Mirror reflective element sub-assembly for exterior rearview mirror of a vehicle

1. A mirror reflective element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

an electrochromic mirror reflective element having a front substrate and a rear substrate with an electrochromic medium disposed therebetween;

wherein said front substrate has a first surface and a second surface;

said second surface of said front substrate having a transparent electrically conductive layer disposed thereat;

wherein said rear substrate has a third surface and a fourth surface;

a mirror reflector disposed at at least a portion of a surface of said rear substrate;

wherein said electrochromic medium is disposed in an interpane cavity established between said third surface of said rear substrate and said second surface of said front substrate and bounded by a perimeter seal;

a heater pad disposed at said fourth surface of said rear substrate, wherein said heater pad comprises a substantially non-light transmitting portion and a light transmitting portion;

a mirror back plate disposed at said heater pad, said mirror back plate comprising a plate portion having a front plate surface facing said heater pad and a rear plate surface rearward of and spaced from said front plate surface by a thickness dimension of said plate portion of said mirror back plate;

wherein said mirror back plate comprises a first structure at said rear plate surface, wherein said first structure is configured to attach at an actuator of an exterior rearview mirror assembly;

wherein said mirror back plate comprises a second structure at said rear plate surface;

wherein said mirror back plate is formed by injection molding and wherein said first structure, said second structure and said plate portion of said mirror back plate are formed during injection molding of said mirror back plate;

an indicator element having a light source that is activatable to emit light;

wherein said indicator element is disposed at said second structure of said mirror back plate;

wherein said indicator element, when said light source is activated, emits light through said light transmitting portion of said heater pad and through said mirror reflective element; and

wherein said indicator element and said second structure are configured so that light emitted by said indicator element, when said light source is activated and when said mirror reflective element sub-assembly is disposed at an exterior rearview mirror of a vehicle, exits said mirror back plate and said mirror reflective element sub-assembly so as to be principally viewed by a driver of the vehicle.

2. The mirror reflective element sub-assembly of claim 1 , wherein said indicator element makes mechanical connection at said second structure when disposed at said second structure.

3. The mirror reflective element sub-assembly of claim 2 , wherein said indicator element makes electrical connection at said second structure when disposed at said second structure.

4. The mirror reflective element sub-assembly of claim 1 , wherein said indicator element comprises a self-contained sealed unit.

5. The mirror reflective element sub-assembly of claim 4 , wherein said self-contained sealed unit is substantially impervious to water ingress.

6. The mirror reflective element sub-assembly of claim 1 , wherein said light source comprises at least one light emitting diode.

7. The mirror reflective element sub-assembly of claim 1 , further comprising an icon, wherein light emitted by said indicator element, when said light source is activated, illuminates said icon so that said illuminated icon is viewable through said mirror reflective element by a person viewing said front substrate of said mirror reflective element sub-assembly.

8. The mirror reflective element sub-assembly of claim 7 , wherein said icon is established at said light transmitting portion of said heater pad.

9. The mirror reflective element sub-assembly of claim 7 , wherein said icon is established at said fourth surface of said rear substrate.

10. The mirror reflective element sub-assembly of claim 7 , wherein said icon is established between said fourth surface and said mirror back plate.

11. The mirror reflective element sub-assembly of claim 7 , wherein said icon is established at an otherwise substantially opaque layer disposed at said fourth surface of said rear substrate.

12. The mirror reflective element sub-assembly of claim 11 , wherein said icon is established by etching said substantially opaque layer.

13. The mirror reflective element sub-assembly of claim 7 , wherein said icon is established through a conductive coating of said rear substrate.

14. The mirror reflective element sub-assembly of claim 7 , wherein said icon is established at said light transmitting portion of said heater pad via a pattern formed thereat.

15. The mirror reflective element sub-assembly of claim 1 , wherein said second structure comprises a portion of a passageway, said emitted light passing through said passageway.

16. The mirror reflective element sub-assembly of claim 15 , further comprising a cover element at least partially at said second structure, and wherein at least one of (i) said cover element substantially seals said passageway of said second structure and (ii) said passageway is at least partially filled with a substantially transparent or translucent material to substantially seal said passageway and to allow light to pass through said passageway.

17. The mirror reflective element sub-assembly of claim 1 , wherein said second structure extends at least partially from said rear plate surface at an angle of less than 90 degrees relative to said rear plate surface.

18. The mirror reflective element sub-assembly of claim 1 , wherein at least one of (i) said heater pad is adhered at said fourth surface of said rear substrate and (ii) said front plate surface of said plate portion of said mirror back plate is adhered at said heater pad.

19. The mirror reflective element sub-assembly of claim 1 , wherein said indicator element is associated with a blind spot detection system of the vehicle.

20. The mirror reflective element sub-assembly of claim 1 , wherein said mirror reflector is disposed at at least a portion of said third surface of said rear substrate.

21. A mirror reflective element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

an electrochromic mirror reflective element having a front substrate and a rear substrate with an electrochromic medium disposed therebetween;

wherein said front substrate has a first surface and a second surface;

said second surface of said front substrate having a transparent electrically conductive layer disposed thereat;

wherein said rear substrate has a third surface and a fourth surface;

a mirror reflector disposed at at least a portion of said third surface of said rear substrate;

wherein said electrochromic medium is disposed in an interpane cavity established between said third surface of said rear substrate and said second surface of said front substrate and bounded by a perimeter seal;

a heater pad disposed at said fourth surface of said rear substrate, wherein said heater pad comprises a substantially non-light transmitting portion and a light transmitting portion;

a mirror back plate disposed at said heater pad, said mirror back plate comprising a plate portion having a front plate surface facing said heater pad and a rear plate surface rearward of and spaced from said front plate surface by a thickness dimension of said plate portion of said mirror back plate;

wherein said mirror back plate comprises a first structure at said rear plate surface, wherein said first structure is configured to attach at an actuator of an exterior rearview mirror assembly;

wherein said mirror back plate comprises a second structure at said rear plate surface;

wherein said mirror back plate is formed by injection molding and wherein said first structure, said second structure and said plate portion of said mirror back plate are formed during injection molding of said mirror back plate;

an indicator element having a light source that is activatable to emit light, wherein said light source comprises at least one light emitting diode;

wherein said indicator element is disposed at said second structure of said mirror back plate;

wherein said indicator element, when said light source is activated, emits light through said light transmitting portion of said heater pad and through said mirror reflective element;

wherein said indicator element and said second structure are configured so that light emitted by said indicator element, when said light source is activated and when said mirror reflective element sub-assembly is disposed at an exterior rearview mirror of a vehicle, exits said mirror back plate and said mirror reflective element sub-assembly so as to be principally viewed by a driver of the vehicle; and

wherein said indicator element is associated with a blind spot detection system of the vehicle.

22. The mirror reflective element sub-assembly of claim 21 , wherein at least one of (i) said indicator element makes mechanical connection at said second structure when disposed at said second structure, and (ii) said indicator element makes electrical connection at said second structure when disposed at said second structure.

23. The mirror reflective element sub-assembly of claim 21 , wherein said indicator element comprises a self-contained sealed unit, and wherein said self-contained sealed unit is substantially impervious to water ingress.

24. The mirror reflective element sub-assembly of claim 21 , wherein said second structure comprises a portion a passageway, said emitted light passing through said passageway.

25. The mirror reflective element sub-assembly of claim 21 , wherein said second structure extends at least partially from said rear plate surface at an angle of less than 90 degrees relative to said rear plate surface.

26. The mirror reflective element sub-assembly of claim 21 , wherein at least one of (i) said heater pad is adhered at said fourth surface of said rear substrate and (ii) said front plate surface of said plate portion of said mirror back plate is adhered at said heater pad.

27. A mirror reflective element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

an electrochromic mirror reflective element having a front substrate and a rear substrate with an electrochromic medium disposed therebetween;

wherein said front substrate has a first surface and a second surface;

said second surface of said front substrate having a transparent electrically conductive layer disposed thereat;

wherein said rear substrate has a third surface and a fourth surface;

a mirror reflector disposed at at least a portion of a surface of said rear substrate;

wherein said electrochromic medium is disposed in an interpane cavity established between said third surface of said rear substrate and said second surface of said front substrate and bounded by a perimeter seal;

a heater pad disposed at said fourth surface of said rear substrate, wherein said heater pad comprises a substantially non-light transmitting portion and a light transmitting portion;

a mirror back plate disposed at said heater pad, said mirror back plate comprising a plate portion having a front plate surface facing said heater pad and a rear plate surface rearward of and spaced from said front plate surface by a thickness dimension of said plate portion of said mirror back plate;

wherein said mirror back plate comprises a first structure at said rear plate surface, wherein said first structure is configured to attach at an actuator of an exterior rearview mirror assembly;

wherein said mirror back plate comprises a second structure at said rear plate surface;

wherein said mirror back plate is formed by injection molding and wherein said first structure, said second structure and said plate portion of said mirror back plate are formed during injection molding of said mirror back plate;

an indicator element having a light source that is activatable to emit light, wherein said light source comprises at least one light emitting diode;

wherein said indicator element is disposed at said second structure of said mirror back plate;

wherein said indicator element, when said light source is activated, emits light through said light transmitting portion of said heater pad and through said mirror reflective element;

wherein said indicator element and said second structure are configured so that light emitted by said indicator element, when said light source is activated and when said mirror reflective element sub-assembly is disposed at an exterior rearview mirror of a vehicle, exits said mirror back plate and said mirror reflective element sub-assembly so as to be principally viewed by a driver of the vehicle;

an icon, wherein light emitted by said indicator element, when said light source is activated, illuminates said icon so that said illuminated icon is viewable through said mirror reflective element by a person viewing said front substrate of said mirror reflective element sub-assembly; and

wherein said indicator element is associated with a blind spot detection system of the vehicle.

28. The mirror reflective element sub-assembly of claim 27 , wherein said icon is at least one of (i) established at said light transmitting portion of said heater pad, (ii) established at said fourth surface of said rear substrate, (iii) established between said fourth surface and said mirror back plate, (iv) established at an otherwise substantially opaque layer disposed at said fourth surface of said rear substrate, (v) established at an otherwise substantially opaque layer disposed at said fourth surface of said rear substrate by etching said substantially opaque layer, (vi) established through a conductive coating of said rear substrate and (vii) established at said light transmitting portion of said heater pad via a pattern formed thereat.

29. The mirror reflective element sub-assembly of claim 27 , wherein at least one of (i) said indicator element makes mechanical connection at said second structure when disposed at said second structure, and (ii) said indicator element makes electrical connection at said second structure when disposed at said second structure.

30. The mirror reflective element sub-assembly of claim 27 , wherein said indicator element comprises a self-contained sealed unit, and wherein said self-contained sealed unit is substantially impervious to water ingress.

31. The mirror reflective element sub-assembly of claim 27 , wherein said second structure comprises a portion of a passageway, said emitted light passing through said passageway.

32. The mirror reflective element sub-assembly of claim 27 , wherein said second structure extends at least partially from said rear plate surface at an angle of less than 90 degrees relative to said rear plate surface.

33. The mirror reflective element sub-assembly of claim 27 , wherein at least one of (i) said heater pad is adhered at said fourth surface of said rear substrate and (ii) said front plate surface of said plate portion of said mirror back plate is adhered at said heater pad.

34. A mirror reflective element sub-assembly for an exterior rearview mirror assembly of a vehicle, said mirror reflective element sub-assembly comprising:

an electrochromic mirror reflective element having a front substrate and a rear substrate with an electrochromic medium disposed therebetween;

wherein said front substrate has a first surface and a second surface;

said second surface of said front substrate having a transparent electrically conductive layer disposed thereat;

wherein said rear substrate has a third surface and a fourth surface;

a mirror reflector disposed at at least a portion of a surface of said rear substrate;

wherein said electrochromic medium is disposed in an interpane cavity established between said third surface of said rear substrate and said second surface of said front substrate and bounded by a perimeter seal;

a heater pad disposed at said fourth surface of said rear substrate, wherein said heater pad comprises a substantially non-light transmitting portion and a light transmitting portion;

a mirror back plate disposed at said heater pad, said mirror back plate comprising a plate portion having a front plate surface facing said heater pad and a rear plate surface rearward of and spaced from said front plate surface by a thickness dimension of said plate portion of said mirror back plate;

wherein said mirror back plate comprises a first structure at said rear plate surface, wherein said first structure is configured to attach at an actuator of an exterior rearview mirror assembly;

wherein said mirror back plate comprises a second structure at said rear plate surface;

wherein said mirror back plate is formed by injection molding and wherein said first structure, said second structure and said plate portion of said mirror back plate are formed during injection molding of said mirror back plate;

an indicator element having a light source that is activatable to emit light;

wherein said indicator element comprises a self-contained sealed unit and wherein said self-contained sealed unit is substantially impervious to water ingress;

wherein said light source comprises at least one light emitting diode;

wherein said indicator element is disposed at said second structure of said mirror back plate;

wherein said indicator element, when said light source is activated, emits light through said light transmitting portion of said heater pad and through said mirror reflective element;

wherein said indicator element and said second structure are configured so that light emitted by said indicator element, when said light source is activated and when said mirror reflective element sub-assembly is disposed at an exterior rearview mirror of a vehicle, exits said mirror back plate and said mirror reflective element sub-assembly so as to be principally viewed by a driver of the vehicle; and

wherein said indicator element is associated with a blind spot detection system of the vehicle.

35. The mirror reflective element sub-assembly of claim 34 , wherein said icon is at least one of (i) established at said light transmitting portion of said heater pad, (ii) established at said fourth surface of said rear substrate, (iii) established between said fourth surface and said mirror back plate, (iv) established at an otherwise substantially opaque layer disposed at said fourth surface of said rear substrate, (v) established at an otherwise substantially opaque layer disposed at said fourth surface of said rear substrate by etching said substantially opaque layer, (vi) established through a conductive coating of said rear substrate and (vii) established at said light transmitting portion of said heater pad via a pattern formed thereat.

36. The mirror reflective element sub-assembly of claim 34 , wherein at least one of (i) said indicator element makes mechanical connection at said second structure when disposed at said second structure, and (ii) said indicator element makes electrical connection at said second structure when disposed at said second structure.

37. The mirror reflective element sub-assembly of claim 34 , wherein said second structure comprises a portion of a passageway, said emitted light passing through said passageway.

38. The mirror reflective element sub-assembly of claim 34 , wherein said second structure extends at least partially from said rear plate surface at an angle of less than 90 degrees relative to said rear plate surface.

39. The mirror reflective element sub-assembly of claim 34 , wherein said mirror reflector is disposed at at least a portion of said third surface of said rear substrate.