CN117279802A - Interior rearview mirror assembly with driver monitoring system - Google Patents
Interior rearview mirror assembly with driver monitoring system Download PDFInfo
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- CN117279802A CN117279802A CN202280032148.6A CN202280032148A CN117279802A CN 117279802 A CN117279802 A CN 117279802A CN 202280032148 A CN202280032148 A CN 202280032148A CN 117279802 A CN117279802 A CN 117279802A
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- mirror assembly
- rearview mirror
- vehicle interior
- interior rearview
- vehicle
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Abstract
An interior rearview mirror assembly for a vehicle includes a lens portion having an interior mirror reflective element. The specular reflective element has a specular transflector that transmits near IR light incident thereon, transmits visible light incident thereon, and reflects visible light incident thereon. The mirror assembly includes a camera disposed within the mirror head and viewed through the mirror transflector. The camera includes an imaging sensor having a Quantum Efficiency (QE) of at least 15% for near infrared (near IR) light having a wavelength of 940 nm. The mirror assembly further includes first, second, and third near IR illumination sources disposed within the lens portion and operable to emit near IR light through the mirror transflector. The near IR illumination sources are respectively angled with respect to the planar front surface of the specular reflective element and, when energized, illuminate a corresponding interior compartment area for either a driver monitoring function or an occupant detection function.
Description
Cross Reference to Related Applications
The present application claims the benefits of U.S. provisional application No.63/267,316, U.S. provisional application No.63/262,642, U.S. provisional application No.63/260,359, U.S. provisional application No.63/201,757, U.S. provisional application No.63/201,371, U.S. provisional application No.63/200,451, U.S. provisional application No. 63/1 to 2021, U.S. provisional application No.63/200,315, and U.S. provisional application No.63/200,315, U.S. provisional application No. 2021 to 2021, U.S. provisional application No. 3 to 2021, all of which are incorporated herein by reference in their entirety.
Technical Field
The present invention relates generally to the field of interior rearview mirror assemblies for vehicles.
Background
It is known to provide mirror assemblies that are adjustably mounted to an interior portion of a vehicle, such as by a single or double ball pivot or joint mounting configuration, wherein the mirror housing and reflective element are adjusted relative to the interior portion of the vehicle by pivotal movement about the single or double ball pivot configuration. The mirror housing and reflective element are pivoted about either or both of the ball pivot joints by a user positively adjusting the rearward field of view of the reflective element.
Disclosure of Invention
The interior rearview mirror assembly has a driver monitoring camera (and which is preferably mounted concealed within the lens portion) disposed at the lens portion/mirror head portion (and wherein the camera views the interior compartment of the equipped vehicle through the transflective mirror element of the interior rearview mirror assembly) to move cooperatively with the lens portion as the lens portion is adjusted relative to the interior portion of the vehicle to adjust the driver's rearward field of view. The processor is operable to process the image data acquired by the driver monitoring camera to determine at least one selected from the group consisting of: (i) driver attention, (ii) driver drowsiness, and (iii) driver gaze direction. The processor is further operable to process the image data acquired by the driver monitoring camera to determine at least one selected from the group consisting of: (i) Whether or not an occupant/passenger is seated in a front passenger side seat of the equipped vehicle; (ii) Whether or not an occupant/passenger is seated in the rear seat of the equipped vehicle; and (iii) whether or not an infant/child is in the interior compartment of the equipped vehicle, and in particular the infant/child is present on the infant/car seat of the equipped vehicle, even if largely covered by the blanket. A driver monitoring camera and one or more Light Emitting Diodes (LEDs) that emit near infrared (near IR) light (and/or one or more laser sources that emit near IR light) may be disposed in a lens portion of an interior rearview mirror assembly of a equipped vehicle and receive and emit light (both visible and near IR light) through a transflector or a transflector of a specular reflective element. The near IR LEDs may be part of a backlight LED array of a video display screen disposed in the lens portion and viewable through the transflector of the specular reflecting element. When a driver of a equipped vehicle adjusts the lens portion to adjust his or her rear view, the processor may adjust the processing of the image data acquired by the driver monitoring camera to accommodate the adjustment of the lens portion in response to the processing of the image data acquired by the driver monitoring camera.
Alternatively and preferably, the interior rear view mirror assembly has a driver monitoring camera disposed at the lens portion (and preferably concealed within the lens portion, wherein the camera views the interior compartment of the equipped vehicle through the transflective mirror element of the interior rear view mirror assembly), the lens portion being adjustable relative to a mounting base configured for attachment at an interior portion of the vehicle. The lens section includes a mirror housing and a mirror reflecting element. The interior rearview mirror assembly includes a driver monitoring camera disposed in the lens portion for viewing a driver area of the vehicle and a driver monitoring illumination source disposed in the lens portion operable to illuminate/illuminate the driver area of the vehicle. The interior rearview mirror assembly further includes an occupant monitoring camera (which may be, and preferably is, the same camera used for driver monitoring) disposed in the mirror head that can view the occupant area of the vehicle and an occupant monitoring illumination source/illumination source (which may be, or at least may include in part, a driver monitoring illumination source) disposed in the rearview mirror head that is operable to illuminate/illuminate the occupant area of the vehicle. The interior rearview mirror assembly preferably includes an Electronic Control Unit (ECU) that includes electronic circuitry (disposed on a printed circuit board) that includes at least one data processor that is operable to process frames of image data acquired by the driver and passenger monitoring cameras. The ECU pulses the driver monitor and/or occupant monitor camera illumination source only during the frame portion of the frame of image data acquired by the driver monitor and/or occupant monitor camera and pulses the occupant monitor camera illumination source during the frame portion of the frame of image data acquired by the occupant monitor camera. The ECU processes image data acquired by the driver monitor camera and/or the passenger monitor camera by the data processor in synchronization with when the drive monitor and/or the passenger monitor irradiation source is pulsed, and monitors the presence of the driver and/or the passenger in the interior compartment of the equipped vehicle.
These and other objects, advantages, uses and features of the invention will become apparent upon reading the following specification in conjunction with the drawings.
Drawings
FIG. 1 is a plan view of an interior rearview mirror assembly;
FIG. 2 is a perspective view of an interior compartment of the vehicle;
FIG. 3 is a plan view of a steering wheel showing possible hand positions for a driver's hand;
FIGS. 4-6 show plan views of a mirror assembly with different camera and IR LED positions;
7-11 illustrate views of an automatically dimming interior rearview mirror assembly;
FIG. 12 is a perspective view of the auto-dimming interior rearview mirror assembly with the rear housing and heat sink removed to show additional detail, with the PCB including electrochromic and/or near infrared LED drivers, and with a data processor for image/data processing of image data acquired by the DMS camera optionally disposed outside of the lens portion;
FIG. 13 is an exploded perspective view of the auto-dimming interior rearview mirror assembly;
14-21 show views of a prismatic interior rearview mirror assembly;
FIG. 22 is an exploded perspective view of the prismatic interior rearview mirror assembly;
23-31 are schematic diagrams illustrating monitored areas for a driver and occupant monitoring system;
FIGS. 32A-32E are plan views of an interior rearview mirror assembly with different camera and infrared LED positions;
FIG. 33 is a schematic diagram showing the performance of the driver monitoring system when the camera and infrared LED(s) are disposed in the lower region of the lens portion;
FIG. 34 is a schematic diagram showing the performance of the driver monitoring system when the camera and infrared LED(s) are disposed behind the specular reflective element;
fig. 35 and 36 are views of an interior rearview mirror assembly with a camera and infrared emitter(s) disposed behind a specular reflective element;
FIGS. 37 and 38 are views of another interior rearview mirror assembly with a camera and infrared emitter(s) disposed behind a specular reflective element;
FIGS. 39 and 40 are views of the interior rearview mirror assembly with the camera and infrared emitter(s) disposed behind the specular reflective element;
FIG. 41 is a schematic view showing a rear glass substrate cut from or formed from a larger glass sheet (preferably by laser cutting);
FIG. 42 is a schematic diagram showing an in-line sputtering process for coating a glass substrate with a transparent electrical conductor on one side and a near infrared transmissive, visible light reflective and transmissive coating(s) on the other side;
FIG. 43 is a schematic diagram showing an in-line sputtering process for coating a glass substrate with near infrared transmissive, visible light reflective and transmissive coating(s) on one side, wherein a transparent electrical conductor is coated or applied over the near infrared transmissive, visible light reflective/transmissive coating(s);
FIG. 44 is a schematic diagram showing another inline sputtering process for coating a glass substrate with a near infrared transmissive, visible reflective/transmissive coating or stack of coatings on one side, using a conveyor belt to move the substrate back and forth between two targets;
FIG. 45 is a schematic diagram showing another inline sputtering process for coating a glass substrate with a near infrared transmissive, visible reflective/transmissive coating or stack of coatings on one side, using a conveyor belt to move the substrate back and forth between two targets;
FIG. 46 is a schematic diagram showing an example of alternating/repeating layers of a near infrared transmissive, visible mirror transflector, and showing transmittance versus wavelength characteristics of a stack of near infrared transmissive, visible reflective/transmissive multilayer coatings;
FIGS. 47 and 48 are views of an interior rearview mirror assembly with a camera and infrared emitter(s) disposed behind the mirror reflective element and having the near infrared transmissive, visible light reflective/transmissive coating of FIG. 46;
FIGS. 49 and 50 are views of another interior rearview mirror assembly with a camera and infrared emitter disposed behind a mirror reflective element and having the near infrared transmissive, visible light reflective/transmissive coating of FIG. 46 with broadband anti-reflective layers at the first and fourth surfaces;
FIG. 51 showsUltrawhite glass (++>Ultra-White Glass);
FIG. 52 is a schematic view of another specular reflective element having the near infrared transmissive, visible reflective/transmissive coating of FIG. 46, with a circumferential conductive channel disposed at the rear glass substrate third surface ITO coating;
53-55 are views of another interior rearview mirror assembly having a camera disposed behind a specular reflective element and having a portion (or all) of the near infrared LED disposed at a lower portion of the lens portion below the specular reflective element;
FIG. 56 is a view of another interior rearview mirror assembly with the PCB and processor disposed in a mirror mount/mounting base, with the mirror head pivotally attached at the base;
FIG. 57 is a schematic diagram showing spectral filtering at a photosensitive sensor of a DMS camera;
fig. 58 and 59 are schematic diagrams showing examples of alternating layers of near infrared transmissive, visible light reflective/transmissive specular reflectors, and showing transmittance versus wavelength characteristics of near infrared transmissive, visible light reflective/transmissive coatings;
Fig. 60 and 61 are schematic diagrams showing examples of alternating layers of near infrared transmissive, visible mirror transflector, and showing the transmittance versus wavelength characteristics of near infrared transmissive, visible reflective coatings;
FIG. 62 is an exploded perspective view of a cassette electrochromic interior DMS rearview mirror assembly (One-Box Electrochromic Interior DMS Rearview Mirror Assembly);
FIG. 62A shows the electrical connector at the ECU PCB of a cassette interior DMS rearview mirror assembly;
FIG. 63A is a schematic diagram of a DMS system of a combined Electrochromic (EC) dimmer circuit and a cassette internal DMS rearview mirror assembly;
FIG. 63B is a schematic diagram showing the electrical connection of the camera and IR light emitters to the ECU;
FIG. 63C is a schematic diagram showing the electrical connection of the IR light emitters to the ECU;
FIG. 63D is a schematic diagram of a DMS system showing a combined Electrochromic (EC) dimmer circuit and a cassette internal DMS rearview mirror assembly;
FIG. 63E is a schematic diagram of the cameras and sensors of the DMS system showing a cassette electrochromic interior DMS rearview mirror assembly;
FIG. 63F is a schematic diagram of a DMS system showing a combined Electrochromic (EC) dimming circuit and a cassette electrochromic interior DMS rearview mirror assembly;
FIG. 63G is a schematic diagram showing the circuitry of a cassette electrochromic interior DMS rearview mirror assembly;
FIG. 64 showsBlack OSLON Black series (940 nm) -50 ° dual stack emitter characteristics;
FIG. 65 showsBlackCharacteristics of the series (940 nm) -130 ° x155 dual stack emitter;
FIG. 66 is a table showing a transflector stack suitable for use with a visible light transmissive/visible light reflective/near infrared light transmissive transflector substrate of a cassette electrochromic interior DMS mirror assembly;
fig. 67A and 67B show the transmittance and color of a visible light transmissive/visible light reflective/near infrared light transmissive/reflective substrate;
68A and 68B illustrate the transmittance and color of a visible light transmissive/visible light reflective/near infrared light transmissive/reflective substrate;
FIG. 69 is a diagram showing GuardianA table of optical properties of low iron glass;
fig. 70 shows characteristics and transmittance of the Kang Ninggong external transmission glass 9754 (Corning Infra Red Transmitting Glass 9754);
fig. 71 is a table showing performance data for peakinton OptiwhiteTM (Pilkington OptiwhiteTM);
72A-72C are views of the one-cartridge electrochromic interior DMS rearview mirror assembly of FIG. 62, with the housing and mounting structure not shown;
FIGS. 73 and 74 are views of a cassette electrochromic interior DMS rearview mirror assembly showing the mirror mounting base/bracket;
FIGS. 75A-75B are views of an ECU PCB;
FIGS. 75C-75E are views of a thermal interface material application at a PCB and attachment plate;
FIGS. 76A-76B are views of the housing of a cassette type inside DMS rearview mirror assembly;
FIG. 77A is a cassette DMS internal Infinity TM Schematic diagram of electrochromic rearview mirror assembly;
FIG. 77B is a cassette DMS internal EVO TM Schematic diagram of electrochromic rearview mirror assembly;
FIG. 78 is a cassette DMS internal Infinity adjustably mounted at a Windshield Electronic Module (WEM) TM Schematic diagram of electrochromic rearview mirror assembly;
FIG. 79 illustrates exemplary visible light transmittance curves for a dual substrate laminated electrochromic transflector element ("EC cell") suitable for use in a cassette electrochromic interior DMS mirror assembly;
FIG. 80 illustrates another exemplary visible light transmission curve for an EC cell in a cassette electrochromic interior DMS mirror assembly;
FIG. 81 illustrates another exemplary visible light transmission curve for an EC cell of a cassette electrochromic interior DMS mirror assembly;
FIG. 82 is a perspective view of an imager assembly with the exterior surface of the driver monitor camera coated with a dark/light absorbing/black coating;
fig. 83 shows a near infrared emission pattern formed by a near infrared reflector of two narrow field LEDs for a left-hand driving vehicle and a near infrared emission pattern formed by a near infrared reflector of two narrow field LEDs for a right-hand driving vehicle;
84A-84C illustrate a near infrared light emitting source disposed in and supported by the lens portion structure of a cassette electrochromic interior DMS mirror assembly;
figures 85A and 85B are top plan views of a cassette interior DMS mirror assembly mounted in a LHD vehicle;
figures 86A-86C are schematic diagrams illustrating exemplary angles and dimensions of a cassette interior DMS mirror assembly in a LHD vehicle;
figure 86D shows a distribution plot of different driver eyepoints illuminated by LHD nffov LEDs in a LHD vehicle in both horizontal and vertical planes;
figure 86E shows illumination within the cabin of the LHD vehicle when the LHD nffov LED is powered;
FIGS. 87A and 87B are top plan views of a cassette interior DMS mirror assembly mounted in a RHD vehicle;
FIGS. 88A and 88B are schematic diagrams illustrating exemplary angles and dimensions of a cassette internal DMS mirror assembly in a RHD vehicle;
FIG. 88C shows the distribution of different driver eyepoints illuminated by RHD nFOV LEDs in a RHD vehicle in both horizontal and vertical planes;
FIG. 88D illustrates illumination within the cabin of the RHD vehicle when the RHD nFOV LEDs are energized;
FIG. 89 shows illumination within the cabin of a vehicle when wFOV LEDs are powered;
FIG. 90 illustrates a cassette internal DMS mirror assembly suitable for use on both RHD vehicles and LHD vehicles;
FIG. 91 illustrates a rear side of an exemplary EC unit for a cassette electrochromic interior DMS mirror assembly;
FIGS. 91A-91C illustrate how the exemplary EC unit of FIG. 91 is oriented when a cassette electrochromic interior DMS mirror assembly is attached to a windshield of a equipped vehicle;
FIG. 92 illustrates a measure to enhance the shielding, wherein the outermost surface of the lens of the driver monitor camera is spaced from the bare glass surface of the back side of the rear glass substrate of the EC unit, with the camera looking through the EC unit;
FIG. 93 is a perspective view of a specular reflective element having a dimensional spacing from a glare sensor and/or near infrared illumination device to enhance shadowing;
FIG. 94 shows spectral characteristics of visible and near infrared spectral regions of a DMS EC unit in its non-dimmed (bleached) state and its fully electrically dimmed (colored) state;
FIG. 95 shows a CIELAB color space diagram;
FIG. 96 shows four exemplary EC cells in which the stack of multi-layer oxide coatings forming the specular reflector has been tuned such that the visible light transmission through the EC cell is about 45% T, about 30% T, about 21% T, and about 14% T;
FIG. 97 shows the overall system output of the camera as seen through a 45% T visible light filter in combination with a 45% T EC cell as 20.25%;
FIG. 98 shows the overall system output of the camera as 24% as viewed through an 80% T visible light filter in combination with a 30% T EC cell;
FIG. 99 shows the overall system output of the camera as seen through a 90% T visible light filter in combination with a 21% T EC cell at 18.9%;
FIG. 100 shows the overall system output of the camera as seen through a 90% T visible light filter in combination with a 14% T EC cell as 12.6%;
FIG. 101A shows a box type of Infinity TM A prismatic internal DMS mirror assembly;
fig. 101B shows a cassette EVO TM A prismatic internal DMS mirror assembly;
FIG. 102 illustrates a box type of Infinity TM Construction of prismatic internal DMS mirror assemblies;
103A and 103B are perspective views of the field of view of the internal camera divided into different regions of interest;
FIGS. 104A and 104B are schematic diagrams of an example sequence of image data frames for a driver monitoring system and an occupant monitoring system;
FIG. 105 is a schematic diagram of an example sequence of image data frames for a driver monitoring system and an occupant monitoring system;
FIG. 106 is a diagram of a MIK module of the safety architecture of a cassette internal DMS mirror assembly;
FIG. 107 shows the optical path of light emitted by the LEDs to the imager of the camera of the cassette internal DMS mirror assembly;
FIG. 108 illustrates a driver's head sash or region captured by the camera of a cassette internal DMS mirror assembly (and illuminated by the LEDs);
FIGS. 109A and 109B illustrate how forward field of view, near infrared illumination, and camera visibility to the eye may be affected by some mask positions;
fig. 110 shows an arrangement of first, second and third near infrared irradiation sources at the right side of the lens section (to the right side of the camera) as seen by the driver of the equipped vehicle;
FIG. 111 shows spectral responses and quantum efficiencies of EV76C660 imaging sensor and EV76C661 imaging sensor;
FIG. 112 shows the transmission spectrum of the luminescence 7276F; and
figures 113A-113E illustrate different positions of the wFOV and nffov near infrared illuminators at the lens portion of a cassette interior DMS rearview mirror assembly.
Detailed Description
Referring now to the drawings and the illustrative embodiments described therein, an interior rearview mirror assembly 10 for a vehicle includes a housing 12 and a reflective element 14 (FIG. 1) located at a front portion of the housing 12. In the illustrated embodiment, the mirror assembly 10 is configured to be adjustably mounted to an interior portion of a vehicle (e.g., to a mirror mounting button/element at an interior or cabin interior surface of a vehicle windshield, or to a ceiling or the like of a vehicle, for example) by a mounting structure or mounting arrangement or assembly. The specular reflective element preferably comprises a variable reflectivity specular reflective element that changes its reflectivity in response to an electrical current applied to a conductive coating or layer of the reflective element.
The mirror assembly includes a Driver Monitoring System (DMS) including a driver monitoring camera 18 disposed in a lower region of the lens portion and capturing at least toward a head region of a driver of the vehicle. The mirror assembly includes a near-infrared (near-IR) or Infrared (IR) Light Emitting Diode (LED) 20 disposed in a lower region of the lens portion and operable to emit near-infrared light to illuminate an interior compartment of the vehicle in an under-light condition. The driver monitoring camera and near infrared LED(s) may utilize aspects of the driver monitoring system described in U.S. patent application nos. 17/650,255 (attorney docket MAG 04P 4412), and/or No.17/649,723 (attorney docket DON 01P 4410), and/or U.S. provisional application nos. 63/267,316, and No.63/262,642, and No.63/201,757, both filed on U.S. publication nos. 2021-0323773 and/or U.S. patent No. 2021-0291739, and/or No. 2022-month 8, and/or No.17/649,723, filed on 2022-month 2, and/or U.S. provisional application No.63/267,316, 2021-month 31, filed on 2021-month 10, and No.63/201,757, both of which are incorporated herein by reference in their entirety.
The DMS camera is disposed in the lens portion which moves with the lens portion (including the lens housing and the lens reflective element, which pivot at a pivot joint that pivotally connects the lens portion to the mounting structure of the interior rearview mirror assembly, which in turn is mounted at the windshield or ceiling of the equipped vehicle) such that the camera is aligned with the driver's line of sight when the driver aligns the lens for rearward viewing. The location of the DMS camera and IR LED(s) at the lens portion provides the driver with an unobstructed view. The DMS is preferably housed separately from the interior rearview mirror assembly and thus can be readily implemented in a variety of vehicles, including existing vehicles and different vehicle models of the same vehicle brand (e.g., on a BMW 3 series vehicle model and a BMW X3 vehicle model, and on a BMW 5 series vehicle model and a BMW X5 vehicle model, and on a BMW 7 series vehicle model, etc.). The driver monitoring camera may also provide acquired image data to an Occupant Monitoring System (OMS), or another separate camera may be provided on the mirror assembly for OMS functions.
The mirror assembly may include a self-adjusting mirror reflective element (e.g., electrochromic mirror reflective element) or a prismatic mirror reflective element. For prismatic mirrors, when the head or housing is set to a particular orientation by the driver of the equipped vehicle, the driver operable toggle moves the housing and reflective element up/down, typically about 4 degrees, to switch between a daytime or no glare position (where the driver can see the reflection at the mirror reflector of the mirror reflective element) and a nighttime or glare position (where the driver can see the reflection at the surface of the glass substrate of the mirror reflective element). With auto-dimming mirrors, the lens portion is typically not moved once it is set for a particular driver.
Both types of mirrors may be provided with a video display screen which is arranged behind the mirror reflective element and is viewable through the mirror reflective element. Such video mirrors include backlit LCD displays, and one particular form of video mirror is a full display mirror (e.g., magna Mirrors of America of Holland, michigan, inc., clearView, inc.) TM An interior rearview mirror assembly, or FDM provided by Gentex Corporation of Zeeland, michigan, usa TM An interior rearview mirror assembly) wherein the video display screen fills the reflective area, such as with No.11,242,008; no.11,214,199; no.10,442,360; no.10,421,404; no.10,166,924; U.S. Pat. Nos. 10,046,706 and/or 10,029,614, and/or U.S. Pat. No. 2021-0162926; no. US-2019-0258131; no. us-2019-0146297; various aspects of the mirror assemblies and systems described in U.S. publication nos. us-2019-018717 and/or us-2017-0355312, all of which are incorporated herein by reference in their entirety. In this type of dual mode internal rearview mirror, the EC lens portion moves when switching from either the traditional reflective mode or the mirror mode to the real-time video display mode.
For prismatic and full-mirror display mirrors, the driver initially views the rear of the vehicle by looking at the mirror reflector to align the mirrors. When the mirror is flipped up (e.g., switched to the glare reducing position of the prismatic mirror or to the video display mode of the video mirror), the DMS may flip down a similar angle to keep its primary viewing axis toward the driver. Alternatively, the DMS camera may have a field of view large enough that when the mirror is flipped, the desired area is not outside the field of view of the camera. The DMS data processor provided at the ECU of the system may adjust or transfer the processing of the image data acquired by the camera depending on the orientation of the lens portion (i.e., when it is flipped up or down) such that the portion of the image data processed for the driver monitoring system represents the desired monitored area within the vehicle cabin.
For different camera positions and driver states, the occlusion rate of the driver's face and body can be calculated. This may not provide a "perfect" result because the camera may be closer or farther from the driver with each change in camera position. Therefore, the constant region used for the occlusion rate calculation is also changed in association. For example, if the camera is very close to the driver, these constant regions may not capture all of the region of interest, and if the camera is too far from the driver, the constant regions capture some background.
As shown in fig. 4, the camera may be disposed below the specular reflective element and, for example, at and behind an aperture through the IR transmissive cover and looking through the aperture. Alternatively, and as shown in fig. 5, a camera may be provided behind the transparent lens cover. Alternatively, and as shown for example in fig. 6, one or more infrared emitters (e.g., infrared or near infrared emitting LEDs or infrared or near infrared emitting Vertical Cavity Surface Emitting Lasers (VCSELs)) may be disposed at and behind the IR transmissive cover.
In the embodiments shown in fig. 4-13, the mirror assembly includes an automatically dimmed or electro-optic, e.g., electrochromic, mirror reflective element. Alternatively, and as shown in fig. 14-22, for example, the mirror assembly (with the DMS camera and infrared light emitter (s)) may include prismatic mirror reflective elements and may be adjusted between a daytime or normal viewing position and an antiglare position by a toggle of the mirror assembly.
As shown in fig. 23-31, the DMS camera views the driver's head area to monitor the driver's head movements, eye position, gaze direction, and drowsiness/attention. The DMS camera may also view other interior cabin areas and/or body parts of the driver (e.g., the driver's hands) to monitor the driver's behavior, such as using a cell phone, placing the hands on a steering wheel, etc. Optionally, the DMS camera may provide occupant monitoring to determine the presence of an occupant and the use of the occupant's seat belt. Fig. 24-31 illustrate example dimensions and viewing angles of DMS cameras for driver monitoring, driver behavior monitoring, and occupant monitoring.
BMW, ford, general purpose, tesla, and Sbaru, etc. (e.g., general purpose SuperCruise as described in https:// www.consumerreports.org/car-safety/driver-monitoring-systems-ford-gm-earn-points-in-cr-tests-a 6530426322) TM Or Ford Blueruise TM ) The conventional Driver Monitoring Systems (DMS) of (a) are all "two-box" DMS, namely: (i) A camera for monitoring the head/eyes of the driver and a near infrared emission light source illuminating the head/eyes of the driver are housed in a first box or module (which is typically located at the steering column of the equipped vehicle or in the overhead area of the equipped vehicle); (ii) The electronics/software for analysing the acquired image data to determine the gaze direction or head position or eye movement or alertness or sleepiness of the driver is accommodated in a separate second box or module which is remote from or at a distance from the first box and which is typically connected to the first box by a wired connection (the second box typically comprises an ECU which may be provided with A portion of the head unit of the vehicle, and other features may optionally be provided in addition to the DMS).
Referring now to fig. 62, a "one-box" DMS electrochromic interior rearview mirror assembly 110 has both a camera 10 housed by the interior rearview mirror assembly for monitoring the head/eyes of a driver and a near infrared emitting light source 8 for illuminating the head/eyes of the driver (and preferably both housed within the lens portion of the interior rearview mirror assembly). Thus, a box-type electrochromic interior DMS rearview mirror assembly allows an Original Equipment Manufacturer (OEM) of a vehicle (e.g., mass or honda or general or ford) to equip the vehicle with a similar DMS interior rearview electrochromic mirror assembly that includes camera/illumination source/driver monitoring software/related driver monitoring electronic circuitry, such as data processing chip(s), memory, electronics, printed circuit board(s) including automatic dimming circuitry, data processing chip(s), memory, electronics, light sensors for detecting glare and ambient illumination and including power source, electrical connector(s), heat sink(s), mechanical components, and the like. A cassette interior DMS rearview mirror assembly is thus commercially available from interior rearview mirror assembly manufacturers by OEMs and can be installed by the OEMs into the vehicle being assembled (typically onto mirror mounting buttons or similar elements adhered to the cabin interior side of the vehicle's windshield). For operation on a equipped vehicle, a cassette interior DMS rearview mirror assembly is connected to a vehicle harness of the vehicle and provides an ignition voltage (nominally 12 volts dc, but can vary from 9 volts (6 volts for automatic stop/start) to 16 volts, alternatively depending on the vehicle type and the operating conditions of the vehicle) through the vehicle harness. A cassette internal DMS rearview mirror assembly is provided with vehicle data via the harness, such data including vehicle and other data, via a CAN bus or link that CAN convey vehicle information to the mirror, and which CAN output distraction alerts, etc. from the mirror, or via a local area network (LIN) bus or line. The wiring harness may include a reverse blocking signal/line in communication with the internal electrochromic mirror assembly when the driver has selected reverse/reverse propulsion, ethernet link, video input/output line, power, ground, and/or GMSL/FPD link (video input/output). Video output may be provided, for example, for video conferencing and/or "self-timer" applications. Alternatively, to protect privacy, the occupant's image may be obscured if displayed on an in-car display (such as during an in-car video conference) or if transmitted wirelessly to a viewer remote from the equipped vehicle. The system may blur the entire image, leaving only the driver/co-driver or all passengers' faces clear. Optionally, a black bar is covered on the face of the person. Image stabilization may be provided to compensate for potential movement of the image and/or to dynamically crop the image.
The vehicle harness also receives output/data from a cassette interior mirror DMS for various features, systems and functions of the equipped vehicle. The output/data from a cassette interior DMS rearview mirror assembly includes data relating to the head position of the driver of the equipped vehicle, the eye gaze direction of the driver of the equipped vehicle, the hand position of the driver of the equipped vehicle, the degree of drowsiness of the driver of the equipped vehicle, the attention of the driver of the equipped vehicle, and the like, as well as other output/data relating to part (and preferably all) of:
emotional state
Cognitive distraction
Detachment from
Visual disturbance
Degree of sleepiness
Microsleep
Sleep mode
Visual state
Posture of human
Nodding/nodding
Activity
Abnormal head posture
Hand position classification
Classification of holding objects
Speaking
Laugh
Cough with cough
Sneeze
Yawning
Smoking article
Telephone processing
Video conference
Viewing target classifications
Child seat detection
Safety belt state
Occupant size
Age of occupant
Sex (sex)
Presence detection
Facilitating identification
Secure identification
Member change
Spoofing
Facial expression
Body posture tracking
Eye tracking
Head tracking
Eyelid dynamics
Brightness control
Face search
Mouth shape
Camera pose estimation
Frozen image detection
Facial occlusion
Lens block
Low image quality
Infrared light shielding
Camera misalignment
The interior DMS rearview mirror assembly provides a self-contained one-box DMS solution having camera/near infrared source/DMS software and its associated data processing chip (s)/auto-dimming circuitry/circuitry for controlling external electrochromic mirror reflective elements that are part of the equipped vehicle's exterior side view mirror/data processing circuitry/communication circuitry/memory/power/associated electronics and hardware/heat sinks, etc., packaged, integrated into and housed within the vehicle's interior rearview mirror assembly, and preferably concealed within the lens portion of the vehicle's interior rearview mirror assembly, behind (and concealed to the driver's view by) the transflector reflective element of the vehicle's interior rearview mirror assembly.
A cassette type internal DMS rearview mirror assembly overcomes and solves many of the problems associated with the ability to conceal the integration of such a complete DMS in the lens portion of the internal mirror assembly. One problem that has been overcome is heat/thermal management. The DMS data processor of a cassette internal DMS rearview mirror assembly may include a FOVIO Driver Monitoring (FDM) processor of the Seeing Machines, described in c_d3_03-Driver-Monitoring systems.pdf (xilinx. Com), which is incorporated herein by reference in its entirety, which employs computer vision algorithms that are capable of measuring a Driver's visual attention to his surroundings in robust, accurate, real-time, assessing the extent of drowsiness, and ultimately detecting whether the Driver has exceeded a risk threshold. For example, DMS solutions built on FDM technology of the timing machinery are automatic, unobtrusive, accurate, reliable and intelligently perceived. The driver does not need to wear any items or change his or her behavior. Such DMS data processing is complex and extensive, and such data processing of DMS data generates heat. For example, a complete DMS process on an FPGA or similar data processing chip would generate at least 2 watts of heat, and multiple near infrared emission sources would further generate at least 2 watts of heat, and various other automatic dimming and other circuitry housed within the lens would generate at least 1 watt of heat in a DMS-box mirror solution. The electronic system housed within the lens portion of a cassette type internal DMS rearview mirror assembly as a whole may consume at least 5 watts to 15 watts of power (e.g., about 10 watts) when energized, which may generate heat within the lens portion of the internal rearview mirror assembly. For example, the ECU may consume about 8.5 watts (e.g., 7.386 watts), the LED may consume about 2.1 watts (e.g., 2.078 watts), and the camera/imager board may consume about 0.3 to 0.4 watts (e.g., 0.345 watts).
The DMS data processor of a cassette internal DMS rearview mirror assembly may include a data processing chip running artificial intelligence based DMS/OSD software/algorithms provided by Smart Eye AB, goldburg, sweden. By studying the eyes, face, head and body movements of a person and the objects they use, the internal vehicle algorithm of Smart Eye can draw conclusions about the alertness, concentration and more.
An interior rearview mirror assembly for use with a vehicle must be capable of being used and operated in all climates/geographic areas (day and night) wherever the vehicle is traveling. In a hot summer day, such as arizona or florida, the housing (typically plastic) of the lens portion of the interior rearview mirror assembly attached to the windshield of a car parked in sunlight can be at temperatures up to 85 degrees celsius or higher. If the driver grasps the lens portion when entering the car to adjust his or her rear view field to his or her desired setting, the fingers of the driver grasping the lens portion will contact the hot surface. Of course, once the driver starts the ignition/engine/propulsion system of the vehicle, the temperature of the outer surface of the lens portion will drop, especially when the air conditioner of the vehicle is on, although this may take several minutes. Accommodating DMS within the lens portion may exacerbate this problem (unless improved as described herein), at least because: (i) Once the driver starts the vehicle, the in-lens DMS is actuated and its extensive data processing generates further heat within the lens section; and (ii) such further heat generated within the lens portion can affect and even compromise/deteriorate/destroy the performance of the electronic device enclosed within the lens portion. Even though hot dip during normal driving is not a problem when parking in sunny hot climates, the heat generated by the extensive data processing of the DMS can raise the temperature of the outer surface of the lens portion (at least locally) to a temperature level that may cause discomfort or unpleasantness to the driver holding the lens portion. And even during normal driving, the heat generated by the extensive data processing of the DMS can affect even the performance of the electronic components enclosed in the lens portion.
To overcome this heat/thermal management problem, and as shown in fig. 62, a cassette electrochromic interior DMS rearview mirror assembly 110 includes a heat sink/chassis 12. The radiator/chassis 12 is formed of metal, for example anodized aluminum or magnesium (preferably lightweight in this case), or zinc or copper or brass, or any alloy of the above materials. For example, the heat sink may comprise a die cast black anodized aluminum alloy having a conductivity of at least 170W/m-K. The ECU 6 of a cassette electrochromic interior DMS rearview mirror assembly 110 includes a rigid multi-layer (e.g., at least 3 layers or at least 5 layers or at least 7 layers, such as 8-10 layers) Printed Circuit Board (PCB) having a front side (which faces the EC mirror reflective element 1) and a rear side (which faces the metallic heat sink/chassis 12), and wherein the rear side is separated from the front side by the thickness dimension of the PCB (preferably FR4 PCB). The ECU 6 includes electronic circuits provided on both sides of the PCB. The conductive traces and vias of the PCB interconnect the circuits disposed on the front and back sides of the PCB. The heat sink/chassis 12 functions to absorb and spread the heat generated by the DMS electronics. Without the heat sink/chassis 12, the localized portion of the driver's grip of the mirror housing/casing may be hotter than the other portions, as the heat generator within the mirror head is proximate to the localized portion. The heat sink/chassis 12 mitigates/ameliorates/avoids such localized hot spots by absorbing and diffusing heat generated locally within the lens portion by the DMS electronics, including the DMS camera and near infrared light source, and also any existing automatic dimming circuitry.
The ECU 6 includes an electrical connector (e.g., a pigtail harness extending from the lens portion and terminating in a multi-pin connector, or a multi-pin connector or the like that is part of the lens portion and is configured to connect to a vehicle harness) for electrical connection with the harness of the vehicle when the cassette interior DMS rearview mirror assembly is installed at the vehicle. For example, and as shown in fig. 62A, the PCB may have an inner connector electrically connected with an outer connector that is electrically connected with the vehicle wiring harness. The wiring harness is electrically connected to a vehicle power source or battery (which provides about 12V) and has a ground line and possibly a reverse blocking line. The CAN communication line (2 wires) or LIN communication line (1 wire) may be connected to the ECU 6 to provide communication/control for other vehicle components. Alternatively, the ECU may have an ethernet interface/connector (e.g., a shielded single twisted pair) and may provide a 100Mbps ethernet interface for video transmission using h.264.
The electronic circuitry provided on the back side of the PCB may comprise a Xilinx XC7Z020 FPGA, commercially available from Xilinx corporation of san Jose, calif., loaded with DMS software running an algorithm provided by Seeingachines corporation of Fyshwick, inc. (website: http:// www.seeingmachines.com), both of the first and second jurisdictions, australia.
The heat generated by the circuitry disposed on the PCB, particularly at the back side of the PCB (which is the side of the PCB where data processing (e.g., for DMS) is performed and concomitant heat generation), is thermally reduced and dissipated by the heat sink/chassis 12. The ECU 6 is nested within the radiator/chassis 12 and the heat transfer of the electrical components of the ECU 6 to the radiator/chassis 12 is enhanced by the various thermally conductive interface materials/elements.
As shown in fig. 62, a plurality of Thermal Interface Material (TIM) elements 7 are disposed at the rear side of the PCB, such as the rear side of the ECU PCB, for example at the heat-generating components (e.g., DMS SoC chip, imager PCB, LED PCB, etc.), and are in contact with corresponding pads or portions of the heat spreader/chassis 12 to dissipate heat generated by the heat-generating components during operation of the inside DMS rearview mirror assembly of a cassette. For example (and as shown in fig. 75C-75E), the TIM element 7 may be disposed at a component at the back side or heat sink side of the PCB (to be disposed between and in contact with the component and the heat sink), such as an SoC, an LED PCB (at the side of the LED PCB opposite the LED), an imager PCB (at the side of the imager PCB opposite the imager), a memory, a Power Management Integrated Circuit (PMIC) chip, a power chip, a schottky diode, an inductor chip, and the like. The TIM element may also be disposed on (to be disposed between and in contact with) a component at the attachment plate side of the PCB, such as ethernet Phy, schottky diode, flash memory, reverse diode, LED driver FETS, LED driver ICs, and the like.
The TIM element may be provided like a thermally conductive paste or pad, and the dispensing device may meter the material to a respective specific volume or weight at each location. Considering the vertical orientation of the surface at the TIM interface connection, the material should have sufficient vertical stability (i.e., the material does not slip due to gravity and/or extreme temperatures, vibrations, etc.). The interface surface of the heat spreader or attachment plate may be designed/molded with additional geometry (e.g., features of grooves, scores, etc.) to mechanically "lock" the TIM element against sliding. If such additional structure is provided, air gaps between the TIM element and the interface surface/material may be minimized or avoided. The TIM element may include a non-silicon based material to avoid paint contamination/adhesion. The heat sink causes the four screw bosses and the ECU, which is sandwiched between pins or bosses on its corresponding sides on both the heat sink and the attachment plate, to bottom out or offset, thereby controlling the thickness of the TIM element and preventing them from being compressed further.
The PCB components of the ECU (see fig. 75A and 75B) include a system on a chip (SoC), (e.g., TI Sitara SoC), a video processing chip (ISP), a detection processing chip and related software, a Multipoint Control Unit (MCU) such as ARM R5F, and four ARM a53 cores (or other suitable components) for processing. The DMS hardware includes a camera (which acquires image data at 60 frames per second) and three sets or rows of light sources (e.g., LEDs). The light source may be powered by a constant current driver, with the entire string (e.g., 6 near infrared LEDs configured into three groups/2 LEDs per group) being powered in series. A FET is included for shorting the RHD LED or LHD LED off. The drive current is about 2.3 amps. Preferably, the current through the near infrared LED is less than 3.5 amps. The ECU operates at a 4 millisecond pulse time (12% duty cycle), but may preferably be between 5% and 35% duty cycle depending on the choice of LED type and other considerations. The exposure time (according to IEC 62174 standard) is greater than 1000 seconds (at least 34 cm apart) during normal operation and in case of misuse is about 20 seconds (10 cm apart or less). The SMR (surface mount reflector) magnification of the reflector for the nffov LED is about 1.78x. The system adjusts the PWM on/off time of the LEDs to reduce operating temperature and thermal problems. The system may also or otherwise regulate the constant current through the near infrared LED. The system may include an on-board thermistor, an LED driver internal temperature sensor, an SoC internal temperature sensor, or other temperature sensing device that determines the temperature at or within the lens portion. When it is determined that the temperature is higher than the threshold temperature, the vehicle may be cooled inside in summer or heated in winter using a remote start function of the vehicle. The system CAN monitor sun exposure and communicate with the vehicle via the CAN/LIN bus to add A/C to the windshield. The system can monitor sun and weather and lower the window slightly to reduce internal heat.
The in-lens DMS chip running DMS software/algorithms (e.g., from Seeingmachines or the like from Smart Eye) may include a Sitara SoC from texas instruments (Texas Instruments Incorporated of Dallas, TX) of dallas, texas. The Sitara Arm processor family developed by Texas instruments (Texas Instruments) features ARM9, ARM Cortex-A8 (which includes a 32 bit RISC ARM processor core), ARM Cortex-A9, ARM Cortex-A15, and ARM Cortex-A53 (which includes a 64 bit RISC ARM processor core) application cores. Sitara SoC (see FIG. 63A) has a computational processing power 2-4 times that of Cortex-A53, up to 1.4GHz (at 0.85V,18.5K DMIPS), for a total of 512kb L2. The computing processing power provides 2770KB of SRAM, ECC (Main Domain 64KB, HSM Module specific 432KB, C7X256V specific 1.25MB for the A53 kernel 512KB L2 and MCU subsystem specific 512 KB) on all critical memories. The SoC provides a camera interface for CSI-2RX (4L) at 2.5Gbps and a display interface for DPI 24 bit RGB parallel interface (up to 2048x1080 at 60 fps). The processor may encode/decode up to 3840x2160, i.e., 4K30, at 30 fps. Processor acquisition, viewing, analysis may include JPEG acquisition (1920x1080 at 60fps, 2K 60), visual HWA (VPAC 3-Lite at 360 MHz) and 12 bit RGB-IR, 300MP/s ISP, and C7x256v (C7x+MMA), 1.25MB sharing SRAM (40 GFLOPS/0-2 TOPS) at 1 GHz. The memory IO of the processor includes a 16-bit LP/DDR4 (LPDDR 4:3733MT/s, DDR4:3200 MT/s) with inline ECC and an Octal-SPI (MCU SS) and 3 MMC/SDs supporting in-place execution. The car IO of the SoC includes three CAN-FDs (full duplex) (2 in MCU subsystem) and Ethernet switches (2 external ports): RMII (10/100) or RGMII (10/100/100), AVB and TSN. The SoC has a high-speed IO with two USB2.0 ports. The security and guarantee of the SoC comprises: (i) Cortex-R5F (800 MHz) MCUSS with FFI, including 32KB I$, 32KB D$, 64KB TCM, dedicated peripherals and 512KB SRAM; (ii) support of ASIL-B/SIL; (iii) Diagnostic kits (into SoC), voltage, temperature, clock, ECC monitor and error signals; and (iv) SHE 1.1/EVITA-Full HSM, secure Start, encryption, wherein the HSM has a dedicated double M4F with an operating frequency of 400MHz, with a total of 432KB of SRAM. At 125dC Tj, the power consumption of the SoC is typically less than 3W. The SoC includes advanced low power standby and suspend states (dedicated R5F, which operates at 400-800 MHz) with CAN standby power of 600uW (50 ua@12v). The SoC may be packaged with a ball pitch of 17x17 millimeters, 0.8 mm. For example, the AM437xSitara processor includes an ARM Cortex-A9 32 bit RISC microprocessor with processing speeds up to 1000MHz.
Floating point (also known as "real") numbers are a collection of all numbers, including integers, decimal numbers, irrational numbers like pi, and the like. The DMS is very data-intensive and requires a large number of floating point calculations. Floating point computing refers to any finite computation from a computing perspective that uses floating point numbers, particularly decimal numbers. FLOPS (floating point count per second) measures how many equations involving floating point numbers a processor can solve in one second. Computing power/capacity/capability/skill may be expressed in mega-times (millions of floating point calculations/second), giga-times (billions of floating point calculations/second), and tera-times (trillion floating point calculations/second). The data processing chip may include FLOPS as a specification to indicate how fast it is overall. In particular, too many refers to the ability of a data processor to perform one trillion floating point calculations per second. For example, "6TFLOPS" means that its processor settings are capable of handling 6 trillion floating point calculations on average per second.
For a data processing chip to be suitable for use with a cassette DMS internal rearview mirror assembly, the computational power must be sufficient to handle the high-intensity calculations required to run the DMS software loaded onto the chip and running thereon. Thus, for a data processing chip running DMS software/algorithm/object code, which is disposed within the lens portion of a cassette DMS interior rearview mirror assembly, the computation speed is preferably at least 0.1 trillion floating point operations per second; more preferably, the calculation speed is at least 0.3 trillion floating point operations per second; and most preferably at least 0.6 trillion floating point operations per second. If the chip needs to run other functions or algorithms in addition to the DMS software, a computational speed of at least 0.5 trillion floating point operations per second is preferred; more preferably at least 1 trillion floating point operations per second; and more preferably at least 1.5 trillion floating point operations per second.
The faster the computation speed, the greater the power consumption of the data processing chip. For a data processing chip suitable for use with a DMS in a cassette DMS interior rearview mirror assembly, the power consumption (when running DMS software/algorithms) is preferably less than 5 watts, more preferably less than 4 watts, and most preferably less than 3 watts. For example, a suitable DMS data processing chip running DMS software/algorithms at a computational speed of about 0.25 trillion floating point operations per second consumes about 2.5 watts of power.
Alternatively, the DMS SoC in the lens portion may comprise a saint 7020FPGA of San Jose, CA, inc. Alternatively, other digital signal processing chips, such as a Cellon data processor (e.g., which may be run on Cellon ADP and Cellon Ride platform) provided by Highway technology Inc. (Qualcomm Technologies Inc. of San Diego, calif.) of San Diego, calif., may be used as the in-lens data processing chip running DMS software. The dragon data processor includes a data processing system on a chip (SoC). The ARM architecture is employed by a Central Processing Unit (CPU) of the Dragon, and a single CellDragon SoC may include multiple CPU cores, adreno Graphics Processing Units (GPUs), wireless modems, hexagon Digital Signal Processors (DSPs), qualcomm Spectra Image Signal Processors (ISPs), and other software and hardware.
The attachment plate may comprise a plastic material (preferably a thermally conductive plastic material), or may comprise aluminum or magnesium or other metallic material to enhance heat transfer and heat dissipation. Alternatively, the attachment plate may comprise a stainless steel fiber reinforced Polycarbonate (PC) Acrylonitrile Butadiene Styrene (ABS) material (such as 15% ss fiber filler provided by lyapyra sambic inc. Of sauta) for EMI shielding. The radiator surrounds the ECU and is grounded by spring fingers at the ECU and attached to the attachment plate (e.g., by screws), with the tongue and groove interface on the attachment plate to form a faraday cage (as described by utilizing U.S. provisional application nos. 63/267,316 (submission 1, 2022), 63/262,642 (submission 18, 2021) and 63/201,757 (submission 12, 2021, 5), respectivelyIn various aspects of the mirror assembly described, all of which are incorporated herein by reference in their entirety). For a box type of Infinity TM The internal DMS rearview mirror assembly, the attachment plate may use PC-ABS material, and for a cassette EVO TM The interior DMS rearview mirror assembly, the attachment plate may include PC-ASA material, which may be necessary or desirable for the class a surface of the attachment plate that surrounds the perimeter edge of the specular reflective element. Alternatively, the attachment plate may comprise a stamped aluminum heat spreader/shield for spreading heat generated by certain components (in operation) and forming the other half of the Faraday cage with the heat spreader. Optionally, and as shown in fig. 62, 76A and 76B, the housing may include one or more channels or vents (e.g., upper and lower vents, and/or vents that may be grasped by a driver of the equipped vehicle to adjust the back or side of the lens housing/enclosure of the lens portion) to increase airflow through the lens portion, thereby reducing the cavity temperature and reducing the touch surface temperature of the lens portion (wherein the temperature of the touch surface temperature of the lens portion is preferably less than about 60 degrees celsius, more preferably less than about 50 degrees celsius). The vents help to reduce the hot junction temperature of heat-generating components (such as SoCs and PMICs) and help to reduce the overall/average touch temperature. There is no thermal material/interface between the heat sink and the housing. The housing includes an ambient light sensor cone that may compress a foam ring or annulus at the sensor. The housing may comprise a single piece housing or a two or three piece housing. An electrical connector of the ECU may be provided through the housing and the mirror mounting base or bracket (see, e.g., fig. 73 and 74) to electrically connect with the wiring harness of the vehicle. The mirror base or mount may comprise aluminum and may be painted black. The mirror glass size may be about 243.5 millimeters by 63 millimeters (141 centimeters 2 )。
Air at room temperature has a thermal conductivity of about 0.025 Watts/m-Kelvin (W.m -1 ·K -1 )。THERM-A-GAP TM GEL25NS (a non-silicon fully cured disposable GEL available from Chomerics corporation of waben, ma) has a thermal conductivity of 2.1W/m-K (conforming to ASTM D5470) and is therefore an order of magnitude higher than air in thermal conductivity. Assembling a cassette of electricity at an interior mirror manufacturerwhenelectrochromicinteriorDMSrearviewmirrorassembly110,therM-A-GAPmaybedispensedasdesiredoncomponentsofacassetteelectrochromicinteriorDMSrearviewmirrorassembly110 TM GEL25NS to enhance thermal conductivity and heat flow from the heat generating components to the heat sink/chassis 12 and/or the housing 18. TIM-PUTTY 45 (available from TIMTRONICS of Yaphank, new york, usa) is a low viscosity, high-conformability one-component, pasty, non-curing gel-type dispensable gap filler having a viscous consistency that ensures stress-free, efficient heat transfer between fine parts with minimal pressure. TIM-PUTTY 45 has a thermal conductivity of 4.5W/m-K (according to ASTM D5470).TG845NS (available from Nystein corporation, new york, usa) is a non-silicon, thermally conductive, dispensable gel having a thermal conductivity of 4.5W/m-K (conforming to ASTM D5470), low thermal resistance, low compressive force, and conforming to the RoHS specifications. BERGQUIST LIQUI FORM TLF 4500CGEL-SF (available from Hangao (Henkel Corporation) Inc. of Stanford, connecticut) has a thermal conductivity of 4.5W/m-K (according to ASTM D5470), has a silicon-free formulation, has optimized shear thinning rheology for improving 1K dispensing rate, has excellent wetting and low assembly stress superplasticity, and is suitable for low stress interface applications. Such high thermal conductivity materials [ having a thermal conductivity preferably greater than 2W/m-K (according to ASTM D5470), more preferably greater than 3W/m-K (according to ASTM D5470), and most preferably greater than 4W/m-K (according to ASTM D5470) ]May be dispensed onto (or otherwise used with) components of a box-type electrochromic interior DMS rearview mirror assembly 110 in amounts necessary to enhance thermal conductivity and heat flow from the heat generating components to the heat sink/chassis 12 and/or to the housing 18.
The thermal performance of a cassette electrochromic interior DMS rearview mirror assembly 110 makes it suitable and safe for use in a vehicle.
Alternatively, a cassette interior DMS rearview mirror assembly may include a thermally conductive element located at a portion of the circuit board in intimate contact therewith to conduct and/or dissipate heat generated by the ECU's circuitry or circuit board, such as by utilizing aspects of the mirror assembly described in U.S. patent No.7,855,755 (which is incorporated herein by reference in its entirety). The thermally conductive element may comprise any suitable thermally conductive material, such as a metallic material or a thermally conductive plastic or the like. Alternatively, the thermally conductive material comprises thermally conductive polyphenylene sulfide (PPS), such as coolpolysulfide available from Cool Polymers of walick (r.i.), r.p.. The heat conducting element is formed, for example by moulding or the like, and is positioned at or in a rear part of the mirror housing, for example a hole or opening formed or provided at the rear part of the mirror housing.
Alternatively, the heat conducting element may be molded, for example by injection molding or the like, into a desired shape such that the rear or outer surface of the heat conducting element matches or substantially matches the outer surface of the mirror housing at the area where the heat conducting element is located. Thus, the thermally conductive element may be injection molded and may be molded with selected or different pigments and/or materials to provide different colors and/or textures to substantially match the outer surface of the mirror housing, so as to be substantially invisible or indistinguishable to the consumer. Preferably, the thermally conductive material is loaded with a material such as graphite or other suitable electrically conductive material to enhance electrical conductivity. U.S. patent No.7,855,755, which is incorporated herein by reference in its entirety, discloses thermally conductive elements and materials suitable for thermally managing heat generated within the lens portion of a box-type electrochromic interior DMS rearview mirror assembly. Furthermore, if active cooling is required for thermal management of the heat generated within the lens portion of a box electrochromic interior DMS rearview mirror assembly, a cooling fan may be used that is attached at the lower housing portion of the mirror housing that can direct the air flow between the heat fins on the outside of the housing (and preferably, the heat fins are thermally conductively connected by thermal elements to the heat generator(s) disposed within the lens portion) and is disclosed, for example, in U.S. patent publication nos. US-2021/0368082 and/or US-2021/0306538 (which are incorporated herein by reference in their entirety).
Alternatively, the one or more thermally conductive elements may comprise a metallic material, such as a magnesium material or other suitable heat dissipating material. For example, magnesium alloy materials, such as magnesium AM40A-F or other suitable metal or metal alloy materials, may be used to achieve the desired heat transfer and dissipation. The metallic heat conductive element(s) may be die cast (or otherwise formed) into a desired shape and may be formed or contoured to substantially match the outer surface of the mirror housing to reduce the legibility of the heat conductive element at the mirror housing. Alternatively and desirably, the metallic heat conductive element may be painted or coated on its outer surface to match its color to the plastic of the mirror housing and thereby at least partially or substantially conceal the presence of the heat conductive element outside the mirror housing. Alternatively, the metal heat conductive element may be powder sprayed to improve durability. Any external coating, paint layer or skin layer at the outer surface of the thermally conductive element preferably also comprises a thermally conductive material or paint to enhance conduction and dissipation of heat through the thermally conductive element and to the exterior of the mirror housing. Alternatively and desirably, a plastic grid or vent-like structure or grid may at least partially cover the outer surface of the heat sink or heat conducting element, making it difficult for a person's hand to contact the actual surface of the heat conducting element to reduce the likelihood of discomfort if a person touches the heat conducting element after the display has been actuated and used for a prolonged period of time. Such a grid or vent or grille allows air flow and heat dissipation at the radiator and may also shield or shadow the radiator at or near the windshield to reduce solar loads at the radiator, such as may occur on sunny days.
During operation of the DMS/OMS functions, heat up to 10 watts or more may be generated. For example, the ECU may generate 7.5 watts of heat, the pulses of the LEDs may generate 2 watts of heat, and the operation of the camera may generate 0.5 watts of heat. The LEDs are pulsed on and off so that the power consumption is less than if they were continuously powered [ the LEDs can be controlled in PWM fashion, with a pulse rate of, for example, 4 milliseconds (12% duty cycle when the DMS camera is acquiring image data at 30 frames per second) ]. The heat generated by the various electronic components within the lens portion (e.g., DMS SoC chip or near infrared light source running DMS software/algorithms) is dissipated by the heat sink/chassis to cool the electronic components in the lens portion and at the housing (to reduce touch temperature). The touch or surface temperature at the housing is preferably less than or equal to 50 degrees celsius. The inclusion of vents at the housing helps to reduce touch temperature. Therefore, the lens portion includes heat dissipation and heat exchange (dissipating and exchanging heat to the outside of the lens portion) functions.
Fig. 63A is a schematic diagram of a combined Electrochromic (EC) dimmer circuit and DMS system of a cassette electrochromic interior DMS rearview mirror assembly 110. Note that instead of an electrically tunable optical EC mirror reflective element, another type of electro-optic mirror reflective element may be used (e.g., a liquid crystal mirror reflective element such as that disclosed in U.S. patent nos. 10,166,92 and 9,493,122, the entire contents of which are incorporated herein by reference). Furthermore, for a box DMS prism type interior rearview mirror assembly, the receptacle 15 of a box electrochromic interior DMS rearview mirror assembly 110 would be replaced with a toggle mechanism and bracket; the EC mirror reflective element 1 of the one-box electrochromic interior DMS rearview mirror assembly 110 would be replaced with a prismatic glass substrate coated on its second surface with a transflector that reflects and transmits visible light as well as transmitting near infrared radiation; and the housing 18 of a cassette electrochromic interior DMS rearview mirror assembly 110 would be replaced with a housing having an aperture for a toggle/tab.
A cassette DMS interior rearview mirror assembly 110 includes a plurality of near infrared light emitting sources. The near infrared light source may comprise a plurality of near infrared Light Emitting Diodes (LEDs) or near infrared emitting Vertical Cavity Surface Emitting Lasers (VCSELs), for example a row or string or group of light sources, such as LEDs or VCSEL lasers. The near infrared light source includes a first wide field of view (wFOV) light source, a second narrow field of view (nFOV) light source located on one side of the wFOV light source, and a third nFOV light source located on the other side of the wFOV light source. The terms "nffov" and "wFOV" as used herein refer to the illumination field or field of view or directivity (directivity) or full width at half maximum (FWHM) or beam angle of an nffov light source and a wFOV light source, respectively, at 50% intensity.
As shown in fig. 63A-63C, a row or string or group of two (or more) narrow field of view (nfv) near infrared light emitting LEDs (which may be arranged horizontally or vertically, or may be arranged in a matrix arrangement of rows and columns or otherwise) are providedWithin (or at least partially surrounded by) a near infrared light reflector (e.g., 14.1mm x 6.92mm x 6.5mm reflector, such as commercially available from CoreLED Systems, LLC, li Woni, michigan) disposed on a first rigid PCB that is connected board-to-board to a second rigid PCB by a flexible multi-wire planar ribbon cable (comprising a plurality of individual conductive wires, such as four wires, tiled and parallel to each other). A row or string or group of two (or more) wide field of view (wFOV) near infrared light emitting diodes (which may be arranged horizontally or vertically, or may be arranged in a matrix or other manner of rows and columns) is provided on the second rigid PCB. The second rigid PCB is connected to the third rigid PCB by a flexible multi-wire planar ribbon cable (comprising a plurality of individual conductive wires lying flat and parallel to each other). A row or string or group of two (or more) narrow field of view (nfv) near infrared light emitting LEDs (which may be arranged horizontally or vertically, or may be arranged in a matrix arrangement of rows and columns or otherwise) are disposed within a reflector on a third rigid PCB. The third rigid PCB comprises a flexible multi-wire planar ribbon cable terminating in an electrical connector that connects with a corresponding electrical connector of the PCB of the ECU 6. While a set of three near infrared light emitting sources (LHD nfv, wFOV, and RHD nfv) on respective rigid PCBs interconnected by flexible ribbon connections are shown in some figures, other arrangements of the respective illumination sources in the lens section are contemplated. For example, all light sources may be located on one PCB, or two rows of light sources may be located on one PCB, and one row of light sources may be located on another PCB, and so on. The reflector may comprise a stamped polished 260 of about 0.01 inch thickness 1 / 2 Hard brass, which may be post-tin plated (e.g., 5 microns tin plated on copper flash), or other suitable near infrared light reflecting material (e.g., aluminum), which may be surface mounted/soldered to the respective LED PCB to direct or concentrate or collimate the near infrared light emitted by the LEDs toward the appropriate driver or passenger area or cabin area in the vehicle.
As shown in fig. 110, the wfv LEDs are horizontally aligned, one next to the other and spaced apart, while the nfv LEDs are vertically aligned, one higher than the other and spaced closer together (and surrounded or surrounded by respective reflectors). In the exemplary embodiment shown in fig. 110, LHD and RHD groups of nffov LEDs each include two vertically stacked LEDs, each with a respective reflector. As can be seen from fig. 110, the horizontally aligned wFOV LEDs are more spaced than the vertically aligned nffov LEDs. The LEDs of each group are vertically stacked to reduce the total distance to the red filter/specular reflective element so that the aperture (the hole through the attachment plate and the hole through the adhesive tape attaching the specular reflective element to the attachment plate) is as small as possible. The arrangement of wFOV LEDs and nFOV LEDs can reduce cost and packaging space.
The illuminator electric driver (see fig. 63C) drives the LEDs and acts to prevent surges (e.g., 2.3A surges) in the power supply of the vehicle by storing energy in a capacitor (see an example schematic diagram of the illuminator driver of fig. 63C). During the "off time" of the LED, the illuminator electrical driver boosts the voltage of the storage capacitor (24 v+), and releases the stored energy into the LED during the "on time". This can reduce the average current consumption of the vehicle.
A cassette DMS interior rearview mirror assembly includes filters at the LEDs for attenuating or blocking visible light. For example, the LED filter may include a luminance TM 7276F a visible light opaque compound which is black and blocks or filters light of 200-860nm and allows transmission of light greater than 990nm (see FIG. 112). The filter comprised a ready-to-mold thermoplastic having the appearance of black polycarbonate particles. The target transmittance values were: 5% at 875nm, 50% at 910nm, 80% at 986nm, and 85% at 1000 nm. The filter is molded into a rectangular plate, or other shape as desired. The thickness of the sheet of near-IR light transmitted at 940nm is at least 0.5mm in its thickness direction, more preferably at least 1mm thick, and most preferably at least 1.25mm thick, but preferably less than 6mm thick, more preferably less than 4mm thick, and most preferably less than 2.5mm thick. For example, the filter may be 63.02mm wide by 23.6mm high by 1.3mm thick. The LED filter improves the shielding of the system by limiting the visible light to avoid any visible light emitted by the near IR emitting LED from being visible through the specular reflective element (and thereby reducing or avoiding light passing through the LED The LED red light emission is visible at the specular reflective element when electrical). The LED filter can also block or limit ambient cabin light from entering the lens portion at a location where the LED is looking through the EC unit to see into the vehicle cabin.
The inside rear view mirror assembly of the cassette DMS also includes an IR blocking filter positioned in front of the EC glare sensor. An IR blocking filter at the EC glare sensor may block a proportion of the IR light from reaching the EC glare sensor. The EC glare sensor IR blocking filter may be 17.28mm wide by 11.85mm high by 1.02mm thick.
During operation of the inside rear view mirror assembly of a cassette DMS, the circuit ECU 6 controls the LEDs and the camera. For example, the camera may acquire image data at a frame acquisition rate of 60 frames per second (fps), and the LHD n-FOV LED, w-FOV LED, and RHD n-FOV LED employ pulse width modulation to acquire certain frames of acquired image data when some or all of the LEDs are powered. During DMS operation (and, for example, every other frame of image data), LHD n-FOV LEDs and w-FOV LEDs are pulsed on; and during OMS operation (and, for example, every tenth image data frame), all LHD n-FOV LEDs, w-FOV LEDs, and RHD n-FOV LEDs are pulsed on. Example pulse patterns and image data frame acquisition rates are shown in fig. 104A, 104B, and 105 and discussed below.
Cameras for security applications and the like typically use near IR flood illumination of around 850nm simultaneously. However, at longer wavelengths in the near IR spectral region, the sensitivity of such conventional cameras may decrease. Therefore, the sensitivity of the traditional security camera to 940nm light is not as good as that of the traditional security camera to 850nm light; such conventional security cameras have a smaller range of 50% when using 940nm near IR light irradiators than when using 850nm near IR light irradiators. Furthermore, although the 850nm infrared light is largely not seen as "light" by the human eye, a slight red light is seen at the LED light source. For the in-cabin DMS and ODS of the present invention, it is preferable to use 940nm near IR irradiation, and particularly when the in-mirror camera has a quantum efficiency of at least 15% at 940 nm. Any "red" that the human eye can sense is less with 940nm illumination than with 850nm illumination, thus enhancing the obscurability of the near IR emitting light source within the lens portion by the specular reflector. In addition, water absorbs near-IR light at 940nm, and therefore solar radiation attenuates at 940nm of its illumination spectrum due to moisture in the atmosphere. Thus, the ambient sunlight present in the cabin (and particularly when driving an open car on sunny days, roof drop) has a dip or valley at 940nm, which reduces any tendency of the ambient sunlight present in the cabin of the vehicle to interfere with the DMS/ODS function.
Preferably, the nFOV LED includes SFH 4728AS A01Black near IR emission (centroid wavelength 940 nm) -50 LED, which is commercially available from European photo semiconductor Co., ltd (OSRAM Opto Semiconductors GmbH) of Leibnitzstraβe4, D-93055, lei Gensi Bara, germany (see FIG. 64). The FOV of the osram Black series (940 nm) LEDs is 50 degrees horizontally and 50 degrees vertically (without reflectors) when a cassette DMS interior rearview mirror assembly 110 is mounted on the windshield portion or the head portion of the equipped vehicle. When a reflector is used, the FOV or directivity of the nffov LED or the beam angle at Full Width Half Maximum (FWHM) or 50% intensity is about 41 degrees vertically and 41 degrees horizontally. The forward current through each OSLON Black series (940 nm) LED is at least 500 milliamps, more preferably at least 750 milliamps, and most preferably about 1000 milliamps when operating in a cassette DMS interior rearview mirror assembly 110. FIG. 64 shows SFH 4728AS A01 +.>The relative spectral emission and other characteristics of Black near IR luminescence (centroid wavelength 940 nm) to 50 ° LEDs. The total radiant flux (measured with an integrating sphere) at a forward current of about 1 amp exceeds 1000mW/sr. The total radiant flux (forward current about 5 amps and pulse duration about 100 microseconds) may exceed 5000mW. Forward current I F Minimum 10mA and maximum 5A. Maximum power consumption P tot About 5W. In the forward direction of current I F 1A, and pulse duration t p 10ms, and ambient temperature T A At 25 ℃, (i) peak wave lambda peak typ. 950nm, and (ii) centroid wavelength lambda centroid typ. 940nm.50% I rel,max The spectral bandwidth (FWHM) Δλ at the bottom is typically 37nm. Half angle->Typically 25 deg.. The forward current through the LED is I F =1.5a and pulse t p When=100 μs, the radiation intensity I e Typically 1980mW/sr. The forward current through the LED is I F =5a and pulse t p When=100 μs, the radiation intensity I e Typically 5900mW/sr. I F =1a and T p Radiation intensity I at 10ms e Is 1350mW/sr. I F =1a and T p Radiation intensity I at 10ms e Ranging from 1120 to 1800mW/sr. The size (LxW) of the active chip area is typically 1mm.
Preferably, the wFOV LEDs comprise SFH 47278AS A01 OSLON Black Series (940 nm) -130 DEG x 155 DEG near IR luminescent (940 nm centroid wavelength) LEDs, which are commercially available from OSRAM Opto Semiconductors GmbH of Leibnitzstraβe4, D-93055, lei Gensi Bara, germany (see FIG. 65). When a cassette DMS interior rearview mirror assembly 110 is mounted to the windshield or nose portion of a vehicle equipped, the FOV or directivity of the wFOV LEDs (for the osram black series (940 nm) LEDs) or the beam angle at half maximum Full Width (FWHM) or 50% intensity is horizontal 155 degrees and vertical 130 degrees. Fig. 65 shows the relative spectral emissions and other characteristics of SFH 47278AS A01 OSLON Black Series (940 nm) -130 ° x 155 ° LEDs. At a forward current of about 1 amp, the total radiant flux (measured with an integrating sphere) exceeds 1000mW/sr. The total radiant flux (forward current of about 5 amps and pulse duration of about 100 microseconds) may exceed 1500mW. Forward current I F Maximum 1.5A. At t p Less than or equal to 450 mu s; the maximum forward current under the pulse D is less than or equal to 0.005 is 5A. Power consumption P tot And a maximum of about 5W. Forward current I F 1A and pulse duration t p 10ms, and ambient temperature T A At 25 degrees Celsius, (i) peak wavelength λ peak typ 950nm, and (ii) centroid wavelength lambda centroid typ 940nm.50% I rel,max The spectral bandwidth Δλ at (FWHM) is typically 37nm. Half angle(minor axis) is typically 65 degrees; half angle->The (major axis) is typically 77.5 degrees. The forward current through the LED is I F =1.5a and pulse t p When=100 μs, the radiation intensity I e Typically 450mW/sr. At I F =1a and t p At =100 μs, the total radiant flux Φ e Typically 1340mW. At I F =1.5a and t p Total radiant flux Φ at =100 μs e Typically 1970mW. The size (lxw) of the active chip area is typically 1mm x1mm.
The forward current through each OSLON black-series (940 nm) LED is at least 500 milliamps, more preferably at least 750 milliamps, and most preferably at least 1000 milliamps when operating in a cassette DMS interior rearview mirror assembly 110.
The combination of nffov and wFOV light sources enables the system to utilize different sets to meet the illumination requirements of LHD and RHD. For LHD vehicles, LHD nffov and wFOV LEDs are the primary light sources for driver monitoring (Driver Monitoring), while LHD nffov, wFOV and RHD nffov LEDs are all used for occupant monitoring (Occupancy Monitoring) to detect front and rear seat passengers, children in child seats, etc.
Irradiance (the received radiant flux per unit area of surface) of the driver's head (and especially at the driver's eyes for drowsiness detection) is important, especially during night driving when the interior cabin is dark, and where the DMS camera in the lens portion relies mainly on near IR illumination by a near IR light source in the lens portion. The near IR irradiance near the driver's eyes is preferably at least 1W/m 2 More preferably at least 1.8W/m 2 And most preferably at least 2.5W/m 2 (especially for a particular driver sitting in the seat of the driver of a particular vehicle equipped with a cassette DMS interior rearview mirror assembly, which is within 99% of the eye ellipse according to SAE J194), whereas the near IR irradiance for occupant detection at the front passenger seat seating position of the front passenger is preferably at least 0.15W/m 2 More preferably at least 0.25W/m 2 And most preferably at least 0.4W/m 2 And near IR irradiance of at least 0.1W/m for occupant detection at rear seats and the like 2 Preferably at least 0.15W/m 2 More preferably, and at least 0.2W/m 2 Most preferably.
As shown in fig. 107, the light path of the light emitted by the LED and reflected by the reflector passes through the red filter and through the specular reflecting element to illuminate the driver's head area and is reflected toward the camera back through the specular reflecting element and the lens of the camera. The optical path (irradiance) of a narrow FOV (nffov) LED at 100% LED power is reduced such that only 74% reaches the driver. In the worst case, however, peak power must be used. Thus, 178% of the LED irradiance power is required for exposure limitation. Irradiance is primarily proportional to the current flowing through the LED.
As shown in fig. 108, the camera sees (and the LEDs illuminate) a driver head box or area. Fig. 109A and 109B show how the front view, near IR illumination, and camera to eye visibility can be affected by certain mask positions (showing different stature drivers in different seating positions relative to a cassette DMS interior rearview mirror assembly). Fig. 86D shows the different eye points projected on a horizontal plane with respect to the light source for a left drive (LHD) vehicle and DMS with the LEDs disposed at the right side of the lens portion, while fig. 88C shows the different eye points projected on a horizontal plane with respect to the light source for a right drive (RHD) vehicle and DMS with the LEDs disposed at the right side of the lens portion. All the closest driver's eye points are bright enough to meet irradiance requirements-the nominal target is 15 vertical/20 horizontal.
The DMS SoC disposed in the lens portion can sense its silicon die (silicon die) temperature and enter a "throttle mode" when needed to reduce power output (and thus operating temperature). The "throttle mode" may include reducing the computational algorithm feature set, and/or reducing the SoC clock frequency, as well as reducing the frame rate (e.g., reducing 60fps to 30 fps). The EC PWM duty cycle and drive voltage may be varied to reduce the power consumption consumed in the mirror. The cell gap may be reduced to allow for lower drive currents. The IR power may also be reduced. The use of LC optical switches in the DMS/OMS single cassette type can reduce thermal problems. This may reduce the required IR LED driving power. Fans, heat pipes, thermally conductive interface materials (TIMs), and alternative heat sink materials (e.g., copper) may be used to improve cooling. The radiator fin design also plays a role in the cooling capacity.
For example, if it is determined that the temperature is above a threshold level, the system may provide thermal management and may roll back or reduce processing operations occurring within the lens portion. The system may determine the temperature within the lens portion by an on-board thermistor or an external thermistor or by an LED driver with a thermistor or by a processor with a thermistor in the lens portion. In order to protect the electronics within the lens portion and/or to avoid exacerbating the skin temperature of the lens housing of the lens portion of a cassette DMS internal rearview mirror assembly that has been parked in high temperature/sun conditions such that the housing of the lens portion reaches or exceeds 85 degrees celsius, various countermeasures may be taken. Depending on the on-board chip and/or external thermistor, on-board thermistor temperature sensing capability, etc., the DMS operation may be temporarily reduced during a period of time (up to 1 minute, up to 5 minutes, up to 10 minutes, up to 15 minutes, etc.) and/or until the temperature detected by the thermistor falls below a threshold temperature. For example, the system may pulse the LEDs at a slower rate and/or acquire image data at a reduced frame rate, or power the LEDs at a reduced power level (i.e., the system may reduce the maximum intensity of the LEDs and/or reduce the switching pulse rate of the LEDs and/or reduce the image acquisition rate). Alternatively, the system may output (e.g., via CAN communication) a signal to turn on the air conditioner of the vehicle. Alternatively, if the temperature is above a threshold temperature, the system may provide an alert to the driver indicating that the DMS/OMS function is temporarily inoperable.
In operation, the DMS camera acquires frames of image data (e.g., at a frame acquisition rate of 30fps or 60 fps), and the appropriate LEDs are pulsed on and off for the corresponding acquired frames of image data. The LED pulse rate is synchronous with the frame acquisition rate of the camera; that is, the LED will only turn on (and emit near IR radiation) when the imager is exposed and collecting energy. For example, if the camera acquires frames of image data at 30fps, each frame has a duration of about 33ms, but the imager is exposed (and collects light energy that photoelectrically converts incoming photons into electrons) for only a portion of that time (e.g., 4ms of that time). The LEDs are electrically repetitively pulsed so that they are energized only during the 4ms period in which the imager is collecting energy (although the LED may be turned on for a slightly longer period to ensure that the LED is energized for the entire period in which the imager is being exposed). The pulse duty cycle is about 12%. The LEDs are synchronized so that they are not energized for the entire frame time (33 ms) to reduce their heat generation and to enhance thermal management and to avoid near IR illumination from continuously illuminating the eyes of the driver or the eyes of the passenger for long periods of time. For DMS, and to facilitate video conferencing and driver self-photographing, the system uses the full color function (RGB) of the DMS camera, so the system merges the three (R, G, B) signals into a single signal or frame. For OMS, the system does not require color and can use a DMS camera as a monochromatic camera while increasing the sensitivity of the camera to incident light. For duty cycle pulses of a near IR light source (e.g., nFOV LED or wFOV LED) disposed within the lens portion, a preferred duty cycle is at least 8%; more preferably the duty cycle is at least 10% and most preferably the duty cycle is at least 12%. However, for eye safety and thermal load relief, the preferred duty cycle is less than 40%; more preferably the duty cycle is less than 30% and most preferably the duty cycle is less than 20%.
Alternatively, the system may reduce the power of the LEDs (the current applied to the LEDs) during daytime operation, and/or may dynamically change or adjust the pulse duty cycle based on prevailing conditions within the cabin (e.g., day or night, or whether to drive on sunny or overcast days, or whether to hot-dip the equipped vehicle immediately after being exposed to hot sunlight outdoors in summer, to bring the temperature of the interior mirror to 60-80 degrees Celsius or higher). Optionally, the system may increase the power (applied current) of the LEDs and/or change or adjust the pulse duty cycle of the LEDs for viewing through the driver's eyeglasses, particularly the driver's sunglasses.
Further, and in accordance with the disclosure of U.S. patent No.11,205,083, which is incorporated herein by reference in its entirety, a DMS camera may acquire frames of image data at a first rate and a near IR light emitter may electrically pulse at a second rate. The plurality of near IR light emitters may operate in two modes: (i) A first mode in which a near-IR light emitter of the plurality of near-IR light emitters disposed in the lens portion operates to emit near-IR light to illuminate an area within the field of view of the DMS camera (e.g., a driver's head area or a front or rear seat area); and (ii) a second mode in which a reduced number of the plurality of near-IR light emitters are operated to emit near-IR light to illuminate the region.
Further, and in accordance with the disclosure of U.S. patent No.11,240,427, which is incorporated herein by reference in its entirety, a near IR illumination source disposed in the lens portion (which emits light that illuminates at least a portion of the driver of the vehicle when powered) is controlled to modulate the intensity of light emitted by the modulated illumination source. The DMS SoC chip within the lens portion processes the image data of the portion of the driver captured by the DMS camera that is illuminated with the intensity modulated near IR to distinguish between (i) the portion of the captured image data that is produced by the illumination source that is illuminated by the intensity modulated near IR to the driver and (ii) the portion of the captured image data that is produced by the ambient car light that is illuminated to the driver. The controller filters the acquired image data to reduce the distinguishing portion generated by the cabin ambient light.
The near IR signal wavelength emitted by the LED is preferably 940nm, so that it is more easily recognized by the DMS processor (ambient sunlight at this wavelength is reduced because water in the atmosphere absorbs light at 940 nm). The DMS camera includes a filter that allows/passes light of that wavelength and attenuates other light. Thus, the camera will operate with an enhanced 940nm signal, which enhances the monitoring of the driver with sunglasses worn by the driver. Other light within the cabin (i.e., ambient light) is filtered so that the camera focuses at 940nm wavelength and then avoids "seeing" the reflection of the sunglasses. The DMS function may provide dynamic camera control (increasing or decreasing exposure time or frame acquisition rate) and LED control (increasing or decreasing LED power and/or increasing or decreasing on time) to accommodate changes in illumination and/or to accommodate driver sunglasses or the like.
A suitable visible light transmissive/visible light reflective/near IR light transmissive transflective substrate for use in a cassette electrochromic interior DMS mirror assembly 110 is shown in fig. 66 (transmittance characteristics and color profiles are shown in fig. 67A and 67B, respectively). The substrate on which the transflector stack was coated was a flat soda-lime glass substrate in the shape of a mirror for a vehicle interior having a plate thickness of 2 mm. For use as a rear substrate in a laminated EC cell (as disclosed in U.S. patent nos. 7,274,501, 7,184,190 and/or 7,255,451, which are incorporated herein by reference in their entirety), and for reducing the weight of the overall assembly, a thinner glass substrate is preferably used. For example, the plate thickness of the glass substrate is preferably 1.6mm or less, and the plate thickness of the glass substrate is preferably 1.1mm or less. In addition, low iron glass (as described herein) is preferably used to increase overall visible light transmission and near IR light (e.g., 940 nm) transmission. For example, guardianLow iron glass (available from company Guardian Glass Company at address 2300Harmon Rd,Auburn Hills,MI,USA) is more translucent and more neutral in color than standard soda-lime float glass and the plate thickness varies from 2mm to 12 mm. Furthermore, guardian +. >Is commercially available from Guardian Glass 19,rue du Puits Romain L-8070Bertrange grade-Duchy de Luxembourg. Guardian->Has the optical characteristics shown in fig. 69. Furthermore, corning Infra Red Transmitting Glass 9754 (see fig. 70) may also be used, preferably together with an infrared cut-off filter that cuts off the transmission of infrared radiation having a wavelength of more than 1 micron through the glass substrate.
For photopic visible light reflectance (measured according to SAE J964a for the first surface, SAE J964a is the SAE recommended practice for determining the total and specular reflectivity of a vehicle mirror having flat and curved surfaces and for determining the diffuse reflectivity and haze of a mirror having flat surfaces) of a glass substrate coated with a transflector (embodiment shown in fig. 66) is preferably at least 45% r, more preferably at least 55% r, and most preferably at least 65% r. The visible light transmittance for the glass substrate coated with the transflector (embodiment as shown in fig. 66) is preferably at least 15% t, more preferably at least 20% t, and most preferably at least 25% t, and preferably less than 35% t, more preferably less than 30% t [ measured using CIE standard illuminant D65 and a photosensitive detector having a spectral response that follows the CIE photosensitive luminous efficacy function (which mimics the response of a human eye in the visible region) ]. The near IR transmission of the near IR emission light source at the near IR emission peak wavelength (e.g., 940 nm) for the transflector coated glass substrate (e.g., the embodiment shown in fig. 66) is preferably at least 60% t, more preferably at least 70% t, and most preferably at least 80% t.
The one-cassette electrochromic interior DMS mirror assembly 110 preferably comprises a dual-substrate laminated EC mirror reflective element having (i) a front glass planar substrate (having a first surface and a second surface separated from the first surface by a thickness dimension of the front glass substrate) and (ii) a back glass planar substrate (having a third surface and a fourth surface separated from the third surface by a thickness dimension of the back glass substrate). In a cassette electrochromic interior DMS mirror assembly 110, the rear substrate comprises the transflector substrate of fig. 66, and the multi-layer stack of coatings comprises a third surface of the rear substrate of a dual-substrate laminated EC mirror reflective element (also known as an "EC cell"). The front substrate and the back substrate are juxtaposed in an EC cell, and an electrochromic medium is sandwiched between (a) a second surface of the front glass substrate (which comprises a transparent conductive coating, preferably ITO, having a sheet resistance preferably less than 30 ohms/square, more preferably less than 25 ohms/square, and most preferably less than 20 ohms/square) and (b) a multi-layer stacked transflector coated surface of the back glass substrate. The electrochromic medium is (i) in contact with the transparent conductive coating at the second surface of the front glass substrate and (ii) in contact with the outermost layer of the multilayer stacked transflector coated third surface of the rear glass substrate. So that conductive contact with the EC medium can be accomplished, the outermost layer of the multilayer stacked transflector coated third surface of the rear glass substrate comprises a transparent conductive coating (preferably an indium tin oxide layer, i.e. ITO) having a sheet resistance preferably of less than 30 ohms/square, more preferably of less than 25 ohms/square, and most preferably of less than 20 ohms/square.
Note that in this alternating multi-layer stack of fig. 66, and depending on other factors in the overall structure, fewer, more, or different layers may be used. For example, as shown in fig. 68A and 68B, a third surface conductive transflector of a cassette electrochromic internal DMS mirror assembly is shown. This approach adds a single semi-metal/semi-conductive silicon (Si) layer at layer 5 of the 7-layer stack and has a high T% (about 90%) at 940nm and about 40% in the visible region. In addition, its visual appearance is neutral. The advantage of this design is that the number of layers is reduced and the total stack thickness is reduced. For a multi-layer stack of thin film coatings that form the mirror transflector of the internal mirror reflective element of a cassette DMS internal rearview mirror assembly suitable for use in the present invention, the total physical stack thickness (i.e., the sum of the physical thicknesses of all the individual thin film coating layers in the multi-layer stack) is preferably less than 1500nm; more preferably less than 1000nm; and most preferably less than 750nm. This makes the DMS stack easier to manufacture and less costly. The overall thickness is less than 600nm. Of course, the use of Si semiconductor layers in more than one layer in a multi-layer stack is contemplated.
Since silicon has a high refractive index (3.5 to 4) (but has an extinction coefficient higher than that of, for example, nbO or TiO 2 Or SiO 2 A dielectric of (c), the specular reflector may include a silicon layer. Alternatively, the specular reflector may use a germanium layer. The layers alternate high and low refractive index layers to achieve the best match of transmittance and reflectance. The number of layers can be reduced by using high refractive index silicon or germanium layers. Each layer has a different refractive index and the magnitude of this difference relates to how many layers are needed to achieve the desired effect. Greater refractive index between layersThe difference can result in fewer layers being required. Due to NbO/Nb 2 O 5 Sputter deposition rate ratio of TiO 2 The sputter deposition rate of (c) is fast, so that the specular reflector may use niobium oxide instead of titanium oxide.
A pressed oxide ceramic target is used to sputter deposit a layer onto a substrate for a specular reflective element. These targets are preferably rotating targets (magnetrons). In a vacuum chamber for depositing a layer, the chamber may include a mixture of oxygen and argon. The layers are preferably sputtered by medium frequency (about 40 KHz) sputtering (MF sputtering). Preferably, a dual rotary magnetron is used, in which two targets are side by side. A 40KHz sine wave alternating voltage (positive and negative) was applied. The process may use two (or more) twin targets per chamber. Silicon can be sputter deposited using a pure silicon target.
The target optical design for the multi-layer stack is such that the transmittance of visible light is at least 20% t and the transmittance of near IR light is at least 60% t, and this is achieved in the most economical and efficient manner. The number of layers, the refractive index of the layers and the sputter rate of the layers are balanced to achieve the desired effect economically. The process may utilize aspects of the process described in U.S. patent No.5,751,489, which is incorporated herein by reference in its entirety.
Intermediate frequency AC sputtering (e.g., at 40 KHz) is a preferred deposition technique for dielectric high refractive index/low refractive index thin film alternating coating layers that constitute a multi-layer stack of mirror transflectors that form the mirror reflecting elements of a cassette DMS internal mirror assembly in a multi-station/multi-target in-line transport tray/disk vacuum deposition process. Intermediate frequency AC sputtering (also known as dielectric AC sputtering) is more suitable for coating dielectrics than RF sputtering because it operates in the frequency range of kHz rather than MHz and therefore requires less complex and expensive power supplies and is a process that can accommodate large scale applications. The MF or intermediate frequency AC power source covers a wide range of voltage outputs between 300V and 1200V (typically in the range 25 to 300 kW), frequencies between 20 and 70kHz, most often 40kHz. To form the niobium oxide or silicon dioxide layer of such a multilayer transflector, reactive sputtering, i.e. the introduction of a reactive gas (oxygen) in a plasma, is preferably used to form an oxide layer deposited on the coated substrate. In medium frequency AC sputtering, two cathodes are used, between which the AC current is switched back and forth, each reverse switching cleans the target surface to reduce charge accumulation on the dielectric that leads to arcing that ejects droplets into the plasma and impedes uniform film growth.
As the substrate moves past the target, the target will sputter deposit material onto the moving substrate. A carrier that moves continuously at 1 meter/min under the sputtering target will deposit a 25nm thick film. For ITO: NDDR is (10 nm.m/min)/(KW/m), with a target length maximum power density of 10KW/m. In general, for a constant deposition power level and size, the deposition rate of NbO is SiO 2 Or TiO 2 About 2.5 times the analog. Typically, for a constant deposition power level and size, the deposition rate of ITO is NbO/Nb 2 O 5 About 2 times and SiO 2 Or TiO 2 About 5 times the analog.
In combination with the arc detection and suppression circuitry, MF or intermediate frequency AC sputtering provides the advantage of improved process stability and increased deposition rates, as well as overcoming the problems faced when reactive sputtering of dielectric coatings with DC sputtering where the anode may be coated with an insulating coating. In the case of AC sputtering, the cathode acts as an anode every half cycle and provides a "clean" anode surface. Intermediate frequency AC sputtering of multi-layer HI/LO index coatings for mirror transflectors of mirror reflective elements of a cassette DMS interior rearview mirror assembly preferably uses dual magnetrons to confine electrons over a target and reduce arcing for process control. Alternatively, the "balanced" or "unbalanced" magnetrons may be arranged side-by-side, tilted toward one another, or face-to-face.
As an alternative to in-line vacuum deposition, the deposition of the various thin film dielectric coatings used to form the multilayer HL stack mirror transflector may be deposited onto the glass substrate in a batch vacuum deposition chamber. For example, a plurality of individual cut mirror-shaped glass substrates may be loaded into a planetary fixture in a vacuum deposition chamber. For deposition of layers of niobium oxide and silicon oxide, for example, the cylindrical vacuum chamber may be equipped with two (one for NbO and one for NbO)For SiO 2 ) The dual intermediate frequency AC sputter deposition target, which sputters a corresponding layer onto the glass substrate as the glass substrate rotates past the sputter target in the vacuum chamber, can improve the uniformity of coating over multiple coated substrates. Alternatively, an electron beam evaporation method may be used in which niobium oxide, silicon oxide/silicon dioxide, or the like from each crucible of a multi-crucible turret (multiple-crucible turret) is evaporated with an electron beam.
A cassette electrochromic interior DMS mirror assembly 110 preferably comprises a cassette infinit electrochromic interior DMS mirror assembly or a cassette EVO electrochromic interior DMS mirror assembly. For various aspects of a cassette type of Infinity electrochromic internal DMS mirror assembly (e.g., using the various aspects of the mirror assemblies described in U.S. patent nos. 9,827,913, 9,174,578, 8,508,831, 8,730,553, 9,598,016 and/or 9,346,403, which are incorporated herein by reference in their entirety), the outer peripheral edge of the first or front glass substrate provides a curved continuous transition between the flat front surface of the front glass substrate and the outer surface of the side wall of the mirror housing in which the rear glass substrate is nested. For a one-box EVO electrochromic interior DMS mirror assembly (e.g., using the various aspects of the mirror assemblies described in U.S. patent nos. 10,261,648; 7,360,932; 7,289,037 and/or 7,255,451, which are incorporated herein by reference in their entirety), the mirror reflective element is attached at an attachment plate, and the mirror housing or wall structure of the attachment plate extends from the front side of the mirror housing, or the attachment plate circumscribes and spans the peripheral circumferential edge of the front glass substrate, and does not encroach upon and overlap the front surface of the glass substrate of the mirror reflective element.
In the EVO shrinkage apparatus, the sheet thickness of the front and rear glass substrates may be less than 2mm (e.g., each may be 1.6mm, or the front glass substrate is 1.6mm and the rear glass substrate is 1.1 mm). However, a cassette type Infinity electrochromic inside DMS rearview mirror assembly uses a front glass substrate having a rounded/curved outermost circumferential edge (accessible to the driver when used in a equipped vehicle) with a radius of at least 2.5mm by grinding/polishing the inside mirror-shaped cut glass substrateThe outermost peripheral edge is formed and the cut glass substrate must have a thickness of greater than 2mm, typically 3mm, in order to achieve the desired circular/arcuate peripheral edge radius of 2.5 mm. Thus, the front glass substrate used in the EC cell of a cassette type Infinicity electrochromic internal DMS mirror assembly may comprise a plate thickness of 3 mm. With such thickness in mind, the use of low Fe glass as the front substrate in the EC cells of a cassette type Infinicity electrochromic interior DMS mirror assembly is particularly advantageous for improving visible and near IR light transmission through the EC cells. In this regard, the plate thickness was Pilkington Optiwhite of 3mm and more TM Low iron light transmissive float glass (commercially available from Pilkington North America of tolado, ohio, usa) is particularly advantageous for use in a cassette type infinitic electrochromic interior DMS mirror assembly. Pilkington Optiwhite TM Is super-transparent low-iron float glass; it is practically colorless and does not exhibit the green-emitting characteristics inherent to other light-transmitting glasses (green cast). Pilkington Optiwhite TM Is between 3mm and 19mm thick. As can be seen in FIG. 71, the visible light transmittance is at least 90% T, which is particularly advantageous for a cassette type Infinicity electrochromic internal DMS mirror assembly such as the like.
Pilkington Optiwhite having a thickness of 6mm TM Also advantageously used in a box prism type internal DMS mirror assembly. Conventional interior prismatic rear-view mirrors (sometimes also referred to as "day/night mirrors" or "roll-over mirrors") can be manually tilted or turned by the driver of the equipped vehicle during night driving to reduce the brightness and glare of light that would otherwise be reflected directly into the driver's eyes during night driving, primarily for high-beam heads of rear-drive vehicles. Conventional prismatic mirrors are made of a piece of glass having a wedge-shaped cross-section (front and rear surfaces thereof are not parallel-flat front surfaces are typically at an angle of 4 degrees to the plane of the rear surface, etc.), and silver is coated on the rear surface (second surface) thereof to form a prismatic mirror element. The wedge-shaped prismatic glass substrate starts from an inner mirror-shaped glass substrate of 6mm thickness with parallel front and rear surfaces. By grinding and polishing, a wedge shape is formed. A cassette type Infinicity prism type internal DMS mirror assembly is preferably Pilkington with a 6mm thickness Optiwhite TM Low Fe float glass begins to be manufactured, which is polished/ground to a desired shape and coated on its rear (second) surface with a multi-layer stack of visible light transmission/visible light reflection/near IR light transmission.
Inside Infinity of a cassette DMS TM Electrochromic rear view mirror assembly (as schematically shown in fig. 77A) comprising a plastic mirror housing or case 18 formed by a plastic injection molding process [ preferably by injection molding of PC/ASA, an amorphous thermoplastic alloy of Polycarbonate (PC) and ASA (acrylic-styrene-acrylate terpolymer) that provides enhanced heat resistance and enhanced mechanical properties]. The electrochromic/electroluminescent specular reflecting element 1 comprises a front glass substrate 1a and a rear glass substrate 1b spaced from the front glass substrate by a perimeter seal 1c, wherein an electrochromic medium 1d (which is electrically dimmable) is sandwiched between the front and rear glass substrates and is bounded by the perimeter seal. The front glass substrate has a flat first glass surface (which is the flat front surface of the internal specular reflective element) and a flat second glass surface spaced from the flat first glass surface by a thickness dimension of the front glass substrate. The front glass substrate includes a peripheral surface extending between the planar first glass surface and the planar second glass surface and spanning a thickness dimension of the front glass substrate. When a box DMS is inside the Infinity TM The flat first surface faces the driver of the vehicle when the electrochromic rearview mirror assembly is mounted (e.g., by mounting structure 19) on the windshield or head portion of the equipped vehicle. The transparent conductive coating is disposed at the planar second glass surface and is in contact with the electro-optic (i.e., electrochromic) medium. The front glass substrate has a specular reflection and an electrically conductive perimeter band established along a perimeter boundary region of the planar second surface of the front glass substrate that circumscribes the perimeter boundary region of the second glass surface of the front glass substrate to conceal the perimeter seal from a driver who is viewing the interior rearview mirror assembly when the interior rearview mirror assembly is mounted in the equipped vehicle. The rear glass substrate has a flat third glass surface and a flat fourth glass surface (which is the flat rear surface of the internal specular reflective element), and the flat third glass surface of the rear glass substrate is coated withA multilayer transflector that transmits visible light/reflects visible light/transmits near IR light (preferably with a dominant wavelength of 940 nm). The outermost layer of the stack constituting the transflector comprises a transparent conductive coating (preferably comprising indium tin oxide, and preferably having a sheet resistance of less than 30 ohms per square, more preferably less than 25 ohms per square, and most preferably less than 20 ohms per square) which is in contact with an electro-optic (typically electrochromic) medium.
The circumferential outer periphery of the front glass substrate of the interior rear view mirror assembly comprises a rounded curved outer glass surface which provides a rounded transition between the flat first glass surface of the front glass substrate 1a and the less curved outer surface of the side wall of the mirror housing 18 or attachment plate 5. The circumferentially curved outer/rounded glass surface of the front glass substrate has a radius of curvature of at least 2.5mm and is exposed to and viewable by a driver of the equipped vehicle when the interior rearview mirror assembly is mounted on the equipped vehicle. No part of the mirror housing (or front plastic mount/attachment element mounting the electrochromic/electro-optic mirror reflective element) extends to/covers the flat first glass surface of the front glass substrate (i.e., the flat front surface of the interior mirror reflective element). The cross-sectional dimension of the front glass substrate is greater than the cross-sectional dimension of the rear glass substrate such that the front glass substrate extends beyond the corresponding edge of the rear glass substrate. The rear glass substrate is received on and surrounded by the side walls of the front plastic bracket/attachment element to which the electrochromic/electro-optic mirror reflective element is mounted. The rear glass substrate 1b is preferably attached to a front plastic holder/attachment element 5 mounting an electrochromic/electro-optic mirror reflective element by means of a double sided adhesive tape 2 (arranged between the fourth glass surface of the rear glass substrate; i.e. the flat rear surface of the internal mirror reflective element).
Thus, at the Infinity TM Inside rear-view mirror assembly (Infinicity) TM Magna Mirrors of America, inc. of Holland, michigan, U.S. in which the mirror reflective element disposed on the mirror housing (and pivotable with the mirror housing relative to the mounting portion of the assembly) comprises an outermost glass substrate (which may be provided with an Infinity TM Driver contact for a vehicle with an interior rearview mirror assembly) The glass substrate has a planar front glass surface, a planar back glass surface, and a circumferential peripheral edge around a periphery of the glass substrate that extends across a thickness dimension separating the planar front glass surface from the planar back glass surface. The front peripheral edge portion of the circumferential peripheral edge includes a circular glass surface circumferentially surrounding and circumscribing the periphery of the glass substrate, and the circular glass surface at least partially spans the thickness dimension of the glass substrate. The rounded glass surface has a radius of curvature of at least 2.5mm. No part of the mirror housing overlaps, covers or encroaches on the circular glass surface of the glass substrate. When the mounting portion is mounted on the cabin inner side of the windshield of the equipped vehicle, the circular glass surface of the glass substrate is exposed to and accessible by the driver of the equipped vehicle. Preferably, the radius of curvature of the circular glass surface is uniform around the periphery of the glass substrate. The mirror assembly includes an attachment surface and preferably the mirror reflective element is adhered to the attachment surface to secure the mirror reflective element in the mirror assembly.
EVO inside a cassette DMS TM In an electrochromic rear view mirror assembly (as schematically shown in fig. 77B), the electrochromic/electro-optic mirror reflective element 1 comprises a front glass substrate 1a and a rear glass substrate 1B spaced from the front glass substrate by a perimeter seal 1c, wherein an electrochromic medium 1d (which is electrically dimmable) is sandwiched between the front and rear glass substrates and is bounded by the perimeter seal. The front glass substrate has a planar first glass surface (which is the planar front surface of the internal specular reflective element) and a planar second glass surface spaced apart from the planar first glass surface by a thickness dimension of the front glass substrate. The front glass substrate includes a peripheral surface extending between the planar first glass surface and the planar second glass surface and spanning a thickness dimension of the front glass substrate. As a cassette DMS internal EVO TM The flat first glass surface faces the driver of the vehicle when the electrochromic rearview mirror assembly is mounted at the windshield or head portion of the equipped vehicle (e.g., by mounting structure 19). The transparent conductive coating is disposed at the planar second glass surface and is in contact with the electro-optic (i.e., electrochromic) medium. The front glass substrate has a front glass substrateA specular reflection and conductive perimeter band established by a perimeter boundary region of the planar second glass surface of the front glass substrate, the perimeter band having a perimeter boundary region of the second surface of the front glass substrate to conceal the perimeter seal from a person viewing the interior rearview mirror assembly when the interior rearview mirror assembly is mounted in a equipped vehicle. The rear glass substrate has a flat third glass surface and a flat fourth glass surface (which is the flat rear surface of the internal specular reflective element), and the flat third glass surface of the rear glass substrate is coated with a visible light transmissive/visible light reflective/near IR light transmissive (preferably with a dominant wavelength of 940 nm) multilayer transflector. The outermost layer of the stack of layers constituting the transflector comprises a transparent conductive coating (preferably comprising indium tin oxide, and preferably having a sheet resistance of less than 30 ohms/square, more preferably less than 25 ohms/square and most preferably less than 20 ohms/square) which is in contact with the electro-optic medium.
Thus, in EVO TM Interior rearview mirror assembly (EVO) TM Magna Mirrors of America, trademark of hollanda, michigan, usa), the mirror reflective element is nested in an attachment element or plastic molding or bracket 5 in/by which the electrochromic/electro-optic mirror reflective element is nested. The rear glass substrate 1b is preferably attached to the front plastic holder/attachment element 5 to which the electrochromic/electro-optic mirror reflective element is mounted by means of a double sided adhesive tape 2 which is provided between the fourth glass surfaces of the rear glass substrate, i.e. the flat rear surface of the internal mirror reflective element. The circumferential wall structure 5a extends from the mirror element attachment side of the attachment element or plastic molding or bracket. The circumferential wall structure spans the rear glass substrate, spans the electrochromic medium, and spans the thickness dimension of the front glass substrate. However, the circumferential wall structure does not overlap with the flat first (front) glass surface of the front glass substrate (i.e., the flat front surface of the internal specular reflective element) and does not cover/encroach upon it. The circumferential wall structure prevents the driver from touching any cut edges of the front and rear glass substrates, and in particular from touching the circumferential outer cut edges of the front glass substrate when the mirror assembly is used in a equipped vehicle.
At EVO TM In an interior rearview mirror assembly, a mirror reflective element packageIncludes an outermost glass substrate having a planar first glass surface and a planar second glass surface, with a circumferential edge along the perimeter of the foremost/outermost glass substrate. The circumferential edge spans a thickness dimension of the glass substrate between the first and second glass surfaces. The first glass surface of the glass substrate includes a front or outermost surface of the interior mirror assembly that is closest to a driver of the vehicle equipped with the interior mirror assembly when the interior mirror assembly is normally installed in the equipped vehicle. The specular reflective element includes a specular transflector disposed on a surface of the specular reflective element that is not the first glass surface of the glass substrate. The plastic molding is disposed circumferentially around and circumscribes the circumferential edge of the glass substrate without overlapping onto or covering/encroaching upon the first glass surface of the glass substrate. The plastic molding comprises the following parts: (a) A portion that meets the circumferential edge of the foremost/outermost glass substrate; and (b) a portion having an outer curved surface extending from substantially adjacent the first glass surface of the foremost/outermost glass substrate and free of sharp edges. The plane of the first glass surface of the foremost/outermost glass substrate is substantially flush with the outermost portion of the plastic molding. The outer curved surface of the plastic molding provides a curved transition between the plane of the first glass surface of the glass substrate and the plane of the generally smaller curved portion of the plastic molding. The substantially smaller curved portion is located behind, adjacent to and abutting the outer curved surface of the plastic molding. The plastic molding includes at least a portion of a mirror housing of the interior rearview mirror assembly. The mirror housing moves in conjunction with the mirror reflective element when the mirror reflective element is moved to set the field of view to a setting desired by the driver of the equipped vehicle. The plastic molding includes a pocket and the specular reflective element is received in the pocket, and at least a portion of the plastic molding is located behind the glass substrate when the specular reflective element is received in the pocket. The plastic molding includes structure for attaching the rear mirror housing cap portion thereto. The rear mirror housing cap portion is configured to be attached to a structure of the plastic molding.
Conventional interior rearview mirror assemblies use a plastic bezel (bezel) that is compatible with conventional interiorThe flat outermost surface of the foremost/outermost glass substrate used in the rearview mirror assembly overlaps and covers/extends over it, and the foremost/outermost glass substrate is framed with plastic to protect the driver from the sharp outer cutting edge of the foremost/outermost glass substrate. While such conventional framed mirrors may be used in a cassette DMS interior rearview mirror assembly, it is not preferred. Infinicity is TM The interior rearview mirror assembly does not use such a bezel or frame. EVO (EVO) TM The interior rearview mirror assembly does not use such a bezel or frame. Infinicity is TM And EVO TM The interior rearview mirror assembly is a rimless (also known as a rimless) interior rearview mirror assembly.
Alternatively, and as shown in FIG. 78, a cassette internal DMS mirror assembly (shown in FIG. 78 as a cassette DMS internal Infinity TM Electrochromic rearview mirror assembly) can be adjustably mounted at pivot joint 20a of mirror mounting base or foot or bracket 20 that includes circuitry and cameras and/or sensors that can operate separately from or with the DMS of a cassette-type internal DMS mirror assembly. For example, the legs or brackets include a PCB 22 having circuitry at either or both sides. The mirror mounting base or foot includes two front-view cameras, one of which includes a front-view camera module 24a for use by the driving assistance system of the vehicle (and for example, acquires image data for lane detection, pedestrian detection, vehicle detection, collision avoidance, ACC, traffic sign recognition, traffic light detection, automatic headlamp control, etc.), and the other of which includes an event recording camera 24b that acquires video images for recording events. One of the front-facing cameras may acquire color video image data for augmented reality display, wherein the video image is displayed on a video screen in the vehicle cabin for viewing by the vehicle driver, and navigation information or instructions or commands are superimposed on the displayed video image to assist the driver in seeing and understanding the navigation commands and how the navigation commands are associated with real-time video in front of the vehicle displayed on the video screen.
The mirror mounting base or bracket 20 also includes a rear view camera 26 disposed in an upper region of the bracket housing (proximate the vehicle roof 30) and angled downwardly for viewing the rear row seating of the vehicle. By positioning the fixed camera 26 higher within the vehicle cabin and above the lens portion, the camera 26 may provide enhanced view of the rear seat of the vehicle. Optionally, the mirror mounting base or bracket may also or otherwise include another non-camera or non-imaging sensor 28 (e.g., a radar sensor or lidar sensor or ultrasonic sensor) that may sense the front of the vehicle or the rear of the vehicle or the cabin interior of the vehicle (for similar occupant detection and having a view/sensing range that is unobstructed by the lens portion of the interior rearview mirror assembly and where there is the advantage of being non-adjustable, i.e., remaining fixed/non-movable, as the driver moves/adjusts the lens portion to set its desired rear view using the interior mirror reflective element). The mirror mounting base or bracket 20 may include a heat sink and/or another printed circuit board housing electronic components and may include a cassette type structure in which the PCB receives power from the vehicle and provides communication with a cassette type internal DMS mirror assembly and/or other vehicle systems. The PCB of the cradle may include a data processor (such as an EYEQ4 or EYEQ5 image processing chip available from jersey MOBILEYE VISION TECHNOLOGIES LTD) for processing the image data acquired by the camera or feeding the output of the camera to electronic components housed within the lens portion of a cassette-type internal DMS mirror assembly or they are fed to other onboard systems of the equipped vehicle. The electronics and/or sensors housed in the mirror mounting base or bracket share (and communicate with) common electronics/circuitry with the electronics and/or sensors housed in the mirror head. For example, image data acquired by a front-view camera located in a cradle may be provided to electronics housed in the lens portion (via wiring that passes through wiring conduits established by a ball-and-socket pivot joint that allows the lens portion to be adjusted relative to the cradle). The power supply housed within the lens portion may energize the electronic components housed in the mirror mounting base or bracket. The memory provided in the lens portion can transfer data to and/or receive data from electronics provided in the lens mounting base or bracket.
The above-described architecture allows manufacturers of internal rearview assemblies to provide OEM automotive manufacturers (e.g., ford or mass or honda, etc.) with multi-functional unit parts/assemblies/modules wherein the mounting base includes a Windshield Electronics Module (WEM) that includes electronics (and related software), connectors, internal wiring/connections, PCBs, and other hardware for internal mirror functions, for DMS/OCS functions, and for ADAS functions. For example, and when an OEM automotive manufacturer installs a WEM-interior mirror unit module in a vehicle assembled by the OEM automotive manufacturer, the WEM-interior mirror unit module includes at least some selected from the group consisting of: (i) automatically dimming electro-optic (e.g., electrochromic) internal mirror transflector elements, (ii) DMS/OCS cameras and associated near IR light emitters and DMS data processors, (iii) cameras looking forward through the vehicle equipped windshield for data processing that acquire image data for detecting objects present outside the vehicle equipped, (iv) color cameras looking forward through the vehicle equipped windshield that acquire color image data for use with vehicle equipped event recorders or augmented reality display systems, etc., and (v) radar or lidar or other sensors that sense fields that may enter the interior compartment of the vehicle for occupant detection. In this regard, the WEM-interior mirror unit module can utilize the structure and incorporated attachment disclosed in U.S. patent No.9,090,213, which is incorporated herein by reference in its entirety, and which discloses an attachment mounting system for a vehicle that includes spaced apart fixing elements adhered at a surface of a vehicle windshield, and a frame having receiving portions spaced apart from one another in a manner corresponding to the spacing of the fixing elements, with each receiving portion being configured to receive a respective one of the fixing elements. Furthermore, WEM-internal mirror unit modules can be utilized as in U.S. patent No.7,188,963; structures and accessories disclosed in nos. 6,690,268 and/or 7,480,149 (these patents are incorporated herein by reference in their entirety) contain structures.
Fig. 79 shows exemplary visible light transmittance curves for a dual substrate laminated electrochromic transflector reflecting element ("EC cell") suitable for use in a cassette electrochromic interior DMS mirror assembly. The visible light transmission in the 380-750nm region is about 45% t. A camera that observes the interior of the cabin from inside the lens section through a multi-layer stack of oxide coatings that constitute a visible light transmissive/visible light reflective/near IR transmissive mirror-transparent reflector coated onto the third surface of the EC unit itself (i.e., the side of the rear substrate that is contacted by the electrochromic medium sandwiched between the front and rear substrates) is observed through a camera lens filter (shown in figure AA) that has a transmissivity of about 45% for visible light in the 380-750nm region. Thus, the overall system has a transmittance of about 20% for visible light in the 380-750nm region.
FIG. 80 illustrates another example visible light transmission curve for an EC cell of a cassette electrochromic interior DMS mirror assembly. The visible light transmission in the 380-750nm region is about 30% t. A camera that observes the interior of the cabin from inside the lens section through a multi-layer stack of oxide coatings that constitute a visible light transmissive/visible light reflective/near IR transmissive mirror-transparent reflector coated onto the third surface of the EC unit itself (i.e., the side of the rear substrate that is contacted by the electrochromic medium sandwiched between the front and rear substrates) is observed through a camera lens filter (as shown in fig. 80) that has a transmittance of about 80% for visible light in the 380-750nm region. Thus, the transmission of the entire system to visible light in the 380-750nm region is about 24%.
FIG. 81 illustrates another example visible light transmission curve for an EC cell of a cassette electrochromic interior DMS mirror assembly. The visible light transmission in the 380-750nm region is about 25% t. A camera that observes the interior of the cabin from inside the lens section through a multi-layer stack of oxide coatings that constitute a visible light transmissive/visible light reflective/near IR transmissive mirror-transparent reflector coated onto the third surface of the EC unit itself (i.e., the side of the rear substrate that is contacted by the electrochromic medium sandwiched between the front and rear substrates) is observed through a camera lens filter (as shown in fig. 81) that has a transmittance of about 80% for visible light in the 380-750nm region. Thus, the overall system has a transmittance of about 20% for visible light in the 380-750nm region. .
When a box-type electrochromic interior DMS mirror assembly is installed in an equipped vehicle (typically on a mirror mounting button or similar mirror mounting element adhered at the inboard side of the windshield of the equipped vehicle), the visible light transmissive/visible light reflective/near IR transmissive mirror transflector coated on the third surface of the EC unit makes it difficult for a driver sitting in the front driver's seat during normal driving (daytime or evening) and viewing the interior rearview mirror normally, especially for the driver to view the presence of the camera (as well as the IR emission source and other electronics). This is at least because some drivers may feel uneasy (for privacy reasons, etc., and even though the DMS has a safety function/purpose) because they are photographed/recorded by the camera during driving. In addition to the camera being viewed through a specular reflector coated on a third surface of the EC unit (and wherein the IR emitting source emits through the specular reflector), light passing through the EC unit into the interior chamber of the lens portion may be blocked by a similar light absorbing (e.g., black) paint, paint or coating or tape or plate or adhesive tape or attachment member or bracket, such that a localized area of the specular reflector viewed by the camera through the unique channel (and through which the IR emitting source emits) passes through the EC unit into the chamber of the lens portion for light.
A box-type electrochromic interior DMS mirror assembly employs various means of enhancing concealment so that the interior structure of the lens portion (and particularly the presence of the driver monitoring camera and the driver-illuminated near IR light source within the cavity of the lens portion) is concealed from the driver of a vehicle equipped for normal operation. Such means of enhancing concealment include preferably having a visible light transmission through the 380-750nm region of the specular reflector (coated onto the third surface of the EC cell) in the range of 20% T to 35% T (more preferably in the range of 15% T to 35% T, and most preferably in the range of 20% T to 30% T). Such a measure to enhance the shielding property includes rendering/coating/coloring the outer surface of the driver monitor camera to dark/light absorbing/black as shown in fig. 82. Such concealment enhancement measures include the use of a dual bandpass limited visible light and near IR limited lens filter (see fig. 79-81) placed behind the mirror transflector of the EC unit so that the driver monitor camera views through the optical filter and thereby causes the optical filter to reduce the driver's perception of the presence of the camera within the lens portion of the interior rearview mirror assembly of the equipped vehicle.
Advanced Driving Assistance Systems (ADASs) of vehicles improve driving/traffic safety through Automatic Emergency Braking (AEB), lane departure warning, blind spot detection, and other types of collision prevention/collision mitigation techniques, among others. The one-cassette DMS interior mirror assembly of the present invention can economically enhance the safety of an ADAS equipped vehicle.
For example, a cassette DMS interior mirror assembly in a equipped vehicle can determine if the driver is distracted. If the in-lens DMS determines that the driver is distracted, the distance that the AEB system of the vehicle starts to stop may be increased, or when distraction or drowsiness of the driver is detected, the lane keeping assist system equipped with the vehicle may become more sensitive and take over more vehicle control. The cameras of the preferred one-box DMS internal DMS mirror assembly of the present invention, which are concealed within the lens portion, monitor the driver using advanced algorithms and techniques to detect data points on the driver's eyes and face. By combining the near IR illumination provided by the nffov near IR LEDs located at the lens portion to the eyes/face/head of the driver, the driver's level of attention is tracked by detecting eye movement, monitoring head position, monitoring eyelid movement, determining the driver's gaze direction, etc. If the DMS electronics housed in the lens portion of a cassette internal DMS mirror assembly determines that the driver is not sufficiently focused on the road surface, or is in the process of being stranded, a warning or alarm (which may be visual, audible and/or tactile) may be raised in the cabin of the equipped vehicle to alert the driver to better notice the drive. The DMS system within the lens portion of a cassette DMS internal mirror assembly will generate and output such a warning or alarm as a signal or message on the onboard communication network/onboard communication network bus of the equipped vehicle, for example, on a Controller Area Network (CAN) communication bus or on an ETHERNET communication bus. In response to such output/signals generated by the in-lens DMS, the equipped vehicle alerts the driver and/or takes other action. Data communications are bi-directional in that vehicle data (including data generated by or associated with the ADAS system of the equipped vehicle) is transmitted/carried/conveyed to a cassette DMS internal mirror assembly via a CAN communication bus or ETHERNET communication bus or the like.
In addition to the driver monitoring camera monitoring the driver's alertness and status and detecting distraction, drowsiness, and microsleep to timely alert the driver, the cassette DMS internal mirror assembly may also process the data acquired by the driver monitoring camera using facial recognition techniques and/or other biometric detection algorithms. Once it is identified that a particular driver is driving the equipped vehicle (preferably based on a driver profile stored within a cassette DMS interior mirror assembly or accessed through wireless cloud communication between the equipped vehicle and a remote database/service provider), a cassette DMS interior mirror assembly may output signals/information over the CAN or ETHERNET communication bus of the vehicle to adjust personal comfort and convenience settings to those typically favored by the identified driver (e.g., optimal seat position, desired exterior mirror position, favorite radio, and/or preferred interior temperature).
The average male head measurement had a circumference of between about 57cm (22.5 inches) and 61cm (24.2 inches). The average face length is about 117mm for men/about 110mm for women. The average face width was about 148mm for men/about 140mm for women. A camera in a cassette DMS internal mirror assembly can acquire frames of image data (typically at least 15 frames per second or at least 30 frames per second, and optionally 60 frames per second). When driving, the driver faces forward and looks directly at the front windshield of the equipped vehicle. The driver is typically seated at an eye-to-mirror center distance of between about 400mm (16 inches) and about 800mm (31 inches).
ISO 4513:2010 (road vehicle-visibility-determination of eye ellipse for driver eye position) describes an eye ellipse (eye movement range), a statistical representation of driver eye position for a driver to use and observe an interior rear view mirror in a vehicle motor vehicle. A three-dimensional elliptical (ocular ellipse) model is used to represent the tangential cut-off percentile of the driver's eye position. A procedure is provided for constructing tangential truncated eye ellipse models for the 95 th and 99 th percentiles of a 50/50 sex mixed adult user population. The interior rearview mirror position, size and shape are defined in RREG 79/795 and E/ECE/324/Rev.1/Add.45/Rev.5-E/ECE/TRANS/505/Rev.1/Add.45/Rev.5, which is then related to the driver's eye position-this eye position is referred to as the "eye ellipse" in society of automotive Engineers recommended practice SAE J941 (Society of Automotive Engineers Recommended Practice SAE J941) and as the "eye point"/"eye point" in RREG 77/649. RREG's are instructions for the European Union Congress (the Council of the European Union) and E/ECE's are instructions for the United nations. The federal motor vehicle safety standard FMVSS111 (Federal Motor Vehicle Safety Standard FMVSS 111) specifies minimum requirements for the field of view of rearview mirrors in the united states, the calculation of which is based on an eye ellipse defined in SAE recommendation J941. An eye ellipse is a tangential ellipse that defines the position of the driver's eyes in a particular vehicle. For a 95% eye ellipse, any plane tangential to the eye ellipse will divide the space into two regions, one of which contains 95% of the predicted eye position and one of which contains the other 5% of the predicted eye position. For 99% of the eye ellipses, any tangent plane will divide the space into regions containing 99% and 1% of the eye positions. Theoretically, an eye ellipse can be generated that divides the space into regions containing any percentage of eye positions. However, SAE J941 only gives definitions of 95% and 99% eye ellipses.
Irradiance (the radiant flux received by the surface per unit area) at the head of the driver (and especially at the driver's eyes for drowsiness detection) is important, especially during night driving when the interior cabin is dark, and the DMS camera in the lens portion relies mainly on near IR illumination from the near IR light source in the lens portion. The near IR irradiance of the driver's eyes or the like is preferably at least 1W/m 2 More preferably at least 2W/m 2 And more preferably at least 2.5W/m 2 And in particular for a particular driver sitting in the driver's seat of a particular vehicle equipped with a cassette DMS interior rearview mirror assembly vehicle of the present invention, particularly within the 99% eye ellipse specified by SAE J194. To ensure that the required irradiance is transmitted to the potential driverDifferent drivers of vehicles equipped with a cassette DMS internal mirror assembly and for their head movements, the near IR emitting light source of the mirror provides a suitably high irradiance at the region where the driver's head can be expected to be found, the region being at least 80mm X80 mm in size; more preferably at least 100mm X100 mm; more preferably at least 150mm X150 mm.
When adjusting the interior mirror assembly so that the driver can see out of the rear window of the vehicle using the interior mirror, the driver can steer his or her head toward the grasped lens portion to adjust the field of view or rear view of the interior rearview mirror to the desired setting/direction of that particular driver. The near IR irradiation reflector used in conjunction with the nffov near IR emitting LEDs within the lens portion can focus and focus the irradiation of the driver's head, particularly the driver's face, more particularly the driver's eyes, and most particularly the driver's eyelid/pupil (this is an indicator of drowsiness, as well as an indicator of where the driver is looking).
With respect to the near IR light source housed in the interior chamber of the lens section, fig. 83 shows a near IR emission pattern formed using two narrow field of view (nffov) 940nm LEDs for use in a left-hand driving vehicle and a near IR emission pattern formed using two narrow field of view (nffov) 940nm LEDs for use in a right-hand driving vehicle. Surface mounted LEDs may emit in all directions-thus the reflector may form a directional cone or pattern of near IR illumination. Figures 84A-84C illustrate how these near IR light emitting sources are disposed in and supported by the lens portion structure of a box electrochromic interior DMS mirror assembly [ plane relative to the rear side of the rear glass surface of the EC cell (its fourth surface) ]. As shown in fig. 84C, the LHD nffov LED is at an angle of about 20 degrees with respect to the front surface of the specular reflective element, the wFOV LED is at an angle of 0 degrees with respect to the front surface of the specular reflective element, and the RHD nffov LED is at an angle of about 10 degrees with respect to the front surface of the specular reflective element. As also shown in fig. 84C, the wfv LED is preferably physically close to the specular reflective element (but may be slightly offset to enhance shielding) such that most or all of the near IR light emitted by the wfv LED enters the vehicle cabin, while the nfv LED is spaced from the specular reflective element (by a surface mounted reflector) and is angled such that the near IR light emitted by the nfv LED is directed or concentrated by the reflector to the driver area within the vehicle cabin.
As shown in fig. 85A, when a cassette interior DMS mirror assembly is mounted at the windshield and angled toward the driver (fig. 85A is shown for a left-hand drive vehicle), the lens portion is tilted or angled at about 10-30 degrees relative to the transverse axis of the vehicle perpendicular to the longitudinal axis of the vehicle. As shown in fig. 85B, the n-FOV light emitter emits light to illuminate the head of the driver, wherein the angle or width of the illuminating beam is about 60 degrees, the principal axis of the illuminating beam is between 10 and 30 degrees relative to a line perpendicular to the planar front surface of the specular reflective element, more preferably between 15 and 25 degrees relative to a line perpendicular to the planar front surface of the specular reflective element, such as about 20 degrees relative to a line perpendicular to the planar front surface of the specular reflective element (i.e., the angle of the circuit board on which the nffov light emitter is disposed is about 10-30 degrees relative to the planar front surface of the specular reflective element, more preferably between 15 and 25 degrees relative to the planar front surface of the specular reflective element, such as about 20 degrees relative to the planar front surface of the specular reflective element). Figures 86A and 86B illustrate the size and angle and configuration of a cassette of internal DMS mirror assemblies mounted on a LHD vehicle. Figure 86C shows the geometry and equations that may be used to determine the angle of the LHD nffov LEDs.
In fig. 87A, when a cassette interior DMS mirror assembly is mounted at the windshield and angled toward the driver (fig. 87A is shown for a right-hand drive vehicle), the lens portion is tilted or angled at about 10-30 degrees relative to the transverse axis of the vehicle perpendicular to the longitudinal axis of the vehicle. As shown in fig. 87B, the n-FOV light emitter emits light to illuminate the head of the driver, wherein the angle or width of the illuminating beam is about 60 degrees, the principal axis of the illuminating beam is between 0 and 20 degrees relative to a line perpendicular to the planar front surface of the specular reflective element, more preferably between 5 and 15 degrees relative to a line perpendicular to the planar front surface of the specular reflective element, such as about 10 degrees relative to a line perpendicular to the planar front surface of the specular reflective element (i.e., the circuit board on which the nffov light emitter is disposed is at a non-zero angle relative to the planar front surface of the specular reflective element, up to about 20 degrees, more preferably between 5 and 15 degrees relative to the planar front surface of the specular reflective element, such as about 10 degrees relative to the planar front surface of the specular reflective element). Fig. 88A illustrates the angle and configuration of a cassette type internal DMS mirror assembly mounted on an RHD vehicle. Figure 88B shows the geometry and equations that may be used to determine the angle of the LHD nffov LEDs.
Thus, the angle of the LHD nffov near IR illumination source (relative to the planar surface of the specular reflective element) may be different from the angle of the RHD wFOV near IR illumination source (relative to the planar surface of the specular reflective element) and opposite in direction (i.e., the primary emission axis of the LHD nffov near IR illumination source is angled toward the left side of the lens portion (and vehicle) and the primary emission axis of the RHD nffov near IR illumination source is angled toward the right side of the lens portion (and vehicle). Alternatively, the angle of the LHD nffov near IR illumination source (relative to the planar surface of the specular reflective element) may be the same as the angle of the RHD wFOV near IR illumination source (relative to the planar surface of the specular reflective element), but in a laterally opposite direction from the angle of the RHD wFOV near IR illumination source. For example, the angle of the nffov near IR illumination source relative to the planar surface of the specular reflective element may be between 5 degrees and 25 degrees, such as between 10 degrees and 20 degrees, e.g., 15 degrees, with the main emission axial lens portion (and vehicle) of the LHD nffov near IR illumination source angled to the left and the main emission axial lens portion (and vehicle) of the RHD nffov near IR illumination source angled to the right. In other words, the LHD nffov near IR illumination source may be at, for example, -15 degrees and the RHD nffov near IR illumination source may be at, for example, +15 degrees relative to the planar surface of the specular reflective element.
The principal line of sight of the DMS camera passes perpendicularly through the flat front surface of the mirror reflective element disposed at the lens portion of a cassette DMS internal mirror assembly. When a cassette DMS internal rearview mirror assembly is mounted on a LHD vehicle or RHD vehicle, the field of view of the DMS camera at the central location includes the driver's eye region of the head/eye ellipse when the driver adjusts the lens portion. For various reasons, the central region of the chamber including the lens portion is crowded with a DMS camera and a ball-and-socket pivot joint or the like about which the lens portion moves when the driver adjusts the mirror in the equipped vehicle, and an nffov near IR emission light source intended to illuminate the eye region of the head/eye elliptical driver is located within the lens portion at a distance d mm from the center line bisecting the center of the length dimension of the mirror reflective element. As shown in fig. 85A, 85B, 86A and 86B, the LHD nffov near IR-emitting light source is angled relative to the flat front side/surface of the specular reflective element such that when a cassette DMS internal rearview mirror assembly is mounted on the LHD vehicle and the lens portion is adjusted by the driver, the main emission axis of the LHD nffov near IR-emitting light source is tilted toward the driver. Likewise, and as shown in fig. 87A, 87B and 88A, the RHD nffov near IR-emitting light source is angled relative to the flat front side/surface of the specular reflective element such that when a cassette DMS interior rearview mirror assembly is mounted on the RHD vehicle and the lens portion is adjusted by the driver, the main emission axis of the RHD nffov near IR-emitting light source is tilted toward the driver.
For LHD applications of a cassette DMS internal rearview mirror assembly, as the dimension d increases (i.e., as the LHD nffov near IR-emitting light source is farther from the centerline of the specular reflective element), the greater the angle that the primary emission axis of the LHD nffov near IR-emitting light source must subtend with respect to the plane of the planar front side/surface of the specular reflective element in order to provide an illumination line to the driver of the LHD vehicle. However, for RHD applications of a cassette DMS internal rearview mirror assembly, as the dimension d increases (i.e., as the RHD nffov near IR-emitting light source is farther from the centerline of the specular reflective element), the smaller the angle that the main emission axis of the RHD nffov near IR-emitting light source must subtend with respect to the plane of the planar front side/surface of the specular reflective element in order to provide an illumination line to the driver of the RHD vehicle. Thus, for applications in which a cassette DMS internal rearview mirror assembly is installed in a LHD vehicle, the LHD nffov near IR-emitting light source is angled, for example, about 20 degrees relative to the flat front side/surface of the mirror reflective element, with a distance d (between the mirror centerline and the LHD nffov near IR-emitting light source) of about 50mm. For applications in which a cassette DMS interior rearview mirror assembly is mounted in a RHD vehicle, the angle of the RHD nFOV near IR emitting light source relative to the flat front side/surface of the mirror reflective element is, for example, about 10 degrees, and the distance d (between the mirror centerline and the RHD nFOV near IR emitting light source) is about 89mm.
Thus, as distance d increases, the corresponding angle of the LHD nffov near IR-emitting light source (relative to the flat front side/surface of the specular reflective element) increases, while the corresponding angle of the RHD nffov near IR-emitting light source (relative to the flat front side/surface of the specular reflective element) decreases.
As shown in FIG. 90, a cassette internal DMS mirror assembly is suitable for use in a LHD vehicle or RHD vehicle (e.g., by utilizing aspects of the systems described in U.S. provisional application Ser. No.63/267,316, U.S. provisional application Ser. No.63/262,642, and U.S. provisional application Ser. No.63/201,757, both filed on 1 month 31 of 2022, and filed on 10 month 18 of 2021, and U.S. provisional application Ser. No.63/201,757, both of which are incorporated herein by reference in their entirety). When a cassette of the internal DMS mirror assembly is installed in the LHD vehicle (see fig. 85A, 85B, 86A, 86B), the camera views the LHD driver's eye position and the illuminator(s) illuminate the LHD driver's eye position as the driver sits in the driver's seat and views the internal specular reflective element.
Accordingly, fig. 85A and 85B illustrate how a driver adjusts the mirrors of a cassette DMS interior rearview mirror assembly (in a left-hand drive vehicle) so that the driver can use the mirror reflective element to look back through the rear window of the equipped vehicle. The front side (outermost side) of the flat interior mirror reflective element subtends an acute angle (in plan view from above) with respect to the transverse axis of the vehicle, ranging from about 10 degrees to 30 degrees, depending on the seating position and size of the particular driver. It can also be seen from fig. 85A that the nffov LED is located a distance to the right of the center of the lens portion (where the DMS camera is located). Fig. 87A and 87B show the situation in an RHD vehicle. As can be seen in fig. 84C, the main emission axis of the LHD nffov near IR emission light source is oriented vertically through the illustrated cassette DMS Infinity TM The angle of the straight line of the flat front glass substrate of the mirror reflective element of the lens portion of the electrochromic interior rearview mirror assembly is θ (for an RDH vehicle, the corresponding angle is δ). The angle θ is typically between about-10 degrees and about-35 degrees (e.g., -20 degrees). The angle delta is typically between about 0 degrees and about 25 degrees (e.g., 10 degrees).
Figure 86D shows a distribution plot of the illumination of different driver eyepoints by LHD nfv LEDs in a LHD vehicle in a horizontal plane (i.e., looking from above) and a vertical plane (i.e., looking rearward from the windshield). As shown in fig. 86D, any head/eye within the contour line a will have a head/eye of at least 2.5W/m 2 Is near I of (2)R irradiance. Figure 86E shows the illumination within the cabin of the LHD vehicle when the LHD nffov LED (with surface mounted reflector) is powered. As shown in fig. 86E, the horizontal half beam angle of the LHD nffov LED is 41.4 degrees and the vertical half beam angle of the LHD nffov LED is 40.9 degrees. Fig. 88C shows a profile of the different driver's eyepoint illuminated by the RHD nffov LEDs in the RHD vehicle in the horizontal plane (i.e., looking from above) and the vertical plane (i.e., looking rearward from the windshield). As shown in fig. 88C, any head/eye within the contour line B will have a head/eye of at least 2.5W/m 2 Near IR irradiance of (c). Fig. 88D shows the illumination of the interior of the RHD vehicle when RHD nffov LEDs (with surface mounted reflectors) are powered. As shown in fig. 88D, the horizontal half-beam angle of the RHD nffov LED is 41.4 degrees and the vertical half-beam angle of the LHD nffov LED is 40.9 degrees. Fig. 89 shows the illumination situation in the cabin of the vehicle when the wFOV LED is powered. As shown in fig. 89, the horizontal half-beam angle of the wfv LED is 155 degrees, and the vertical half-beam angle of the wfv LED is 130 degrees.
As can be seen from fig. 90, the LHD nffov (relative to the plane of the flat rear side of the interior mirror reflective element) is angled, and the RHD nffov (relative to the plane of the flat rear side of the interior mirror reflective element) is also angled. However, the main emission axis direction of the RHD nffov is different and opposite to the direction of the main emission axis of the LHD nffov.
The illumination provided by the light source meets automotive Safety requirements, including Safety target 2 (ASIL B) (Safety gold 2 (ASIL B)). According to the IEC62471:2006 standard, the system should be classified as an exemption system. The system operates in a safe state, whereby the system should not emit IR radiation.
As shown in fig. 84A to 90, the driver monitor camera is located at the center of the lens portion. The nffov near IR LED monitoring the driver's head in the RHD vehicle is positioned towards one lateral side of the lens portion and is inclined at an acute angle of around 10 degrees [ relative to the plane of the rear side of the rear glass surface of the EC unit (its fourth surface) ] and viewed in a direction away from that lateral side of the lens portion. An nffov near IR LED illuminating the head of the driver in the LHD vehicle is positioned closer to the center area of the lens portion (where the driver monitor camera is located) and is at an acute angle of around 20 degrees [ relative to the plane of the rear side of the rear glass surface of the EC unit (its fourth surface) ] and viewed in a direction opposite to that of the other nffov LEDs. A wFOV near IR LED providing general cabin/occupant illumination is disposed in the lens portion between the locations of the nFOV LEDs and has its primary viewing axis perpendicular to the plane of the rear side of the rear glass plane of the EC unit.
Thus, upon ignition and/or start-up of the propulsion system of the equipped vehicle (e.g., an engine in an internal combustion engine vehicle or an electric drive in an electric vehicle), a cassette internal DMS rearview mirror assembly is powered. When powered, the DMS camera acquires frames of image data at a frame acquisition rate of at least 15fps, preferably at least 30fps, more preferably at least 60 fps. During driving, the ECU of a cassette internal DMS rearview mirror assembly can know whether the vehicle is traveling in a left-hand driving (LHD) country or a right-hand driving (RHD) country. This may be based on data provided by the equipped vehicle based on the current geographic location of a similarly equipped vehicle as determined by a similar GPS system. Furthermore, when the vehicle first leaves its vehicle assembly plant, the relevant automotive manufacturer will place the steering column at the left side of the front compartment area for the LHD vehicle and at the right side of the front compartment area for the RHD vehicle. When configured as a left-hand or right-hand drive vehicle/knowing the driving position of the vehicle, the image processing of the image data acquired by the DMS camera is configured to process image data representative of a driver region (e.g., a left-hand front seat region of a left-hand drive vehicle or a right-hand front seat region of a right-hand drive vehicle) for DMS frame acquisition and to control or power the light source to provide enhanced illumination of the driver region for DMS frame acquisition. In a preferred embodiment, the light sources of a cassette interior DMS rearview mirror assembly include a first set of light sources (wFOV light sources) disposed between a second set of light sources (e.g., left side (LH) light sources) and a third set of light sources (e.g., right side (RH) light sources).
For left-hand driving vehicles equipped with a cassette internal DMS rearview mirror assembly, during acquisition of a set of DMS's of acquired image data frames (for driver monitoring functions), LHD nFOV light source #Preferably a plurality of near IR light emitting LEDs comprising at least two LEDs, and more preferably four or less LEDs) and a wFOV light source (preferably a plurality of near IR light emitting LEDs comprising at least two LEDs, and more preferably four or less LEDs) are energized. The illumination provided by the LHD nffov light source and the wFOV light source are combined together to be at least 1.25W/m 2 More preferably at least 1.8W/m 2 And most preferably at least 2.3W/m 2 Is used to illuminate the head area of the driver, who sits at the left side of the vehicle. The LHD nffov near IR light source has a narrow illumination field cone/area that contains/illuminates the driver's head sash area (and thus provides enhanced irradiance at the driver's face). During this acquisition of the acquired image data frames for the DMS group of the driver monitoring function, the wFOV near IR light source is also energized, but the LHD nffov near IR light source is not. Such selective powering of one of the LHD and RHD light sources over the other (in the example of LHD driving, where the LHD light source is powered and the RHD light source is not), avoids wasteful heat generation within the lens portion by powering the RHD light source, where the RHD light source has little effect on the illumination of the driver sitting on the left driver's seat. However, the wFOV light source adds a certain degree of irradiance to the driver's head sash area, while also illuminating the area where the driver's hand is located (steering wheel, center console, etc.), so in either LDH or RHD vehicles, the wFOV light source is powered all the time the vehicle is powered and running. Thus, for DMS frame acquisition in a left-hand drive vehicle, a cassette interior DMS rearview mirror assembly would only power LHD nffov light sources and wFOV light sources, as these light sources would illuminate the driver of the left-hand drive vehicle. The RHD nfv light source does not cover any part of the LH driver in any sense when powered, and therefore is not powered during DMS frame acquisition in the LHD vehicle. Of course, in an RHD vehicle, the situation is the opposite. For DMS frame acquisition in a right-hand-drive vehicle, a cassette interior DMS rearview mirror assembly would only power the RHD nfv light source and the wFOV light source, as these light sources would illuminate the driver of the right-hand-drive vehicle.
For left or right hand drive vehicles equipped with a cassette interior DMS rearview mirror assembly, during acquisition of the OMS set in the acquired image data frames (for occupant monitoring functions), all three sets of near IR light sources (LHD nffov and wFOV and RHD nffov) will be energized so that near IR flood illumination within the vehicle cabin is maximized and in particular for illuminating a second or even third row like backseat.
For left-hand drive vehicles equipped with a cassette interior DMS rearview mirror assembly, during acquisition of the OMS group in the acquired image data frame (for occupant monitoring or occupant detection functions), the LHD nffov light source, the wFOV light source, and the RHD nffov light source (preferably a plurality of near IR light emitting LEDs including at least two LEDs, and more preferably four or less LEDs) are energized. The illumination provided by the LHD nFOV light source, the wFOV light source, and the RHD nFOV light source are combined together to be at least 0.1W/m 2 Preferably at least 0.15W/m 2 And more preferably at least 0.2W/m 2 The second row or rear seat and passenger seating area are illuminated by irradiance of at least 0.15W/m, and the illumination provided by the wFOV light source and the RHD nffov light source are combined together 2 Preferably at least 0.25W/m 2 And more preferably at least 0.4W/m 2 The irradiance of (2) illuminates the front passenger seating area.
Thus, for DMS frame acquisition of a left-hand-drive vehicle, a cassette interior DMS rearview mirror assembly would only power LHD nffov and wFOV light sources, as these would illuminate the driver of the left-hand-drive vehicle; and for OMS frame acquisition for left-hand drive vehicles, a cassette interior DMS rearview mirror assembly will power LHD nffov, wFOV, and RHD nffov light sources.
Likewise, for right-hand drive vehicles equipped with a cassette interior DMS rearview mirror assembly, during acquisition of the DMS set (for driver monitoring functions) in the acquired image data frame, a RHD nFOV light source (preferably a plurality of near IR light emitting LEDs including at least two LEDs, and more preferably four or less LEDs) and a wFOV light source (preferably a plurality of near IR light emitting LEDs including at least two LEDs, and more preferably four or less LEDs) are energized. Illumination junction provided by RHD nFOV light source and wFOV light sourceTaken together to at least 1.25W/m 2 More preferably at least 1.8W/m 2 And most preferably at least 2.3W/m 2 Is used to illuminate the head area of the driver (located at the right side of the vehicle). The RHD nfv light source has a narrow illumination field cone covering the driver's head sash area (thus providing enhanced irradiance at the driver's face without increasing the RHD nfv light source input power, while also reducing heat generation in the system and reducing the number of LEDs required), while the wFOV light source may increase irradiance at the driver's head sash area to some extent, but at the same time also illuminate the area where the driver's hand is located (steering wheel, center console, etc.). Thus, for DMS frame acquisition for a right-hand-drive vehicle, a cassette interior DMS rearview mirror assembly would only power the RHD nfv light source and the wFOV light source, as these light sources would illuminate the driver of the right-hand-drive vehicle. The LHD nffov light source when powered does not cover any part of the RH driver and therefore is not powered during DMS frame acquisition.
For right-hand drive vehicles equipped with a cassette interior DMS rearview mirror assembly, the RHD nfv light source, the wFOV light source, and the LHD nfv light source (preferably a plurality of near IR light emitting LEDs including at least two LEDs, and more preferably four or less LEDs) are energized during acquisition of the OMS group in an acquired image data frame (for occupant monitoring or occupant detection functions). The illumination provided by the RHD nFOV light source, the wFOV light source, and the LHD nFOV light source are combined together to be at least 0.1W/m 2 Preferably at least 0.15W/m 2 And more preferably at least 0.2W/m 2 The second row or rear seat and passenger seat areas are illuminated by irradiance provided by the wFOV light source and the LHD nffov light source combined to be at least 0.15W/m 2 Preferably at least 0.25W/m 2 And more preferably at least 0.4W/m 2 The irradiance of (2) illuminates the front passenger seating area.
Thus, for DMS frame acquisition of a right-hand-drive vehicle, a cassette interior DMS rearview mirror assembly would only power the RHD nfv light source and the wFOV light source, as these light sources would illuminate the driver of the right-hand-drive vehicle; and for OMS frame acquisition for right-hand-drive vehicles, a cassette interior DMS rearview mirror assembly will power the RHD nffov light source, the wFOV light source, and the LHD nffov light source.
The illumination protocols/schemes described herein may be dynamic in that they may be adjusted according to the current driving situation. For example, the illumination protocol may be adjusted according to daytime/nighttime (by time of day or time of night) conditions; the illumination protocol may be adjusted in response to the level of ambient car illumination, such as on sunny and cloudy days, dawn and dusk; or the illumination protocol may be adjusted (e.g., for thermal management) to temporarily reduce illumination in the cabin for a brief limited time after ignition or start-up occurs when the vehicle is parked in the sun on a hot sunny day.
Whether a cassette interior DMS rearview mirror assembly is disposed in a LHD vehicle or a RHD vehicle, the field of illumination of the DMS camera preferably covers the seating position (front and rear) of the occupant of the vehicle for occupant detection purposes. Also, to provide near IR flood illumination to such passengers seated in the interior compartment of the vehicle, the illumination field of the wFOV near IR illuminator covers the seating position (front and rear) of the passengers of the vehicle, whether the cassette interior DMS rearview mirror assembly is for a LHD or RHD vehicle. However, in order to implement the DMS function, it is desirable that the face/head/body of the driver be irradiated with near IR as strongly as possible. Thus, for LHD vehicles it is desirable to have the LHD nffov near IR illuminator directed toward the driver of the LHD vehicle, while for RHD vehicles it is desirable to have the RHD nffov near IR illuminator directed toward the driver of the RHD vehicle. Whereas the central region of the DMS lens portion has limited space to accommodate the camera, wFOV near IR illuminator, nffov near IR illuminator and mirror pivot joint and similar/related hardware, the nffov near IR illuminator is placed to the left side of the camera or to the right side of the camera, for practical considerations.
Thus, and as shown in fig. 84C, 86B, 86C, 88A, 88B, and 90 (and as described above), the LHD nffov near IR illuminator is tilted or angled toward the left hand side of the vehicle, wherein the farther the LHD nffov near IR illuminator is from the center of the lens portion, the greater the tilt angle, and the RHD nffov near IR illuminator needs to be tilted or angled toward the right hand side of the vehicle, wherein the further the RHD nffov near IR illuminator is from the center of the lens portion, the tilt angle decreases.
Alternatively, for practical reasons, such as manufacturing and packaging, and cost reasons, it may be desirable to place the nffov near IR illuminator on one side (e.g., left side) or the other side (e.g., right side) of the camera centrally disposed in the lens portion, or to place the LHD nffov near IR illuminator on one side (e.g., left side) and the RHD nffov near IR illuminator on the other side (e.g., right side). For example, and as shown in fig. 113A, a cassette interior DMS rearview mirror assembly may have a camera and a wFOV near IR illuminator centrally disposed in the lens portion (with the camera centrally located above or below the wFOV near IR illuminator), with one nffov near IR illuminator (e.g., LHD nffov near IR illuminator for illuminating a driver of a LHD vehicle) disposed at the left side of the lens portion (at the left side of the camera) and the other nffov near IR illuminator (e.g., RHD nffov near IR illuminator for illuminating a driver of a RHD vehicle) disposed at the right side of the lens portion (at the right side of the camera). Alternatively, it is contemplated that the LHD nffov near IR illuminator is disposed at the right side of the lens portion and the RHD nffov near IR illuminator is disposed at the left side of the lens portion.
Alternatively, the nffov near IR illuminator may be more centrally disposed in the lens portion (e.g., above or below the centrally located wFOV near IR illuminator). For example, and as shown in fig. 113B, the wFOV near IR illuminator may be located at a central location (e.g., above or below a centrally located camera), and the nffov near IR illuminator may be disposed at or above (or below) the wFOV near IR illuminator. As shown in fig. 113B, one of the nffov near IR illuminators (e.g., LHD nffov near IR illuminator for illuminating the driver of the LHD vehicle) is disposed at the left side of the center line of the lens portion (to the left of the camera) and the other nffov near IR illuminator (e.g., RHD nffov near IR illuminator for illuminating the driver of the RHD vehicle) is disposed at the right side of the center line of the lens portion (to the right of the camera). Alternatively, it is contemplated that the LHD nffov near IR illuminator may be disposed to the right of the center line of the lens portion and the RHD nffov near IR illuminator may be disposed at the left of the center line of the lens portion. It is also contemplated to arrange the LHD nffov near IR illuminator and the RHD nffov near IR illuminator vertically on the centerline of the lens portion, one above the other.
Alternatively, the wFOV near IR illuminator may be centrally disposed (e.g., above or below a centrally disposed camera), and both nffov near IR illuminators may be disposed at one side or the other of the lens portion. For example, and as shown in fig. 113C, the wFOV near IR illuminator is located at a central location (e.g., above or below a centrally-located camera), and the LHD and RHD nffov near IR illuminators are disposed at the right side of the lens portion, with the LHD nffov near IR illuminator disposed closer to the center of the lens portion than the RHD nffov near IR illuminator. Alternatively, and as shown in fig. 113D, the wFOV near IR illuminator is centrally disposed (e.g., above or below a centrally disposed camera), and the LHD and RHD nffov near IR illuminators are disposed at the left side of the lens portion, with the RHD nffov near IR illuminator disposed closer to the center of the lens portion than the LHD nffov near IR illuminator. Alternatively, the wFOV near IR illuminator and/or the nffov near IR illuminator may be disposed at a lower region of the lens portion (see fig. 113C and 113D), or may be disposed at an upper region of the lens portion (see fig. 113E). Thus, and as shown in fig. 113E, one or both of the nffov near IR illuminators may be located at a higher position of the upper region of the lens portion, and/or the wFOV near IR illuminator may be located at a higher position of the upper region of the lens portion.
In a vehicle (whether LHD or RHD), the driver grasps the lens portion to adjust the viewing angle of the interior specular reflective element so that the driver sees out of the rear window of the equipped vehicle. The camera moves in conjunction with the driver moving the lens section. In so doing, the driver moves the lens section into a position/orientation where the driver's head can be seen by the driver's monitoring camera within the lens section.
FIG. 91 illustrates the back side of an exemplary EC cell for a cassette electrochromic interior DMS mirror assembly. Fig. 91A-91C illustrate how the exemplary EC cell shown in fig. 91 is oriented when a cassette electrochromic interior DMS mirror assembly is attached at the windshield of a equipped vehicle. An automobile produced by an OEM automobile manufacturer (e.g., GM, BMW, ford, toyota, honda, etc.) may be used in left-hand driving countries (e.g., united states, france, china, and germany) and in right-hand driving countries (e.g., united kingdom, irish, india, and japan). Taking BMW X5 SUV as an example, BMW X5 SUV is assembled at the BMW Assembly plant of SPARTABao located in south Carolina, U.S.A. A cassette electrochromic interior DMS mirror assembly according to the present invention can be mounted on the windshields of all X5 SUV vehicles assembled by bma in south carolina, usa, whether any of the provided X5 SUVs assembled in the usa are used in the united states (LHD country), or exported to and used in the united kingdom (RHD country).
The measure of enhancing the shielding (which enhances the shielding of the camera and near IR illuminator disposed in the lens section and behind the specular reflecting element) includes a measure as shown in fig. 92, in which the outermost surface of the lens of the driver monitor camera is spaced apart from the bare glass surface (where the camera is viewed through the EC unit) of the back surface of the rear glass substrate of the EC unit (i.e., there is a size of air gap). The size of the space is preferably at least 0.5mm, more preferably at least 1mm, and most preferably at least 2mm, but preferably not more than 4mm. Also, such a sized spacing of glare sensors or near IR illumination devices (as shown in figure AJ) may be used to enhance shadowing. Fig. 93 shows the double sided tape spacing (with release film still attached).
Such measures to enhance the shielding include: minimizing the size of the reflector used with the nffov near IR LEDs, removing (or darkly coating) any light reflecting surfaces (where possible), and positioning these components within the lens portion at a position away from the lateral edges of the mirror assembly to be as far as possible from the side windows of the vehicle through which sunlight may enter the cabin of the vehicle. Further, as shown in fig. 84A-84C, the IR filter box may be configured/constructed with a degree of FOV blocking (preferably a lesser degree) with minimized horizontal gaps.
Such means of enhancing the shielding include the use of small, reflection-free glare sensors such as the high-speed, high-precision, digital ambient light sensor of the TIOPT4001 commercially available from texas instruments (Texas Instruments Incorporated of Dallas) of dallas, texas. The TIOPT4001 has accurate optical filtering properties at high speed, high accuracy, and digital ambient light sensors to closely match the human eye with excellent near Infrared (IR) rejection capabilities.
Such means/elements/devices to enhance the shielding include the use of a coating or the like within the chamber of the lens portion (and for and/or on the hardware/structure housed by the lens portion) that absorbs light that may enter the lens portion. Thus, a dark coating or surface treatment, light capturing element or surface, flocked surface (involving the application of short monofilament fibers (typically nylon, rayon or polyester fibers) directly to a substrate that has been previously coated with adhesive), and the like may be used within the cavity of the lens portion to absorb/capture extraneous ambient light that enters the lens portion and adversely affects the shielding.
Such measures to enhance the shielding include: an opaque thin film coating of metallic chromium (preferably having a coating physical thickness of at least 50 nm) is applied to a fourth surface of the rear substrate of the EC cell to form a fourth surface specular metal mirror, such coating having a first reflectivity of about 60% r to about 68% r according to SAE J964a (if sputter deposited by a sputter vacuum deposition process). Such fourth surface chromium (or other metallic mirror reflector coating, such as titanium or Hastelloy (Hastelloy) or Ruthenium (Ruthenium) or thin Ru/thick Cr bilayer) enhances/enhances the total visible light reflectivity of the EC cell at those areas of the EC cell mirror reflective element that are outside the areas where the light transmission window is formed (preferably by laser ablating/etching a metallic thin film mirror reflector on the fourth surface). In the case where the fourth surface metal reflector has been ablated using laser ablation to form a light transmissive window, the metal coating may be only partially ablated to form a localized partially light reflective/light transmissive region through which the DMS camera views or through which the near IR LED illuminates. Alternatively, a metal specular reflector may be deposited on the fourth surface of the rear substrate, and a gradient mask may be employed to reduce having abrupt/sharp transitions from high light reflection to high light transmission at the localized window regions.
Such means for enhancing the shielding include the use of 3M TM Light control films or 3M light redirecting films (available from 3M company of santalo, minnesota) were used, 3M micro louver films controlling the distribution of light perpendicular to their louver structure (viewing angle). ALCF-A and LCF are louver films with low birefringence polycarbonate substrates. ALCF-A has Sub>A viewing angle of 60 degrees. ALCF-A+ is Sub>A louver film that incorporates Sub>A reflective polarizer (DBEF). 3M ALCF-P is a louvered film with a 60 degree viewing angle and has a matte hard coat layer alternative.
In addition to monitoring alertness, DMS cameras can also be used for video conferences in vehicles and for, for example, driver self-photographing. In case e.g. a video conference is required, preferably a high resolution camera is used (preferably a color camera using a CMOS imaging array with at least one million light sensitive elements arranged in rows and columns). For example, a DMS camera preferably uses at least 2.3 megapixels of cameras; more preferably, a camera of at least 5.0 megapixels is used; and most preferably at least 5.5 megapixels of cameras are used, in particular for detecting details/features/biological features of the eyes of the driver being monitored.
FIG. 94 shows spectral characteristics of the DMS EC unit over the visible and near IR spectral regions in its non-dimmed (faded) state and its fully electrically dimmed (colored) state. Balancing the requirements of the EC power supply so that it (i) has enough% of visible light T to meet the requirements of the DMS and is also suitable for video conferencing; (ii) Having a non-colored spectral reflectance (in its fade state) that appears "silvery" and "normal" to the driver compared to the normal observation of a driver observing an interior electrochromic rearview mirror assembly provided to OEM automotive manufacturers by, for example, migner united states lens company (Magna Mirrors of America, inc.) of hollandan, michigan; (iii) A photopic reflectance of at least 40% r (measured according to SAE J964a, which standard is incorporated herein by reference in its entirety); (iv) Near IR is highly transmissive, and especially at the peak emission wavelength of the near IR illumination used (e.g., 940 nm); and (v) providing concealment to a driver seated in the driver's seat, i.e., the lens portion houses the camera, near IR illuminator, DMS processor, associated mechanical hardware (e.g., PCB), a typical EC cell suitable for use in a cassette electrochromic interior DMS mirror assembly having:
In the faded state of the EC unit, the visible light transmittance in the 380-750nm region is in the range of 20% T-30% T (for shielding, preferably in the range of about 22% T to about 25% T);
in the fully darkened state of the EC cell, the visible light transmission in the 380-750nm region is in the range 10% T-20% T (to balance other factors, preferably about 16% T);
visible light reflectance (measured according to SAE J946 a) is in the range of 40% r to 65% r (in balance with other factors, preferably in the range of about 43% r to about 55% r);
the near IR transmittance around 940nm is preferably at least 50% t (more preferably at least 60% t, and most preferably at least 70%) in both the fade (full visible reflection) and full darkening (EC coloration) states; and
the colorless, achromatic silvery appearance was observed and judged by the driver looking from the seat equipped with the driver of the vehicle.
Color may be characterized by the CIELAB color space (also known as L x a x b x), which was defined by the international commission on illumination (CIE for short) in 1976. CIELAB represents color with three values: l represents perceived brightness, and a and b represent four distinct colors in human vision: red, green, blue and yellow. The color values used herein are based on CIE standard D65 illuminant and a 10 degree observer, L representing the brightness of the object, a defining the green and red (positive) components, and b defining the blue and yellow (positive) components.
For the multilayer mirror reflector used in the DMS mirrors described herein, the first surface reflectivity (i.e., the reflectivity of the back glass substrate where incident radiation directly impinges the multilayer mirror reflector without being deposited by the multilayer mirror reflector) peaks at about 550nm at the multilayer stack design wavelength. When the design wavelength drops below about 450nm, the color of the reflected light changes to blue (indicated by a decrease in b's value) and changes to yellow/red (indicated by an increase in b's and a's values) for design wavelengths of about 500nm and above. Depending on the requirements of the particular application of the DMS EC element (or DMS prismatic substrate), specific reflectance spectral distributions may be provided by adjusting the optical thickness, refractive index, and/or number of layers in the multi-layer stack that make up the specular transflector stack. For example, by appropriate adjustment of the layer thicknesses for the multilayer transflector, a given reflectivity with a more or less slightly yellow hue or a different reflectivity with a more or less slightly blue or red hue can be obtained.
Conventional interior rearview mirrors for vehicles use a highly reflective metallic thin film coating of silver metal (or e.g., ag/Au or Ag/Pd alloy, e.g., 90% Ag/10% Au) for their mirror reflectors.
Drivers observing and using internal mirrors while driving are accustomed to seeing achromatic/neutral/achromatic specular reflectivity, for example, as observed in CIELAB color space (see fig. 95) and using CIE standard D65 illuminant and 10 degree observer (D65 stands for white light and XYZ tri-base color value is x=94.811; y=100; z= 107.304). For prismatic internal specular reflective elements (as used in prismatic internal rearview mirror assemblies provided by Magna Mirrors of America, inc. Of hollanda, michigan, usa), the metallic silver "color" seen by the driver (in CIELAB color space) is lx=96.28; a= -2.81; and b=2.46 [ using illuminant D65; c=3.58 (chromaticity) ]. For electrochromic interior specular reflective elements (as used in the auto-tuning electrochromic interior rearview mirror assembly provided by Magna Mirrors of America, inc. Of holland, michigan, usa), the metallic silver "color" seen by the driver (in the CIELAB color space) is: l=83.1; a= -4.03; and b=3.58 [ using illuminant D65; c=4.34 (chromaticity), and for electrochromic internal mirror transflector elements the metallic silver "color" seen by the driver (in CIELAB color space) is l=89.39; a= -3.84; and b=4.92 [ using illuminant D65; c=4.96 (chromaticity) ].
Furthermore, when a driver views such an internal specular reflecting element at an angle, color neutrality (as seen/measured by a driver who normally drives a equipped vehicle while sitting on a front seat on the driver side) is maintained by the multi-layer stacked thin films for the specular reflector. The HL stack coating of the specular reflector constituting the specular reflecting element is designed/selected such that the absolute value of a is less than 5 at normal incidence and the absolute value of b is also less than 5 at normal incidence.
The multi-layer stacked films of the mirror transflector for the mirror reflective element of a cassette DMS interior rearview mirror of the present invention maintain/preserve the achromatic/neutral/uncolored reflection desired and customary for the driver to see while driving, and the mirror transflector element of a cassette DMS interior rearview mirror has neutral reflection colors of |a|, |b| <12 for viewing angles up to at least 45 degrees. If any color shift occurs in the viewing angle, the multi-layer stacked films for the specular reflector may minimize such shift.
Given two colors in the CIELAB color space: (L) 1 *,a 1 *,b 1 * ) Sum (L) 2 *,a 2 *,b 2 * ) The color difference formula is:
c (chromaticity, relative saturation) of a color with CIELAB color space coordinates (L, a, b) is:
/>
The hue h° (hue angle, hue angle in the CIELAB color wheel) of the color with the CIELAB color space coordinates (L, a, b) is:
h°＝atan(b * /a * )
the multi-layer stacked films of the mirror transflector for the mirror reflective element of the one-box DMS internal rearview mirror of the present invention preferably retain/retain any chromatic aberration (at any viewing angle up to 45 degrees by the driver) preferably between 2.3 and 3.2; more preferably between 2.3 and 2.8; and most preferably between 2.3 and 2.5.
The three primary color system is standardizedUnder the condition, one color is visually matched with three primary colors of red, green and blue; the three results are denoted X, Y and Z, respectively, and are referred to as tristimulus values, and can be graphically represented on a standard chromaticity diagram. The chromaticity diagram is obtained from the International Commission on illumination (CIE, commission Internationaled') In 1931, it was formulated based on X, Y and Z values, where x=x/(x+y+z), y=y/(x+y+z) and z=z/(x+y+z). Since x+y+z=1, if two values are known, the third value can always be calculated and therefore the z value is usually omitted. The Y value under the three primary color system represents the mirror reflectivity experienced/seen by a driver (during the day) driving a vehicle equipped with a box electrochromic interior DMS mirror assembly having the EC element in its non-darkened/discolored state or a box prismatic interior DMS when viewing and using the interior mirror. The mirror reflective element of a cassette interior DMS rearview mirror assembly preferably has a Y value (using CIE standard illuminant D65 and normal incidence) of at least 41; more preferably at least 50 and most preferably at least 55. Y as used herein represents the overall visible light reflectance of the DMS EC element or DMS prismatic reflective element.
Fig. 96 shows four example EC cells in which the stack of multi-layer oxide coatings forming the mirror transflector is tuned such that the visible light transmission through the EC cells is about 45% t, about 30% t, about 21% t, and about 14% t. As can be seen from fig. 97, the overall system output of the camera combined with the 45% t EC unit, as viewed through the 45% t visible lens filter, was 20.25%. As shown in fig. 98, the overall system output of the camera combined with 30% t EC units as viewed through the 80% t visible lens filter was 24%. As shown in fig. 99, the overall system output of the camera combined with the 21% t EC unit, as viewed through the 90% t visible lens filter, was 18.9%. As can be seen from graph 100, the overall system output of the camera combined with the 14% t EC unit, as viewed through the 90% t visible lens filter, is 12.6%. The lower the% transmission of visible light T through the EC cell, the higher the visible light reflectance of the EC cell. The balance of system visible light transmission through the EC unit is required to use a color DMS camera in the lens section (which is viewed through the mirror transilluminator of the EC unit) from about 18% t to about 28% t (about 20% t to about 25% t more preferably, and most preferably about 22% to about 24%) while allowing the DMS/OMS to provide the desired illumination intensity for near IR illuminated drivers and other members, while accommodating a variety of cassette DMS hardware hidden in the lens section while providing the driver with uncolored, "silvery" mirror reflective elements that allow them to view with sufficiently high reflectivity during day or night driving.
FIG. 101A shows a box type of Infinity TM Prismatic internal DMS mirror assembly and fig. 101B shows a cassette EVO TM Prismatic internal DMS mirror assemblies. FIG. 102 illustrates a box type of Infinity TM Construction of prismatic internal DMS mirror assemblies.
Thus, a cassette interior DMS mirror assembly provides a cassette DMS solution with electrical/electronic/mechanical/mirror components (camera, near IR illuminator, vision processing ECU and mirror reflective element) integrated into the interior rearview mirror assembly of the vehicle. For an automatically dimming interior mirror, electronics and a photosensor (under conditions of glare during night driving) for adjusting the reflectivity of the interior mirror reflective element (as well as any electrically dimming exterior mirror element present on the equipped vehicle) are housed within the lens portion. The camera, near IR light source (e.g., near IR LED) and ECU are preferably disposed in the lens portion behind the specular reflective element. Cameras use RGB/IR CMOS image sensors to support DMS/OMS, self-timer, and video streaming features. The supported features include driver monitoring, video streaming, facial recognition, internal monitoring, self-timer, presence detection, child seat detection, child presence detection. Preferably including a 100Mbps ethernet interface for video transmission.
Alternatively, a cassette internal DMS rearview mirror assembly may include a security architecture as shown in fig. 106. The ECU's processor may communicate with the vehicle system through CAN full duplex communication (module level security 1) and through ethernet (module level security 2). Alternatively, such communication may be via coaxial cable or other communication means. The camera serial interface is a specification of the mobile industry processor interface alliance (Mobile Industry Processor Interface Alliance). It defines the interface between the camera and the host processor. The CSI-2 protocol includes transport and application layers and the native supports C-PHY, D-PHY or C/D-PHY combinations. MIPI C-PHY provides high throughput, minimized interconnect signal count, and excellent energy efficiency to connect displays and cameras to application processors. This is due to the efficient three-phase encoding that is unique to the C-PHY. D-PHY is a serial interface technology that uses differential signals to provide an extensible data channel and source synchronous clock for bandwidth limited channels to support energy efficient interfaces for streaming media applications such as displays and cameras. It provides half duplex functionality for applications that benefit from bi-directional communications at transmission rates up to 2.5 gigabits per channel. The C-PHY requires fewer conductors, does not require separate clock lanes, and provides flexibility in assigning individual lanes in any combination to any port on the application processor through software control. Because of the similar basic electrical specifications, the C-PHY and D-PHY may be implemented on the same device pin. Three-phase symbol encoding techniques provide about 2.28 bits per symbol over three-wire conductor sets of each line. This enables higher data transfer rates at lower switching frequencies, further reducing power consumption.
As shown in fig. 32B-32E, the mirror assembly can include an IR light emitter (fig. 32B and 32E) located behind the mirror reflective element and/or a camera (fig. 32C-32E) located behind the mirror reflective element. By positioning the camera and the IR light emitter behind the specular reflective element, the camera is hidden or hidden from view by the driver or passenger of the vehicle and there is no need to enlarge the lower area or chin area of the lens portion to provide space for the camera and/or light emitter. The camera may be tilted or offset to provide an optimal driver or passenger viewing angle. Fig. 33 and 34 show an embodiment where the camera and IR light emitters are disposed below the specular reflective element (fig. 33), which shows the transmission characteristics of a lens or cover, or an embodiment where the lens or cover is disposed behind and viewed/emitted through the specular reflective element (fig. 34), which shows the transmission characteristics of a transflector or a transflector.
As shown in fig. 35 and 36, the lens portion may include a driver monitoring camera and a near IR emitter or flood light element disposed behind the specular reflective element. Alternatively, the specular reflective element may comprise a backlit Thin Film Transistor (TFT) video display screen or element disposed behind and viewable through the specular reflective element. The mirror assembly of fig. 35 and 36 has a transflector or a transflector disposed at a third surface of the rear glass substrate, the third surface being opposite and in contact with an electrochromic medium that also contacts the transparent electrical conductor or conductive coating at the second surface of the front glass substrate. The transflector may have apertures or windows created therethrough (e.g., by laser ablation), with the DMS camera and near IR flood illumination devices disposed behind and viewing/emitting through the respective windows. The near IR transmissive/visible reflective layer is disposed at the fourth surface of the rear glass substrate, at least at the location where the near IR flood illumination device is disposed, and optionally at the location where the DMS camera is disposed.
The window or opening formed through the specular reflector may include an area without the specular reflector coating, or may include a plurality of stripe-shaped or dot-shaped specular reflector coatings at areas where the camera and near-IR flood lighting devices are disposed. For example, and as in U.S. patent No.8,743,203; as described in nos. 8,727,547 and 7,636,188, which are incorporated herein by reference in their entirety, the partial removal (e.g., by laser etching or ablation) of a metal highly specular reflective layer or coating (e.g., a silver alloy reflective layer) allows light incident (in the absence/complete removal of the metal layer) in front of the internal specular reflective element (EC or prism) to reach the imager disposed behind the reflective element and behind the specular reflector unimpeded by the metal layer and not absorbed by it. Also, near IR radiation emitted by one or more sets of near IR light emitting diodes (disposed behind and emitting light through the specular reflective element) is not hindered and absorbed by the metal layer. However, the elements of the metal mirror layer are prison rail-like fringes that remain where the mirror reflective coating is laser ablated, making the presence of the camera and IR flood lighting device behind the mirror reflective element partially hidden/less noticeable to the driver or occupants in the vehicle. The extent of the transmittance of a localized area by laser ablation is proportional to the ratio of ablated metal mirror coating material to the localized area (where the remaining metal mirror coating material and ablated area are located).
Instead of using a silver or silver alloy based reflector coating, a series of stacks of visible light reflection and IR transmission can alternatively be used with a specular reflector (e.g., by utilizing aspects of the specular reflective element described in U.S. patent No.7,274,501, which is incorporated herein by reference in its entirety). Alternatively, the specular reflective element may have a glass substrate coated with a silver-based transflector, with one or more windows laser etched at the third surface reflector, and at the fourth surface, the sheet glass formed therein has a special IR transmissive coating (of the type described in U.S. Pat. No.7,274,501, incorporated herein above).
As shown in fig. 37 and 38, the mirror assembly has a transflector disposed at a fourth surface of the rear glass substrate, wherein the third surface of the rear glass substrate has transparent electrical conductors that oppose and contact an electrochromic medium that also contacts the transparent electrical conductors or conductive coatings at a second surface of the front glass substrate. The fourth surface transflector may have openings or windows formed therethrough (e.g., by laser ablation), wherein the DMS camera and the near IR flood illumination device are disposed behind and view/emit through the respective windows. The near IR transmissive/visible reflective layer is disposed at the fourth surface of the rear glass substrate, at least at the location where the near IR flood illumination device is disposed, and optionally also at the location where the DMS camera is disposed.
Alternatively, and as shown in fig. 39 and 40, the fourth surface may have a near IR transmissive/visible reflective layer that provides a specular reflector over the entire fourth surface of the rear glass substrate, with the DMS camera and near IR flood illumination device disposed behind and viewed/emitted through the near IR transmissive/visible reflective layer.
Thus, the rear glass substrate of the specular reflective element of fig. 39 and 40 is coated with a transparent electrical conductor on one side (third surface) and a near IR transmissive, visible reflective/transmissive coating on the other side (fourth surface). Referring to fig. 41 and 42, a plurality of rear glass substrates may be cut (e.g., by laser cutting) or formed from a larger glass sheet, and each glass substrate is coated on both sides. As shown in fig. 42, the formed glass substrate is placed on a conveyor and coated on one side (the final third surface of the specular reflective element) with a transparent electrical conductor (such as an ITO layer or coating) and then flipped over so that on the other side (the final fourth surface of the specular reflective element) multiple layers can be applied to create a near IR transmissive, visible reflective, transflector coating at the fourth surface (e.g., by utilizing aspects of the specular reflective element and coating process described in U.S. patent No.7,274,501, which is incorporated herein by reference in its entirety).
Optionally, the formed glass substrate is placed on a conveyor and coated on only one side (the final third surface of the electrochromic mirror reflective element) to provide a third surface transflective reflector mirror element. For example, and as shown in fig. 43, the formed glass substrate is placed on a conveyor and a plurality of layers are coated on only one side (the final third surface of the specular reflective element) to create a near IR transmissive, visible reflective transflector coating at the third surface (e.g., by utilizing aspects of the specular reflective element and coating process described in U.S. patent No.7,274,501, incorporated herein by reference). The coated substrate may then be further coated with a transparent electrical conductor (e.g., an ITO layer or coating) that is in contact with the electrochromic medium of the specular reflective element.
The glass substrate may comprise a glass substrate for a prismatic mirror reflective element (typically formed by grinding/polishing a glass substrate of 6mm or the like thickness to have a prismatic/wedge-shaped cross-section) or may comprise a flat/planar rear glass substrate for an internal electrochromic mirror reflective element (wherein a layer of visible light reflective, near IR light transmissive coating may be provided or coated at the third or fourth surface depending on the particular application). For example, and in accordance with U.S. Pat. No.7,274,501, incorporated above, the fourth surface stack of layers may comprise alternating layers of a low index material (e.g., silicon oxide or silicon dioxide) and a high index material (e.g., titanium dioxide or the like). The number of alternating layers and the respective thicknesses of the layers are selected to spectrally tune the stack of layers to provide a desired transmittance of light or radiation having a particular spectral band (e.g., near-IR light) while reflecting light within another spectral band (e.g., visible light).
The manufacturing or coating process includes providing a glass sheet, cutting a mirror shape or glass substrate from the sheet, and coating the surface of the glass substrate with, for example, half-wave ITO (which preferably has a sheet resistance of less than 20 ohms/square, e.g., about 10-15 ohms/square) or full-wave ITO (which has a sheet resistance of less than 10 ohms/square, e.g., about 8 ohms/square). The coated glass substrate was placed in a sputter deposition chamber with the coated side facing up for further coating of the alternating layers.
The reactive sputtering vacuum deposition chamber may have two chamber segments or isolation zones, each with a corresponding set of cathodes (planar magnetron or rotary magnetron sputtering deposition cathodes as known in the vacuum art). For example, and as shown in fig. 44, one set of cathodes/targets (see "a" in fig. 44) may be disposed in one chamber section and another set of cathodes/targets (see "B" in fig. 44) may be disposed in another chamber section adjacent to and aligned with the first chamber section, with a wall or barrier or shield between the two chambers having an aperture through which a conveyor transporting the substrate passes such that the conveyor extends through the two chamber sections, and which wall or barrier or shield may reduce cross-deposition from one chamber section to the other adjacent chamber section.
The glass substrate (or alternatively, a large planar/flat glass sheet, if coated with a stack of multilayer transflectors) is placed on a carriage or on a conveyor or on a tray and moved to the first chamber section before cutting the individual mirror-shaped substrates from the large glass sheet that has been coated with the transflector at the time. In the process shown in fig. 44, the glass substrate is first coated on one side with a transparent conductive coating or layer (e.g., ITO) and then flipped over with the uncoated side of the glass substrate facing up. The substrate is then transferred to an a-chamber or coating station where the a-target is activated and then transferred to a B-chamber where the B-target is opened such that the upwardly facing side of the substrate is coated with a layer or coating. The a-target in the first chamber or coating location may comprise, for example, a titanium target, and the target in the second chamber may comprise, for example, a silicon target. When the glass substrate is positioned at the first coating location (below the a-target), the a-group/target is energized or actuated to coat the upward or exposed surface of the glass substrate (by oxygen reactive sputter deposition) with titania. Once the desired thickness of the titanium dioxide layer is sputter coated onto the glass substrate, the target may be deactivated and/or the conveyor moves the substrate to a second position to coat the next layer.
The second chamber may be spaced apart or separated from the first chamber (e.g., by a barrier or shield). The carrier or tray on which the substrate is placed is moved under the barrier between the coating positions. When the glass substrate is positioned in the second position, the group B/target is energized or activated to coat the upward or exposed surface of the glass substrate (which has been coated with the a material) with a second material, such as silicon dioxide (deposited by oxygen reactive sputtering). Once the desired thickness of the silica layer has been sputter coated onto the glass substrate, the target and/or the conveyor movable glass substrate can be deactivated.
The conveyor may then move the substrate from the B target/position back to the a target/position to coat the next layer of titanium oxide. The conveyor thus reverses direction and moves the glass substrate back to group a/target, and then begins sputter deposition or coating of a third layer (e.g., a second layer of titanium dioxide) onto the glass substrate. After the desired thickness of the third layer is established, the group a/target is stopped and the conveyor is again reversed (back to the "forward direction") to move the glass substrate back into the second chamber and the group/target in the second chamber is activated to sputter deposit or coat the fourth layer (e.g., the second layer of silicon dioxide) onto the glass substrate.
The process of activating/deactivating the group/target and shuttling or moving the conveyor back and forth is repeated until a desired or selected number of alternating layers (at a desired or selected respective thickness) are coated on the glass substrate to provide a desired or selected spectrally modulated alternating layer. Thus, the alternating layers are provided by a single chamber and conveyor with a barrier/shield between the regions of the chamber through which the pallet/conveyor supporting the coated glass substrate(s) passes. Alternatively, by activating and deactivating a DC magnetron target (which may be a planar magnetron target or may be a rotating magnetron target; the rotating target is adapted for reactive DC sputtering from a silicon target in an oxygen-enriched vacuum chamber to deposit silicon dioxide), the vacuum chamber may not require a barrier, and the computer control of the system may instead position the substrate under the appropriate group or target and activate only the group/target for depositing the layer. The alternating layers may be coated on the surface of the back glass substrate that ultimately becomes the third surface of the EC mirror reflective element or on the surface of the back glass substrate that ultimately becomes the fourth surface of the EC mirror reflective element.
In the embodiment shown in fig. 44, the glass substrate is first coated with ITO on one side (the side that ultimately becomes the third surface of the reflective element) and then flipped over so that on the other side (i.e., the side that ultimately becomes the fourth surface of the reflective element) is coated with alternating layers that form a visible light reflective, near IR light transmissive coating.
Alternatively, and as shown in FIG. 45, a glass substrate may be loaded into a vacuum chamber and coated with TiO on one side (eventually the side of the third surface of the reflective element) 2 、SiO 2 、TiO 2 、SiO 2 And alternating layers (e.g., back and forth between group a/target/position and group B/target/position by a conveyor and glass substrate). After the desired alternating layer stack is completed, the coated glass substrate is moved to a third (C) set/target for coating the coating stack with a transparent conductive layer (e.g., ITO or the like).
Alternatively, the transfer device may shuttle back and forth between targets/locations, with a transfer line and a sputter chamber/system including a transfer line with two load locks. The glass substrate(s) may be loaded at one end at a load lock, coated with ITO, and then coated with A, B material (by shuttling back and forth between the a and B targets, then removed by another load lock at the opposite end of the conveyor). Alternatively, the ITO coating may be applied as a final coating, depending on the particular application of the coated glass substrate. Furthermore, the ITO is preferably coated on a substrate heated to at least 200 degrees celsius; more preferably on a substrate heated to at least 275 degrees celsius; and most preferably is coated on a substrate heated to at least 350 degrees celsius.
Alternatively, the cathode may be turned on or off as the substrate moves into or out of these positions. The target may comprise a rotating sputter target and rotates during use. In the illustrated process, the targets include metallic titanium and silicon targets that can provide reactive sputter deposition in an oxygen-rich environment to deposit TiO 2 And SiO 2 Deposited onto a glass substrate. Alternatively, the glass substrate may be heated (e.g., to a temperature greater than 150 degrees celsius, or greater than 250 degrees celsius, or greater than 350 degrees celsius) during reactive sputter deposition of the coating in the alternating layers (in an oxygen-enriched vacuum chamber environment).
The control of the sputtering process may cause the alternating layers to have different thicknesses. The different thicknesses are achieved by either or both of the foregoing by adjusting the speed of the conveyor as it moves the glass substrate beneath the respective target, and/or by increasing/decreasing the electrical power to the DC magnetron sputtering target to increase/decrease the sputtering/deposition rate of the respective target. The process may include selecting specific metal and dielectric materials for sputtering (and determining the appropriate or desired thickness for each layer), and then selecting the conveyor speed and/or sputtering device power to achieve the desired or selected or determined thickness for each layer in the layer stack. The system may provide alternating layers by a conveyor and a sputtering system, wherein a plurality of alternating targets (with barriers between adjacent targets) are along the conveyor such that the conveyor may move the substrate through a plurality of coating locations. Alternatively, the conveyor may be operated at a constant speed (a plurality of glass substrates are placed on the conveyor and sequentially moved through a plurality of coating locations), and each sputter target may be operated at a selected power level to provide a selected or determined degree of sputter/deposition rate for the respective target to provide a desired or determined specific layer thickness at the glass substrate.
Thus, the coating process can be performed on a glass substrateOne side or surface of the substrate (or multiple glass substrates or glass sheets that have not been cut into individual mirror glass shapes or substrates) is alternately coated with multiple layers (e.g., tiO 2 And SiO 2 Is a layer of alternating layers). Fig. 46 shows an example of such a stack of layers (with ITO layers), and also shows the transmittance versus wavelength for a coated glass substrate. The computer control of the vacuum deposition chamber can selectively control the individual DC magnetron sputtering targets and control the speed and direction of travel of the pallet/conveyor to coat alternating prescribed multi-layer stacks of high RI (e.g., titania or niobia)/low IR (e.g., silica) on the inner mirror-shaped glass substrate layer by layer, which is covered with the last layer of ITO for the third surface transflector of the dual substrate stacked EC specular reflective element.
Fig. 47 and 48 illustrate electrochromic mirror reflective elements whose third surface transflector or transflector comprises a stack of layers as illustrated in fig. 46. The near IR flood irradiation device and the driver monitoring camera are arranged behind the specular reflecting element.
Fig. 49 and 50 illustrate another electrochromic specular reflective element whose third surface transflector or transflector comprises a stack of layers as shown in fig. 46. The specular reflective element includes a broadband (including near IR at 940 nm) anti-reflective layer/stack at the first surface (front or outer surface of the front glass substrate) and/or at the fourth surface (rear surface of the rear glass substrate). Such anti-reflective coatings reflect visible and near IR light. The anti-reflective coating may be provided or established at the rear surface (fourth surface) and/or the front surface (first surface) of the specularly reflective element. The near IR flood irradiation device and the driver monitoring camera are disposed behind the specular reflecting element. In the embodiment shown in fig. 49 and 50, the glass substrate includes a schottky Ultrawhite glass (see fig. 51) can provide uniform transmittance of light in a wavelength range from ultraviolet rays to near IR, as described below.
Referring now to fig. 52, an internal dual substrate stacked electrochromic mirror transflector element includes a metallic conductive reflective perimeter hiding layer on an ITO coating at a second surface of a front glass substrate, and a circumferential metallic highly conductive channel on the ITO coating on top of an alternating stack of layers at a third surface of a rear glass substrate. Such metallic conductive channels at the second surface ITO coating may reduce the thickness of the ITO coating. To increase the overall near IR transmission through the EC mirror reflective element, the ITO layer deposited at the second glass surface of the front substrate may have a sheet resistance of greater than 20 ohms/square, such as greater than 25 ohms/square, or greater than 30 ohms/square, and preferably less than 70 ohms/square, more preferably less than 50 ohms/square, and more preferably less than 35 ohms/square. By having the sheet resistance of the metallic conductive reflective peripheral hiding layer be less than 5 ohms/square (preferably less than 3 ohms/square, and more preferably less than 1 ohm/square) and simultaneously reducing the physical thickness of the ITO layer, a simultaneous increase in near IR transmittance can be achieved. Selecting a metallic material (e.g., silver or silver alloy as compared to chromium) and/or increasing the physical coating thickness (e.g., 150nm as compared to 15 nm) and/or the width of the hidden layer (e.g., 12mm as compared to 8 mm) may make the peripheral hidden layer more conductive and thereby facilitate the use of a thinner second surface ITO layer.
Also, the circumferential metallic highly conductive channels at the coated rear glass substrate may provide similar advantages. As can be seen in fig. 52, the rear perimeter band is circumferentially disposed on the deposited TiO 2 And SiO 2 At the ITO layers on the alternating stack of layers, and allows the thickness of the ITO layers to be reduced while still achieving the desired dimming performance.
For in-car flood lighting devices (e.g., illuminating the head and/or eyes of a driver with a near IR illumination device, such as for driver monitoring in SAE grade 3 Advanced Driving Assistance Systems (ADAS)), the interior rearview mirror assembly provides a large number of areas to place a plurality of (e.g., at least two, preferably at least six, and more preferably at least ten) near IR LEDs that emit near IR radiation through the specular reflective element. The principal axes of the near IR radiation emitted by such plurality of near IR LEDs may be angled with respect to each other so as to preferentially direct the emitted near IR radiation to a location where the head of the driver of the interior cabin may be found, wherein the lens portion of the interior rearview mirror assembly has been adjusted by the driver of the vehicle so that the driver may view rearward through the rear window of the vehicle. The use of such a large number of near IR LEDs, preferably at different angles, has the advantage that local hot spots behind the reflective element can be avoided when the near IR LEDs are maximally powered.
As shown in fig. 53-55, the interior rearview mirror assembly may have a visible/near IR driver monitoring camera disposed behind (and viewed through) the electrochromic mirror reflective element, with some (or all) of the near IR LEDs disposed at the lens portion and not emitting light through the mirror reflective element. The lens portion may include a lens housing in which is received a lens reflective element, such as EVO for example TM Mirror assemblies (as described in U.S. Pat. Nos. 8,277,059; 8,049,640 and/or 7,289,037, incorporated herein by reference in their entireties) and/or INFINITY TM Mirror assemblies (as in U.S. Pat. Nos. 9,827,913; 9,174,578; 8,508,831; 8,730,553; 9,598,016 and/or 9,346,403, which are incorporated herein by reference in their entirety).
Currently, at least three configurations of EC interior rearview mirror assemblies are commercially available and are used in global vehicles. One type of mirror structure is an EC interior rearview mirror assembly of the basic/additional feature, another type of mirror structure is a video mirror utilizing a video display screen of about 3.5 inches disposed behind and positioned toward/at the passenger side (when the interior rearview mirror assembly is used in a vehicle), and a third type of mirror structure is a full display mirror, such as FDM commercially available from genetex corporation TM Mirror assembly and CLEARVIEW commercially available from migna united states mirror corporation (Magna Mirrors of America, inc.) TM The mirror assembly may be operated in two modes (e.g., by utilizing aspects of the description in U.S. Pat. Nos. 11,214,199; 10,442,360; 10,421,404; 10,166,924 and/or 10,046,706 and/or U.S. publication Nos. US-2021-0162926; US-2021-0155167; US-2019-0258131; US-2019-0146297; US-2019-01188717 and/or US-2017-0355312, which are incorporated herein by reference in their entirety).
In the EC mirror structure of the base/add-on and video mirrors, only a portion of the mirror reflective element may be transflective (partially light transmissive and partially light reflective). In any of the three mirror configurations or types described above, it is desirable to mount the camera and near IR LEDs (for DMS and for other internal purposes) behind the EC mirror reflective element from the standpoint of driver/consumer appreciation, as the presence of such hardware is largely hidden from the driver. However, alternatively, part or all of the near IR LEDs may be positioned (as shown in FIGS. 53-55) at a lower basket portion of the mirror housing or at an upper brow portion of the mirror housing or at left and/or right side portions of the mirror housing, such that near IR radiation emitted by the near IR LEDs so positioned does not pass through and be attenuated by the interior rearview mirror reflective element. Since the size/diameter of these near IR LEDs is significantly smaller than that of cameras used in driver monitoring systems, hiding the camera behind the reflective element, but at least some or all of the near IR LEDs in the mirror assembly are not hidden, can be an economically attractive option between DMS performance and styling/consumer appreciation.
Prismatic and electrochromic interior mirrors commercially produced by, for example, gentex Corporation (Zeeland, michigan, usa) and Magna Mirrors of America, inc. (Holland, michigan, usa) use soda lime glass substrates having an iron oxide (iron) content of approximately 0.1%. While this use works well in most automotive rearview applications, it is preferred that the specular reflective element use a low iron (also known as low Fe) glass substrate in which the iron oxide level is as low as only 0.01% or even lower. Ultra-clear low-iron glass (iron content only 10% of ordinary soda-lime glass) is a "water-white" glass with a visible light transmission as good as at least 8% better than conventional soda-lime glass. Reducing the iron content also reduces absorption in the near IR region (e.g., at or near 940 nm), so the use of such low iron glasses for the front and rear substrates in a dual-substrate laminated EC mirror structure allows one or more sets of near IR LEDs behind the glass to emit more near IR light from the LEDs through the EC mirror reflective element in the EC interior mirror assembly mounted at the inboard side of the windshield of the equipped vehicle to illuminate the EC interior cabin presentSuch as the head/eyes of the driver. Also, the use of such low iron glass for the front and rear substrates in a dual substrate laminated EC mirror structure allows more near IR light reflected from the driver's head/face to pass through the EC mirror reflective elements in the EC inner mirror assembly to be detected by the post-glass cameras of the DMS. Glasses suitable for use as EC mirror reflective elements in EC interior mirror assemblies include crown glasses (crown glass /> ) The glass may be designed to provide consistent light transmittance over a range of wavelengths from ultraviolet to near infrared and is commercially available from SCHOTT North America, inc. of Rye Brook, N.Y. 10573 in the United states (https:// www.schott.com/en-us/products/b-270). The spectral and product properties of schottky B270 glass (schottky B270 glass) are given in fig. 51.
The conventional soda lime glass has a transmittance of about 80% and an absorptivity of about 9%, while the low iron glass has a transmittance of about 90% and an absorptivity of about 2%.
Another Glass having high near IR transmittance is Corning 9754 (https:// www.corning.com/microsite/coc/oem/documents/aerospace-safe-Transmitting-Glass-9754. Pdf), which is a transparent germanate Glass composition having high transmittance in both the visible and near IR regions of the electromagnetic spectrum and commercially available from Corning France of Bagneux-sur-Loing, france.
Another Glass having high near IR transmittance is Guardian available from Guardian Industries' Glass Group of Bertrange of LuxembourgLow iron glass (https:// www.guardianglass.com/eu/en/products/glass-type/lo)w-iron-glass)
In a dual substrate layer pressure type EC mirror structure, both visible light and near IR transmittance through the EC mirror reflective element can be increased by: (i) Coating the rearmost glass surface (i.e., the rear glass surface of the rear glass substrate, known in EC technology as the fourth surface) with a stack of broadband anti-reflective coatings/coatings (as known in optical anti-reflective technology) that reduce the reflectivity of both incident visible light and incident near IR radiation from a typical about 4% r level to about 0.5% (or even lower), and/or (ii) coating the foremost glass surface (i.e., the front glass surface of the front glass substrate, known in EC technology as the first surface) with a stack of broadband anti-reflective coatings/coatings (as known in optical anti-reflective technology) that reduce the reflectivity of both incident visible light and incident near IR radiation from a typical about 4% r level to about 0.5% (or even lower). For example, anti-reflective coatings, stacks of coatings, and techniques/processes disclosed in U.S. patent No.5,076,674 (which is incorporated herein by reference in its entirety) filed by Niall r.lynam as U.S. patent application No.07/491.447 at 3/9 1990 and entitled "Reduced first surface reflectivity electrochromic/electrochemichromic rearview mirror assembly" may be used. Broadband anti-reflective coatings for the visible and infrared ranges are described by F.Lemarquis et al in DOI 10.1117/12.2536066; international Conference on Space Optics-ICSO 2018 (month 7 of 2019) publication "Broadband antireflection coatings for visible and infrared ranges" (https:// www.researchgate.net/publication/334640999_Broadband_antiref lection_coatings_for_visible_and_infrared_ranges), which is incorporated herein by reference in its entirety. AR coatings suitable for mirror assemblies are disclosed in "Multilayer antireflection coatings for the visible and near-infused regions" of appl. Opt.36,6339-6351 (1997), h.ganesha Shanbhogue, C.L.Nagendra, M.N.Annapurna, S.Ajith Kumar, and "Multilayer antireflection coatings for the visible and near-infused regions" of g.k.m. thutuali (https:// www.osapublishing.org/ao/abstract. Cfmturi = ao-36-25-6339), which are incorporated herein by reference in their entirety.
When the EC medium in, for example, a dual-substrate laminated EC mirror structure is darkened/dimmed to reduce glare to the driver due to glare from headlights of other vehicles traveling in the rear, both the visible and near IR transmittance through the dual-substrate laminated EC mirror structure is reduced, typically by 10-20%, depending on the degree of glare caused by the other vehicles traveling in the rear. To compensate for this deficiency, when the EC medium is darkened/dimmed, the gain of the camera located behind the EC medium (and through which the vehicle cabin is viewed) may be correspondingly increased to maintain the overall viewing sensitivity of the camera into the interior cabin of the equipped vehicle. Also, to compensate for darkening/dimming of the EC medium, the electrical power of the near IR LED behind (and emitting light through) the EC medium may be increased to increase the intensity of the near IR light emitted by the near IR LED (typically emitting light at around 940nm or 940 nm) so that a desired level of near IR floodlight/illumination is maintained within the interior compartment of the equipped vehicle even when the EC medium is darkened/dimmed.
In addition, to improve the signal-to-noise ratio of the desired DMS signal detected/resolved by the camera in the presence of background noise (e.g., due to near IR radiation in the environment/cabin from sun insolation or from interior illumination of equipped vehicles or from other road traffic or from street illumination, etc.), the near IR light emitted by the near IR LED may be modulated (amplitude modulated or frequency modulated or phase modulated or a combination thereof) and the signal acquired by the camera may be filtered/demodulated/digitally analyzed to enhance true signal detection and reduce noise. In this regard, phase-locked loop synchronization/detection (also known as phase-locked loop) known in the detection arts may be used. A phase locked loop or Phase Locked Loop (PLL) is a control system that produces an output signal that has a phase that is related to the phase of an input signal. There are several different types; the simplest is an electronic circuit consisting of a variable frequency oscillator and a phase detector in a feedback loop. The oscillator generates a periodic signal and the phase detector compares the phase of the signal with the phase of the input periodic signal, adjusting the oscillator to maintain a phase match. Suitable or applicable PLL circuits and techniques May be disclosed, for example, in "Introduction to phase-locked loop system modeling" in journal of Analog applications (Analog Applications Journal) (SLYT 015-May 2000Analog and Mixed-Signal Products) (https:// www.ti.com/li/an/SLYT 169/slyt169.Pdfts = 1615122679096& ref_url = https%253 a%252f%252fww.google. Com%252 f) by the design manager jan meiers of advanced systems engineers WenLi and Mixed-Signal Products (Mixed-Signal Product Group) of advanced Analog Products (Advanced Analog Product Group), which is incorporated herein by reference in its entirety. For example, the intensity of light emitted by the in-lens near-IR LED may be amplitude and/or frequency and/or phase modulated, and the PLL may be used to lock the signal output by the in-lens camera (which is based on the near-IR light/radiation received by the camera) to distinguish between (i) a desired near-IR component that is co-phased with the emitted modulated near-IR radiation and has its modulation characteristics, and (ii) signal noise (due to the near-IR level in the cabin of the environment and/or other extraneous near-IR sources, such as sun sunlight) that is not in phase with the near-IR component in the output signal of the camera, which is of interest and is representative of near-IR radiation reflected back from, for example, the driver's head or the driver's eye, to the in-lens camera.
Maintaining input and output phase synchronization also means maintaining input and output frequencies the same. Thus, in addition to the synchronization signal, the phase locked loop can track the input frequency or produce a frequency that is a multiple of the input frequency. These characteristics can be used for computer clock synchronization, demodulation, and frequency synthesis.
For example, and as disclosed in U.S. publication No. US-2020-0327123 (which is incorporated herein by reference in its entirety) entitled "SYSTEM AND METHOD FOR IMPROVING SIGNAL TO NOISE RATIO IN OBJECT TRACKING UNDER POOR LIGHT CONDITIONS" filed as PCT/AU2018/050776 (7 months 27 days 2018) per 371, entitled "SYSTEM AND METHOD FOR IMPROVING SIGNAL TO NOISE RATIO IN OBJECT TRACKING UNDER POOR LIGHT CONDITIONS" and published U.S. publication No. 2020-0327123 (which is incorporated herein by reference in its entirety) within the lens portion of an internal rearview mirror assembly, a microprocessor-based circuit controller housed within the lens portion of the internal rearview mirror assembly can process at least a subset of images acquired by a camera disposed behind the mirror reflective element and generate LED control signals to control a plurality of near IR LEDs also positioned within the lens portion (and emitting near IR light therethrough) behind the mirror reflective element to control the drive current amplitude and pulse time thereof to vary the intensity of the near IR radiation emitted by the LEDs. The controller may selectively adjust the drive current amplitude and/or pulse time of the near IR LED based on the determined illumination characteristics of the previous acquired image or images acquired by the in-car viewing camera (viewing through the specular reflective element) located within the lens portion. When the EC medium darkens and/or radiates back near IR reflection on the lens portion away from an object in the cabin (such as the driver's head or eyes) or is diluted by high ambient or other extraneous in-cabin near IR radiation, the controller may then increase the gain of the camera and/or the intensity of the near IR radiation emitted by the LED. Thus, in the event that the signal-to-noise ratio of the image is too low to accurately distinguish/track the driver's eyes and surrounding objects in the image (e.g., when the driver wears colored glasses or sunglasses, or when the vehicle interior insolation is high due to incident solar radiation, such as inside an open canopy, or when a sunroof, particularly a panoramic sunroof, is opened), the near IR radiation flood illumination within the vehicle interior is encoded/marked by frequency/amplitude/phase modulation (and the encoded/marked signal is distinguished from the non-encoded noise using, for example, digital filtering and phase-locking techniques known in the signal processing arts), in combination with the determined illumination characteristics of the previous acquired image or images acquired from the vehicle interior viewing camera, the drive current amplitude and/or pulse time of the near IR LEDs is selectively adjusted, which not only helps to achieve good DMS performance, but also allows and makes the optical multilayer stack design of the transflector of the interior specular reflective element less complex and more economical, and helps to achieve higher visible light reflectivity of the interior specular reflective element.
The outermost layer of the third surface multilayer mirror reflector/transflector is in direct contact with the EC medium and must be electrically conductive in order to dim the EC medium. It must also be transmissive to both visible and near IR radiation to meet the needs of the DMS when viewing/transmitting/receiving radiation through the EC medium at the camera and/or near IR LED (located behind the specular reflective element). The outermost layer of the third surface multilayer mirror reflector/transflector may be a transparent electrically conductive layer, preferably Indium Tin Oxide (ITO). To meet the commercial desire for fast and uniform dimming of the internal EC mirror reflective element, the sheet resistance of the ITO outermost layer of the third surface multilayer mirror reflector/transflector is preferably less than about 30 ohms per square, more preferably less than about 20 ohms per square, and more preferably less than about 15 ohms per square. Since ITO is a near IR absorber (up to around 10% depending on the physical thickness of the ITO coating), it is preferred that the ITO outermost layer of the third surface multilayer mirror reflector/transflector is thin and in optical equilibrium with the alternating high RI/low RI layers of the multilayer stack. Thus, the sheet resistance of the ITO layer is made to be at or even higher than 20 ohms per square, which helps achieve overall higher near IR transmittance through the EC mirror reflective element.
In this regard, a stack of metallic highly conductive channel coatings/coatings (as shown in fig. 52) is used that surrounds the perimeter boundary of the ITO outermost layer of the third surface multilayer mirror reflector/transflector (which is sized so as not to encroach upon the area of the EC reflective element visible to the driver), which may use a thinner (and thus higher sheet resistance) ITO outermost layer of the third surface multilayer mirror reflector/transflector. The circumferential metallic highly conductive channel may be, for example, a chromium metal layer or a silver alloy layer (e.g., 93% ag/7% au alloy), the coating physical thickness being greater than 30nm, more preferably greater than 50nm, and more preferably greater than 100nm, and the width extending inward from the outer edge of the rear glass substrate preferably being about 3mm to 15mm, more preferably about 5mm to 12mm, and more preferably about 7mm to 9mm, and having a sheet resistance preferably less than about 5 ohms/square, more preferably less than about 3 ohms/square, and more preferably less than about 1 ohm/square.
Furthermore, since the ITO transparent electrical conductor itself on the second glass surface at the rear of the front glass substrate is surrounded by a metallic conductive reflective peripheral hiding layer (sheet resistance less than 5 ohms per square), this second surface ITO coating can be made thinner to further enhance near IR transmission through the EC mirror reflective element. The effect on the speed or uniformity of EC dimming is addressed, for example, by adjusting the spacing between the front and back substrates, adjusting the concentration of the EC component of the EC medium, utilizing leakage current inhibitors, and methods as are known in EC technology.
Thus, the mirror assembly includes a near IR light emitter behind the DMS camera and the reflective element and viewed/emitted through the mirror reflective element. During daytime or higher ambient lighting conditions, near IR flood light may not be necessary or desirable because the driver area may be fully illuminated by ambient light in the vehicle. However, in dusk to dawn, such near IR irradiation may be necessary or useful when the irradiation conditions are low. In addition, under such lower illumination conditions, the required backlight level of the video display screen (e.g., for a full-mirror display video mirror, or for a video mirror with a smaller video display screen, which is disposed behind and viewable through the mirror reflective element) may also be reduced (thereby reducing the intensity of the displayed video image during the night). Therefore, the heat load generated by the video display backlight is low at night.
For video mirrors with full mirror display, a larger video display screen is provided at and behind the entire reflective area. And a backlight TFT display screen is adopted, and the display screen is backlit by an array of light emitting diodes. For larger full-mirror displays, backlight LEDs generate heat when operated at higher intensities under daytime illumination conditions to display video images. However, under lower light conditions (e.g., dusk to dawn conditions), the backlight LEDs operate at reduced intensities and thus generate less heat than during daytime operation.
Thus, the near IR LED for the DMS camera may be part of the backlight array of LEDs, so that at night, the near IR LED may operate at a higher intensity, but not generate as much heat as the entire backlight array when the daytime video mirror is running. Thus, the backlight array may incorporate near IR LEDs (e.g., nested or a set of near IR LEDs, or a circle of near IR LEDs or the like) that are powered under low ambient illumination conditions for use with the DMS camera and the driver monitoring system. The near IR LEDs of the backlight LED array may be selectively addressed separately from the visible light emitting LEDs of the backlight array for backlighting of the video display screen and may be powered at a higher level during the night because the visible light emitting LEDs of the backlight array are not powered at a higher level under such lower lighting conditions.
The available area behind the internal mirror reflector, where the near IR LED can be placed, is large, e.g. 120cm 2 To 150cm 2 Or left and right. Moreover, since the transflective mirror reflector may cause its presence in the lens portion behind the mirror reflective element to become hidden from a driver viewing the mirror reflective element while driving a equipped vehicle, a large number of near IR LEDs (e.g., 10 or 20 or 50 or more) may be placed behind (and hidden from) the transflective reflector of the internal mirror reflective element. Thus, by using a large number of near IR diodes placed behind the interior specular reflective element and radiating radiation through the interior specular reflective element (when energized), adequate in-cabin flood illumination (e.g., illuminating the driver's eyes) can be achieved even when near IR transmittance through the interior specular reflective element is low (e.g., greater than 10% T but less than 20% T; or greater than 20% T but less than 30% T; or greater than 30% T but less than 40% T; or greater than 40% T but less than 50% T). Furthermore, not all of the plurality of near IR LEDs need be powered all the time [ although each is typically operable by Pulse Width Modulation (PWM) to vary the emitted near IR intensity by PWM ]. Some groups of near IR LEDs need not be powered all the time, but rather are powered when appropriate/needed. For example, when the EC medium is darkened/dimmed (thereby reducing near IR transmission through the EC internal specular element), the near IR LED that is not powered when the EC medium is in its non-darkened/faded state will power to compensate for the near IR transmission loss caused by the darkened/dimmed EC medium. In addition, anamorphic lenses (rather than spherical lenses that project a circular image onto the camera sensor) are used for the post-mirror element cameras to project an elliptical image onto the camera sensor through optical elements that squeeze more horizontal information from the image scene, which helps to increase S/N by pooling the reflected visible light collected/reflected near IR collected by the camera into a more limited/smaller in-car region of interest (e.g., the region of interest where the driver' S head/eyes are expected to be).
Furthermore, an internal mirror reflection element (the internal mirror reflectionThe elements are typically about 20cm to 22cm or so long and about 6cm to 9cm wide and have a surface area of about 120cm 2 Up to 198cm 2 Or in the region of the left and right) a large amount of space is within the chamber behind (formed and surrounded by the mirror housing/shell) to accommodate (i) multiple cameras, and/or (ii) cameras with physically large light condensing/shrinking/concentrating optics, and/or (iii) cameras with physically large imaging arrays. Also, the presence of such camera(s) and such physically large camera/optics/imaging arrays is not objectionable from the standpoint of vehicle styling or driver/consumer acceptance, as such camera(s) and such physically large camera/camera optics are hidden behind the transflective mirror element of the interior (EC or prismatic) mirror assembly. For example, two separate 3cm diameter lenses/optics may be housed in the inner mirror assembly and hidden behind its transflector. The use of multiple cameras (and particularly cameras with high dynamic range and high gain opportunities) and/or large optics and/or large imaging arrays may allow the use of DMS for the transflective inner mirror element in cases where the visible and near IR light transmission through the inner mirror element may be low (e.g., the inner mirror element may have less than 15% t of visible light but greater than 5%T, have less than 50% t of near IR but greater than 15% t of near IR, or the inner mirror element may have less than 15% t of visible light but greater than 7%T of visible light, have less than 50% t of near IR but greater than 20% t of near IR, or the inner mirror element may have less than 15% t of visible light but greater than 10% t of visible light, have less than 50% t of near IR but greater than 30% t of near IR).
The system may determine a low illumination condition from image processing of image data acquired by the DMS camera or by another camera of the vehicle (or alternatively by an ambient light sensor at the vehicle), and may actuate the near-IR emitter when the system determines that the ambient light level is below a threshold level. Alternatively, the system may adjust the threshold level of near IR emitter operation depending on whether the sunroof or moon roof of the vehicle is open or whether the convertible of the vehicle is down, which may affect the amount of light in the cabin of the vehicle. Alternatively, the system may determine the low illumination condition in response to global positioning of the vehicle. For example, the global positioning system may determine whether the vehicle is in the daytime or at night (and thus approximately the ambient light level) based on the location and the current time.
Thus, the interior rearview mirror has an embedded camera, an IR illuminator, and a processor for processing the acquired image data for driver monitoring applications. The DMS camera and IR illuminator are fixed within the lens portion and thus both components are coupled to the lens body. Thus, the field of view of the camera may be changed from driver to driver because the lens portion is adjusted to the rear viewing angle that the driver prefers.
A processor may be disposed within the lens portion and process the acquired image data to detect and inform the driver of distraction or other valuable information. For example, the processor may determine the driver's attention and/or the driver's gaze direction (by processing the image data acquired by the driver's surveillance camera) and may, in response thereto, alert the driver to inform the driver of the potential hazard that he or she needs to pay attention to when it is determined that there is a hazard in front of the vehicle (by processing the image data acquired by the front view camera) and at an area that the driver is not currently observing. The alert may include an audible alert, a tactile alert, or a visual alert (e.g., a warning indicator or displaying the detected hazard on a video display screen or heads-up display of the vehicle).
An electroluminescent (e.g., electrochromic (EC)) mirror reflective element subassembly transmits near infrared light and reflects visible light. Thus, the specular reflective element effectively allows the IR LED to emit light through the reflective element and allows the camera to "view" through the specular reflective element, while allowing the specular reflective element to achieve its intended rear viewing purpose. The IR LEDs may be actuated at least partially in response to ambient light levels within the cabin of the vehicle and at the head area of the driver, where the light levels are determined by the processing of the image data acquired by the light sensor or by the driver monitoring camera.
Mounting a fixed inward DMS camera in a pivotable rearview mirror head presents unique challenges to the view angle of the camera. In order to take into account the change in the field of view of the camera when adjusting the lens portion, the driver monitor processor of the mirror calculates the position and angle of the camera within the vehicle from the image data acquired by the camera and processed by the processor. For example, the system may process image data acquired by the camera to determine where in the camera field of view a particular feature is located (e.g., relative to a particular region of the field of view, such as a center region), and thus, the driver monitoring system determines the position of the driver's head by determining one or more positions of a particular stationary vehicle feature (e.g., a rear window, a pillar, a center console, or the like) in the acquired image data. The system may adjust the processing of the image data acquired by the camera to accommodate changes in the location of known or specific vehicle features. For example, if the nominal setting of the mirror has a particular feature that is a predetermined distance laterally and/or vertically from the center of the image data, if it is determined that the particular feature is moved or offset to one side or the other from the predetermined distance location, the processor moves or adjusts the processing of the acquired image data to accommodate the lateral and/or vertical movement of the particular feature.
In DMS, a high resolution camera (preferably a CMOS camera with an imaging sensor comprising at least one million pixels of photosensors, and preferably at least 3 megapixels of photosensors and more preferably at least 8 megapixels of photosensors arranged in rows and columns) is used so that details of the driver's eyes (e.g. iris expansion, blink rate, drowsiness, etc. and/or the like) can be tracked/detected. Image data acquired by the camera(s) in the lens portion in the interior cabin observed through the interior mirror reflective element is subjected to complex and extensive image processing/data processing to extract information required for the DMS from the acquired image data. Therefore, a data/image processing chip capable of processing billions or trillions of operations per second is used. For example, a data/image processor capable of at least 0.1TOPS (trillion operations per second), more preferably at least 0.2TOPS, and most preferably at least 0.5TOPS is preferably used.
Processing DMS data at such high processing rates consumes power. For example, the DMS process may consume/dissipate at least 2W of power, in some applications at least 5W of power, and in other applications at least 10W of power. Thus, as shown in fig. 56, the PCB including circuitry for the DMS and the data processor/image processor/controller is optionally not disposed within the lens portion, but may be disposed in the mirror support/mirror mounting base of the interior rearview mirror assembly to which the lens portion is pivotally attached. The electrical/signal cable may pass between (i) circuitry located at the mirror support/mounting base and (ii) a camera located within the mirror portion and the near IR LED by passing through a pivot joint that pivotally attaches the mirror portion to the mirror support/mounting base. By not mounting the data processor within the lens portion, but mounting the processor at the lens holder/mounting base, heat dissipation due to the power consumption of the circuit so arranged is enhanced.
For a DMS camera disposed behind and looking through the mirror transflector of the mirror reflecting element of a cassette DMS internal rearview mirror assembly of the present invention, a back illumination (BSI) imaging sensor is preferably used. As described in U.S. patent No.7,741,666, which is incorporated by reference in its entirety, a backside illuminated imaging sensor includes an imaging array fabricated on the front surface of a semiconductor Si wafer. The imaging array receives light passing through the back side of the silicon wafer. However, in order to detect visible light from the back surface, the silicon wafer must be very thin. Microlenses may be included on the back side of the wafer to increase the sensitivity of the back side illumination sensor to visible light. The DMS camera requires good visible light sensitivity (for e.g. in-car color video conferencing), but also high near IR sensitivity (e.g. 940 nm) to be able to detect eye/pupil details of the driver of the equipped vehicle (and/or to detect the presence of occupants at the second or third row of rear seat areas of the equipped vehicle) based on relatively weak reflections back to the DMS camera located in the lens part away from the body part irradiated by near IR (e.g. eyes/head/hands of the driver) and away from other objects present in the interior car of the vehicle away from the position of the lens part of the DMS camera. Thus, for a visible/infrared DMS camera adapted for use in a cassette DMS interior rearview mirror assembly of the present invention, increasing the thickness of the Si semiconductor wafer for the imaging sensor of the DMS camera allows near IR light to be more efficiently collected by the Si wafer; thicker silicon layers are particularly important because near IR light penetrates deeper into the silicon before being absorbed. Imaging for the near IR (700 to 1000 nm) spectral region compared to imaging for the visible spectral region (400-700 nm), near IR sensitive imaging sensors thus require a thicker photon absorption region because infrared photons absorb deeper in silicon than visible photons. The epitaxial or epitaxial layer thickness of the Si substrate used in CMOS imaging sensors used in DMS cameras is increased, thereby improving near IR sensitivity. To mitigate degradation of the ability of the imaging sensor to resolve spatial features, a thicker Si layer may be combined with a higher pixel bias voltage and/or a lower epitaxial doping level.
Quantum Efficiency (QE) refers to the efficiency with which an imaging sensor converts incident light photons into electrons (e.g., if the sensor has a QE of 100% and is exposed to 100 photons, it will produce 100 electronic signals). For Complementary Metal Oxide Semiconductor (CMOS) imaging sensors (such as those currently used in car cameras), the sensitivity of the near IR spectrum is limited by the absorption length in the silicon layer, where impinging photons produce electrons. The QE of such conventional imaging sensors is typically below 15%, and somewhat below 10%, around 940nm in the near infrared region of the spectrum. Because infrared photons in silicon are absorbed deeper than visible photons, imaging sensors need to have thicker photon absorption regions to image effectively in the near infrared (700 nm to 1000 nm). For example, increasing the silicon thickness of the epitaxial silicon layer of the substrate used in CMOS imaging sensors to 3.0 μm to 5.1 μm can increase QE by nearly 40% at near IR wavelengths of 940 nm. Preferably, a thicker epitaxial silicon layer is used with a higher pixel bias voltage and/or a lower epitaxial silicon doping level. The use of anti-reflective layers and/or back scattering techniques can increase the QE of the image sensor above 40% at 940nm wavelength, which is about 400% improvement over conventional CMOS imaging sensors.
CMOS imaging sensors with enhanced near IR sensitivity are preferably used in a cassette DMS internal rearview mirror assembly. For example, a near IR optimized variant of the CMV4000 imaging sensor commercially available from AMS AG of Austrian Premstaetten may be used. The CMV4000 imaging sensor is a high sensitivity, pipelined global shutter CMOS image sensor having 2048x2048 pixel resolution. Preferably, a color version of the CMV4000 imaging sensor is used with color filters applied in a Bayer RGB pattern, and with an in-lens camera that uses microlenses to image incident light onto the CMV4000 imaging sensor. Near IR optimized variants of standard CMV4000 image sensors were fabricated on 12 μm epitaxial silicon wafers. The thicker epitaxial silicon layer significantly improves the QE at wavelengths above 600 nm. Around 900nm, the QE doubles approximately and increases from 8% to 16%. This represents a doubling of sensitivity values around 940nm compared to cameras using imaging sensors that are not optimized for near IR detection.
For example, the EV76C660 image sensor or EV76C661 image sensor commercially available from Teledyne 2v SAS of Saint-Egreve Cedex, france, may be used in a cassette DMS interior rearview mirror assembly. The EV76C661 imaging sensor is a 130 ten thousand pixel (square pixel with micro-lens) CMOS image sensor with an electronic global shutter and operable to provide high readout speed of 60fps at full resolution. EV76C660 and EV76C661 are members of the Teledyne 2v's Ruby family of CMOS imaging sensors that can provide enhanced sensitivity and performance beyond that typically provided by front side illumination imaging sensors. The pixels were 5.3 mu m X5.3 mu square with microlenses. Fig. 111 shows spectral responses and quantum efficiencies of the EV76C660 imaging sensor and the EV76C661 imaging sensor. Quantum efficiency in the Near IR (NIR) spectrum is excellent (greater than 20% at 940 nm).
For example, an OX05B1S imaging sensor available from OMNIVISION, santa Clara, calif., may be used in a cassette DMS interior rearview mirror assembly. OX05B1S imaging sensor using OMNIVISIONNear Infrared (NIR) technology. />The technology has the feature of QE improvements that increase sensitivity to the near infrared spectrum, such improvements including imaging sensors that utilize thicker silicon to increase the opportunity for photon absorption; the imaging sensor uses deep trench isolation to create a barrier between pixels to eliminate cross talk and improve module transfer function; also, the image sensor uses a carefully managed optical scattering layer to prevent defects in dark areas of the image and lengthen photon paths. OX05B1S is a 5 Megapixel (MP) RGB-IR BSI global shutter imaging sensor and has a pixel size of 2.2 μm X2.2 μm and contains integrated network security functions. OX05B1S had a near IR QE of 36%.
CMOS imaging sensors for a cassette DMS internal rearview mirror assembly preferably have a near IR QE of at least 15% around 940 nm; more preferably at least 22%; and most preferably at least about 32%. The thickness of the epitaxial silicon layer for a CMOS imaging sensor of a cassette DMS internal rearview mirror assembly is preferably at least about 3.5 μm; more preferably at least about 4.5 μm; and most preferably at least about 5.5 μm.
Preferably, the housing/packaging of the circuitry within the interior rearview mirror assembly, except within the lens portion, is performed as follows: wherein the mirror support/mounting base is minimally invasive to the driver's front line of sight through the vehicle windshield. The mounting or housing of the mirror support/mounting base and PCB therein may utilize U.S. patent No.9,487,159; no.8,256,821; no.7,480,149; aspects of the modules described in nos. 6,824,281 and/or 6,690,268, the entire contents of which are incorporated herein by reference.
Thus, the system may include a DMS PCB, IR LED, and DMS camera disposed inside the lens portion of the mirror assembly. The DMS PCB receives vehicle inputs from the vehicle (e.g., via a Local Interconnect Network (LIN) bus of the vehicle and/or a Controller Area Network (CAN) bus of the vehicle). The DMS PCB may also receive input from an external or front-view camera. The DMS PCB may also provide control signals to the camera and IR LEDs to activate and deactivate and control the operation of the camera and LEDs.
A driver monitoring system (including a camera and a processor) may utilize U.S. patent No.10,065,574; no.10,017,114; no.9,405,120 and/or No.7,914,187 and/or U.S. publication No. US-2021-0323773; US-2021-0291739; US-2020-0202151; US-2020-0143560; US-2020-032920; US-2018-023696; US-2018-0222414; US-2017-0274906; US-2017-0217367; US-2016-0209647; US-2016-0137726; US-2015-0352953; US-2015-0296235; US-2015-0294169; US-2015-023430; US-2015-0092042; US-2015-0022664; US-2015-0015710; aspects of the system described in U.S. patent application Ser. No.17/450,721 (attorney docket number MAG04P 4306), filed on even date 13 at 10 of 2021, and/or U.S. Pat. No. 2015-0009010 and/or U.S. Pat. No. 2014-0336876, the entire contents of which are incorporated herein by reference.
Alternatively, the mirror assembly may include a memory actuator that positions the lens portion in a preselected orientation in response to a determination of a particular driver of the vehicle (or in response to user input, e.g., similar to memory seat settings and features). When the memory actuator and DMS are combined in the internal rearview mirror assembly, image processing by an image processor of circuitry of a controller disposed in the lens portion behind the specular element using machine vision object detection techniques and algorithms can physically calibrate or optimize the lens portion position (and thus the specular reflection seen by the driver at the specular element) with respect to the driver's particular eyepoint. By doing so, the field of view of the driver's surveillance camera will also be optimized by locating the driver's face/head in a common area within the camera's imager. The camera will be fixed to the lens part (and therefore the camera will adjust as the mirror angle is adjusted) and the processing of the image processor using object detection techniques and algorithms will detect the position of the driver's face in the image data acquired by the camera, and then based on this position information the controller or ECU can drive the memory actuator to a new position using feedback from the memory system in the actuator.
The mirror system uses image processing of image data acquired by the DMS camera in the lens section to identify signs of distraction and/or fatigue by determining/tracking the driver's head position and eye position (e.g., pitch, roll, and/or yaw of the driver's head or eyes), and can determine whether other objects are present in the driver's hand, such as a cell phone or water bottle or coffee cup or food or the like. The mirror system may also use image processing of the image data acquired by the DMS camera to perform driver identification, such as identifying the driver, to associate the driver with corresponding memory characteristics (e.g., external mirror memory settings and/or internal mirror memory settings). The inwardly facing DMS camera may position the driver's head and adjust the lens portion (and/or mirror element) accordingly. The system may identify the driver when he or she enters the vehicle and may move the camera and lens to a previously recorded or stored position (which may be initially set by the driver when he or she first drives the vehicle).
The system may utilize any suitable face or eye tracking software or system, such as FaceTrackNoIR or the like, which may utilize standard cameras without associated illumination. The inner lens portion includes an inward camera, a memory actuator, and drivers for the EC and the infrared LEDs that control or drive the EC unit and the infrared LEDs. The DMS PCB may be disposed external to the lens portion (e.g., at a vehicle console or similar location) and include circuitry and related software for processing image data acquired by the camera and controlling the memory actuators accordingly. The DMS PCB may also operate at least partially in response to vehicle data provided via the CAN bus of the vehicle.
Alternatively, the driver monitoring system may be integrated with a Camera Monitoring System (CMS) of the vehicle. The integrated vehicle system contains multiple inputs, such as inputs from an inward looking or driver monitoring camera, a forward looking or outward looking camera, and from a rear looking camera and a side looking camera of the CMS, providing the driver with unique collision mitigation capabilities based on the complete vehicle environment and driver awareness status. Image processing and detection and determination are performed locally within the interior rearview mirror assembly and/or overhead console area, depending on the available space and electrical connections for a particular vehicle application.
CMS cameras and systems may utilize U.S. patent No.11,242,008, U.S. publication No. US-2021-0162926; US-2021-0155167; aspects of the systems described in PCT application number PCT/US2022/070062, filed on 1 month 6 of US-2018-013217 and/or US-2014-0285666, and/or 2022, are incorporated herein by reference in their entirety. The connection between the camera and the controller or PCB(s) and/or between the display and the controller or PCB may be made via a respective coaxial cable, which may provide power and control of the camera (through the controller) and may provide image data from the camera to the controller, and may provide video images from the controller to the display device. Connection and communication may utilize U.S. patent No.10,264,219; aspects of the systems described in No.9,900,490 and/or No.9,609,757, the entire contents of which are incorporated herein by reference.
The specular reflective element comprises a variable reflectivity electro-optic specular reflective element, such as an electrochromic specular reflective element or a liquid crystal specular reflective element. For example, the specular reflective element may include a laminated variable reflectivity electro-optic (e.g., electrochromic) reflective element assembly having a front glass substrate and a back glass substrate with an electro-optic medium (e.g., electrochromic medium) sandwiched therebetween and defined by a perimeter seal. The front substrate has a front or first surface (the surface that normally faces the driver of the vehicle when the mirror assembly is mounted on the vehicle) and a rear or second surface opposite the front surface, and the rear substrate has a front or third surface and a rear or fourth surface opposite the front surface, the electro-optic medium being disposed between the second and third surfaces and being defined by a perimeter seal of the reflective element (as is known in the electrochromic mirror art, for example). The second surface has a transparent conductive coating (e.g., an Indium Tin Oxide (ITO) layer, or a doped tin oxide layer, or any other transparent semiconductive layer or coating or the like (e.g., indium Cerium Oxide (ICO)), indium tungsten oxide (IWO), or Indium Oxide (IO) layer or the like, or a zinc oxide layer or coating, or a zinc oxide coating or the like doped with aluminum or other metallic material (e.g., silver or gold or the like), or other oxide or the like doped with a suitable metallic material, or as disclosed in, for example, U.S. patent No.7,274,501, the entire contents of which are incorporated herein by reference), established thereat, and the third surface has a metallic transflector coating (or layers or coatings) established thereat. The front or third surface of the rear substrate may include one or more transparent semiconductor layers (e.g., ITO layers or the like) and one or more metallic conductive layers (e.g., layers of silver, aluminum, chromium, or the like, or alloys thereof), and may include, for example, those described in U.S. Pat. nos. 7,274,501; a number of layers as disclosed in No.7,184,190 and/or No.7,255,451, the entire contents of which are incorporated herein by reference. The specular transflector may comprise any suitable coating or layer, such as a transflector coating or layer, as described in U.S. Pat. nos. 7,626,749; no.7,274,501; no.7,255,451; no.7,195,381; no.7,184,190; no.6,690,268; no.5,140,455; no.5,151,816; no.6,178,034; no.6,154,306; no.6,002,511; no.5,567,360; no.5,525,264; no.5,610,756; no.5,406,414; no.5,253,109; no.5,076,673; no.5,073,012; no.5,115,346; no.5,724,187; no.5,668,663; no.5,910,854; the coatings or layers described in nos. 5,142,407 and/or 4,712,879, the entire contents of which are incorporated herein by reference, are disposed at the front surface of the rear substrate (commonly referred to as the third surface of the reflective element) and opposite the electro-optic medium (e.g., electrochromic medium disposed between the front and rear substrates), and are defined by a perimeter seal (although alternatively, a specular reflector may be disposed at the rear surface of the rear substrate (commonly referred to as the fourth surface of the reflective element)).
The third surface defines an active EC region or surface of the rear substrate within the perimeter seal. The coated third surface may also be coated to define a protruding region (e.g., by utilizing aspects of the mirror assembly described in U.S. Pat. nos. 7,274,501; 7,184,190 and/or 7,255,451, the entire contents of which are incorporated herein by reference) for providing electrical connection of the conductive layer to the electrical clip of the connector or bus bar, such as the types described in U.S. Pat. nos. 5,066,112 and 6,449,082 (the entire contents of which are incorporated herein by reference).
Alternatively, the reflective element may comprise an opaque or substantially opaque or hidden perimeter layer or coating or band disposed about a perimeter edge region of the front substrate (e.g., at a perimeter region of the rear or second surface of the front substrate) to hide or conceal or perimeter seal the line of sight of the driver of the vehicle when the mirror assembly is normally installed in the vehicle. Such hidden layers or perimeter bands may be reflective or non-reflective and may utilize U.S. patent No.5,066,112; no.7,626,749; no.7,274,501; no.7,184,190; no.7,255,451; aspects of the perimeter band and mirror assembly described in nos. 8,508,831 and/or 8,730,553 (all of which are incorporated herein by reference in their entirety). Alternatively, the perimeter band may include a chrome/chrome coating or a metal coating, and/or may include a chrome/chrome or metal coating having reduced reflectivity, such as by using an oxidized chrome coating or a chrome oxide coating or a "black chrome" coating or the like (e.g., by utilizing aspects of the mirror assembly described in U.S. Pat. nos. 7,184,190 and/or 7,255,451, the entire contents of which are incorporated herein by reference). Alternatively, other opaque or substantially opaque coatings or bands may be implemented.
The reflective element and the mirror housing are adjustable relative to the base portion or mounting assembly to adjust the driver's rearward view when the mirror assembly is normally mounted at or within the vehicle. The mounting assembly may comprise a single ball or single pivot mounting assembly whereby the reflective element and housing are adjustable about a single pivot joint relative to the vehicle windshield (or other interior portion of the vehicle), or the mounting assembly may comprise other types of mounting configurations, such as a dual ball or dual 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 (e.g., 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; 6,877,709; 6,329,925; 7,289,037; pivot mounting assemblies of the type described in U.S. Pat. Nos. 7,249,860 and/or 6,483,438, the entire contents of which are incorporated herein by reference).
The mirror assembly may comprise any suitable configuration, for example, a mirror assembly in which the reflective element is nested in a mirror housing and has a rim portion circumscribing a peripheral region of the front surface of the reflective element, alternatively the mirror housing has a curved or sloped periphery around the reflective element Edges and not overlapping the front surface of the reflective element (e.g., by utilizing aspects of the mirror assembly described in U.S. Pat. nos. 7,184,190; 7,274,501; 7,255,451; 7,289,037; 7,360,932; 7,626,749; 8,049,640; 8,277,059 and/or 8,529,108, the entire contents of which are incorporated herein by reference), or a mirror assembly having a rear substrate of an electro-optic or electrochromic reflective element nested in a mirror housing, for example, and the front substrate having a curved or beveled perimeter edge, or a mirror assembly having a prismatic reflective element disposed at the outer perimeter edge of the mirror housing, for example, and the prismatic substrate having a curved or beveled perimeter edge, for example, in U.S. Pat. No.8,508,831; no.8,730,553; 9,598,016 and/or 9,346,403 and/or U.S. publication Nos. US-2014-0313563 and/or US-2015-0097955, which are incorporated herein by reference in their entireties (and electrochromic mirrors and prismatic mirrors of such construction may be under the trade name INFINITY) TM Mirrors are commercially available from the assignee of the present application).
Alternatively, the mirror housing may comprise a rim portion circumscribing a peripheral region of the front surface of the reflective element, or a peripheral region of the front surface of the reflective element may be exposed (e.g. by utilizing aspects of the mirror reflective element described in U.S. Pat. nos. 8,508,831 and/or 8,730,553 and/or US publication nos. US-2014-0022390; US-2014-0293169 and/or US-2015-0097955, the entire contents of which are incorporated herein by reference).
Alternatively, the mirror assembly may comprise a prismatic reflective element. The prismatic mirror assembly may be mounted or attached to an interior portion of the vehicle (e.g., at the interior surface of a vehicle windshield) by 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 by any suitable toggle means, such as by using U.S. patent No.7,420,756; no.7,338,177; no.7,289,037; no.7,274,501; no.7,255,451; no.7,249,860; no.6,318,870; no.6,598,980; no.5,327,288; no.4,948,242; no.4,826,289; each aspect of the mirror assembly described in No.4,436,371 and/or No.44,435,042, and/or U.S. publication No. US-2010-0085653, is incorporated by reference herein in its entirety.
The mirror configuration and DMS embodiments described herein can utilize the configuration and coatings disclosed in U.S. patent No.7,274,501, filed as U.S. patent application serial No.10/528,269, filed by McCabe et al at 9/19/2003, and titled "Mirror Reflective Element Assembly" (the entire contents of which are incorporated herein by reference). For example, a specular reflective element, such as a third surface reflective element or a mirror element or a fourth surface reflective element or a prismatic reflective element or the like, that is sufficiently and spectrally selectively transmissive or spectrally tuned to allow a particular spectral range or band of light to pass through the display at the rear surface of the specular reflective element. The layers of the reflective element are selected or spectrally tuned to match one or more predetermined or selected spectral bands or wavelength ranges and thus pass light of the predetermined spectral bands therethrough while substantially reflecting light of other spectral bands or wavelengths and without the need for windows or apertures formed in the reflective metal layer of the reflective element. For example, a transflective electrochromic element or cell may be configured to include front and back substrates, and a near IR illumination source/floodlight and imaging device at the back or fourth surface of the back substrate. A semiconductor layer or coating (e.g., ITO, tin oxide, or the like) is deposited on the front or third surface of the rear substrate, and a semiconductor layer (e.g., ITO, tin oxide, or the like) is deposited on the rear or second surface of the front substrate. The electrochromic medium and the seal are disposed or sandwiched between the semiconductor layers, with the electrical connector positioned at least partially along at least one edge of each semiconductor layer. The transflector unit also includes an infrared or near infrared transmitting (IRT) stack or layer positioned or stacked on the rear surface of the rear substrate. The protective cover or glass sheet is adhered or secured to the rear surface of the IRT stack, for example, via an optically matching adhesive layer, which is preferably an index matching adhesive (index matching adhesive) that is index matched to the protective cover or sheet. The protective cover may comprise glass, or may comprise other transparent or substantially light transmissive materials, such as plastic, polycarbonate, acrylic, or the like. The IRT stack includes a multi-layer dielectric layer or coating (e.g., at least five layers or at least seven layers) across the rear surface of the rear substrate that functions as a cold mirror stack allowing near infrared and infrared light or radiant energy to pass therethrough while substantially reflecting visible light. The IRT stack may include titanium oxide layers alternating with silicon oxide layers. The titanium oxide layer provides a higher refractive index (2.385) while the silicon oxide layer provides a lower refractive index (1.455). The alternating combination of lower and higher refractive indices of the alternating layers provides enhanced near infrared transmission while providing reflectivity for visible light.
In one exemplary embodiment, the IRT stack includes nineteen such alternating layers having: a first titanium oxide layer about 72nm thick on the rear surface of the rear substrate, a first titanium oxide layer about 32nm thick on the first titanium oxide layer, a fifth titanium oxide layer about 94nm thick on the first titanium oxide layer, a sixth titanium oxide layer about 110nm thick on the fifth titanium oxide layer, a third titanium oxide layer about 64nm thick on the third titanium oxide layer, a fourth titanium oxide layer about 85nm thick on the third titanium oxide layer, a fourth titanium oxide layer about 62nm thick on the fourth titanium oxide layer, a fifth titanium oxide layer about 60nm thick on the fourth titanium oxide layer, a fifth titanium oxide layer about 98nm thick on the fifth titanium oxide layer, a sixth titanium oxide layer about 57nm thick on the fifth titanium oxide layer, a seventh titanium oxide layer about 94nm thick on the sixth titanium oxide layer, a seventh titanium oxide layer about 54nm thick on the sixth titanium oxide layer, a seventh titanium oxide layer about 58nm thick on the seventh titanium oxide layer, a seventh titanium oxide layer about 58nm thick on the eighth titanium oxide layer, a seventh titanium oxide layer about 58nm thick on the ninth titanium oxide layer, a seventh titanium oxide layer about 58nm thick on the eighth titanium oxide layer, a seventh titanium oxide layer about 28nm thick on the eighth titanium oxide layer. Obviously, other thicknesses and combinations of layers may be employed to achieve the desired level of transmittance and reflectance. Thus, the transflector element provides a fourth surface transflector element having a plurality of alternating layers of silicon oxide and titanium oxide to enhance near infrared transmission through the ITO layer and the substrate.
The titanium oxide layer provides a higher refractive index and the silicon oxide layer provides a lower refractive index. The combination of alternating layers of lower and higher refractive index provides enhanced near infrared transmission while providing high photopic reflectivity of most visible light, except for visible light in the desired spectral region or having a desired or selected or target wavelength. Thus, the transflector element may be used with a near IR light emitting source, which may be used in combination with an imaging source or camera and an on-demand display element that may emit light at a desired or selected wavelength or color (e.g., blue light at a wavelength of 430 nm) so that it is viewable by a driver or occupant of the vehicle through the reflector element. IRT stacks of other dielectric materials (e.g., alternating stacks of higher refractive index niobium oxide and lower refractive index oxide silicon dioxide) may be used.
The IRT stack preferably provides a NIR transmittance of greater than or equal to 15%, more preferably greater than 20% t and most preferably greater than 25% t, and provides a specular, color neutral (preferably silver) reflectance level of greater than or equal to 50% r, more preferably greater than 60% r and most preferably greater than 70% r (as seen/available to a driver in a equipped vehicle and viewing interior mirror reflective elements), and preferably such IRT stack is environmentally resilient/resistant to degradation due to heat/cold/weathering and the like when used with interior mirror reflective elements.
Alternatively, near IR transmission through the transflector (which preferably comprises a multi-layer stack of dielectric coatings) may exceed photopic visible transmission through the transflector. Preferably, the higher or increased near IR transmittance is between 800nm and 1000nm wavelength, more preferably between 820nm and 980nm wavelength, and more preferably between 920nm and 960nm wavelength.
Visible light blocking/near-IR light transmission spectral filtering can take a variety of forms. For example, one form of spectral filtering may be clear visible light transmission (e.g., less than 10% t of clear visible light, preferably less than 5%T of clear visible light, more preferably less than 2%T of clear visible light), at least 35% transmission for light having a wavelength greater than about 900nm, more preferably at least 45% transmission for light having a wavelength greater than about 900nm, and more preferably at least 55% transmission for light having a wavelength greater than about 900 nm. Furthermore, the high near IR region of the spectral filter may be notch/band shaped so that infrared transmission is attenuated above about 1000nm using the principles described in U.S. Pat. No.7,274,501 incorporated above.
Alternatively, spectral filtering may be used and overlaid on each pixel of a multi-pixel imaging array that constitutes a DMS camera, such that the pixels are spectrally filtered such that visible light incident at an interior rearview mirror assembly mounted at the windshield of the equipped vehicle is attenuated or blocked (to reduce saturation of the imaging array when the sunroof is opened on sunny days/in a convertible/due to high ambient/sun exposure in an interior vehicle). The spectral filter used has a high near IR transmittance to allow near IR light emitted by the row or rows of near IR LEDs behind the specular reflector to leave the internal specular reflective element, to be incident at the driver's head in the DMS, and to be reflected back to the internal specular reflective element and to pass through the near IR transmission spectral element again and to the infrared sensing pixels of the imager of the DMS camera. Alternatively, spectral filtering for an imaging sensor array may be constructed as described in U.S. patent No.8,446,470, the entire contents of which are incorporated herein by reference, wherein color (R, G, B) filters and IR filters are disposed at pixels of a light sensing imaging array such that some photosensors or pixels are sensitive to visible light and other photosensors or pixels are sensitive to near infrared light (see fig. 57). With this configuration employing interspersed RGB color sensitive pixels and near IR primary sensitive pixels, a mirror mounted DMS camera can acquire full color video seen in the interior cabin of the vehicle, while the near IR pixels of the DMS camera respond primarily to near IR light (which may be provided by near IR light emitters when the illumination level is below a threshold level, such as during dusk and nighttime), and are not saturated with visible light. If it is not necessary to display the video image acquired by the in-lens camera on a video screen located in the interior compartment of the equipped vehicle for viewing by the driver, the pixels of the imaging array may be spectrally filtered such that visible light is over-blocked (or at least blocked to be incident at pixels below a low threshold level, for example below 5% of the incident visible light), while near-IR radiation is passed (or at least passed to reach pixels above a high threshold, for example above 80% of the incident near-IR radiation). In this regard, step spectral filtering may be used when the percent transmission in the visible region of the electromagnetic spectrum is relatively low (e.g., less than 5%), and when the transmission rises to a high percent transmission level (e.g., greater than 80%) at the beginning of (or after) the near IR region. For near IR LEDs emitting at 940nm, for example, the transmission percentage of spectral filtering at 940nm or near 940nm should be high to enhance the performance of the DMS.
In another exemplary embodiment, the second surface (non-electrochromic) transflector may be about 90% t at 940 nm. The stack uses alternating Nb 2 O 5 And SiO 2 A layer. The IRT stack (see fig. 58 and 59) includes alternating layers having: a niobium layer (Nb) of about 13nm thick on the rear surface or the second surface of the glass substrate 2 O 5 ) Then a silicon oxide layer about 36nm thick on the niobium layer, then another silicon oxide layer about 44nm thick on the silicon oxide layer, then another silicon oxide layer about 22nm thick on the niobium layer, then another silicon oxide layer about 41nm thick, then another silicon oxide layer about 29nm thick, then another silicon oxide layer about 131nm thick, then another silicon oxide layer about 31nm thick, then another silicon oxide layer about 49nm thick, then another silicon oxide layer about 23nm thick, then another silicon oxide layer about 29nm thick, then another silicon oxide layer about 106nm thick, then another niobium layer about 91nm thick, then another silicon oxide layer about 100nm thick, then another niobium layer about 28nm thick, then another niobium layer about 27nm thick, then another silicon oxide layer about 84nm thick, then another niobium layer about 33nm thick, and then another silicon oxide layer about 179nm thick. Obviously, other thicknesses and combinations of layers may be employed to achieve the desired level of transmittance and reflectance. The transflector element thus provides a second surface transflector reflecting element having a plurality of alternating silicon oxide and niobium (Nb 2 O 5 ) To enhance near infrared transmission through the silicon oxide and niobium layers and the glass substrate.
Alternatively, the mirror substrate may be coated with an elemental silicon (silicon metal) layer. For example, and referring to fig. 60 and 61, the third surface conductive transflector of an Electrochromic (EC) Driver Monitoring System (DMS) mirror has a high transmittance T (about 90%) at 940nm and a reflectivity of about 40% r in the visible region (in fig. 60, the darker curve is the T% curve). Furthermore, the visual appearance is neutral. The stack of coatings disposed on a glass substrate (e.g., a 1.6mm thick glass substrate) includes titanium oxide (TiO) about 164nm thick 2 ) A layer, then about 20nm thick of silicon oxide (SiO 2 ) A layer, then a layer of titanium oxide about 43nm thick, then a layer of silicon oxide about 128nm thick, then a layer of silicon metal (Si) about 20nm thick, then a layer of silicon oxide about 63nm thick, and then a layer of ITO about 120nm thick.
Thus, the reflective element incorporates a single semi-metallic layer of silicon (Si) at layer 5 of the 7-layer stack, and has a high T% (about 90%) at 940nm and about 40% r in the visible region. The advantage of this design is a significant reduction in the number of layers and total stack thickness. This makes DMS stacking easier and less costly to manufacture. The overall thickness is less than 600nm.
Advantages of using an elemental silicon layer (silicon metal layer) in the coating stack include the specific optical properties provided by the elemental silicon layer and the excellent rate of sputtering elemental silicon (preferably by sputtering from a cylindrically formed elemental silicon target in a rotating sputtering target, preferably by DC magnetron sputtering), compared to the sputtering rate of a silicon oxide target or the sputtering rate of reactive sputtering in an oxygen atmosphere to form a silicon oxide/silicon dioxide layer or coating. Alternatively, and less preferably, elemental germanium (Ge) or germanium metal (Ge metal) layers may be used in the stack instead of silicon metal layers.
Full Display Mirror (FDM), e.g., commercially available from Gentex Corporation TM Mirror assembly and CLEARVIEW commercially available from Magna Mirrors of America, inc TM Mirror assembly with video display screen [ e.g., backlight Thin Film Transistor (TFT) Liquid Crystal (LC) display screen or organic light emittingDiode (OLED) video screen]Which is disposed behind the transflector, with the video screen spanning the entire driver viewable electrochromic dimming area of the interior EC mirror reflective element. Such FDM may operate in two modes (one mode may be changed to the other by the driver operating a toggle or by actuating a motor that changes modes, for example, by touch input). In one mode, the driver views the rear of the vehicle through reflection by the transflector, and the video display screen does not display any video images and is hidden behind the transflector. In another mode, the driver cannot see behind the vehicle by reflection from the transflector, and the video display screen displays a video image (typically acquired by a rear view image camera mounted at the rear of the equipped vehicle) that is visible to the driver driving the equipped vehicle. In FDM using a backlight TFT LCD video screen, a cabin monitoring camera and a cabin illumination near IR LED in a lens part provided behind an internal EC mirror reflection element are located behind a video display screen, and the camera has to observe through the video display screen, and the near IR LED has to emit light through the video display screen, whether or not the video screen is displaying a video image. Thus, to achieve this, high power near IR LEDs may be used (if desired, appropriate heat dissipation/cooling may be provided, including the use of forced air, such as by a fan). For example, high power near IR LEDs are available from Opto Diode Corporation of carbamatoin, california, which can generate up to 250mW of direct current from a single chip; up to 1000mW direct current can be generated from the array (https:// www.osapublishing.org/ao/viewmedia cfmuri = ao-36-25-6339 &seq=0). High power near IR LEDs are also available from lumines, inc. Of sanyverer, california, which provides single and double junction LEDs with high power density and uniform emission, provides multiple wavelengths from 730nm to 940nm and multiple viewing angles (lens types) from 40 degrees to 130 degrees, with drive current density operation (up to 5A/mm 2 ) Providing multiple package configurations (3.45mm x 3.45mm SMT or large copper core package), providing surface mount technology packages for cost effective compact high power near IR LEDs employing integrated board mounted coresThe chip design allows for easy system integration and optimal cooling in ultra-high radiation intensity (mW/sr) packages, providing near IR illumination (https:// www.luminus.com/products/IR) of a focused long projected beam. One or more such compact high power near IR LEDs (which are SMD mountable) may be included in a backlight device provided for a backlight TFT LCD video screen for use in FDM. Further, and at the location where the lens optics of the camera in the lens section will observe through the specular reflective element, the LCD pixels at the location where the lens optics of the camera will observe through the TFT LCD screen may remain unswitched in the FDM mode, with the remaining pixels of the video screen displaying video images, and the lens optics of the camera being provided by the near IR LEDs through the backlight at the TFT LCD screen observation.
The camera mounted in the interior rear view mirror and the accompanying near IR flood lighting device may observe/near IR flood lighting within the interior compartment of the vehicle and may be used, for example, to determine if there is a child or the like inadvertently left in the parked vehicle, which may otherwise be dangerous due to heat or cold or other dangerous factors. The interior cabin monitoring provided by the DMS of the vehicle may be enhanced or supplemented by other sensors mounted elsewhere in the interior rearview mirror assembly or the cabin of the vehicle, such as the roof portion or roof console portion or side wall portion of the seat or vehicle. Such supplemental occupant sensing sensors may include any one of ultrasonic sensor(s), lidar sensor(s), passive Infrared Detection (PID) sensor(s), or any combination thereof. Thus, the system may utilize and improve an internal occupant detection safety system, such as that described in U.S. Pat. No.7,097,226; no.6,783,167; no.6,768,420; no.6,621,411; a system of the type described in No.6,485,081 and/or No.6,480,103, the entire contents of which are incorporated herein by reference. For example, and preferably, the system may detect the presence of, for example, a child or infant, such as sleeping under a blanket or squatting on the floor in the gap between the front and rear seats, or in an open area behind the rear seat, alone or in addition to any other occupant sensor. Further, the occupant detection system may utilize a sensor such as a heartbeat sensor (e.g., by utilizing aspects of the system described in U.S. patent No.8,258,932, which is incorporated herein by reference in its entirety) or similar biometric sensing device.
The mirror assembly may include user-actuatable inputs operable to control any accessory and/or accessory module or the like of or associated with the mirror assembly. For example, the mirror assembly may include a touch sensitive element or touch sensor or proximity sensor, such as those described in U.S. Pat. nos. 5,594,222; no.6,001,486; no.6,310,611; no.6,320,282; no.6,627,918; a touch sensitive element of the type described in No.7,224,324 and/or No.7,253,723 and/or U.S. publication nos. US-2014-0022390 and/or US-2014-0293169 (the entire contents of which are incorporated herein by reference), or for example, U.S. patent No.7,224,324; a proximity sensor of the type described in No.7,249,860 and/or No.7,446,924 and/or U.S. publication No. US-2006-0050018 (the entire contents of which are incorporated herein by reference), or for example a membrane switch, such as described in U.S. patent No.7,360,932 (the entire contents of which are incorporated herein by reference), or for example a detector, etc., such as U.S. patent No.7,255,541; no.6,504,531; no.6,501,465; no.6,492,980; no.6,452,479; 6,437,258 and/or 6,369,804 (the entire contents of which are incorporated herein by reference), and/or the like.
Alternatively, the user input or buttons may include user input for a garage door opening system, such as U.S. patent No.6,396,408; no.6,362,771; a vehicle-based garage door opening system of the type described in No.7,023,322 and/or No.5,798,688 (the entire contents of which are incorporated herein by reference). Optionally, the user input may also or otherwise include user input for a telematics system of the vehicle, such as found in a vehicle of a utility vehicleA system and/or, for example, U.S. patent No.4,862,594; no.4,937,945; no.5,131,154; no.5,255,442; no.5,632,092; no.5,798,688; no.5,971,552; no.5,924,212; no.6,243,003; no.6,278,377; and No.6,420,975; no.6,477,464; no.6,946,978; no.7,308,341; no.7,167,796; no.7,004,593; 7,657,052 and/or 6,678,614, and/or U.S. patent publication No. US-2006-0050018 (all of which are incorporated herein by reference in their entirety).
Alternatively, the mirror assembly may include one or more other displays, such as a transflective display of the type disclosed in U.S. Pat. Nos. 5,530,240 and/or 6,329,925 (the entire contents of which are incorporated herein by reference), and/or a video display or screen, such as U.S. Pat. No.8,890,955, which are displayed on demand; no.7,855;755, a method for manufacturing the same; no.7,734,392; no.7,370,983; no.7,338,177; no.7,274,501; no.7,255,451; no.7,195,381; no.7,184,190; no.7,046,448; no.6,902,284; no.6,690,268; no.6,428,172; no.6,420,975; no.6,329,925; no.5,724,187; no.5,668,663; no.5,530,240; no.5,416,313; no.5,285,060; no.5,193,029 and/or No.4,793,690, and/or in U.S. patent publication No. US-2006-0050018; US-2009-0015736; US-2009-0015736 and/or US-2010-0097469 (the entire contents of which are incorporated herein by reference).
Video cameras or sensors may utilize aspects of various cameras or sensors, such as CMOS imaging array sensors, CCD sensors, or the like, and the system may utilize image processors or image processing techniques, such as those described in U.S. Pat. nos. 5,550,677; no.5,670,935; no.5,760,962; no.6,690,268; no.6,498,620; no.6,396,397; no.6,222,447; no.6,201,642; no.6,097,023; no.5,877,897; no.5,796,094; no.5,715,093; no.6,922,292; no.6,757,109; no.6,717,610; no.6,590,719; no.6,320,176; no.6,559,435; no.6,831,261; no.6,806,452; no.6,822,563; no.6,946,978; no.7,038,577; no.7,004,606; no.7,720,580; no.8,446,470; 8,451,107 and/or 9,126,525, and/or U.S. patent publication No. US-2006-0171704; aspects of the camera and image processor described in US-2009-024361 and/or US-2010-0214791 (the entire contents of which are incorporated herein by reference). The image sensor or camera may be actuated and the display screen may be actuated in response to the vehicle switching to reverse, causingThe display screen may be viewable by the driver and display an image of the rear scene when the driver is reversing. It is contemplated that the image processor or controller includes EYEQ available from jerusalem cold Mobileye Vision Technologies Ltd TM An image processing chip, etc., and processes image data acquired by the forward looking camera and the driver monitoring camera (and optionally the look-around camera and/or the CMS camera of the vehicle).
The vehicle may include one or more sensors of any type, such as imaging sensors or radar sensors or lidar sensors or ultrasonic sensors or the like. The imaging sensor or camera may acquire image data for image processing and may include any suitable camera or sensing device, such as a two-dimensional array of a plurality of photosensor elements arranged in at least 640 columns and 480 rows (at least 640 x 480 imaging array, such as a megapixel imaging array or the like), with respective lenses focusing the image onto respective portions of the array. The photosensor array may include a plurality of photosensor elements arranged in a photosensor array having rows and columns. The imaging array may comprise a CMOS imaging array having at least 300,000, preferably at least 500,000, and more preferably at least 100 tens of thousands of photosensor elements or pixels arranged in rows and columns. The imaging array may acquire color image data, for example via spectral filtering at the array, for example via RGB (red, green and blue) filters or via red/red complementary color filters or for example via RCC (red, transparent) filters or the like. The logic and control circuitry of the imaging sensor may function in any known manner and the image processing and algorithmic processing may include any suitable means for processing the image and/or image data.
Alternatively, the camera may comprise a front-view camera, for example provided at a Windscreen Electronic Module (WEM) or the like. A front-view camera may utilize U.S. patent No.9,896,039; no.9,871,971; no.9,596,387; no.9,487,159; no.8,256,821; no.7,480,149; 6,824,281 and/or 6,690,268, and/or U.S. publication No. US-2020-0039447; US-2015-0327498; US-2015-0015713; US-2014-0160284; aspects of the systems described in US-2014-0226012 and/or US-2009-0295181, the entire contents of which are incorporated herein by reference.
The camera module and circuit chip or board and image sensor may be implemented and operated in conjunction with various vehicle vision-based systems and/or may operate using the principles of such other vehicle systems, such as: for example, in U.S. patent No.5,796,094; no.6,097,023; no.6,320,176; no.6,559,435; no.6,831,261; no.7,004,606; a vehicle headlamp control system of the type disclosed in nos. 7,339,149 and/or 7,526,103 (the entire contents of which are incorporated herein by reference), such as commonly assigned U.S. patent No.6,353,392; no.6,313,454; rain sensors of the type disclosed in nos. 6,320,176 and/or 7,480,149 (the entire contents of which are incorporated herein by reference), vehicle vision systems, for example, using U.S. Pat. nos. 5,550,677; no.5,670,935; no.5,760,962; no.5,877,897; no.5,949,331; no.6,222,447; no.6,302,545; no.6,396,397; no.6,498,620; no.6,523,964; no.6,611,202; no.6,201,642; no.6,690,268; no.6,717,610; no.6,757,109; no.6,802,617; no.6,806,452; no.6,822,563; no.6,891,563; forward, sideways or rearward vehicle vision systems of the principles disclosed in nos. 6,946,978 and/or 7,859,565 (the entire contents of which are incorporated herein by reference), such as trailer hitch aids or traction check systems of the type disclosed in U.S. Pat. No.7,005,974 (the entire contents of which are incorporated herein by reference), reverse or sideways imaging systems, such as for lane change aids or lane departure warning systems or for blind spot or object detection systems, such as U.S. Pat. No.7,881,496; no.7,720,580; no.7,038,577; imaging or detection systems of the type disclosed in nos. 5,929,786 and/or 5,786,772 (the entire contents of which are incorporated herein by reference), such as U.S. patent No.5,760,962; no.5,877,897; no.6,690,268; no.7,370,983; a video device for interior cabin monitoring and/or video telephony functions, a traffic sign recognition system, a system for determining distance to a lead or trailing vehicle or object, such as a system utilizing the principles disclosed in U.S. patent nos. 6,396,397 and/or 7,123,168, the entire contents of which are incorporated herein by reference, and/or the like, as disclosed in nos. 7,937,667 and/or 9,800,983, and/or in U.S. publication No. US-2006-0050018, the entire contents of which are incorporated herein by reference.
The camera may include electrical connection elements that accommodate tolerances in the housing and/or PCB mount and/or connector portions. The electrical connection element may utilize U.S. Pat. No.9,233,641 and/or U.S. publication No. US-2013-024999; US-2014-0373345; US-2015-0222795; US-2015-0266430; US-2015-0365569; US-2016-0268716; US-2017-013811; aspects of cameras and electrical connectors described in US-2017-0295306 and/or US-2017-0302829 (the entire contents of which are incorporated herein by reference). Alternatively, the electrical connection may be established by Molded Interconnect Device (MID) technology, for example by utilizing U.S. publication No. US-2018-007439; aspects of the cameras described in US-2017-0295306 and/or US-2016-0037028, the entire contents of which are incorporated herein by reference.
The system may utilize sensors such as radar sensors or imaging radar sensors or lidar sensors or the like to detect the presence of and/or distance from other vehicles and objects at the intersection. The sensing system may utilize U.S. patent No.10,866,306; no.9,954,955; no.9,869,762; no.9,753,121; no.9,689,967; no.9,599,702; no.9,575,160; no.9,146,898; no.9,036,026; no.8,027,029; no.8,013,780; no.7,408,627; no.7,405,812; no.7,379,163; no.7,379,100; no.7,375,803; no.7,352,454; no.7,340,077; no.7,321,111; no.7,310,431; no.7,283,213; no.7,212,663; no.7,203,356; no.7,176,438; no.7,157,685; no.7,053,357; no.6,919,549; no.6,906,793; no.6,876,775; no.6,710,770; no.6,690,354; no.6,678,039; no.6,674,895 and/or No.6,587,186, and/or U.S. publication No. US-2019-0339382; US-2018-023665; US-2018-0045812; US-2018-0015875; US-2017-0356994; US-2017-0315231; US-2017-0276788; US-2017-0254873; aspects of the systems described in US-2017-0222311 and/or US-2010-0245066, the entire contents of which are incorporated herein by reference.
Alternatively, for example, one or more of the above descriptionsThe plurality of accessories may be positioned at or within the mirror housing and/or mirror cover portion or the like and may be contained on or integrated in a printed circuit board positioned within the mirror housing and/or cover portion, such as along a rear surface of the reflective element or elsewhere within the cavity defined by the housing. The user-actuatable input and/or touch sensors and/or proximity sensors and displays described above may be actuated to control and/or adjust the mirror assembly/system and/or the overhead console and/or accessory module and/or accessories of the vehicle. The connections or links between the controller and the display screen device and/or the navigation system and/or other systems and accessories of the mirror system may be provided by vehicle electronics or communication systems, etc., and may be provided by various protocols or nodes, such as, for example, according to the particular application of the mirror/accessory system and the vehicleSCP,UBP,J1850,CAN J2284,Fire Wire 1394,MOST,LIN,FLEXRAY TM Byte Flight and/or the like, or other vehicle-based or in-vehicle communication links or systems (e.g., WIFI and/or IRDA) and/or the like, or by VHF or UHF or other wireless transmission formats. Alternatively, the connection or link may be provided via various wireless connections or links.
Referring now to fig. 103A and 103b, the dms and OMS may implement distinguishable feature sets from eye tracking to drowsiness detection and from presence detection to belt detection, respectively. To support these different feature sets, irradiance requirements for DMS features (e.g., eye tracking and drowsiness) may be several times higher than OMS features (e.g., seat belt detection).
Thus, these distinguishable feature sets typically require different optical requirements, resulting in hardware complexity. To improve the thermal and optical efficiency of both DMS and OMS hardware, the system can evaluate the DMS features and OMS features in separate frames and provide only the necessary illumination to the given features and regions of interest of the frame. For example, fig. 103A shows two types of frame/illumination requirements for DMS and OMS. The bounding box 22 encloses the region of interest of the DMS (i.e. the head region of the driver). The region of interest 22 is the region where the DMS is most focused on acquisition/irradiation. The bounding box 24 encloses an area of interest for the OMS (i.e., a passenger seating area). The region of interest 24 is the acquisition/illumination region of most interest to the OMS. Notably, the regions 22, 24 have significant portions that do not overlap.
In another example of fig. 103B, the scene is divided into three separate regions of interest, rather than two regions of interest. Here, the first bounding box 26 encloses a region of interest for eye tracking and/or drowsiness tracking. Another bounding box 28 encloses the region of interest of the OMS (i.e., the occupant seating area), while a third bounding box 30 encloses the region of interest of the driver distraction detection (DMS for a portion). Each individual region of interest may require different levels of illumination or acquisition techniques (e.g., resolution, frames per second, etc.). Acquiring an entire frame of image data using the same illumination and dynamic range may consume more power and/or generate more heat than is required to meet the illumination/dynamic range requirements of each particular region of interest.
Referring now to fig. 104A and 104b, the dms/OMS may acquire frames of image data at different times using different illumination levels based on characteristics of the respective systems. For example, a controller of the DMS and/or OMS (e.g., an Electronic Control Unit (ECU) of the vehicle) may pulse one or more narrow field-of-view (n-FOV) illuminators for n consecutive frames while evaluating the DMS features, then pulse one or more wide field-of-view (w-FOV) illuminators for one frame, and monitor only OMS features (e.g., micro-scale). The ECU may control the illumination/camera in different ways for different features of the same system (e.g., for eye tracking with the DMS and for distraction detection of the DMS, as shown in fig. 103B).
As shown in fig. 104A, the camera may acquire frames of image data at a rate of 30 Frames Per Second (FPS), and the system may acquire DMS frames 34 and OMS frames 32 in a decentralized manner. The controller may pulse the respective light sources (e.g., DMS light source and OMS light source) or adjust the intensity, frequency, or any other characteristic of the individual light sources based on which system the frame of acquired image data is for. For example, a DMS frame may require stronger or brighter illumination, so the brighter illumination may be pulsed only during acquisition of the frame for use by the DMS. Alternatively, the OMS may require relatively less illumination than the DMS, and thus may pulse less bright illumination only during acquisition of frames for use by the OMS. As shown in fig. 104B, in evaluating the DMS function, the ECU may pulse the narrow FOV illuminator for a threshold period of time (e.g., a selected fraction of a second or x seconds or minutes, where the pulsing of the narrow FOV illuminator coincides with the frame acquisition of the camera) and then pulse the wide FOV illuminator for a different threshold period of time (possibly less than the threshold period of pulsing the narrow FOV illuminator) to monitor only OMS features (e.g., macro-scale). For example, when the DMS feature requires more illumination, the threshold time period of the DMS feature may be greater than the threshold time period of the OMS feature. For example, and as shown in fig. 104B, the camera may acquire frames of image data at a rate of 30 frames per second, and the DMS light source (narrow illuminator) may be pulsed on to acquire multiple consecutive frames (while the OMS light source is off), and then the OMS light source may be pulsed on to acquire multiple consecutive frames (while the DMS light source is off). Alternatively, and as shown in figure 105, the light emitter or narrow FOV illuminator may pulse n frames as the system evaluates the DMS features, and the wide FOV illuminator may pulse one frame as the system monitors both the DMS and OMS features.
Thus, the ECU may pulse different light sources or vary the intensity/frequency of individual light sources, etc., based on the characteristics of the DMS/OMS being evaluated for a given frame of image data. Thus, the system can customize energy usage and heat generation as necessary to support only the features of the corresponding system. A single camera may acquire image data for both the DMS and OMS, with different frames of each system interspersed with each other. Alternatively, a plurality of cameras may acquire image data for different data. The ECU may control the acquisition rate and other features of the camera to synchronize with pulsing the illumination source.
When the DMS camera is disposed in the lens portion, the camera may move with the lens portion (including the lens housing and the lens reflective element, which pivot at a pivot joint that pivotally mounts the lens portion at the mounting structure) such that when the driver aligns the lens for viewing behind, the camera is aligned with the driver's line of sight. The location of the DMS and/or OMS camera(s) and IR LED(s) at the lens portion provides an unobstructed view for the driver and/or other occupants. The DMS can be housed independently in the mirror and thus can be easily implemented in vehicles (including existing vehicles).
The mirror assembly may include a self-adjusting mirror reflective element (e.g., electrochromic mirror reflective element) or a prismatic mirror reflective element. For prismatic mirrors, when the head or housing is set to a particular orientation, the toggle moves the housing and reflective element to flip up/down, typically about 4 degrees, to switch between a daytime or non-glare reducing position (where the driver observes the reflection at the mirror reflector of the mirror reflective element) and a nighttime or glare reducing position (where the driver observes the reflection at the surface of the glass substrate of the mirror reflective element). For auto-dimming mirrors, once the lens section is set for a particular driver, it is generally not moved.
Both types of mirrors may be provided with a video display screen which is arranged behind and viewable through the mirror reflective element. The video mirror includes a backlit LCD display screen and one particular form of video mirror is a full display mirror in which the video display screen fills the reflective area, for example by using U.S. patent No.10,442,360; no.10,421,404; no.10,166,924; no.10,046,706 and/or No.10,029,614 and/or U.S. publication No. US-2019-0258131; US-2019-0146297; aspects of the mirror assembly and system described in U.S. patent application Ser. No.16/949,976 (attorney docket MAG 04P 4024) and/or U.S. patent application Ser. No.17/247,127 (attorney docket MAG 04P 4043) and/or U.S. patent application Ser. No. 11/0355312 and/or 23, respectively, filed 11/2020, the disclosures of which are incorporated herein by reference in their entireties. In this type of dual mode interior rearview mirror, even the EC lens portion moves when switching from the conventional reflective mode or mirror mode to the real-time video display mode.
For prismatic and full-mirror display mirrors, the driver first views the vehicle behind through a mirror reflector to pair Ji Jing. When the mirror is flipped up (e.g., switched to the anti-glare position of a prismatic mirror or to the video display mode of a video mirror), the DMS camera may flip down a similar angle to maintain its primary viewing axis toward the driver. Alternatively, the DMS camera may have a sufficiently large field of view that the desired area does not exceed the field of view of the camera when the mirror is flipped over. The ECU or processor of the system may adjust or transfer the processing of the image data acquired by the camera depending on the orientation of the lens portion (i.e., when it is flipped up or down) so that the portion of the image data for the driver monitoring system being processed represents the desired monitored area within the vehicle cabin.
Thus, the mirror assembly includes the DMS/OMS camera(s) and the near IR light emitter(s). In daylight or higher ambient illumination conditions, near IR flood illumination may not be necessary or desirable because the acquisition area may be adequately illuminated by ambient light in the vehicle. However, from dusk to dawn, such near IR irradiation may be necessary or helpful when the irradiation conditions are low.
For video mirrors with full mirror display, a larger video display screen may be provided at and behind the entire reflective area. When a backlight TFT display screen is used, the display screen is backlit by an array of light emitting diodes.
Thus, the backlight array may be comprised of near-IR LEDs (e.g., nested or grouped near-IR LEDs, or looped near-IR LEDs or the like) that are powered for use with the DMS camera and the driver monitoring system under low ambient illumination conditions. The near IR LEDs of the backlight array of LEDs are selectively addressable separately from the visible light emitting LEDs of the backlight array for backlighting a video display screen and may be powered at a higher level at night because the visible light emitting LEDs of the backlight array are not powered at a higher level under such lower level illumination conditions.
The system may determine a low illumination condition based on image processing of image data acquired by the DMS camera or another camera of the vehicle (or alternatively by an ambient photosensor at the vehicle), and may actuate the near-IR emitter when the system determines that the ambient light level is below a threshold level. Alternatively, the system may adjust the threshold level of the operating near IR emitter based on whether the sunroof or roof of the vehicle is open or whether the convertible roof of the vehicle is down (which may affect the amount of light in the cabin of the vehicle). Alternatively, the system may determine the low illumination condition in response to global positioning of the vehicle. For example, the global positioning system determines whether the vehicle is in the daytime or nighttime (and thus roughly determines the ambient light level) based on the location and the current time.
The interior rearview mirror may include one or more embedded cameras, an IR illuminator, and a processor for processing acquired image data for driver monitoring applications. The DMS camera and IR illuminator may be fixed within the lens portion, and thus both components are coupled to the lens body. Thus, when the lens portion is adjusted to set the driver's preferred rearward view, the view of the camera may change from driver to driver.
A processor may be disposed within the lens portion and process the acquired image data to detect and notify the driver of distraction or other valuable information (e.g., occupant monitoring). For example, the processor may determine driver attention and/or driver gaze direction (by processing image data acquired by the driver monitoring camera) and in response to determining a hazard ahead of the vehicle (by processing image data acquired by the front-view camera) and at an area not seen by the driver at the time, the system may alert the driver to inform the driver of the potential hazard that he or she needs to pay attention to. The alert may include an audible alert or a tactile alert or a visual alert (e.g., an alert indicator or displaying a detected hazard on a video display screen or head up display (heads up display) of the vehicle).
An electro-optic (e.g., electrochromic (EC)) mirror reflective element subassembly transmits near infrared light and reflects visible light. Thus, the specular reflective element effectively allows the IR LED to emit light through the reflective element and allows the camera to "view" through the specular reflective element, while allowing the specular reflective element to achieve its intended rearview purpose. The IR LEDs may be actuated at least partially in response to ambient light levels within the vehicle cabin and at the head area of the driver, where the light levels are determined by light sensors or by processing image data acquired by the driver monitoring cameras.
The advantages and benefits of a cassette DMS interior rearview mirror assembly are described above and herein. However, if it is not desired to include a DMS SoC chip running DMS software/algorithms in the lens portion of the interior rearview mirror assembly, it may instead be located as part of an Electronic Control Unit (ECU) or as part of a Domain Controller (DC) that is located in the equipped vehicle remote, separate and apart from the DMS camera and near IR illuminator housed within the lens portion of the equipped vehicle interior rearview mirror assembly. Preferably, the image data acquired by the DMS camera housed within the lens section is serialized by a serializer that is part of the electronic circuitry provided within the lens section and transmitted as digital serial data from the lens section to the remote ECU or DC via a wired connection between the circuitry within the lens section and the circuitry of the remote ECU or DC. The digital serial data sent from the DMS camera within the lens section is deserialized when it arrives at the ECU or DC and is processed by the DMS SoC running DMS software/algorithms that are part of the remote ECU or DC circuitry. The wired connection carrying digital serial data and connecting the internal rear view mirror to the remote ECU or DC may include coaxial cable and may utilize communication protocols and other connection methods, protocols, networks and elements, such as U.S. patent No.11,252,376; no.11,201,994; no.10,922,563 and/or No.10,567,705 (all of which are incorporated herein by reference in their entirety). As an alternative to coaxial cable, the wired connection carrying digital serial data and connecting the internal rear view mirror to the remote ECU or DC may comprise a shielded twisted pair cable. The bi-directional communication between the electronics of the interior rearview mirror assembly and the remote ECU or DC may include data transmission utilizing an ethernet protocol/network in accordance with the disclosure of U.S. patent No.10,567,633, the entire contents of which are incorporated herein by reference. Low Voltage Differential Signaling (LVDS) may be used to reduce transmission/communication errors. Camera calibration data may be digitally communicated from a DMS camera disposed in the lens section to a remote ECU or DC. The DMS camera disposed in the lens portion may be controlled via data/signals carried by a wired connection from the ECU or DC that connects the ECU or DC to the interior rearview mirror assembly. The power of the circuitry housed in the lens portion may be provided by a power-over-cable and carried by a wired connection from an ECU or DC connected to the interior rearview mirror assembly.
Accordingly, the present application provides a vehicle interior rearview mirror assembly comprising a lens portion adjustably disposed at a mounting base configured to attach the vehicle interior rearview mirror assembly to an interior portion of a vehicle equipped with the vehicle interior rearview mirror assembly, wherein the lens portion comprises an interior mirror reflective element. The internal specular reflective element has a planar front surface and a planar back surface opposite the planar front surface. When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle, the planar front surface is closer to a driver of the vehicle than the planar rear surface. The internal specular reflective element includes a specular transflector that transmits near IR light incident thereon, transmits visible light incident thereon, and reflects visible light incident thereon. The vehicle interior mirror assembly further includes a camera disposed within the lens portion and viewed through the mirror transflector of the interior mirror reflective element, wherein the camera moves in concert with the lens portion when the lens portion is adjusted relative to the mounting base to adjust the driver's rearward view when the vehicle interior mirror assembly is attached at the interior portion of the equipped vehicle. The camera includes an imaging sensor having a Quantum Efficiency (QE) of at least 15% for near infrared (near IR) light having a wavelength of 940 nm. The camera is operable to acquire frames of image data. The vehicle interior rearview mirror assembly further includes a Driver Monitoring System (DMS) data processor. The vehicle interior rearview mirror assembly further includes first, second and third near IR illumination sources disposed within the mirror head and operable to emit near IR light through the specular reflector of the interior specular reflective element. The first near IR radiation source is at a first angle relative to the planar front surface of the internally specular reflective element. The second near IR radiation source is at a second angle relative to the planar front surface of the internal specular reflective element. The third near IR radiation source is at a third angle relative to the planar front surface of the internal specular reflective element. The first angle is a different angle than the second angle, and the third angle is a different angle than the first angle. When the vehicle interior rearview mirror assembly is attached to an interior portion of the equipped vehicle and the lens portion is adjusted to provide a rearward view of the driver, the first near IR radiation source, when energized, irradiates a driver-side front seat area of the equipped vehicle and a passenger-side front seat area of the equipped vehicle. When the vehicle interior rearview mirror assembly is attached to an interior portion of the equipped vehicle and the lens portion is adjusted to provide a rear view of the driver, the second near IR radiation source, when energized, irradiates the driver-side front seat area of the equipped vehicle. When the vehicle interior rearview mirror assembly is attached to an interior portion of the equipped vehicle and the lens portion is adjusted to provide a driver's rearward view, the third near IR radiation source, when energized, irradiates the passenger-side front seat area of the equipped vehicle. The DMS data processor is operable to provide a driver monitoring function and an occupant detection function. The camera acquires the frame of driver monitor image data and powers the first and second near-IR illumination sources when the camera acquires the frame of driver monitor image data, and wherein data derived from the acquired frame of driver monitor image data is processed at the DMS data processor for driver monitoring, and wherein the third near-IR illumination source is not powered when the camera is acquiring the frame of driver monitor image data. The camera acquires the occupant detection image data frames while the DMS data processor is operating to provide the occupant detection function, and powers the first, second, and third near IR illumination sources while the camera is acquiring the occupant detection image data frames, and wherein data derived from the acquired occupant detection image data frames is processed at the DMS data processor for occupant detection.
The first near IR illumination source may include at least one near IR emitting light emitting diode, and the second near IR illumination source may include at least one near IR emitting light emitting diode, and the third near IR illumination source may include at least one near IR emitting light emitting diode. When the vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle, the first near IR illumination source may include at least two near IR emitting light emitting diodes arranged side-by-side with one another. When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle, the second near IR illumination source may include at least two near IR emitting light emitting diodes vertically arranged one above the other. When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle, the third near IR illumination source may include at least two near IR emitting light emitting diodes vertically arranged one above the other.
The first angle may be an angle in the range of about 80 degrees to about 100 degrees relative to the planar front surface of the internal specular reflective element. For example, the first angle is an angle of about 90 degrees relative to the planar front surface of the internally specular reflective element. The second angle may be an angle in the range of about 5 degrees to about 35 degrees relative to the planar front surface of the internal specular reflective element. For example, the second angle may be an angle of about 20 degrees relative to the planar front surface of the internal specular reflective element. The third angle may be an angle in the range of about 5 degrees to about 35 degrees relative to the planar front surface of the internal specular reflective element. For example, the third angle may be an angle of about 10 degrees relative to the planar front surface of the internal specular reflective element.
The first near IR illumination source may include (i) a first circuit board and (ii) at least one near IR emitting light emitting diode disposed at the first circuit board. The second near-IR illumination source may include (i) a second circuit board, (ii) at least one near-IR emitting light emitting diode disposed at the second circuit board, and (iii) a reflector surface mounted at the second circuit board and configured to concentrate near-IR light emitted by the second near-IR illumination source toward a front seat area on a driver side of the equipped vehicle. The third near-IR illumination source may include (i) a third circuit board, (ii) at least one near-IR emitting light emitting diode disposed at the third circuit board, and (iii) a reflector surface mounted at the third circuit board and configured to concentrate near-IR light emitted by the third near-IR illumination source toward a front seat area on a driver side of the equipped vehicle. The first circuit board may be disposed between the second circuit board and the third circuit board and electrically connected to the second circuit board and the third circuit board via respective ribbon cables. At least two of the first, second and third near-IR illumination sources are powered to illuminate an area within an interior compartment of the equipped vehicle on which a driver operating the equipped vehicle sits in response to processing of data derived at least in part from image data acquired by the camera by the DMS data processor. The vehicle interior rearview mirror assembly may include an illuminator driver for controlling illumination of the first, second and third near IR illumination sources. The first, second and third circuit boards may be electrically interconnected with each other via respective ribbon cables.
According to one aspect of the vehicle interior rearview mirror assembly, when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the equipped vehicle includes a left-hand drive vehicle, the first, second, and third near IR illumination sources are disposed on a right-hand side of the lens portion as viewed by a driver of the equipped vehicle, and wherein the third near IR illumination source is farther from a position of the camera within the lens portion than the second near IR illumination source. The second angle of the second near IR illumination source is at an angle of between 10 and 30 degrees relative to the planar front surface of the interior specular reflective element, such as between 15 and 25 degrees relative to the planar front surface of the interior specular reflective element, when the vehicle interior rearview mirror assembly is attached at the interior portion of the equipped vehicle. For example, the second angle of the second near IR radiation source may be at an angle of about 20 degrees relative to the planar front surface of the internal specular reflective element. The third angle of the third near IR illumination source may include a non-zero angle of up to 20 degrees relative to the planar front surface of the internal specular reflective element, such as an angle of between 5 degrees and 15 degrees relative to the planar front surface of the internal specular reflective element. For example, the third angle of the third near IR radiation source may be at an angle of about 10 degrees to the planar front surface of the internal specular reflective element.
According to another aspect of the vehicle interior rearview mirror assembly, when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle, and when the equipped vehicle includes a left-hand driving vehicle, the first, second, and third near IR illumination sources may be disposed at a left-hand side of the lens portion as viewed by a driver of the equipped vehicle, and wherein the second near IR illumination source is farther from the camera than the third near IR illumination source. The second angle of the second near IR illumination source may include a non-zero angle of up to 20 degrees relative to the planar front surface of the internal specular reflective element, such as an angle of between 5 degrees and 15 degrees relative to the planar front surface of the internal specular reflective element. For example, the second angle of the second near-IR illumination source may include an angle of about 10 degrees relative to the planar front surface of the internal specular reflective element. The third angle of the third near IR illumination source may include an angle between 10 degrees and 30 degrees relative to the planar front surface of the internal specular reflective element, e.g., an angle between 15 degrees and 25 degrees relative to the planar front surface of the internal specular reflective element. For example, the third angle of the third near IR radiation source may comprise an angle of about 20 degrees relative to the planar front surface of the internal specular reflective element.
According to another aspect of the vehicle interior rearview mirror assembly, the first, second, and third near IR illumination sources may be disposed on a right hand side of the lens portion as viewed by a driver of the equipped vehicle when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle, and when the equipped vehicle includes a right hand driving vehicle. The second angle of the second near IR illumination source may include an angle between 10 degrees and 30 degrees relative to the planar front surface of the internal specular reflective element, e.g., an angle between 15 degrees and 25 degrees relative to the planar front surface of the internal specular reflective element. For example, the second angle of the second near-IR illumination source may include an angle of about 20 degrees relative to the planar front surface of the internal specular reflective element. The third angle of the third near IR illumination source comprises a non-zero angle of up to 20 degrees with respect to the planar front surface of the internal specular reflective element, e.g., an angle of between 5 degrees and 15 degrees with respect to the planar front surface of the internal specular reflective element. For example, the third angle of the third near IR radiation source may comprise an angle of about 10 degrees relative to the planar front surface of the internal specular reflective element.
According to another aspect of the vehicle interior rearview mirror assembly, the first, second and third near IR illumination sources may be disposed on a left-hand side of the lens portion as viewed by a driver of the equipped vehicle when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle, and when the equipped vehicle includes a right-hand driving vehicle. The second angle of the second near IR illumination source may include a non-zero angle of up to 20 degrees relative to the planar front surface of the internal specular reflective element, such as an angle of between 5 degrees and 15 degrees relative to the planar front surface of the internal specular reflective element. For example, the second angle of the second near-IR illumination source may include an angle of about 10 degrees relative to the planar front surface of the internal specular reflective element. The third angle of the third near IR illumination source may include an angle between 10 degrees and 30 degrees relative to the planar front surface of the internal specular reflective element, e.g., an angle between 15 degrees and 25 degrees relative to the planar front surface of the internal specular reflective element. For example, the third angle of the third near IR radiation source may comprise an angle of about 20 degrees relative to the planar front surface of the internal specular reflective element.
Optionally, the specular reflector includes a multi-layer stack formed from a plurality of thin film coating layers. The specular reflector includes at least one silicon layer. The plurality of thin film coating layers includes repeated alternating layers of higher refractive index layers and lower refractive index layers, and wherein the higher refractive index layers have a refractive index greater than 2 and the lower refractive index layers have a refractive index less than 1.5. The lower refractive index layer comprises a silicon oxide layer. The higher refractive index layer comprises a titanium oxide layer. The higher refractive index layer comprises a niobium oxide layer. The plurality of film coating layers may include at least five (5) layers or at least seven (7) layers. A plurality of thin film coatings forming a multi-layer stack of specular reflectors are applied to a flat glass surface of a glass substrate of an internal specular reflective element. The multi-layer stack forming the specular reflector includes an innermost thin film coating closest to the planar glass surface of the glass substrate and includes an outermost thin film coating furthest from the planar glass surface of the glass substrate. The innermost thin film coating closest to the planar glass surface of the glass substrate has a higher refractive index than the next closest thin film coating to the planar glass surface of the glass substrate. The outermost film coating furthest from the planar glass surface of the glass substrate comprises a transparent conductive film having a refractive index that is higher than the refractive index of the layer of the multi-layer stack to which it is applied. The transparent conductive film includes an Indium Tin Oxide (ITO) layer. The Indium Tin Oxide (ITO) layer has a sheet resistance of less than 20 ohms/square. The glass substrate is heated to a temperature of at least 250 degrees celsius during the deposition of the Indium Tin Oxide (ITO) layer.
The layer of the specular reflector may be deposited on the glass substrate of the internal specular reflective element using medium frequency AC sputtering. The layers of the specular reflector may be deposited on the glass substrate of the internal specular reflective element using medium frequency AC sputtering in a multi-station/multi-target in-line sputter deposition process. The layers of the specular reflector may be deposited onto the glass substrate of the internal specular reflective element in a batch vacuum deposition chamber.
According to one aspect of the vehicle interior rearview mirror assembly, the first near IR illumination source emits near IR light having a wavelength of approximately 940nm when energized, and wherein the second near IR illumination source emits near IR light having a wavelength of approximately 940nm when energized, and wherein the third near IR illumination source emits near IR light having a wavelength of approximately 940nm when energized.
According to one aspect of the vehicle interior rearview mirror assembly, the vehicle interior rearview mirror assembly includes a vehicle EVO TM An interior rearview mirror assembly.
According to one aspect of the vehicle interior rearview mirror assembly, the vehicle interior rearview mirror assembly includes a vehicle Infinity TM An interior rearview mirror assembly.
According to one aspect of the vehicle interior rearview mirror assembly, the vehicle interior rearview mirror assembly includes a rimless interior rearview mirror assembly.
According to one aspect of the vehicle interior rearview mirror assembly, the interior specular reflective element comprises an electrochromic specular reflective element having a front glass substrate and a rear glass substrate, and wherein the flat rear surface of the front glass substrate has a transparent conductive coating disposed thereat, and wherein the flat front surface of the rear glass substrate has a conductive coating disposed thereat, and wherein the electrochromic medium is disposed between and in contact with the transparent conductive coating disposed at the flat rear surface of the front glass substrate and the conductive coating disposed at the flat front surface of the rear glass substrate, and wherein the specular reflector is disposed at the flat front surface or the flat rear surface of the rear glass substrate.
The rear glass substrate has a plate thickness of about 1.6mm or less. The front glass substrate includes an exposed rounded peripheral edge having a radius of curvature of at least 2.5mm, and wherein the exposed rounded peripheral edge provides a curved transition between a planar front surface of the front glass substrate and an outer surface of a wall portion of the mirror housing of the mirror head. The front glass substrate is at least about 2mm thick. The front glass substrate comprises a low iron (low Fe) soda lime glass. The rear glass substrate has a plate thickness of about 1.6mm or less.
Alternatively, the housing portion of the mirror housing of the lens portion may circumscribe the peripheral edge of the front glass substrate, and wherein the housing portion has a rounded outer surface providing a curved transition between the flat front surface of the front glass substrate and the outer surface of the wall portion of the mirror housing of the lens portion.
Alternatively, the front glass substrate can have an exposed rounded peripheral edge having a radius of curvature of at least 2.5mm, and wherein the exposed rounded peripheral edge provides a curved transition between the planar front surface of the front glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head.
The specular reflector includes a plurality of thin film coating layers. The specular transflector is disposed at the planar rear surface of the rear glass substrate. The rear glass substrate has a plate thickness of about 1.6mm or less. The specular reflector includes at least one silicon layer. The plurality of thin film coating layers includes repeated alternating layers of higher refractive index layers and lower refractive index layers, and wherein the higher refractive index layers have a refractive index greater than 2 and the lower refractive index layers have a refractive index less than 1.5. The lower refractive index layer may comprise a silicon oxide layer. The higher refractive index layer may comprise a niobium oxide layer. The higher refractive index layer may comprise a titanium oxide layer. The layer of specular reflector may be deposited onto the back glass substrate using medium frequency AC sputtering. The layers of specular reflectors may be deposited onto the rear glass substrate using intermediate frequency AC sputtering in a multi-station/multi-target inline vacuum deposition process. The layer of specular transflector may be deposited onto the back glass substrate in a batch vacuum deposition chamber.
A specular transflector is coated onto the rear glass substrate. The rear glass substrate coated with the transflector may have a photopic visible light reflectance of at least 45% r. The rear glass substrate coated with the transflector may have a photopic visible light reflectance of at least 55% r. The rear glass substrate coated with the transflector may have a photopic visible light reflectance of at least 65% r. The back glass substrate coated with the transflector may have a visible light transmission of at least 15% t. The back glass substrate coated with the transflector may have a visible light transmission of at least 20% t. The back glass substrate coated with the transflector may have a visible light transmission of at least 25% t. The back glass substrate coated with the transflector may have a visible light transmission of less than 35% t. The rear glass substrate coated with the transflector may have a visible light transmission of less than 30% t. The back glass substrate coated with the transflector may have a near-IR light transmittance of at least 60% t. The back glass substrate coated with the transflector may have a near-IR light transmittance of at least 70% t. The back glass substrate coated with the transflector may have a near-IR light transmittance of at least 80% t. The rear glass substrate coated with the transflector may have a visible light transmittance in the range of 20% t to 35% t. The rear glass substrate coated with the transflector may have a visible light transmittance in the range of 15% t to 35% t. The rear glass substrate coated with the transflector may have a visible light transmittance in the range of 20% t to 30% t.
The electrochromic specular reflective element may have a visible light transmittance in the range of 20% t to 30% t in the fully faded state. The electrochromic specular reflective element may have a visible light transmittance in the range of 22% t to 25% t in the fully faded state. The electrochromic specular reflective element may have a visible light transmittance in the range of 10% t to 20% t in the fully darkened state. The electrochromic specular reflective element may have a visible light transmittance of about 16% t in a fully darkened state. The electrochromic specular reflective element may have a visible light reflectance in the range of 40% r to 65% r in the fully faded state. The electrochromic specular reflective element may have a visible light reflectance in the range of 43% r to 55% r in the fully faded state. The electrochromic specular reflective element may have a near IR transmittance near 940nm of at least 50% t in a fully darkened state. The electrochromic specular reflective element may have a near IR transmittance near 940nm of at least 70% t in a fully darkened state. The electrochromic specular reflective element may have a near IR transmittance near 940nm of at least 50% t in a fully faded state. The electrochromic specular reflective element may have a near IR transmittance near 940nm of at least 70% t in a fully faded state.
The front glass substrate may include a circumferential conductive channel disposed at the transparent conductive coating. The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of less than 50 ohms/square. The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of greater than 20 ohms/square. The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of greater than 30 ohms/square.
The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of less than 30 ohms/square. The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of less than 25 ohms/square. The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of less than 20 ohms/square. The transparent conductive coating disposed at the flat rear surface of the front glass substrate may have a sheet resistance of 10-15 ohms/square.
The rear glass substrate may include a circumferential conductive channel disposed at an outermost layer of the conductive coating. The outermost layer of the conductive coating disposed at the flat front surface of the rear glass substrate may have a sheet resistance of greater than 30 ohms/square. The outermost layer of the conductive coating disposed at the flat front surface of the rear glass substrate may have a sheet resistance of less than 30 ohms/square.
The outermost layer of the conductive coating disposed at the planar front surface of the rear glass substrate may have a sheet resistance of less than 25 ohms/square. The outermost layer of the conductive coating disposed at the planar front surface of the rear glass substrate may have a sheet resistance of less than 20 ohms/square. The outermost layer of the conductive coating disposed at the flat front surface of the rear glass substrate may have a sheet resistance of 10-15 ohms/square.
The internally specular reflective element may have (i) a visible light transmittance of 20-25% (ii) a near IR transmittance of at least 60% near 940nm, and (iii) a visible light reflectance of at least 43%. The internal specular reflective element may have a near IR transmittance near 940nm of at least 70%. The internal specular reflective element may have a near IR transmittance near 940nm of at least 80%. The internal specular reflective element may have a visible light reflectivity of at least 48%. The internal specular reflective element may have a visible light reflectivity of at least 53%.
The internal specular reflective element may include an electrochromic specular reflective element having a front glass substrate and a back glass substrate, and wherein the flat back surface of the front glass substrate has a transparent conductive coating disposed thereat, and wherein the flat front surface of the back glass substrate has a conductive coating disposed thereat, and wherein an electrochromic medium is disposed between and in contact with the transparent conductive coating and the conductive coating disposed at the flat back surface of the front glass substrate, and wherein the specular transflector is disposed at the flat front surface or the flat back surface of the back glass substrate.
The internal specular reflective element may have (i) a visible light transmission of 20-25% (ii) a near IR transmission around 940nm of at least 60%, and (iii) a visible light reflection of at least 43%, and the internal specular reflective element may comprise a prismatic specular reflective element, and wherein the planar front surface is not parallel to the planar back surface, and wherein the specular reflector is disposed at the planar back surface of the prismatic specular reflective element.
The internal specular reflective element comprises a prismatic specular reflective element, and wherein the planar front surface of the glass substrate is not parallel to the planar back surface, and wherein the specular reflector is disposed at the planar back surface of the prismatic specular reflective element. The vehicle interior rearview mirror assembly may include a rimless interior rearview mirror assembly. Alternatively, the housing portion of the mirror housing of the lens portion may circumscribe the peripheral edge of the glass substrate of the internal mirror reflective element, wherein the housing portion has a rounded outer surface providing a curved transition between the flat front surface of the glass substrate and the outer surface of the wall portion of the mirror housing of the lens portion. Alternatively, the glass substrate can have an exposed rounded peripheral edge having a radius of curvature of at least 2.5mm, wherein the exposed rounded peripheral edge provides a curved transition between the planar front surface of the glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head.
The specular reflector maintains the chromatic aberration between 2.3 and 3.2 at any viewing angle up to 45 degrees for the driver. The specular reflector may maintain a chromatic aberration between 2.3 and 2.8 at any viewing angle up to 45 degrees for the driver. The specular reflector may maintain a chromatic aberration between 2.3 and 2.5 at any viewing angle up to 45 degrees for the driver. .
The camera acquires a series of image data frames, wherein the series of acquired image data frames includes a plurality of driver monitoring image data frames and a plurality of occupant detection image data frames. The driver monitor image data frame and the occupant detection image data frame do not overlap.
The second near-IR illumination source is oriented at the lens portion such that if the vehicle interior rearview mirror assembly is mounted in a left-hand-drive vehicle and adjusted to provide a rearview view to a driver of the left-hand-drive vehicle, the light beam emitted by the second near-IR illumination source will be directed toward an area of the driver of the left-hand-drive vehicle, and wherein the third near-IR illumination source is oriented at the lens portion such that if the vehicle interior rearview mirror assembly is mounted in a right-hand-drive vehicle and adjusted to provide a rearview view to a driver of the right-hand-drive vehicle, the light beam emitted by the third near-IR illumination source will be directed toward an area of the driver of the right-hand-drive vehicle.
An internal specular reflective element is attached at the mirror attachment plate, and wherein the camera and the first, second, and third near IR illumination sources are disposed behind the mirror attachment plate and aligned with respective holes through the mirror attachment plate. The heat dissipating element is attached at the mirror attachment plate, wherein the mirror attachment plate and the heat dissipating element enclose the camera, the first, second and third near IR illumination sources and the DMS data processor and function to limit electromagnetic interference of the camera, the first, second and third near IR illumination sources and the DMS data processor.
The second near-IR illumination source comprises at least one narrow field-of-view illuminator and the third near-IR illumination source comprises at least one narrow field-of-view illuminator.
The first near IR radiation source comprises at least one wide field of view illuminator.
The DMS data processor may have a computational speed of at least 0.1 trillion floating point operations per second. The DMS data processor may have a computational speed of at least 0.3 trillion floating point operations per second. The DMS data processor may have a computational speed of at least 0.6 trillion floating point operations per second. The DMS data processor may have a computational speed of at least 1 trillion floating point operations per second. The DMS data processor may have a computational speed of at least 1.5 trillion floating point operations per second. The DMS data processor may operate with less than 5 watts of power consumption. The DMS data processor may operate with less than 4 watts of power consumption. The DMS data processor operates with less than 3 watts of power consumption. The DMS data processor may have a computational speed of at least 0.25 trillion floating point operations per second at less than 3 watts of power consumption. The DMS data processor may have a computation speed of at least 0.1 Trillion Operations Per Second (TOPS). The DMS data processor may have a computation speed of at least 0.2 Trillion Operations Per Second (TOPS). The DMS data processor may have a computation speed of at least 0.5 Trillion Operations Per Second (TOPS).
The vehicle interior rearview mirror assembly may include a thermal element that maintains the touch surface of the mirror head at a temperature less than 60 degrees celsius, such as a temperature less than 50 degrees celsius. The thermal element may include at least one vent through the mirror housing of the mirror head. The thermal element may include a heat sink thermally coupled to the heat-generating components of the DMS data processor. The thermal element may comprise a thermal interface material element disposed between at least some of the heat-generating components of the DMS data processor and the heat sink. The thermal interface material element may have a thermal conductivity greater than 2W/m-K, such as greater than 3W/m-K, such as greater than 4W/m-K.
The vehicle interior rearview mirror assembly may include filters positioned at the first, second, and third near IR illumination sources, wherein the filters transmit 940nm near IR light and attenuate visible light. The optical filters may have a corresponding plate thickness of at least 0.8mm, such as at least 1.4mm, such as at least 1.9 mm. The filter may have a corresponding plate thickness of less than 6mm, for example less than 4mm, for example less than 2 mm.
The first, second, and third near IR illumination sources may include first, second, and third groups of light emitting diodes. Each of the first, second, and third groups of light emitting diodes operates with a forward current through each light emitting diode of at least 500 milliamps, such as at least 750 milliamps, such as at least 1000 milliamps.
The pulse duty cycle of the first and second near IR illumination sources may be at least 8% when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality. The pulse duty cycle of the first and second near IR illumination sources may be at least 5% when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality. The pulse duty cycle of the first and second near IR illumination sources may be at least 10% when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality. The pulse duty cycle of the first and second near IR illumination sources may be less than 40% when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality. The pulse duty cycle of the first and second near IR illumination sources may be less than 30% when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality. The pulse duty cycle of the first and second near IR illumination sources may be less than 20% when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality.
The first and second near IR illumination sources provide at least 1W/m at the head of the driver when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality 2 For example at least 1.8W/m 2 For example at least 2W/m 2 For example at least 2.3W/m 2 For example at least 2.5W/m 2 Near IR irradiance of (c).
When the vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality,the first and third near IR radiation sources provide at least 0.15W/m in the front passenger area of the equipped vehicle 2 For example at least 0.25W/m 2 For example at least 0.4W/m 2 Near IR irradiance of (c).
The first, second and third near IR illumination sources provide at least 0.1W/m at a rear seat area of the equipped vehicle when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality 2 For example at least 0.15W/m 2 For example at least 0.2W/m 2 Near IR irradiance of (c).
The second near IR radiation source emits light toward the head area of the driver. The head area of the driver comprises a head sash area of at least 80mm x 80mm, such as at least 100mm x 100mm, such as at least 150mm x 150 mm.
The camera may include an imaging sensor having a Quantum Efficiency (QE) of at least 22% for near infrared (near IR) light having a wavelength of 940 nm. The camera may include an imaging sensor having a Quantum Efficiency (QE) of at least 32% for near infrared (near IR) light having a wavelength of 940 nm.
The camera may include a CMOS imaging sensor. The CMOS imaging sensor of the camera may comprise a silicon layer having a thickness of at least 3.5 μm. The CMOS imaging sensor of the camera may comprise a silicon layer having a thickness of at least 4.5 μm. The CMOS imaging sensor of the camera may comprise a silicon layer having a thickness of at least 5.5 μm.
The imaging sensor of the camera may include a Back Side Illumination (BSI) imaging sensor.
The camera may acquire frames of image data at a frame acquisition rate of at least 15 frames per second. The camera may acquire frames of image data at a frame acquisition rate of at least 30 frames per second. The camera may acquire frames of image data at a frame acquisition rate of at least 60 frames per second.
The camera head includes a lens, and wherein an outermost surface of the lens of the camera head may be spaced apart from a rear portion of the internal specular reflecting element where the camera head is viewed through the specular reflector of the internal specular reflecting element. The camera may be spaced at least 0.5mm from the rear of the internal specular reflecting element where the camera is viewed through the specular reflector of the internal specular reflecting element. The camera may be spaced at least 1mm from the rear of the internal specular reflecting element where the camera is viewed through the specular reflector of the internal specular reflecting element. The camera may be spaced at least 2mm from the rear of the internal specular reflecting element where the camera is viewed through the specular reflector of the internal specular reflecting element. Where the camera is viewed through the specular reflector of the internal specular reflecting element, the camera may be spaced less than 4mm from the rear of the internal specular reflecting element.
The camera may include an imaging array of at least 2.3 megapixels. The camera may include an imaging array of at least 5 megapixels. The camera may include an imaging array of at least 5.5 megapixels. The imaging sensor of the camera may include a plurality of photosensors and a spectral filter disposed at the photosensors such that some photosensors are sensitive to visible light and others are sensitive to near infrared light.
By processing the acquired driver monitor image data frames at the DMS data processor, the DMS data processor may determine at least one selected from the group consisting of: (i) driver attention, (ii) driver drowsiness, and (iii) driver gaze direction. The DMS data processor may determine the presence of an occupant in the equipped vehicle by processing acquired occupant detection image data frames at the DMS data processor.
When the driver adjusts the lens portion to adjust his or her rearview field of view, the DMS data processor adjusts the processing of the acquired driver monitor image data frames to accommodate the adjustment of the lens portion.
The vehicle interior rearview mirror assembly may include a display screen disposed in a mirror head and viewable through an interior specular reflective element when displaying an image, and wherein the display screen is backlit by a backlight array comprising a plurality of backlit Light Emitting Diodes (LEDs) that emit visible light. The display screen may comprise a video display screen that, when actuated, displays video images derived from image data acquired by an external viewing camera of the vehicle. The vehicle interior rearview mirror assembly may operate in a display mode in which the video display screen displays video images derived from image data acquired by a rearview camera of an equipped vehicle and a mirror mode in which the video display screen is deactivated and a driver views the rear of the equipped vehicle through reflection at an interior mirror reflective element.
The lens portion is adjustable about the mounting base via a ball and socket pivot joint. The mounting base may include a ball pivot element and the lens portion may include a ball pivot element, wherein the ball pivot joint includes the ball pivot element of the mounting base and the ball pivot element of the lens portion. The portion of the equipped vehicle to which the mounting base is configured to be attached may include a portion of the cabin interior side of the front windshield of the equipped vehicle. The mirror mounting button is adhesively bonded to a portion of the cabin interior side of the vehicle windshield, and wherein the mounting base includes a mirror attachment portion configured to mount the vehicle interior rearview mirror assembly to the mirror mounting button bonded to the vehicle windshield.
Alternatively, the mounting base may house a front-view camera that views the front of the equipped vehicle through the vehicle windshield when the vehicle interior rearview mirror assembly is mounted at the cabin interior side of the vehicle windshield. The front-view camera acquires image data for use by a driving assistance system of the equipped vehicle. A driving assistance system of the equipped vehicle processes image data acquired by the front-view camera for at least one selected from the group consisting of: (i) lane detection, (ii) pedestrian detection, (iii) vehicle detection, (iv) collision avoidance, (v) Adaptive Cruise Control (ACC), (vi) traffic sign recognition, (vii) traffic light detection, and (viii) automatic headlamp control.
Alternatively, the mounting base may house a color camera that, when the vehicle interior mirror assembly is mounted at the cabin interior side of the vehicle windshield, observes the front of the equipped vehicle through the vehicle windshield and acquires image data for at least one selected from the group consisting of: (i) An event recording system for a equipped vehicle and (ii) an augmented reality video display system for a equipped vehicle.
Alternatively, the mounting base may house at least one sensor having a sensing field into the interior compartment of the equipped vehicle when the vehicle interior rearview mirror assembly is mounted at the inboard side of the vehicle windshield. The at least one sensor may comprise a radar sensor. The at least one sensor may comprise a lidar sensor. The at least one sensor may comprise an ultrasonic sensor.
Alternatively, the mounting base may house a camera having a field of view into the interior compartment of the equipped vehicle when the vehicle interior rearview mirror assembly is mounted at the inboard side of the vehicle windshield.
The DMS data processor may include an integrated circuit chip. The integrated circuit chip may include at least one 32-bit RISC ARM processor core. The integrated circuit chip may include at least one 64-bit RISC ARM processor core. The integrated circuit chip may have a computation speed of at least 0.1 Trillion Operations Per Second (TOPS). The integrated circuit chip may have a computation speed of at least 0.2 Trillion Operations Per Second (TOPS). The integrated circuit chip may have a computation speed of at least 0.5 Trillion Operations Per Second (TOPS). The integrated circuit chip may operate with less than 5 watts of power consumption. The integrated circuit chip may operate with less than 4 watts of power consumption. The integrated circuit chip may operate with less than 3 watts of power consumption. The integrated circuit chip may have a computational speed of at least 0.25 trillion floating point operations per second at power consumption of less than 3 watts.
The vehicle interior rearview mirror assembly may include an electrochromic interior rearview mirror assembly, wherein the interior specular reflective element includes an electrochromic interior specular reflective element, and wherein the electrochromic interior specular reflective element has a visible light transmittance in a range of 20% t to 25% t and a near IR transmittance around 940nm of at least 65% t when in a fully faded state, and wherein the imaging sensor includes a back-illuminated (BSI) imaging sensor having a Quantum Efficiency (QE) of at least 22% for near infrared (near-IR) light having a wavelength of 940nm, and wherein the camera includes at least a 2.3 megapixel imaging array and acquires frames of image data at a frame acquisition rate of at least 60 frames per second, and wherein the data processor includes an integrated circuit chip having a computation speed of at least 0.1 trillion times per second (TOPS) and operates at a power consumption of less than 5 watts.
The first near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 2000mW when powered, wherein the second near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 2000mW when powered, and the third near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 2000mW when powered. The first near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 3500mW when powered, wherein the second near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 3500mW when powered, and the third near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 3500mW when powered. The first near IR illumination source may comprise at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered, wherein the second near IR illumination source may comprise at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered, and the third near IR illumination source may comprise at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered.
The first near IR illumination source may include at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and the second near IR illumination source may include at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and the third near IR illumination source may include at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL).
The electrochromic interior rearview mirror assembly may include a frameless electrochromic interior rearview mirror assembly. The frameless electrochromic interior rear view mirror assembly can include an Infinity TM Electrochromic interior rearview mirror assembly. The frameless electrochromic interior rearview mirror assembly may include an EVO TM Electrochromic interior rearview mirror assembly.
The vehicle interior rearview mirror assembly may include a prismatic interior rearview mirror assembly, wherein the interior specular reflective element includes a prismatic interior specular reflective element, and wherein the prismatic interior specular reflective element has a visible light transmission in a range of 20% t to 25% t and a near IR transmission around 940nm of at least 65% t, and wherein the imaging sensor includes a Back Side Illumination (BSI) imaging sensor having a Quantum Efficiency (QE) of at least 22% for near infrared (near IR) light having a wavelength of 940nm, and wherein the camera includes at least a 2.3 megapixel imaging array and acquires frames of image data at a frame acquisition rate of at least 60 frames per second, and wherein the data processor includes an integrated circuit chip having a computational speed of at least 0.1 Trillion Operations Per Second (TOPS) and operates with a power consumption of less than 5 watts. The first near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 2000mW when powered, and the second near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 2000mW when powered, and the third near IR illumination source may comprise at least one near IR LED having a total radiant flux of at least 2000mW when powered. The first near IR illumination source may include at least one near IR LED having a total radiant flux of at least 3500mW when powered, and the second near IR illumination source may include at least one near IR LED having a total radiant flux of at least 3500mW when powered, and the third near IR illumination source may include at least one near IR LED having a total radiant flux of at least 3500mW when powered. The first near IR illumination source may include at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered, and the second near IR illumination source may include at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered, and the third near IR illumination source may include at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered.
The first near IR illumination source may include at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and the second near IR illumination source may include at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and the third near IR illumination source may include at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL).
The prismatic interior rearview mirror assembly may include a frameless prismatic interior rearview mirror assembly. The frameless prism type interior rear-view mirror assembly can include an Infinity TM A prismatic interior rearview mirror assembly. The frameless prism type interior rearview mirror assembly can include an EVO TM Prism type internal rear viewA mirror assembly.
When the vehicle interior rearview mirror assembly is installed in a left-hand drive (LHD) vehicle, the second near IR illumination source may include (i) a circuit board and (ii) a reflector surface mounted at the circuit board and configured to concentrate near IR light emitted by the second near IR illumination source toward a front seat area at a left-hand side of the equipped LHD vehicle. When the first near IR illumination source and the second near IR illumination source are powered and the third near IR illumination source is not powered, the first and second near IR illumination sources may provide at least 1W/m at the eyes of a driver sitting in a front seat area at the left hand side of the equipped LHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the second near IR illumination source are powered and the third near IR illumination source is not powered, the first and second near IR illumination sources may provide at least 1.8W/m at the eyes of a driver sitting in a front seat area at the left hand side of the equipped LHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the second near IR illumination source are powered and the third near IR illumination source is not powered, the first and second near IR illumination sources may provide at least 2W/m at the eyes of a driver sitting in a front seat area at the left hand side of the equipped LHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the second near IR illumination source are powered and the third near IR illumination source is not powered, the first and second near IR illumination sources provide at least 2.3W/m at the eyes of a driver sitting in a front seat area at the left hand side of the equipped LHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the second near IR illumination source are powered and the third near IR illumination source is not powered, the first and second near IR illumination sources may provide at least 2.5W/m at the eyes of a driver sitting in a front seat area at the left hand side of the equipped LHD vehicle 2 Near IR irradiance of (c).
When the vehicle interior rearview mirror assembly is mounted in a right-hand drive (RHD) vehicle, the third near IR illumination source may include (i) a circuit board and (ii) a reflector surface mounted at the circuit board and configured to concentrate near IR light emitted by the third near IR illumination source toward a front seat region at a right-hand side of the equipped RHD vehicle. When the first near IR illumination source and the third near IR illumination source are powered and the second near IR illumination source is not powered, The first and third near IR illumination sources may provide at least 1W/m at the eyes of a driver sitting in a front seat area at the right hand side of the equipped RHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the third near IR illumination source are powered and the second near IR illumination source is not powered, the first and third near IR illumination sources may provide at least 1.8W/m at the eyes of a driver sitting in a front seat area at the right hand side of the equipped RHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the third near IR illumination source are powered and the second near IR illumination source is not powered, the first and third near IR illumination sources may provide at least 2W/m at the eyes of a driver sitting in a front seat area at the right hand side of the equipped RHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the third near IR illumination source are powered and the second near IR illumination source is not powered, the first and third near IR illumination sources may provide at least 2.3W/m at the eyes of a driver sitting in a front seat area at the right hand side of the equipped RHD vehicle 2 Near IR irradiance of (c). When the first near IR illumination source and the third near IR illumination source are powered and the second near IR illumination source is not powered, the first and third near IR illumination sources may provide at least 2.5W/m at the eyes of a driver sitting in a front seat area at the right hand side of the equipped RHD vehicle 2 Near IR irradiance of (c).
When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality, the first, second and third near IR illumination sources are powered and can provide at least 0.15W/m at the front seat region of the equipped vehicle 2 Near IR irradiance of (c). When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality, the first, second and third near IR illumination sources are powered and can provide at least 0.25W/m at the front seat region of the equipped vehicle 2 Near IR irradiance of (c). When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality, the first, second and third near IR illumination sources are powered and can provide at least 0.4W at the front seat region of the equipped vehicle/m 2 Near IR irradiance of (c).
When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality, the first, second and third near IR illumination sources are powered and can provide at least 0.1W/m at the rear seat region of the equipped vehicle 2 Near IR irradiance of (c). When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality, the first, second and third near IR illumination sources are powered and can provide at least 0.1W/m at the rear seat region of the equipped vehicle 2 Near IR irradiance of (c). When the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide occupant detection functionality, the first, second and third near IR illumination sources are powered and can provide at least 0.2W/m at the rear seat region of the equipped vehicle 2 Near IR irradiance of (c).
The specular reflector includes a multi-layer stack of a plurality of thin film coating layers coated onto a planar glass surface of a glass substrate of an internal specular reflective element, wherein the plurality of thin film coating layers include repeated alternating layers of higher refractive index layers having a first refractive index and lower refractive index layers having a second refractive index, wherein the first refractive index may be at least 0.5 greater than the second refractive index. The first refractive index may be at least 0.7 greater than the second refractive index. The first refractive index may be greater than 2. The first refractive index may be less than 1.5.
The higher refractive index layer may comprise a metal oxide thin film coating. The higher refractive index layer may comprise a niobium metal oxide thin film coating. The higher refractive index layer may comprise a titanium metal oxide thin film coating. The higher refractive index layer may comprise a semiconductor metal film coating. The semiconductor metal may have a refractive index of at least 2.4. The semiconductor metal may be silicon. The semiconductor metal may be germanium.
The lower refractive index layer may comprise a metal oxide thin film coating. The lower refractive index layer may comprise a metal oxide thin film coating. The lower refractive index layer may comprise a silicon metal oxide thin film coating. The specular reflector may include at least one silicon thin film coating. The plurality of film coating layers may include at least five (5) film coating layers. The plurality of film coating layers may include at least seven (7) film coating layers. The plurality of film coating layers may include at least ten (10) film coating layers.
The multi-layer stack forming the specular reflector includes an innermost thin film coating closest to the planar glass surface of the glass substrate and includes an outermost thin film coating furthest from the planar glass surface of the glass substrate. The innermost thin film coating closest to the planar glass surface of the glass substrate may comprise a metal oxide thin film coating having a first refractive index. The innermost thin film coating closest to the planar glass surface of the glass substrate may comprise a niobium oxide thin film coating. The innermost thin film coating closest to the planar glass surface of the glass substrate may comprise a titanium oxide thin film coating. The innermost thin film coating closest to the planar glass surface of the glass substrate may have a higher refractive index than the next closest thin film coating to the planar glass surface of the glass substrate. The next closest thin film coating film may comprise a metal oxide thin film coating having a second refractive index. The next closest thin film coating may comprise a silicon oxide thin film coating.
The outermost thin film coating furthest from the planar glass surface of the glass substrate may include a thin film coating having a third refractive index that is higher than the first refractive index. The third refractive index may be at least 0.15 higher than the first refractive index. The third refractive index may be at least 0.2 higher than the first refractive index.
The outermost thin film coating furthest from the planar glass surface of the glass substrate may comprise a transparent conductive thin film coating having a refractive index that is higher than the refractive index of the layer of the multi-layer stack to which it is applied. The transparent conductive film coating may include an Indium Tin Oxide (ITO) layer. The Indium Tin Oxide (ITO) layer may have a sheet resistance of less than 20 ohms/square. The glass substrate may be heated to a temperature of at least 250 degrees celsius during the deposition of the Indium Tin Oxide (ITO) layer.
The interior specular reflective element may include an electrochromic interior specular reflective element having a front glass substrate and a back glass substrate, wherein the back glass substrate includes a glass substrate coated with a specular reflector, and wherein a planar back surface of the front glass substrate has a transparent conductive coating disposed thereat, and wherein a planar front surface of the back glass substrate has a specular reflector disposed thereat, and wherein an electrochromic medium is disposed between and in contact with the transparent conductive coating and the specular reflector disposed at the planar back surface of the front glass substrate. The vehicle interior rearview mirror assembly may include a vehicle EVOTM interior rearview mirror assembly. The rear glass substrate may have a sheet thickness of about 1.6mm or less. The housing portion of the mirror housing of the mirror head circumscribes the peripheral edge of the front glass substrate, wherein the housing portion has a rounded outer surface that provides a curved transition between the flat front surface of the front glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head.
The vehicle interior rearview mirror assembly may include a rimless interior rearview mirror assembly. The rear glass substrate may have a sheet thickness of about 1.6mm or less.
The vehicle interior rearview mirror assembly may include a vehicle Infinity TM An interior rearview mirror assembly. The front glass substrate includes an exposed rounded peripheral edge having a radius of curvature of at least 2.5mm, wherein the exposed rounded peripheral edge provides a curved transition between a planar front surface of the front glass substrate and an outer surface of a wall portion of a mirror housing of the mirror head. The front glass substrate may have a thickness of at least about 2mm. The front glass substrate can have an exposed rounded peripheral edge with a radius of curvature of at least 2.5 mm. The exposed rounded peripheral edge provides a curved transition between the flat front surface of the front glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head. The front glass substrate may comprise a low iron (low Fe) soda lime glass.
The layer of specular reflector may be deposited onto the glass substrate using medium frequency AC sputtering. The thin film coating of the specular reflector may be deposited onto the glass substrate using medium frequency AC sputtering in a multi-station/multi-target in-line sputter deposition process. The layer of specular reflector may be deposited onto the glass substrate in a batch vacuum deposition chamber.
The vehicle interior rearview mirror assembly may include a vehicle electrochromic interior rearview mirror assembly, wherein the interior mirror reflective element includes an electrochromic interior mirror reflective element having a front flat glass substrate and a rear flat glass substrate, and wherein the front flat glass substrate includes a first flat glass surface spaced from a second flat glass surface by a gauge dimension of the front flat glass substrate, and wherein the rear flat glass substrate includes a third flat glass surface spaced from a fourth flat glass surface by a gauge dimension of the rear flat glass substrate, and wherein the second flat glass surface of the front flat glass substrate has a transparent conductive coating disposed thereat, and wherein the third flat glass surface of the rear flat glass substrate has a transparent conductive coating disposed thereat, and wherein the electrochromic medium is disposed between and in contact with the transparent conductive coating disposed at the second flat glass surface of the front flat glass substrate and the transparent conductive coating disposed at the third flat glass surface of the rear flat glass substrate, and wherein the mirror transflector is disposed at the fourth flat glass surface of the rear flat glass substrate.
The transparent conductive thin film coating disposed at the second flat glass surface of the front flat glass substrate may include an Indium Tin Oxide (ITO) layer, and the transparent conductive thin film coating disposed at the third flat glass surface of the rear flat glass substrate may include an Indium Tin Oxide (ITO) layer. The Indium Tin Oxide (ITO) layer disposed at the second planar glass surface of the front planar glass substrate may have a sheet resistance of less than 20 ohms/square, and wherein the Indium Tin Oxide (ITO) layer disposed at the third planar glass surface of the rear planar glass substrate may have a sheet resistance of less than 20 ohms/square. The specular reflector disposed at the fourth planar glass surface of the rear planar glass substrate may include a multi-layer stack formed of a plurality of thin film coating layers. The specular reflector may include at least one silicon layer. The plurality of thin film coating layers may include repeated alternating layers of higher refractive index layers and lower refractive index layers, wherein the higher refractive index layers may have a refractive index greater than 2 and the lower refractive index layers may have a refractive index less than 1.5. The lower refractive index layer may comprise a silicon oxide layer. The higher refractive index layer may comprise a titanium oxide layer. The higher refractive index layer may comprise a niobium oxide layer. The plurality of film coating layers may include at least five (5) layers. The plurality of film coating layers may include at least seven (7) layers.
The vehicle electrochromic interior rearview mirror assembly may comprise a frameless vehicle electrochromic interior rearview mirror assembly. The frameless vehicle electrochromic interior rearview mirror assembly may include an Infinity TM A frameless vehicle electrochromic interior rearview mirror assembly. Infinicity is TM An electrochromic interior mirror reflective element of a vehicle electrochromic interior mirror assembly includes a front planar substrate having a plate thickness of at least about 2mm and a rear planar substrate having a plate thickness of about 1.6mm or less. Infinicity is TM The electrochromic interior mirror reflective element of the vehicle electrochromic interior rearview mirror assembly can include a front planar substrate formed of low iron (low Fe) glass.
The frameless vehicle electrochromic interior rearview mirror assembly may include an EVO TM A frameless vehicle electrochromic interior rearview mirror assembly. EVO (EVO) TM An electrochromic interior mirror reflective element of a vehicle electrochromic interior mirror assembly includes a front planar substrate having a plate thickness of about 1.6mm or less and a rear planar substrate having a plate thickness of about 1.6mm or less.
The vehicle interior rearview mirror assembly may include a vehicle prismatic interior rearview mirror assembly, wherein the interior specular reflective element comprises a prismatic interior specular reflective element, and wherein the prismatic interior specular reflective element comprises a glass substrate, and wherein the glass substrate has a wedge-shaped cross-section with a first planar glass surface separated from a second planar glass surface, and wherein a plane of the first planar glass surface is inclined at an angle relative to a plane of the second planar glass surface, and wherein the second planar glass surface is an uncoated glass surface, and wherein the specular reflector is disposed at the second planar glass surface of the glass substrate of the prismatic interior specular reflective element.
The specular reflector disposed at the second planar glass surface of the glass substrate may include a multi-layer stack formed of a plurality of thin film coating layers. The specular reflector may include at least one silicon layer. The plurality of thin film coating layers may include repeated alternating layers of higher refractive index layers and lower refractive index layers, wherein the higher refractive index layers may have a refractive index greater than 2 and the lower refractive index layers may have a refractive index less than 1.5. The lower refractive index layer may comprise a silicon oxide layer. The higher refractive index layer may comprise a titanium oxide layer. The higher refractive index layer may comprise a niobium oxide layer. The plurality of film coating layers may include at least seven (7) layers.
The plurality of film coating layers may include at least five (5) layers, wherein the vehicle prismatic interior rearview mirror assembly includes a frameless vehicle prismatic interior rearview mirror assembly. The frameless vehicle prismatic interior rearview mirror assembly may include an Infinity TM Frameless vehicle prismatic interior rearview mirror assembly and Infinity TM The glass substrate of the prismatic interior mirror reflective element of the vehicle prismatic interior mirror assembly may be formed of a low iron (low Fe) glass. The frameless vehicle prismatic interior rearview mirror assembly may include an EVO TM Frameless vehicle prismatic interior rearview mirror assembly, and EVO TM The glass substrate of the prismatic interior mirror reflective element of the vehicle prismatic interior mirror assembly may be formed of a low iron (low Fe) glass.
The third angle (of the third near IR illumination source relative to the planar front surface of the internal specular reflective element) may be a different angle than the second angle (of the second near IR illumination source relative to the planar front surface of the internal specular reflective element). The third angle (of the third near IR illumination source relative to the planar front surface of the internal specular reflective element) may be the same angle as the second angle (of the second near IR illumination source relative to the planar front surface of the internal specular reflective element), but in a laterally opposite direction from the second angle.
The specular transflector comprises a multi-layer stack of thin film coatings, and wherein the total physical stack thickness of the specular transflector may be less than 1500nm, for example less than 1000nm. The multi-layer stack of thin film coatings, such as specular reflectors, may have a total physical stack thickness of less than 750 nm.
Changes and modifications to 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 (364)
1. A vehicle interior rearview mirror assembly, the vehicle interior rearview mirror assembly comprising:
A lens portion adjustably disposed at a mounting base configured to attach a vehicle interior mirror assembly at an interior portion of a vehicle equipped with the vehicle interior mirror assembly, wherein the lens portion includes an interior mirror reflective element;
wherein the interior specular reflective element has a planar front surface and a planar rear surface opposite the planar front surface, and wherein the planar front surface is closer to a driver of the vehicle than the planar rear surface when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle;
wherein the internal specular reflective element comprises a specular transflector, and wherein the specular transflector transmits near-IR light incident thereon, transmits visible light incident thereon, and reflects visible light incident thereon;
a camera disposed within the lens portion and viewed through the mirror transflector of the interior specular reflecting element, wherein the camera moves in conjunction with the lens portion when the lens portion is adjusted relative to the mounting base to adjust a driver's rearward view with the vehicle interior rearview mirror assembly attached at the interior portion of the equipped vehicle;
Wherein the camera comprises an imaging sensor having a Quantum Efficiency (QE) of at least 15% for near infrared (near IR) light having a wavelength of 940 nm;
wherein the camera is operable to acquire an image data frame;
a Driver Monitoring System (DMS) data processor;
first, second and third near-IR illumination sources disposed within the lens portion and operable to emit near-IR light through the specular reflector of the internal specular reflective element;
wherein the first near IR radiation source is at a first angle relative to the planar front surface of the internal specular reflective element;
wherein the second near IR radiation source is at a second angle relative to the planar front surface of the internal specular reflective element;
wherein the third near IR radiation source is at a third angle relative to the planar front surface of the internal specular reflective element;
wherein the first angle is a different angle than the second angle;
wherein the third angle is a different angle than the first angle;
wherein the first near IR illumination source, when energized, illuminates a front seat area at a driver side of the equipped vehicle and a front seat area at a passenger side of the equipped vehicle when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and the mirror head is adjusted to provide a rearview view of the driver;
Wherein the second near IR illumination source, when energized, illuminates a front seat area at a driver side of the equipped vehicle when the vehicle interior rearview mirror assembly is attached to an interior portion of the equipped vehicle and the mirror head is adjusted to provide a rear view of the driver;
wherein the third near IR illumination source, when energized, illuminates a front seat area at a passenger side of the equipped vehicle when the vehicle interior rearview mirror assembly is attached to an interior portion of the equipped vehicle and the mirror head is adjusted to provide a driver's rearward view;
wherein the DMS data processor is operable to provide a driver monitoring function and an occupant detection function;
wherein the camera acquires a frame of driver monitor image data while the DMS data processor is operating to provide a driver monitor function, and the first and second near IR illumination sources are powered while the camera acquires the frame of driver monitor image data, and wherein data derived from the acquired frame of driver monitor image data is processed at the DMS data processor for driver monitoring, and wherein the third near IR illumination source is not powered while the camera is acquiring the frame of driver monitor image data; and is also provided with
Wherein the camera acquires a frame of occupant detection image data while the DMS data processor is operating to provide the occupant detection function, and the first, second, and third near IR illumination sources are powered while the camera is acquiring the frame of occupant detection image data, and wherein data derived from the acquired frame of occupant detection image data is processed at the DMS data processor for occupant detection.
2. The vehicle interior rearview mirror assembly of claim 1, wherein said first near IR illumination source comprises at least one near IR emitting light emitting diode, and wherein said second near IR illumination source comprises at least one near IR emitting light emitting diode, and wherein a third near IR illumination source comprises at least one near IR emitting light emitting diode.
3. The vehicle interior rearview mirror assembly of claim 2, wherein said first near IR illumination source comprises at least two near IR emitting light emitting diodes arranged side-by-side one with the other when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle.
4. A vehicle interior rearview mirror assembly according to claim 3, wherein said second near IR illumination source comprises at least two near IR emitting light emitting diodes vertically arranged one above the other when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle.
5. The vehicle interior rearview mirror assembly of claim 4, wherein said third near IR illumination source comprises at least two near IR emitting light emitting diodes vertically disposed one above the other when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle.
6. The vehicle interior rearview mirror assembly of claim 5, wherein said first angle is an angle in the range of about 80 degrees to about 100 degrees relative to a flat front surface of said interior specular reflective element.
7. The vehicle interior rearview mirror assembly of claim 6, wherein said first angle is an angle of about 90 degrees relative to a planar front surface of said interior specular reflective element.
8. The vehicle interior rearview mirror assembly of claim 6, wherein said second angle is an angle in the range of about 5 degrees to about 35 degrees relative to a flat front surface of said interior specular reflective element.
9. The vehicle interior rearview mirror assembly of claim 8, wherein said second angle is an angle of about 20 degrees relative to a planar front surface of said interior specular reflective element.
10. The vehicle interior rearview mirror assembly of claim 6, wherein said third angle is an angle in the range of about 5 degrees to about 35 degrees relative to a flat front surface of said interior specular reflective element.
11. The vehicle interior rearview mirror assembly of claim 10, wherein said third angle is an angle of about 10 degrees relative to a planar front surface of said interior specular reflective element.
12. The vehicle interior rearview mirror assembly of claim 1, wherein said first near IR illumination source comprises (i) a first circuit board and (ii) at least one near IR emitting light emitting diode disposed at said first circuit board.
13. The vehicle interior rearview mirror assembly of claim 12, wherein said second near IR illumination source includes (i) a second circuit board, (ii) at least one near IR emitting light emitting diode disposed at said second circuit board, and (iii) a reflector surface mounted at said second circuit board and configured to concentrate near IR light emitted by the second near IR illumination source toward a front seat area at a driver side of the equipped vehicle.
14. The vehicle interior rearview mirror assembly of claim 13, wherein said third near IR illumination source includes (i) a third circuit board, (ii) at least one near IR emitting light emitting diode disposed at said third circuit board, and (iii) a reflector surface mounted at the third circuit board and configured to concentrate near IR light emitted by the third near IR illumination source toward a front seat area at a driver side of the equipped vehicle.
15. The vehicle interior rearview mirror assembly of claim 14, wherein said first circuit board is disposed between said second and third circuit boards and electrically connected thereto via respective ribbon cables.
16. The vehicle interior rearview mirror assembly of claim 15, wherein at least two of said first, second and third near IR illumination sources are powered to illuminate an area within an interior cabin of a equipped vehicle in which a driver operating the equipped vehicle is seated in response to processing at said DMS data processor data derived at least in part from image data acquired from said camera.
17. The vehicle interior rearview mirror assembly of claim 16, including an illuminator driver for controlling illumination by said first, second and third near IR illumination sources.
18. The vehicle interior mirror assembly of claim 16, wherein the first, second, and third circuit boards are electrically interconnected to one another via respective ribbon cables.
19. The vehicle interior rearview mirror assembly of claim 1, wherein the first, second, and third near IR illumination sources are disposed on a right hand side of the lens portion as viewed by a driver of the equipped vehicle when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the equipped vehicle includes a left hand driving vehicle, and wherein the third near IR illumination source is farther from a position of the camera within the lens portion than the second near IR illumination source.
20. The vehicle interior rearview mirror assembly of claim 19, wherein said second angle of said second near IR illumination source is an angle of between 10 and 30 degrees relative to a planar front surface of an interior specular reflective element when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle.
21. The vehicle interior rearview mirror assembly of claim 19, wherein said second angle of said second near IR illumination source is an angle of between 15 and 25 degrees relative to a planar front surface of said interior specular reflective element.
22. The vehicle interior rearview mirror assembly of claim 19, wherein said second angle of said second near IR illumination source is at an angle of about 20 degrees relative to a planar front surface of said interior specular reflective element.
23. The vehicle interior rearview mirror assembly of claim 19, wherein said third near IR illumination source third angle comprises a non-zero angle of up to 20 degrees relative to a planar front surface of said interior specular reflective element.
24. The vehicle interior rearview mirror assembly of claim 19, wherein said third near IR illumination source third angle is an angle of between 5 and 15 degrees relative to a planar front surface of said interior specular reflective element.
25. The vehicle interior rearview mirror assembly of claim 19, wherein said third near IR illumination source third angle is at an angle of about 10 degrees to a planar front surface of said interior specular reflective element.
26. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources are disposed on a left hand side of the lens portion as viewed by a driver of the equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the equipped vehicle includes a left hand driving vehicle, and wherein the second near IR illumination source is farther from the camera than the third near IR illumination source.
27. The vehicle interior rearview mirror assembly of claim 26, wherein said second near IR illumination source second angle comprises a non-zero angle of up to 20 degrees relative to a planar front surface of said interior specular reflective element.
28. The vehicle interior rearview mirror assembly of claim 26, wherein said second near IR illumination source second angle comprises an angle of between 5 and 15 degrees relative to a planar front surface of said interior specular reflective element.
29. The vehicle interior rearview mirror assembly of claim 26, wherein said second near IR illumination source second angle comprises an angle of approximately 10 degrees relative to a planar front surface of said interior specular reflective element.
30. The vehicle interior rearview mirror assembly of claim 26, wherein a third angle of said third near IR illumination source includes an angle of between 10 and 30 degrees relative to a planar front surface of said interior specular reflective element.
31. The vehicle interior rearview mirror assembly of claim 26, wherein a third angle of said third near IR illumination source includes an angle of between 15 and 25 degrees relative to a planar front surface of said interior specular reflective element.
32. The vehicle interior rearview mirror assembly of claim 26, wherein a third angle of said third near IR illumination source includes an angle of approximately 20 degrees relative to a planar front surface of said interior specular reflective element.
33. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources are disposed on a right hand side of the lens portion as viewed by a driver of the equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the equipped vehicle includes a right hand driving vehicle.
34. The vehicle interior rearview mirror assembly of claim 33, wherein said second near IR illumination source second angle comprises an angle of between 10 and 30 degrees relative to a planar front surface of said interior specular reflective element.
35. The vehicle interior rearview mirror assembly of claim 33, wherein said second near IR illumination source second angle comprises an angle of between 15 and 25 degrees relative to a planar front surface of said interior specular reflective element.
36. The vehicle interior rearview mirror assembly of claim 33, wherein said second near IR illumination source second angle comprises an angle of approximately 20 degrees relative to a planar front surface of said interior specular reflective element.
37. The vehicle interior rearview mirror assembly of claim 33, wherein said third near IR illumination source third angle comprises a non-zero angle of up to 20 degrees relative to a planar front surface of said interior specular reflective element.
38. The vehicle interior rearview mirror assembly of claim 33, wherein a third angle of said third near IR illumination source includes an angle of between 5 and 15 degrees relative to a planar front surface of said interior specular reflective element.
39. The vehicle interior rearview mirror assembly of claim 33, wherein said third angle of said third near IR illumination source includes an angle of about 10 degrees relative to a planar front surface of said interior specular reflective element.
40. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources are disposed on a left hand side of the lens portion as viewed by a driver of the equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the equipped vehicle includes a right hand driving vehicle.
41. The vehicle interior rearview mirror assembly of claim 40, wherein said second near IR illumination source second angle comprises a non-zero angle of up to 20 degrees relative to a planar front surface of said interior specular reflective element.
42. The vehicle interior rearview mirror assembly of claim 40, wherein said second near IR illumination source second angle comprises an angle of between 5 and 15 degrees relative to a planar front surface of said interior specular reflective element.
43. The vehicle interior rearview mirror assembly of claim 40, wherein said second near IR illumination source second angle comprises an angle of about 10 degrees relative to a planar front surface of said interior specular reflective element.
44. The vehicle interior rearview mirror assembly of claim 40, wherein a third angle of said third near IR illumination source includes an angle of between 10 and 30 degrees relative to a planar front surface of said interior specular reflective element.
45. The vehicle interior rearview mirror assembly of claim 40, wherein a third angle of said third near IR illumination source includes an angle of between 15 and 25 degrees relative to a planar front surface of said interior specular reflective element.
46. The vehicle interior rearview mirror assembly of claim 40, wherein said third angle of said third near IR illumination source comprises an angle of about 20 degrees relative to a planar front surface of said interior specular reflective element.
47. The vehicle interior rearview mirror assembly of claim 1, wherein said specular reflector comprises a multi-layer stack formed of a plurality of thin film coating layers.
48. The vehicle interior rearview mirror assembly of claim 47, wherein said specular reflector comprises at least one silicon layer.
49. The vehicle interior rearview mirror assembly of claim 47, wherein said plurality of film coating layers comprises repeating alternating layers of higher and lower refractive index layers, and wherein the higher refractive index layers have a refractive index greater than 2 and the lower refractive index layers have a refractive index less than 1.5.
50. The vehicle interior rearview mirror assembly of claim 49, wherein said lower refractive index layer comprises a silicon oxide layer.
51. The vehicle interior rearview mirror assembly of claim 50, wherein said higher refractive index layer comprises a titanium oxide layer.
52. The vehicle interior rearview mirror assembly of claim 50, wherein said higher refractive index layer comprises a niobium oxide layer.
53. The vehicle interior rearview mirror assembly of claim 47, wherein said plurality of film coating layers includes at least five (5) layers.
54. The vehicle interior rearview mirror assembly of claim 47, wherein said plurality of film coating layers includes at least seven (7) layers.
55. The vehicle interior rearview mirror assembly of claim 47, wherein said plurality of thin film coatings of said multi-layer stack forming said specular reflector are applied to a flat glass surface of a glass substrate of said interior specular reflective element.
56. The vehicle interior rearview mirror assembly of claim 55, wherein said multi-layer stack forming said specular reflector includes an innermost thin film coating nearest said planar glass surface of said glass substrate and includes an outermost thin film coating furthest from said planar glass surface of said glass substrate.
57. The vehicle interior rearview mirror assembly of claim 56, wherein the innermost film coating closest to the planar glass surface of said glass substrate has a higher refractive index than the next closest film coating to the planar glass surface of said glass substrate.
58. The vehicle interior rearview mirror assembly of claim 56, wherein said outermost film coating furthest from the planar glass surface of said glass substrate comprises a transparent conductive film having a refractive index that is higher than the refractive index of the layer of said multi-layer stack to which it is applied.
59. The vehicle interior rearview mirror assembly of claim 58, wherein said transparent conductive film comprises an Indium Tin Oxide (ITO) layer.
60. The vehicle interior rearview mirror assembly of claim 59, wherein said Indium Tin Oxide (ITO) layer has a sheet resistance of less than 20 ohms/square.
61. The vehicle interior rearview mirror assembly of claim 60, wherein said glass substrate is heated to a temperature of at least 250 degrees celsius during deposition of said Indium Tin Oxide (ITO) layer.
62. The vehicle interior rearview mirror assembly of claim 47, wherein said layer of specular reflector is deposited on the glass substrate of said interior specular reflective element using medium frequency AC sputtering.
63. The vehicle interior rearview mirror assembly of claim 47, wherein said layer of specular reflector is deposited on the glass substrate of said interior specular reflective element using intermediate frequency AC sputtering in a multi-station/multi-target in-line sputter deposition process.
64. The vehicle interior rearview mirror assembly of claim 47, wherein said layer of specular reflector is deposited onto the glass substrate of said interior specular reflective element in a batch vacuum deposition chamber.
65. The vehicle interior rearview mirror assembly of any one of the preceding claims, wherein said first near IR radiation source, when energized, emits near IR light having a wavelength of approximately 940nm, and wherein said second near IR radiation source, when energized, emits near IR light having a wavelength of approximately 940nm, and wherein said third near IR radiation source, when energized, emits near IR light having a wavelength of approximately 940 nm.
66. The vehicle interior mirror assembly of any one of claims 1-64, wherein the vehicle interior mirror assembly comprises a vehicle EVO TM An interior rearview mirror assembly.
67. The vehicle interior rearview mirror assembly of any one of claims 1-64, wherein said vehicle interior rearview mirror assembly comprises a vehicle Infinity TM An interior rearview mirror assembly.
68. The vehicle interior mirror assembly of any one of claims 1-64, wherein the vehicle interior mirror assembly comprises a rimless interior mirror assembly.
69. The vehicle interior rearview mirror assembly of any one of claims 1-64, wherein said interior specular reflective element comprises an electrochromic specular reflective element having a front glass substrate and a rear glass substrate, and wherein the planar rear surface of said front glass substrate has a transparent conductive coating disposed thereat, and wherein the planar front surface of the rear glass substrate has a conductive coating disposed thereat, and wherein an electrochromic medium is disposed between and in contact with the transparent conductive coating and the conductive coating disposed at the planar front surface of the front glass substrate, and wherein a specular reflector is disposed at the planar front surface or planar rear surface of the rear glass substrate.
70. The vehicle interior rearview mirror assembly of claim 69, wherein said rear glass substrate has a plate thickness of about 1.6mm or less.
71. The vehicle interior rearview mirror assembly of claim 70, wherein said front glass substrate includes an exposed rounded peripheral edge having a radius of curvature of at least 2.5mm, and wherein said exposed rounded peripheral edge provides a curved transition between a flat front surface of said front glass substrate and an outer surface of a wall portion of a mirror housing of a mirror head.
72. The vehicle interior rearview mirror assembly of claim 71, wherein said front glass substrate is at least about 2mm thick.
73. The vehicle interior rearview mirror assembly of claim 71, wherein said front glass substrate comprises a low iron (low Fe) soda lime glass.
74. The vehicle interior rearview mirror assembly of claim 69, wherein said rear glass substrate has a plate thickness of about 1.6mm or less.
75. The vehicle interior rearview mirror assembly of claim 69, wherein a housing portion of the mirror housing of the mirror head circumscribes a peripheral edge of the front glass substrate, and wherein said housing portion has a rounded outer surface that provides a curved transition between a flat front surface of the front glass substrate and an outer surface of the wall portion of the mirror housing of the mirror head.
76. The vehicle interior rearview mirror assembly of claim 69, wherein said front glass substrate has an exposed rounded peripheral edge with a radius of curvature of at least 2.5mm, and wherein said exposed rounded peripheral edge provides a curved transition between the planar front surface of said front glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head.
77. The vehicle interior rearview mirror assembly of claim 69, wherein said specular reflector comprises a plurality of thin film coating layers.
78. The vehicle interior rearview mirror assembly of claim 77, wherein said specular reflector is disposed at a planar rear surface of said rear glass substrate.
79. The vehicle interior rearview mirror assembly of claim 77, wherein said rear glass substrate has a plate thickness of about 1.6mm or less.
80. The vehicle interior rearview mirror assembly of claim 77, wherein said specular reflector comprises at least one silicon layer.
81. The vehicle interior rearview mirror assembly of claim 77, wherein said plurality of film coating layers comprises repeating alternating layers of higher and lower refractive index layers, and wherein said higher refractive index layer has a refractive index greater than 2 and said lower refractive index layer has a refractive index less than 1.5.
82. The vehicle interior rearview mirror assembly of claim 81, wherein said lower refractive index layer comprises a silicon oxide layer.
83. The vehicle interior rearview mirror assembly of claim 82, wherein said higher refractive index layer comprises a niobium oxide layer.
84. The vehicle interior rearview mirror assembly of claim 82, wherein said higher refractive index layer comprises a titanium oxide layer.
85. The vehicle interior rearview mirror assembly of claim 77, wherein said layer of a specular reflector is deposited onto said rear glass substrate using medium frequency AC sputtering.
86. The vehicle interior rearview mirror assembly of claim 77, wherein said layer of a mirror transflector is deposited onto said rear glass substrate using intermediate frequency AC sputtering in a multi-station/multi-target in-line vacuum deposition process.
87. The vehicle interior rearview mirror assembly of claim 77, wherein said layer of specular reflector is deposited onto said rear glass substrate in a batch vacuum deposition chamber.
88. The vehicle interior rearview mirror assembly of claim 77, wherein said specular reflector is coated onto said rear glass substrate.
89. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a photopic visible light reflectance of at least 45% r.
90. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a photopic visible light reflectance of at least 55% r.
91. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a photopic visible light reflectance of at least 65% r.
92. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a visible light transmission of at least 15% t.
93. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a visible light transmission of at least 20% t.
94. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a visible light transmission of at least 25% t.
95. The vehicle interior mirror assembly of any one of claims 92-94, wherein the rear glass substrate coated with the transflector has a visible light transmittance of less than 35% t.
96. The vehicle interior mirror assembly of any one of claims 92-94, wherein the rear glass substrate coated with the transflector has a visible light transmittance of less than 30% t.
97. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a near IR light transmittance of at least 60% t.
98. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a near IR light transmittance of at least 70% t.
99. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a near IR light transmittance of at least 80% t.
100. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a visible light transmission in the range of 20% t to 35% t.
101. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a visible light transmission in the range of 15% t to 35% t.
102. The vehicle interior rearview mirror assembly of claim 88, wherein the rear glass substrate coated with the transflector has a visible light transmission in the range of 20% t to 30% t.
103. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a visible light transmission in the range of 20% t to 30% t in a fully faded state.
104. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a visible light transmission in the range of 22% t to 25% t in a fully faded state.
105. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a visible light transmission in the range of 10% t to 20% t in a fully darkened state.
106. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a visible light transmission of about 16% t in a fully darkened state.
107. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a visible light reflectance in the range of 40% r to 65% r in a fully faded state.
108. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a visible light reflectance in the range of 43% r to 55% r in a fully faded state.
109. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a near IR transmission of at least 50% t near 940nm in a fully darkened state.
110. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a near IR transmission of at least 70% t near 940nm in a fully darkened state.
111. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a near IR transmission of at least 50% t near 940nm in a fully faded state.
112. The vehicle interior rearview mirror assembly of claim 69, wherein said electrochromic mirror reflective element has a near IR transmission of at least 70% t near 940nm in a fully faded state.
113. The vehicle interior rearview mirror assembly of claim 69, wherein said front glass substrate includes a circumferential conductive channel disposed at said transparent conductive coating.
114. The vehicle interior rearview mirror assembly of claim 113, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of less than 50 ohms/square.
115. The vehicle interior rearview mirror assembly of claim 113, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of greater than 20 ohms/square.
116. The vehicle interior rearview mirror assembly of claim 113, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of greater than 30 ohms/square.
117. The vehicle interior rearview mirror assembly of claim 69, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of less than 30 ohms/square.
118. The vehicle interior rearview mirror assembly of claim 69, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of less than 25 ohms/square.
119. The vehicle interior rearview mirror assembly of claim 69, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of less than 20 ohms/square.
120. The vehicle interior rearview mirror assembly of claim 69, wherein said transparent conductive coating disposed at the planar rear surface of said front glass substrate has a sheet resistance of 10-15 ohms/square.
121. The vehicle interior rearview mirror assembly of claim 69, wherein said rear glass substrate includes a circumferential conductive channel disposed at an outermost layer of said conductive coating.
122. The vehicle interior rearview mirror assembly of claim 121, wherein an outermost layer of said conductive coating disposed at a planar front surface of said rear glass substrate has a sheet resistance of greater than 30 ohms/square.
123. The vehicle interior rearview mirror assembly of claim 121, wherein an outermost layer of said conductive coating disposed at a planar front surface of said rear glass substrate has a sheet resistance of less than 30 ohms/square.
124. The vehicle interior rearview mirror assembly of claim 69, wherein an outermost layer of said conductive coating disposed at a flat front surface of said rear glass substrate has a sheet resistance of less than 25 ohms/square.
125. The vehicle interior rearview mirror assembly of claim 69, wherein an outermost layer of said conductive coating disposed at a flat front surface of said rear glass substrate has a sheet resistance of less than 20 ohms/square.
126. The vehicle interior rearview mirror assembly of claim 69, wherein an outermost layer of said conductive coating disposed at a flat front surface of said rear glass substrate has a sheet resistance of 10-15 ohms/square.
127. The vehicle interior rearview mirror assembly of claim 1, wherein said interior specular reflective element has (i) a visible light transmission of 20-25 percent, (ii) a near IR transmission of at least 60 percent near 940nm, and (iii) a visible light reflection of at least 43 percent.
128. The vehicle interior rearview mirror assembly of claim 127, wherein said interior mirror reflective element has a near IR transmission of at least 70% near 940 nm.
129. The vehicle interior rearview mirror assembly of claim 127, wherein said interior mirror reflective element has a near IR transmission of at least 80% near 940 nm.
130. The vehicle interior rearview mirror assembly of claim 127, wherein said interior mirror reflective element has a visible light reflectance of at least 48%.
131. The vehicle interior rearview mirror assembly of claim 127, wherein said interior mirror reflective element has a visible light reflectance of at least 53%.
132. The vehicle interior rearview mirror assembly of claim 127, wherein said interior mirror reflective element comprises an electrochromic mirror reflective element having a front glass substrate and a rear glass substrate, and wherein the planar rear surface of said front glass substrate has a transparent conductive coating disposed thereat, and wherein the planar front surface of the rear glass substrate has a conductive coating disposed thereat, and wherein an electrochromic medium is disposed between and in contact with the transparent conductive coating disposed at the planar rear surface of the front glass substrate and the conductive coating disposed at the planar front surface of the rear glass substrate, and wherein a mirror transflector is disposed at the planar front surface or the planar rear surface of the rear glass substrate.
133. The vehicle interior rearview mirror assembly of claim 127, wherein said interior specular reflective element comprises a prismatic specular reflective element, and wherein said planar front surface is non-parallel to said planar rear surface, and wherein said specular reflector is disposed at said planar rear surface of prismatic specular reflective element.
134. The vehicle interior rearview mirror assembly of claim 1, wherein the interior specular reflective element comprises a prismatic specular reflective element, and wherein the planar front surface is non-parallel to the planar rear surface, and wherein the specular reflector is disposed at the planar rear surface of the prismatic specular reflective element.
135. The vehicle interior rearview mirror assembly of claim 134, wherein said vehicle interior rearview mirror assembly comprises a rimless interior rearview mirror assembly.
136. The vehicle interior rearview mirror assembly of claim 135, wherein the housing portion of the mirror housing of the mirror head circumscribes the peripheral edge of the glass substrate of the interior mirror reflective element, and wherein the housing portion has a rounded outer surface that provides a curved transition between the planar front surface of the glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head.
137. The vehicle interior rearview mirror assembly of claim 135, wherein said interior mirror reflective element comprises a glass substrate having an exposed rounded peripheral edge with a radius of curvature of at least 2.5mm, and wherein said exposed rounded peripheral edge provides a curved transition between a planar front surface of the glass substrate and an outer surface of a wall portion of a mirror housing of the mirror head.
138. The vehicle interior rearview mirror assembly of claim 1, wherein said specular reflector maintains a chromatic aberration of between 2.3 and 3.2 at any viewing angle of up to 45 degrees for the driver.
139. The vehicle interior rearview mirror assembly of claim 1, wherein said specular reflector maintains a chromatic aberration of between 2.3 and 2.8 at any viewing angle of up to 45 degrees for the driver.
140. The vehicle interior rearview mirror assembly of claim 1, wherein said specular reflector maintains a chromatic aberration of between 2.3 and 2.5 at any viewing angle of up to 45 degrees for the driver.
141. The vehicle interior rearview mirror assembly of claim 1, wherein said camera acquires a series of image data frames, and wherein said series of acquired image data frames includes a plurality of driver monitor image data frames and a plurality of occupant detection image data frames.
142. The vehicle interior rearview mirror assembly of claim 141, wherein said driver and passenger detection image data frames do not overlap.
143. The vehicle interior rearview mirror assembly of claim 1, wherein the second near IR illumination source is oriented at the lens portion such that if the vehicle interior rearview mirror assembly is installed in a left-hand drive vehicle and adjusted to provide a rearview field of view to a driver of the left-hand drive vehicle, the light beam emitted by the second near IR illumination source will be directed toward an area of the driver of the left-hand drive vehicle, and wherein the third near IR illumination source is oriented at the lens portion such that if the vehicle interior rearview mirror assembly is installed in a right-hand drive vehicle and adjusted to provide a rearview field of view to a driver of the right-hand drive vehicle, the light beam emitted by the third near IR illumination source will be directed toward an area of the driver of the right-hand drive vehicle.
144. The vehicle interior rearview mirror assembly of claim 1, wherein said interior specular reflective element is attached at a mirror attachment plate, and wherein said camera and said first, second, and third near IR illumination sources are disposed behind said mirror attachment plate and aligned with respective holes through the mirror attachment plate.
145. The vehicle interior rearview mirror assembly of claim 144, comprising a heat dissipation element attached at said mirror attachment plate, and wherein said mirror attachment plate and said heat dissipation element enclose said camera, said first, second and third near IR illumination sources and DMS data processor and function to limit electromagnetic interference of the camera, first, second and third near IR illumination sources and DMS data processor.
146. The vehicle interior rearview mirror assembly of claim 1, wherein said second near IR illumination source comprises at least one narrow field of view illuminator, and wherein said third near IR illumination source comprises at least one narrow field of view illuminator.
147. The vehicle interior rearview mirror assembly of claim 1, wherein said first near IR illumination source comprises at least one wide field of view illuminator.
148. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a computational speed of at least 0.1 trillion floating point operations per second.
149. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a computational speed of at least 0.3 trillion floating point operations per second.
150. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a computational speed of at least 0.6 trillion floating point operations per second.
151. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a computational speed of at least 1 trillion floating point operations per second.
152. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a computational speed of at least 1.5 trillion floating point operations per second.
153. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor operates with less than 5 watts of power consumption.
154. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor operates with less than 4 watts of power consumption.
155. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor operates with less than 3 watts of power consumption.
156. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a computational speed of at least 0.25 trillion floating point operations per second at a power consumption condition of less than 3 watts.
157. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a calculated speed of at least 0.1 Trillion Operations Per Second (TOPS).
158. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a calculated speed of at least 0.2 Trillion Operations Per Second (TOPS).
159. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor has a calculated speed of at least 0.5 Trillion Operations Per Second (TOPS).
160. The vehicle interior rearview mirror assembly of claim 1, comprising a thermal element that maintains a touch surface of the lens portion at a temperature of less than 60 degrees celsius.
161. The vehicle interior rearview mirror assembly of claim 1, comprising a thermal element that maintains a touch surface of the lens portion at a temperature of less than 50 degrees celsius.
162. The vehicle interior rearview mirror assembly of claim 161, wherein said thermal element includes at least one vent opening through a mirror housing of said mirror head.
163. The vehicle interior rearview mirror assembly of claim 161, wherein said thermal element comprises a heat sink thermally conductively coupled to a heat generating component of said DMS data processor.
164. The vehicle interior rearview mirror assembly of claim 163, wherein said thermal element comprises a thermal interface material element disposed between at least some of the heat generating components of said DMS data processor and said heat sink.
165. The vehicle interior rearview mirror assembly of claim 164, wherein said thermal interface material element has a thermal conductivity greater than 2W/m-K.
166. The vehicle interior rearview mirror assembly of claim 164, wherein said thermal interface material element has a thermal conductivity greater than 3W/m-K.
167. The vehicle interior rearview mirror assembly of claim 164, wherein said thermal interface material element has a thermal conductivity greater than 4W/m-K.
168. The vehicle interior rearview mirror assembly of claim 1, comprising filters at said first, second and third near IR illumination sources, wherein said filters transmit 940nm near IR light and attenuate visible light.
169. The vehicle interior rearview mirror assembly of claim 168, wherein said optical filter has a respective plate thickness of at least 0.8 mm.
170. The vehicle interior rearview mirror assembly of claim 168, wherein said optical filter has a respective plate thickness of at least 1.4 mm.
171. The vehicle interior rearview mirror assembly of claim 168, wherein said optical filter has a respective plate thickness of at least 1.9 mm.
172. The vehicle interior rearview mirror assembly of claim 168, wherein said optical filter has a respective plate thickness of less than 6 mm.
173. The vehicle interior rearview mirror assembly of claim 168, wherein said optical filter has a respective plate thickness of less than 4 mm.
174. The vehicle interior rearview mirror assembly of claim 168, wherein said optical filter has a respective plate thickness of less than 2 mm.
175. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources comprise first, second and third sets of light emitting diodes.
176. The vehicle interior rearview mirror assembly of claim 175, wherein each of said first, second and third groups of light emitting diodes operates with a forward current of at least 500 milliamps through each light emitting diode.
177. The vehicle interior rearview mirror assembly of claim 175, wherein each of said first, second and third groups of light emitting diodes operates with a forward current of at least 750 milliamps through each light emitting diode.
178. The vehicle interior rearview mirror assembly of claim 175, wherein each of said first, second and third groups of light emitting diodes operates with a forward current of at least 1000 milliamps through each light emitting diode.
179. The vehicle interior rearview mirror assembly of claim 175, wherein said first and second near IR illumination sources have a pulse duty cycle of at least 8% when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide said driver monitoring function.
180. The vehicle interior rearview mirror assembly of claim 175, wherein said first and second near IR illumination sources have a pulse duty cycle of at least 5% when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide said driver monitoring function.
181. The vehicle interior rearview mirror assembly of claim 175, wherein said first and second near IR illumination sources have a pulse duty cycle of at least 10% when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide said driver monitoring function.
182. The vehicle interior rearview mirror assembly of claim 175, wherein the pulse duty cycles of the first and second near IR illumination sources are less than 40% when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality.
183. The vehicle interior rearview mirror assembly of claim 175, wherein the first and second near IR illumination sources have a pulse duty cycle of less than 30% when the vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide said driver monitoring function.
184. The vehicle interior rearview mirror assembly of claim 175, wherein the first and second near IR illumination sources have pulse duty cycles of less than 20% when the vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide said driver monitoring function.
185. The vehicle interior rearview mirror assembly of claim 1, wherein said first and second near IR illumination sources provide at least 1W/m at a driver's head when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide driver monitoring functionality 2 Near IR irradiance of (c).
186. The vehicle interior rearview mirror assembly of claim 1, wherein said first and second near IR illumination sources provide at least 1.8W/m at a driver's head when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide driver monitoring functionality 2 Near IR irradiance of (c).
187. The vehicle interior rearview mirror assembly of claim 1, wherein said first and second near IR illumination sources provide at least 2W/m at a driver's head when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide driver monitoring functionality 2 Near IR irradiance of (c).
188. The vehicle interior rearview mirror assembly of claim 1, wherein said first and second near IR illumination sources provide at least 2.3W/m at a driver's head when said vehicle interior rearview mirror assembly is attached at an interior portion of a equipped vehicle and when said DMS data processor is operating to provide a driver monitoring function 2 Near IR irradiance of (c).
189. The vehicle interior rearview mirror assembly of claim 1, Wherein the first and second near IR illumination sources provide at least 2.5W/m at the head of the driver when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide driver monitoring functionality 2 Near IR irradiance of (c).
190. The vehicle interior rearview mirror assembly of claim 1, wherein said first and third near IR illumination sources provide at least 0.15W/m in a front passenger region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when said DMS data processor is operating to provide occupant detection functionality 2 Near IR irradiance of (c).
191. The vehicle interior rearview mirror assembly of claim 1, wherein said first and third near IR illumination sources provide at least 0.25W/m in a front passenger region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when said DMS data processor is operating to provide occupant detection functionality 2 Near IR irradiance of (c).
192. The vehicle interior rearview mirror assembly of claim 1, wherein said first and third near IR illumination sources provide at least 0.4W/m in a front passenger region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when said DMS data processor is operating to provide occupant detection functionality 2 Near IR irradiance of (c).
193. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources provide at least 0.1W/m in a rear seat area of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when said DMS data processor is operating to provide occupant detection functionality 2 Near IR irradiance of (c).
194. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources provide at least 0.15W/m in a rear seat area of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of said equipped vehicle and when said DMS data processor is operating to provide occupant detection functionality 2 Near IR irradiance of (c).
195. The vehicle interior rearview mirror assembly of claim 1, wherein said first, second and third near IR illumination sources provide at least 0.2W/m in a rear seat area of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of said equipped vehicle and when said DMS data processor is operating to provide occupant detection functionality 2 Near IR irradiance of (c).
196. The vehicle interior rearview mirror assembly of claim 1, wherein said second near IR illumination source emits light toward a driver's head region.
197. The vehicle interior rearview mirror assembly of claim 196, wherein said driver's head region comprises a head sash region of at least 80mm x 80 mm.
198. The vehicle interior rearview mirror assembly of claim 196, wherein said driver's head region comprises a head sash region of at least 100mm x 100 mm.
199. The vehicle interior rearview mirror assembly of claim 196, wherein said driver's head region comprises a head sash region of at least 150mm x 150 mm.
200. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes an imaging sensor having a Quantum Efficiency (QE) of at least 22% for near infrared (near IR) light having a wavelength of 940 nm.
201. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes an imaging sensor having a Quantum Efficiency (QE) of at least 32% for near infrared (near IR) light having a wavelength of 940 nm.
202. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes a CMOS imaging sensor.
203. The vehicle interior rearview mirror assembly of claim 202, wherein said camera CMOS imaging sensor comprises a silicon layer having a thickness of at least 3.5 μm.
204. The vehicle interior rearview mirror assembly of claim 202, wherein said camera CMOS imaging sensor comprises a silicon layer having a thickness of at least 4.5 μm.
205. The vehicle interior rearview mirror assembly of claim 202, wherein said camera CMOS imaging sensor comprises a silicon layer having a thickness of at least 5.5 μm.
206. The vehicle interior rearview mirror assembly of any one of claims 1-64 and 127-205, wherein the imaging sensor of said camera comprises a back illumination (BSI) imaging sensor.
207. The vehicle interior rearview mirror assembly of claim 1, wherein said camera acquires frames of image data at a frame acquisition rate of at least 15 frames per second.
208. The vehicle interior rearview mirror assembly of claim 1, wherein said camera acquires frames of image data at a frame acquisition rate of at least 30 frames per second.
209. The vehicle interior rearview mirror assembly of claim 1, wherein said camera acquires frames of image data at a frame acquisition rate of at least 60 frames per second.
210. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes a lens, and wherein an outermost surface of said camera lens is spaced from a rear portion of said interior specular reflective element where said camera is viewed through a specular reflector of said interior specular reflective element.
211. The vehicle interior rearview mirror assembly of claim 210, wherein said camera is spaced from a rear of said interior specular reflective element by at least 0.5mm where said camera is viewed through a specular reflector of said interior specular reflective element.
212. The vehicle interior rearview mirror assembly of claim 210, wherein said camera is spaced at least 1mm from a rear of said interior specular reflective element where said camera is viewed through a specular reflector of said interior specular reflective element.
213. The vehicle interior rearview mirror assembly of claim 210, wherein said camera is spaced at least 2mm from a rear of said interior specular reflective element where said camera is viewed through a specular reflector of said interior specular reflective element.
214. The vehicle interior rearview mirror assembly of claim 210, wherein said camera is spaced less than 4mm from a rear of said interior specular reflective element where said camera is viewed through a specular reflector of said interior specular reflective element.
215. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes an imaging array of at least 2.3 megapixels.
216. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes an imaging array of at least 5 megapixels.
217. The vehicle interior rearview mirror assembly of claim 1, wherein said camera includes an imaging array of at least 5.5 megapixels.
218. The vehicle interior rearview mirror assembly of claim 1, wherein said camera imaging sensor includes a plurality of photosensors and a spectral filter disposed at said photosensors such that some photosensors are sensitive to visible light and others are sensitive to near infrared light.
219. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor determines at least one selected from the group consisting of: (i) driver attention, (ii) driver drowsiness, and (iii) driver gaze direction.
220. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor determines the presence of an occupant in a equipped vehicle by processing acquired occupant detection image data frames at said DMS data processor.
221. The vehicle interior rearview mirror assembly of claim 1, wherein said DMS data processor adjusts the processing of the acquired driver monitor image data frames to accommodate adjustment of the lens portion as the driver adjusts the lens portion to adjust his or her rearview field of view.
222. The vehicle interior rearview mirror assembly of claim 1, comprising a display screen disposed in said lens portion and viewable through said interior specular reflective element when displaying an image, and wherein said display screen is backlit by a backlight array comprising a plurality of backlit visible Light Emitting Diodes (LEDs).
223. The vehicle interior rearview mirror assembly of claim 222, wherein said display screen comprises a video display screen that, when actuated, displays a video image derived from image data acquired by an exterior viewing camera of said vehicle.
224. The vehicle interior rearview mirror assembly of claim 223, wherein said vehicle interior rearview mirror assembly is operable in a display mode wherein said video display screen displays video images derived from image data acquired by a rear viewing camera of an equipped vehicle and a mirror mode wherein said video display screen is deactivated and a driver views the rear of the equipped vehicle via reflection at an interior mirror reflective element.
225. The vehicle interior mirror assembly of any one of claims 1-64, 127-205, and 207-224, wherein the lens portion is adjustable about the mounting base via a ball and socket pivot joint.
226. The vehicle interior rearview mirror assembly of claim 225, wherein said mounting base comprises a ball pivot element, and wherein said lens portion comprises a ball pivot element, and wherein said ball pivot joint comprises a ball pivot element of said mounting base and a ball pivot element of said lens portion.
227. The vehicle interior rearview mirror assembly of claim 225, wherein the portion of the equipped vehicle to which said mounting base is configured to be attached comprises a portion of a cabin interior side of a front windshield of the equipped vehicle.
228. The vehicle interior rearview mirror assembly of claim 227, wherein a mirror mounting button is adhesively bonded to said portion of the inboard side of the vehicle windshield, and wherein the mounting base comprises a mirror attachment portion configured to mount the vehicle interior rearview mirror assembly to said mirror mounting button bonded to the vehicle windshield.
229. The vehicle interior rearview mirror assembly of claim 228, wherein said mounting base houses a front view camera that views the front of the equipped vehicle through the vehicle windshield when said vehicle interior rearview mirror assembly is mounted at the inboard side of the vehicle windshield.
230. The vehicle interior rearview mirror assembly of claim 229, wherein said forward looking camera acquires image data for use by a drive assist system of an equipped vehicle.
231. The vehicle interior rearview mirror assembly of claim 230, wherein the equipped vehicle's driving assistance system processes image data acquired by the forward looking camera for at least one selected from the group consisting of: (i) lane detection, (ii) pedestrian detection, (iii) vehicle detection, (iv) collision avoidance, (v) Adaptive Cruise Control (ACC), (vi) traffic sign recognition, (vii) traffic light detection, and (viii) automatic headlamp control.
232. The vehicle interior rearview mirror assembly of claim 228, wherein said mounting base houses a color camera that, when said vehicle interior rearview mirror assembly is mounted at a cabin interior side of said vehicle windshield, views a front of an equipped vehicle through said vehicle windshield and acquires image data for at least one selected from the group consisting of: (i) An event recording system for a equipped vehicle and (ii) an augmented reality video display system for a equipped vehicle.
233. The vehicle interior rearview mirror assembly of claim 228, wherein said mounting base houses at least one sensor having a sensing field into an interior compartment of an equipped vehicle when said vehicle interior rearview mirror assembly is mounted at an inboard side of a compartment of said vehicle windshield.
234. The vehicle interior rearview mirror assembly of claim 233, wherein said at least one sensor comprises a radar sensor.
235. The vehicle interior rearview mirror assembly of claim 233, wherein said at least one sensor comprises a lidar sensor.
236. The vehicle interior rearview mirror assembly of claim 233, wherein said at least one sensor comprises an ultrasonic sensor.
237. The vehicle interior rearview mirror assembly of claim 228, wherein said mounting base houses a camera having a field of view into an interior compartment of an equipped vehicle when said vehicle interior rearview mirror assembly is mounted at an inboard side of a vehicle windshield.
238. The vehicle interior rearview mirror assembly of any one of claims 1-64, 127-205 and 207-224, wherein said DMS data processor comprises an integrated circuit chip.
239. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip comprises at least one 32-bit RISC ARM processor core.
240. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip comprises at least one 64-bit RISC ARM processor core.
241. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip has a calculated speed of at least 0.1 Trillion Operations Per Second (TOPS).
242. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip has a calculated speed of at least 0.2 Trillion Operations Per Second (TOPS).
243. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip has a calculated speed of at least 0.5 Trillion Operations Per Second (TOPS).
244. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip operates with less than 5 watts of power consumption.
245. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip operates with less than 4 watts of power consumption.
246. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip operates with less than 3 watts of power consumption.
247. The vehicle interior rearview mirror assembly of claim 238, wherein said integrated circuit chip has a computational speed of at least 0.25 trillion floating points per second at a power consumption condition of less than 3 watts.
248. The vehicle interior rearview mirror assembly of claim 1, wherein the vehicle interior rearview mirror assembly comprises an electrochromic interior rearview mirror assembly, and wherein the interior specular reflective element comprises an electrochromic interior specular reflective element, and wherein the electrochromic interior specular reflective element has a visible light transmission in the range of 20% t to 25% t and a near IR transmission around 940nm of at least 65% t when in a fully faded state, and wherein the imaging sensor comprises a back-illuminated (BSI) imaging sensor having a Quantum Efficiency (QE) of at least 22% for near infrared (near-IR) light having a wavelength of 940nm, and wherein the camera comprises at least a 2.3 megapixel imaging array and acquires frames of image data at a frame acquisition rate of at least 60 frames per second, and wherein the DMS data processor comprises an integrated circuit chip having a computational speed of at least 0.1 Trillion Operations Per Second (TOPS) and operates at a power consumption of less than 5 watts.
249. The vehicle interior rearview mirror assembly of claim 248, wherein said first near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 2000mW when powered, and wherein said second near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 2000mW when powered, and wherein said third near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 2000mW when powered.
250. The vehicle interior rearview mirror assembly of claim 248, wherein said first near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 3500mW when powered, and wherein said second near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 3500mW when powered, and wherein said third near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 3500mW when powered.
251. The vehicle interior rearview mirror assembly of claim 248, wherein said first near IR illumination source comprises at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered, and wherein said second near IR illumination source comprises at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered, and wherein said third near IR illumination source comprises at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when powered.
252. The vehicle interior rearview mirror assembly of claim 248, wherein said first near IR illumination source comprises at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and wherein said second near IR illumination source comprises at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and wherein said third near IR illumination source comprises at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL).
253. The vehicle interior rearview mirror assembly of claim 248, wherein said electrochromic interior rearview mirror assembly comprises a frameless electrochromic interior rearview mirror assembly.
254. The vehicle interior rearview mirror assembly of claim 253, wherein said frameless electrochromic interior rearview mirror assembly comprises an Infinity TM Electrochromic interior rearview mirror assembly.
255. The vehicle interior rearview mirror assembly of claim 253, wherein said frameless electrochromic interior rearview mirror assembly comprises EVO TM Electrochromic interior rearview mirror assembly.
256. The vehicle interior rearview mirror assembly of claim 1, wherein the vehicle interior rearview mirror assembly comprises a prismatic interior rearview mirror assembly, and wherein the interior specular reflective element comprises a prismatic interior specular reflective element, and wherein the prismatic interior specular reflective element has a visible light transmission in the range of 20% t to 25% t and a near IR transmission around 940nm of at least 65% t, and wherein the imaging sensor comprises a back illumination (BSI) imaging sensor having a Quantum Efficiency (QE) of at least 22% for near infrared (near IR) light having a wavelength of 940nm, and wherein the camera comprises at least a 2.3 megapixel imaging array and acquires frames of image data at a frame acquisition rate of at least 60 frames per second, and wherein the DMS data processor comprises an integrated circuit chip having a computation speed of at least 0.1 Trillion Operations (TOPS) per second and operates with a power consumption of less than 5 watts.
257. The vehicle interior rearview mirror assembly of claim 256, wherein said first near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 2000mW when powered, and wherein said second near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 2000mW when powered, and wherein said third near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 2000mW when powered.
258. The vehicle interior rearview mirror assembly of claim 256, wherein said first near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 3500mW when powered, and wherein said second near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 3500mW when powered, and wherein said third near IR radiation source comprises at least one near IR LED having a total radiant flux of at least 3500mW when powered.
259. The vehicle interior rearview mirror assembly of claim 256, wherein said first near IR illumination source comprises at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when energized, and wherein said second near IR illumination source comprises at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when energized, and wherein said third near IR illumination source comprises at least two near IR LEDs, each near IR LED having a total radiant flux of at least 3000mW when energized.
260. The vehicle interior rearview mirror assembly of claim 256, wherein said first near IR illumination source comprises at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and wherein said second near IR illumination source comprises at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL), and wherein said third near IR illumination source comprises at least one near IR emitting Vertical Cavity Surface Emitting Laser (VCSEL).
261. The vehicle interior rearview mirror assembly of claim 256, wherein said prismatic interior rearview mirror assembly comprises a rimless prismatic interior rearview mirror assembly.
262. The vehicle interior rearview mirror assembly of claim 261, wherein said frameless prismatic interior rearview mirror assembly comprises an InfinityTM prismatic interior rearview mirror assembly.
263. The vehicle interior rearview mirror assembly of claim 261, wherein said frameless prismatic interior rearview mirror assembly comprises an EVOTM prismatic interior rearview mirror assembly.
264. The vehicle interior rearview mirror assembly of any one of claims 248-263, wherein the second near IR illumination source comprises (i) a circuit board and (ii) a reflector surface mounted at the circuit board and configured to concentrate near IR light emitted by the second near IR illumination source toward a front seat area at a left hand side of the equipped LHD vehicle when the vehicle interior rearview mirror assembly is installed in a Left Hand Drive (LHD) vehicle.
265. The vehicle interior rearview mirror assembly of claim 264, wherein said first and second near IR illumination sources provide at least 1W/m to a driver's eyes in a front seat area seated at the left hand side of a equipped LHD vehicle when said first and second near IR illumination sources are energized and said third near IR illumination source is not energized 2 Near IR irradiance of (c).
266. The vehicle interior rearview mirror assembly of claim 264, wherein said first and second near IR radiation sources are powered and said third near IR radiation source is unpowered when said first and second near IR radiation sources are poweredThe two near IR radiation sources provide at least 1.8W/m at the eyes of a driver sitting in a front seat area at the left hand side of the equipped LHD vehicle 2 Near IR irradiance of (c).
267. The vehicle interior rearview mirror assembly of claim 264, wherein said first and second near IR illumination sources provide at least 2W/m to a driver's eyes in a front seat area seated at the left hand side of a equipped LHD vehicle when said first and second near IR illumination sources are energized and said third near IR illumination source is not energized 2 Near IR irradiance of (c).
268. The vehicle interior rearview mirror assembly of claim 264, wherein said first and second near IR illumination sources provide at least 2.3W/m to a driver's eyes in a front seat area seated at the left hand side of a equipped LHD vehicle when said first and second near IR illumination sources are energized and said third near IR illumination source is not energized 2 Near IR irradiance of (c).
269. The vehicle interior rearview mirror assembly of claim 264, wherein said first and second near IR illumination sources provide at least 2.5W/m to a driver's eyes in a front seat area seated at the left hand side of a equipped LHD vehicle when said first and second near IR illumination sources are energized and said third near IR illumination source is not energized 2 Near IR irradiance of (c).
270. The vehicle interior rearview mirror assembly of any one of claims 248-263, wherein, when the vehicle interior rearview mirror assembly is mounted in a right drive (RHD) vehicle, the third near IR illumination source comprises (i) a circuit board and (ii) a reflector surface mounted at the circuit board and configured to concentrate near IR light emitted by the third near IR illumination source toward a front seat region at a right hand side of the equipped RHD vehicle.
271. According to claimThe vehicle interior rearview mirror assembly of claim 270, wherein said first and third near IR illumination sources provide at least 1W/m to the eyes of a driver seated in a front seat area at the right hand side of an equipped RHD vehicle when said first and third near IR illumination sources are energized and said second near IR illumination source is not energized 2 Near IR irradiance of (c).
272. The vehicle interior rearview mirror assembly of claim 270, wherein said first and third near IR radiation sources provide at least 1.8W/m to the eyes of a driver seated in the front seat area at the right hand side of an equipped RHD vehicle when said first and third near IR radiation sources are powered and said second near IR radiation source is not powered 2 Near IR irradiance of (c).
273. The vehicle interior rearview mirror assembly of claim 270, wherein said first and third near IR radiation sources provide at least 2W/m to a driver's eyes in a front seat area seated at the right hand side of an equipped RHD vehicle when said first and third near IR radiation sources are powered and said second near IR radiation source is not powered 2 Near IR irradiance of (c).
274. The vehicle interior rearview mirror assembly of claim 270, wherein said first and third near IR radiation sources provide at least 2.3W/m to the eyes of a driver seated in the front seat area at the right hand side of an equipped RHD vehicle when said first and third near IR radiation sources are powered and said second near IR radiation source is not powered 2 Near IR irradiance of (c).
275. The vehicle interior rearview mirror assembly of claim 270, wherein said first and third near IR illumination sources are provided to an eye of a driver seated in a front seat area at the right hand side of an equipped RHD vehicle when said first and third near IR illumination sources are powered and said second near IR illumination source is not powered2.5W/m less 2 Near IR irradiance of (c).
276. The vehicle interior rearview mirror assembly of any one of claims 248-263, wherein the first, second and third near IR illumination sources are powered and provide at least 0.15W/m at a front seat region of an equipped vehicle when the vehicle interior rearview mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide the occupant detection function 2 Near IR irradiance of (c).
277. The vehicle interior rearview mirror assembly of claim 276, wherein said first, second and third near IR illumination sources are powered and provide at least 0.25W/m at a front seat region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of said equipped vehicle and when said DMS data processor is operating to provide said occupant detection function 2 Near IR irradiance of (c).
278. The vehicle interior rearview mirror assembly of claim 277, wherein said first, second and third near IR illumination sources are powered and provide at least 0.4W/m at a front seat region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of said equipped vehicle and when said DMS data processor is operating to provide said occupant detection function 2 Near IR irradiance of (c).
279. The vehicle interior rearview mirror assembly of claim 276, wherein said first, second and third near IR illumination sources are powered and provide at least 0.1W/m at a rear seat region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of said equipped vehicle and when said DMS data processor is operating to provide said occupant detection function 2 Near IR irradiance of (c).
280. The vehicle interior rear of claim 279A mirror assembly, wherein the first, second and third near IR illumination sources are powered and provide at least 0.1W/m at a rear seat area of the equipped vehicle when the vehicle interior mirror assembly is attached at an interior portion of the equipped vehicle and when the DMS data processor is operating to provide the occupant detection function 2 Near IR irradiance of (c).
281. The vehicle interior rearview mirror assembly of claim 280, wherein said first, second and third near IR illumination sources are powered and provide at least 0.2W/m at a rear seat region of an equipped vehicle when said vehicle interior rearview mirror assembly is attached at an interior portion of said equipped vehicle and when said DMS data processor is operating to provide said occupant detection function 2 Near IR irradiance of (c).
282. The vehicle interior mirror assembly of any one of claims 1-64, 127-205, 207-224, and 248-263, wherein the specular reflector comprises a multi-layer stack of a plurality of thin film coating layers that are applied to a planar glass surface of a glass substrate of the interior specular reflective element, wherein the plurality of thin film coating layers comprises repeated alternating layers of higher refractive index layers having a first refractive index and lower refractive index layers having a second refractive index, and wherein the first refractive index is at least 0.5 greater than the second refractive index.
283. The vehicle interior rearview mirror assembly of claim 282, wherein said first refractive index is at least 0.7 greater than said second refractive index.
284. The vehicle interior rearview mirror assembly of claim 282, wherein said second refractive index is greater than 2.
285. The vehicle interior rearview mirror assembly of claim 282, wherein said first refractive index is less than 1.5.
286. The vehicle interior rearview mirror assembly of claim 282, wherein said higher refractive index layer comprises a metal oxide thin film coating.
287. The vehicle interior rearview mirror assembly of claim 286, wherein said higher refractive index layer comprises a niobium metal oxide thin film coating.
288. The vehicle interior rearview mirror assembly of claim 286, wherein said higher refractive index layer comprises a titanium metal oxide thin film coating.
289. The vehicle interior rearview mirror assembly of claim 282, wherein said higher refractive index layer comprises a semiconductor metal film coating.
290. The vehicle interior rearview mirror assembly of claim 289, wherein said semiconductor metal has a refractive index of at least 2.4.
291. The vehicle interior rearview mirror assembly of claim 289, wherein said semiconductor metal is silicon.
292. The vehicle interior rearview mirror assembly of claim 289, wherein said semiconductor metal is germanium.
293. The vehicle interior rearview mirror assembly of claim 282, wherein said lower refractive index layer comprises a metal oxide thin film coating.
294. The vehicle interior rearview mirror assembly of claim 282, wherein said lower refractive index layer comprises a metal oxide thin film coating.
295. The vehicle interior rearview mirror assembly of claim 294, wherein said lower refractive index layer comprises a silicon metal oxide thin film coating.
296. The vehicle interior rearview mirror assembly of claim 282, wherein said specular reflector comprises at least one silicon film coating.
297. The vehicle interior mirror assembly of claim 282, wherein the plurality of film coating layers includes at least five (5) film coating layers.
298. The vehicle interior mirror assembly of claim 282, wherein the plurality of film coating layers includes at least seven (7) film coating layers.
299. The vehicle interior mirror assembly of claim 282, wherein the plurality of film coating layers includes at least ten (10) film coating layers.
300. The vehicle interior rearview mirror assembly of claim 282, wherein said multi-layer stack forming said specular reflector comprises an innermost thin film coating closest to said flat glass surface of said glass substrate and comprises an outermost thin film coating furthest from said flat glass surface of said glass substrate.
301. The vehicle interior mirror assembly of claim 300, wherein the innermost thin film coating closest to the planar glass surface of the glass substrate comprises a metal oxide thin film coating having a first refractive index.
302. The vehicle interior rearview mirror assembly of claim 301, wherein the innermost thin film coating of the planar glass surface nearest said glass substrate comprises a niobium oxide thin film coating.
303. The vehicle interior rearview mirror assembly of claim 301, wherein the innermost thin film coating of the planar glass surface nearest said glass substrate comprises a titanium oxide thin film coating.
304. The vehicle interior rearview mirror assembly of claim 300, wherein an innermost thin film coating closest to the planar glass surface of said glass substrate has a higher refractive index than a next closest thin film coating from the planar glass surface of said glass substrate.
305. The vehicle interior rearview mirror assembly of claim 304, wherein said next-to-closest thin film coating film comprises a metal oxide thin film coating having a second refractive index.
306. The vehicle interior rearview mirror assembly of claim 305, wherein said next-to-closest thin film coating comprises a silicon oxide thin film coating.
307. The vehicle interior rearview mirror assembly of claim 282, wherein said outermost thin film coating furthest from the planar glass surface of said glass substrate comprises a thin film coating having a third refractive index that is higher than said first refractive index.
308. The vehicle interior rearview mirror assembly of claim 307, wherein said third refractive index is at least 0.15 higher than said first refractive index.
309. The vehicle interior rearview mirror assembly of claim 307, wherein said third refractive index is at least 0.2 higher than said first refractive index.
310. The vehicle interior mirror assembly of any one of claims 307-309, wherein the outermost thin film coating furthest from the flat glass surface of the glass substrate comprises a transparent conductive thin film coating having a refractive index that is higher than the refractive index of the layer of the multi-layer stack to which it is applied.
311. The vehicle interior rearview mirror assembly of claim 310, wherein said transparent conductive film coating comprises an Indium Tin Oxide (ITO) layer.
312. The vehicle interior rearview mirror assembly of claim 311, wherein said Indium Tin Oxide (ITO) layer has a sheet resistance of less than 20 ohms/square.
313. The vehicle interior rearview mirror assembly of claim 312, wherein said glass substrate is heated to a temperature of at least 250 degrees celsius during deposition of said Indium Tin Oxide (ITO) layer.
314. The vehicle interior rearview mirror assembly of claim 311, wherein said interior mirror reflective element comprises an electrochromic interior mirror reflective element having a front glass substrate and a rear glass substrate, and wherein said rear glass substrate comprises a glass substrate coated with said specular reflector, and wherein a planar rear surface of the front glass substrate has a transparent conductive coating disposed thereat, and wherein a planar front surface of said rear glass substrate has a specular reflector disposed thereat, and wherein an electrochromic medium is disposed between and in contact with the transparent conductive coating disposed at the planar rear surface of the front glass substrate and the specular reflector disposed at the planar front surface of the rear glass substrate.
315. The vehicle interior rearview mirror assembly of claim 314, wherein said vehicle interior rearview mirror assembly comprises a vehicle EVO TM An interior rearview mirror assembly.
316. The vehicle interior rearview mirror assembly of claim 315, wherein said rear glass substrate has a plate thickness of about 1.6mm or less.
317. The vehicle interior rearview mirror assembly of claim 316, wherein a housing portion of the mirror housing of the mirror head circumscribes a peripheral edge of the front glass substrate, and wherein said housing portion has a rounded outer surface that provides a curved transition between the planar front surface of the front glass substrate and the outer surface of the wall portion of the mirror housing of the mirror head.
318. The vehicle interior rearview mirror assembly of claim 314, wherein said vehicle interior rearview mirror assembly comprises a rimless interior rearview mirror assembly.
319. The vehicle interior rearview mirror assembly of claim 318, wherein said rear glass substrate has a plate thickness of about 1.6mm or less.
320. The vehicle interior rearview mirror assembly of claim 314, wherein said vehicle interior rearview mirror assembly comprises a vehicle Infinity TM An interior rearview mirror assembly.
321. The vehicle interior rearview mirror assembly of claim 320, wherein said front glass substrate includes an exposed rounded peripheral edge having a radius of curvature of at least 2.5 mm.
322. The vehicle interior rearview mirror assembly of claim 321, wherein said front glass substrate is at least about 2mm thick.
323. The vehicle interior rearview mirror assembly of claim 322, wherein said front glass substrate has an exposed rounded peripheral edge with a radius of curvature of at least 2.5 mm.
324. The vehicle interior rearview mirror assembly of claim 323, wherein said exposed rounded peripheral edge provides a curved transition between the planar front surface of said front glass substrate and the outer surface of the wall portion of the mirror housing of said lens portion.
325. The vehicle interior rearview mirror assembly of claim 322, wherein said front glass substrate comprises a low iron (low Fe) soda lime glass.
326. The vehicle interior rearview mirror assembly of claim 282, wherein said layer of a specular reflector is deposited onto said glass substrate using medium frequency AC sputtering.
327. The vehicle interior rearview mirror assembly of claim 282, wherein said thin film coating of said specular reflector is deposited onto said glass substrate using intermediate frequency AC sputtering in a multi-station/multi-target in-line sputter deposition process.
328. The vehicle interior rearview mirror assembly of claim 282, wherein said layer of a specular reflector is deposited onto said glass substrate in a batch vacuum deposition chamber.
329. The vehicle interior rearview mirror assembly of any one of claims 1-46, wherein the vehicle interior rearview mirror assembly comprises a vehicle electrochromic interior rearview mirror assembly, and wherein the interior mirror reflective element comprises an electrochromic interior mirror reflective element having a front flat glass substrate and a rear flat glass substrate, and wherein the front flat glass substrate comprises a first flat glass surface spaced from a second flat glass surface by a plate thickness dimension of the front flat glass substrate, and wherein the rear flat glass substrate comprises a third flat glass surface spaced from a fourth flat glass surface by a plate thickness dimension of the rear flat glass substrate, and wherein the second flat glass surface of the front flat glass substrate has a transparent conductive coating disposed thereat, and wherein the third flat glass surface of the rear flat glass substrate has a transparent conductive coating disposed thereat, and wherein an electrochromic medium is disposed between the transparent conductive coating disposed at the second flat glass surface of the front flat glass substrate and the conductive coating disposed at the third flat glass surface of the rear flat glass substrate and is disposed in contact with the transparent conductive coating disposed at the fourth flat glass surface, and wherein the transparent conductive coating is disposed at the rear flat glass substrate.
330. The vehicle interior rearview mirror assembly of claim 329, wherein said transparent conductive thin film coating disposed at the second planar glass surface of said front planar glass substrate comprises an Indium Tin Oxide (ITO) layer, and wherein said transparent conductive thin film coating disposed at the third planar glass surface of the rear planar glass substrate comprises an Indium Tin Oxide (ITO) layer.
331. The vehicle interior rearview mirror assembly of claim 330, wherein said Indium Tin Oxide (ITO) layer disposed at said second planar glass surface of said front planar glass substrate has a sheet resistance of less than 20 ohms/square, and wherein said Indium Tin Oxide (ITO) layer disposed at the third planar glass surface of said rear planar glass substrate has a sheet resistance of less than 20 ohms/square.
332. The vehicle interior rearview mirror assembly of claim 331, wherein said specular reflector disposed at the fourth planar glass surface of said rear planar glass substrate comprises a multi-layer stack formed of a plurality of thin film coating layers.
333. The vehicle interior rearview mirror assembly of claim 332, wherein said specular reflector comprises at least one silicon layer.
334. The vehicle interior mirror assembly of claim 332, wherein the plurality of film coating layers comprises repeated alternating layers of higher refractive index layers and lower refractive index layers, and wherein the higher refractive index layers have a refractive index greater than 2 and the lower refractive index layers have a refractive index less than 1.5.
335. The vehicle interior rearview mirror assembly of claim 334, wherein said lower refractive index layer comprises a silicon oxide layer.
336. The vehicle interior rearview mirror assembly of claim 334, wherein said higher refractive index layer comprises a titanium oxide layer.
337. The vehicle interior rearview mirror assembly of claim 334, wherein said higher refractive index layer comprises a niobium oxide layer.
338. The vehicle interior rearview mirror assembly of claim 334, wherein said plurality of film coating layers comprises at least five (5) layers.
339. The vehicle interior rearview mirror assembly of claim 334, wherein said plurality of film coating layers includes at least seven (7) layers.
340. The vehicle interior rearview mirror assembly of claim 338, wherein said vehicle electrochromic interior rearview mirror assembly comprises a frameless vehicle electrochromic interior rearview mirror assembly.
341. The vehicle interior rearview mirror assembly of claim 340, wherein said frameless vehicle electrochromic interior rearview mirror assembly comprises an Infinity TM A frameless vehicle electrochromic interior rearview mirror assembly.
342. The vehicle interior rearview mirror assembly of claim 340, wherein said Infinity is TM An electrochromic interior mirror reflective element of a vehicle electrochromic interior mirror assembly includes a front planar substrate having a plate thickness of at least about 2mm and a rear planar substrate having a plate thickness of about 1.6mm or less.
343. The method according to claim 340The vehicle interior rearview mirror assembly, wherein the Infinity TM The electrochromic interior mirror reflective element of the vehicle electrochromic interior rearview mirror assembly includes a front planar substrate formed of low iron (low Fe) glass.
344. The vehicle interior rearview mirror assembly of claim 340, wherein said frameless vehicle electrochromic interior rearview mirror assembly comprises EVO TM A frameless vehicle electrochromic interior rearview mirror assembly.
345. The vehicle interior rearview mirror assembly of claim 344, wherein said EVO TM An electrochromic interior mirror reflective element of a vehicle electrochromic interior mirror assembly includes a front planar substrate having a plate thickness of about 1.6mm or less and a rear planar substrate having a plate thickness of about 1.6mm or less.
346. The vehicle interior rearview mirror assembly of any one of claims 1-46, wherein the vehicle interior rearview mirror assembly comprises a vehicle prismatic interior rearview mirror assembly, and wherein the interior specular reflective element comprises a prismatic interior specular reflective element, and wherein the prismatic interior specular reflective element comprises a glass substrate, and wherein the glass substrate has a wedge-shaped cross-section with a first planar glass surface spaced from a second planar glass surface, and wherein a plane of the first planar glass surface is inclined at an angle relative to a plane of the second planar glass surface, and wherein the second planar glass surface is an uncoated glass surface, and wherein a specular reflector is disposed at the second planar glass surface of the glass substrate of the prismatic interior specular reflective element.
347. The vehicle interior rearview mirror assembly of claim 346, wherein said specular reflector disposed at said second planar glass surface of said glass substrate comprises a multi-layer stack formed of a plurality of thin film coating layers.
348. The vehicle interior rearview mirror assembly of claim 347, wherein said specular reflector comprises at least one silicon layer.
349. The vehicle interior mirror assembly of claim 347, wherein the plurality of film coating layers comprises repeating alternating layers of higher refractive index layers and lower refractive index layers, and wherein the higher refractive index layers have a refractive index greater than 2 and the lower refractive index layers have a refractive index less than 1.5.
350. The vehicle interior rearview mirror assembly of claim 349, wherein said lower refractive index layer comprises a silicon oxide layer.
351. The vehicle interior rearview mirror assembly of claim 349, wherein said higher refractive index layer comprises a titanium oxide layer.
352. The vehicle interior rearview mirror assembly of claim 349, wherein said higher refractive index layer comprises a niobium oxide layer.
353. The vehicle interior mirror assembly of claim 349, wherein the plurality of film coating layers comprises at least seven (7) layers.
354. The vehicle interior mirror assembly of claim 349, wherein the plurality of film coating layers comprises at least five (5) layers.
355. The vehicle interior rearview mirror assembly of claim 354, wherein said vehicle prismatic interior rearview mirror assembly comprises a frameless vehicle prismatic interior rearview mirror assembly.
356. The vehicle interior rearview mirror assembly of claim 355, wherein said frameless vehicle prismatic interior rearview mirror assembly comprises an Infinity TM A frameless vehicle prismatic interior rearview mirror assembly.
357. The vehicle interior rearview mirror assembly of claim 356, wherein said Infinity is TM The glass substrate of the prismatic interior mirror reflective element of the vehicle prismatic interior mirror assembly is formed of a low iron (low Fe) glass.
358. The vehicle interior rearview mirror assembly of claim 355, wherein said frameless vehicle prismatic interior rearview mirror assembly comprises EVO TM A frameless vehicle prismatic interior rearview mirror assembly.
359. The vehicle interior rearview mirror assembly of claim 358, wherein said EVO TM The glass substrate of the prismatic interior mirror reflective element of the vehicle prismatic interior mirror assembly is formed of a low iron (low Fe) glass.
360. The vehicle interior mirror assembly of any one of claims 1-64, 127-205, 207-224, and 248-263, wherein the third angle is a different angle than the second angle.
361. The vehicle interior mirror assembly of any one of claims 1-64, 127-205, 207-224, and 248-263, wherein the third angle is the same angle as the second angle, but in a laterally opposite direction from the second angle.
362. The vehicle interior rearview mirror assembly of any one of claims 1-64, 127-205, 207-224 and 248-263, wherein the specular reflector comprises a multi-layer stack of thin film coatings, and wherein the total physical stack thickness of the specular reflector is less than 1500nm.
363. The vehicle interior rearview mirror assembly of any one of claims 1-64, 127-205, 207-224 and 248-263, wherein the specular reflector comprises a multi-layer stack of thin film coatings, and wherein the total physical stack thickness of the specular reflector is less than 1000nm.
364. The vehicle interior rearview mirror assembly of any one of claims 1-64, 127-205, 207-224 and 248-263, wherein the specular reflector comprises a multi-layer stack of thin film coatings, and wherein the total physical stack thickness of the specular reflector is less than 750nm.
Applications Claiming Priority (9)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US63/200,315 | 2021-03-01 | ||
| US63/200,451 | 2021-03-08 | ||
| US63/201,371 | 2021-04-27 | ||
| US63/201,757 | 2021-05-12 | ||
| US63/260,359 | 2021-08-18 | ||
| US63/262,642 | 2021-10-18 | ||
| US202263267316P | 2022-01-31 | 2022-01-31 | |
| US63/267,316 | 2022-01-31 | ||
| PCT/US2022/070882 WO2022187805A1 (en) | 2021-03-01 | 2022-03-01 | Interior rearview mirror assembly with driver monitoring system |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117279802A true CN117279802A (en) | 2023-12-22 |
Family
ID=89206769
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202280032148.6A Pending CN117279802A (en) | 2021-03-01 | 2022-03-01 | Interior rearview mirror assembly with driver monitoring system |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117279802A (en) |
-
2022
- 2022-03-01 CN CN202280032148.6A patent/CN117279802A/en active Pending
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