WO2025231198A1 - Vehicular interior rearview mirror assembly with spectral-selective mirror reflective element - Google Patents
Vehicular interior rearview mirror assembly with spectral-selective mirror reflective elementInfo
- Publication number
- WO2025231198A1 WO2025231198A1 PCT/US2025/027206 US2025027206W WO2025231198A1 WO 2025231198 A1 WO2025231198 A1 WO 2025231198A1 US 2025027206 W US2025027206 W US 2025027206W WO 2025231198 A1 WO2025231198 A1 WO 2025231198A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- mirror
- interior rearview
- thin film
- mirror assembly
- rearview mirror
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R1/00—Optical viewing arrangements; Real-time viewing arrangements for drivers or passengers using optical image capturing systems, e.g. cameras or video systems specially adapted for use in or on vehicles
- B60R1/02—Rear-view mirror arrangements
- B60R1/08—Rear-view mirror arrangements involving special optical features, e.g. avoiding blind spots, e.g. convex mirrors; Side-by-side associations of rear-view and other mirrors
- B60R1/083—Anti-glare mirrors, e.g. "day-night" mirrors
- B60R1/088—Anti-glare mirrors, e.g. "day-night" mirrors using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R1/00—Optical viewing arrangements; Real-time viewing arrangements for drivers or passengers using optical image capturing systems, e.g. cameras or video systems specially adapted for use in or on vehicles
- B60R1/02—Rear-view mirror arrangements
- B60R1/04—Rear-view mirror arrangements mounted inside vehicle
-
- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B5/00—Optical elements other than lenses
- G02B5/20—Filters
- G02B5/26—Reflecting filters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R1/00—Optical viewing arrangements; Real-time viewing arrangements for drivers or passengers using optical image capturing systems, e.g. cameras or video systems specially adapted for use in or on vehicles
- B60R1/12—Mirror assemblies combined with other articles, e.g. clocks
- B60R2001/1223—Mirror assemblies combined with other articles, e.g. clocks with sensors or transducers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R1/00—Optical viewing arrangements; Real-time viewing arrangements for drivers or passengers using optical image capturing systems, e.g. cameras or video systems specially adapted for use in or on vehicles
- B60R1/12—Mirror assemblies combined with other articles, e.g. clocks
- B60R2001/1253—Mirror assemblies combined with other articles, e.g. clocks with cameras, video cameras or video screens
Definitions
- the present invention relates generally to the field of interior rearview mirror assemblies for vehicles.
- 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 via a 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.
- the mirror casing and reflective element are pivotable about either or both of the ball pivot joints by a user that is adjusting a rearward field of view of the reflective element.
- a vehicular interior rearview mirror assembly includes a mounting structure configured to mount the vehicular interior rearview mirror assembly at an interior portion of a cabin of a vehicle.
- a mirror head accommodates a mirror reflective element that includes a glass substrate having a first surface and a second surface. The second surface is opposite the first surface and is separated from the first surface by a thickness of the glass substrate, and a spectral-selective mirror transflector is disposed at the second surface of the glass substrate.
- the spectral-selective mirror transflector comprises a stack of dielectric coatings comprising a higher refractive index (at 589 nm) oxide coating coated on a soda-lime glass surface, upon which is coated a lower refractive index (at 589 nm) oxide coating, and optionally upon which is coated a higher refractive index (at 589 nm) oxide coating.
- the mirror transflector may comprise a stack of dielectric thin film coatings comprising a first coating of an oxide of niobium (e.g., Nb2O5), a second coating of an oxide of silicon (e.g., SiO2) and a third coating of an oxide of niobium (e.g., Nb2O5).
- the first coating is closer to the second surface than the second and third coatings, and the second coating is sandwiched between the first coating and the third coating.
- the mirror head may accommodate a video display screen that is electrically operable to display video images for viewing by the driver.
- the video display screen When the mirror assembly is operating in a mirror mode, the video display screen is not activated, so that reflections at the mirror reflective element provide the rearward view for the driver.
- the video display screen When the mirror assembly is operating in a display mode, the video display screen is electrically operated to display video images representative of the rearward view for viewing by the driver through the spectral-selective mirror transflector of the mirror reflective element.
- the mirror head may covertly accommodate a cabin monitoring camera (e.g., a driver monitoring camera or an occupant monitoring camera or a combined driver monitoring / occupant monitoring camera) that views the driver of the vehicle through the spectral-selective mirror transflector.
- Image data captured by the driver monitoring camera is processed to determine attentiveness of the driver of the vehicle.
- near-infrared light emitters are covertly accommodated by the mirror head.
- the near-infrared light emitters when electrically operated, emit near-infrared light that passes through the spectral-selective mirror transflector to illuminate at least a portion of the driver of the vehicle.
- FIG. 1 is a perspective view of an interior rearview mirror assembly
- FIG. 2A is a table showing mirror properties for different material mirror reflectors at a zero degree incidence angle
- FIG. 2B is another table showing mirror properties for different material mirror reflectors at a 25 degree incidence angle;
- FIG. 3 is a schematic showing properties of a blue mirror that has the mirror reflective element coated with an Nb2O5 stack of coatings;
- FIG. 4 is a graph that overlays the blue mirror properties
- FIG. 5 is a graph showing the blue mirror properties with properties of typical
- FIG. 6 shows the reflective color coordinates in CIE LAB color space for the different types of mirror reflectors
- FIGS. 7A and 7B show CIE D65 sunlight representative standard llluminant per CIE 1931 with a 2 degree observer;
- FIG. 8A shows a Monte Carlo tolerance study of physical thickness variances for an example of the blue mirror with an Nb2O5 stack of coatings
- FIG. 8B shows a Monte Carlo tolerance study of physical thickness variance and color for the example of the blue mirror with an Nb2O5 stack of coatings
- FIG. 9 shows a comparison of indices of refraction for different Nb2O5 coatings and TiO2 coatings
- FIG. 10 is a graph showing the reflection spectrum for the different mirror reflector constructions
- FIG. 11 is a graph showing the transmission spectrum for the different mirror reflector constructions
- FIG. 12 is a stack profile showing a physical thickness profile of the blue mirror stack of coatings
- FIGS. 13 and 14 show properties of an example blue mirror with an Nb2O5- SiO2-Nb2O5 stack of coatings
- FIGS. 15 and 16 show properties of an example mirror with an TiO2-SiO2-TiO2 stack of coatings
- FIGS. 17 and 18 show properties of an example mirror with a layer of silver (Ag);
- FIGS. 19 and 20 show properties of an example mirror with a layer of chromium
- FIG. 21 is a stack profile showing a physical thickness profile of another blue mirror stack of coatings
- FIGS. 22 and 23 show properties of an example mirror with S i-S iO2 stack of coatings; [0028] FIG. 24 shows thicknesses and indexes of refraction of the layers of the blue mirror element;
- FIG. 25 is a stack profile showing a physical thickness profile of another blue mirror stack of coatings
- FIGS. 26 and 27 show properties of an example mirror with an Si-SiO2-Nb2O5- SiO2-Nb2O5 stack of coatings
- FIG. 28 is a graph showing the effects of adding a silver layer to an electrochromic mirror cell
- FIG. 29 is a schematic of a mirror assembly having a fourth surface reflector and a driver monitoring camera disposed behind the mirror reflective element and viewing through a region of the mirror reflective element that is devoid of the fourth surface reflector and that has a stack of thin film layers or coatings thereat;
- FIG. 30 is a table and graph showing reflectivity and transmissivity properties of silver coatings or films of various thicknesses.
- FIG. 31 is a table and graph showing reflectivity and transmissivity properties of silicon coatings or films of various thicknesses.
- an interior rearview mirror assembly 10 for a vehicle includes a mirror head 12 that includes a casing 14 and a mirror reflective element 16 positioned at a front portion of the casing 14 (FIG. 1 ).
- 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 a vehicle 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 substrate (preferably a glass substrate) that is coated on one side (e.g., the second or rear surface of the substrate) with a stack of thin film layers or coatings.
- the layers may include a first, higher refractive index (at 589 nm) coating at the glass (e.g., a layer of an oxide of niobium such as Nb2O5), with a second, lower refractive index (at 589 nm) coating (e.g., a layer of an oxide of silicon such as SiO2) coated at the first coating or layer, and with a third, higher refractive index (at 589 nm) coating (e.g., another layer of an oxide of niobium such as Nb2O5) coated at the second coating or layer, with the physical thicknesses of the layers or coatings selected to provide the desired color-tinted spectral appearance and reflectance and transmission properties of the mirror reflective element.
- a first, higher refractive index (at 589 nm) coating at the glass e.g., a layer of an oxide of niobium such as Nb2O5
- the mirror reflective element 16 comprises a glass substrate having a front or first planar surface (the surface that generally faces the driver of the vehicle when the mirror assembly is normally mounted at the vehicle) and a rear or second planar surface opposite the first surface, where the first surface and the second surface may be parallel to one another.
- the second surface has the spectral-selective mirror reflector or transflector coating, established thereat for reflecting at least a portion of light incident at the glass substrate to provide the reflections for viewing by the driver of the vehicle.
- mirror reflective element may comprise a single glass substrate, and the single glass substrate may comprise a curved or bent substrate or a prismatic substrate (where the rear surface is not parallel to the front surface).
- the mirror reflective element may be non-planar, convex-curved so as to give a wide angle rearward view for the driver of the vehicle.
- the curvature of the glass substrate of the mirror reflective element may be a free-form curvature, such as a curved glass substrate formed utilizing aspects of the mirrors and systems described in U.S. Pat. Nos. 10,166,924; 9,487,142 and/or 8,917,437, which are hereby incorporated herein by reference in their entireties.
- the mirror head 12 may accommodate a video display screen 20 that is operable to display video images that are viewable by the driver of the vehicle through the mirror reflective element 16.
- the video display screen 20 when operated, displays video images that are viewable at a display region 22, which encompasses at least about 75 percent of the reflective region, or at least about 85 percent of the reflective region, or at least about 95 percent of the reflective region.
- the interior rearview mirror assembly may comprise a dual-mode mirror assembly, where the mirror assembly is operable in a mirror mode or a display mode.
- the mirror assembly when operating in the mirror mode, the mirror reflective element reflects the rearward view to the driver of the vehicle, and when operating in the display mode, the video display screen operates to display video images that are viewable through the spectral-selective mirror transflector of the mirror reflective element for viewing by the driver of the vehicle.
- the mirror is provided with a video display screen that is disposed behind and is viewable through the mirror reflective element.
- the mirror head 12 may be tiltable or pivotable between a mirror mode orientation, where the reflective element 16 is positioned to provide reflections for the desired driver’s rearward field of view, and a display mode orientation, where the mirror head is tilted upward (or downward) from the mirror mode orientation, such that video images displayed at the display screen 20 are viewable by the driver while the reflective element 16 reflects light from rearward of the vehicle and incident thereon upward or downward away from the driver’s eyes.
- the mirror head 12 may be tiltable or pivotable between the mirror mode orientation and the display mode orientation via a toggle element 22.
- the mirror head 12 may be manually pivotable between the mirror mode orientation and the display mode orientation by a user grasping the toggle element 22 to pivot the mirror head 12.
- the single glass substrate may comprise a prismatic substrate (where the rear surface of the substrate is not parallel to the front surface of the substrate) or may comprise a planar substrate (where the rear surface of the substrate is parallel to the front surface of the substrate).
- Such video mirrors include a backlit LCD display screen, and a particular form of video mirror is a full display mirror (such as a ClearViewTM Interior Rearview Mirror Assembly available from Magna Mirrors of America, Inc. of Holland, Ml USA, or an FDM TM Interior Rearview Mirror Assembly available from Gentex Corporation of Zeeland, Ml USA), where the video display screen fills or substantially fills the reflective region (e.g., fills or encompasses at least about 75 percent of the reflective region, or at least about 85 percent of the reflective region, or at least about 95 percent of the reflective region), such as by utilizing aspects of the mirror assemblies and systems described in U.S. Pat. Nos.
- the video display screen 20 of the video mirror when the mirror is operating in the display mode, may display video images derived from video image data captured by a rearward viewing camera, such as a rearward camera disposed at a center high-mounted stop lamp (CHMSL) location, and/or video image data captured by one or more other cameras at the vehicle, such as side-mounted rearward viewing cameras or the like, such as by utilizing aspects of the display systems described in U.S. Pat. No. 11 ,242,008, which is hereby incorporated herein by reference in its entirety.
- a rearward viewing camera such as a rearward camera disposed at a center high-mounted stop lamp (CHMSL) location
- video image data captured by one or more other cameras at the vehicle such as side-mounted rearward viewing cameras or the like
- the operating mode of the mirror and video display screen may be selected by actuation of a user actuatable input (e.g., a touch input or button or switch at the mirror head) or by flipping the mirror head upward or downward (e.g., via a toggle located at the mirror head), or responsive to another user input.
- a user actuatable input e.g., a touch input or button or switch at the mirror head
- flipping the mirror head upward or downward e.g., via a toggle located at the mirror head
- the video display screen 20 is deactivated and rendered covert by the mirror reflective element 16, and the driver views rearward via reflection of light incident at the mirror reflective element 16.
- the video display screen 20 is operated to display video images that are viewable through the mirror reflective element 16 by the driver of the vehicle.
- the video display screen 20 is accommodated within the mirror head and behind the glass substrate of the mirror reflective element 16 and the spectral-selective mirror transflector coating allows at least a portion of light incident thereat to pass through the glass substrate so that, when the video display screen 20 is operated to display video images, the video images are viewable through the mirror reflective element 16.
- the spectral-selective mirror transflector coating at the glass substrate at least partially hides or renders covert the video display screen 20 so that the driver may not be able to view the video display screen 20 and instead views reflections at the mirror reflective element 16.
- the mirror head 12 When the mirror head 12 is operating in the mirror mode, the mirror head 12 is positioned so that the mirror reflective element 16 provides a desired field of view rearward of the vehicle to the driver and the video display screen 20 is not operated.
- the video display screen 20 When the mirror head 12 is toggled or switched or controlled to operate in the display mode, the video display screen 20 is operated so that video images at the video display screen 20 are viewable by the driver (and optionally the mirror head may be pivoted upward or downward relative to the mirror mode orientation so that the reflections from the mirror reflective element are directed upward or downward away from view of the driver).
- the video display screen 20 may be automatically operated upon movement of the mirror head 12 to the display mode orientation or responsive to another user input.
- the mirror head 12 may be manually pivotable between the mirror mode orientation and the display mode orientation by grasping a toggle element and pivoting the mirror head 12 about the mounting base. Responsive to the mirror head 12 being moved to a display mode orientation, the display screen 20 may be automatically operated to display video images and, responsive to the mirror head 12 being moved away from the display orientation, the display screen 20 may cease operation. In some examples, the mirror head 12 may be moved between the mirror mode orientation and the display mode orientation via operation of an actuator, such as by utilizing characteristics of U.S. Pat. No. 10,442,360, which is incorporated herein by reference in its entirety.
- the mirror reflective element 16 may comprise a single glass substrate with a single surface spectral-selective mirror transflector and may not include an electrically operable dimming mechanism (such as a dimmable electrochromic medium) such that the reflections from the spectral-selective transflector coating of the mirror reflective element are not electronically dimmable.
- the video images displayed at the mirror assembly 10 may be representative of the rearward field of view provided by the mirror assembly and the video images may be digitally adjusted to dim the displayed images, such as to account for glare from headlights of other vehicles following the equipped vehicle.
- the mirror reflective element includes a transflective spectral-selective mirror transflector disposed at a side (preferably disposed on the rear side/surface or second side/surface) of the reflective element glass substrate, with the transflective spectral- selective mirror transflector provides a high level of transmission of visible light, such as at least 30 percent transmission, preferably 40 percent transmission, preferably at least 50 percent transmission, while also providing sufficient photopic reflectance, such as being at least 42 percent reflectant (as determined in accordance with SAE Recommended Practice J964 (Mar2024), which is hereby incorporated herein by reference in its entirety) of visible light incident thereat, preferably at least 45 percent reflectant of visible light incident thereat, and more preferably at least 48 percent reflectant of visible light incident thereat.
- the transflective spectral-selective mirror transflector preferably comprises a trilayer stack of dielectric coatings or oxides.
- the glass substrate may comprise soda-lime glass having a physical thickness of at least 1 .6 mm, such as a physical thickness of 1 .6 mm or 1 .8 mm or 2 mm or 2.3 mm or 2.5 mm or 3 mm (or more or less), with the second or rear surface of the glass substrate coated with a stack of thin film layers or coatings.
- the layers of the tri-layer stack have a first, higher refractive index (at 589 nm) coating or layer coated at the glass surface (e.g., a layer of an oxide of niobium such as Nb2O5), with a second, lower refractive index (at 589 nm) coating or layer (e.g., a layer of an oxide of silicon such as SiO2) coated at the first coating or layer, followed by a third, higher refractive index (at 589 nm) coating or layer (e.g., another layer of an oxide of niobium such as Nb2O5) coated at the second coating or layer, with the physical thicknesses of the layers or coatings selected to provide the desired color-tinted spectral appearance and reflectance and transmission properties of the mirror reflective element in both the visible spectral region of light and the near infrared spectral region of light.
- a first, higher refractive index (at 589 nm) coating or layer coated at the glass surface e.g
- the coatings and physical thicknesses may be selected to provide a blue colored or tinted automotive mirror that uses a 3-layer thin film dielectric oxide coating that meets the minimum industry reflectivity requirements of greater than 35% (as determined for FMVSS 111 in accordance with SAE Recommended Practice J964 (Mar2024), which are both hereby incorporated herein by reference in their entireties), with increased transmission for use with displays and cameras, including near-infrared cameras.
- Typical mirror reflective elements may, for example, use a relatively thin metallic silver (Ag) coating to achieve reflectivity and transmission for displays showing through the mirror.
- Chromium (Cr) versions may have lower reflectivity.
- Design 1 of FIG. 2A is the visible light transmission, visible light reflectivity, absorption, color and near IR transmission of a ClearViewTM dual-mode electrochromic interior rearview mirror assembly (with the reflectivity and color values as experienced by a driver viewing the subject mirror within a vehicle).
- the mirror reflective element 12 preferably provides a “blue mirror” (that has a blue tint when viewed by the driver of the vehicle).
- the blue mirror may have a tri-layer stack of Nb2O5 (as the higher refractive index (at 589 nm) coating) and SiO2 (as the lower refractive index (at 589 nm) coating), or may have a tri-layer stack of TiO2 (as the higher refractive index (at 589 nm) coating) and SiO2 (as the lower refractive index (at 589 nm) coating). See FIGS. 2A and 2B for comparison of exemplary typical mirrors and examples of the blue mirrors. See FIG. 3 for details on an example of the Nb2O5 blue mirror.
- the absorption of the silver (Ag) based coating (having a physical thickness of 200nm) is 17% as compared to the dielectric designs of 2% and 4%, and the chromium (having a physical thickness of 200nm) has 41 % absorption.
- the lower absorption of the oxide dielectrics can be used to increase the transmission of visible light through the mirror from a display or lights behind the mirror.
- the reflection can be kept to meet requirements or even slightly increased while also increasing the transmission. In this case the transmission is increased 10% from the baseline design #1 to a preferred design #2 (FIGS. 2A and 2B).
- near-infrared transmission (e.g., 940 nm) may be at least
- the dielectric coatings using oxides of niobium are able to achieve a higher reflectivity than the oxides of titanium (e.g., TiO2) coatings because Nb2O5 has a higher index of refraction (n) according to this table of indices:
- Previous mirrors for driver monitoring system and passenger safety monitoring system have included near infrared LEDs covertly disposed behind the mirror reflective element and transmitting near IR light through the mirror reflector coating.
- a camera is also covertly disposed behind the mirror reflective element and views through the mirror reflector and receives near infrared (NIR) light that passes through the mirror reflector coating.
- NIR near infrared
- transmission of near infrared light at 940nm is used.
- the dielectric designs can achieve significant increases in efficiency at this wavelength leading to decreased NIR LED power needs and less sensitive cameras, reducing system costs including heat sink sizes and increasing feasibility of DMS/OMS systems.
- the exemplary design shown in FIG. 3 provides 82% transmission of near infrared light at 940nm.
- the transmissive color can be compensated in both displays and cameras using color balance. An important factor is variability.
- the spectrum of headlights are a key consideration.
- the design represented in FIG. 5 emphasizes the blue portion over the yellow portion of the headlight spectrum, reducing yellow glare.
- Color is defined by the CIELAB color space, also referred to as L*a*b*, which is a color space defined by the International Commission on Illumination (abbreviated CIE).
- the L*a*b* expresses color as three values: L* for perceptual lightness and a* and b* for the four unique colors of human vision: red, green, blue and yellow.
- ISO/CIE 11664-2 Colorimetry - Part 2 CIE standard illuminants.
- Optical thin films including dielectric oxides deposited on glass substrates via mass production using sputter deposition, is a preferred technology.
- the process produces variance for optical film physical thickness that must be considered.
- Experience has shown that less than 7% variance is achievable, while the thin film industry is achieving as low as 3% variance.
- This variance has been considered for the blue mirror design and is presented in various charts.
- the target is to maintain greater than 40% reflectivity of visible light while also maintaining at least 45% transmissivity of visible light and at least 70% transmissivity of near infrared light (e.g., at 940 nm).
- Tooling factor variations are made to thin film designs based on the exact process at a particular manufacturer. This may involve a variation in the actual index of refraction produced (see FIG. 9). As the index approaches that of TiO2 there is risk regarding meeting the reflectivity minimum of 40%. This risk is partly counteracted by the increased nominal reflectivity of the preferred design at 47%, allowing more portability between manufacturers. See FIGS. 10 and 11 for graphs of the reflection spectrum and transmission spectrum for various mirror constructions.
- the physical thickness of the glass substrate and the coatings or layers are selected to provide the desired appearance and properties of the mirror reflective element, such as when operating in the display mode and when operating in the mirror mode for a dual-mode rearview mirror assembly.
- the blue mirror Nb2O5 stack may have the first (glass side) coating of Nb2O5 at a physical thickness of 43 nm, the second (middle) coating of SiO2 at a physical thickness of 79 nm, and the third (outer) coating of Nb2O5 at a physical thickness of 47 nm (for a total stack physical thickness of about 169 nm).
- FIG. 12 shows the stack profile for this example.
- FIG. 13 shows the percent transmission and percent reflectance for an example Nb2O5 spectral-selective mirror transflector (comprising a thin film stack that includes a layer of Nb2O5 at the glass having a physical thickness of 47 nm, a layer of SiO2 having a physical thickness of 79 nm, and a layer of Nb2O5 having a physical thickness of 43 nm) on a glass substrate
- FIG. 14 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles.
- the physical thicknesses may vary depending on the particular application, such as by plus or minus three percent, or by plus or minus 5 percent, or by plus or minus 8 percent (preferably less than plus or minus 20 percent, more preferably less than plus or minus 15 percent, and more preferably less than plus or minus 10 percent).
- Nb205 reflective elements with different thickness of glass, and with the second surface coated with the thin film layers (similar results would be achieved if the first surface were coated).
- the visible spectrum is evaluated between 380nm and 750nm wavelengths.
- the visible average reflection R is obtained by taking the sum of reflection coefficients in this range and dividing by the number of sample points
- the visible average transmission T is obtained by taking the sum of transmission coefficients in this range and dividing by the number of sample points.
- the illumination source for reflection and transmission percentages is perfect white light. Conversion to photopic with A illuminant and 1924 CIE photopic observer as in SAE J964 has not been performed. Also, the incident angle of measurement for the design is 0 degrees according to the common practice for designing optical thin films.
- Color is as determined by ISO/CIE 11664-4:2019 Colorimetry - Part 4: CIE 1976 L*a*b* colour space using the D65 sunlight representative standard llluminant per CIE 1931 with a 2 degree observer (see FIGS. 7A and 7B).
- FIG. 15 shows the percent transmission and percent reflectance for an example TiO2 spectral-selective mirror transflector (comprising a thin film stack that includes a layer of TiO2 at the glass having a physical thickness of 49 nm, a layer of SiO2 having a physical thickness of 84.4 nm, and a layer of Ti02 having a physical thickness of 44.3 nm) on a glass substrate, and
- FIG. 16 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles.
- FIG. 17 shows the percent transmission and percent reflectance for an example silver (Ag) mirror reflector (having a thickness of 200 nm) on a glass substrate
- FIG. 18 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles
- FIG. 19 shows the percent transmission and percent reflectance for an example chromium mirror reflector (having a thickness of 200 nm) on a glass substrate
- FIG. 20 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles.
- an automotive mirror (whether an electrically-dimmable automotive mirror (such as an electrochromic automotive mirror or a liquid crystal automotive mirror) or a fixed- reflectance automotive mirror (such as a prismatic automotive mirror)) utilizing a blue- tinted spectrally-selective mirror reflective element of the present invention is at least 42%R, more preferably is at least 44%R and most preferably is at least 46%R.
- the glass substrate may be coated with a stack of two layers or coatings: a first layer of silicon deposited on the glass surface and a second layer of silicon dioxide (SiO2) deposited on the first layer of silicon.
- the first layer (the elemental silicon layer) is, for example, less than 30 nm thick, such as, for example, 27 nm (see FIG. 21 ).
- the second layer (the SiO2 layer) is relatively thin compared to the first layer, such as for example less than 20 nm, preferably less than 15 nm, and more preferably less than 10 nm (but at least 1 nm, and preferably at least 5 nm).
- Such a mirror reflective element has a light blue tint (viewing at the first surface of the glass substrate) and has greater than 35% visible light transmission, preferably greater than 40% visible light transmission, and more preferably greater than 45% visible light transmission (see FIGS. 22 and 23).
- the mirror reflective element also has greater than 50% near infrared light transmission (at 940 nm), preferably greater than 55% near infrared light transmission, and more preferably greater than 60% near infrared light transmission.
- near infrared light transmission at 940 nm
- the elemental silicon layer stack / construction enables near infrared light transmission (at 940 nm) of at least 50%, and does so without a metallic layer in the two- layer stack.
- a metallic layer is a thin film coating of a metal such as sliver or aluminum or chromium or titanium or tungsten.
- a metal oxide thin film coating of elemental silicon is not a metallic layer.
- a thin film coating of an oxide of silicon is not a metallic layer.
- a thin film coating of an oxide of niobium is not a metallic layer.
- a thin film coating of an oxide of titanium is not a metallic layer.
- a thin film coating of an oxide of tungsten is not a metallic layer.
- the two-layer stack is disposed at the first or front surface of the glass substrate.
- the elemental silicon layer is deposited on the glass substrate, and the SiO2 layer is deposited on the elemental silicon layer, providing a light blue tint with the transmission and reflection properties shown in FIGS. 22 and 23.
- the silicon thin coating layer has visible light reflectivity and visible light transmission and near infrared (at 940 nm) transmission based on thickness of the coating or layer, such as shown in FIG. 31.
- an elemental Germanium-Si02 bi-layer stack can be used.
- the relatively high refractive index (at 589 nm) of elemental silicon (3.698) and refractive index (at 589 nm) of Germanium (5.724) are useful in the optical stacks described herein due to their large difference between their optical constants and that of the likes of SiO2 (1 .461 ) and MgF2 (1 .378).
- a difference in refractive index (at 589 nm) between the higher refractive index (at 589 nm) layer and the adjacent lower refractive index (at 589 nm) layer of at least 0.5 is preferred, of at least 0.7 is more preferred, and of at least 1 is more preferred.
- a multi-layer stack of oxides of niobium and oxides of silicon may include a layer or coating of elemental silicon.
- a glass substrate e.g., a 1.6 mm soda-lime glass substrate
- a layer of elemental silicon e.g., a 13 nm Si layer
- a first layer of SiO2 e.g., a 20.8 nm SiO2 layer
- a first layer of Nb2O5 e.g., a 21 .1 nm Nb2O5 layer
- a second layer of SiO2 e.g., a 98.8 nm SiO2 layer
- a second layer of Nb2O5 e.g., a 27.6 nm Nb2O5 layer
- Such a stack of coatings (coated onto the second surface of the glass substrate) provides (at an angle of 25 degrees) 41 .4% visible light reflectivity viewing through the first surface of the glass substrate and 37.7% visible light transmission and 85.7% transmission of near infrared light (at 940 nm).
- Advantages of the blue-tinted spectrally-selective mirror reflective elements/constructions include that preferably no more than three thin film layers (one or more being a transparent oxide thin film and none a metallic thin film) are used to achieve the desired at least 43%R reflectivity level accompanied by greater than 45%T visible light transmission and greater than 70%T near-IR transmission at 940 nm.
- a thin silver layer is used as a third surface reflector in a laminate type electrochromic mirror cell (such as an electrochromic mirror cell of the types described in U.S. Pat. Nos. 7,626,749;
- the electrochromic mirror cell includes a front glass substrate (e.g., a 2.3 mm thick soda-lime glass substrate), which has a 85 nm transparent conductive layer (e.g., ITO) at the rear or second surface of the front glass substrate, and includes an electrochromic medium (e.g., a solid polymer matrix medium), with the rear glass substrate (e.g., a 2.3 mm thick soda-lime glass substrate) having the third surface reflector and a 110 nm transparent conductive layer (e.g., ITO) disposed on the third surface reflector and in contact with the electrochromic medium.
- the properties shown in FIG. 28 are for visible light reflectivity and visible light transmission and near infrared light transmission through the front glass substrate, the ITO coating at the second surface, the electrochromic medium, the ITO coating at the third surface reflector, and the third surface reflector at the rear glass substrate.
- a further advantage with use of the stacks described herein is that the materials used are environmentally stable and do not necessarily require encapsulating protective layers, such as needed for the likes of a thin film environmentally unstable material such as a silver thin film coating or the like.
- the tri-layer HI Refractive index (at 589 nm); LOW Refractive index (at 589 nm); HI Refractive index (at 589 nm) stack of coatings is deposited onto the second surface of the glass substrate used. This has the advantage of having the glass substrate itself protect the second-surface coated tri-layer of oxide thin films from scratching or environmental exposure or the like.
- the second-surface coated tri-layer of oxide thin films can be overcoated or blanked off by a dark colored visible light-absorbing element such as a dark colored lightabsorbing paint or lacquer or plastic film/molding.
- a dark colored visible light-absorbing element such as a dark colored lightabsorbing paint or lacquer or plastic film/molding.
- interior mirror such as of the types described in U.S. Pat. Nos. 11 ,827,153; 11 ,780,372; 11 ,639,134; 11 ,582,425; 11 ,518,401 ; 10,958,830; 10,065,574; 10,017,114; 9,405,120 and/or 7,914,187, and/or U.S. Publication Nos.
- the second-surface coated tri-layer stack of oxide thin films can be overcoated or blanked off by a near-IR transmitting dark plastic film/molding (such as for example, a black PMMA — Poly(methyl methacrylate) plastic film/molding).
- a near-IR transmitting dark plastic film/molding such as for example, a black PMMA — Poly(methyl methacrylate) plastic film/molding.
- the single glass substrate coated with, for example, the Nb2O5-SiO2-Nb2O5 stack of layers, provides a reduction in cost and complexity and weight of the likes of an electrochromic mirror element that comprises two glass substrates sandwiching an EC medium (such as the types of mirrors described in U.S. Pat. Nos.
- the image data as captured by the rearward-viewing camera may be image processed to determine ambient light (and/or glare light) present at the vehicle.
- image processing of captured image data can be used to appropriately dim intensity of backlighting of the video display screen to be appropriate for nighttime driving (such as by utilizing aspects of the systems described in U.S. Pat. Nos.
- a single ambient light detecting photosensor and associated simple electronics can be provided at the mirror assembly for adjusting backlighting intensities.
- ambient sensors already present in the vehicle can provide ambient sensing.
- ambient light levels can be estimated, and operation of the display screen may be adjusted based at least in part on the estimated ambient light levels.
- the field of view of the rearward-viewing camera may be wider than a rearward view provided by the mirror reflective element when the mirror is operating in the mirror mode.
- the mirror assembly may be adjustable (such as responsive to actuation of a switch or button or touch sensor) when operating in the display mode to set the displayed images to correspond to or represent the field of view that the mirror reflective element would provide in the mirror mode.
- the driver may push a button to set the video display to match what would be viewed if the mirror assembly were in the mirror mode.
- the interior rearview mirror assembly when installed and being used in a vehicle, may be selectively operated in a mirror-mimic mode, where the displayed video images correspond to or represent a view similar to what is provided to the driver when viewing the mirror assembly while it is operating in the mirror mode.
- the reflected view often includes portions of the interior of the vehicle at and around the rear window.
- the displayed video images at the mirror may not provide a frame of reference to what the driver would otherwise see when operating in the mirror mode.
- the displayed video images at the mirror reflective element mimic or match or correspond to the rearward mirror view provided when the interior rearview mirror assembly operates in the mirror mode.
- the display may be cropped and/or graphic overlays may be overlaid at the displayed video images to provide an appearance of portions of the interior of the vehicle at the rear window to provide the frame of reference that the driver is used to seeing when viewing a reflected rearward view at the mirror reflective element.
- the video display screen may turn on automatically, and the video images displayed at the mirror reflective element may be tailored to mimic the same rearward view as reflected off the mirror reflector of the mirror reflective element. This may be achieved with or without actuation of a toggle depending on the amount of glare mitigation desired and the glare detected.
- the displayed video images may be cropped and/or overlaid to provide the desired rearward view that generally corresponds to the reflected rearward view, and such cropping and overlays may be adjusted based on the driver’s eye location and gaze direction and preferred mirror head position (such as determined responsive to processing of image data captured by a driver monitoring camera at the mirror head and/or by other sensors within the vehicle that may determine an orientation of the mirror head).
- the displayed video images may be adjusted to mimic or replicate the reflected images.
- the video display screen may display wider angle views rearward of the vehicle that do not include graphic overlays to provide the interior frame of reference.
- the mirror assembly could automatically alternate modes or the mirror assembly could stay in video mode or mirror-mimic mode similar to the way a prismatic mirror stays in the night mode once it is flipped.
- any effect on the color may vary due to the transmission properties of the coatings and glass substrate. For example, it may appear as blue when looking at it one way, and may appear as a different color when viewed through the glass/coating.
- the system may adjust the color of the displayed images and/or may adjust the color balance of the rearward-viewing camera to mitigate/compensate color transmission through the spectral-selective mirror reflector and the glass substrate.
- the driver may choose to operate the mirror head in the mirror mode during daytime driving and choose to operate the mirror head in the display mode during nighttime driving, or the driver may choose to operate the mirror head in the display mode during daytime and nighttime driving and the video images may be adjusted based on glare light and/or ambient light detected at the mirror assembly.
- the driver may adjust the mirror head 12 from the mirror mode orientation to the display mode orientation so that reflections from the mirror reflective element may be directed generally upward toward the headliner of the vehicle and the display screen 20 may be operated to display video images representative of the view rearward of the vehicle.
- the mirror assembly may automatically switch to operating in the display mode (and the display screen may be activated) responsive to glare light being detected that is greater than a threshold level for the determined ambient light level.
- the display screen may be operated to adjust the color of the display screen and thus to adjust a background color of the mirror reflective element, such as to reduce reflections of glare light incident at the mirror reflective element. That is, based on determination or detection of glare light incident at the mirror reflective element, the display screen may be operated to display a color that better absorbs light incident at the mirror reflective element and thus reduces reflections of glare light incident thereat. For example, the backlight of the LCD display screen may be adjusted or operated to emit light at a color that absorbs or attenuates at least a portion of light incident at the mirror reflective element.
- the mirror assembly does not include an electrically operable dimming mechanism, the mirror assembly does not include circuitry, components or software associated with electronic dimming. This allows for cost and size reduction of the mirror assembly.
- the mirror assembly comprises a single surface spectral- selective reflector full video mirror vehicular interior rearview mirror assembly. Cost reduction is accomplished by providing a flat glass spectral-selective reflector and removing the electrochromic (EC) cell. By doing this, it allows for removal of the EC electrification circuitry, components, and software.
- the mirror assembly may have dual position toggle functionality. In the standard position, when the toggle has not been actuated, the mirror assembly may act as a single surface spectral-selective reflector interior mirror.
- the mirror When the toggle is actuated, the mirror is tilted upward (or optionally downward), which shifts the reflections from the interior rearview mirror assembly toward the vehicle’s headliner (or toward the floor of the vehicle).
- the actuation also powers on the video functionality, which provides to the driver a view from the vehicle’s camera or cameras, which may be located throughout the exterior of the vehicle (such as a rearward viewing camera).
- the mirror assembly may include a single glass substrate having a spectral-selective mirror reflector coating for providing reflections for viewing by the driver of the vehicle.
- a display screen is disposed behind the mirror reflective element for displaying video images representative of the rearward view that are viewable by the driver through the mirror reflective element.
- the mirror reflective element may include a single glass substrate without electrically operable dimming components, the mirror head may be pivotable relative to the mounting structure upward or downward to direct reflections upward or downward and away from view of the driver when the display screen is operated to display video images.
- the mirror reflective element and coatings are suitable for use in a mirror head that accommodates a driver monitoring camera and a near infrared (NIR) light emitter, such as by utilizing aspects of the systems described in U.S. Pat. Nos. 11 ,827,153; 11 ,780,372; 11 ,639,134; 11 ,582,425; 11 ,518,401 ; 10,958,830; 10,065,574; 10,017,114; 9,405,120 and/or 7,914,187, and/or U.S. Publication Nos.
- NIR near infrared
- a One-Box interior DMS prismatic rearview mirror assembly (having the camera used to monitor the driver's head/eyes and the near-IR emitting light sources that illuminate the driver’s head/eyes and the electronic control unit (ECU) accommodated by the interior rearview mirror assembly) or 1.5-Box interior DMS prismatic rearview mirror assembly can be made using no more than three, and optionally only two, thin film stacked coatings on the second surface of the wedge-shaped cross section glass substrate, with a viewer viewing the coated second surface seeing a blue-tinted reflection.
- the stack of coatings may include an elemental silicon thin film coating or coatings and/or an elemental Germanium thin film coating or coatings within the multi-layer stack comprising alternating dielectric coatings such as a stack of high refractive index (at 589 nm) dielectric coating - low refractive index (at 589 nm) dielectric coating - high refractive index (at 589 nm) dielectric coating.
- a DMS data processor is disposed at the ECU of the system for processing image data captured by the DMS camera.
- the DMS data processor may adjust or shift processing of image data captured by the camera based on the orientation of the mirror head (i.e. , when it is flipped up or down), so that the portion of the image data that is being processed for the driver monitoring system is representative of the desired monitored region in the vehicle cabin.
- a near-IR illumination source e.g., one or more light emitting diodes that emits near infrared light
- the near-IR illumination source when powered, illuminates at least a front seat region at a driver-side of the vehicle.
- the driver of the vehicle is monitored via processing by the DMS data processor of image data captured by the camera.
- the near-IR illumination source is powered while the camera is capturing image data.
- the near-IR illumination source may comprise a plurality of near-IR light emitters, such as a plurality of near-IR light emitting diodes.
- the alternating stack may comprise a stack of coatings such as niobium oxide or titanium oxide as the higher refractive index (at 589 nm) coating and silicon dioxide as the lower refractive index (at 589 nm) coating. Fewer layers are thus needed to achieve, viewing the first surface of the mirror reflective element, a desired spectrally neutral reflectivity (i.e. , silvery) or a non-spectrally neutral reflectivity (e.g., blue tinted).
- a desired spectrally neutral reflectivity i.e. , silvery
- a non-spectrally neutral reflectivity e.g., blue tinted
- the high transmission (about 82 percent) of nearinfrared (NIR) light of the spectral-selective mirror reflector allows the system to utilize a lower intensity near infrared light emitter and a camera having a lower sensitivity to near infrared light.
- a black out coating or tape may be applied to enhance the reflectivity at those regions.
- any “red glow” perceivable by the human eye using 940 nm illumination is less, and thus covertness of the near-IR emitting light sources within the mirror head emitting through the mirror transflector is enhanced.
- water absorbs 940 nm near-IR light, and thus solar radiation exhibits a dip at 940 nm in its irradiation spectrum due to moisture in the atmosphere.
- ambient solar lighting present in the cabin (and especially when driving on a sunny day in a convertible car with the top down) has a dip or valley at 940 nm which reduces any propensity of ambient solar lighting present in the cabin of the vehicle to interfere with DMS/ODS functionality.
- Quantum efficiency indicates the effectiveness of an imaging sensor’s conversion of incident photons of light into electrons (for example, if a sensor had a QE of 100% and is exposed to 100 photons, it will produce 100 electrons of signal).
- CMOS complementary metal-oxide semiconductor
- sensitivity in the near-infrared spectrum is limited by the absorption length in the silicon layer where, in the imaging sensor, impinging light photons generate electrons.
- QE in such conventional imaging sensors typically is below 15% and for some, below 10%.
- imaging sensors need to have a thicker photon absorption region in order to image efficiently in the near infrared (700 nm to 1 ,000 nm).
- increasing the Si thickness of the epi-Si layer of the substrate used in a CMOS imaging sensor to 3.0pm to 5.1 pm can increase QE by nearly 40% at the near-IR wavelength of 940nm.
- use of a thicker epi-Si layer is accompanied by a higher pixel bias voltage and/or a lower epi-Si doping level.
- Use of an anti-reflecting layer and/or backside scattering technology can increase the QE of the image sensor to greater than 40% at 940nm wavelength, which is around a 400% enhancement compared to a conventional CMOS imaging sensor.
- CMOS imaging sensors with enhanced near-IR sensitivity are preferred for use in the One-Box DMS Interior Rearview Mirror Assemblies.
- a near-IR optimized variant of a CMV4000 imaging sensor available from AMS AG of Premstaetten, Austria can be used.
- the CMV4000 imaging sensor is a high sensitivity, pipelined global shutter CMOS image sensor with 2048 x 2048 pixel resolution.
- a color version of the CMV4000 imaging sensor is used with the color filters applied in a Bayer RGB pattern, and with the in-mirror camera utilizing the micro lenses to image incident light onto the CMV4000 imaging sensor.
- the near-IR optimized variant from the standard CMV4000 image sensor is processed on 12 pm epi Si wafers.
- the thicker epi-Si layer increases significantly the QE for wavelengths above 600 nm. Around 900 nm the QE is about doubled and increases from 8% to 16%. Compared to cameras using imaging sensors that are not optimized for near-IR detection, this represents a doubling of the sensitivity value at around 940 nm.
- an EV76C660 imaging sensor or an EV76C661 imaging sensor available from Teledyne e2v SAS of Saint-Egreve Cedex, France can be used in the One- Box DMS Interior Rearview Mirror Assemblies.
- the EV76C661 imaging sensor is a 1.3 million pixel (square pixels with micro-lens) CMOS image sensor with an electronic global shutter and operable to provide a high readout speed at 60 fps in full resolution.
- the EV76C660 and EV76C661 are members of Teledyne e2v’s Ruby family of CMOS imaging sensors that provide enhanced sensitivity and performance beyond that typically available from a front side illuminated imaging sensor.
- FIG. 111 shows the spectral response and quantum efficiency of the EV76C660 imaging sensor and of the EV76C661 imaging sensor. Quantum Efficiency in the nearinfrared (NIR) spectrum is excellent (greater than 20% at 940 nm).
- NIR nearinfrared
- an OX05B1 S imaging sensor available from OMNIVISION of Santa Clara, CA USA can be used in the One-Box DMS Interior Rearview Mirror Assemblies.
- the OX05B1 S imaging sensor uses OMNIVISION’s NYXEL® near-infrared (NIR) technology.
- NYXEL® technology features QE improvements that increase sensitivity to the near-infrared spectrum, such improvements comprising utilization by the imaging sensor of thicker silicon to increases the chance of photon absorption; use by the imaging sensor of deep trench isolation to create a barrier between the pixels to eliminate crosstalk and improve modular transfer function; and use by the imaging sensor of a carefully managed optical scattering layer to prevent defects in the image’s dark area and to lengthen the photon path.
- the OX05B1 S is a 5 megapixel (MP) RGB-IR BSI global shutter imaging sensor and has a pixel size of 2.2 pm X 2.2 pm, and includes integrated cybersecurity.
- the OX05B1 S has a near-IR QE of 36%.
- a CMOS imaging sensor for use in the One-Box DMS Interior Rearview Mirror Assemblies preferably has a near-IR QE at around 940 nm of at least 15%, more preferably is at least 22%, and most preferably is at least about 32%.
- Thickness of the episilicon layer of a CMOS imaging sensor for use in the One-Box DMS Interior Rearview Mirror Assemblies preferably is at least about 3.5pm, more preferably is at least about 4.5pm, and most preferably is at least about 5.5pm.
- an interior electro-optic (e.g., electrochromic) rearview mirror assembly 110 may include a mirror reflective element 116 that has a front glass substrate 130 (e.g., a 1.6 mm thick glass substrate) and a rear glass substrate 132 (e.g., a 1.1 mm thick glass substrate), with an electro-optic medium 134 (e.g., an electrochromic solid polymer matrix (SPM) medium) sandwiched between the glass substrates and bounded by a perimeter seal 136.
- SPM electrochromic solid polymer matrix
- the front glass substrate 130 has an electrically conductive coating 138 (e.g., a half-wave ITO coating) at a rear or second surface of the front glass substrate (and may also have a perimeter hiding layer 139 (e.g., a chrome ring hiding layer) at the rear or second surface of the front glass substrate), and the rear glass substrate 132 has an electrically conductive coating 140 (e.g., a half-wave ITO coating) at a front or third surface of the rear glass substrate.
- a dark colored or black hiding layer may be used that is preferably matched to the color of the main seal so that both blend one into the other (such as by utilizing aspects of the mirrors described in U.S. Pat. No.
- the transparent electrically conductive coating disposed at the second surface of the front substrate and the transparent electrically conductive coating disposed at the third surface of the rear substrate oppose and contact the electrochromic medium 134.
- the mirror reflective element includes a fourth surface mirror reflector 142 disposed at a rear or fourth surface of the rear glass substrate 132.
- the fourth surface reflector 142 is a thick (e.g., 100 nm or more) silver coating or layer.
- the silver layer or film provides auxiliary visible light reflectivity and visible light transmission and near infrared (at 940 nm) transmission based on thickness of the coating or layer, such as shown in FIG. 30.
- the thick silver layer (at, for example, 100 nm or 1 ,000 Angstroms) provides high visible light reflection (greater than 70%) and low visible light transmission (less than 20%) and low near infrared light transmission (less than 8%).
- the rear surface of the rear glass substrate is devoid of the fourth surface reflector at a camera region 144 (which may be centrally located at the mirror reflective element or may be at an upper region or a lower region or a side region of the mirror reflective element).
- a thin mirror coating 146 e.g., a silver coating of 10 nm thickness or more or less
- the 10 nm auxiliary or augmenting reflective silver coating provides visible light reflectivity of about 32%, visible light transmission of about 60% and near infrared light transmission (at 940 nm) of about 33%.
- a 4 nm auxiliary or augmenting reflective silver coating may be used and provides visible light reflectivity of 13.2%, visible light transmission of 81 .5% and near infrared light transmission (at 940 nm) of 66.5%.
- the thickness of the thin auxiliary or augmenting reflective silver coating may be selected to provide, for example, at least 10% visible light reflectivity, at least 60% visible light transmission and at least 30% near infrared light transmission (at 940 nm).
- a high refractive index (at 589 nm) /low refractive index (at 589 nm) I high refractive index (at 589 nm) stack of alternating thin films 148 is disposed at the thin mirror coating 146 at the camera region 144.
- the stack of alternating thin films 148 may comprise a stack of metal oxide films, or may comprise a stack of Nb2O5-SiO2- Nb2O5 layers or films, or a stack of TiO2-SiO2-TiO2 layers or films, or a stack of S iO2-S i layers or films, such as discussed above, depending on the particular application and desired or targeted appearance and characteristics of the mirror reflective element.
- a reflective polarizing film 150 (e.g., a 3M® reflecting polarizing mirror film) is disposed behind the stack of alternating thin films 148.
- Reflecting polarizing mirror (“RPM”) films are available from 3M of St. Paul, MN USA and are described at https://www.3m.eom/3M/en_US/p/d/b5005074010/. For example, the reflective polarizing film 150 shown in FIG.
- RPM films are reflective of visible light, are transmissive of visible light and are transmissive of near IR light (such as at 940nm).
- the reflective polarizing film 150 adds to and augments the visible reflectivity such that the visible light reflectivity at the camera region 144 is close to or matches the visible light reflectivity of the thick silver reflector coating 142.
- the camera region 144 may provide at least 40% visible light reflectivity, preferably at least 43% visible light reflectivity, and more preferably at least 46% visible light reflectivity.
- the camera region may also provide enhanced transmission of near infrared light (e.g., at 940 nm).
- the thick silver mirror reflector adjacent to and outside of the camera region provides at least 40% visible light reflectivity, preferably at least 43% visible light reflectivity, and more preferably at least 46% visible light reflectivity.
- a camera 152 disposed behind and viewing through the camera region views through the reflective polarizing film 150, the stack of alternating thin films 148, the thin mirror coating 146 and the glass substrates and electrochromic medium to view a driver region within the interior cabin of the vehicle.
- one or more near-infrared light emitters 154 may be disposed at the camera region and operable to, when electrically powered, emit near infrared light that passes through the reflective polarizing film 150, the stack of alternating thin films 148, the thin mirror coating 146 and the glass substrates and electrochromic medium to illuminate the driver region within the interior cabin of the vehicle.
- LEDs light emitting diodes
- VCSEL vertical-cavity surface-emitting lasers
- the mirror reflective element may comprise an electro-optic mirror reflective element (e.g., an electrochromic mirror reflective element or liquid crystal mirror reflective element) that has a front glass substrate (e.g., a 1 .6 mm thick glass substrate) and a rear glass substrate (e.g., a 1 .1 mm thick glass substrate), with an electro-optic medium (e.g., an electrochromic solid polymer matrix (SPM) medium) sandwiched between the glass substrates and bounded by a perimeter seal.
- an electro-optic mirror reflective element e.g., an electrochromic mirror reflective element or liquid crystal mirror reflective element
- a front glass substrate e.g., a 1 .6 mm thick glass substrate
- a rear glass substrate e.g., a 1 .1 mm thick glass substrate
- an electro-optic medium e.g., an electrochromic solid polymer matrix (SPM) medium
- the front glass substrate has an electrically conductive coating (e.g., a half-wave ITO coating) at a rear or second surface of the front glass substrate (and may also have a perimeter hiding layer (e.g., a chrome ring hiding layer) at the rear or second surface of the front glass substrate), and the rear glass substrate has an electrically conductive coating (e.g., a half-wave ITO coating) at a front or third surface of the rear glass substrate.
- the mirror reflective element may comprise a third-surface mirror reflector, whereby the electrically conductive coating includes or is disposed at the mirror reflector coating.
- the transparent electrically conductive coating disposed at the second surface of the front substrate and the electrically conductive coating disposed at the third surface of the rear substrate oppose and contact the electrochromic medium.
- the reflective element and mirror casing are adjustable relative to a base portion or mounting assembly to adjust the driver’s rearward field of view when the mirror assembly is normally mounted at or in the vehicle.
- the mounting assembly may comprise a single-ball or single-pivot mounting assembly, whereby the reflective element and casing are adjustable relative to the vehicle windshield (or other interior portion of the vehicle) about a single pivot joint, or the mounting assembly may comprise other types of mounting configurations, such as a double-ball or double-pivot mounting configuration or the like.
- the socket or pivot element is configured to receive a ball member of the base portion, such as for a single pivot or single ball mounting structure or a double pivot or double ball mounting structure or the like (such as a pivot mounting assembly of the types described in U.S. Pat. Nos. 6,318,870; 6,593,565; 6,690,268; 6,540,193; 4,936,533; 5,820,097;
- the mounting base includes an attaching portion that is configured to be attached to an interior surface of a vehicle windshield (such as to a mounting button or attachment element adhered to the interior surface of the vehicle windshield or such as to a headliner or overhead console of the vehicle).
- the mounting base may comprise a metallic ball portion or may comprise a molded (such as injection molded) polymeric mounting base or may be otherwise formed, depending on the particular application of the mirror assembly.
- the respective physical thickness and refractive index (measured at 589 nm) and order within the multi-layer stack relative to the glass (or plastic) surface of individual non-metallic thin film coatings forming the spectral-selective mirror transflector disposed at a surface of a glass (or plastic) substrate of the mirror reflective element is selected so that the driver of an equipped vehicle viewing the mirror reflective element sees a blue-tinted mirror reflective element.
- the optical design of the multi-layer stack may be chosen so as to provide other color tints as viewed by the driver (for example, a reddish tint or a greenish tint).
- the blue-tinted mirror reflective element having high (at least 50%T) transmissivity in the near-IR spectral region at 940 nm is preferably achieved using a tri-layer stack of non-metallic thin films of metal oxides (or via a bi-layer stack of elemental silicon overcoated with a metal oxide, such as an oxide of silicon).
- each individual metal oxide thin film coating is transparent and absorbs little to no incident visible or near-IR light
- the lens of the likes of a DMS camera can view through the spectral-selective mirror transflector.
- a light absorbing mask or tape or element is disposed behind the mirror reflective element other than where the DMS camera views through the spectral-selective mirror transflector of the mirror reflective element (and/or other than where any near-IR illuminators disposed in the mirror head emit light through the spectral-selective mirror transflector of the mirror reflective element).
- total physical thickness of all three non-metallic thin film coatings forming the spectral-selective mirror transflector is preferably less than 350 nm, more preferably less than 300 nm, and most preferably less than 250 nm.
- the mirror assembly may comprise a prismatic reflective element.
- the prismatic mirror assembly may be mounted or attached at an interior portion of a vehicle (such as at an interior surface of a vehicle windshield) via the mounting means described above, and the reflective element may be toggled or flipped or adjusted between its daytime reflectivity position and its nighttime reflectivity position via any suitable toggle means, such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 6,318,870 and/or 7,249,860, and/or U.S. Publication No. US-2010-0085653, which are hereby incorporated herein by reference in their entireties.
- the interior rearview mirror assembly may utilize aspects of a prismatic mirror assembly, such as the types described in U.S. Pat.
- the prismatic reflective element may comprise a conventional prismatic reflective element or prism or may comprise a prismatic reflective element of the types described in U.S. Pat. Nos.
- the mirror assembly may include one or more other displays, such as the types disclosed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925, which are hereby incorporated herein by reference in their entireties, and/or display-on-demand transflective type displays, and/or video displays or display screens, such as the types disclosed in U.S. Pat. Nos.
- a vehicular interior rearview mirror assembly includes a mounting structure configured to mount the vehicular interior rearview mirror assembly at an interior portion of an interior cabin of a vehicle.
- a mirror head accommodates a mirror reflective element.
- a spectral-selective mirror transflector is disposed at a surface of a substrate of the mirror reflective element.
- the spectral-selective mirror transflector comprises a multilayer stack of thin film coatings.
- the deposited multi-layer stack of non-metallic thin film coatings of the spectral-selective mirror transflector at least comprises a first non-metallic thin film coating deposited at the surface of the substrate of the mirror reflective element and a second non-metallic thin film coating deposited onto the first non-metallic thin film coating.
- the first non-metallic thin film coating has a first refractive index (at 589 nm), and the second non-metallic thin film coating has a second refractive index (at 589 nm).
- the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjustable by a driver of the vehicle to set a rearward view for the driver.
- the driver of the vehicle viewing the mirror reflective element sees a blue-tinted mirror reflective element.
- the spectral- selective mirror transflector transmits near-infrared (near-IR) light incident thereon, transmits visible light incident thereon and reflects visible light incident thereon.
- near-IR near-infrared
- Reflectivity of visible light incident at the mirror reflective element is at least 40 percent as determined in accordance with SAE Recommended Practice J964. Transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 45 percent.
- a camera is disposed within the mirror head and views through the spectral- selective mirror transflector of the mirror reflective element. The camera moves in tandem with the mirror head when, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjusted to adjust the driver’s rearward view. The camera is operable to capture image data.
- a near-IR illumination source is disposed within the mirror head.
- the near-IR illumination source when powered, illuminates at least a front seat region at a driver-side of the vehicle.
- DMS driver monitoring system
- the substrate may comprise a single glass substrate of the mirror reflective element, the single glass substrate having a first surface and a second surface that is opposite the first surface and is separated from the first surface by a thickness of the single glass substrate.
- the spectral-selective mirror transflector may be disposed at the second surface of the single glass substrate.
- the spectral-selective mirror transflector may be disposed at the first surface of the single glass substrate.
- the single glass substrate may comprise a prismatic glass substrate.
- the second surface of the single glass substrate may be parallel to the first surface of the single glass substrate.
- the mirror reflective element may comprise an electro-optic mirror reflective element having a front glass substrate and a rear glass substrate with an electrooptic medium sandwiched between the front glass substrate and the rear glass substrate.
- the substrate having the spectral-selective mirror transflector disposed thereat comprises the rear glass substrate of the electro-optic mirror reflective element.
- the spectral-selective mirror transflector disposed at the surface of the rear glass substrate may oppose and contact the electro-optic medium of the electro-optic mirror reflective element.
- the rear glass substrate may have an electrically conductive coating that opposes and contacts the electro-optic medium of the electro-optic mirror reflective element, with the spectral-selective mirror transflector disposed at the surface opposite from the electrically conductive coating.
- transmission of visible light through the mirror reflective element is at least 15 percent as determined in accordance with SAE Recommended Practice J964.
- transmission of visible light through the mirror reflective element is at least 30 percent as determined in accordance with SAE Recommended Practice J964.
- transmission of visible light through the mirror reflective element is at least 45 percent as determined in accordance with SAE Recommended Practice J964.
- transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 55 percent.
- transmission through the mirror reflective element of visible light is at least 50 percent.
- transmission through the mirror reflective element of visible light is at least 55 percent.
- reflectivity of visible light incident at the mirror reflective element is at least 42 percent as determined in accordance with SAE Recommended Practice J964.
- reflectivity of visible light incident at the mirror reflective element is at least 45 percent as determined in accordance with SAE Recommended Practice J964.
- the camera may comprise an imaging sensor having a quantum efficiency (QE) of at least 15% for near-infrared (near-IR) light having a wavelength of 940 nm.
- QE quantum efficiency
- a data processor of the DMS is disposed at the vehicle remote from the vehicular interior rearview mirror assembly.
- the vehicular interior rearview mirror assembly comprises a data processor of the DMS.
- the interior portion of the interior cabin of the vehicle comprises an incabin side of a windshield of the vehicle.
- the near-IR illumination source comprises a plurality of near-IR light emitters.
- the mirror head accommodates a video display screen
- the video display screen is electrically operable to display video images for viewing by the driver through the spectral-selective mirror transflector of the mirror reflective element.
- the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the vehicular interior rearview mirror assembly may be operable in (i) a mirror mode, where the mirror head is positioned so that reflections at the mirror reflective element provide the rearward view for the driver, and (ii) a display mode, where the video display screen is electrically operated to display video images representative of the rearward view for viewing by the driver.
- a toggle mechanism may be operable to adjust the mirror head between (i) a mirror mode orientation, where the mirror head is positioned so that reflections at the mirror reflective element provide the rearward view for the driver, and (ii) a display mode orientation, where the mirror head is tilted from the mirror mode orientation so that reflections at the mirror reflective element are directed away from the driver.
- the video display screen Responsive to the mirror head being adjusted to the display mode orientation, the video display screen may be automatically electrically operated to display video images representative of the rearward view for viewing by the driver.
- the mirror head When the mirror head is adjusted between the mirror mode orientation and the display mode orientation, the mirror head is tilted about a pivot axis that is parallel to a longitudinal axis of the mirror head. When the mirror head is adjusted from the mirror mode orientation to the display mode orientation, the mirror head is tilted upward about the pivot axis. When the mirror head is adjusted from the mirror mode orientation to the display mode orientation, the mirror head is tilted downward about the pivot axis.
- the video display screen may be electrically operated to reduce glare light that is reflected by the mirror reflective element toward the driver of the vehicle.
- Glare light may be determined via processing of image data captured by a rearward-viewing camera of the vehicle.
- a field of view provided by the displayed images may be adjustable by the driver of the vehicle.
- the driver via actuation of a user input, sets the field of view provided by the displayed images to mimic a field of view provided by the mirror reflective element when the vehicular interior rearview mirror assembly operates in the mirror mode.
- the vehicular interior rearview mirror assembly may operate in a mirror-mimic mode that sets the field of view provided by the displayed images to mimic a field of view provided by the mirror reflective element when the vehicular interior rearview mirror assembly operates in the mirror mode.
- the near-IR illumination source disposed within the mirror head when operated, emits near-IR light that passes through the spectral-selective mirror transflector of the mirror reflective element. Presence of the near-IR illumination source disposed within the mirror head is covert from view by the driver of the vehicle.
- an occupant-monitoring camera may be disposed within the mirror head, and the occupant-monitoring camera moves in tandem with the mirror head when, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjusted to adjust the driver’s rearward view.
- the occupant-monitoring camera may view through the spectral-selective mirror transflector of the mirror reflective element, and presence of the occupant-monitoring camera disposed within the mirror head and viewing through the spectral-selective mirror transflector of the mirror reflective element is covert from view by the driver of the vehicle.
- the near-IR illumination source may comprise at least one emitting diode (LED).
- the near-IR illumination source may comprise at least verticalcavity surface-emitting laser (VCSEL).
- the multi-layer stack of non-metallic thin film coatings comprises a third non-metallic thin film coating having a third refractive index (at 589 nm), with the third non-metallic thin film coating having the third refractive index (at 589 nm) being deposited onto the second non-metallic thin film coating.
- the first non-metallic thin film coating may comprise a first metal oxide coating
- the second non-metallic thin film coating may comprise a second metal oxide coating
- the third non-metallic thin film coating may comprise a third metal oxide coating.
- the spectral-selective mirror transflector comprises a tri-layer stack of the first metal oxide coating, the second metal oxide coating and the third metal oxide coating.
- the first non-metallic thin film coating is closer to the surface of the substrate than the second and third non-metallic thin film coatings, and the second non- metallic thin film coating is sandwiched between the first non-metallic thin film coating and the third non-metallic thin film coating.
- the first non-metallic thin film coating comprises a higher refractive index (at 589 nm) coating having a first refractive index (at 589 nm)
- the second non-metallic thin film coating comprises a lower refractive index (at 589 nm) coating having a second refractive index (at 589 nm) that is lower than the first refractive index (at 589 nm)
- the third non-metallic thin film coating comprises a higher refractive index (at 589 nm) coating having the third refractive index (at 589 nm) that is higher than the second refractive index (at 589 nm).
- the first non-metallic thin film coating comprises an oxide of niobium
- the second non-metallic thin film coating comprises an oxide of silicon
- the third non-metallic thin film coating comprises an oxide of niobium
- the first non- metallic thin film coating comprises a layer of Nb2O5
- the second non-metallic thin film coating comprises a layer of SiO2
- the third non-metallic thin film coating comprises a layer of Nb2O5.
- the first non-metallic thin film coating comprises an oxide of titanium
- the second non-metallic thin film coating comprises an oxide of silicon
- the third non-metallic thin film coating comprises an oxide of titanium.
- the first non-metallic thin film coating comprises elemental silicon
- the second non-metallic thin film coating comprises an oxide of silicon
- Transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm may be at least 80 percent.
- the multi-layer stack of non-metallic thin film coatings comprises a third non-metallic thin film coating having a third refractive index (at 589 nm).
- the third non-metallic thin film coating having the third refractive index (at 589 nm) may be deposited onto the second non-metallic thin film coating.
- the third refractive index may be higher than the second refractive index (at 589 nm).
- the first refractive index may be similar to that of the third refractive index (at 589 nm) and may be higher than the second refractive index (at 589 nm).
- the first refractive index is higher than 2 and the second refractive index (at 589 nm) is lower than 1 .5 and the third refractive index (at 589 nm) is higher than 2.
- the first refractive index comprises an oxide of niobium
- the second non-metallic thin film coating comprises an oxide of silicon
- the third non-metallic thin film coating comprises an oxide of niobium.
- the first refractive index comprises an oxide of titanium
- the second non-metallic thin film coating comprises an oxide of silicon
- the third non-metallic thin film coating comprises an oxide of titanium.
- the difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating may be at least 0.5.
- the difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating may be at least 0.7.
- the difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating may be at least 1 .0.
- the multi-layer stack of non-metallic thin film coatings consists of the first non-metallic thin film coating and the second non-metallic thin film coating, and the first non-metallic thin film coating may have a refractive index (at 589 nm) greater than 3, and the second non-metallic thin film coating may have a refractive index (at 589 nm) less than 3.
- the first non-metallic thin film coating may comprise elemental silicon, and the second non-metallic thin film coating may have a refractive index (at 589 nm) less than 1 .5.
- the second non-metallic thin film coating may comprise a thin film coating of an oxide of silicon.
- the physical thickness of the first non-metallic thin film coating may be larger than the physical thickness of the second non-metallic thin film coating.
- the physical thickness of the first non-metallic thin film coating may be less than 30 nm, and the physical thickness of the first non-metallic thin film coating may be less than 20 nm.
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Abstract
A vehicular interior rearview mirror assembly includes a mounting structure and a mirror head that accommodates a mirror reflective element. The mirror reflective element includes a substrate having a first surface and a second surface opposite the first surface. A spectral-selective mirror transflector is disposed at the substrate. The spectral-selective mirror transflector includes a stack of coatings having a first coating of an oxide of niobium, a second coating of an oxide of silicon and a third coating of an oxide of niobium. The first coating is closer to the second surface than the second and third coatings, and the second coating is sandwiched between the first coating and the third coating. With the vehicular interior rearview mirror assembly mounted at an interior portion of an interior cabin of a vehicle, a driver of the vehicle viewing the mirror reflective element sees a blue-tinted mirror reflective element.
Description
VEHICULAR INTERIOR REARVIEW MIRROR ASSEMBLY WITH SPECTRAL- SELECTIVE MIRROR REFLECTIVE ELEMENT
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the filing benefits of U.S. provisional application Ser. No. 63/651 ,537, filed May 24, 2024, and U.S. provisional application Ser. No. 63/641 ,574, filed May 2, 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 via a 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. The mirror casing and reflective element are pivotable about either or both of the ball pivot joints by a user that is adjusting a rearward field of view of the reflective element.
SUMMARY OF THE INVENTION
[0004] A vehicular interior rearview mirror assembly includes a mounting structure configured to mount the vehicular interior rearview mirror assembly at an interior portion of a cabin of a vehicle. A mirror head accommodates a mirror reflective element that includes a glass substrate having a first surface and a second surface. The second surface is opposite the first surface and is separated from the first surface by a thickness of the glass substrate, and a spectral-selective mirror transflector is disposed at the second surface of the glass substrate. The spectral-selective mirror transflector comprises a stack of dielectric coatings comprising a higher refractive index (at 589 nm) oxide coating coated on a soda-lime glass surface, upon which is coated a lower refractive index (at 589 nm) oxide coating, and optionally upon which is coated a higher refractive index (at 589 nm) oxide coating. For example, the mirror transflector may comprise a stack of dielectric thin
film coatings comprising a first coating of an oxide of niobium (e.g., Nb2O5), a second coating of an oxide of silicon (e.g., SiO2) and a third coating of an oxide of niobium (e.g., Nb2O5). The first coating is closer to the second surface than the second and third coatings, and the second coating is sandwiched between the first coating and the third coating. With the vehicular interior rearview mirror assembly mounted at the interior portion of the cabin of the vehicle, the mirror head is adjustable by a driver of the vehicle to set a rearward view for the driver.
[0005] Optionally, the mirror head may accommodate a video display screen that is electrically operable to display video images for viewing by the driver. When the mirror assembly is operating in a mirror mode, the video display screen is not activated, so that reflections at the mirror reflective element provide the rearward view for the driver. When the mirror assembly is operating in a display mode, the video display screen is electrically operated to display video images representative of the rearward view for viewing by the driver through the spectral-selective mirror transflector of the mirror reflective element.
[0006] Optionally, the mirror head may covertly accommodate a cabin monitoring camera (e.g., a driver monitoring camera or an occupant monitoring camera or a combined driver monitoring / occupant monitoring camera) that views the driver of the vehicle through the spectral-selective mirror transflector. Image data captured by the driver monitoring camera is processed to determine attentiveness of the driver of the vehicle.
Optionally, near-infrared light emitters are covertly accommodated by the mirror head. The near-infrared light emitters, when electrically operated, emit near-infrared light that passes through the spectral-selective mirror transflector to illuminate at least a portion of the driver of the vehicle.
[0007] 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
[0008] FIG. 1 is a perspective view of an interior rearview mirror assembly;
[0009] FIG. 2A is a table showing mirror properties for different material mirror reflectors at a zero degree incidence angle;
[0010] FIG. 2B is another table showing mirror properties for different material mirror reflectors at a 25 degree incidence angle;
[0011] FIG. 3 is a schematic showing properties of a blue mirror that has the mirror reflective element coated with an Nb2O5 stack of coatings;
[0012] FIG. 4 is a graph that overlays the blue mirror properties;
[0013] FIG. 5 is a graph showing the blue mirror properties with properties of typical
LED headlamps of vehicles;
[0014] FIG. 6 shows the reflective color coordinates in CIE LAB color space for the different types of mirror reflectors;
[0015] FIGS. 7A and 7B show CIE D65 sunlight representative standard llluminant per CIE 1931 with a 2 degree observer;
[0016] FIG. 8A shows a Monte Carlo tolerance study of physical thickness variances for an example of the blue mirror with an Nb2O5 stack of coatings;
[0017] FIG. 8B shows a Monte Carlo tolerance study of physical thickness variance and color for the example of the blue mirror with an Nb2O5 stack of coatings;
[0018] FIG. 9 shows a comparison of indices of refraction for different Nb2O5 coatings and TiO2 coatings;
[0019] FIG. 10 is a graph showing the reflection spectrum for the different mirror reflector constructions;
[0020] FIG. 11 is a graph showing the transmission spectrum for the different mirror reflector constructions;
[0021] FIG. 12 is a stack profile showing a physical thickness profile of the blue mirror stack of coatings;
[0022] FIGS. 13 and 14 show properties of an example blue mirror with an Nb2O5- SiO2-Nb2O5 stack of coatings;
[0023] FIGS. 15 and 16 show properties of an example mirror with an TiO2-SiO2-TiO2 stack of coatings;
[0024] FIGS. 17 and 18 show properties of an example mirror with a layer of silver (Ag);
[0025] FIGS. 19 and 20 show properties of an example mirror with a layer of chromium
(Cr);
[0026] FIG. 21 is a stack profile showing a physical thickness profile of another blue mirror stack of coatings;
[0027] FIGS. 22 and 23 show properties of an example mirror with S i-S iO2 stack of coatings;
[0028] FIG. 24 shows thicknesses and indexes of refraction of the layers of the blue mirror element;
[0029] FIG. 25 is a stack profile showing a physical thickness profile of another blue mirror stack of coatings;
[0030] FIGS. 26 and 27 show properties of an example mirror with an Si-SiO2-Nb2O5- SiO2-Nb2O5 stack of coatings;
[0031] FIG. 28 is a graph showing the effects of adding a silver layer to an electrochromic mirror cell;
[0032] FIG. 29 is a schematic of a mirror assembly having a fourth surface reflector and a driver monitoring camera disposed behind the mirror reflective element and viewing through a region of the mirror reflective element that is devoid of the fourth surface reflector and that has a stack of thin film layers or coatings thereat;
[0033] FIG. 30 is a table and graph showing reflectivity and transmissivity properties of silver coatings or films of various thicknesses; and
[0034] FIG. 31 is a table and graph showing reflectivity and transmissivity properties of silicon coatings or films of various thicknesses.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] Referring now to the drawings and the illustrative embodiments depicted therein, an interior rearview mirror assembly 10 for a vehicle includes a mirror head 12 that includes a casing 14 and a mirror 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 a vehicle 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 substrate (preferably a glass substrate) that is coated on one side (e.g., the second or rear surface of the substrate) with a stack of thin film layers or coatings. For example, the layers may include a first, higher refractive index (at 589 nm) coating at the glass (e.g., a layer of an oxide of niobium such as Nb2O5), with a second, lower refractive index (at 589 nm) coating (e.g., a layer of an oxide of silicon such as SiO2) coated at the first coating or layer, and with a third, higher refractive index (at 589 nm) coating (e.g., another layer of an oxide of niobium such as Nb2O5) coated at the second coating or layer, with the physical thicknesses of the layers or coatings selected to provide the
desired color-tinted spectral appearance and reflectance and transmission properties of the mirror reflective element.
[0036] The mirror reflective element 16 comprises a glass substrate having a front or first planar surface (the surface that generally faces the driver of the vehicle when the mirror assembly is normally mounted at the vehicle) and a rear or second planar surface opposite the first surface, where the first surface and the second surface may be parallel to one another. The second surface has the spectral-selective mirror reflector or transflector coating, established thereat for reflecting at least a portion of light incident at the glass substrate to provide the reflections for viewing by the driver of the vehicle. Optionally, mirror reflective element may comprise a single glass substrate, and the single glass substrate may comprise a curved or bent substrate or a prismatic substrate (where the rear surface is not parallel to the front surface). For example, the mirror reflective element may be non-planar, convex-curved so as to give a wide angle rearward view for the driver of the vehicle. Optionally, the curvature of the glass substrate of the mirror reflective element may be a free-form curvature, such as a curved glass substrate formed utilizing aspects of the mirrors and systems described in U.S. Pat. Nos. 10,166,924; 9,487,142 and/or 8,917,437, which are hereby incorporated herein by reference in their entireties.
[0037] Optionally, and such as shown in FIG. 1 , the mirror head 12 may accommodate a video display screen 20 that is operable to display video images that are viewable by the driver of the vehicle through the mirror reflective element 16. The video display screen 20, when operated, displays video images that are viewable at a display region 22, which encompasses at least about 75 percent of the reflective region, or at least about 85 percent of the reflective region, or at least about 95 percent of the reflective region.
[0038] The interior rearview mirror assembly may comprise a dual-mode mirror assembly, where the mirror assembly is operable in a mirror mode or a display mode. For example, when operating in the mirror mode, the mirror reflective element reflects the rearward view to the driver of the vehicle, and when operating in the display mode, the video display screen operates to display video images that are viewable through the spectral-selective mirror transflector of the mirror reflective element for viewing by the driver of the vehicle. In other words, the mirror is provided with a video display screen that is disposed behind and is viewable through the mirror reflective element.
[0039] Optionally, the mirror head 12 may be tiltable or pivotable between a mirror mode orientation, where the reflective element 16 is positioned to provide reflections for the desired driver’s rearward field of view, and a display mode orientation, where the mirror head is tilted upward (or downward) from the mirror mode orientation, such that video images displayed at the display screen 20 are viewable by the driver while the reflective element 16 reflects light from rearward of the vehicle and incident thereon upward or downward away from the driver’s eyes. The mirror head 12 may be tiltable or pivotable between the mirror mode orientation and the display mode orientation via a toggle element 22. For example, the mirror head 12 may be manually pivotable between the mirror mode orientation and the display mode orientation by a user grasping the toggle element 22 to pivot the mirror head 12. The single glass substrate may comprise a prismatic substrate (where the rear surface of the substrate is not parallel to the front surface of the substrate) or may comprise a planar substrate (where the rear surface of the substrate is parallel to the front surface of the substrate).
[0040] Such video mirrors include a backlit LCD display screen, and a particular form of video mirror is a full display mirror (such as a ClearView™ Interior Rearview Mirror Assembly available from Magna Mirrors of America, Inc. of Holland, Ml USA, or an FDMTM Interior Rearview Mirror Assembly available from Gentex Corporation of Zeeland, Ml USA), where the video display screen fills or substantially fills the reflective region (e.g., fills or encompasses at least about 75 percent of the reflective region, or at least about 85 percent of the reflective region, or at least about 95 percent of the reflective region), such as by utilizing aspects of the mirror assemblies and systems described in U.S. Pat. Nos. 11 ,766,968; 11 ,242,008; 11 ,214,199; 10,442,360; 10,421 ,404; 10,166,924; 10,046,706; 10,029,614 and/or 5,179,471 , and/or U.S. Publication Nos. US-2024-0383406; US-2024- 0383405; US-2021-0162926; US-2021-0155167; US-2020-0377022; US-2019-0258131 ; US-2019-0146297; US-2019-0118717 and/or US-2017-0355312, and/or U.S. patent application Ser. No. 18/966,218, filed Dec. 3, 2024 (Attorney Docket DON01 P5276), which are all hereby incorporated herein by reference in their entireties.
[0041] The video display screen 20 of the video mirror, when the mirror is operating in the display mode, may display video images derived from video image data captured by a rearward viewing camera, such as a rearward camera disposed at a center high-mounted stop lamp (CHMSL) location, and/or video image data captured by one or more other
cameras at the vehicle, such as side-mounted rearward viewing cameras or the like, such as by utilizing aspects of the display systems described in U.S. Pat. No. 11 ,242,008, which is hereby incorporated herein by reference in its entirety. The operating mode of the mirror and video display screen may be selected by actuation of a user actuatable input (e.g., a touch input or button or switch at the mirror head) or by flipping the mirror head upward or downward (e.g., via a toggle located at the mirror head), or responsive to another user input. When the mirror is operating in the mirror mode, the video display screen 20 is deactivated and rendered covert by the mirror reflective element 16, and the driver views rearward via reflection of light incident at the mirror reflective element 16. When the mirror is operating in the display mode, the video display screen 20 is operated to display video images that are viewable through the mirror reflective element 16 by the driver of the vehicle.
[0042] The video display screen 20 is accommodated within the mirror head and behind the glass substrate of the mirror reflective element 16 and the spectral-selective mirror transflector coating allows at least a portion of light incident thereat to pass through the glass substrate so that, when the video display screen 20 is operated to display video images, the video images are viewable through the mirror reflective element 16. When the video display screen 20 is not operating to display video images, the spectral-selective mirror transflector coating at the glass substrate at least partially hides or renders covert the video display screen 20 so that the driver may not be able to view the video display screen 20 and instead views reflections at the mirror reflective element 16.
[0043] When the mirror head 12 is operating in the mirror mode, the mirror head 12 is positioned so that the mirror reflective element 16 provides a desired field of view rearward of the vehicle to the driver and the video display screen 20 is not operated. When the mirror head 12 is toggled or switched or controlled to operate in the display mode, the video display screen 20 is operated so that video images at the video display screen 20 are viewable by the driver (and optionally the mirror head may be pivoted upward or downward relative to the mirror mode orientation so that the reflections from the mirror reflective element are directed upward or downward away from view of the driver). The video display screen 20 may be automatically operated upon movement of the mirror head 12 to the display mode orientation or responsive to another user input.
[0044] The mirror head 12 may be manually pivotable between the mirror mode orientation and the display mode orientation by grasping a toggle element and pivoting the mirror head 12 about the mounting base. Responsive to the mirror head 12 being moved to a display mode orientation, the display screen 20 may be automatically operated to display video images and, responsive to the mirror head 12 being moved away from the display orientation, the display screen 20 may cease operation. In some examples, the mirror head 12 may be moved between the mirror mode orientation and the display mode orientation via operation of an actuator, such as by utilizing characteristics of U.S. Pat. No. 10,442,360, which is incorporated herein by reference in its entirety.
[0045] The mirror reflective element 16 may comprise a single glass substrate with a single surface spectral-selective mirror transflector and may not include an electrically operable dimming mechanism (such as a dimmable electrochromic medium) such that the reflections from the spectral-selective transflector coating of the mirror reflective element are not electronically dimmable. The video images displayed at the mirror assembly 10 may be representative of the rearward field of view provided by the mirror assembly and the video images may be digitally adjusted to dim the displayed images, such as to account for glare from headlights of other vehicles following the equipped vehicle.
[0046] The mirror reflective element includes a transflective spectral-selective mirror transflector disposed at a side (preferably disposed on the rear side/surface or second side/surface) of the reflective element glass substrate, with the transflective spectral- selective mirror transflector provides a high level of transmission of visible light, such as at least 30 percent transmission, preferably 40 percent transmission, preferably at least 50 percent transmission, while also providing sufficient photopic reflectance, such as being at least 42 percent reflectant (as determined in accordance with SAE Recommended Practice J964 (Mar2024), which is hereby incorporated herein by reference in its entirety) of visible light incident thereat, preferably at least 45 percent reflectant of visible light incident thereat, and more preferably at least 48 percent reflectant of visible light incident thereat. The transflective spectral-selective mirror transflector preferably comprises a trilayer stack of dielectric coatings or oxides.
[0047] For example, the glass substrate may comprise soda-lime glass having a physical thickness of at least 1 .6 mm, such as a physical thickness of 1 .6 mm or 1 .8 mm or 2 mm or 2.3 mm or 2.5 mm or 3 mm (or more or less), with the second or rear surface of
the glass substrate coated with a stack of thin film layers or coatings. For example, the layers of the tri-layer stack have a first, higher refractive index (at 589 nm) coating or layer coated at the glass surface (e.g., a layer of an oxide of niobium such as Nb2O5), with a second, lower refractive index (at 589 nm) coating or layer (e.g., a layer of an oxide of silicon such as SiO2) coated at the first coating or layer, followed by a third, higher refractive index (at 589 nm) coating or layer (e.g., another layer of an oxide of niobium such as Nb2O5) coated at the second coating or layer, with the physical thicknesses of the layers or coatings selected to provide the desired color-tinted spectral appearance and reflectance and transmission properties of the mirror reflective element in both the visible spectral region of light and the near infrared spectral region of light.
[0048] For example, the coatings and physical thicknesses may be selected to provide a blue colored or tinted automotive mirror that uses a 3-layer thin film dielectric oxide coating that meets the minimum industry reflectivity requirements of greater than 35% (as determined for FMVSS 111 in accordance with SAE Recommended Practice J964 (Mar2024), which are both hereby incorporated herein by reference in their entireties), with increased transmission for use with displays and cameras, including near-infrared cameras. Typical mirror reflective elements may, for example, use a relatively thin metallic silver (Ag) coating to achieve reflectivity and transmission for displays showing through the mirror. Chromium (Cr) versions may have lower reflectivity. A non-spectrally-selective automotive mirror using a silver coating with thickness of around 200 nm, and such as having the properties shown in FIGS. 2A and 2B, is commonly used in interior automotive mirrors, and a non-spectrally-selective automotive mirror using a chromium coating with thickness of around 200 nm, and such as having the properties shown in FIGS. 2A and 2B, is commonly used in exterior automotive mirrors. Design 1 of FIG. 2A is the visible light transmission, visible light reflectivity, absorption, color and near IR transmission of a ClearView™ dual-mode electrochromic interior rearview mirror assembly (with the reflectivity and color values as experienced by a driver viewing the subject mirror within a vehicle). Design 4 of FIG. 2A is the visible light transmission, visible light reflectivity, absorption, color and near IR transmission of an exterior rearview mirror assembly (with the reflectivity and color values as experienced by a driver viewing the subject mirror at the outside of a vehicle).
[0049] The mirror reflective element 12 preferably provides a “blue mirror” (that has a blue tint when viewed by the driver of the vehicle). The blue mirror may have a tri-layer stack of Nb2O5 (as the higher refractive index (at 589 nm) coating) and SiO2 (as the lower refractive index (at 589 nm) coating), or may have a tri-layer stack of TiO2 (as the higher refractive index (at 589 nm) coating) and SiO2 (as the lower refractive index (at 589 nm) coating). See FIGS. 2A and 2B for comparison of exemplary typical mirrors and examples of the blue mirrors. See FIG. 3 for details on an example of the Nb2O5 blue mirror. Referring to the comparison, the absorption of the silver (Ag) based coating (having a physical thickness of 200nm) is 17% as compared to the dielectric designs of 2% and 4%, and the chromium (having a physical thickness of 200nm) has 41 % absorption. The lower absorption of the oxide dielectrics can be used to increase the transmission of visible light through the mirror from a display or lights behind the mirror. The absorption is a measure of efficiency as the transmission plus reflection plus absorption = 100%. By minimizing absorption, the reflection can be kept to meet requirements or even slightly increased while also increasing the transmission. In this case the transmission is increased 10% from the baseline design #1 to a preferred design #2 (FIGS. 2A and 2B). Additionally, with the tri-layer stack of dielectric oxides, near-infrared transmission (e.g., 940 nm) may be at least
45 percent, preferably at least 55 percent, preferably at least 60 percent.
[0050] The dielectric coatings using oxides of niobium (such as, for example, Nb2O5) are able to achieve a higher reflectivity than the oxides of titanium (e.g., TiO2) coatings because Nb2O5 has a higher index of refraction (n) according to this table of indices:
[0051] Material n@589nm
[0052] Soda Lime 1.52
[0053] Nb2O5 2.37
[0054] Si 02 1.46
[0055] TiO2 2.15
[0056] Previous mirrors for driver monitoring system and passenger safety monitoring system (DMS/OMS) have included near infrared LEDs covertly disposed behind the mirror reflective element and transmitting near IR light through the mirror reflector coating. A camera is also covertly disposed behind the mirror reflective element and views through the mirror reflector and receives near infrared (NIR) light that passes through the mirror reflector coating. For the basic comparison of mirror designs, transmission of near infrared
light at 940nm is used. The dielectric designs can achieve significant increases in efficiency at this wavelength leading to decreased NIR LED power needs and less sensitive cameras, reducing system costs including heat sink sizes and increasing feasibility of DMS/OMS systems. The exemplary design shown in FIG. 3 provides 82% transmission of near infrared light at 940nm.
[0057] The blue color reflectance is desired because industry research shows improved driver awareness, and suppression of melatonin - driving is the perfect time to do this. Also, the style / cosmetics can be seen as a luxury color. It is more difficult and expensive to produce color neutral mirrors using dielectric optical thin film, since more layers are needed (at least 5 layers) and the variation needs more control (closer to a*=0, b*=0 the tighter the tolerance needed). The transmissive color can be compensated in both displays and cameras using color balance. An important factor is variability.
[0058] When choosing the spectral design, the scotopic and photopic responses should be considered. The design represented in FIG. 4 emphasizes scotopic vision slightly.
When choosing the spectral design, the spectrum of headlights are a key consideration. The design represented in FIG. 5 emphasizes the blue portion over the yellow portion of the headlight spectrum, reducing yellow glare.
[0059] Color is defined by the CIELAB color space, also referred to as L*a*b*, which is a color space defined by the International Commission on Illumination (abbreviated CIE). The L*a*b* expresses color as three values: L* for perceptual lightness and a* and b* for the four unique colors of human vision: red, green, blue and yellow. ISO/CIE 11664-2 Colorimetry - Part 2: CIE standard illuminants.
[0060] Optical thin films, including dielectric oxides deposited on glass substrates via mass production using sputter deposition, is a preferred technology. The process produces variance for optical film physical thickness that must be considered. Experience has shown that less than 7% variance is achievable, while the thin film industry is achieving as low as 3% variance. This variance has been considered for the blue mirror design and is presented in various charts. The target is to maintain greater than 40% reflectivity of visible light while also maintaining at least 45% transmissivity of visible light and at least 70% transmissivity of near infrared light (e.g., at 940 nm).
[0061] Tooling factor variations are made to thin film designs based on the exact process at a particular manufacturer. This may involve a variation in the actual index of
refraction produced (see FIG. 9). As the index approaches that of TiO2 there is risk regarding meeting the reflectivity minimum of 40%. This risk is partly counteracted by the increased nominal reflectivity of the preferred design at 47%, allowing more portability between manufacturers. See FIGS. 10 and 11 for graphs of the reflection spectrum and transmission spectrum for various mirror constructions.
[0062] The physical thickness of the glass substrate and the coatings or layers are selected to provide the desired appearance and properties of the mirror reflective element, such as when operating in the display mode and when operating in the mirror mode for a dual-mode rearview mirror assembly. For example, the blue mirror Nb2O5 stack may have the first (glass side) coating of Nb2O5 at a physical thickness of 43 nm, the second (middle) coating of SiO2 at a physical thickness of 79 nm, and the third (outer) coating of Nb2O5 at a physical thickness of 47 nm (for a total stack physical thickness of about 169 nm). FIG. 12 shows the stack profile for this example. FIG. 13 shows the percent transmission and percent reflectance for an example Nb2O5 spectral-selective mirror transflector (comprising a thin film stack that includes a layer of Nb2O5 at the glass having a physical thickness of 47 nm, a layer of SiO2 having a physical thickness of 79 nm, and a layer of Nb2O5 having a physical thickness of 43 nm) on a glass substrate, and FIG. 14 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles. The physical thicknesses may vary depending on the particular application, such as by plus or minus three percent, or by plus or minus 5 percent, or by plus or minus 8 percent (preferably less than plus or minus 20 percent, more preferably less than plus or minus 15 percent, and more preferably less than plus or minus 10 percent).
[0063] Below are examples of different Nb205 reflective elements, with different thickness of glass, and with the second surface coated with the thin film layers (similar results would be achieved if the first surface were coated).
[0064] The visible spectrum is evaluated between 380nm and 750nm wavelengths. The visible average reflection R is obtained by taking the sum of reflection coefficients in this range and dividing by the number of sample points, while the visible average transmission T is obtained by taking the sum of transmission coefficients in this range and dividing by the number of sample points. The illumination source for reflection and transmission percentages is perfect white light. Conversion to photopic with A illuminant and 1924 CIE
photopic observer as in SAE J964 has not been performed. Also, the incident angle of measurement for the design is 0 degrees according to the common practice for designing optical thin films. Color is as determined by ISO/CIE 11664-4:2019 Colorimetry - Part 4: CIE 1976 L*a*b* colour space using the D65 sunlight representative standard llluminant per CIE 1931 with a 2 degree observer (see FIGS. 7A and 7B).
[0065] Nb2O5 VERSIONS:
[0066] 3mm Soda-lime glass, 2nd surface coated.
[0067] Visible Average Reflection = 47%
[0068] Visible Average Transmission = 51 %
[0069] 940nm Transmission = 81 %
[0070] 2mm Soda-lime glass, 2nd surface coated.
[0071] Visible Average Reflection = 47%
[0072] Visible Average Transmission = 52%
[0073] 940nm Transmission = 84%
[0074] 3mm Soda-lime glass, 1st surface coated.
[0075] Visible Average Reflection = 46%
[0076] Visible Average Transmission = 47%
[0077] 940nm Transmission = 77%
[0078] 2mm Soda-lime glass, 1 st surface coated.
[0079] Visible Average Reflection = 46%
[0080] Visible Average Transmission = 48%
[0081] 940nm Transmission = 80%
[0082] Below are examples of different TiO2 reflective elements, with different thickness of glass, and with the second surface coated with the thin film layers (similar results would be achieved if the first surface were coated). FIG. 15 shows the percent transmission and percent reflectance for an example TiO2 spectral-selective mirror transflector (comprising a thin film stack that includes a layer of TiO2 at the glass having a physical thickness of 49 nm, a layer of SiO2 having a physical thickness of 84.4 nm, and a
layer of Ti02 having a physical thickness of 44.3 nm) on a glass substrate, and FIG. 16 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles.
[0083] TiO2 VERSIONS:
[0084] 3mm Soda-lime glass, 2nd surface coated.
[0085] Visible Average Reflection = 39%
[0086] Visible Average Transmission = 58%
[0087] 940nm Transmission - 82%
[0088] 2mm Soda-lime glass, 2nd surface coated.
[0089] Visible Average Reflection = 40%
[0090] Visible Average Transmission = 59%
[0091] 940nm Transmission = 85%
[0092] 3mm Soda-lime glass, 1st surface coated.
[0093] Visible Average Reflection = 39%
[0094] Visible Average Transmission = 54%
[0095] 940nm Transmission = 78%
[0096] 2mm Soda-lime glass, 1st surface coated.
[0097] Visible Average Reflection = 39%
[0098] Visible Average Transmission = 55%
[0099] 940nm Transmission = 81 %
[00100] For comparison, FIG. 17 shows the percent transmission and percent reflectance for an example silver (Ag) mirror reflector (having a thickness of 200 nm) on a glass substrate, and FIG. 18 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles, while FIG. 19 shows the percent transmission and percent reflectance for an example chromium mirror reflector (having a thickness of 200 nm) on a glass substrate, and FIG. 20 shows the percent transmission and percent reflectance of visible and near IR light at different incident angles.
[00101] The value of the normal coefficient of reflection, as determined according to the method described in Annex 6 of UNITED NATIONS AGREEMENT CONCERNING THE ADOPTION OF UNIFORM TECHNICAL PRESCRIPTIONS FOR WHEELED VEHICLES, EQUIPMENT AND PARTS WHICH CAN BE FITTED AND/OR BE USED ON WHEELED VEHICLES AND THE CONDITIONS FOR RECIPROCAL RECOGNITION OF APPROVALS GRANTED ON THE BASIS OF THESE PRESCRIPTIONS (Revision 2, including the amendments entered into force on October 16, 1995), Addendum 45: Regulation No. 46 (which is hereby incorporated herein by reference in its entirety), of an automotive mirror (whether an electrically-dimmable automotive mirror (such as an electrochromic automotive mirror or a liquid crystal automotive mirror) or a fixed- reflectance automotive mirror (such as a prismatic automotive mirror)) utilizing a blue- tinted spectrally-selective mirror reflective element of the present invention is at least 42%R, more preferably is at least 44%R and most preferably is at least 46%R.
[00102] Optionally, the glass substrate may be coated with a stack of two layers or coatings: a first layer of silicon deposited on the glass surface and a second layer of silicon dioxide (SiO2) deposited on the first layer of silicon. The first layer (the elemental silicon layer) is, for example, less than 30 nm thick, such as, for example, 27 nm (see FIG. 21 ). The second layer (the SiO2 layer) is relatively thin compared to the first layer, such as for example less than 20 nm, preferably less than 15 nm, and more preferably less than 10 nm (but at least 1 nm, and preferably at least 5 nm). Such a mirror reflective element has a light blue tint (viewing at the first surface of the glass substrate) and has greater than 35% visible light transmission, preferably greater than 40% visible light transmission, and more preferably greater than 45% visible light transmission (see FIGS. 22 and 23). The mirror reflective element also has greater than 50% near infrared light transmission (at 940 nm), preferably greater than 55% near infrared light transmission, and more preferably greater than 60% near infrared light transmission. In contrast to known mirror constructions (see, for example, U.S. Pat. No. 5,179,471 , which is hereby incorporated herein by reference in its entirety), the elemental silicon layer stack / construction enables near infrared light transmission (at 940 nm) of at least 50%, and does so without a metallic layer in the two- layer stack. As used herein, a metallic layer is a thin film coating of a metal such as sliver or aluminum or chromium or titanium or tungsten. As used herein, a metal oxide thin film coating of elemental silicon is not a metallic layer. As used herein, a thin film coating of an
oxide of silicon is not a metallic layer. A thin film coating of an oxide of niobium is not a metallic layer. A thin film coating of an oxide of titanium is not a metallic layer. A thin film coating of an oxide of tungsten is not a metallic layer.
[00103] In the embodiment represented in FIGS. 21 -23, the two-layer stack is disposed at the first or front surface of the glass substrate. As shown in FIG. 24, the elemental silicon layer is deposited on the glass substrate, and the SiO2 layer is deposited on the elemental silicon layer, providing a light blue tint with the transmission and reflection properties shown in FIGS. 22 and 23. The silicon thin coating layer has visible light reflectivity and visible light transmission and near infrared (at 940 nm) transmission based on thickness of the coating or layer, such as shown in FIG. 31.
[00104] Furthermore, and less preferably, an elemental Germanium-Si02 bi-layer stack can be used.
[00105] The relatively high refractive index (at 589 nm) of elemental silicon (3.698) and refractive index (at 589 nm) of Germanium (5.724) are useful in the optical stacks described herein due to their large difference between their optical constants and that of the likes of SiO2 (1 .461 ) and MgF2 (1 .378). A difference in refractive index (at 589 nm) between the higher refractive index (at 589 nm) layer and the adjacent lower refractive index (at 589 nm) layer of at least 0.5 is preferred, of at least 0.7 is more preferred, and of at least 1 is more preferred.
[00106] Optionally, a multi-layer stack of oxides of niobium and oxides of silicon may include a layer or coating of elemental silicon. For example, and as shown in FIGS. 25-27, a glass substrate (e.g., a 1.6 mm soda-lime glass substrate) is coated with a layer of elemental silicon (e.g., a 13 nm Si layer), a first layer of SiO2 (e.g., a 20.8 nm SiO2 layer) on the elemental silicon layer, a first layer of Nb2O5 (e.g., a 21 .1 nm Nb2O5 layer) on the first layer of SiO2, a second layer of SiO2 (e.g., a 98.8 nm SiO2 layer) on the first layer of Nb2O5, and a second layer of Nb2O5 (e.g., a 27.6 nm Nb2O5 layer) on the second layer of SiO2. Such a stack of coatings (coated onto the second surface of the glass substrate) provides (at an angle of 25 degrees) 41 .4% visible light reflectivity viewing through the first surface of the glass substrate and 37.7% visible light transmission and 85.7% transmission of near infrared light (at 940 nm).
[00107] Advantages of the blue-tinted spectrally-selective mirror reflective elements/constructions include that preferably no more than three thin film layers (one or
more being a transparent oxide thin film and none a metallic thin film) are used to achieve the desired at least 43%R reflectivity level accompanied by greater than 45%T visible light transmission and greater than 70%T near-IR transmission at 940 nm.
[00108] Optionally, and such as can be seen with reference to FIG. 28, when a thin silver layer is used as a third surface reflector in a laminate type electrochromic mirror cell (such as an electrochromic mirror cell of the types described in U.S. Pat. Nos. 7,626,749;
7,274,501 ; 7,255,451 ; 7,195,381 ; 7,184,190 and/or 6,690,268, which are hereby incorporated herein by reference in their entireties), as the thickness of the silver layer is increased, the percent transmission of near infrared light and the percent transmission of visible light decreases, and the percent reflectivity of visible light increases, as seen by a viewer viewing the first or front surface of the electrochromic mirror cell. For example, at 100 angstroms of silver, visible light reflectivity is increased by 18.3% and near infrared light (at 940 nm) transmission is reduced to 48% of the original (71 %*48% = 34%), and visible light transmission is reduced to 73% of the original. Due to the ITO, the baseline without a mirror coating is approximately 71 % transmission at 940nm.
[00109] In the illustrated embodiment of FIG. 28, the electrochromic mirror cell includes a front glass substrate (e.g., a 2.3 mm thick soda-lime glass substrate), which has a 85 nm transparent conductive layer (e.g., ITO) at the rear or second surface of the front glass substrate, and includes an electrochromic medium (e.g., a solid polymer matrix medium), with the rear glass substrate (e.g., a 2.3 mm thick soda-lime glass substrate) having the third surface reflector and a 110 nm transparent conductive layer (e.g., ITO) disposed on the third surface reflector and in contact with the electrochromic medium. The properties shown in FIG. 28 are for visible light reflectivity and visible light transmission and near infrared light transmission through the front glass substrate, the ITO coating at the second surface, the electrochromic medium, the ITO coating at the third surface reflector, and the third surface reflector at the rear glass substrate.
[00110] A further advantage with use of the stacks described herein is that the materials used are environmentally stable and do not necessarily require encapsulating protective layers, such as needed for the likes of a thin film environmentally unstable material such as a silver thin film coating or the like.
[00111] The tri-layer HI Refractive index (at 589 nm); LOW Refractive index (at 589 nm); HI Refractive index (at 589 nm) stack of coatings is deposited onto the second surface of
the glass substrate used. This has the advantage of having the glass substrate itself protect the second-surface coated tri-layer of oxide thin films from scratching or environmental exposure or the like.
[00112] The second-surface coated tri-layer of oxide thin films can be overcoated or blanked off by a dark colored visible light-absorbing element such as a dark colored lightabsorbing paint or lacquer or plastic film/molding. When used in likes of a DMS (driver or occupant or cabin monitoring system) interior mirror (such as of the types described in U.S. Pat. Nos. 11 ,827,153; 11 ,780,372; 11 ,639,134; 11 ,582,425; 11 ,518,401 ; 10,958,830; 10,065,574; 10,017,114; 9,405,120 and/or 7,914,187, and/or U.S. Publication Nos. US- 2024-0190456; US-2024-0168355; US-2022-0377219; US-2022-0254132; US-2022- 0242438; US-2021-0323473; US-2021-0291739; US-2020-0320320; US-2020-0202151 ;
US-2020-0143560; US-2019-0210615; US-2018-0231976; US-2018-0222414; US-2017- 0274906; US-2017-0217367; US-2016-0209647; US-2016-0137126; US-2015-0352953; US-2015-0296135; US-2015-0294169; US-2015-0232030; US-2015-0092042; US-2015- 0022664; US-2015-0015710; US-2015-0009010 and/or US-2014-0336876, and/or International Publication No. WO 2023/220222, which are all hereby incorporated herein by reference in their entireties), the second-surface coated tri-layer stack of oxide thin films can be overcoated or blanked off by a near-IR transmitting dark plastic film/molding (such as for example, a black PMMA — Poly(methyl methacrylate) plastic film/molding).
[00113] The single glass substrate coated with, for example, the Nb2O5-SiO2-Nb2O5 stack of layers, provides a reduction in cost and complexity and weight of the likes of an electrochromic mirror element that comprises two glass substrates sandwiching an EC medium (such as the types of mirrors 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 all hereby incorporated herein by reference in their entireties). Additionally, an accompanying electronics-populated PCB comprising auto-dimming circuitry and mirror ambient photosensors is not needed.
[00114] Optionally, with the single substrate mirror reflective element, the image data as captured by the rearward-viewing camera (e.g., a rear backup camera or other rearwardviewing camera disposed at a rear portion of the vehicle, or a driver or occupant or cabin
monitoring camera that views rearward within the cabin of the vehicle and rearward of the vehicle via a rear window of the vehicle) may be image processed to determine ambient light (and/or glare light) present at the vehicle. Thus, for example, during nighttime driving, image processing of captured image data can be used to appropriately dim intensity of backlighting of the video display screen to be appropriate for nighttime driving (such as by utilizing aspects of the systems described in U.S. Pat. Nos. 11 ,780,372; 11 ,242,008; 10,967,796 and/or 10,948,798, and/or U.S. Publication No. US-2024-0064274, which are all hereby incorporated herein by reference in their entireties). Also, for example, during high ambient driving, the backlighting is increased so the displayed images are not washed out.
[00115] Alternatively, a single ambient light detecting photosensor and associated simple electronics can be provided at the mirror assembly for adjusting backlighting intensities. Alternatively, ambient sensors already present in the vehicle can provide ambient sensing. Optionally, based on map data of a global positioning system (GPS) of the vehicle, and time of day / night at that location, and based on weather conditions at that location, ambient light levels can be estimated, and operation of the display screen may be adjusted based at least in part on the estimated ambient light levels.
[00116] The field of view of the rearward-viewing camera may be wider than a rearward view provided by the mirror reflective element when the mirror is operating in the mirror mode. Thus, the mirror assembly may be adjustable (such as responsive to actuation of a switch or button or touch sensor) when operating in the display mode to set the displayed images to correspond to or represent the field of view that the mirror reflective element would provide in the mirror mode. Thus, the driver may push a button to set the video display to match what would be viewed if the mirror assembly were in the mirror mode. [00117] For example, the interior rearview mirror assembly, when installed and being used in a vehicle, may be selectively operated in a mirror-mimic mode, where the displayed video images correspond to or represent a view similar to what is provided to the driver when viewing the mirror assembly while it is operating in the mirror mode. When a driver is driving the vehicle and looks toward the interior mirror (when the mirror assembly is installed and being used in a vehicle and operating in the mirror mode), the reflected view often includes portions of the interior of the vehicle at and around the rear window.
When the mirror assembly operates in the display mode, the displayed video images at the
mirror may not provide a frame of reference to what the driver would otherwise see when operating in the mirror mode. Optionally, when the mirror is selectively operated in the mirror-mimic mode (either by user selection and/or system selection by glare detection or driving condition sensed or driver profile/preferences or geographical location and time and conditions), the displayed video images at the mirror reflective element mimic or match or correspond to the rearward mirror view provided when the interior rearview mirror assembly operates in the mirror mode. Optionally, the display may be cropped and/or graphic overlays may be overlaid at the displayed video images to provide an appearance of portions of the interior of the vehicle at the rear window to provide the frame of reference that the driver is used to seeing when viewing a reflected rearward view at the mirror reflective element.
[00118] Thus, for example, if glare light is detected at night due to light emanating from rearward approaching vehicles, the video display screen may turn on automatically, and the video images displayed at the mirror reflective element may be tailored to mimic the same rearward view as reflected off the mirror reflector of the mirror reflective element. This may be achieved with or without actuation of a toggle depending on the amount of glare mitigation desired and the glare detected. The displayed video images may be cropped and/or overlaid to provide the desired rearward view that generally corresponds to the reflected rearward view, and such cropping and overlays may be adjusted based on the driver’s eye location and gaze direction and preferred mirror head position (such as determined responsive to processing of image data captured by a driver monitoring camera at the mirror head and/or by other sensors within the vehicle that may determine an orientation of the mirror head). Thus, when a mirror-mimic mode is selected, the displayed video images may be adjusted to mimic or replicate the reflected images. When the display mode is selected, the video display screen may display wider angle views rearward of the vehicle that do not include graphic overlays to provide the interior frame of reference. The mirror assembly could automatically alternate modes or the mirror assembly could stay in video mode or mirror-mimic mode similar to the way a prismatic mirror stays in the night mode once it is flipped.
[00119] With a full mirror display, any effect on the color may vary due to the transmission properties of the coatings and glass substrate. For example, it may appear as blue when looking at it one way, and may appear as a different color when viewed through
the glass/coating. Thus, using software, the system may adjust the color of the displayed images and/or may adjust the color balance of the rearward-viewing camera to mitigate/compensate color transmission through the spectral-selective mirror reflector and the glass substrate.
[00120] Accordingly, the driver may choose to operate the mirror head in the mirror mode during daytime driving and choose to operate the mirror head in the display mode during nighttime driving, or the driver may choose to operate the mirror head in the display mode during daytime and nighttime driving and the video images may be adjusted based on glare light and/or ambient light detected at the mirror assembly. During nighttime driving, the driver may adjust the mirror head 12 from the mirror mode orientation to the display mode orientation so that reflections from the mirror reflective element may be directed generally upward toward the headliner of the vehicle and the display screen 20 may be operated to display video images representative of the view rearward of the vehicle. Optionally, the mirror assembly may automatically switch to operating in the display mode (and the display screen may be activated) responsive to glare light being detected that is greater than a threshold level for the determined ambient light level.
[00121] In some examples, with the mirror head operating in the mirror mode and with the display screen not displaying video images representative of the rearward view provided by the mirror assembly, the display screen may be operated to adjust the color of the display screen and thus to adjust a background color of the mirror reflective element, such as to reduce reflections of glare light incident at the mirror reflective element. That is, based on determination or detection of glare light incident at the mirror reflective element, the display screen may be operated to display a color that better absorbs light incident at the mirror reflective element and thus reduces reflections of glare light incident thereat. For example, the backlight of the LCD display screen may be adjusted or operated to emit light at a color that absorbs or attenuates at least a portion of light incident at the mirror reflective element.
[00122] Because the mirror assembly does not include an electrically operable dimming mechanism, the mirror assembly does not include circuitry, components or software associated with electronic dimming. This allows for cost and size reduction of the mirror assembly. In other words, the mirror assembly comprises a single surface spectral- selective reflector full video mirror vehicular interior rearview mirror assembly. Cost
reduction is accomplished by providing a flat glass spectral-selective reflector and removing the electrochromic (EC) cell. By doing this, it allows for removal of the EC electrification circuitry, components, and software. To control glare, the mirror assembly may have dual position toggle functionality. In the standard position, when the toggle has not been actuated, the mirror assembly may act as a single surface spectral-selective reflector interior mirror. When the toggle is actuated, the mirror is tilted upward (or optionally downward), which shifts the reflections from the interior rearview mirror assembly toward the vehicle’s headliner (or toward the floor of the vehicle). The actuation also powers on the video functionality, which provides to the driver a view from the vehicle’s camera or cameras, which may be located throughout the exterior of the vehicle (such as a rearward viewing camera).
[00123] Thus, the mirror assembly may include a single glass substrate having a spectral-selective mirror reflector coating for providing reflections for viewing by the driver of the vehicle. A display screen is disposed behind the mirror reflective element for displaying video images representative of the rearward view that are viewable by the driver through the mirror reflective element. Because the mirror reflective element may include a single glass substrate without electrically operable dimming components, the mirror head may be pivotable relative to the mounting structure upward or downward to direct reflections upward or downward and away from view of the driver when the display screen is operated to display video images.
[00124] Although shown and described as being a video display mirror with a full mirror video display accommodated by the mirror head and behind the mirror reflective element, the mirror reflective element and coatings are suitable for use in a mirror head that accommodates a driver monitoring camera and a near infrared (NIR) light emitter, such as by utilizing aspects of the systems described in U.S. Pat. Nos. 11 ,827,153; 11 ,780,372; 11 ,639,134; 11 ,582,425; 11 ,518,401 ; 10,958,830; 10,065,574; 10,017,114; 9,405,120 and/or 7,914,187, and/or U.S. Publication Nos. US-2024-0383406; US-2024-0190456; US- 2024-0168355; US-2022-0377219; US-2022-0254132; US-2022-0242438; US-2021- 0323473; US-2021-0291739; US-2020-0320320; US-2020-0202151 ; US-2020-0143560; US-2019-0210615; US-2018-0231976; US-2018-0222414; US-2017-0274906; US-2017- 0217367; US-2016-0209647; US-2016-0137126; US-2015-0352953; US-2015-0296135; US-2015-0294169; US-2015-0232030; US-2015-0092042; US-2015-0022664; US-2015-
0015710; US-2015-0009010 and/or US-2014-0336876, and/or U.S. provisional application Ser. No. 63/673,225, filed Jul. 19, 2024, and/or International Publication No. WO 2023/220222, which are all hereby incorporated herein by reference in their entireties.
[00125] In accordance with the constructions described herein, a One-Box interior DMS prismatic rearview mirror assembly (having the camera used to monitor the driver's head/eyes and the near-IR emitting light sources that illuminate the driver’s head/eyes and the electronic control unit (ECU) accommodated by the interior rearview mirror assembly) or 1.5-Box interior DMS prismatic rearview mirror assembly can be made using no more than three, and optionally only two, thin film stacked coatings on the second surface of the wedge-shaped cross section glass substrate, with a viewer viewing the coated second surface seeing a blue-tinted reflection. Furthermore, the stack of coatings may include an elemental silicon thin film coating or coatings and/or an elemental Germanium thin film coating or coatings within the multi-layer stack comprising alternating dielectric coatings such as a stack of high refractive index (at 589 nm) dielectric coating - low refractive index (at 589 nm) dielectric coating - high refractive index (at 589 nm) dielectric coating.
[00126] A DMS data processor is disposed at the ECU of the system for processing image data captured by the DMS camera. The DMS data processor may adjust or shift processing of image data captured by the camera based on the orientation of the mirror head (i.e. , when it is flipped up or down), so that the portion of the image data that is being processed for the driver monitoring system is representative of the desired monitored region in the vehicle cabin. A near-IR illumination source (e.g., one or more light emitting diodes that emits near infrared light) is disposed within the mirror head and is operable to emit near-IR light that passes through the spectral-selective mirror reflector of the mirror reflective element. With the vehicular interior rearview mirror assembly attached at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, the near-IR illumination source, when powered, illuminates at least a front seat region at a driver-side of the vehicle. The driver of the vehicle is monitored via processing by the DMS data processor of image data captured by the camera. When the DMS data processor is operating to monitor the driver of the vehicle, the near-IR illumination source is powered while the camera is capturing image data. The near-IR illumination source may comprise a plurality of near-IR light emitters, such as a plurality of near-IR light emitting diodes.
[00127] For example, the alternating stack may comprise a stack of coatings such as niobium oxide or titanium oxide as the higher refractive index (at 589 nm) coating and silicon dioxide as the lower refractive index (at 589 nm) coating. Fewer layers are thus needed to achieve, viewing the first surface of the mirror reflective element, a desired spectrally neutral reflectivity (i.e. , silvery) or a non-spectrally neutral reflectivity (e.g., blue tinted).
[00128] With such an application, the high transmission (about 82 percent) of nearinfrared (NIR) light of the spectral-selective mirror reflector allows the system to utilize a lower intensity near infrared light emitter and a camera having a lower sensitivity to near infrared light. At the regions of the mirror reflective element where the camera and light emitter are not present, a black out coating or tape may be applied to enhance the reflectivity at those regions.
[00129] For the in-cabin DMS and ODS, use of 940 nm near-IR illumination is preferred, and especially when the in-mirror camera has a Quantum Efficiency at 940 nm of at least 15%. Compared to illumination at 850 nm, any “red glow” perceivable by the human eye using 940 nm illumination is less, and thus covertness of the near-IR emitting light sources within the mirror head emitting through the mirror transflector is enhanced. Furthermore, water absorbs 940 nm near-IR light, and thus solar radiation exhibits a dip at 940 nm in its irradiation spectrum due to moisture in the atmosphere. Therefore, ambient solar lighting present in the cabin (and especially when driving on a sunny day in a convertible car with the top down) has a dip or valley at 940 nm which reduces any propensity of ambient solar lighting present in the cabin of the vehicle to interfere with DMS/ODS functionality.
[00130] Quantum efficiency (QE) indicates the effectiveness of an imaging sensor’s conversion of incident photons of light into electrons (for example, if a sensor had a QE of 100% and is exposed to 100 photons, it will produce 100 electrons of signal). For a complementary metal-oxide semiconductor (CMOS) imaging sensor (such as is used currently in vehicular cameras), sensitivity in the near-infrared spectrum is limited by the absorption length in the silicon layer where, in the imaging sensor, impinging light photons generate electrons. At around 940 nm in the near-IR spectral region, QE in such conventional imaging sensors typically is below 15% and for some, below 10%. Because infrared photons are absorbed deeper than visible photons in silicon, imaging sensors need to have a thicker photon absorption region in order to image efficiently in the near
infrared (700 nm to 1 ,000 nm). For example, increasing the Si thickness of the epi-Si layer of the substrate used in a CMOS imaging sensor to 3.0pm to 5.1 pm can increase QE by nearly 40% at the near-IR wavelength of 940nm. Preferably, use of a thicker epi-Si layer is accompanied by a higher pixel bias voltage and/or a lower epi-Si doping level. Use of an anti-reflecting layer and/or backside scattering technology can increase the QE of the image sensor to greater than 40% at 940nm wavelength, which is around a 400% enhancement compared to a conventional CMOS imaging sensor.
[00131] CMOS imaging sensors with enhanced near-IR sensitivity are preferred for use in the One-Box DMS Interior Rearview Mirror Assemblies. For example, a near-IR optimized variant of a CMV4000 imaging sensor available from AMS AG of Premstaetten, Austria can be used. The CMV4000 imaging sensor is a high sensitivity, pipelined global shutter CMOS image sensor with 2048 x 2048 pixel resolution. Preferably, a color version of the CMV4000 imaging sensor is used with the color filters applied in a Bayer RGB pattern, and with the in-mirror camera utilizing the micro lenses to image incident light onto the CMV4000 imaging sensor. The near-IR optimized variant from the standard CMV4000 image sensor is processed on 12 pm epi Si wafers. The thicker epi-Si layer increases significantly the QE for wavelengths above 600 nm. Around 900 nm the QE is about doubled and increases from 8% to 16%. Compared to cameras using imaging sensors that are not optimized for near-IR detection, this represents a doubling of the sensitivity value at around 940 nm.
[00132] For example, an EV76C660 imaging sensor or an EV76C661 imaging sensor available from Teledyne e2v SAS of Saint-Egreve Cedex, France can be used in the One- Box DMS Interior Rearview Mirror Assemblies. The EV76C661 imaging sensor is a 1.3 million pixel (square pixels with micro-lens) CMOS image sensor with an electronic global shutter and operable to provide a high readout speed at 60 fps in full resolution. The EV76C660 and EV76C661 are members of Teledyne e2v’s Ruby family of CMOS imaging sensors that provide enhanced sensitivity and performance beyond that typically available from a front side illuminated imaging sensor. Pixels are 5.3pm X 5.3 pm square with microlens. FIG. 111 shows the spectral response and quantum efficiency of the EV76C660 imaging sensor and of the EV76C661 imaging sensor. Quantum Efficiency in the nearinfrared (NIR) spectrum is excellent (greater than 20% at 940 nm).
[00133] For example, an OX05B1 S imaging sensor available from OMNIVISION of Santa Clara, CA USA can be used in the One-Box DMS Interior Rearview Mirror Assemblies. The OX05B1 S imaging sensor uses OMNIVISION’s NYXEL® near-infrared (NIR) technology. NYXEL® technology features QE improvements that increase sensitivity to the near-infrared spectrum, such improvements comprising utilization by the imaging sensor of thicker silicon to increases the chance of photon absorption; use by the imaging sensor of deep trench isolation to create a barrier between the pixels to eliminate crosstalk and improve modular transfer function; and use by the imaging sensor of a carefully managed optical scattering layer to prevent defects in the image’s dark area and to lengthen the photon path. The OX05B1 S is a 5 megapixel (MP) RGB-IR BSI global shutter imaging sensor and has a pixel size of 2.2 pm X 2.2 pm, and includes integrated cybersecurity. The OX05B1 S has a near-IR QE of 36%.
[00134] A CMOS imaging sensor for use in the One-Box DMS Interior Rearview Mirror Assemblies preferably has a near-IR QE at around 940 nm of at least 15%, more preferably is at least 22%, and most preferably is at least about 32%. Thickness of the episilicon layer of a CMOS imaging sensor for use in the One-Box DMS Interior Rearview Mirror Assemblies preferably is at least about 3.5pm, more preferably is at least about 4.5pm, and most preferably is at least about 5.5pm.
[00135] Optionally, and such as shown in FIG. 29, an interior electro-optic (e.g., electrochromic) rearview mirror assembly 110 may include a mirror reflective element 116 that has a front glass substrate 130 (e.g., a 1.6 mm thick glass substrate) and a rear glass substrate 132 (e.g., a 1.1 mm thick glass substrate), with an electro-optic medium 134 (e.g., an electrochromic solid polymer matrix (SPM) medium) sandwiched between the glass substrates and bounded by a perimeter seal 136. The front glass substrate 130 has an electrically conductive coating 138 (e.g., a half-wave ITO coating) at a rear or second surface of the front glass substrate (and may also have a perimeter hiding layer 139 (e.g., a chrome ring hiding layer) at the rear or second surface of the front glass substrate), and the rear glass substrate 132 has an electrically conductive coating 140 (e.g., a half-wave ITO coating) at a front or third surface of the rear glass substrate. Optionally, and alternative to use of a chrome ring, a dark colored or black hiding layer may be used that is preferably matched to the color of the main seal so that both blend one into the other (such as by utilizing aspects of the mirrors described in U.S. Pat. No. 5,066,112, which is hereby
incorporated herein by reference in its entirety) when viewed by the driver of the vehicle. The transparent electrically conductive coating disposed at the second surface of the front substrate and the transparent electrically conductive coating disposed at the third surface of the rear substrate oppose and contact the electrochromic medium 134.
[00136] The mirror reflective element includes a fourth surface mirror reflector 142 disposed at a rear or fourth surface of the rear glass substrate 132. In the illustrated embodiment, the fourth surface reflector 142 is a thick (e.g., 100 nm or more) silver coating or layer. The silver layer or film provides auxiliary visible light reflectivity and visible light transmission and near infrared (at 940 nm) transmission based on thickness of the coating or layer, such as shown in FIG. 30. The thick silver layer (at, for example, 100 nm or 1 ,000 Angstroms) provides high visible light reflection (greater than 70%) and low visible light transmission (less than 20%) and low near infrared light transmission (less than 8%).
[00137] The rear surface of the rear glass substrate is devoid of the fourth surface reflector at a camera region 144 (which may be centrally located at the mirror reflective element or may be at an upper region or a lower region or a side region of the mirror reflective element). A thin mirror coating 146 (e.g., a silver coating of 10 nm thickness or more or less) is established at the camera region 144. As shown in FIG. 30, the 10 nm auxiliary or augmenting reflective silver coating provides visible light reflectivity of about 32%, visible light transmission of about 60% and near infrared light transmission (at 940 nm) of about 33%. Optionally, for example, a 4 nm auxiliary or augmenting reflective silver coating may be used and provides visible light reflectivity of 13.2%, visible light transmission of 81 .5% and near infrared light transmission (at 940 nm) of 66.5%. Thus, the thickness of the thin auxiliary or augmenting reflective silver coating may be selected to provide, for example, at least 10% visible light reflectivity, at least 60% visible light transmission and at least 30% near infrared light transmission (at 940 nm).
[00138] As shown in FIG. 29, a high refractive index (at 589 nm) /low refractive index (at 589 nm) I high refractive index (at 589 nm) stack of alternating thin films 148 is disposed at the thin mirror coating 146 at the camera region 144. The stack of alternating thin films 148 may comprise a stack of metal oxide films, or may comprise a stack of Nb2O5-SiO2- Nb2O5 layers or films, or a stack of TiO2-SiO2-TiO2 layers or films, or a stack of S iO2-S i layers or films, such as discussed above, depending on the particular application and desired or targeted appearance and characteristics of the mirror reflective element. The
stack of alternating thin films 148 augments the reflectivity of the thin mirror coating 146. A reflective polarizing film 150 (e.g., a 3M® reflecting polarizing mirror film) is disposed behind the stack of alternating thin films 148. Reflecting polarizing mirror (“RPM”) films are available from 3M of St. Paul, MN USA and are described at https://www.3m.eom/3M/en_US/p/d/b5005074010/. For example, the reflective polarizing film 150 shown in FIG. 29 may comprise a reflective polarizing mirror film that uses a multilayer polyester-based film with adhesive such as is described at https://multimedia.3m.com/mws/media/1963407O/3m-reflective-polarizing-mirror-3m-rpm- technical-data-sheet.pdf?&fn=RPM%20Tech%20Data%20Sheet.pdf. Such RPM films are reflective of visible light, are transmissive of visible light and are transmissive of near IR light (such as at 940nm). The reflective polarizing film 150 adds to and augments the visible reflectivity such that the visible light reflectivity at the camera region 144 is close to or matches the visible light reflectivity of the thick silver reflector coating 142. For example, the camera region 144 may provide at least 40% visible light reflectivity, preferably at least 43% visible light reflectivity, and more preferably at least 46% visible light reflectivity. The camera region may also provide enhanced transmission of near infrared light (e.g., at 940 nm). Also, the thick silver mirror reflector adjacent to and outside of the camera region provides at least 40% visible light reflectivity, preferably at least 43% visible light reflectivity, and more preferably at least 46% visible light reflectivity.
[00139] Thus, a camera 152 disposed behind and viewing through the camera region views through the reflective polarizing film 150, the stack of alternating thin films 148, the thin mirror coating 146 and the glass substrates and electrochromic medium to view a driver region within the interior cabin of the vehicle. Optionally, one or more near-infrared light emitters 154 (e.g., light emitting diodes (LEDs) or vertical-cavity surface-emitting lasers (VCSEL)) may be disposed at the camera region and operable to, when electrically powered, emit near infrared light that passes through the reflective polarizing film 150, the stack of alternating thin films 148, the thin mirror coating 146 and the glass substrates and electrochromic medium to illuminate the driver region within the interior cabin of the vehicle.
[00140] Optionally, the mirror reflective element may comprise an electro-optic mirror reflective element (e.g., an electrochromic mirror reflective element or liquid crystal mirror reflective element) that has a front glass substrate (e.g., a 1 .6 mm thick glass substrate)
and a rear glass substrate (e.g., a 1 .1 mm thick glass substrate), with an electro-optic medium (e.g., an electrochromic solid polymer matrix (SPM) medium) sandwiched between the glass substrates and bounded by a perimeter seal. The front glass substrate has an electrically conductive coating (e.g., a half-wave ITO coating) at a rear or second surface of the front glass substrate (and may also have a perimeter hiding layer (e.g., a chrome ring hiding layer) at the rear or second surface of the front glass substrate), and the rear glass substrate has an electrically conductive coating (e.g., a half-wave ITO coating) at a front or third surface of the rear glass substrate. The mirror reflective element may comprise a third-surface mirror reflector, whereby the electrically conductive coating includes or is disposed at the mirror reflector coating. The transparent electrically conductive coating disposed at the second surface of the front substrate and the electrically conductive coating disposed at the third surface of the rear substrate oppose and contact the electrochromic medium.
[00141] The reflective element and mirror casing are adjustable relative to a base portion or mounting assembly to adjust the driver’s rearward field of view when the mirror assembly is normally mounted at or in the vehicle. The mounting assembly may comprise a single-ball or single-pivot mounting assembly, whereby the reflective element and casing are adjustable relative to the vehicle windshield (or other interior portion of the vehicle) about a single pivot joint, or the mounting assembly may comprise other types of mounting configurations, such as a double-ball or double-pivot mounting configuration or the like. The socket or pivot element is configured to receive a ball member of the base portion, such as for a single pivot or single ball mounting structure or a double pivot or double ball mounting structure or the like (such as a pivot mounting assembly of the types described in U.S. Pat. Nos. 6,318,870; 6,593,565; 6,690,268; 6,540,193; 4,936,533; 5,820,097;
5,100,095; 7,249,860; 6,877,709; 6,329,925; 7,289,037; 7,249,860 and/or 6,483,438, which are hereby incorporated herein by reference in their entireties).
[00142] The mounting base includes an attaching portion that is configured to be attached to an interior surface of a vehicle windshield (such as to a mounting button or attachment element adhered to the interior surface of the vehicle windshield or such as to a headliner or overhead console of the vehicle). The mounting base may comprise a metallic ball portion or may comprise a molded (such as injection molded) polymeric
mounting base or may be otherwise formed, depending on the particular application of the mirror assembly.
[00143] Preferably the respective physical thickness and refractive index (measured at 589 nm) and order within the multi-layer stack relative to the glass (or plastic) surface of individual non-metallic thin film coatings forming the spectral-selective mirror transflector disposed at a surface of a glass (or plastic) substrate of the mirror reflective element is selected so that the driver of an equipped vehicle viewing the mirror reflective element sees a blue-tinted mirror reflective element. However, the optical design of the multi-layer stack may be chosen so as to provide other color tints as viewed by the driver (for example, a reddish tint or a greenish tint). The blue-tinted mirror reflective element having high (at least 50%T) transmissivity in the near-IR spectral region at 940 nm is preferably achieved using a tri-layer stack of non-metallic thin films of metal oxides (or via a bi-layer stack of elemental silicon overcoated with a metal oxide, such as an oxide of silicon).
Because each individual metal oxide thin film coating is transparent and absorbs little to no incident visible or near-IR light, the lens of the likes of a DMS camera can view through the spectral-selective mirror transflector. Preferably, a light absorbing mask or tape or element is disposed behind the mirror reflective element other than where the DMS camera views through the spectral-selective mirror transflector of the mirror reflective element (and/or other than where any near-IR illuminators disposed in the mirror head emit light through the spectral-selective mirror transflector of the mirror reflective element). For the tri-layer design, total physical thickness of all three non-metallic thin film coatings forming the spectral-selective mirror transflector is preferably less than 350 nm, more preferably less than 300 nm, and most preferably less than 250 nm.
[00144] The mirror assembly may comprise a prismatic reflective element. The prismatic mirror assembly may be mounted or attached at an interior portion of a vehicle (such as at an interior surface of a vehicle windshield) via the mounting means described above, and the reflective element may be toggled or flipped or adjusted between its daytime reflectivity position and its nighttime reflectivity position via any suitable toggle means, such as by utilizing aspects of the mirror assemblies described in U.S. Pat. Nos. 6,318,870 and/or 7,249,860, and/or U.S. Publication No. US-2010-0085653, which are hereby incorporated herein by reference in their entireties. Optionally, for example, the interior rearview mirror assembly may utilize aspects of a prismatic mirror assembly, such as the types described
in U.S. Pat. Nos. 7,289,037; 7,249,860; 6,318,870; 6,598,980; 5,327,288; 4,948,242; 4,826,289; 4,436,371 and/or 4,435,042, and/or U.S. Publication Nos. US-2025-0074308 and/or US-2024-0075878, which are hereby incorporated herein by reference in their entireties. Optionally, the prismatic reflective element may comprise a conventional prismatic reflective element or prism or may comprise a prismatic reflective element of the types described in U.S. Pat. Nos. 7,420,756; 7,289,037; 7,274,501 ; 7,249,860; 7,338,177 and/or 7,255,451 , which are all hereby incorporated herein by reference in their entireties. [00145] Optionally, the mirror assembly may include one or more other displays, such as the types disclosed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925, which are hereby incorporated herein by reference in their entireties, and/or display-on-demand transflective type displays, and/or video displays or display screens, such as the types disclosed in U.S. Pat. Nos. 8,890,955; 7,855;755; 7 ,338,177; 7,274,501 ; 7,255,451 ; 7,195,381 ; 7,184,190; 7,046,448; 5,668,663; 5,724,187; 5,530,240; 6,329,925; 6,690,268; 7,734,392; 7,370,983; 6,902,284; 6,428,172; 6,420,975; 5,416,313; 5,285,060; 5,193,029 and/or 4,793,690, and/or in U.S. Pat. Pub. Nos. US-2006-0050018; US-2009-0015736; US-2009-0015736 and/or US-2010-0097469, which are all hereby incorporated herein by reference in their entireties.
[00146] Thus, a vehicular interior rearview mirror assembly includes a mounting structure configured to mount the vehicular interior rearview mirror assembly at an interior portion of an interior cabin of a vehicle. A mirror head accommodates a mirror reflective element. A spectral-selective mirror transflector is disposed at a surface of a substrate of the mirror reflective element. The spectral-selective mirror transflector comprises a multilayer stack of thin film coatings. The deposited multi-layer stack of non-metallic thin film coatings of the spectral-selective mirror transflector at least comprises a first non-metallic thin film coating deposited at the surface of the substrate of the mirror reflective element and a second non-metallic thin film coating deposited onto the first non-metallic thin film coating. The first non-metallic thin film coating has a first refractive index (at 589 nm), and the second non-metallic thin film coating has a second refractive index (at 589 nm). With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjustable by a driver of the vehicle to set a rearward view for the driver. With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the driver of the vehicle viewing
the mirror reflective element sees a blue-tinted mirror reflective element. The spectral- selective mirror transflector transmits near-infrared (near-IR) light incident thereon, transmits visible light incident thereon and reflects visible light incident thereon. Reflectivity of visible light incident at the mirror reflective element is at least 40 percent as determined in accordance with SAE Recommended Practice J964. Transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 45 percent. A camera is disposed within the mirror head and views through the spectral- selective mirror transflector of the mirror reflective element. The camera moves in tandem with the mirror head when, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjusted to adjust the driver’s rearward view. The camera is operable to capture image data. A near-IR illumination source is disposed within the mirror head. With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, the near-IR illumination source, when powered, illuminates at least a front seat region at a driver-side of the vehicle. With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, and via processing by a driver monitoring system (DMS) of image data captured by the camera, the driver of the vehicle is monitored. Presence of the camera disposed within the mirror head and viewing through the spectral-selective mirror transflector of the mirror reflective element is covert from view by the driver of the vehicle. [00147] Optionally, the substrate may comprise a single glass substrate of the mirror reflective element, the single glass substrate having a first surface and a second surface that is opposite the first surface and is separated from the first surface by a thickness of the single glass substrate. With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, the first surface is closer to the driver of the vehicle than the second surface.
[00148] The spectral-selective mirror transflector may be disposed at the second surface of the single glass substrate. The spectral-selective mirror transflector may be disposed at the first surface of the single glass substrate. The single glass substrate may comprise a
prismatic glass substrate. The second surface of the single glass substrate may be parallel to the first surface of the single glass substrate.
[00149] Optionally, the mirror reflective element may comprise an electro-optic mirror reflective element having a front glass substrate and a rear glass substrate with an electrooptic medium sandwiched between the front glass substrate and the rear glass substrate. The substrate having the spectral-selective mirror transflector disposed thereat comprises the rear glass substrate of the electro-optic mirror reflective element.
[00150] The spectral-selective mirror transflector disposed at the surface of the rear glass substrate may oppose and contact the electro-optic medium of the electro-optic mirror reflective element. The rear glass substrate may have an electrically conductive coating that opposes and contacts the electro-optic medium of the electro-optic mirror reflective element, with the spectral-selective mirror transflector disposed at the surface opposite from the electrically conductive coating.
[00151] Optionally, transmission of visible light through the mirror reflective element is at least 15 percent as determined in accordance with SAE Recommended Practice J964. Optionally, transmission of visible light through the mirror reflective element is at least 30 percent as determined in accordance with SAE Recommended Practice J964. Optionally, transmission of visible light through the mirror reflective element is at least 45 percent as determined in accordance with SAE Recommended Practice J964. Optionally, transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 55 percent. Optionally, transmission through the mirror reflective element of visible light is at least 50 percent. Optionally, transmission through the mirror reflective element of visible light is at least 55 percent. Optionally, reflectivity of visible light incident at the mirror reflective element is at least 42 percent as determined in accordance with SAE Recommended Practice J964. Optionally, reflectivity of visible light incident at the mirror reflective element is at least 45 percent as determined in accordance with SAE Recommended Practice J964.
[00152] Optionally, the camera may comprise an imaging sensor having a quantum efficiency (QE) of at least 15% for near-infrared (near-IR) light having a wavelength of 940 nm.
[00153] Optionally, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, a data processor of the DMS is disposed
at the vehicle remote from the vehicular interior rearview mirror assembly. Optionally, the vehicular interior rearview mirror assembly comprises a data processor of the DMS.
[00154] Optionally, the interior portion of the interior cabin of the vehicle comprises an incabin side of a windshield of the vehicle. Optionally, the near-IR illumination source comprises a plurality of near-IR light emitters.
[00155] Optionally, the mirror head accommodates a video display screen, and, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the video display screen is electrically operable to display video images for viewing by the driver through the spectral-selective mirror transflector of the mirror reflective element. With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the vehicular interior rearview mirror assembly may be operable in (i) a mirror mode, where the mirror head is positioned so that reflections at the mirror reflective element provide the rearward view for the driver, and (ii) a display mode, where the video display screen is electrically operated to display video images representative of the rearward view for viewing by the driver. With the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, a toggle mechanism may be operable to adjust the mirror head between (i) a mirror mode orientation, where the mirror head is positioned so that reflections at the mirror reflective element provide the rearward view for the driver, and (ii) a display mode orientation, where the mirror head is tilted from the mirror mode orientation so that reflections at the mirror reflective element are directed away from the driver. Responsive to the mirror head being adjusted to the display mode orientation, the video display screen may be automatically electrically operated to display video images representative of the rearward view for viewing by the driver. When the mirror head is adjusted between the mirror mode orientation and the display mode orientation, the mirror head is tilted about a pivot axis that is parallel to a longitudinal axis of the mirror head. When the mirror head is adjusted from the mirror mode orientation to the display mode orientation, the mirror head is tilted upward about the pivot axis. When the mirror head is adjusted from the mirror mode orientation to the display mode orientation, the mirror head is tilted downward about the pivot axis.
[00156] With the vehicular interior rearview mirror assembly operating in the mirror mode, and based on determination of glare light incident at the mirror reflective element,
the video display screen may be electrically operated to reduce glare light that is reflected by the mirror reflective element toward the driver of the vehicle. Glare light may be determined via processing of image data captured by a rearward-viewing camera of the vehicle.
[00157] With the vehicular interior rearview mirror assembly operating in the display mode, a field of view provided by the displayed images may be adjustable by the driver of the vehicle. With the vehicular interior rearview mirror assembly operating in the display mode, the driver, via actuation of a user input, sets the field of view provided by the displayed images to mimic a field of view provided by the mirror reflective element when the vehicular interior rearview mirror assembly operates in the mirror mode. With the vehicular interior rearview mirror assembly operating in the mirror mode, and responsive to determination of glare light emanating from rearward of the vehicle, the vehicular interior rearview mirror assembly may operate in a mirror-mimic mode that sets the field of view provided by the displayed images to mimic a field of view provided by the mirror reflective element when the vehicular interior rearview mirror assembly operates in the mirror mode.
[00158] Optionally, the near-IR illumination source disposed within the mirror head, when operated, emits near-IR light that passes through the spectral-selective mirror transflector of the mirror reflective element. Presence of the near-IR illumination source disposed within the mirror head is covert from view by the driver of the vehicle.
[00159] Optionally, an occupant-monitoring camera may be disposed within the mirror head, and the occupant-monitoring camera moves in tandem with the mirror head when, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjusted to adjust the driver’s rearward view. The occupant-monitoring camera may view through the spectral-selective mirror transflector of the mirror reflective element, and presence of the occupant-monitoring camera disposed within the mirror head and viewing through the spectral-selective mirror transflector of the mirror reflective element is covert from view by the driver of the vehicle. [00160] Optionally, the near-IR illumination source may comprise at least one emitting diode (LED). Optionally, the near-IR illumination source may comprise at least verticalcavity surface-emitting laser (VCSEL).
[00161] Optionally, the multi-layer stack of non-metallic thin film coatings comprises a third non-metallic thin film coating having a third refractive index (at 589 nm), with the third
non-metallic thin film coating having the third refractive index (at 589 nm) being deposited onto the second non-metallic thin film coating. The first non-metallic thin film coating may comprise a first metal oxide coating, and the second non-metallic thin film coating may comprise a second metal oxide coating, and the third non-metallic thin film coating may comprise a third metal oxide coating. The spectral-selective mirror transflector comprises a tri-layer stack of the first metal oxide coating, the second metal oxide coating and the third metal oxide coating. The first non-metallic thin film coating is closer to the surface of the substrate than the second and third non-metallic thin film coatings, and the second non- metallic thin film coating is sandwiched between the first non-metallic thin film coating and the third non-metallic thin film coating. Optionally, the first non-metallic thin film coating comprises a higher refractive index (at 589 nm) coating having a first refractive index (at 589 nm), and the second non-metallic thin film coating comprises a lower refractive index (at 589 nm) coating having a second refractive index (at 589 nm) that is lower than the first refractive index (at 589 nm), and the third non-metallic thin film coating comprises a higher refractive index (at 589 nm) coating having the third refractive index (at 589 nm) that is higher than the second refractive index (at 589 nm).
[00162] Optionally, the first non-metallic thin film coating comprises an oxide of niobium, and the second non-metallic thin film coating comprises an oxide of silicon, and the third non-metallic thin film coating comprises an oxide of niobium. Optionally, the first non- metallic thin film coating comprises a layer of Nb2O5, and the second non-metallic thin film coating comprises a layer of SiO2, and the third non-metallic thin film coating comprises a layer of Nb2O5. Optionally, the first non-metallic thin film coating comprises an oxide of titanium, and the second non-metallic thin film coating comprises an oxide of silicon, and the third non-metallic thin film coating comprises an oxide of titanium.
[00163] Optionally, the first non-metallic thin film coating comprises elemental silicon, and the second non-metallic thin film coating comprises an oxide of silicon.
[00164] Transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm may be at least 80 percent.
[00165] Optionally, the multi-layer stack of non-metallic thin film coatings comprises a third non-metallic thin film coating having a third refractive index (at 589 nm). The third non-metallic thin film coating having the third refractive index (at 589 nm) may be deposited onto the second non-metallic thin film coating. The third refractive index may be
higher than the second refractive index (at 589 nm). The first refractive index may be similar to that of the third refractive index (at 589 nm) and may be higher than the second refractive index (at 589 nm). For example, the first refractive index is higher than 2 and the second refractive index (at 589 nm) is lower than 1 .5 and the third refractive index (at 589 nm) is higher than 2. Optionally, the first refractive index comprises an oxide of niobium, and the second non-metallic thin film coating comprises an oxide of silicon, and the third non-metallic thin film coating comprises an oxide of niobium. Optionally, the first refractive index comprises an oxide of titanium, and the second non-metallic thin film coating comprises an oxide of silicon, and the third non-metallic thin film coating comprises an oxide of titanium.
[00166] The difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating may be at least 0.5. The difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating may be at least 0.7. The difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating may be at least 1 .0.
[00167] Optionally, the multi-layer stack of non-metallic thin film coatings consists of the first non-metallic thin film coating and the second non-metallic thin film coating, and the first non-metallic thin film coating may have a refractive index (at 589 nm) greater than 3, and the second non-metallic thin film coating may have a refractive index (at 589 nm) less than 3. The first non-metallic thin film coating may comprise elemental silicon, and the second non-metallic thin film coating may have a refractive index (at 589 nm) less than 1 .5. The second non-metallic thin film coating may comprise a thin film coating of an oxide of silicon. The physical thickness of the first non-metallic thin film coating may be larger than the physical thickness of the second non-metallic thin film coating. The physical thickness of the first non-metallic thin film coating may be less than 30 nm, and the physical thickness of the first non-metallic thin film coating may be less than 20 nm.
[00168] 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
1 . A vehicular interior rearview mirror assembly, the vehicular interior rearview mirror assembly comprising: a mounting structure configured to mount the vehicular interior rearview mirror assembly at an interior portion of an interior cabin of a vehicle; a mirror head accommodating a mirror reflective element; a spectral-selective mirror transflector disposed at a surface of a substrate of the mirror reflective element, and wherein the spectral-selective mirror transflector comprises a multi-layer stack of thin film coatings; wherein the deposited multi-layer stack of non-metallic thin film coatings of the spectral-selective mirror transflector at least comprises a first non-metallic thin film coating deposited at the surface of the substrate of the mirror reflective element and a second non- metallic thin film coating deposited onto the first non-metallic thin film coating; wherein the first non-metallic thin film coating has a first refractive index (at 589 nm), and wherein the second non-metallic thin film coating has a second refractive index (at 589 nm); wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjustable by a driver of the vehicle to set a rearward view for the driver; wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the driver of the vehicle viewing the mirror reflective element sees a blue-tinted mirror reflective element; wherein the spectral-selective mirror transflector transmits near-infrared (near-IR) light incident thereon, transmits visible light incident thereon and reflects visible light incident thereon; wherein reflectivity of visible light incident at the mirror reflective element is at least 40 percent as determined in accordance with SAE Recommended Practice J964; wherein transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 45 percent; a camera disposed within the mirror head and viewing through the spectral- selective mirror transflector of the mirror reflective element, wherein the camera moves in
tandem with the mirror head when, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjusted to adjust the driver’s rearward view; wherein the camera is operable to capture image data; a near-IR illumination source disposed within the mirror head; wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, the near-IR illumination source, when powered, illuminates at least a front seat region at a driver-side of the vehicle; wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, and via processing by a driver monitoring system (DMS) of image data captured by the camera, the driver of the vehicle is monitored; and wherein presence of the camera disposed within the mirror head and viewing through the spectral-selective mirror transflector of the mirror reflective element is covert from view by the driver of the vehicle.
2. The vehicular interior rearview mirror assembly of claim 1 , wherein the substrate comprises a single glass substrate of the mirror reflective element, and wherein the single glass substrate has a first surface and a second surface, and wherein the second surface is opposite the first surface and is separated from the first surface by a thickness of the single glass substrate, and wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle and with the mirror head adjusted to provide the driver’s rearward view, the first surface is closer to the driver of the vehicle than the second surface.
3. The vehicular interior rearview mirror assembly of claim 2, wherein the spectral- selective mirror transflector is disposed at the second surface of the single glass substrate.
4. The vehicular interior rearview mirror assembly of claim 2, wherein the spectral- selective mirror transflector is disposed at the first surface of the single glass substrate.
5. The vehicular interior rearview mirror assembly of claim 2, wherein the single glass substrate comprises a prismatic glass substrate.
6. The vehicular interior rearview mirror assembly of claim 2, wherein the second surface of the single glass substrate is parallel to the first surface of the single glass substrate.
7. The vehicular interior rearview mirror assembly of claim 1 , wherein the mirror reflective element comprises an electro-optic mirror reflective element having a front glass substrate and a rear glass substrate with an electro-optic medium sandwiched between the front glass substrate and the rear glass substrate, and wherein the substrate having the spectral-selective mirror transflector disposed thereat comprises the rear glass substrate of the electro-optic mirror reflective element.
8. The vehicular interior rearview mirror assembly of claim 7, wherein the spectral- selective mirror transflector disposed at the surface of the rear glass substrate opposes and contacts the electro-optic medium of the electro-optic mirror reflective element.
9. The vehicular interior rearview mirror assembly of claim 7, wherein the rear glass substrate has an electrically conductive coating that opposes and contacts the electrooptic medium of the electro-optic mirror reflective element, and wherein the spectral- selective mirror transflector is disposed at the surface opposite from the electrically conductive coating.
10. The vehicular interior rearview mirror assembly of claim 1 , wherein transmission of visible light through the mirror reflective element is at least 15 percent as determined in accordance with SAE Recommended Practice J964.
11 . The vehicular interior rearview mirror assembly of claim 1 , wherein transmission of visible light through the mirror reflective element is at least 30 percent as determined in accordance with SAE Recommended Practice J964.
12. The vehicular interior rearview mirror assembly of claim 1 , wherein transmission of visible light through the mirror reflective element is at least 45 percent as determined in accordance with SAE Recommended Practice J964.
13. The vehicular interior rearview mirror assembly of claim 1 , wherein transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 55 percent.
14. The vehicular interior rearview mirror assembly of claim 1 , wherein transmission through the mirror reflective element of visible light is at least 50 percent.
15. The vehicular interior rearview mirror assembly of claim 1 , wherein transmission through the mirror reflective element of visible light is at least 55 percent.
16. The vehicular interior rearview mirror assembly of claim 1 , wherein reflectivity of visible light incident at the mirror reflective element is at least 42 percent as determined in accordance with SAE Recommended Practice J964.
17. The vehicular interior rearview mirror assembly of claim 1 , wherein reflectivity of visible light incident at the mirror reflective element is at least 45 percent as determined in accordance with SAE Recommended Practice J964.
18. The vehicular interior rearview mirror assembly of claim 1 , wherein the camera comprises an imaging sensor having a quantum efficiency (QE) of at least 15% for nearinfrared (near-IR) light having a wavelength of 940 nm.
19. The vehicular interior rearview mirror assembly of claim 1 , wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, a data processor of the DMS is disposed at the vehicle remote from the vehicular interior rearview mirror assembly.
20. The vehicular interior rearview mirror assembly of claim 1 , wherein the vehicular interior rearview mirror assembly comprises a data processor of the DMS.
21 . The vehicular interior rearview mirror assembly of claim 1 , wherein the interior portion of the interior cabin of the vehicle comprises an in-cabin side of a windshield of the vehicle.
22. The vehicular interior rearview mirror assembly of claim 1 , wherein the near-IR illumination source comprises a plurality of near-IR light emitters.
23. The vehicular interior rearview mirror assembly of claim 1 , wherein the mirror head accommodates a video display screen, and wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the video display screen is electrically operable to display video images for viewing by the driver through the spectral-selective mirror transflector of the mirror reflective element.
24. The vehicular interior rearview mirror assembly of claim 23, wherein, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the vehicular interior rearview mirror assembly is operable in (i) a mirror mode, where the mirror head is positioned so that reflections at the mirror reflective element provide the rearward view for the driver, and (ii) a display mode, where the video display screen is electrically operated to display video images representative of the rearward view for viewing by the driver.
25. The vehicular interior rearview mirror assembly of claim 24, further comprising a toggle mechanism that, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, is operable to adjust the mirror head between (i) a mirror mode orientation, where the mirror head is positioned so that reflections at the mirror reflective element provide the rearward view for the driver, and (ii) a display mode orientation, where the mirror head is tilted from the mirror mode orientation so that reflections at the mirror reflective element are directed away from the driver, and wherein, responsive to the mirror head being adjusted to the display mode orientation, the
video display screen is automatically electrically operated to display video images representative of the rearward view for viewing by the driver.
26. The vehicular interior rearview mirror assembly of claim 25, wherein, when the mirror head is adjusted between the mirror mode orientation and the display mode orientation, the mirror head is tilted about a pivot axis that is parallel to a longitudinal axis of the mirror head.
27. The vehicular interior rearview mirror assembly of claim 26, wherein, when the mirror head is adjusted from the mirror mode orientation to the display mode orientation, the mirror head is tilted upward about the pivot axis.
28. The vehicular interior rearview mirror assembly of claim 26, wherein, when the mirror head is adjusted from the mirror mode orientation to the display mode orientation, the mirror head is tilted downward about the pivot axis.
29. The vehicular interior rearview mirror assembly of claim 24, wherein, with the vehicular interior rearview mirror assembly operating in the mirror mode, and based on determination of glare light incident at the mirror reflective element, the video display screen is electrically operated to reduce glare light that is reflected by the mirror reflective element toward the driver of the vehicle.
30. The vehicular interior rearview mirror assembly of claim 29, wherein glare light is determined via processing of image data captured by a rearward-viewing camera of the vehicle.
31 . The vehicular interior rearview mirror assembly of claim 24, wherein, with the vehicular interior rearview mirror assembly operating in the display mode, a field of view provided by the displayed images is adjustable by the driver of the vehicle.
32. The vehicular interior rearview mirror assembly of claim 31 , wherein, with the vehicular interior rearview mirror assembly operating in the display mode, the driver, via
actuation of a user input, sets the field of view provided by the displayed images to mimic a field of view provided by the mirror reflective element when the vehicular interior rearview mirror assembly operates in the mirror mode.
33. The vehicular interior rearview mirror assembly of claim 31 , wherein, with the vehicular interior rearview mirror assembly operating in the mirror mode, and responsive to determination of glare light emanating from rearward of the vehicle, the vehicular interior rearview mirror assembly operates in a mirror-mimic mode that sets the field of view provided by the displayed images to mimic a field of view provided by the mirror reflective element when the vehicular interior rearview mirror assembly operates in the mirror mode.
34. The vehicular interior rearview mirror assembly of claim 1 , wherein the near-IR illumination source disposed within the mirror head, when operated, emits near-IR light that passes through the spectral-selective mirror transflector of the mirror reflective element.
35. The vehicular interior rearview mirror assembly of claim 34, wherein presence of the near-IR illumination source disposed within the mirror head is covert from view by the driver of the vehicle.
36. The vehicular interior rearview mirror assembly of claim 1 , wherein an occupantmonitoring camera is also disposed within the mirror head, and wherein the occupantmonitoring camera moves in tandem with the mirror head when, with the vehicular interior rearview mirror assembly mounted at the interior portion of the interior cabin of the vehicle, the mirror head is adjusted to adjust the driver’s rearward view.
37. The vehicular interior rearview mirror assembly of claim 36, wherein the occupantmonitoring camera views through the spectral-selective mirror transflector of the mirror reflective element, and wherein presence of the occupant-monitoring camera disposed within the mirror head and viewing through the spectral-selective mirror transflector of the mirror reflective element is covert from view by the driver of the vehicle.
38. The vehicular interior rearview mirror assembly of claim 1 , wherein the near-IR illumination source comprises at least one emitting diode (LED).
39. The vehicular interior rearview mirror assembly of claim 1 , wherein the near-IR illumination source comprises at least vertical-cavity surface-emitting laser (VCSEL).
40. The vehicular interior rearview mirror assembly of any preceding claim, wherein the multi-layer stack of non-metallic thin film coatings comprises a third non-metallic thin film coating having a third refractive index (at 589 nm), and wherein the third non-metallic thin film coating having the third refractive index (at 589 nm) is deposited onto the second non- metallic thin film coating, and wherein the first non-metallic thin film coating comprises a first metal oxide coating, and wherein the second non-metallic thin film coating comprises a second metal oxide coating, and wherein the third non-metallic thin film coating comprises a third metal oxide coating, and wherein the spectral-selective mirror transflector comprises a tri-layer stack of the first metal oxide coating, the second metal oxide coating and the third metal oxide coating.
41 . The vehicular interior rearview mirror assembly of claim 40, wherein the first non- metallic thin film coating is closer to the surface of the substrate than the second and third non-metallic thin film coatings, and wherein the second non-metallic thin film coating is sandwiched between the first non-metallic thin film coating and the third non-metallic thin film coating.
42. The vehicular interior rearview mirror assembly of claim 41 , wherein the first non- metallic thin film coating comprises a higher refractive index (at 589 nm) coating having a first refractive index (at 589 nm), and wherein the second non-metallic thin film coating comprises a lower refractive index (at 589 nm) coating having a second refractive index (at 589 nm) that is lower than the first refractive index (at 589 nm), and wherein the third non- metallic thin film coating comprises a higher refractive index (at 589 nm) coating having the third refractive index (at 589 nm) that is higher than the second refractive index (at 589 nm).
43. The vehicular interior rearview mirror assembly of claim 42, wherein the first non- metallic thin film coating comprises an oxide of niobium, and wherein the second non- metallic thin film coating comprises an oxide of silicon, and wherein the third non-metallic thin film coating comprises an oxide of niobium.
44. The vehicular interior rearview mirror assembly of claim 43, wherein the first non- metallic thin film coating comprises a layer of Nb2O5, and wherein the second non-metallic thin film coating comprises a layer of SiO2, and wherein the third non-metallic thin film coating comprises a layer of Nb2O5.
45. The vehicular interior rearview mirror assembly of claim 42, wherein the first non- metallic thin film coating comprises an oxide of titanium, and wherein the second non- metallic thin film coating comprises an oxide of silicon, and wherein the third non-metallic thin film coating comprises an oxide of titanium.
46. The vehicular interior rearview mirror assembly of claim 42, wherein the first non- metallic thin film coating comprises elemental silicon, and wherein the second non-metallic thin film coating comprises an oxide of silicon.
47. The vehicular interior rearview mirror assembly of claim 41 , wherein transmission through the mirror reflective element of near-infrared (near-IR) light having a wavelength of 940 nm is at least 80 percent.
48. The vehicular interior rearview mirror assembly of any of claims 1 -39, wherein the multi-layer stack of non-metallic thin film coatings comprises a third non-metallic thin film coating having a third refractive index (at 589 nm).
49. The vehicular interior rearview mirror assembly of claim 48, wherein the third non- metallic thin film coating having the third refractive index (at 589 nm) is deposited onto the second non-metallic thin film coating.
50. The vehicular interior rearview mirror assembly of claim 49, wherein the third refractive index is higher than the second refractive index (at 589 nm).
51 . The vehicular interior rearview mirror assembly of claim 50, wherein the first refractive index is similar to that of the third refractive index (at 589 nm) and is higher than the second refractive index (at 589 nm).
52. The vehicular interior rearview mirror assembly of claim 51 , wherein the first refractive index is higher than 2 and the second refractive index (at 589 nm) is lower than 1 .5 and the third refractive index (at 589 nm) is higher than 2.
53. The vehicular interior rearview mirror assembly of claim 52, wherein the first refractive index comprises an oxide of niobium, and wherein the second non-metallic thin film coating comprises an oxide of silicon, and wherein the third non-metallic thin film coating comprises an oxide of niobium.
54. The vehicular interior rearview mirror assembly of claim 52, wherein the first refractive index comprises an oxide of titanium, and wherein the second non-metallic thin film coating comprises an oxide of silicon, and wherein the third non-metallic thin film coating comprises an oxide of titanium.
55. The vehicular interior rearview mirror assembly of claim 52, wherein the difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating is at least 0.5.
56. The vehicular interior rearview mirror assembly of claim 52, wherein the difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating is at least 0.7.
57. The vehicular interior rearview mirror assembly of claim 52, wherein the difference between the refractive index (at 589 nm) of the first non-metallic thin film coating and that of the second non-metallic thin film coating is at least 1 .0.
58. The vehicular interior rearview mirror assembly of any of claims 1 -39, wherein the multi-layer stack of non-metallic thin film coatings consists of the first non-metallic thin film coating and the second non-metallic thin film coating, and wherein the first non-metallic thin film coating has a refractive index (at 589 nm) greater than 3, and wherein the second non-metallic thin film coating has a refractive index (at 589 nm) less than 3.
59. The vehicular interior rearview mirror assembly of claim 58, wherein the first non- metallic thin film coating comprises elemental silicon, and wherein the second non-metallic thin film coating has a refractive index (at 589 nm) less than 1 .5.
60. The vehicular interior rearview mirror assembly of claim 59, wherein the second non-metallic thin film coating comprises a thin film coating of an oxide of silicon.
61 . The vehicular interior rearview mirror assembly of claim 58, wherein the physical thickness of the first non-metallic thin film coating is larger than the physical thickness of the second non-metallic thin film coating.
62. The vehicular interior rearview mirror assembly of claim 61 , wherein the physical thickness of the first non-metallic thin film coating is less than 30 nm, and wherein the physical thickness of the first non-metallic thin film coating is less than 20 nm.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202463641574P | 2024-05-02 | 2024-05-02 | |
| US63/641,574 | 2024-05-02 | ||
| US202463651537P | 2024-05-24 | 2024-05-24 | |
| US63/651,537 | 2024-05-24 |
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| Publication Number | Publication Date |
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| WO2025231198A1 true WO2025231198A1 (en) | 2025-11-06 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2025/027206 Pending WO2025231198A1 (en) | 2024-05-02 | 2025-05-01 | Vehicular interior rearview mirror assembly with spectral-selective mirror reflective element |
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| Country | Link |
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| WO (1) | WO2025231198A1 (en) |
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| US20240025344A1 (en) * | 2021-03-01 | 2024-01-25 | Magna Mirrors Of America, Inc. | Vehicular cabin monitoring system with camera and near ir light emitter at interior rearview mirror assembly |
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| US20060017868A1 (en) * | 2004-07-23 | 2006-01-26 | Wintek Corporation | Apparatus of liquid crystal display for compensating chromaticity of reflected light and the method of fabrication |
| US20140247415A1 (en) * | 2013-03-01 | 2014-09-04 | Vladimir Kleptsyn | Reflective color filter and color display device |
| US20240025344A1 (en) * | 2021-03-01 | 2024-01-25 | Magna Mirrors Of America, Inc. | Vehicular cabin monitoring system with camera and near ir light emitter at interior rearview mirror assembly |
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