Abstract: A method of making a mirror reflective element suitable for use in a vehicular exterior rearview mirror assembly includes providing front and rear substrates, and disposing an electrically conductive layer and a metallic reflector at respective surfaces thereof. With the substrates joined and with an electrochromic medium disposed in an interpane cavity, light that reflects off of the mirror reflector and passes through the electrochromic medium and the front substrate is non-spectrally selective when no voltage is applied to the electrochromic medium. At least a portion of the mirror reflector extends under the perimeter seal and towards a perimeter edge of the rear substrate. A display is disposed to the rear of the rear substrate of the mirror reflective element at a light-transmitting window. The display is operable responsive to a blind spot detector of a vehicle equipped with an exterior rearview mirror assembly that incorporates the mirror reflective element.

Abstract: A process for filling an electro-optic rearview mirror reflective element assembly includes providing an unfilled mirror cell and providing a filling element having a fluid reservoir, a mirror cell receiving portion, and a channel that provides fluid communication between the fluid reservoir and the mirror element receiving portion. The unfilled mirror cell and the filling element and compressible sealing element are positioned in a vacuum chamber such that the mirror cell receiving portion receives an upper portion of the unfilled mirror cell. Negative pressure is established in the vacuum chamber and electro-optic fluid is provided at the fluid reservoir of the filling element, with the fluid flowing through the channel and passageway and fill port to fill an interpane cavity of the mirror cell with electro-optic fluid. After filling the interpane cavity, the filling element and sealing element are removed and the fill port is plugged.

Abstract: A variable reflectance exterior mirror reflective element suitable for use in a vehicular exterior rearview mirror assembly a front substrate and a rear substrate and an electrochromic medium disposed therebetween. A mirror reflector is disposed at a third surface of the rear substrate. A perimeter layer is disposed at a second surface of the front substrate proximate a perimeter edge and generally conceals the perimeter seal from view by a person viewing through the front substrate. Light that reflects off of the mirror reflector and passes through the electrochromic medium and the front substrate exhibits a substantially non-spectrally selective reflectance characteristic when no voltage is applied to the electrochromic medium. A display is disposed proximate a fourth surface of the rear at a light-transmitting portion of the mirror reflector established by laser ablation. The display is configured to be operated responsive to a blind spot detector of the vehicle.

Abstract: An interior rearview mirror assembly for a vehicle includes a mirror-display assembly adapted to pivotally attach at an interior surface of the vehicle. The mirror-display assembly includes a mirror reflective element and a display device that has a display screen. The mirror reflective element is disposed at a mirror side of the mirror-display assembly and the display screen is disposed at a display side of the mirror-display assembly. The mirror-display assembly is pivotable between a mirror position and a display position. When the mirror-display assembly is in the mirror position, a driver of the vehicle views the mirror reflective element and does not view the display screen, and when the mirror-display assembly is in the display position, the driver of the vehicle views the display screen and does not view the mirror reflective element. The mirror-display assembly pivots about a pivot axis between the mirror position and the display position.

Abstract: A rearview mirror assembly for a vehicle includes a mirror reflective element having a first glass substrate and a second glass substrate with an electro-optic medium sandwiched therebetween and bounded by a perimeter seal. The first glass substrate has a first surface and a second surface and the second glass substrate has a third surface and a fourth surface. The second surface has a transparent electrically conductive coating that opposes and contacts the electro-optic medium and the third surface has an electrically conductive coating that opposes and contacts the electro-optic medium. A front substrate has a rounded perimeter edge region that has a radius of curvature of at least 2.5 mm and that spans between a front side and a rear side of the front substrate. The rear side of the front substrate is adhesively attached at the first surface of the first glass substrate of the mirror reflective element.

Abstract: A mirror reflective element assembly for a vehicle includes an electrically variable reflectance mirror reflective element that includes front and rear substrates with an electrochromic medium disposed therebetween and bounded by a perimeter seal. A perimeter layer is disposed at a second surface of the front substrate proximate a perimeter edge of the front substrate that conceals the perimeter seal from view by a driver of a vehicle. At least a portion of the mirror reflector extends from under the perimeter seal outward towards at least a portion of the perimeter edge of the rear substrate. The mirror reflective element includes a more curved outboard region and a less curved inboard region. A laser-etched demarcation may demarcate the more curved outboard region of the mirror reflective element from the less curved inboard region of the mirror reflective element.

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

Abstract: An exterior rearview mirror assembly suitable for a vehicle includes an attachment portion and a casing portion having a variable reflectance mirror reflective element. A mirror reflector is disposed at at least a portion of a surface of a rear substrate of the reflective element. The mirror reflector includes a stack of thin films having at least a first metal thin film and a second metal thin film. The first metal thin film is formed of a metal material that has a specific resistivity of less than about 1×10?3 ohm·cm and the second metal thin film is formed of a metal material that has a specific resistivity of less than about 1×10?3 ohm·cm. No part of the rear substrate extends beyond any part of a front substrate of the reflective element. An indicator is disposed rearward of the reflective element and, when actuated, illuminates through the reflective element.

Abstract: A process for filling an electro-optic rearview mirror reflective element assembly includes providing an unfilled mirror cell and providing a filling element having a fluid reservoir, a mirror cell receiving portion, and a channel that provides fluid communication between the fluid reservoir and the mirror element receiving portion. The unfilled mirror cell and the filling element and compressible sealing element are positioned in a vacuum chamber such that the mirror cell receiving portion receives an upper portion of the unfilled mirror cell. Negative pressure is established in the vacuum chamber and electro-optic fluid is provided at the fluid reservoir of the filling element, with the fluid flowing through the channel and passageway and fill port to fill an interpane cavity of the mirror cell with electro-optic fluid. After filling the interpane cavity, the filling element and sealing element are removed and the fill port is plugged.

Abstract: A method for making electrical connection to a mirror reflective element for a vehicular rearview mirror assembly includes providing a mirror reflective element having a front substrate and a rear substrate with an electro-optic medium disposed therebetween and in contact with a transparent conductive coating and a third surface reflector. A metallic electrical connector is provided that includes an attachment portion and a wire receiving portion. An electrical wire is inserted in the wire receiving portion such that at least one tang of the wire receiving portion engages the electrical wire to secure the electrical wire in the wire receiving portion and to make electrically-conductive connection with the electrical wire. The attachment portion is attached at the front or rear substrate to attach the electrical connector at the mirror reflective element such that the attachment portion electrically conductively connects to the transparent conductive coating or the third surface reflector.

Abstract: A mirror element sub-assembly for a vehicular exterior rearview mirror assembly includes a mirror reflective element, a mirror back plate and an indicator. The front side of the mirror back plate includes a reflective element attaching portion and the rear side of the mirror back plate includes (i) an actuator attaching portion and (ii) an indicator attaching portion, all of which are integrally formed during injection molding of the mirror back plate. The indicator attaching portion includes structure extending from the rear side of the mirror back plate and having a passageway therethrough. The indicator is attached at the structure, and light emitted by the indicator passes through the passageway and through an opening of the mirror back plate and through the mirror reflective element so as to exit from the mirror reflective element at an angle relative to the reflective element attaching portion.

Abstract: A system for filling a variable reflectance vehicular electro-optic element assembly (such as for a rearview mirror assembly) includes a front substrate, a rear substrate and a perimeter seal disposed between the front and rear substrates. The perimeter seal spaces the front and rear substrates apart and forms an interpane cavity therebetween. The perimeter seal has a gap between terminal ends of the perimeter seal to provide a fill port for the mirror reflective element assembly when the front and rear substrates are mated together. The fill port allows an electro-optic medium to flow therethrough during the filling process. During the filling process, the front and rear substrates are fixtured in a chamber with the fill port disposed at an upper portion of the front and rear substrates, with the filling process being one of (i) a gravity feed filling process and (ii) a pressurized filling process.

Abstract: A reflective element assembly for a vehicular rearview mirror assembly includes front and rear substrates with an electro-optic medium disposed therebetween. An electrical connector has an attachment portion and a wire receiving portion for receiving an electrical wire therein. A flange of the attachment portion is configured to be disposed at a fourth surface of the rear substrate and a tab is configured to extend at least partially across a perimeter edge of the rear substrate. An electrically conductive material is disposed in an uncured state and uncured electrically conductive material flows at least partially through the aperture and is cured to secure the electrical connector at the rear substrate. The wire receiving portion of the electrical connector is configured to receive the electrical wire therein and includes at least one tang that engages the electrical wire when the electrical wire is inserted into the wire receiving portion.

Abstract: A variable reflectance exterior mirror reflective element suitable for use in a vehicular exterior rearview mirror assembly a front substrate and a rear substrate and an electrochromic medium disposed therebetween. A mirror reflector is disposed at a third surface of the rear substrate. A perimeter layer is disposed at a second surface of the front substrate proximate a perimeter edge and generally conceals the perimeter seal from view by a person viewing through the front substrate. Light that reflects off of the mirror reflector and passes through the electrochromic medium and the front substrate exhibits a substantially non-spectrally selective reflectance characteristic when no voltage is applied to the electrochromic medium. A display is disposed proximate a fourth surface of the rear at a light-transmitting portion of the mirror reflector established by laser ablation. The display is configured to be operated responsive to a blind spot detector of the vehicle.

Abstract: An exterior rearview mirror system for a vehicle includes an exterior rearview mirror assembly configured for attachment at a side of the vehicle and having a mirror reflective element housed by a mirror shell formed of plastic. The mirror reflective element includes at least one glass substrate and a mirror reflector established at a surface of the at least one glass substrate. A turn signal display element is provided in a moldable form and integrated into the mirror shell. The turn signal display element includes a plurality of printable light emitting diodes and is operable to function as a turn signal indicator that illuminates when a driver of the vehicle activates a turn signal system of the vehicle.

Abstract: A variable reflectance mirror reflective element for a vehicular exterior rearview mirror assembly includes a front substrate and a rear substrate, with an electrochromic medium disposed therebetween. A mirror reflector is disposed at a third surface of the rear substrate and includes a stack of thin films and has a sheet resistance of less than about 5 ohms per square. Light that reflects off of the mirror reflector and passes through the electrochromic medium and the front substrate exhibits a substantially non-spectrally selective reflectance characteristic to a person viewing the exterior mirror reflective element when no voltage is applied to the electrochromic medium. At least a portion of the mirror reflector extends out under the seal towards a perimeter edge of the rear substrate. An electrical connection, which may include a conductive epoxy, is made to the portion of the mirror reflector outboard of the perimeter seal.

Abstract: A rearview mirror assembly for a vehicle includes a mirror reflective element having at least one glass substrate and a mirror reflector established at a surface of said at least one glass substrate. The mirror assembly includes a display element disposed at the rear of the mirror reflective element and operable to emit light that is viewable through the mirror reflective element. The display element includes a printable light emitting diode. The mirror assembly may include at least one of (a) a printable electrically conductive layer at a surface of the at least one glass substrate, (b) a printable heater pad established at a rear surface of the at least one glass substrate, (c) a printable touch sensor and (d) a moldable light emitting diode element.

Abstract: A sun visor assembly for a vehicle includes a front transparent glass substrate having first and second surfaces and a rear transparent glass substrate having third and fourth surfaces, with an electro-optic medium sandwiched between the second surface of the front glass substrate and the third surface of the rear glass substrate. A vanity mirror including a mirror reflector is established at one of (i) the first surface of the front glass substrate and (ii) the second surface of the front glass substrate. When not electrically powered, the electro-optic medium is substantially transparent, and when electrically powered, the electro-optic medium is darkened so as to have reduced light transmission. When the electro-optic medium behind the mirror reflector is darkened, the mirror reflector is usable as a vanity mirror by a user of the sun visor.

Abstract: An interior rearview mirror system for a vehicle includes an interior rearview mirror assembly having a mirror head with a mirror reflective element. The mirror reflective element includes a transflective mirror reflector. A video display screen is disposed behind the mirror reflective element and is operable for displaying video images viewable through the transflective mirror reflector of the mirror reflective element. When not operated to display video images, the presence of the video display screen behind the mirror reflective element is rendered covert by the transflective mirror reflector. The interior rearview mirror assembly includes a mechanism operable to change the orientation of the mirror reflective element relative to the vehicle driver. The mechanism operates to flip the orientation of the mirror reflective element between a first position that is tilted towards the vehicle driver and a second position that is tilted away from the vehicle driver.

Abstract: A variable reflectance mirror reflective element for a vehicular exterior rearview mirror assembly includes a front substrate and a rear substrate, with an electrochromic medium disposed therebetween. A mirror reflector is disposed at a third surface of the rear substrate and includes a stack of thin films and has a sheet resistance of less than about 5 ohms per square. Light that reflects off of the mirror reflector and passes through the electrochromic medium and the front substrate exhibits a substantially non-spectrally selective reflectance characteristic to a person viewing the exterior mirror reflective element when no voltage is applied to the electrochromic medium. At least a portion of the mirror reflector extends out under the seal towards a perimeter edge of the rear substrate. An electrical connection, which may include a conductive epoxy, is made to the portion of the mirror reflector outboard of the perimeter seal.