Single-substrate electrochromic mirror reflective element for vehicular mirror assembly

Abstract

An electrochromic mirror reflective element for a vehicular rearview mirror assembly includes a single glass substrate with a transparent electrically conductive coating disposed at a side of the single glass substrate. An electrochromic medium is disposed at and contacting the transparent electrically conductive coating at the second side of the single glass substrate. The electrochromic medium includes an electrically conductive polymer. An electrically conductive mirror reflector is disposed at and contacts the electrochromic medium at the second side of the single glass substrate. The electrochromic medium is disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector. The electrochromic medium is electro-formed.

Description

SINGLE-SUBSTRATE ELECTROCHROMIC MIRROR REFLECTIVE ELEMENT FOR VEHICULAR MIRROR ASSEMBLYCROSS REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims the filing benefits of U.S. provisional application Ser. No. 63 / 770,396, filed Mar. 12, 2025, and U.S. provisional application Ser. No. 63 / 669,816, filed Jul. 11 , 2024, which are hereby incorporated herein by reference in their entireties.FIELD OF THE INVENTION

[0002] The present invention relates generally to the field of interior rearview mirror assemblies for vehicles.BACKGROUND OF THE INVENTION

[0003] It is known to provide a mirror assembly that is adjustably mounted to an interior portion of a vehicle, such as via a single ball pivot or joint mounting configuration or double ball pivot or joint mounting configuration where the mirror casing and reflective element are adjusted relative to the interior portion of a vehicle by pivotal movement about the single or double ball pivot configuration. Traditionally, an electrochromic mirror reflective element includes a front glass substrate and a rear glass substrate with an electrochromic medium sandwiched between the glass substrates and bounded by a perimeter seal.SUMMARY OF THE INVENTION

[0004] A vehicular rearview mirror assembly, such as an interior rearview mirror assembly or exterior rearview mirror assembly, includes an electrochromic mirror reflective element that is operable to adjust its reflectance responsive to an electrical voltage applied to the electrochromic mirror reflective element. The electrochromic mirror reflective element includes a single glass substrate having an electrochromic medium sandwiched between or at least partially integrated with a transparent electrically conductive coating and an electrically conductive mirror reflector coating at a rear or second side or surface of the single glass substrate. The electrochromic medium includes an electrically conductive polymer that is electro-formed at the transparent electrically conductive coating, such as via electrochemical polymerization to provide a substantially smooth and uniformapplication surface for the mirror reflector. The electrically conductive polymer may be electro-formed by electrically charging the transparent electrically conductive coating while the single glass substrate is submerged in a liquid medium, such as an aqueous solution, containing monomer molecules so that the monomer molecules may form the polymeric network at the transparent electrically conductive coating. For example, the monomer may comprise 3,4-Ethylenedioxythiophene (EDOT) molecules, which forms a Poly 3,4- Ethylenedioxythiophene (PEDOT) network. Optionally, a viologen or pendant viologen may be disposed at, such as trapped in or bonded to or reacted with, the electrically conductive polymer.

[0005] These and other objects, advantages, purposes and features of the present invention will become apparent upon review of the following specification in conjunction with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a perspective view of an interior rearview mirror assembly;

[0007] FIG. 2 is a diagram showing electrochemical polymerization of an electrically conductive polymer at a single glass substrate of a reflective element of the interior rearview mirror assembly;

[0008] FIG. 3 is a perspective view of a two electrode system for performing the electrochemical polymerization;

[0009] FIG. 4 is a rear side view of the reflective element;

[0010] FIG. 5 is a front side view of the reflective element;

[0011] FIG. 6 is a perspective view of the single glass substrate having the electrically conductive polymer, with the electrically conductive polymer in an oxidized state and a reduced state;

[0012] FIG. 7 is a diagram showing the addition of a pendant viologen to the electrically conductive polymer during electrochemical polymerization;

[0013] FIG. 8 is a structural formula of EDOT modified viologen;

[0014] FIG. 9 is a structural formula of 5, 10 dihydro dianiline phenazine;

[0015] FIG. 10 is a structural formula of polyaniline phenazine;

[0016] FIG. 11 is a structural formula of 5, 10 dihydro dimethyl, 2, 7 dianiline phenazine;

[0017] FIG. 12 is a structural formula of aniline derivative viologen;

[0018] FIG. 13 is a structural formula of polyaniline viologen;

[0019] FIG. 14 is a structural formula of monoaniline viologen;

[0020] FIG. 15 is a schematic diagram of an electrically conductive polymer electroformed at the transparent electrically conductive coating of the single glass substrate, where the electrically conductive polymer includes polyaniline viologen and 5, 10 dihydro dimethyl, 2, 7 dianiline phenazine;

[0021] FIG. 16 is a schematic diagram of an electrically conductive polymer electroformed at the transparent electrically conductive coating of the single glass substrate, where the electrically conductive polymer includes monoaniline viologen and 5, 10 dihydro dimethyl, 2, 7 dianiline phenazine;

[0022] FIG. 17 is a sectional view of the single-substrate electrochromic mirror reflective element;

[0023] FIG. 18 is a sectional view of the single glass substrate having the transparent electrically conductive coating disposed thereat;

[0024] FIGS. 19A, 19B and 20 are views of a holder configured to retain the single glass substrate during the electropolymerization process;

[0025] FIG. 21 is a sectional view of the single glass substrate having the electrically conductive polymer electro-formed at the transparent electrically conductive coating;

[0026] FIG. 22 is a sectional view of the single glass substrate having the electrically conductive mirror reflector layer disposed at the electrically conductive polymer;

[0027] FIG. 23 is a sectional view of the single glass substrate having an electrically conductive tab disposed at the electrically conductive mirror reflector layer and another electrically conductive tab disposed at the transparent electrically conductive coating; and

[0028] FIG. 24 is a sectional view of the electrochromic mirror reflective element, showing the reflectance of the electrochromic mirror reflective element in a dimmed state.DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0029] Referring now to the drawings and the illustrative embodiments depicted therein, a vehicular interior rearview mirror assembly 10 includes a mirror head 12 that includes a casing 14 and a reflective element 16 positioned at a front portion of the casing 14 (FIG.1 ). In the illustrated embodiment, the mirror assembly 10 is configured to be adjustably mounted to an interior portion of a vehicle (such as to an interior or in-cabin surface of avehicle windshield or a headliner of a vehicle or the like) via a mounting structure or mounting configuration or assembly 18. The mirror reflective element 16 comprises a variable reflectance mirror reflective element that varies its reflectance responsive to electrical voltage or current applied to conductive coatings or layers of the reflective element.

[0030] The mirror reflective element 16 includes a single glass substrate 20 having a front or first side or surface 20a (the surface that generally faces the driver of a vehicle when the mirror assembly is normally mounted at the vehicle) and a rear or second side or surface 20b opposite the front surface 20a (FIG. 2). A transparent conductive coating 22 is established at the rear surface 20b of the single glass substrate 20. For example, the transparent conductive coating 22 may include an indium tin oxide (ITO) layer, an aluminum zinc oxide (AZO) layer, a doped tin oxide layer or any other transparent electrically semi-conductive layer or coating or the like (such as indium cerium oxide (ICO), indium tungsten oxide (IWO), or indium oxide (IO) layers or the like, or a zinc oxide layer or coating, or a zinc oxide coating or the like doped with aluminum or other metallic materials, such as silver or gold or the like, or other oxides doped with a suitable metallic material or the like, or such as disclosed in U.S. Pat. Nos. 7,274,501 ; 7,255,451 and / or 7,195,381 , which are hereby incorporated herein by reference in their entireties).

[0031] An electro-optic medium or electrochromic medium 24 including an electrically conductive polymer 26 is disposed between the transparent conductive coating 22 and a mirror reflector. For example, and as discussed further below, the electrically conductive polymer 26 may be electro-formed on and at least partially integrated with the transparent conductive coating 22, and the mirror reflector may be applied onto the electrically conductive polymer 26. The light transmissivity of the electrochromic medium 24 is adjustable responsive to an applied electrical voltage or current to adjust the reflectance of the mirror reflective element 16. The mirror reflector may comprise any suitable coatings or layers, such as a transflective coating or layer, such as described in U.S. Pat. Nos. 7,626,749; 7,274,501 ; 7,255,451 ; 7,195,381 ; 7,184,190; 6,690,268; 5,140,455; 5,151 ,816; 6,178,034; 6,154,306; 6,002,511 ; 5,567,360; 5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012; 5,115,346; 5,724,187; 5,668,663; 5,910,854; 5,142,407 and / or 4,712,879, which are hereby incorporated herein by reference in their entireties.

[0032] Because the mirror reflector requires a solid and flat surface to avoid a distorted or crinkled appearance, the electrochromic medium 24 may comprise a conductive thin film to provide a uniform, distortion-free surface for applying the metallic reflective coating of the mirror reflector. The electrically conductive polymer 26 may be electrochemically polymerized onto the ITO, AZO or other transparent conductive coating 22 on the rear glass surface 20b to provide the uniform and flat surface at which the mirror reflector is disposed.

[0033] Referring to FIGS. 2 and 3, the electrically conductive polymer 26 is a common and reproducible polymer including an electron-rich double-bond containing molecule such as Polyaniline or Poly 3,4-ethlenedioxythiphene (PEDOT). Monomers 28, such as 3,4- ethlenedioxythiphene (EDOT) monomers or aniline monomers, are attached to the transparent conductive coating 22 through electropolymerization to electro-form the polymeric network onto the surface. For example, the monomers 28 may be added to a liquid medium 30, such as an aqueous solution, with the single glass substrate 20 having the transparent conductive coating 22 disposed at the second surface 20b also disposed within the liquid medium 30. A positive electrical connector 34 of a power source 32 is electrically conductively connected to the conductive coating 22 and a negative electrical connector 36 of the power source 32 is electrically conductively connected to a counter electrode 38 disposed in the liquid medium 30. The counter electrode 38 may be a copper bar or other suitable conductive material. By applying a known DC voltage (e.g., between 0.9 volts and 1 .5 volts) via the power source 32, the monomers 28 polymerize onto the conductive surface 22, forming a thin film coating of the conductive polymer 26.

[0034] In the illustrated example of FIGS. 2 and 3, the EDOT monomers 28 are electrochemically polymerized to form the PEDOT polymer 26, which is an inherently electrochromic material. Specifically, a liquid medium 30 containing salt, such as about 0.25M potassium nitrate (KNO3), and about 0.01 M EDOT in deionized water may lead to a uniform thin film coating of PEDOT polymer 26 when applying a voltage of about 0.9 volts for about 15 minutes in the two electrode system. Thickness of the layer of the electrically conductive polymer 26 may be controlled by adjusting the voltage and polymerization time. Applying a higher voltage (e.g., about 1 volt, about 1.2 volts, about 1.5 volts or more, and the like) may result in a faster and greater polymerization rate while applying a givenvoltage (e.g., less than 0.9 volts, about 1 volt, about 1.2 volts, about 1.5 volts or more, and the like) for a longer polymerization time (e.g., greater than 15 minutes, greater than 20 minutes, greater than 30 minutes, and the like) may result in a thicker coating of the electrically conductive polymer 26.

[0035] With the PEDOT polymer 26 disposed at the transparent conductive coating 22, the reflective metallic coating may be disposed at the PEDOT polymer 26 to form the mirror reflector. For example, the reflective metallic coating may include aluminum, silver, chromium, or alloys of these metals. With the mirror reflector disposed at the electrochromic medium 24, electrical connectors 40 such as metallic tabs may be disposed at the mirror reflective element 16 and electrically conductively connected to the electrochromic medium 24, such as via conductive epoxy 42, to electrify the system (FIG. 4). For example, the mirror reflector may comprise an electrically conductive mirror reflective coating and / or the mirror reflective element 16 may include a tab-out region to allow for connection between the electrical connectors and the transparent electrically conductive coating 22 and / or the electrochromic medium (such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 7,274,501 ; 7,184,190 and / or 7,255,451 , which are hereby incorporated herein by reference in their entireties) for providing electrical connection of the conductive layers to an electrical clip of connector or bus-bar, such as the types described in U.S. Pat. Nos. 5,066,112 and 6,449,082, which are hereby incorporated herein by reference in their entireties.

[0036] Optionally, the reflective element may include an opaque or substantially opaque or hiding perimeter layer or coating or band disposed at portions of the reflective element corresponding to the electrical connectors to conceal or hide the electrical connectors from view by the driver of the vehicle. For example, the hiding layer may be disposed at least partially around a perimeter edge region of the mirror reflective element. Such a hiding layer or perimeter band may be reflective or not reflective and may utilize aspects of the perimeter bands and mirror assemblies described in U.S. Pat. Nos. 5,066,112; 7,626,749; 7,274,501 ; 7,184,190; 7,255,451 ; 8,508,831 and / or 8,730,553, which are all hereby incorporated herein by reference in their entireties. Optionally, the perimeter band may comprise a chrome / chromium coating or metallic coating and / or may comprise a chrome / chromium or metallic coating that has a reduced reflectance, such as by using anoxidized chrome coating or chromium oxide coating or "black chrome" coating or the like (such as by utilizing aspects of the mirror assemblies described in U.S. Pat. No. 7,184,190 and / or 7,255,451 , which are hereby incorporated herein by reference in their entireties). Optionally, other opaque or substantially opaque coatings or bands may be implemented.

[0037] The PEDOT polymer 26 is an inherently electrochromic material with a blue coloring or tint to it (FIGS. 5 and 6). As PEDOT grows on the single glass substrate 20, the polymer 26 may change from a light blue to a darker blue. The resulting reduced state of the PEDOT polymer 26 may thus become an even darker shade of indigo or purple. That is, oxidizing and reducing the PEDOT polymer 26 may cause it to undergo a very quick color change from a light blue to a dark blue or purple color.

[0038] To provide a more neutral bleached state color and a dark colored state color during operation of the mirror reflective element 16, the electrochromic medium 24 may include one or more additional materials and layers between the transparent conductive layer 22 and the mirror reflector, such as an electrically conductive layer including one or more of tungsten trioxide (WO3), niobium pentoxide (Nb20s), titanium dioxide (TiC ), molybdenum trioxide (MoOs), vanadium pentoxide (V2O5), iridium dioxide (lrO2), nickel oxide (NiO), rhodium oxide (Rt s), nickel hydroxide (Ni(OH)2), cobalt oxide (CoOx) and the like. For example, the electrochromic medium 24 may include multiple metallic and / or electrically conductive and / or dielectric layers such as described in U.S. Pat. Nos. 11 ,780,372; 11 ,766,968; 7,274,501 ; 7,184,190 and / or 7,255,451 , and / or International Application No. PCT / US2025 / 027206, filed May 1 , 2025 (Attorney Docket DON01 FP5372WO), which are all hereby incorporated herein by reference in their entireties. That is, the additional material or neutralizing layer of the electrochromic medium 24 may cause the mirror reflective element to look less blue or less colored or less tinted, such that the mirror reflective element may appear substantially un-tinted or clear (or provide un-tinted reflections) in the bleached state and may appear darkened black or gray (or provide darkened reflections) in the darkened state.

[0039] Further, a viologen 44, such as a pendant viologen, may be incorporated into the electrically conductive polymer 26 during the electropolymerization process (FIG. 7). For example, the viologen may be reacted with or bonded to the EDOT monomer 28 and / or the pendant viologen may be electropolymerized and trapped with the electricallyconductive polymer 26 onto the transparent conductive surface 22. The pendant viologen may effectively trap the coloring system inside the conductive polymer 26. Thus, incorporating the viologen 44 and / or one or more additional electrochromic materials and layers with the electrochromic medium 24 may allow the electrochromic mirror reflective element 16 to provide the desired coloring effect when electrically operated.

[0040] As shown in FIG. 8, the electrochromic mirror with PEDOT conductive polymer 26 may include a viologen modified with the EDOT monomer 28 to successfully electropolymerize onto the transparent conductive oxide (TCO) surface 22 of the single glass substrate 20. However, the EDOT-modified viologen 46 and electrochromic properties of the PEDOT 26 may lead to a mirror with a blue hue in the non-colored state and a very dark shade of blue in the colored state. An aniline-modified viologen conductive polymer may provide a silver or chrome colored mirror as it polymerizes onto the single glass substrate clear and colorless. This silver or chrome coloration may more closely resemble traditional mirrors.

[0041] In some examples, the conductive polymer 26 may include a dimethyl phenazine (DMPA) molecule. DMPA may be modified with an aniline group instead of a methyl group. By replacing the methyl group with the aniline group, a 5, 10 dihydro dianiline phenazine 48 is formed (FIG. 9). Further, additional aniline monomers are added to the aniline groups of the synthesized 5, 10 dihydro dianiline phenazine 48 to polymerize into polyaniline phenazine 50 (FIG. 10).

[0042] Optionally, the conductive polymer 26 may include a 5, 10 dihydro dimethyl 2, 7 dianiline phenazine molecule 52 (FIG. 11 ). Where the 5, 10 dihydro dianiline phenazine 48 has the bonding location of the aniline groups at the center of the molecule, the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine 52 has the bonding location of the aniline groups at the edges or ends of the molecule.

[0043] Referring to FIG. 12, an aniline derivative viologen 54 may be synthesized to incorporate aniline monomers with the viologen 44, allowing the molecule 54 to be electropolymerized onto the TCO coating 22 of the single glass substrate 20. Further, NH2 may bond the benzene rings or viologen 54 to form polyaniline viologen 56 (FIG. 13). Additional viologens 54 may be bonded to the polyaniline 56. That is, the viologen 54 may be modified to act like polyaniline, leaving a benzene ring on a bottom side to open a topside for an additional bonding area. A monoaniline viologen 58 shown in FIG. 14 may be the modified version of the aniline derivative viologen that ensures it is possible to continue bonding additional viologens 54 to the polyaniline 56.

[0044] The molecules shown in FIGS. 8-14 may be added to the solution or liquid medium 30 used during electropolymerization. For example, and as shown in FIG. 15, the aniline-functional viologen 56 and the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine molecule 52 may be combined and grow upon the transparent conductive coating 22 to electro-form the conductive polymer layer 26 on the single glass substrate 20. In some examples, the conductive polymer layer 26 on the single glass substrate 20 may include the monoaniline viologen 58 and the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine molecule 52 (FIG. 16). This may allow for the bonding of additional viologen and result in a growth of the polymer layer on the transparent conductive coating 22 of the single glass substrate 20. In the illustrated examples of FIG. 15 and 16, the molecules of the conductive polymer layer may grow on top of each other, choosing the path of least resistance, leading to a fairly uniform and level surface post polymerization.

[0045] Thus, the mirror reflective element 16 includes a single glass substrate 20 including a transparent conductive coating 22 including a TCO layer such as ITO, AZO, and the like (FIG. 17). The TCO-layered glass is coated with the conductive polymer 26, such as the incorporated viologen. This conductive polymer 26 may include PEDOT, polyaniline, and the like. Incorporating viologen or phenazine with the EDOT or aniline monomer may result in the proper coloration of the electrochromic mirror. A mirror reflector coating 60 may be deposited on the top of the last layer of the conductive polymer 26, resulting in the mirror surface. An encapsulant or sealing layer 62, such as an optically clear adhesive, may be disposed over the reflector coating 60 to seal the mirror reflective element. Before the sealing layer 62 is added, the electrode tabs 40 may be electrically connected with a wire or conductive epoxy inlaid with a wire 42 or the like to complete the circuit between the transparent conductive coating 22 and the reflector 60. In the illustrated example, the electrode tabs 40 are disposed at and electrically connected to the TCO layer 22 and the reflector layer 40, respectively. The single substrate mirror reflective element 16 may adhere to federal and global reflectance requirements, such as those establishedin the Federal Motor Vehicle Safety Standards (FMVSS) or the Economic Commission for Europe Regulation 46 (ECE R46).

[0046] Coating the single glass substrate 20 with the TCO layer 22 may be performed in a variety of ways (FIG. 18). For example, a large glass sheet may be score-cut or lasercut into smaller pieces, such as plates having dimensions of about 295 millimeters by about 300 millimeters, to form the individual glass substrates. The glass plate or single glass substrate (e.g., the single glass substrate or piece of glass) may then be sent through an inline washer to remove any particulate or contamination. Then, the single glass substrate may be loaded into a carrier that will be sent into a magnetron or sputtering coater to apply the TCO layer 22 onto the single glass substrate 20, such as at a thickness of about 90 nanometers to about 140 nanometers. In some examples, additional TCO layers 22 may be added onto the initial TCO layer 22 for optical properties.

[0047] Given the nature of the viologen and its susceptibility to interaction with the atmosphere, the polymer / viologen layer at the mirror reflective element is protected from any exposure to oxygen prior to being encapsulated by the sealing layer 60. The layer is protected by performing processing steps in a vacuum or under a nitrogen purge. For example, following the TCO coating step, the coated glass substrate is disposed in a chamber or room or other space that is sealed and oxygen in the space is vacuumed out and replaced with nitrogen.

[0048] Unloading of the single glass substrate from carriers used during TCO coating may be automated using multi axis robot arms or a multi-axis gantry system. After removal of the atmosphere and introduction of the nitrogen blanket, the single glass substrate is robotically loaded into a fixture 64 and attached to a monorail system for the electropolymerization process (FIGS. 19A and 19B). As shown in FIG. 20, the fixture 64 includes a first portion or base portion 66 and a second portion or lid portion 68 that join together with the ITO-coated glass substrate disposed between the first portion 66 and the second portion 68. A window or through hole may be formed through the first portion 66 of the fixture 64 and configured to align with at least a portion of the single glass substrate disposed between the first portion 66 and the second portion 68 of the fixture 64. A plurality of fasteners 70, such as threaded fasteners received by threaded receivers, may join the first portion 66 and the second portion 68 together. Moreover, a first seal orperimeter seal 72 may be disposed between the first portion 66 and the second portion 68 outboard of the ITO-coated glass substrate. A second seal or viewing area seal 74 may be disposed between the first portion 66, the second portion 68 and / or the ITO-coated glass substrate. A portion of the second seal 74 may engage the transparent conductive coating 22 at the surface of the single glass substrate 20.

[0049] Thus, the fixture 64 may seal around a coupon or portion of the glass substrate, allowing for only a small, controlled area of the glass substrate to be coated with the conductive polymer 26 when the fixture is lowered into the solution or liquid medium 30 that contacts the glass substrate through the window. Hooks on the top of the fixture 64 (e.g., integrally formed with the first portion 66) may be used to lower the fixture 64 holding the glass substrate into the electropolymerization solution or liquid medium 30. Moreover, a tab area 76 of the glass substrate may extend through or outboard of the first seal 72 and above a top edge portion of the fixture (e.g., at or near the hooks) to be exposed above the fixture for a direct electrical connection during the electropolymerization. Optionally, electrical connection to the glass substrate may be internal to the fixture (i.e. , between the first portion 66 and the second portion 68). That is, an electrical connector may be disposed between the first portion 66 and the second portion 68 and engage the ITO-coated glass substrate for charging the glass substrate during the electropolymerization process. The electrical connector may include a biased electrical connector biased into engagement with the glass substrate when the fixture is joined together, such as a pogo pin or leaf spring.

[0050] The seals of the fixture 64 may serve as masking points where the glass substrate is sealed from contacting the liquid medium 30 and thus will not be coated with the conductive polymer 26. These portions of the glass substrate not coated with the conductive polymer 26 may allow for the tabs 40 to be attached to the ITO coating 22 for electrifying the mirror reflective element 16. Materials of the fixture 64 may be non- conductive to avoid being coated with the polymer during electropolymerization, and the materials may be resistant to chemicals in the liquid medium 30, such as propylene carbonate.

[0051] During the coating process, after an individual single glass substrate of the glass plates or shapes or substrates is loaded into a respective fixture 54, a gate or door of anair lock may open and allow one or more fixtures 54 (each loaded with a respective single glass substrate) onto a monorail system. The glass substrate inside the fixture 54 may be transported along the rail until it reaches a first tank that contains an initial rinse. The fixture 54 and the glass substrate may be at least partially submerged in the first tank to expose the portion of the glass substrate through the window in the first portion 66 to the contents of the first tank and ensure that the coating surface is cleaned and prepared for deposition of the conductive polymer and viologen.

[0052] After lifting the fixture 54 and the glass substrate from the first tank, the fixture 54 and the glass substrate may be lowered into a second tank containing the main solution or liquid medium 30, which may include propylene carbonate, aniline-functionalized viologen 5, 10 dihydro dimethyl 2,7, dianiline phenazine, and a salt such as lithium perchlorate (to make the liquid medium conductive). A voltage is applied to the glass substrate for a prescribed amount of time as the glass substrate is submerged in the liquid medium 30 to electro-form the conductive polymer 26 including the viologen on the transparent conductive coating 22 (FIG. 21 ). Once desired film thickness and uniformity is achieved, the monorail may continue moving the fixture 54 and glass substrate out of the main bath 30 and into a third tank to rinse the coated surface, removing any excess nonpolymerized chemicals off the surface of the glass substrate. Following the third tank rinse, the monorail may continue to carry the fixture 54 and glass substrate into an oven, where the glass substrate may be heated and the conductive polymer 26 cured. This solidifies the polymerization and cures the conductive polymer 26 on top of the TCO coating 22 of the glass substrate.

[0053] After the reflector 60 is successfully coated onto the conductive polymer 26 disposed at the glass substrate, the glass substrate may be removed from the fixture 54 and transferred to a conveyor belt. Removal of the glass substrate from the fixture 54 may be performed automatically, such as via robot arm or multi-axis gantry system. The conveyor may move the coated glass substrate to the next process step where a robot may dispense conductive epoxy and place an electrode tab 40 into the dispensed conductive epoxy (FIG. 23). This may occur on both the TCO surface 22 and on the back side of the reflector and near the edge regions of the mirror reflective element so that the tabs 40 are obscured from view when looking at the front side of the mirror reflectiveelement 16. The tabs 40 may be secured by curing the conductive epoxy via heating in an oven. Following this bake step, the part may be unloaded from the oven and transported to another station where wires 42 may be pushed in or inserted into the tabs 40 to establish a means of applying power to the two surfaces. When the mirror assembly is mounted at the vehicle, one tab 40 may be configured to electrically connect to a positive electrical connector and the other tab 40 may be configured to electrically connect to a negative electrical connector to charge the conductive polymer 26 disposed between the reflector 60 and the transparent conductive coating 22.

[0054] After the tabs 40 and wires 42 are attached to the mirror reflective element, the conveyor may transport the mirror reflective element to receive the optically clear adhesive sealing layer 62. Application of the sealing layer 62 may be accomplished via spray coating or rolling. For example, the sealing layer 62 may be applied while the conveyor transports the mirror reflective element past a sprayer or roller. Following application of the sealing layer 62, the sealing layer 62 may be cured by subjecting the mirror reflective element to ultraviolet (UV) light for a period of time or by disposing the mirror reflective element in an oven for heating. Once the sealing layer 62 is cured, the mirror reflective elements may exit the controlled and oxygen-free environment. Further, the mirror reflective element may undergo further finishing, such as to grind and / or polish a beveled or rounded edge of the mirror reflective element 16. Moreover, the mirror reflective element may be assembled with a mirror casing to form the mirror assembly.

[0055] Typically, an electrochromic mirror reflective element having a front glass substrate, a rear glass substrate, and an electrochromic dimmable medium disposed between the substrates may transition from a bleached state having a reflectance of about 73 percent to a fully dimmed state having a reflectance of about 7 percent in response to a voltage of 1 .2 volts applied to the mirror reflective element. The interpane gap between the front glass substrate and the rear glass substrate and accommodating the electrochromic dimmable medium may have a thickness of about 130 microns.

[0056] In the illustrated example of FIG. 24, the electrochromic mirror reflective element 16 having a single glass substrate 20 with the TOO layer 22, the conductive polymer 26, and the reflector layer 60 disposed at the rear side of the single glass substrate 20 may be operable in a fully dimmed state with a reflectance of about 7 percent in response to avoltage of about 1 .2 volts applied to the mirror reflective element. That is, the mirror reflective element 16 may reflect about 7 percent of the visible light incident at the mirror reflective element when about 1.2 volts is applied to the mirror reflective element 16 in the fully dimmed state. In the bleached or non-dimmed state, the mirror reflective element 16 may have a reflectance of about 73 percent. The transparent conductive coating 22 may include a half-wave ITO layer. The conductive polymer 26 may include an electrodeposited / cured transparent electrically-conducting polymer layer with EC-colorable dyes bound into the polymeric backbone of the polymer layer, and the conductive polymer 26 may have a thickness of about 5 microns to about 10 microns. The conductive polymer layer 26 may have a dye concentration of viologen and / or DMPA in polymer of about 0.2 M / liter or greater. Thus, the single-substrate mirror reflective element may provide similar or improved dimming performance as compared to typical mirror reflective elements, with less glass usage and a substantially thinner layer of electrochromic material.

[0057] The electrochromic mirror reflective element and dimmable medium may utilize characteristics of the mirror assemblies described in U.S. Pat. Nos. 9,669,764; 5,140,455 and / or 4,902,108, which are hereby incorporated herein by reference in their entireties.

[0058] Thus, the mirror assembly includes an electrochromic mirror reflective element where a conductive polymer is electrochemically polymerized onto a transparent conductive coating on the single glass substrate. The polymer is applied to the transparent conductive coating in this manner to form a thin and flat or uniform surface. A mirror reflector or reflective coating may then be applied on top of the conductive polymer coating. The conductive polymer coating may be electrified to adjust the dimming level of the mirror. Additional electrochromic materials may be disposed between the conductive polymer coating and the mirror reflector (or optionally a viologen may be incorporated with the conductive polymer coating), such as to adjust the dimming color of the conductive coating.

[0059] The reflective element for the mirror assembly has a single glass substrate with a conductive polymer deposited as a uniform thin film on the single glass substrate, with the use of the single glass substrate reducing glass consumption, reducing scrap materials, eliminating or reducing the size of a perimeter seal, spacer beads, cell gap, and the like. A chrome band may only be used to hide or render covert the electrification tabs,which results in minimal to no chrome band present on the mirror assembly as there is no perimeter seal to hide. Further, the single glass substrate reduces the weight of the mirror assembly. Another benefit of a mirror with a single piece of glass is reducing the chance of double image or distortion because there are not two pieces of glass that need to be kept parallel to one another.

[0060] Moreover, by adding a conductive polymer such as PEDOT, it allows for the removal of the current solid polymer matrix (SPM). The viologen may instead be incorporated into the conductive polymer system, such as trapped during the electropolymerization of EDOT or reacted with the EDOT monomer as a pendant viologen. This is a benefit to the construction of the EC mirror as the electrochromic element is contained within the coating stack of the system and is protected from atmospheric conditions. In contrast, in traditional mirrors, if a seal breach occurs the auto-dimming is compromised and a brown coloring may become apparent on the first surface viewing area.

[0061] Although shown and described as a mirror reflective element for an interior rearview mirror assembly that mounts at an interior portion of the vehicle (e.g., at a windshield or headliner of a vehicle equipped with the mirror assembly) via mounting structure, the mirror reflective element is suitable for use in an exterior rearview mirror assembly. For example, the exterior rearview mirror assembly may include a mounting arm having an attaching end that attaches at an exterior portion of the vehicle and a distal end distal from the attaching end. A mirror head is disposed at the distal end of the mounting arm and accommodates the electrochromic mirror reflective element, whereby the mirror reflective element is adjustable to set a rearward view of the driver along the side of the vehicle. Optionally, the mirror reflective element may adjust together and in tandem with the mirror head so that the mirror head may be positionable or adjustable relative to a side of the vehicle to set the rearward view of the driver along the side of the vehicle.

[0062] In one aspect, an electrochromic mirror reflective element for a vehicular rearview mirror assembly includes a single glass substrate having a first side and a second side opposite the first side. A transparent electrically conductive coating is disposed at the second side of the single glass substrate. An electrochromic medium is disposed at and contacting the transparent electrically conductive coating at the second side of the singleglass substrate. The electrochromic medium comprises an electrically conductive polymer. An electrically conductive mirror reflector disposed at and contacting the electrochromic medium is disposed at the second side of the single glass substrate. The electrochromic medium is disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector. The electrochromic medium is disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector is electro-formed.

[0063] In some examples, the electrochromic mirror reflective element comprises part of a vehicular interior rearview mirror assembly that is configured for mounting at an interior portion of a vehicle. In other examples, the electrochromic mirror reflective element comprises part of a vehicular exterior rearview mirror assembly that is configured for mounting at an exterior portion of a vehicle.

[0064] In some implementations, the electrochromic medium disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector is electro-formed by (i) disposing the single glass substrate in a liquid medium that includes a monomer and (ii) applying an electrical voltage across the transparent electrically conductive coating and the liquid medium to polymerize the monomer and electro-form an electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate. Further, the monomer may comprise 3,4-Ethylenedioxythiophene (EDOT) molecules. The electrically conductive polymer may comprise a Poly 3,4-Ethylenedioxythiophene (PEDOT) network. In further implementations, the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes formation of the PEDOT network from the EDOT molecules. In further implementations, the liquid medium includes the EDOT molecules and a salt. The salt may comprise potassium nitrate (KNOs). For example, the liquid medium includes 0.25M KNOs to 0.01 M EDOT molecules. Optionally, the EDOT molecules are modified with a viologen.

[0065] In some further implementations, the monomer comprises 5, 10 dihydro dimethyl 2, 7 dianiline phenazine. In some even further implementations, the liquid medium includes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and an aniline-functional viologen. The electrical voltage applied across the transparent electrically conductive coating and theliquid medium causes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and the aniline- functional viologen to combine and electro-form the electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate. In other further implementations, the liquid medium includes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and a monoaniline viologen. The electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and the monoaniline viologen to combine and electro-form the electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.

[0066] In some implementations, the electrochromic medium comprises the electrically conductive polymer and one or more electrically conductive layers. The one or more electrically conductive layers may include one or more selected from the group consisting of (i) tungsten trioxide (WO3), (ii) niobium pentoxide (Nb20s), (iii) titanium dioxide (Tit ), (iv) molybdenum trioxide (MoOs), (v) vanadium pentoxide (V2O5), (vi) iridium dioxide (IrCh), (vii) nickel oxide (NiO), (viii) rhodium oxide (Rt s), (ix) nickel hydroxide (Ni(OH)2) and (x) cobalt oxide (CoOx).

[0067] In some implementations, the electrochromic medium comprises a viologen. The viologen may include an aniline-modified viologen. The viologen may include a polyaniline viologen. The viologen may include a monoaniline viologen. In some implementations, the viologen is disposed in the liquid medium. The electrical voltage applied across the transparent electrically conductive coating and the liquid medium traps the viologen with the electrically conductive polymer during electro-formation of the electrically conductive polymer. The viologen may comprise a pendant viologen disposed in the liquid medium. The electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the pendant viologen to react with the monomer during electroformation of the electrically conductive polymer. Further, the liquid medium may include an aqueous solution.

[0068] In some aspects, a sealing layer encapsulates the transparent electrically conductive coating, the electrochromic medium and the electrically conductive mirrorreflector between the second side of the single glass substrate and the sealing layer. The sealing layer may include an optically clear adhesive.

[0069] In some examples, a first electrical connector is electrically connected to the transparent electrically conductive coating. A second electrical connector is electrically connected to the electrically conductive mirror reflector.

[0070] According to another aspect, a method for manufacturing an electrochromic mirror reflective element for a vehicular rearview mirror assembly includes providing a single glass substrate. The single glass substrate includes a first side and a second side opposite the first side. A transparent electrically conductive coating is disposed at the second side of the single glass substrate. The method includes electro-forming an electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate. The method includes applying an electrically conductive mirror reflector at the electrochromic medium at the second side of the single glass substrate. The electrochromic medium is disposed between the electrically conductive mirror reflector and the transparent electrically conductive coating disposed at the second side of the single glass substrate.

[0071] In some examples, the electrochromic mirror reflective element comprises part of a vehicular interior rearview mirror assembly that is configured for mounting at an interior portion of a vehicle. In other examples, the electrochromic mirror reflective element comprises part of a vehicular exterior rearview mirror assembly that is configured for mounting at an exterior portion of a vehicle.

[0072] In some implementations, electro-forming the electrochromic medium at the second side of the single glass substrate comprises (i) disposing the single glass substrate in a liquid medium that includes a monomer and (ii) applying an electrical voltage across the transparent electrically conductive coating and the liquid medium to polymerize the monomer and electro-form an electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate. In further implementations, the monomer comprises 3,4- Ethylenedioxythiophene (EDOT) molecules. The electrically conductive polymer comprises a Poly 3,4-Ethylenedioxythiophene (PEDOT) network. Further, the electrical voltageapplied across the transparent electrically conductive coating and the liquid medium causes the formation of the PEDOT network from the EDOT molecules.

[0073] In some implementations, the liquid medium includes the EDOT molecules and a salt. The salt may comprise potassium nitrate (KNO3). For example, the liquid medium may include 0.25M KNO3 to 0.01 M EDOT molecules. In some implementations, the EDOT molecules are modified with a viologen.

[0074] In some further implementations, the monomer comprises 5, 10 dihydro dimethyl 2, 7 dianiline phenazine. In further implementations, the liquid medium includes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and an aniline-functional viologen. The electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and the aniline- functional viologen to combine and electro-form the electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.

[0075] In some implementations, the electrochromic medium comprises the electrically conductive polymer and one or more electrically conductive layers. The one or more electrically conductive layers may include one or more selected from the group consisting of (i) tungsten trioxide (WO3), (ii) niobium pentoxide (Nb20s), (iii) titanium dioxide (Tit ), (iv) molybdenum trioxide (MoOs), (v) vanadium pentoxide (V2O5), (vi) iridium dioxide (IrCh), (vii) nickel oxide (NiO), (viii) rhodium oxide (Rh^Os), (ix) nickel hydroxide (Ni(OH)2) and (x) cobalt oxide (CoOx).

[0076] In some implementations, the electrochromic medium comprises a viologen. The viologen may include an aniline-modified viologen. The viologen may include a polyaniline viologen. The viologen may include a monoaniline viologen. In some implementations, the viologen is disposed in the liquid medium. The electrical voltage applied across the transparent electrically conductive coating and the liquid medium traps the viologen with the electrically conductive polymer during electro-formation of the electrically conductive polymer.

[0077] In some further implementations, the viologen comprises a pendant viologen disposed in the liquid medium. The electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the pendant viologen to reactwith the monomer molecules during electro-formation of the electrically conductive polymer.

[0078] In some implementations, the electrical voltage comprises a DC voltage between 0.9 volts and 1 .5 volts. The electrical voltage may be applied for less than or equal to 15 minutes. In some implementations, the liquid medium contains 3,4- Ethylenedioxythiophene (EDOT) molecules and potassium nitrate molecules.

[0079] In some implementations, the method further includes securing the single glass substrate at a holder and at least partially submerging the holder and the single glass substrate in the liquid medium. Further, prior to at least partially submerging the holder and the single glass substrate in the liquid medium, the method includes at least partially submerging the holder and the single glass substrate in a first rinse bath to remove chemicals and debris from the single glass substrate. After at least partially submerging the holder and the single glass substrate in the liquid medium, the method may further include at least partially submerging the holder and the single glass substrate in a second rinse bath. After at least partially submerging the holder and the single glass substrate in the second rinse bath, the method may further include applying heat to the single glass substrate to cure the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate upon cooling. The holder and the single glass substrate may be transported between the first rinse bath, the liquid medium and the second rinse bath via a monorail system.

[0080] In some implementations, the holder comprises a first housing portion and a second housing portion joined together with the single glass substrate disposed between the first housing portion and the second housing portion. A portion of the second side of the single glass substrate is exposed via a window of the first housing portion. Further, the holder may include a first seal disposed between the first housing portion and the second housing portion and outboard of at least a portion of the single glass substrate. Moreover, the holder may include a second seal disposed between the second side of the single glass substrate and the first housing portion and circumscribing the window of the first housing portion. The second seal may engage the transparent electrically conductive coating at the second side of the single glass substrate.

[0081] In some implementations, a tab area of the single glass substrate extends outboard of the first seal and away from the holder to be exposed outside of the liquid medium. An electrical connector may be attached to the tab area for applying the electrical voltage across the transparent electrically conductive coating.

[0082] In some implementations, an electrical connector is disposed between the first housing portion and the second housing portion and engages the transparent electrically conductive coating at the second side of the sing glass substrate for applying the electrical voltage across the transparent electrically conductive coating.

[0083] Optionally, the single glass substrate is secured at the holder during the step of applying the electrically conductive mirror reflector at the electrochromic medium. With the electrically conductive polymer electro-formed at the transparent electrically conductive coating at the second side of the single glass substrate, the method further includes removing the single glass substrate from the holder. After removing the single glass substrate from the holder, the method may further include dispensing conductive epoxy at a portion of the transparent electrically conductive coating and dispensing conductive epoxy at a portion of the electrically conductive mirror reflector, and disposing a first electrical connector at the conductive epoxy at the portion of the transparent electrically conductive coating, and disposing a second electrical connector at the conductive epoxy at the portion of the electrically conductive mirror reflector. The method may further include attaching a first wire to the first electrical connector and attaching a second wire to the second electrical connector. The method may include applying a sealing layer at the second side of the single glass substrate. The sealing layer encapsulates the transparent electrically conductive coating, the electrochromic medium, the electrically conductive mirror reflector, the first electrical connector, the second electrical connector, a portion of the first wire, and a portion of the second wire between the second side of the single glass substrate and the sealing layer. In some implementations, the liquid medium includes an aqueous solution.

[0084] In some examples, the method further includes applying a sealing layer to the second side of the single glass substrate to encapsulate the transparent electrically conductive coating. The electrochromic medium and the electrically conductive mirror reflector are between the second side of the single glass substrate and the sealing layer.The sealing layer may include an optically clear adhesive. The method may further include disposing a first electrical connector at the transparent electrically conductive coating and disposing a second electrical connector at the electrically conductive mirror reflector.

[0085] The mirror casing may include a bezel portion that circumscribes a perimeter region of the front surface of the reflective element, or the perimeter region of the front surface of the reflective element may be exposed (such as by utilizing aspects of the mirror reflective elements described in U.S. Pat. Nos. 8,508,831 and / or 8,730,553, and / or U.S. Publication Nos. US-2014-0022390; US-2014-0293169 and / or US-2015-0097955, which are hereby incorporated herein by reference in their entireties).

[0086] The mirror assembly may comprise any suitable construction, such as, for example, a mirror assembly with the reflective element being nested in the mirror casing and with a bezel portion that circumscribes a perimeter region of the front surface of the reflective element, or with the mirror casing having a curved or beveled outermost exposed perimeter edge around the reflective element and with no overlap onto the front surface of the reflective element (such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 7,184,190; 7,274,501 ; 7,255,451 ; 7,289,037; 7,360,932; 7,626,749;8,049,640; 8,277,059 and / or 8,529,108, which are hereby incorporated herein by reference in their entireties) or such as a mirror assembly described in U.S. Pat. Nos. 9,827,913;9,174,578; 8,508,831 ; 8,730,553; 9,598,016 and / or 9,346,403, and / or U.S. Des. Pat. Nos. D633,423; D633,019; D638,761 and / or D647,017, which are hereby incorporated herein by reference in their entireties (and with electrochromic and prismatic mirrors of such construction are commercially available from Magna Mirrors of America, Inc. of Holland, Ml USA under the trade name INFINITY™ mirror).

[0087] As discussed above, the mirror assembly may comprise an electro-optic or electrochromic mirror assembly that includes an electro-optic or electrochromic variably reflective mirror reflective element. The variably reflective mirror reflective element of the mirror assembly may utilize aspects of the mirror reflective elements described in commonly assigned U.S. Pat. Nos. 7,626,749; 7,274,501 ; 7,255,451 ; 7,195,381 ;7,184,190; 6,690,268; 5,140,455; 5,151 ,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360; 5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673; 5,073,012; 5,115,346; 5,724,187;5,668,663; 5,910,854; 5,142,407 and / or 4,712,879, and / or U.S. Publication No. US-2022- 0371513, which are hereby incorporated herein by reference in their entireties.

[0088] Changes and modifications in the specifically described embodiments may be carried out without departing from the principles of the present invention, which is intended to be limited only by the scope of the appended claims as interpreted according to the principles of patent law.

Claims

CLAIMS:1 . An electrochromic mirror reflective element for a vehicular rearview mirror assembly, the electrochromic mirror reflective element comprising: a single glass substrate having a first side and a second side opposite the first side, wherein a transparent electrically conductive coating is disposed at the second side of the single glass substrate; an electrochromic medium disposed at and contacting the transparent electrically conductive coating at the second side of the single glass substrate, wherein the electrochromic medium comprises an electrically conductive polymer; an electrically conductive mirror reflector disposed at and contacting the electrochromic medium that is disposed at the second side of the single glass substrate, wherein the electrochromic medium is disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector; and wherein the electrochromic medium disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector is electro-formed.

2. The electrochromic mirror reflective element of claim 1 , wherein the electrochromic mirror reflective element comprises part of a vehicular interior rearview mirror assembly that is configured for mounting at an interior portion of a vehicle.

3. The electrochromic mirror reflective element of claim 1 , wherein the electrochromic mirror reflective element comprises part of a vehicular exterior rearview mirror assembly that is configured for mounting at an exterior portion of a vehicle.

4. The electrochromic mirror reflective element of claim 1 , wherein the electrochromic medium disposed between the transparent electrically conductive coating and the electrically conductive mirror reflector is electro-formed by (i) disposing the single glass substrate in a liquid medium that includes a monomer and (ii) applying an electrical voltage across the transparent electrically conductive coating and the liquid medium to polymerize the monomer and electro-form an electrically conductive polymer that provides theelectrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.

5. The electrochromic mirror reflective element of claim 4, wherein the monomer comprises 3,4-Ethylenedioxythiophene (EDOT) molecules, and wherein the electrically conductive polymer comprises a Poly 3,4-Ethylenedioxythiophene (PEDOT) network.

6. The electrochromic mirror reflective element of claim 5, wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes formation of the PEDOT network from the EDOT molecules.

7. The electrochromic mirror reflective element of claim 5, wherein the liquid medium includes the EDOT molecules and a salt.

8. The electrochromic mirror reflective element of claim 7, wherein the salt comprises potassium nitrate (KNOs).

9. The electrochromic mirror reflective element of claim 8, wherein the liquid medium includes 0.25M KNO3 to 0.01 M EDOT molecules.

10. The electrochromic mirror reflective element of claim 5, wherein the EDOT molecules are modified with a viologen.11 . The electrochromic mirror reflective element of claim 4, wherein the monomer comprises 5, 10 dihydro dimethyl 2, 7 dianiline phenazine.

12. The electrochromic mirror reflective element of claim 11 , wherein the liquid medium includes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and an aniline-functional viologen, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and the aniline-functional viologen to combine and electro-form the electricallyconductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.

13. The electrochromic mirror reflective element of claim 11 , wherein the liquid medium includes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and a monoaniline viologen, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and the monoaniline viologen to combine and electro-form the electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.

14. The electrochromic mirror reflective element of claim 4, wherein the electrochromic medium comprises the electrically conductive polymer and one or more electrically conductive layers.

15. The electrochromic mirror reflective element of claim 14, wherein the one or more electrically conductive layers includes one or more selected from the group consisting of (i) tungsten trioxide (WO3), (ii) niobium pentoxide (Nb20s), (iii) titanium dioxide (TiC ), (iv) molybdenum trioxide (MoOa), (v) vanadium pentoxide (V2O5), (vi) iridium dioxide (lrC>2), (vii) nickel oxide (NiO), (viii) rhodium oxide (Rh^Os), (ix) nickel hydroxide (Ni(OH)2) and (x) cobalt oxide (CoOx).

16. The electrochromic mirror reflective element of claim 4, wherein the electrochromic medium comprises a viologen.

17. The electrochromic mirror reflective element of claim 16, wherein the viologen comprises an aniline-modified viologen.

18. The electrochromic mirror reflective element of claim 16, wherein the viologen comprises a polyaniline viologen.

19. The electrochromic mirror reflective element of claim 16, wherein the viologen comprises a monoaniline viologen.

20. The electrochromic mirror reflective element of claim 16, wherein the viologen is disposed in the liquid medium, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium traps the viologen with the electrically conductive polymer during electro-formation of the electrically conductive polymer.21 . The electrochromic mirror reflective element of claim 16, wherein the viologen comprises a pendant viologen disposed in the liquid medium, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the pendant viologen to react with the monomer during electro-formation of the electrically conductive polymer.

22. The electrochromic mirror reflective element of claim 4, wherein the liquid medium comprises an aqueous solution.

23. The electrochromic mirror reflective element of claim 1 , wherein a sealing layer encapsulates the transparent electrically conductive coating, the electrochromic medium and the electrically conductive mirror reflector between the second side of the single glass substrate and the sealing layer.

24. The electrochromic mirror reflective element of claim 23, wherein the sealing layer comprises an optically clear adhesive.

25. The electrochromic mirror reflective element of claim 1 , wherein a first electrical connector is electrically connected to the transparent electrically conductive coating, and wherein a second electrical connector is electrically connected to the electrically conductive mirror reflector.

26. A method for manufacturing the electrochromic mirror reflective element of any of claims 1-25.

27. A method for manufacturing an electrochromic mirror reflective element for a vehicular rearview mirror assembly, the method comprising: providing a single glass substrate, wherein the single glass substrate comprises a first side and a second side opposite the first side, and wherein a transparent electrically conductive coating is disposed at the second side of the single glass substrate; electro-forming an electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate; and applying an electrically conductive mirror reflector at the electrochromic medium at the second side of the single glass substrate, wherein the electrochromic medium is disposed between the electrically conductive mirror reflector and the transparent electrically conductive coating disposed at the second side of the single glass substrate.

28. The method of claim 27, wherein the electrochromic mirror reflective element comprises part of a vehicular interior rearview mirror assembly that is configured for mounting at an interior portion of a vehicle.

29. The method of claim 27, wherein the electrochromic mirror reflective element comprises part of a vehicular exterior rearview mirror assembly that is configured for mounting at an exterior portion of a vehicle.

30. The method of claim 27, wherein electro-forming the electrochromic medium at the second side of the single glass substrate comprises (i) disposing the single glass substrate in a liquid medium that includes a monomer and (ii) applying an electrical voltage across the transparent electrically conductive coating and the liquid medium to polymerize the monomer and electro-form an electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.31 . The method of claim 30, wherein the monomer comprises 3,4- Ethylenedioxythiophene (EDOT) molecules, and wherein the electrically conductive polymer comprises a Poly 3,4-Ethylenedioxythiophene (PEDOT) network.

32. The method of claim 31 , wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes formation of the PEDOT network from the EDOT molecules.

33. The method of claim 31 , wherein the liquid medium includes the EDOT molecules and a salt.

34. The method of claim 33, wherein the salt comprises potassium nitrate (KNO3).

35. The method of claim 34, wherein the liquid medium includes 0.25M KNO3 to 0.01 MEDOT molecules.

36. The method of claim 31 , wherein the EDOT molecules are modified with a viologen.

37. The method of claim 30, wherein the monomer comprises 5, 10 dihydro dimethyl 2,7 dianiline phenazine.

38. The method of claim 37, wherein the liquid medium includes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and an aniline-functional viologen, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the 5, 10 dihydro dimethyl 2, 7 dianiline phenazine and the aniline- functional viologen to combine and electro-form the electrically conductive polymer that provides the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate.

39. The method of claim 30, wherein the electrochromic medium comprises the electrically conductive polymer and one or more electrically conductive layers.

40. The method of claim 39, wherein the one or more electrically conductive layers includes one or more selected from the group consisting of (i) tungsten trioxide (WO3), (ii) niobium pentoxide (Nb20s), (iii) titanium dioxide (TiC ), (iv) molybdenum trioxide (MoOs), (v) vanadium pentoxide (V2O5), (vi) iridium dioxide (IrOs), (vii) nickel oxide (NiO), (viii) rhodium oxide (Rt s), (ix) nickel hydroxide (Ni(OH)2) and (x) cobalt oxide (CoOx).41 . The method of claim 30, wherein the electrochromic medium comprises a viologen.

42. The method of claim 41 , wherein the viologen comprises an aniline-modified viologen.

43. The method of claim 41 , wherein the viologen comprises a polyaniline viologen.

44. The method of claim 41 , wherein the viologen comprises a monoaniline viologen.

45. The method of claim 41 , wherein the viologen is disposed in the liquid medium, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium traps the viologen with the electrically conductive polymer during electro-formation of the electrically conductive polymer.

46. The method of claim 41 , wherein the viologen comprises a pendant viologen disposed in the liquid medium, and wherein the electrical voltage applied across the transparent electrically conductive coating and the liquid medium causes the pendant viologen to react with the monomer during electro-formation of the electrically conductive polymer.

47. The method of claim 30, wherein the electrical voltage comprises a DC voltage between 0.9 volts and 1.5 volts.

48. The method of claim 30, wherein the electrical voltage is applied for less than or equal to 15 minutes.

49. The method of claim 30, wherein the liquid medium contains 3,4- Ethylenedioxythiophene (EDOT) molecules and potassium nitrate molecules.

50. The method of claim 30, further comprising securing the single glass substrate at a holder and at least partially submerging the holder and the single glass substrate in the liquid medium.51 . The method of claim 50, further comprising, prior to at least partially submerging the holder and the single glass substrate in the liquid medium, at least partially submerging the holder and the single glass substrate in a first rinse bath to remove chemicals and debris from the single glass substrate.

52. The method of claim 51 , further comprising, after at least partially submerging the holder and the single glass substrate in the liquid medium, at least partially submerging the holder and the single glass substrate in a second rinse bath.

53. The method of claim 52, further comprising, after at least partially submerging the holder and the single glass substrate in the second rinse bath, applying heat to the single glass substrate to cure the electrochromic medium at the transparent electrically conductive coating at the second side of the single glass substrate upon cooling.

54. The method of claim 52, wherein the holder and the single glass substrate are transported between the first rinse bath, the liquid medium and the second rinse bath via a monorail system.

55. The method of claim 50, wherein the holder comprises a first housing portion and a second housing portion joined together with the single glass substrate disposed between the first housing portion and the second housing portion, and wherein a portion of thesecond side of the single glass substrate is exposed via a window of the first housing portion.

56. The method of claim 55, wherein the holder includes a first seal disposed between the first housing portion and the second housing portion and outboard of at least a portion of the single glass substrate.

57. The method of claim 56, wherein the holder includes a second seal disposed between the second side of the single glass substrate and the first housing portion and circumscribing the window of the first housing portion.

58. The method of claim 57, wherein the second seal engages the transparent electrically conductive coating at the second side of the single glass substrate.

59. The method of claim 56, wherein a tab area of the single glass substrate extends outboard of the first seal and away from the holder to be exposed outside of the liquid medium.

60. The method of claim 59, wherein an electrical connector is attached to the tab area for applying the electrical voltage across the transparent electrically conductive coating.61 . The method of claim 55, wherein an electrical connector is disposed between the first housing portion and the second housing portion and engages the transparent electrically conductive coating at the second side of the sing glass substrate for applying the electrical voltage across the transparent electrically conductive coating.

62. The method of claim 50, wherein the single glass substrate is secured at the holder during the step of applying the electrically conductive mirror reflector at the electrochromic medium.

63. The method of claim 50, further comprising, with the electrically conductive polymer electro-formed at the transparent electrically conductive coating at the second side of the single glass substrate, removing the single glass substrate from the holder.

64. The method of claim 63, further comprising, after removing the single glass substrate from the holder, dispensing conductive epoxy at a portion of the transparent electrically conductive coating and dispensing conductive epoxy at a portion of the electrically conductive mirror reflector, and disposing a first electrical connector at the conductive epoxy at the portion of the transparent electrically conductive coating, and disposing a second electrical connector at the conductive epoxy at the portion of the electrically conductive mirror reflector.

65. The method of claim 64, further comprising attaching a first wire to the first electrical connector and attaching a second wire to the second electrical connector.

66. The method of claim 65, further comprising applying a sealing layer at the second side of the single glass substrate, the sealing layer encapsulating the transparent electrically conductive coating, the electrochromic medium, the electrically conductive mirror reflector, the first electrical connector, the second electrical connector, a portion of the first wire, and a portion of the second wire between the second side of the single glass substrate and the sealing layer.

67. The method of claim 30, wherein the liquid medium comprises an aqueous solution.

68. The method of claim 27, further comprising applying a sealing layer to the second side of the single glass substrate to encapsulate the transparent electrically conductive coating, the electrochromic medium and the electrically conductive mirror reflector between the second side of the single glass substrate and the sealing layer.

69. The method of claim 68, wherein the sealing layer comprises an optically clear adhesive.

70. The method of claim 27, further comprising disposing a first electrical connector at the transparent electrically conductive coating and disposing a second electrical connector at the electrically conductive mirror reflector.

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