Patent ID: 12246647

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and the illustrative embodiments depicted therein, an interior rearview mirror assembly10for a vehicle includes a mirror head12including a casing14and a reflective element16positioned at a front portion of the casing14(FIG.1). In the illustrated example, the mirror assembly10is configured to be adjustably mounted to an interior portion of an interior cabin 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 assembly18. The mirror reflective element may include a variable reflectance mirror reflective element that varies its reflectance responsive to electrical current applied to conductive coatings or layers of the reflective element.

The interior rearview mirror assembly10accommodates one or more heat generating electronic components within the mirror head12. For example, a printed circuit board (PCB) having one or more heat generating electronic components (e.g., image or data processors, light emitters, cameras and the like) and/or a video display screen may be accommodated within an interior cavity of the mirror casing14behind the mirror reflective element16. When the electronic components (including the display screen) are electrically operated, heat is generated at the interior of the mirror head12and can, if operated without sufficient cooling, exceed the functional thermal load of the components. Thus, the mirror assembly10is configured to provide at least passive cooling for the heat generating electronic components accommodated by the mirror head. For example, one or more heatsinks may be thermally coupled to the heat generating electronic components to draw heat away from the components to be dissipated from the heatsink and exterior of the mirror head12. For example, the heat drawn by the heatsink may be dissipated to the ambient air of the cabin through thermal transfer to the exterior surface of the mirror casing14and/or via one or more vents or slots formed through the mirror casing that allow cooling airflow to flow along the heatsink and draw heat away from the heatsink. As discussed further below, the heatsink may include a two-phase heatsink formed via additive manufacturing with an increased thermal capacity compared to standard or traditional heatsinks.

The mirror assembly10may include or may be associated with a driver monitoring system (DMS) and/or an occupant monitoring system (OMS), with the mirror assembly including a driver/occupant monitoring camera20disposed at a back plate (and viewing through an aperture of the back plate) behind the reflective element16and viewing through the reflective element16toward at least a head region of the driver of the vehicle. Further, the DMS includes an infrared light (IR light) or near infrared light (near IR light) emitter22disposed at the back plate and emitting IR light or near IR light that passes through another aperture of the back plate and, optionally, through the mirror reflective element16. Further, the monitoring system includes an electronic control unit (ECU) having electronic circuitry and associated software, including an image processor for processing image data captured by the DMS/OMS camera. Image data captured by the camera may be processed for a head and face direction and position tracking system and/or eye tracking system and/or gesture recognition system. The DMS camera and monitoring system and/or head and face direction and/or position tracking systems and/or eye tracking systems and/or gesture recognition systems may utilize aspects of the systems described in U.S. Pat. Nos. 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-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. patent application Ser. No. 18/508,351, filed Nov. 14, 2023, Ser. No. 18/535,183, filed Dec. 11, 2023 and/or Ser. No. 18/666,959, filed May 17, 2024, and/or U.S. provisional application Ser. No. 63/641,574, filed May 2, 2024, and/or International Publication Nos. WO 2023/220222; WO 2023/034956; WO 2022/241423 and/or WO 2022/187805, which are all hereby incorporated herein by reference in their entireties.

Optionally, the driver monitoring system may be integrated with a camera monitoring system (CMS) of the vehicle. The integrated vehicle system incorporates multiple inputs, such as from the inward viewing or driver monitoring camera and from a forward or outward viewing camera, as well as from a rearward viewing camera and sideward viewing cameras of the CMS, to provide the driver with unique collision mitigation capabilities based on full vehicle environment and driver awareness state. The image processing and detections and determinations are performed locally within the interior rearview mirror assembly and/or the overhead console region, depending on available space and electrical connections for the particular vehicle application. The CMS cameras and system may utilize aspects of the systems described in U.S. Pat. No. 11,242,008 and/or U.S. Publication Nos. US-2021-0162926; US-2021-0155167; US-2018-0134217 and/or US-2014-0285666, and/or International Publication No. WO 2022/150826, which are all hereby incorporated herein by reference in their entireties.

Electronic components associated with the DMS and/or the CMS may generate heat at the interior of the mirror head12when electrically operated. For example, the near IR light emitter22, when electrically operated to emit light that passes through the mirror reflective element16, generates heat. Further, the ECU disposed within the mirror head includes one or more data processors or image processors for processing image data and/or sensor data for the DMS, OMS, and/or CMS functions. When the one or more processors are operated to process the sensor data, heat is generated within the mirror head12.

The ECU may receive image data captured by a plurality of cameras of the vehicle, such as by a plurality of surround view system (SVS) cameras and a plurality of camera monitoring system (CMS) cameras and optionally one or more driver monitoring system (DMS) cameras. The ECU may comprise a central or single ECU that processes image data captured by the cameras for a plurality of driving assist functions and may provide display of different video images to a video display screen in the vehicle (such as at an interior rearview mirror assembly or at a central console or the like) for viewing by a driver of the vehicle. The system may utilize aspects of the systems described in U.S. Pat. Nos. 11,242,008; 10,442,360 and/or 10,046,706, and/or U.S. Publication Nos. US-2021-0155167 and/or US-2019-0118717, and/or International Publication No. WO 2022/150826, which are all hereby incorporated herein by reference in their entireties.

The mirror assembly may comprise an auto-dimming mirror reflective element (e.g., an electrochromic mirror reflective element) or a prismatic mirror reflective element. Both types of mirrors may be provided with a video display screen that is disposed behind and is viewable through the mirror reflective element. Such video mirrors include a backlit LCD display screen, and a particular form of video mirror is a full display mirror (such a ClearView™ Interior Rearview Mirror Assembly available from Magna Mirrors of America, Inc. of Holland, MI USA, or an FDM™ Interior Rearview Mirror Assembly available from Gentex Corporation of Zeeland, MI USA), where the video display screen fills the reflective region, such as by utilizing aspects of the mirror assemblies and systems described in U.S. Pat. Nos. 11,242,008; 11,214,199; 10,442,360; 10,421,404; 10,166,924; 10,046,706 and/or 10,029,614, and/or U.S. Publication Nos. US-2021-0162926; US-2019-0258131; US-2019-0146297; US-2019-0118717 and/or US-2017-0355312, which are all hereby incorporated herein by reference in their entireties. When electrically operated to display images that are viewable through the mirror reflective element16, the video display screen generates heat within the mirror head12.

Referring toFIGS.2-8, one or more of the heat generating electronic components are thermally coupled to a hybrid heatsink assembly26within the mirror head12for dissipating heat generated by the electronic component exterior the mirror head12. For example, a heat source24, such as a PCB accommodating the one or more heat generating electronic components (e.g., the DMS camera, the image and/or data processor and the like) or the video display screen, is thermally coupled to the heatsink assembly26. The PCB or video display screen may be directly attached to the heatsink assembly26, such as via a thermal paste, snap attachment, threaded fasteners, and the like.

The heatsink assembly26may include a first half or portion, such as a backing plate portion28, and a second half or portion, such as a heat dissipating portion30, that join together to define an interior pocket or recess or vapor chamber32. The heat source24is thermally coupled to the backing plate portion28of the heatsink assembly26and the backing plate portion28may attach the mirror reflective element16to the mirror casing14, such that the heat source24is disposed between the mirror reflective element16and the backing plate portion28.

The backing plate portion28is coupled to or integrally formed with the hollowed heat dissipating portion30, such that the vapor chamber32is between the backing plate portion28and the heat dissipating portion30. The vapor chamber32may be defined by or extend between respective inner surfaces of the backing plate portion28and the heat dissipating portion30. The heat dissipating portion30extends from the backing plate portion28and toward the inner surface of the mirror casing14. For example, the heat dissipating portion30may include one or more heat dissipating fins30aextending away from the backing plate portion28. The heat dissipating portion30may be in thermally conductive connection with the mirror casing14to dissipate heat to the mirror casing14and exterior the mirror head12. For example, a thermally conductive paste or interface may be disposed between the heat dissipating portion30and the inner surface of the mirror casing14.

Optionally, the heat dissipating portion30may substantially conform to the shape of the mirror casing and/or other components within the mirror head12. That is, and as shown inFIGS.3-5, a profile or shape of the heat dissipating portion30may generally correspond to a contour or shape of the inner surface of the mirror casing14. In the illustrated example, the heat dissipating portion30has an arcuate or curved profile to substantially match the curved contour of the inner surface of the mirror casing14. This allows the heat dissipating portion30to be in contact or close proximity to the inner surface of the mirror casing14and more uniformly dissipate heat across the mirror casing14. Indentations or cutouts may be formed along the heat dissipating portion30to accommodate other components within or structure of the mirror head, such as a socket receiving a ball member of the mounting structure, electrical connectors, and the like.

A phase-changing liquid or refrigerant is disposed within the chamber32to assist in the thermal transfer from the backing plate portion28along the heat dissipating portion30and away from the heatsink assembly26. With the backing plate portion28and the heat dissipating portion30joined together, the phase-changing refrigerant may be sealed within the chamber32. The backing plate portion28may include a porous internal lattice or wick structure34and the heat dissipating portion30may include a porous internal lattice or wick structure36(FIG.2) such that the phase-changing liquid may be free to flow along the interior surfaces of the backing plate portion28and the heat dissipating portion30and at least partially through and within the backing plate wick or lattice structure34and/or the heatsink wick or lattice structure36. In other words, the internal lattice structure34of the backing plate portion28and the internal lattice structure36of the heat dissipating portion30extend along the inner surface of the heat sink assembly26so that the phase-changing refrigerant may flow along and at least partially within the inner surfaces of the heat sink assembly26. This may increase the surface area of the heatsink assembly26in contact with the phase-changing refrigerant to improve or enhance thermal transfer between the heatsink assembly26and the refrigerant. The backing plate wick34may also act to retain refrigerant across the backing plate portion28and at or near the heat source24despite changes in orientation of the mirror head (e.g., due to the driver adjusting the mirror head to adjust the rearward view provided by the mirror assembly).

As shown inFIG.2, heat generated by the heat source24is dissipated to the backing plate portion28and the phase-changing refrigerant boils to transfer or convey the heat along the heat dissipating portion30. That is, refrigerant in liquid form within the vapor chamber32at or near or adjacent the backing plate portion28, such as at least partially within the lattice structure or wick34of the backing plate portion28, boils or vaporizes in response to the heat generated by the heat source24. The phase-changing refrigerant may be selected or configured to have a boiling point suitable to maintain an acceptable operating temperature at the heat source24. That is, the phase-changing refrigerant may be configured to boil (and thus transfer or convey heat away from the heat source24) at a temperature that is below a maximum operating temperature of the heat source24to preclude the heat source24from reaching its maximum operating temperature. For example, the phase-changing refrigerant may boil when heated to a temperature of 80 degrees Fahrenheit or more, 100 degrees Fahrenheit or more, 120 degrees Fahrenheit or more, 200 degrees Fahrenheit or more and the like. The gaseous refrigerant may then return to liquid form when cooled to a temperature below the boiling point.

Thus, after the liquid refrigerant boils or vaporizes, gaseous refrigerant then moves or flows along the vapor chamber32and the hollowed heat dissipating portion30, such as within and along respective heat dissipating fins30a, where the heated and gaseous refrigerant condenses at or against the cooler surface of the heat dissipating portion30to transfer or convey heat to the heat dissipating portion30. The lattice structure36may increase the surface area of the heat dissipating portion30in contact with the gaseous refrigerant to improve or enhance thermal transfer between the gaseous refrigerant and the heat dissipating portion30. The transferred or conveyed heat may then be dissipated exterior the mirror head12from the heat dissipating portion30. The condensed refrigerant may then flow along the heat dissipating portion30, such as at least partially within the lattice structure36of the heat dissipating portion30, back toward the backing plate portion28. Thus, the heatsink assembly26may provide the functionality of a heatsink, a heat pipe and a vapor chamber to dissipate heat away from the heat source24and exterior the mirror head12.

The backing plate portion28of the heatsink assembly26may be formed via additive manufacturing or3D printing. Thus, the backing plate portion28may include a receiving surface or layer (e.g.,FIG.6) for interfacing with the one or more heat sources within the mirror head12. For example, the receiving layer may receive the mirror reflective element16and attach to the mirror casing14to secure the mirror reflective element16at the mirror casing14with the one or more heat generating electronic components between the mirror reflective element16and the backing plate portion28. The porous internal lattice structure or wick34(e.g.,FIG.7) is added to (e.g., via additive manufacturing) or extends from the receiving layer so that the phase-changing liquid may flow within and along the wick34of the backing plate portion28for absorbing heat dissipated to the backing plate portion28. A portion or layer may extend from the wick34(e.g.,FIG.8) to engage the heat dissipating portion30for joining the two portions of the heatsink assembly26together to define the vapor chamber32. The heat dissipating portion30may be formed via additive manufacturing, or the heat dissipating portion30may comprise a die cast or stamped heat dissipating portion30that may or may not include the heat dissipating fins30a. In some examples, the refrigerant may be injected or added into the chamber32during the additive manufacturing process, such as via a port formed through the backing plate portion28or heat dissipating portion30that is closed over or filled in following addition of the refrigerant. Optionally, the refrigerant may be added to one or both of the backing plate portion28and the heat dissipating portion30prior to joining the two portions together, such as via a coating process (where the refrigerant is applied to surfaces of the portion) or a filling process and the like.

Additive manufacturing of the heatsink assembly26allows for conformal designs, where the heatsink assembly26may substantially conform to or accommodate internal structure and other components within the mirror head12and the interior surface of the mirror casing14. Thus, the heatsink assembly26may be uniquely shaped to provide passive cooling to heat generating components at any suitable position within the mirror head12. Further, the additive manufacturing may provide for reduced packaging and lower mass compared to standard heatsinks. The heatsink assembly26may comprise any thermally conductive material suitable for use with additive manufacturing processes, such as a thermoplastic material (e.g., polyactic acid) or metallic material (e.g., titanium or stainless steel). The internal lattice structure or wick of the backing plate portion28and/or heat dissipating portion30may increase the capillary force for liquid transport within the vapor chamber32, resulting in higher heat removal and increasing the thermal capacity of the heatsink assembly26. The additive manufacturing process and internal lattice structure may include characteristics of the heatsinks described in International Publication No. WO 2021/163312, which is hereby incorporated herein by reference in its entirety.

Thus, the hybrid heatsink assembly26includes two halves or portions that form the vapor chamber32. The first half or portion or backing plate portion28includes a3D printed backing plate with integrated lattice wicking structure. The second half or portion or heat dissipating portion30includes a die cast or stamped metal or plastic that may embody the traditional appearance of a heatsink (e.g., it may or may not contain fins). The two halves or portions form the vapor chamber32containing the phase-changing liquid/vapor.

Heat transferred or conveyed to the heat dissipating portion30of the heatsink assembly26via the phase-changing refrigerant is dissipated from the heatsink assembly26and exterior the mirror head12. For example, the heatsink assembly26may be thermally coupled to the mirror casing14for transferring heat to the mirror casing14to be dissipated to the ambient air of the vehicle cabin. Optionally, one or more slits or vents may be formed in the mirror casing so that cooling airflow may pass along and across the heat dissipating portion30to draw heat from the mirror head12. Further, one or more electrically operable cooling fans may be disposed within the mirror head12. When the cooling fan is electrically operated, the cooling fan directs airflow within the mirror head and along and across the heatsink assembly26to provide active cooling of the interior of the mirror head12. For example, the interior rearview mirror assembly and mirror casing may include characteristics of the mirror assemblies described in U.S. patent application Ser. No. 18/390,166, filed Dec. 20, 2023, which is hereby incorporated herein by reference in its entirety.

The video display screen of the video mirror, when the mirror is 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.

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.