Patent Description:
In many mirror products today, a precise and uniform fit between an edge of a glass shape and a surrounding flush mounted bezel or housing is desirable to produce an aesthetically pleasing product. A uniform, yet minimal, gap produces a smooth, pleasing, seamless transition between the bezel or housing and the mirror element. In some instances where the bezel is flush to the mirror, it may be difficult to provide electrical connections to electrical components. Processes that form a bezel incorporated with a mirror element may benefit from unique electrical pathways between mirror element and its electrical drive circuit.

<CIT> describes an anti-glare mirror, vehicle, and manufacturing method for the anti-glare mirror.

<CIT> describes an apparatus, method, and process that includes a substantially transparent substrate having a first surface, a second surface, and edge extending around at least a portion of a perimeter of the substantially transparent substrate, wherein the edge being a laser induced channel edge having enhanced edge characteristics.

<CIT> describes an electrochromic assembly including a transparent front element and a rear element each having front and rear surfaces. At least one of the front and rear elements is made from a plastic that maintains its integrity when exposed to organic solvents. A layer of transparent conductive material is disposed on the rear surface of the front element. A layer of conductive material is also disposed on the front surface of the rear element. The front element and the rear element when joined form a chamber therebetween. The chamber contains at least one electrochromic material in solution with the organic solvent, which is effective to attenuate light passing therethrough.

The underlying technical problem is solved by a rearview device having the features disclosed in the independent claim. Specific embodiments are defined in the dependent claims.

Aspects, objects, and features of the present disclosure will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings. It will also be understood that features of each example disclosed herein may be used in conjunction with, or as a replacement for, features of the other examples.

Additional features and advantages of the invention will be set forth in the detailed description which follows and will be apparent to those skilled in the art from the description or recognized by practicing the invention as described in the following description together with the claims and appended drawings.

As used herein, the term "and/or," when used in a list of two or more items, means that any one of the listed items can be employed by itself, or any combination of two or more of the listed items, can be employed.

In this document, relational terms, such as first and second, top and bottom, and the like, are used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by "comprises. a" does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Referring now to <FIG>, reference numeral <NUM> generally designates a rearview device or rearview mirror assembly which includes a housing <NUM>, a bezel <NUM> and an electro-optic element <NUM>. The electro optic-element <NUM> includes a first substantially transparent substrate <NUM> defining a first surface <NUM> and a second surface <NUM>. The second surface <NUM> includes a first electrically conductive layer <NUM>. A second substrate <NUM> defines a third surface <NUM> and a fourth surface <NUM>. The second substrate <NUM> also defines a hole <NUM> extending between the third surface <NUM> and the fourth surface <NUM>. The third surface <NUM> includes a second electrically conductive layer <NUM>. A primary seal <NUM> is disposed between the first and second substrates <NUM>, <NUM>. The primary seal <NUM> and the first and second substrates <NUM>, <NUM> define a cavity <NUM> therebetween. A conductive bus <NUM> is positioned proximate the hole <NUM> of the second substrate <NUM>. An electro-optic material <NUM> is disposed within the cavity <NUM>.

With reference now to the depicted example of <FIG>, the illustrated rearview mirror assembly <NUM> can be an interior rearview assembly positioned within an interior of a vehicle. When the rearview mirror assembly <NUM> is an interior rearview assembly, the rearview mirror assembly <NUM> may be connected to a mount <NUM>, which is adapted to be mounted inside the vehicle in a location proximate to or on a front windshield of the vehicle. It should be noted that the present disclosure is equally applicable to exterior mirrors, as well as other optical assemblies positioned within bezels and/or housings. The first substrate <NUM> may include a variety of transparent materials transparent in the visible region of the electromagnetic spectrum including soda-lime float glass, EAGLE® glass, alkaline earth boro-aluminosilacate glass, GORILLA° glass, alkalialuminosilicate glass, chemically strengthened glass, insulated glass, tempered glass, sapphire, optical crystals, diamond, quartz, ceramics, polymers or plastics. The second substrate <NUM> may include the same materials as the first substrate <NUM>, but does not need to be transparent and therefore may include polymers, metals, glass, ceramics, and/or composites. The bezel <NUM> may be formed of a thermosetting polymer (e.g., a reactive injection molding (RIM) suitable polymer, reinforced RIM suitable polymer, a structural RIM suitable polymer, a castable polymer and combinations thereof) and/or a thermoplastic polymer (e.g., polycarbonate, nylon, acrylic, combinations thereof, etc.). In some examples, the bezel <NUM> may include a clear polymeric material. The bezel <NUM> may be formed via machining, casting, resin transfer molding, reactive injection molding, injection molding, and/or compression injection molding. The first substrate <NUM> defines a first edge 26A and the second substrate <NUM> defines a second edge 42A. The first and second edges 26A, 42A extend circumferentially around the respective first and second substrates <NUM>, <NUM>. The first and second edges 26A, 42A are in direct contact with the bezel <NUM>, as described in greater detail below. The first and second substrates <NUM>, <NUM> may have a thickness between about <NUM> to about <NUM>, between about <NUM> to about <NUM>, or between about <NUM> to about <NUM>. In some examples, the thicknesses of the first and second substrates <NUM>, <NUM> may differ from one another. Furthermore, a reflector material may be located on either the third surface <NUM> (<FIG>) or the fourth surface <NUM> of the second substrate <NUM>, depending upon the type of electro-optic element <NUM>.

The rearview mirror assembly <NUM> also includes a circuit board <NUM> and a carrier plate <NUM>. The carrier plate <NUM> can be located behind the electro-optic element <NUM> and have the circuit board <NUM> connected thereto. If the rearview mirror assembly <NUM> is an interior rearview assembly, the carrier plate <NUM> is typically fixed in position within the housing <NUM>. The carrier plate <NUM> of the rearview mirror assembly <NUM> can be used to maintain the position of the electro-optic element <NUM> and/or carry the circuit board <NUM>. An example of an interior rearview assembly including a carrier plate and a circuit board is disclosed in <CIT>, entitled "MIRROR WITH INTERNAL SUPPORT PLATE," assigned to Gentex Corporation. In the rearview mirror assembly <NUM>, the carrier plate <NUM> assists in maintaining the electro-optic element <NUM> in position within the housing <NUM>. An example of the housing <NUM>, bezel <NUM>, carrier plate <NUM>, circuit board <NUM> and their interconnections may be found in <CIT> entitled "REFLECTIVE ELEMENT HOLDER FOR REARVIEW MIRROR," assigned to Gentex Corporation. However, it is contemplated that the rearview mirror assembly <NUM> may omit a bezel, circuit board and/or carrier plate from the rearview mirror assembly <NUM>.

The illustrated electro-optic element <NUM> has the electro-optic material <NUM> positioned between the first substrate <NUM> and the second substrate <NUM>. In some examples, the electro-optic material <NUM> may be an electrochromic material. In such examples, the electro-optic material <NUM> may be a solution phase as disclosed in <CIT> entitled "SINGLE-COMPARTMENT, SELF-ERASING, SOLUTION-PHASE ELECTROCHROMIC DEVICES, SOLUTIONS FOR USE THEREIN, AND USES THEREOF" and <CIT> entitled "TINTED SOLUTION-PHASE ELECTROCHROMIC MIRRORS," commonly assigned to Gentex Corporation. In other examples, the electro-optic material <NUM> may be in a solid-state. In addition, a hybrid system, where part of the electro-optic material <NUM> is solid-state and part is solution phase, is also contemplated. Solution-phase materials, because of their liquidic or flowable properties, do not rigidly bond the first and second substrates <NUM>, <NUM> together like completely solid-state electro-optic material <NUM>. The electro-optic material <NUM> may have a thickness between about <NUM> micron and about <NUM> microns.

The flexibility of the electro-optic element <NUM> may be dependent on a variety of factors, including thickness of the first and second substrates <NUM>, <NUM>, type (e.g., solution-phase or solid-state) of electro-optic material <NUM>, and overall thickness of the electro-optic element <NUM>. For example, in examples of the rearview mirror assembly <NUM> having solid-state electro-optic material <NUM>, the first and second substrates <NUM>, <NUM> are bonded together in a manner that causes them to bend much like a piece having their total thickness. Contrastingly, electro-optic elements <NUM> having a solution-phase electro-optic material <NUM> bend in a complex manner wherein the first and second substrates <NUM>, <NUM> bend simultaneously, but independently. Additionally, the solution phase electro-optic material <NUM> may ebb and flow somewhat in reaction to the stress. The net result is that the electro-optic element <NUM>, in examples with solution phase electro-optic material <NUM>, tends to be more flexible than electro-optic elements <NUM> with solid-state phase electro-optic material <NUM>, even where the first and second substrates <NUM>, <NUM> have the same thickness and other properties.

The first and second substrates <NUM>, <NUM> may be cut to shape in a variety of processes. In one example, the first and second substrates <NUM>, <NUM> are cut to shape with the use of a score and break technique. In another example, an abrasive wheel or a high pressure water jet may be used to cut the first and second substrates <NUM>, <NUM>. In yet another example, the first and second substrates <NUM>, <NUM> may be cut using a laser. Examples of laser systems and laser cutting are described in <CIT>, entitled "APPARATUS, METHOD, AND PROCESS WITH LASER INDUCED CHANNEL EDGE" and <CIT>, entitled "LASER SYSTEM AND METHOD THEREOF," each of which is assigned to Gentex Corporation.

Traditionally, design of the bezel <NUM> or housing <NUM> around the electro-optic element <NUM> takes into account the differences in the coefficient of thermal expansion ("CTE") of the materials used in the electro-optic element <NUM>, as well as the bezel <NUM> and housing <NUM>. Polymeric materials typically have a greater CTE than glass, ceramic, or metal components. This means that as the temperature of the rearview mirror assembly <NUM> changes, the different materials of the rearview mirror assembly <NUM> expand and contract at different rates. The differential expansion of the components of the rearview mirror assembly <NUM> may result in the generation of stresses within the assembly <NUM> if not properly accounted for. In the case of automotive applications, typical temperature testing takes place in a range between about -<NUM>° C to about <NUM>° C. Conventional bezels are made out of strong and fairly rigid engineering plastics such as polypropylene, Acrylonitrile butadiene styrene/Polycarbonate, Acrylonitrile Styrene Acrylate, and have thermal expansion coefficients that are much larger than glasses, ceramics, and metals. This expansion difference can create hoop stress as conventional bezels shrink around glass and metal elements at cold temperatures. As a result, conventional bezels may have ribs or large gaps to accommodate the different thermal size changes between bezels/housings and mirrors.

The bezel <NUM> may include a polymeric material having a low enough CTE such that temperature changes in the bezel <NUM> do not cause undue contraction of the bezel <NUM> around the electro-optic element <NUM> and result in stress formation. In various examples, the CTE of the polymeric material of the bezel <NUM> and the housing <NUM> may be less than about <NUM> ppm, less than about <NUM> ppm, less than about <NUM> ppm, less than about <NUM> ppm, less than about <NUM> ppm, less than about <NUM> ppm, and less than about <NUM> ppm. Exemplary low CTE polymers may include polyetherimides, filled polyetherimides, liquid crystal polymer, filled liquid crystal polymer, nylon, filled nylon, filled polycarbonate, filled acrylonitrile butadiene styrene, polyamide-imide, filled polyamide-imide, filled polyphenylene sulfide, high density polyethylene, polystyrene and other polymers having a CTE below about <NUM> ppm. It should be noted that the bezel <NUM> may include combinations of low CTE polymers as well as combinations of low CTE polymers with regular CTE polymers. Additionally, the bezel <NUM> may include one or more fillers configured to further reduce the CTE of the bezel <NUM>. Exemplary filler materials may include glasses, metals, minerals, organic materials or ceramics which may lower the overall CTE of the polymer. The filler materials may be in the form of powders, flakes, and fibers. Exemplary fibers may include glass fibers and/or carbon fibers. The bezel <NUM> may have a volume fraction of filler material greater than about <NUM>%, greater than about <NUM>%, greater than about <NUM>%, greater than about <NUM>%, and greater than about <NUM>%. In a specific example, the bezel <NUM> may include nylon with an approximately <NUM>% by volume glass filler. In some examples, the bezel <NUM> may have different local compositions of polymer or filler material in order to locally minimize the CTE of the bezel <NUM>. For example, corners or long portions at the top and bottom of the bezel <NUM> may include a different polymer or higher volume fraction of filler material than other portions of the bezel <NUM>. It should be understood that in examples of the rearview mirror assembly <NUM> not including the bezel <NUM>, the housing <NUM> may alternatively include the aforementioned materials described in connection with the bezel <NUM>.

Referring now to <FIG>, depicted are various configurations of the first and second substrates <NUM>, <NUM> which have been integrally molded with the bezel <NUM>. Aesthetically, a gap between the bezel <NUM> and the first edge 26A of the first substrate <NUM> may appear unsightly by a viewer of the rearview mirror assembly <NUM>. Accordingly, the bezel <NUM> may be integrally molded to the first and second substrates <NUM>, <NUM> if the polymeric examples of the bezel <NUM> are filled with a sufficient loading of a CTE reducing filler (e.g., glass fiber or carbon fiber). In integrally molded examples, the bezel <NUM> may be laminated directly to the first and/or second substrates <NUM>, <NUM> or the bezel <NUM> may be injection molded around the first and/or second substrates <NUM>, <NUM> such that no gap exists or may be reduced to non-visible size (e.g., less than about <NUM> microns, less than about <NUM> microns, less than about <NUM> microns or less than about <NUM> microns). An exemplary method of laminating the bezel <NUM> to the first or second substrates <NUM>, <NUM> may be accomplished via a method similar to SURFIC™ as developed by Asahi Glass Co. LTD of Chiyoda, Tokyo, Japan and/or glass insert molding performed by Yoshida Technoworks Co. of Sumida-ku, Tokyo, Japan. Use of SURFIC™ or the other integrated molding techniques described above would reduce the gap size between the first and/or second substrate <NUM>, <NUM> and the bezel <NUM> to near zero and produce an aesthetically pleasing rearview mirror assembly <NUM>. From a structural perspective, contacting the bezel <NUM> with both the first and second substrates <NUM>, <NUM> may provide a more robust and secure connection between the bezel <NUM> and the first and second substrates <NUM>, <NUM>. Various advantages may be achieved through such a design, such as ease of manufacturing (e.g., process and/or mold shutoffs) and enhanced adhesion between the substrates <NUM>, <NUM> and the bezel <NUM> through an increase in surface area contact.

In some comparative examples that may be useful in understanding the invention, the second edge 42A is positioned inboard, or in an inward direction, relative to the bezel <NUM> of the first edge 26A. Such an example may be accomplished by using a smaller dimensioned second substrate <NUM> relative to the first substrate <NUM>, or through positioning of the first and second substrates <NUM>, <NUM>. In accordance with the invention, the second edge 42A is positioned outboard, or in an outward direction relative to the first edge 26A. Such an example may be accomplished by using a smaller dimensioned first substrate <NUM> relative to the second substrate <NUM>, or through positioning of the first and second substrates <NUM>, <NUM>. Exemplary advantages that may be achieved through such an example include a structural "lock" being formed due to the three dimensional aspect of the configuration (e.g., which may increase structural rigidity of the rearview assembly <NUM>) and a reduced dimension bezel <NUM> (e.g., thinner, reduced and/or more compact) which may be aesthetically pleasing. In yet another comparative example that may be useful in understanding the invention, the second edge 42A is positioned substantially flush, or in substantial alignment, with the first edge 26A. The first and second 26A, 42A can be flat and at a <NUM> degree angle relative to the first and fourth surfaces <NUM>, <NUM> or at an angle other than <NUM> degrees relative to surfaces <NUM>, <NUM>. The first and second edges 26A, 42A can also be shaped such as a semicircle or pencil edge or contoured such as with a step, slot or notch. The texture of the first and second edges 26A, 42A can be smooth or rough depending on the edge appearance that is desired.

To facilitate adhesion between the bezel <NUM> and the first and/or second substrates <NUM>, <NUM>, one or more adhesion promoters may be included in the material of the bezel <NUM>, in a resin base coating pre-applied to the first and second substrates <NUM>, <NUM> and/or applied directly to the first and/or second substrates <NUM>, <NUM>. Exemplary adhesion promoters include silane coupling agents such as Dow Corning® Z-<NUM> and/or Dow Corning® Xiameter OF S-<NUM> and/or solvent based organic solutions that may etch the substrates <NUM>, <NUM> such as LORD Chemlok® primers. It will be understood that although several examples are provided herein, other adhesion promoters, etchants or surface treatments and combinations of adhesion promoters and/or etchants or surface treatments may be used. The adhesion promoter used may be selected based at least in part on the material of the bezel <NUM> and the substrates <NUM>, <NUM> in order to achieve a desired level of adhesion. The first and second edges 26A, 42A can also be coated with an elastomeric resin to help mitigate mechanical or thermal stresses that may develop in the rearview assembly <NUM>.

Referring now to <FIG>, the first and second electrically conductive layers <NUM>, <NUM> may each define an ablation area <NUM>. The ablation area <NUM> of the first electrically conductive layer <NUM> splits the first electrically conductive layer <NUM> into a first portion <NUM> and a second portion <NUM>. The ablation area <NUM> of the second electrically conductive layer <NUM> splits the second electrically conductive layer <NUM> into a third portion <NUM> and a fourth portion <NUM>. Positioned on an outboard end of the primary seal <NUM> is the conductive bus <NUM>. The conductive bus <NUM> may function as a shut off for the material of the bezel <NUM> when the bezel <NUM> is formed. The conductive bus <NUM> may include a metal laden epoxy (e.g., silver epoxy), a conductive metal, a conductive polymer, or combinations thereof. In various examples, the conductive bus <NUM> may have a resistance of less than about <NUM> ohm. In the depicted example, the conductive bus <NUM> is positioned inboard of the first edge 26A and is in electrical communication with the first electrically conductive layer <NUM>. The second substrate <NUM> defines one or more holes <NUM> extending between the third and fourth surfaces <NUM>, <NUM>. In other words, the fourth surface <NUM> may define one or more holes <NUM>. The holes <NUM> may be circular, square, rectangular (e.g., slot like), triangular or other shapes. The holes <NUM> may have a diameter, or longest cross-sectional dimension (e.g., diameter) of between about <NUM> and about <NUM>. The holes <NUM> may be formed using conventional mechanical processes (e.g., drilling with a bit) or may be formed through chemical etching or laser cutting. An example of a hole incorporated into an electro-optic element is disclosed in <CIT> entitled "SHAPED REARVIEW ASSEMBLY," assigned to Gentex Corporation. One or more holes <NUM> may be positioned or formed proximate the second edge 42A of the second substrate <NUM>. One or more holes <NUM> may be positioned or formed in an inboard location of the second substrate <NUM>. For example, one or more of the holes <NUM> may be positioned from about <NUM> to about <NUM> inboard from the second edge 42A.

Disposed within the holes <NUM> may be a conductive filler <NUM>. The filler <NUM> may include a metal tube (e.g., a via such as a multicore Copperset through hole plating system), conductive polymer, solder paste, a monolithic piece of metal, a thermal setting epoxy or combinations thereof. Any filler <NUM> may contain on its outer portion, an electrically insulating portion to isolate the electrical conductance from electrically conductive sections found on the third or fourth surfaces <NUM>, <NUM>. Optionally, a separate insulating member could be inserted into the hole <NUM> prior to the installation of the conductive filler. An insulator used in this method would be used to bring electrical conductance from the fourth surface <NUM> to the second surface <NUM>. Further, any of the materials of the conductive bus <NUM> may be used as the filler <NUM> and any of the materials of the filler <NUM> may be used as the conductive bus <NUM>. The filler <NUM> may be placed within the holes <NUM> at the time of assembling the electro-optic element <NUM> prior to formation of the bezel <NUM>. The filler <NUM> may be flush with the third surface <NUM> or form a protruding connector. The filler <NUM> may be flush with the fourth surface <NUM> or form a protruding connector. In examples where the filler <NUM> is flush with the third and/or fourth surfaces <NUM>, <NUM>, the filler <NUM> may define a surface which is a distance of about <NUM> to about <NUM> from the third and/or fourth surfaces <NUM>, <NUM>. According to various examples, the filler <NUM> may define a surface (e.g., a filler surface) which is partially, substantially or completely parallel with the third and/or fourth surfaces <NUM>, <NUM>. According to various examples, the surface of the filler <NUM> is planar with the third and/or fourth surfaces <NUM>, <NUM>. The filler <NUM> may be partially or fully covered by the bezel <NUM>. The filler material <NUM>, depending on the example, may be held in place using an adhesive material (e.g., thermal or ultraviolet curing). The filler <NUM> is in electrical connection with the conductive bus <NUM> and the second electrically conductive layer <NUM> thereby providing electrical connection to both the first and second electrically conductive layers <NUM>, <NUM>. The filler <NUM> may cure with the conductive bus <NUM> to form a single continuous electrical connection. Use of the ablation areas <NUM> allows for the holes <NUM> to be in electrical connection with either the first and third portions <NUM>, <NUM> or the second and fourth portions <NUM>, <NUM> such that the electro-optic element <NUM> does not short out across the second electrically conductive layer <NUM>. After lamination or formation of the bezel <NUM> to the electro-optic element <NUM>, the circuit board <NUM> (<FIG>) may be electrically connected to the electro-optic element <NUM>. In one example, a wire may make electrical contact with the filler <NUM> (e.g., inserted in the metal tube or soldered) to provide electrical connection. In other examples, the filler <NUM> may be omitted and the wire electrically connected with the conductive bus <NUM> and/or the second electrically conductive layer <NUM>. In yet other examples, the wire may be placed in the hole <NUM> and the filler <NUM> used to conductively secure the connection.

Referring now to the comparative example of <FIG> that may be useful in understanding the invention, the conductive bus <NUM> may be positioned outboard of the first edge 26A. In such an example, the holes <NUM> may similarly positioned outboard of the first edge 26A and positioned below the conductive bus <NUM>. In such an example, a conductive coating <NUM> may be disposed on the first edge 26A and wrap onto the second surface <NUM>. The conductive coating <NUM> may include at least one of a conductive ink, a vacuum deposited metal, a transparent conductor (e.g., indium tin oxide), carbon (graphene and/or graphite), a conductive metal foil, a conductive tape, a sputtered metal and combinations thereof. The conductive coating <NUM> is in electrical communication with the conductive bus <NUM> and the first portion <NUM> of the first electrically conductive layer <NUM>. Such an example may be advantageous in that the electrical connection of the conductive bus <NUM> may be made after the primary seal <NUM> has been formed and cured.

Referring now to the comparative example of <FIG> that may be useful in understanding the invention, disposed around the second edge 42A is a conductive member <NUM>. The conductive member <NUM> may be in electrical communication with the first electrically conductive layer <NUM> and may be in physical contact with the bezel <NUM>. The conductive member <NUM> may extend from the fourth surface <NUM>, around the second edge 42A and extend onto the third surface <NUM> to make electrical contact with the second electrically conductive layer <NUM>. The conductive member <NUM> may include at least one of a conductive ink, a conductive tape, a thermoplastic polymer, a thermosetting polymer (e.g., metal filled such as a silver epoxy), a flex circuit, a conductive metal foil, a conductive tape, a metal component (e.g., a "J-clip" or an "L-clip") and combinations thereof. In the depicted example, the electro-optic element <NUM> include the conductive bus <NUM>, but may not without departing from the teachings provided herein. In examples not utilizing the conductive bus <NUM>, the conductive member <NUM> may extend upwards to electrically and physically contact the conductive coating <NUM>. Further, the conductive member <NUM> may be configured to elastically deflect in a spring-like manner such that sufficient electrical connection between the conductive member <NUM> and the conductive coating <NUM> is achieved. According to various examples, the conductive member <NUM> may function as a shut-off for the molding of the bezel <NUM>. In such examples, the conductive member <NUM> may be formed of a "pre-preg" material which is solid at room temperature, but has not been cured yet. The pre-preg may be a solid resin and a solid curing agent which have been mixed to form a pliable mixture. Further, the pre-preg may be mixed with a conductive material to make the pre-preg electrically conductive. The pliable nature of the pre-preg may be useful in that the pre-preg may be wrapped from the fourth surface <NUM> to the third surface <NUM> at room temperature, and at elevated temperatures, the curing agent may activate to cure the pre-preg to form the conductive member <NUM>. It will be understood that one or more components of the pre-preg may also be subject to melting without departing from the teachings provided herein. As depicted, the bezel <NUM> may substantially cover the conductive coating <NUM> and the conductive member <NUM>.

Referring now to the comparative example of <FIG> that may be useful in understanding the invention, a conductive insert <NUM> may be disposed in contact with the second edge 42A of the second substrate <NUM>. The electrically conductive insert <NUM> may be in electrical communication with at least one of the third surface <NUM> of the second substrate <NUM> and the second surface <NUM> of the first substrate <NUM>. The conductive insert <NUM> may function as a shut-off during lamination and or formation of the bezel <NUM> to the electro-optic element <NUM>. The conductive insert <NUM> may be a metal, conductive polymer, conductive epoxy, flex circuit or other conductive material. The conductive insert <NUM> may extend onto the third surface <NUM> and be in electrical communication with the second electrically conductive layer <NUM>. The insert <NUM> may define a contact surface 156A to which the circuit board <NUM> (<FIG>) or other electrical connection may be coupled. The contact surface 156A may be flush with the fourth surface <NUM> of the second substrate <NUM>. The conductive insert <NUM> and contact surface 156A may be left partially exposed (i.e., partially covered) after formation or lamination of the bezel <NUM>, or may be buried (i.e., fully covered) such that post processing (e.g., drilling through or removing a portion of the bezel <NUM>) is used to expose the conductive surface 156A. It will be understood that a similar process may be employed for examples where the filler <NUM> is covered (substantially or partially) by the bezel <NUM>. In a specific example, the insert <NUM> may be one or more electromagnetic or radio frequency interference shields. The shields may include one or more metal components. In an example, the shield may be utilized to replace the conductive bus <NUM> (<FIG>) connecting with one or more of the first and second electrically conductive layers <NUM>, <NUM>. Further, the shield may extend from the bezel <NUM> and provide an electrical connection contact point to power the electro-optic element <NUM>.

Referring now to the comparative example of <FIG> that may be useful in understanding the invention, the bezel <NUM> may define an aperture <NUM>. In such an example, the bezel <NUM> may extend onto the fourth surface <NUM> of the second substrate <NUM>. The aperture <NUM> may be formed into the bezel <NUM> after formation of the bezel <NUM> (e.g., via mechanical drilling, laser ablation, etching, etc.) to expose an electrical contact point (e.g., the hole <NUM>/filler <NUM> (<FIG>), the conductive member <NUM> (<FIG>), other electrical contacts for the electro-optic element <NUM>). It will be understood that the aperture <NUM> may be filled with a conductive material (e.g., the filler <NUM>) or be left open to allow for electrical contact (e.g., through a wire).

Referring now to the comparative example of <FIG> that may be useful in understanding the invention, the bezel <NUM> may include a conductive component <NUM> positioned within the bezel <NUM>. The conductive component <NUM> may be co-molded (e.g., inserted during molding/lamination and have the bezel <NUM> formed around it) with the bezel <NUM> or may be added in post processing (e.g., by drilling a hole and inserting the conductive component <NUM> or by heating the conductive component <NUM> and sinking it into the material of the bezel <NUM>). The conductive component <NUM> may be metal, a conductive polymer, a wire or other electrically conductive material. The conductive component <NUM> may be in electrical communication with a contact point on the electro-optic element <NUM> (e.g., the hole <NUM>/filler <NUM> (<FIG>), the conductive member <NUM> (<FIG>), other electrical contacts for the electro-optic element <NUM>) to power the electro-optic element <NUM>.

Referring now to <FIG> as a comparative example that may be useful in understanding the invention, the bezel <NUM> may include a decorative film <NUM>. The decorative film <NUM> may be laid down in a mold prior to the formation of the bezel <NUM> such that the decorative film <NUM> is on an A-surface, or exterior of the bezel <NUM>. The decorative film <NUM> may be used to enhance the appearance of the bezel <NUM> by providing a smooth surface and/or one or more decorations (e.g., metallized layer, pattern, etc.). Positioned on a B-surface of the decorative film <NUM> (e.g., within the bezel <NUM>) may be a flex circuit <NUM> and an electrical connector <NUM>. It will be understood that the flex circuit <NUM> may additionally or alternatively be a metal foil, conductive coating, conductive polymer configured to transmit electricity and/or combinations thereof. The electrical connector <NUM> is configured to make electrical connection between the second electrically conductive layer <NUM> and the flex circuit <NUM>. In the depicted example, the electrical connector <NUM> is a spring, but may be any other electrically conductive component capable of elastic deformation. As the electro-optic element <NUM> is placed in the mold with the decorative film <NUM>, the elastic deformation of the electrical connector <NUM> ensures a secure connection with the second electrically conductive layer <NUM>. Electrical connection between the electrical connector <NUM> and the flex circuit <NUM> allows for electrical communication with the electro-optic element <NUM> through the flex circuit <NUM>. It will be understood that the flex circuit <NUM> may be combined with, or replaced by, the decorative film <NUM> without departing from the teachings provided herein.

Referring now to <FIG> as comparative examples that may be useful in understanding the invention, the second substrate <NUM> may define a notch <NUM> extending between the fourth surface <NUM> and the third surface <NUM>. The notch <NUM>, unlike the hole <NUM>, is not completely surrounded by the second substrate <NUM>. The notch <NUM> may be filled with the same filler <NUM> as the hole <NUM>. The filler <NUM> may be in contact with the second electrically conductive layer <NUM> and form an electrical contact point proximate the fourth surface <NUM>. The filler <NUM> may be flush with the third and fourth surfaces <NUM>, <NUM>. During molding or lamination of the bezel <NUM> to the electro-optic element <NUM>, the notch <NUM> may be filled with a portion of the mold to prevent the polymer of the bezel <NUM> from flowing into the notch <NUM>. In another example, the notch <NUM> may be prefilled with the filler <NUM> such that the filler <NUM> functions as a shut-off and the notch <NUM> is not filled with the polymeric material of the bezel <NUM> (<FIG>).

It will be understood that although multiple separate examples have been described herein, combination of the examples are contemplated. For example, the holes <NUM> may be used with examples utilizing the notch <NUM>, the conductive coating and member <NUM>, <NUM>, the conductive insert <NUM>, the aperture <NUM>, the conductive component <NUM> and the decorative film <NUM> without departing from the teachings provided herein. Similarly, any of the examples provided may be utilized with any other example provided.

According to various examples provided herein, the fourth surface <NUM> of the second substrate <NUM> may be substantially flush or flat (i.e., the filler <NUM>, conductive bus <NUM>, conductive coating <NUM>, conductive member <NUM>, conductive insert <NUM>, flex circuit <NUM>, and/or electrical connector <NUM> may be substantially flush or not extend onto the fourth surface <NUM>). Such a flush example of the fourth surface <NUM> may be useful during the formation of the bezel <NUM>. For example, in injection molded examples of the bezel <NUM>, the fourth surface <NUM> may function as a surface for a mold of an injection molding machine to press against during formation of the bezel <NUM>. Specifically, the pressure may be provided proximate the primary seal <NUM>. In examples where the fourth surface <NUM> includes electrical contacts is otherwise is not flush, the molding equipment used to form the bezel <NUM> may apply unequal pressure which can result in damage to the electro-optic element <NUM>. In such examples, the mold may need to be precisely machined to account for this variation such that uniform pressure may be applied. Accordingly, by creating a flush fourth surface <NUM> as disclosed herein, the bezel <NUM> may be formed in a cost effective manner.

Use of the present disclosure offers several advantages. First, the use of the present disclosure permits the formation of rearview mirror assemblies <NUM>, and other structures having bezels <NUM>, to include electrical components with low visibility electrical contacts. Second, use of the present disclosure allows for the formation of rearview mirror assemblies <NUM> which have a low profile and aesthetically pleasing design. Third, use of the present disclosure may allow for the reduction in the width of a concealment structure (e.g., a spectral filter, chrome ring, etc.) used to conceal the conductive bus <NUM>, primary seal or other unsightly components located at edges of the electro-optic element <NUM>. For example, by burying the electrical contacts (e.g., the conductive bus <NUM>, conductive coating <NUM>, conductive member <NUM>, conductive insert <NUM>, flex circuit <NUM>, and/or electrical connector <NUM>) within the bezel <NUM>, the concealment structures may not need to be as wide. Thinner concealment structures may be advantageous in reducing the time and money required to manufacture them. Fourth, by positioning the electrical contacts within the bezel <NUM> and/or within the second substrate <NUM>, the fourth surface <NUM> may be made flush (i.e., flat or substantially without changes in height). A flush fourth surface <NUM> may allow for uniform back pressure to be applied to the electro-optic element <NUM> during formation of the bezel <NUM>. Further, a flush fourth surface <NUM> may allow for a more uniform formation of the bezel <NUM> onto the fourth surface <NUM>.

It will be understood by one having ordinary skill in the art that construction of the described disclosure, and other components, is not limited to any specific material.

For purposes of this disclosure, the term "coupled" (in all of its forms: couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be permanent in nature, or may be removable or releasable in nature, unless otherwise stated.

It is also important to note that the construction and arrangement of the elements of the disclosure, as shown in the exemplary embodiments, is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.). For example, elements shown as integrally formed may be constructed of multiple parts, or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, and the nature or numeral of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the desired and other exemplary embodiments.

It will be understood that any described processes, or steps within described processes, may be combined with other disclosed processes or steps to form structures. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

As used herein, the term "about" means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. When the term "about" is used in describing a value or an end-point of a range, the disclosure should be understood to include the specific value or end-point referred to. Whether or not a numerical value or end-point of a range in the specification recites "about," the numerical value or end-point of a range is intended to include two embodiments: one modified by "about," and one not modified by "about. " It will be further understood that the end-points of each of the ranges are significant both in relation to the other end-point, and independently of the other end-point.

Claim 1:
A rearview device (<NUM>), comprising:
a bezel (<NUM>); and
an electro-optic element (<NUM>), comprising:
a first substantially transparent substrate (<NUM>) defining first and second surfaces (<NUM>, <NUM>) and a first edge (26A) extending around at least a portion of a perimeter of the first substantially transparent substrate (<NUM>), wherein the second surface (<NUM>) comprises a first electrically conductive layer (<NUM>);
a second substrate (<NUM>) defining third and fourth surfaces (<NUM>, <NUM>) and a second edge (42A) extending around at least a portion of a perimeter of the second substrate (<NUM>), the second substrate (<NUM>) defining a hole (<NUM>) between the third and fourth surfaces (<NUM>, <NUM>), wherein the third surface (<NUM>) comprises a second electrically conductive layer (<NUM>);
a primary seal (<NUM>) disposed between the first and second substrates (<NUM>, <NUM>), wherein the seal (<NUM>) and the first and second substrates (<NUM>, <NUM>) define a cavity (<NUM>) therebetween;
an electro-optic material (<NUM>) disposed within the cavity (<NUM>); and
a conductive bus (<NUM>) positioned proximate the hole (<NUM>) of the second substrate (<NUM>);
wherein the bezel (<NUM>) extends onto the third and fourth surfaces (<NUM>, <NUM>) of the second substrate (<NUM>), wherein the first and second edges (26A, 42A) are in direct contact with the bezel (<NUM>) and the second edge (42A) is positioned outboard of the first edge (26A) to form a structural lock of the electro-optic element (<NUM>) within the bezel (<NUM>).