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 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 vision system for a vehicle includes a first imager located at a front portion of the vehicle, a second imager located at the rear of the vehicle, a third imager located in a first exterior rearview mirror assembly of the vehicle and a fourth imager located in a second exterior rearview mirror assembly of the vehicle. Responsive to the vehicle being shifted into a reverse gear, (a) video images derived from image data captured by the second imager are displayed on a video display screen and (b) responsive at least in part to processing of captured image data by a common image processor, the driver of the vehicle is alerted to the presence of an object exterior the equipped vehicle. When the vehicle travels forward, the common image processor processes first image data captured by the first imager for at least a lane departure warning 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 variable reflectance vehicular electro-optic rearview mirror reflective element assembly includes a front substrate and a rear substrate with a perimeter seal disposed therebetween. The front substrate has a first surface and a second surface opposite the first surface, with the second surface having a transparent electrically conductive coating disposed thereat. The rear substrate has a third surface and a fourth surface, with the third surface having a conductive reflector coating disposed thereat. The reflector coating may include a plurality of layers having first and second layers of nickel chromium. The front substrate may have a perimeter band disposed along a perimeter region of the second surface. The perimeter band may include a plurality of layers having first and second layers of nickel chromium.

Abstract: A method of coating a rear glass substrate for an electrochromic reflective element includes providing a fixture having a recess and a masking element extending from a perimeter region of the recess over a portion of the recess. The masking element includes a disc portion and an arm portion extending between the disc portion and the perimeter region of the recess of the fixture. A rear glass substrate is positioned in the recess and the masking element extends over and is spaced from the surface of the glass substrate. The glass substrate surface is coated with a mirror reflector coating. The masking element is shaped such that the mirror reflector coating is deposited at the surface behind the arm portion but is substantially not deposited behind the disc portion so as to establish a window region through the mirror reflector coating at the glass substrate surface.

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 vision system for a vehicle includes at least a first imager, an image processor, and at least a second imager. The first imager has a field of view through the windshield of the vehicle in the direction of forward travel of the vehicle. The second imager captures video images of a scene occurring exteriorly and rearwardly of the vehicle. When the vehicle is executing a reversing maneuver, the image processor processes image data captured by the second imager to detect objects in the exterior scene to assist the driver in reversing the vehicle, and when the vehicle is traveling forward, the image processor and the first imager are part of at least one of (i) a headlamp control system of the vehicle, (ii) a rain sensing system of the vehicle, (iii) a lane departure warning system of the vehicle and (iv) a traffic sign recognition system of the vehicle.

Abstract: A variable reflectance vehicular electro-optic rearview mirror reflective element assembly includes a front substrate and a rear substrate and a perimeter seal disposed therebetween. The front substrate has a first surface and a second surface that has a transparent electrically conductive coating disposed thereat. The rear substrate has a third surface and a fourth surface, with the third surface having a conductive coating disposed thereat. The perimeter seal spaces the front and rear substrates apart and forms an interpane cavity therebetween. The third surface conductive coating includes a plurality of layers, which includes a first layer of nickel chromium. The first layer of nickel chromium is overcoated with a silver or silver alloy layer, and the silver or silver alloy layer is overcoated with a second layer of nickel chromium, and the second layer of nickel chromium is overcoated with a reflective layer.

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 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: An exterior rearview mirror assembly includes a variable reflectance mirror reflective element. A mirror reflector of the mirror reflective element includes a stack of thin films having at least two thin films. At least one of the thin films is formed of a material that has a specific resistivity of less than about 1×10?2 ohm·cm, and at least one of the thin films is a thin metal film. An electrochromic medium is disposed in an interpane cavity of the mirror reflective element and is bounded by a perimeter seal. A reflective perimeter layer is disposed at a second surface of a front substrate proximate a perimeter edge of the front substrate. The perimeter layer generally conceals the perimeter seal from view by a driver of the vehicle normally viewing the front substrate when the exterior rearview mirror assembly is mounted at the vehicle.

Abstract: A method of sputter coating a glass substrate includes providing a glass substrate and providing a sputtering assembly for sputtering a coating onto the glass substrate in a vacuum deposition chamber. The sputtering assembly includes a backing plate and a separating element disposed on the backing plate. At least one target element is provided and disposed at and in contact with a surface of the separating element. The target element is not bonded the separating element when disposed at and in contact with the surface of the separating element. An expansion gap is provided at or adjacent to the target element to allow for expansion of the target element during the sputtering process. Material from the target element is sputtered and the target element is heated to a substantially elevated temperature during the sputtering process. The sputtering process coats a surface of the glass substrate with the target element material.

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 method of coating a rear glass substrate for an electrochromic reflective element includes providing a fixture having a recess and a masking element extending from a perimeter region of the recess over a portion of the recess. The masking element includes a disc portion and an arm portion extending between the disc portion and the perimeter region of the recess of the fixture. A rear glass substrate is positioned in the recess and the masking element extends over and is spaced from the surface of the glass substrate. The glass substrate surface is coated with a mirror reflector coating. The masking element is shaped such that the mirror reflector coating is deposited at the surface behind the arm portion but is substantially not deposited behind the disc portion so as to establish a window region through the mirror reflector coating at the glass substrate surface.

Abstract: An exterior mirror reflective element includes front and rear substrates and a mirror reflector having a stack of thin films. No part of the rear substrate extends beyond any part of the front substrate. A perimeter layer is disposed at a second surface of the front substrate proximate a perimeter edge of 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 to a person viewing the reflective element when no voltage is applied to the electrochromic medium. The substantially non-spectrally selective reflectance characteristic is established by the refractive index and physical thickness of the individual thin films of the stack of thin films. At least a portion of the mirror reflector extends out under the seal towards a perimeter edge of the rear substrate.

Abstract: A system and method for sputtering a coating onto a glass substrate in a vacuum deposition chamber includes providing a backing plate with a separating element disposed at the backing plate. At least one target element or tile is disposed on a surface of the separating element, wherein an expansion gap is provided to allow for expansion of the target relative to the separating element during the sputtering process. The method includes sputtering material from the target and heating the target to a substantially elevated temperature during the sputtering process. The separating element may be a sheet having a low-coefficient of friction surface, and the target may be disposed on the low-coefficient of friction surface of the separating element. The separating element may thermally insulate the target from the backing plate, whereby the target may be heated to a substantially greater temperature than the backing plate during the sputtering 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 rearview mirror assembly for a vehicle includes an electrochromic reflective element having a specularly reflective perimeter layer established at least partially around a perimeter border region of a second surface of a front substrate. The perimeter layer is, at least in part, visible through the front substrate to a viewer when viewing the first surface of the front substrate of the reflective element. The perimeter layer conceals at least a portion of the seal from direct view by the driver of the vehicle. At least one of (a) at least one light source is disposed behind the perimeter layer and emits light that is visible to a viewer viewing the first surface of the front substrate of the reflective element at the perimeter layer, and (b) a light sensor is disposed behind the perimeter layer and senses light that passes through the front substrate at the perimeter layer.

Abstract: An exterior mirror reflective element includes front and rear substrates and a mirror reflector having a stack of thin films. No part of the rear substrate extends beyond any part of the front substrate. A perimeter layer is disposed at a second surface of the front substrate proximate a perimeter edge of 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 to a person viewing the reflective element when no voltage is applied to the electrochromic medium. The substantially non-spectrally selective reflectance characteristic is established by the refractive index and physical thickness of the individual thin films of the stack of thin films. At least a portion of the mirror reflector extends out under the seal towards a perimeter edge of the rear substrate.