphs and are further characterized as a combination of any and all of the aspects described herein.

[0031] According to one aspect of this disclosure, a mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite the first surface. The electro-optic assembly also has a second element substrate having a third surface and a fourth surface opposite the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is located between the first and second electrodes. The mirror assembly further includes a heating assembly defining an outer periphery comprising a pair of conductive paths, each conductive path including either a through-hole or a notch defined by the outer periphery located within the outer periphery and extending completely through the heating assembly. Heating traces distribute heat along a region of the heating assembly. The first and second conductive traces each extend to one of the conductive paths. A first conductive intermediate is located in one of the conductive paths and electrically couples the first conductive trace to the first electrode, and a second conductive intermediate is located in the other conductive path and electrically couples the second conductive trace to the second electrode.

[0032] According to another aspect, a pair of conductive traces extend to the outer periphery of the heating component, and a pair of conductive intermediates wrap around the outer periphery of the heating component.

[0033] According to another aspect, the outer periphery defines a pair of notches, and the first conductive intermediate and the second conductive intermediate are respectively wrapped around the outer periphery in one of the notches.

[0034] According to another aspect, a heater assembly includes a first heater substrate covering a front surface of heating traces and conductive traces, and a second heater substrate covering a rear surface of heating traces and conductive traces.

[0035] According to yet another aspect, the notch is defined by at least one of the first heater substrate and the second heater substrate.

[0036] On the other hand, a pair of conductive intermediates cover the front surface of the conductive trace within the notch.

[0037] According to another aspect, a pair of conductive intermediates cover the back surface of the conductive trace within the notch.

[0038] According to another aspect, a pair of conductive traces and a pair of conductive intermediates each extend along at least 50% of the outer periphery of the electrode.

[0039] According to yet another aspect, at least one of the first conductive intermediate and the second conductive intermediate is a spring element.

[0040] According to another aspect, each of the pair of conductive traces extends to a pair of through holes and extends through the heating assembly, and a conductive intermediate is located in each of the through holes.

[0041] According to another aspect, a pair of conductive intermediates cover the front surface of a pair of conductive traces within a pair of through holes.

[0042] According to another aspect of this disclosure, a pair of conductive intermediates cover the back surface of a pair of conductive traces within a pair of through holes.

[0043] According to yet another aspect, at least one of the first electrode and the second electrode is wrapped around the edge of the front substrate to be electrically coupled to the first conductive intermediate or the second conductive intermediate.

[0044] According to another aspect of this disclosure, a mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite the first surface. The electro-optic assembly also has a second element substrate having a third surface and a fourth surface opposite the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is located between the first and second electrodes. The mirror assembly further includes a heating assembly defining an outer periphery comprising a pair of conductive paths, each of the conductive paths including a through-hole or an opening. Heating traces distribute heat along a region of the heating assembly. The first and second conductive traces each extend to one of the conductive paths. A first conductive intermediate is located in one of the conductive paths and electrically couples the first conductive trace to the first electrode, and a second conductive intermediate is located in the other conductive path and electrically couples the second conductive trace to the second electrode.

[0045] According to another aspect, the first conductive intermediate and the second conductive intermediate include a conductive spring located in the opening, the conductive spring being electrically coupled to the conductive path and biased toward the first electrode and the second electrode.

[0046] According to another aspect, the conductive spring is electrically coupled to the conductive clamp.

[0047] According to another aspect of this disclosure, a mirror assembly for a vehicle includes an electro-optic assembly having a front element substrate having a first surface and a second surface opposite to the first surface. The electro-optic assembly also has a second element substrate having a third surface and a fourth surface opposite to the third surface, the second and third surfaces facing each other to define a gap. A first electrode is coupled to the second surface, and a second electrode is coupled to the third surface. An electro-optic medium is located between the first and second electrodes. The mirror assembly further includes a heating assembly defining an outer periphery comprising a pair of conductive paths. Heating traces distribute heat along a region of the heating assembly. The first and second conductive traces each extend to one of the conductive paths. A first conductive intermediate is located in one of the conductive paths and electrically couples the first conductive trace to the first electrode, and a second conductive intermediate is located in the other conductive path and electrically couples the second conductive trace to the second electrode.

[0048] According to another aspect, at least one of the first electrode and the second electrode is wrapped around the edge of the front substrate to be electrically coupled to the first conductive intermediate or the second conductive intermediate.

[0049] According to another aspect, a pair of conductive paths includes a pair of notches defined by the outer periphery of the heating component, and conductive intermediates are respectively wrapped around the outer periphery within one of the notches.

[0050] Those skilled in the art will understand that the construction of the described disclosure and other components is not limited to any particular material. Unless otherwise described herein, other exemplary embodiments of this disclosure can be formed from a wide variety of materials.

[0051] For the purposes of this disclosure, the term "coupled" (in all its forms "couple," "coupling," "coupled," etc.) generally refers to the direct or indirect engagement of two (electrical or mechanical) components with each other. Such engagement can be inherently static or inherently movable. Such engagement can be achieved using two (electrical or mechanical) components and any additional intermediate member that forms a single unit with or integrally with these two components. Unless otherwise stated, such engagement can be inherently permanent, or inherently removable or releasable.

[0052] As used herein, the term "about" means that a quantity, size, formulation, parameter, and other quantity and characteristic is not exact and need not be exact, but may be approximate and / or larger or smaller as needed, reflecting tolerances, conversion factors, rounding, measurement errors, and other factors known to those skilled in the art. When the term "about" is used to describe a range value or endpoint, this disclosure is to be understood to include the specific value or endpoint mentioned. Regardless of whether the numerical value or endpoint of a range in the specification refers to "about," the numerical value or endpoint of a range is intended to include two embodiments: one modified by "about" and one not modified by "about." It should be further understood that each endpoint of a range is meaningful relative to and independent of the other endpoint.

[0053] As used herein, the terms “substantially,” “basically,” and their variations are intended to indicate that the described feature is equal to or approximately equal to a value or description. For example, a “substantially flat” surface is intended to mean a flat or substantially flat surface. Furthermore, “substantially” is intended to mean that two values ​​are equal or approximately equal. In some embodiments, “substantially” may mean values ​​within about 10% of each other, such as values ​​within about 5% of each other, or values ​​within about 2% of each other.

[0054] It should also be noted that the construction and arrangement of the elements of this disclosure as shown in the exemplary embodiments are merely illustrative. Although only a few embodiments of the invention have been described in detail in this disclosure, those skilled in the art who consult this disclosure will readily understand that many modifications are possible (e.g., variations in the size, dimensions, structure, shape and proportion, parameter values, mounting arrangements, use of materials, color, orientation, etc. of various elements) without substantially departing from the novel teachings and advantages of the subject matter. For example, elements shown as integrally formed may be constructed from multiple parts, or elements shown as multiple parts may be integrally formed; the operation of interfaces may be reversed or otherwise altered; the structure and / or the length or width of components or connectors or other elements of the system may be changed; and the nature or number of adjustment positions provided between elements may be changed. It should be noted that the elements and / or components of the system may be made of any of a wide variety of materials that provide sufficient strength or durability, and may be available in any of a wide variety of colors, textures, and combinations. Therefore, all such modifications are intended to be included within the scope of this invention. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of desired and other exemplary embodiments without departing from the spirit of this invention.

[0055] It should be understood that any described process or step within a described process may be combined with other disclosed processes or steps to form a structure within the scope of this disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and should not be construed as limiting.

[0056] It should also be understood that changes and modifications may be made to the above structures and methods without departing from the concept of this disclosure, and it should also be understood that such concept is intended to be covered by the following claims unless the wording of those claims expressly states otherwise.

Claims

1. A mirror assembly for a vehicle, characterized by, include: Electro-optic component, the electro-optic component comprising: A front element substrate having a first surface and a second surface opposite to the first surface; A second element substrate having a third surface and a fourth surface opposite to the third surface, the second surface and the third surface facing each other to define a gap; A first electrode, the first electrode being coupled to the second surface; A second electrode, the second electrode being coupled to the third surface; and An electro-optic medium, wherein the electro-optic medium is located between the first electrode and the second electrode; Heating assembly, the heating assembly comprising: An outer periphery having a pair of conductive paths, each of the conductive paths including either a through-hole located within the outer periphery and extending completely through the heating assembly, or a notch defined by the outer periphery. A heating trace that distributes heat along a region of the heating assembly; A first conductive trace and a second conductive trace, each extending into one of the conductive paths; and A first conductive intermediate, the first conductive intermediate being located in one of the conductive paths and electrically coupling the first conductive trace to the first electrode; and A second conductive intermediate is located in another conductive path within the conductive path and electrically couples the second conductive trace to the second electrode.

2. The mirror assembly of claim 1, wherein, The conductive traces extend to the outer periphery of the heating component, and the conductive intermediates wrap around the outer periphery of the heating component.

3. The mirror assembly of claim 2, wherein, The pair of conductive paths includes a pair of notches, and the conductive intermediates are respectively wrapped around the outer periphery within one of the notches.

4. The mirror assembly of claim 3, wherein, The heating assembly also includes: A first heater substrate, the first heater substrate covering the front surface of the heating trace and the conductive trace; and A second heater substrate covers the back surface of the heating trace and the conductive trace.

5. The mirror assembly of claim 4, wherein, The notch is defined by at least one of the first heater substrate and the second heater substrate.

6. The mirror assembly of claim 5, wherein, The conductive intermediate element covers the front surface of the conductive trace within the notch.

7. The mirror assembly of claim 5 or 6, wherein, The conductive intermediate element covers the rear surface of the conductive trace within the notch.

8. The mirror assembly of claim 5 or 6, wherein, The conductive trace and the conductive intermediate each extend along at least 50% of the outer periphery of the electrode.

9. The mirror assembly according to one of claims 1-6, wherein, At least one of the first conductive intermediate component and the second conductive intermediate component is a spring element.

10. The mirror assembly of claim 1, wherein, The pair of conductive paths includes a pair of through holes extending through the heating assembly, and the conductive intermediate is located in each of the through holes.

11. The mirror assembly of claim 10, wherein, The conductive intermediate component covers the front surface of the conductive trace within the through-hole.

12. The mirror assembly of claim 10 or 11, wherein, The conductive intermediate component covers the rear surface of the conductive trace within the through-hole.

13. The mirror assembly of claim 1, wherein, At least one of the first electrode and the second electrode is wrapped around the edge of the front substrate to be electrically coupled to the first conductive intermediate or the second conductive intermediate.

14. A mirror assembly for a vehicle, characterized by, include: Electro-optic component, the electro-optic component comprising: A front element substrate having a first surface and a second surface opposite to the first surface; A second element substrate having a third surface and a fourth surface opposite to the third surface, the second surface and the third surface facing each other to define a gap; A first electrode, the first electrode being coupled to the second surface; A second electrode, the second electrode being coupled to the third surface; and An electro-optic medium, wherein the electro-optic medium is located between the first electrode and the second electrode; Heating assembly, the heating assembly comprising: An outer periphery having a pair of conductive paths, each of the conductive paths including one of a through hole or an opening; A heating trace that distributes heat along a region of the heating assembly; A first conductive trace and a second conductive trace, each extending into one of the conductive paths; and A first conductive intermediate, the first conductive intermediate being located in one of the conductive paths and electrically coupling the first conductive trace to the first electrode; and A second conductive intermediate is located in another conductive path within the conductive path and electrically couples the second conductive trace to the second electrode.

15. The mirror assembly of claim 14, wherein, The first conductive intermediate and the second conductive intermediate include conductive springs located in the opening, the conductive springs being electrically coupled to the conductive path and biased toward the first electrode and the second electrode.

16. The mirror assembly of claim 15, wherein, The conductive spring is electrically coupled to the conductive clamp.

17. The mirror assembly according to one of claims 14-16, wherein, The pair of conductive paths includes a pair of through holes extending through the heating assembly, and the conductive intermediate is located in each of the through holes.

18. A mirror assembly for a vehicle, characterized by: include: Electro-optic component, the electro-optic component comprising: A front element substrate having a first surface and a second surface opposite to the first surface; A second element substrate having a third surface and a fourth surface opposite to the third surface, the second surface and the third surface facing each other to define a gap; A first electrode, the first electrode being coupled to the second surface; A second electrode, the second electrode being coupled to the third surface; and An electro-optic medium, wherein the electro-optic medium is located between the first electrode and the second electrode; Heating assembly, the heating assembly comprising: An outer periphery having a pair of conductive paths; A heating trace that distributes heat along a region of the heating assembly; A first conductive trace and a second conductive trace, each extending into one of the conductive paths; and A first conductive intermediate, the first conductive intermediate being located in one of the conductive paths and electrically coupling the first conductive trace to the first electrode; and A second conductive intermediate is located in another conductive path within the conductive path and electrically couples the second conductive trace to the second electrode.

19. The mirror assembly of claim 18, wherein, At least one of the first electrode and the second electrode is wrapped around the edge of the front substrate to be electrically coupled to the first conductive intermediate or the second conductive intermediate.

20. The mirror assembly of claim 18, wherein, The pair of conductive paths includes a pair of notches defined by the outer periphery of the heating assembly, and the conductive intermediates respectively wrap around the outer periphery within one of the notches.

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