US20020030892A1 - Digital electrochromic mirror system - Google Patents

Abstract

A vehicular electrochromic rearview mirror system includes an interior electrochromic rearview mirror assembly and at least one exterior electrochromic rearview mirror assembly. Each mirror assembly includes an electrochromic reflective element that assumes a partial reflectance level in response to a signal applied thereto. A drive circuit applies a drive signal to each of the electrochromic reflective elements. The drive circuit may include a digital controller, a master drive circuit responsive to the digital controller to apply a first drive signal to one of the electrochromic reflective elements and a slave drive circuit responsive to the digital controller to apply a second drive signal to a second of the electrochromic reflective elements. The second drive signal may be derived from the first drive signal. The drive circuit may include a digital controller and a switching power supply controlled by the digital controller to produce a drive signal.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
• This application is a continuation-in-part of application Ser. No. 08/832,380 filed on Apr. 2, 1997, by Kenneth L. Schierbeek, the disclosure of which is hereby incorporated herein by reference, and further claims priority from provisional patent applications Ser. No. 60/103,721 filed on Oct. 9, 1998, by Kenneth Schofield and Kenneth L. Schierbeek, and Ser. No. 60/117,633 filed on Jan. 28, 1999, by Kenneth Schofield and Kenneth L. Schierbeek, the disclosures of which are hereby incorporated herein by reference.[0001]
BACKGROUND OF THE INVENTION
• This invention relates generally to vehicle rearview mirror systems and, more particularly, to electrochromic mirror systems, including an interior electrochromic rearview mirror assembly and at least one exterior electrochromic rearview mirror assembly.[0002]
• An electrochromic rearview mirror assembly includes an electrochromic reflective element that responds to a signal applied across a pair of terminals by varying the light reflected by the reflective element. In this manner, the reflectance level of the reflective element can be varied by varying the signal applied to the electrochromic cell. The electrochromic reflective element has characteristics which makes control of its reflectance level difficult. The electrochromic reflective element operates at a relatively low voltage, which typically may not exceed approximately 2 volts DC, more typically not more than about 1.5 volts DC, for more than a brief period of time or else useful life of the reflective element is compromised. Furthermore, the amount of voltage necessary to establish a particular value of the light transmissivity of the cell varies with the temperature of the cell, the amount of change in light transmittance undertaken, and the surface area of the cell. Therefore, optimum control of the electrochromic reflective element may require more than merely applying a DC voltage corresponding to the desired reflectance level.[0003]
• Electrochromic mirror systems have incorporated therein many additional electronic functions in addition to mirror drive. These include compass functions; namely, determination and display of vehicle heading, display of the interior and/or exterior temperature as well as other functions as disclosed in commonly assigned U.S. Pat. No. 5,798,575, the disclosure of which is hereby incorporated herein by reference. By combining multiple functions in a single system, it is possible to utilize the computational power of a microcomputer in order to perform a wide range of functions. Although a microcomputer has extensive computational capability, its ability to supply a drive signal to external components, such as an electrochromic cell, is limited. Therefore, it has been necessary to provide an interface circuit between the microprocessor and the electrochromic cell in order to supply the electrochromic cell with a desired reflectance level established by the microcomputer. U.S. Pat. No. 5,451,822 integrates a Pulse-Width Modulated (PWM) output of a microcomputer and amplifies the integrated PWM signal utilizing a conventional analog DC amplifier. The use of analog components to amplify the output of the microcomputer not only increases the cost of the system, but, additionally, increases its power consumption. The increase in power consumption requires larger components, which increases the physical size of the assembly and also increases the necessity for enhanced heat dissipation capabilities.[0004]
• In published International Publication No. WO 99/14619, a plurality of electrochromic mirror elements used in an automobile are controlled by individual drive circuits for each of the electrochromic elements. The individual drive circuits are supplied with PWM signals generated by a microcomputer from photosensors positioned inside the automobile. Additionally, separate glare signals are supplied to each of the electrochromic elements such that the reflected light at a predetermined reference point is relatively constant. The system described in Publication No. WO 99/14619 multiplies the number of analog components and the increase in energy consumption resulting therefrom. Thereby, not only is the advantage derived from the generation of digital signals by the microcomputer not realized, the problems associated with analog circuitry are multiplied.[0005]
• In U.S. Pat. 5,675,438 complementary push-pull transistors, connected between positive and negative voltages of positive 1.6 volts DC and negative 1.6 volts DC, respectively, are operated by an oscillation circuit to supply drive pulses to an electrochromic mirror. The duty factor of the pulses are adjusted by the oscillation circuit in response to light levels sensed by forward and rearward facing light sensors. Power supplies convert positive 12 volt vehicle battery voltage to the positive 1.6 volt and negative 1.6 volt levels needed to operate the push-pull transistors. The power supplies add components to the circuit and increases the power consumption thereof.[0006]
SUMMARY OF THE INVENTION
• The present invention provides a vehicular electrochromic mirror system which significantly reduces the power consumption and thereby the component size and heat dissipation requirements thereby beneficially utilizing the digital output of a digital controller. Furthermore, the present invention provides an electrochromic vehicular mirror system which the interior rearview mirror assembly and exterior rearview mirror assemblies are all commonly driven off of a common drive circuit.[0007]
• According to an aspect of the invention, a vehicular electrochromic rearview mirror system includes at least one electrochromic rearview assembly having an electrochromic reflective element. The electrochromic reflective element assumes a partial reflectance level in response to a signal applied thereto. The system further includes a drive circuit applying a drive signal to the electrochromic reflectance element establishing a partial reflectance level of the reflective element. The drive circuit includes a digital controller and a switching power supply controlled by the digital controller producing the drive signal.[0008]
• In a preferred form, the switching power supply is a switching step-down converter. Most preferably, the switching power supply is a buck converter which includes an inductor and an electronic switch in electrical series connection between the electrochromic reflective element and a voltage source. The use of a switching power supply which is controlled by a digital controller greatly reduces power consumption of the individual components. This may be enhanced by operating the electrical switch in a saturated condition, further reducing power consumption.[0009]
• According to another aspect of the invention, a vehicle electrochromic rearview mirror system includes an interior electrochromic rearview mirror assembly and at least one exterior electrochromic rearview mirror assembly. The system further includes a plurality of electrochromic reflective elements each associated with an electrochromic rearview mirror assembly. Each of the electrochromic reflective elements assumes a partial reflectance level in response to a signal applied thereto. The system further includes a drive signal that applies a drive signal to each of the electrochromic reflective elements. The drive circuit includes a digital controller, a master drive circuit responsive to the digital controller developing a first drive signal applied to one of the electrochromic cells and a slave drive circuit responsive to the digital controller developing a second drive signal applied to a second of the electrochromic cells. The second drive signal is derived from the first drive signal.[0010]
• Because the second drive signal is derived from the first drive signal, the reflectance level of the second of the electrochromic cells must necessarily be greater than or equal to the first of the electrochromic cells. While this could reduce the flexibility of control of the reflective elements, it has been discovered that exceptional performance can be achieved along with a substantial reduction in system component count and energy usage. Preferably, the first drive signal derived from the master drive circuit is applied to one or both exterior rearview mirrors and the second drive signal derived from the slave drive circuit is supplied to the interior rearview mirror assembly.[0011]
• These and other objects, advantages, and features of this invention will become apparent upon review of the following specification in conjunction with the drawings.[0012]
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a side elevation of a vehicle incorporating an electrochromic mirror system according to the invention;[0013]
• FIG. 2 is a side elevation of a portion of an electrochromic mirror system according to the invention;[0014]
• FIG. 3 is a block diagram of a drive circuit according to the invention;[0015]
• FIG. 4 is a block diagram of a master/slave drive circuit according to the invention;[0016]
• FIG. 5 is a generalized electrical schematic diagram of the drive circuit in FIG. 3;[0017]
• FIG. 6 is a detailed circuit diagram of the drive circuit in FIG. 5;[0018]
• FIG. 7 is a diagram showing waveforms of various electrical signals generated by the drive circuit in FIG. 6;[0019]
• FIG. 8 is a generalized circuit diagram of a slave drive circuit according to the invention;[0020]
• FIG. 9 is a detailed schematic diagram of the master/slave drive circuit in FIG. 4; and[0021]
• FIG. 10 is the same view as FIG. 6 of an alternative embodiment.[0022]
DESCRIPTION OF THE PREFERRED EMBODIMENT
• Referring now specifically to the drawings, and the illustrative embodiments depicted therein, a[0023]vehicle9 includes anelectrochromic mirror system10 having an electrochromic interiorrearview mirror assembly11 and one or more exteriorrearview mirror assemblies19 including a driver siderearview mirror assembly19 on the driver side of the vehicle and/or a passenger side rearview mirror system on an opposite side of vehicle9 (FIG. 1).
• [0024]Electrochromic mirror system10 includes anelectronic control12 which, preferably, is positioned within ahousing14 of interior rearview mirror assembly11 (FIG. 2).Electronic control12 includes adrive circuit13 which receives a first input from a rearward-facinglight sensor20, which faces rearwardly in the direction of travel of the vehicle, and a second input from forward-facinglight sensor22, which faces forward with respect to the direction of travel ofvehicle9. Drivecircuit13 supplies a drive signal to electrochromicreflective element18 included with interiorrearview mirror assembly11. It may also supply a drive signal to other electrochromic reflective elements, such as electrochromicreflective element24 associated with exteriorrearview mirror assembly19.
• In the illustrative embodiment,[0025]electronic control12 may include a display that may be positioned behindreflective element18 and viewed by the driver through the electrochromic reflective element as disclosed in U.S. Pat. No. 5,285,060, issued to Larson et al., for a DISPLAY FOR AUTOMATIC REARVIEW MIRROR, the disclosure of which is incorporated herein by reference. Alternatively, the display may be positioned on a lip portion ofhousing14 belowreflective element18 or on any other portion of the housing visible to the driver as illustrated in commonly assigned U.S. Pat. No. 5,786,772, the disclosure of which is hereby incorporated herein by reference. Alternatively, the display could be in the form of a heads-up display projected fromhousing14 on the vehicle windshield.
• [0026]Electronic control12 may additionally include a heading sensor, or compass, which produces outputs indicative of the heading of the vehicle. Such heading sensor may be of the magneto-resistive type, such as disclosed in commonly assigned U.S. Pat. No. 5,255,442, issued to Schierbeek et al., for a VEHICLE COMPASS WITH ELECTRONIC SENSOR, or may be of the magneto-inductive type, such as disclosed in commonly assigned provisional patent application Ser. No. 60/027,996, filed Oct. 9, 1996, by Domanski for an ELECTRONIC COMPASS, the disclosures of which are hereby incorporated herein by reference, or may be of the flux-gate type, or may be of the magneto-capacitive type.
• Electrochromic[0027]reflective elements18 and24 may be of any type such as disclosed in U.S. Pat. No. 4,902,108 issued to Byker; commonly assigned U.S. Pat. No. 5,140,455 issued to Varaprasad et al.; commonly assigned U.S. Pat. No. 5,910,854 issued to Varaprasad et al. and commonly assigned U.S. patent application Ser. No. 08/429,643 filed Apr. 27, 1995, by Varaprasad et al. entitled ELECTROCHROMIC MIRRORS AND DEVICES, the disclosures of which are hereby all incorporated herein by reference. Electrochromicreflective elements18 and24 include electrochromic units, or cells, that decrease in transmissivity in response to a drive signal applied thereto. The decrease in transmissivity of the electrochromic unit, or cell, results in a decrease in reflectance level of the associated reflective element.
• [0028]Light sensors20 and22 are conventional and may be applied as described in U.S. Pat. 4,917,477 issued to Bechtel et al.; U.S. Pat. No. 3,601,614 issued to Platzer, Jr.; and commonly assigned U.S. Pat. No. 4,793,690 issued to Graham et al. and U.S. Pat. No. 5,715,093 issued to Schierbeek et al., the disclosures of which are hereby incorporated herein by reference. Outputs of the light sensors are supplied as inputs to amicrocomputer controller26 which produces an output supplied to a switching power supply28 (FIGS. 3 and 5-7).Switching power supply28 reduces a voltage from avoltage source33 which, preferably, is on an order of magnitude of vehicle ignition voltage to an electrochromic drive signal.Voltage source33 is between 5 volts DC and 18 volts DC and preferably between 8 volts DC and 12 volts DC. Most preferably,voltage source33 is a regulated supply of approximately 8 volts DC, which requires minimum voltage reduction from ignition voltage levels of approximately 12 volt nominal, while facilitating a regulated voltage source. Alternatively,voltage source33 can be vehicle battery voltage or ignition voltage. While use of vehicle battery/ignition voltage eliminates the requirement for even the minimal voltage regulator needed to produce a regulated source at, say, 8 volts DC, the use of an unregulated supply increases the desirability of monitoring voltage across the electrochromic reflective element as discussed in more detail below and as disclosed in commonly assigned application Ser. No. 08/832,380. Drivecircuit13 supplies to electrochromic reflective element24 a signal with a current capability of at least about 50 milliamperes, preferably of at least about 100 milliamperes and, most preferably of at least about 200 milliamperes.
• For solution-phase, single-compartment, self-erasing electrochromic mirror elements commonly used commercially today, the maximum voltage tolerable for a sustained period is in the 1.0 volt to 2.0 volt range, typically less than 1.5 volts, and most typically about 1.4 volts. For solid-film electrochromic devices that utilize a layer, such as a tungsten oxide thin-filmed layer, the maximum voltage tolerable for a sustained period is in the 1.0 volt to the 3.0 volt range, typically in the 1.3 volt to 1.5 volt range. Usually, application of a voltage much in excess of such maximum tolerable voltage to the electrochromic cell for a sustained period, typically at least several seconds, may cause change to the electrochromic medium in the electrochromic cell. Electrochromic[0029]reflective element24 can be modeled as having a series resistance shown as R₁and a shunt resistance shown as R₂(FIG. 5). The series resistance R₁in the model arises from resistance of the electrodes and is on the order of 1 to 2 ohms. Shunt resistance R₂in the model arises from internal losses of the electrochromic cell. When the cell is fully colored, the internal shunt resistance is approximately 10 ohms. Theelectrochromic element24 typically develops a voltage, which is the potential stored on the cell. Upon application of external voltage thereto, the electrochromic element temporarily retains said potential even when the external voltage potential is removed and the cell is open-circuited. This property ofelectrochromic element24 can be represented in the model by a capacitance C cell which is on the order of a half of farad for an interior mirror electrochromic reflective element. The capacitance will vary as a function of the surface area of the electrochromic reflective element.
• Referring now to FIG. 5, switching[0030]power supply28 utilizes an electronic switch Q₁in series electrical connection with an inductor L₁betweenvoltage source33 andelectrochromic element24. As described above,voltage source33 is preferably on an order of magnitude of ignition voltage. This eliminates the necessity for additional power supply to drop ignition voltage to an operating voltage level ofelectrochromic element24. By eliminating the requirement for an additional power supply, a reduction in component cost and size, as well as power consumption, can be realized.Switching power supply28 additionally includes a second switch D₁connected between ajunction30, which is the junction between switch Q₁and inductor L₁, and ground. Switch D₁is operated oppositely of switch Q₁such that whenever switch Q₁is open, switch D₁is closed and vice versa.Switching power supply28 preferably additionally includes a capacitor C₁, connected between ajunction32, which is a junction between inductor L₁andcell24, and ground.Switching power supply28 may additionally includes a third switch Q₂which is connected in parallel with capacitor C₁betweenjunction32 and ground. Switch Q₂is for the purpose of rapidly removing charge fromelement24 when it is desired to cause the reflective element to assume a high reflectance state, such as when the vehicle is placed in reverse gear and the like.
• Operation of switching[0031]power supply28 can be understood by reference to FIG. 7 in which the waveform V_DIODEis the voltage across switch D₁, the waveform I_INDUCTORis the current through inductor L₁and the waveform V_CELLis the voltage acrosselectrochromic cell24. Whenever switch Q₁is closed, voltage V_DIODEincreases to the voltage level ofvoltage source33 which, in the illustrated embodiment, is approximately 8 volts DC. Whenever switch Q₁is open, the voltage V_DIODEdecreases to around 0 volts DC. If switch D₁is a diode, then V_DIODEdecreases to one diode forward drop below 0 volts which is approximately negative 0.6 volts DC. This voltage level is sufficient to cause switch D₁to conduct if D₁is a diode. Other schemes would suggest themselves to the skilled artisan for providing a second switch other than a diode for switch D₁as will be described particularly in reference to thedrive circuit13″ in FIG. 10. In operation, when switch Q₁is closed, voltage level V causes a current to flow through inductor L₁which stores energy in the inductor in addition to causing a current to flow throughelectrochromic cell24. When switch Q₁opens, the decrease in V_DIODEcauses switch D₁to become conducting, which conducts the current from inductor L₁in order to allow the current in inductor L₁to continue flowing as energy is discharged from inductor L₁. As can be seen from the waveform I_INDUCTORin FIG. 7, the current in inductor L₁is kept flowing by the alternating opening of switches Q₁and D₁producing a voltage acrosselectrochromic cell24. For a drive signal applied toelectrochromic element24 that varies from approximately 0 volts DC to 1.5 volts DC, the ripple acrosselectrochromic cell24 as represented by “RIPPLE” in FIG. 5 may be less than 200 millivolts and preferably less than 100 millivolts.
• In the illustrative embodiment, switch Q[0032]₁is a transistor, such as a bipolar transistor, a P channel field effect transistor, an N channel field effect transistor, or the like. Switch D₁is a diode, but could be replaced with a bipolar transistor, a P channel field effect transistor, an N channel field effect transistor, or the like. Switch Q₂may be a bipolar transistor, P channel or N channel field effector transistor, or the like. Capacitor C₁is for the purpose of reducing ripple on the voltage applied toelectrochromic cell24. While the capacitance C_CELLof the model ofelectrochromic cell24 is substantially larger than the capacitance of capacitor C₁, capacitor C₁, avoids undesirable voltage spikes being applied toelectrochromic cell24 as a result of series resistor R₁.
• A detailed embodiment of[0033]drive circuit13 is set forth in FIG. 6. Amicrocomputer controller26 has anoutput34 which supplies a Pulse-Width Modulated (PWM) signal through a resistor R44 to the base of a PNP bipolar transistor Q₁. It should be understood that Q₁transistors could alternatively be an NPN transistor or MOSFET with suitable adjustments to circuit configuration. Transistor Q₁is supplied through a 22 ohm resistor R51 to avoltage source33 which may be in the range of from 5 volts DC to 16 volts DC and preferably between 8 volts and 12 volts and most preferably approximately 8 volts DC. Transistor Q₁is in electrical series connection with inductor L₂betweenvoltage source33 andelectrochromic cell24. The purpose of series resistor R51 is in order to reduce any over-voltage condition onelectrochromic cell24 should transistor Q₁, remain closed for any reason. Diode D₁is connected betweenjunction30 and ground.Microcomputer26 has asecond output36 which is supplied through a resistor R58 to the base of an NPN transistor Q₂which is connected across the terminals T₁and T₂ofelectrochromic element24.Microcomputer26 activatesoutput36 in order to rapidly dissipate voltage across electrochromicreflective element24 thereby rapidly driving the reflective element to a high reflectance level.Microcontroller26 has aninput68 which is connected through a resistor R62 to terminal T₁, of electrochromicreflective element24. The purpose ofinput68 is to allowmicrocomputer26 to monitor the voltage across electrochromicreflective element24, which is proportional to the light transmittance of electrochromicreflective element24, thereby providing an indication of the reflectance level of the exteriorelectrochromic mirror assembly19.
• In operation,[0034]microcomputer26 samples light levels sensed bylight sensors20,22 and supplies a PWM signal on itsoutput34 sufficient to alternatingly drive transistor Q₁, between a saturated state and an open-circuit state. The proportion in time of the PWM signal outputted bymicrocomputer26 onoutput34 that Q₁, is saturated varies in duty cycle from approximately 0 percent to 65 percent, preferably from 0 percent to 50 percent and most preferably from 0 percent to 30 percent. The higher the portion of the duty cycle during which Q₁is saturated, the higher voltage supplied toelectrochromic cell24. The repetition rate of the signal supplied tooutput34 is preferably above the allowable range of human hearing, such as 15 kilohertz or higher.Microcomputer controller26 periodically samples the voltage oninput68 in order to be apprised of the voltage across the electrochromic element which is indicative of the reflectance level of the corresponding rearview mirror assembly. Preferably, the periodic voltage sampling is carried out at a consistent portion of the waveform applied toelectrochromic element24 in order to avoid oscillation in the feedback loop. Most preferably, the voltage sample is taken during a period when transistor Q₁is not conducting. This provides a more accurate determination of the residual charge on the electrochromic cell. As disclosed in commonly assigned patent application Ser. No. 08/832,380, filed on Apr. 2, 1997, the disclosure of which is hereby incorporated herein by reference,microcomputer26 may additionally supply a voltage toelectrochromic cell24 that is temporarily higher than permissible prolonged coloration voltage levels in order to rapidly change the transmittance ofelectrochromic cell24 such as when a vehicle with bright headlights pulls up behindvehicle9. Under such conditions,microcomputer26 is able to ensure that the over voltage supplied toelectrochromic cell24 is kept within a safe level by monitoringinput68.
• However, it should be understood that even during normal operating conditions, or steady-state conditions, in which[0035]electrochromic cell24 is not being driven in an over voltage condition, it may still be desirable to monitor the voltage acrosselectrochromic cell24 to endeavor that the desired reflectance level calculated bymicrocomputer26 in response to inputs received fromsensors20,22 corresponds with the actual reflectance level produced by switchingpower supply28. For example, monitoring of the voltage across the electrochromic reflective element allows the same drive circuit to be able to drive a wide variety of reflective element surface areas. For example, an electrochromic reflective element utilized as an interior mirror of a vehicle may have a surface area in the range of 90 cm²to 150 cm²and typically in the range of 110 cm²to 130 cm². A steady state steady-state reflectance level current draw, after color transitions have settled, is typically in the range of between 60 milliamperes and 180 milliamperes with a range of 80 milliamperes to 150 milliamperes being typical. Exterior rearview mirrors can be even larger with a surface area of approximately 350 cm², and greater, with a commensurate increase in current. Furthermore, in cases where the drive circuit is driven directly from an unregulated supply, such as vehicle battery or ignition voltage, monitoring voltage across the cell facilitates a more stable and accurate drive signal being applied to the electrochromic reflective element notwithstanding significant variation in supply voltage.
• Furthermore, temperature variation experienced in the mirror assembly, especially exterior mirror assemblies, can significantly alter the current of the drive signal needed to achieve a particular voltage and, hence, the desired reflectance level. By monitoring voltage level across the electrochromic reflectance element, drive[0036]circuit13 can accommodate such variation in surface area, temperature, and the like. It may also be advantageous to provide an input from a temperature sensor tomicrocomputer26 indicative of the environment the electrochromic reflective element is operating in. This is especially relevant in the case of exterior electrochromicrearview mirror assembly19, which is exposed to a wide range of temperature. However, temperature monitoring may also be used with the interior electrochromicrearview mirror assembly11.Microcomputer26 may use the information on the temperature environment of the electrochromic reflective element to enhance the monitoring of the voltage across the electrochromic reflective element and producing a resulting voltage across the reflective element, such as by varying the duty cycle of the switching power supply. This is because the relationship between the voltage across the reflective element and its reflectivity is non-linear, with the non-linearity related to the temperature environment of the electrochromic reflective element.
• Although switching[0037]power supply28 is illustrated as a buck converter made up of individual discrete components, other configurations are possible. The individual components of the buck converter could be combined into an integrated circuit package of the type which is commercially available. Additionally, the inductor could be replaced with a resistor. Although energy efficiency would be reduced, the reduction may be acceptable especially in view of the cost reduction realized by eliminating a rather costly component, the inductor. Instead of adjusting the voltage level of the output ofbuck converter28 by varying the duty cycle of a PWM signal applied to its input, any type of waveform, such as a DC voltage level, from the microcomputer to the switching power supply may be varied in order to control switchingpower supply28. Alternatively, a PWM pulse signal produced by the microcomputer could be integrated prior to being supplied as an input to such alternative switching power supply. Other suitable means for signaling the desired output of the switching power supply may be used.
• Because transistors Q[0038]₁, and diode D₆are operated in a saturated mode, exceptional energy utilization efficiency is realized. In the illustrated embodiment, switching power supply, or switching step-down converter28, operates at an efficiency level of at least 75 percent and may achieve an 85 or even 95 percent energy efficiency. Because a high energy efficiency reduces the amount of energy which must be removed as waste heat, the component size and heat dissipation requirements are substantially reduced.
• In an alternative electrochromic mirror system for a vehicle, an electronic control has a[0039]drive circuit13′ including amaster drive circuit40 and a slave drive circuit42 (FIGS. 4, 8 and9).Master drive circuit40, which is illustrated in FIG. 8 as a voltage source, produces a drive signal at itsoutput32 which may be supplied to an electrochromicreflective element24.Slave drive circuit42 derives from output32 a second signal which is supplied to another rearview mirror electrochromicreflective element18. In the illustrated embodiment, master drive circuit may be of the type illustrated in FIGS. 5 and 6, although other commonly available drive circuits, such as the type disclosed in Bechtel et al. U.S. Pat. 5,451,822, could be utilized.Slave drive circuit42 includes a first electronic switch Q₃in electrical series connection betweenmaster drive circuit40 and electrochromicreflective element18 and a second electronic switch Q₄which shunts electrochromicreflective element18 when closed. Electronic switch Q₄is for the purpose of rapidly discharging accumulated charge on electrochromicreflective element18 when it is desired to rapidly increase the reflectivity of the associated reflective element such as when the vehicle is replaced in reverse gear.
• Electronic switch Q[0040]₃is opened and closed in a PWM fashion in order to supply a pulsed DC voltage to slave driven electrochromicreflective element18 that is derived from the drive signal produced by themaster drive circuit32. The drive signal supplied to slave electrochromicreflective element18 is at a level that is less than or equal to the master drive signal at32. If transistor Q3 is closed 100 percent of the time, then the slave drive signal supplied to slaveelectrochromic element18 will be equal to the master drive signal supplied tomaster cell24. As the duty cycle of electronic switch Q₃being in a saturated state decreases below 100 percent, the slave voltage supplied toelectrochromic element18 will decrease as a proportion of master drive signal44 supplied toelectrochromic element24. In the illustrated embodiment, switch Q₃is operated at a duty cycle that is greater than or equal to 65 percent and preferably in a range of between 75 percent and 100 percent. Advantageously, transistor Q₃can be operated at a relatively slow repetition rate without producing undesirable ripple in the voltage supplied to slaveelectrochromic element18. This is accomplished by utilizing the significant capacitance C_CELLofelectrochromic element18.
• Preferably, electronic switch Q[0041]₃is operated at a pulse repetition rate that is at the low end of the audio perception of humans, but above a rate that may produce noticeable flicker; namely, below 200 hertz and preferably less than or equal to 100 hertz. Most preferably, the pulse repetition rate of electronic switch Q₃is approximately 50 hertz. In addition to allowing the repetition rate of electronic switch Q₃to be relatively low, the large capacitance of electrochromic cell15 allows the change in reflectance level thereof to be changed in relatively coarse steps. For example, the change in duty cycle of electronic switch Q₃could be changed in 5 percent steps, 10 percent steps, or even 15 percent steps. This results in a lessening of the software requirement for controlling the slave drive. Alternatively, switches Q₁and D₁ofmaster drive40 could operate at a repetition rate below human audible reception and switches Q₄of slave drive42 operate at a rate above human audible perception.
• In the illustrated embodiment,[0042]slave drive circuit42 supplies a drive signal toelectrochromic element18 that is part of interiorelectrochromic mirror assembly11 andmaster drive circuit40 supplies a drive signal toelectrochromic element24 that is a part of exterior electrochromicrearview mirror assembly19 of which two are preferred on a vehicle. This is based upon a preference that the reflectance level of the interior rearview mirror should be no less than the reflectance level of the exterior rearview mirrors. This arrangement is particularly advantageous in providing a relationship between the reflectivity of the interior rearview mirror assembly and exterior rearview mirror assemblies that takes into account the configuration of the vehicle as disclosed in commonly assigned provisional patent applications Ser. No. 60/103,721 filed on Oct. 9, 1998, by Kenneth Schofield and Kenneth L. Schierbeek, and Ser. No. 60/117,633 filed on Jan. 28, 1999, by Kenneth Schofield and Kenneth L. Schierbeek, the disclosures of which are hereby incorporated herein by reference. However, it may be desirable for particular applications to drive the interior electrochromic reflective element with the master drive circuit and one or both exterior electrochromic reflective elements with the slave drive circuit. Although a master/slave drive circuit according to the invention has more design constraints than other known electrochromic mirror systems, which provide independent drive signals for each mirror controlled, it has been discovered that any differences are not perceived by the driver.
• A detailed embodiment of[0043]drive circuit13′ is illustrated in FIG. 9 in which an inductor L₄and capacitor C₄filter noise for avoltage source33 to the emitter of transistor Q₁. A diode D₂is connected fromoutput34 ofmicrocomputer26 to a voltage source, such as 5 volts. The purpose of diode D₂is to clip any voltage spikes that may be fed toline34 such as from inductor L₆. Otherwise, the master drive ofdrive circuit13′ is identical with switchingpower supply28 in FIG. 6.Microcomputer26 has anoutput46 which supplies a PWM drive signal to an NPN transistor Q₃. The emitter of transistor Q₃is supplied at48 to a terminal of slaveelectrochromic element18. Transistor Q₃selectively interconnectsline48, which supplies a drive signal to slaveelectrochromic element18, withline32 which supplies a drive signal to masterelectrochromic cell24. Transistor Q₃is selectively switched between an open state and a saturated state in response to anoutput46 frommicrocomputer26. By varying the duty cycle of the PWM signal atoutput46,microcontroller26 selectively adjusts the relative proportion between the drive signal supplied to slaveelectrochromic element18 and the drive signal supplied to masterelectrochromic element24.Microcomputer26 additionally has anoutput50 which is supplied to a base of a transistor Q₄. Transistor Q₄is connected betweenline48 and ground. Whenmicrocomputer26 switches transistor Q₄to a saturated state, electrical charge on slave electrochromicreflective element18 is rapidly dissipated. Transistors Q₃and Q₄are placed in saturation at different times.Microcomputer26 additionally receives an input at52 which is connected through a resistor R29 toline48.Input52 supplies to microcomputer26 a signal representative of the voltage across slaveelectrochromic element18.
• In operation,[0044]microcomputer26 determines a desired reflectance level for interior electrochromicrearview mirror assembly11 and electrochromicexterior mirror assembly19. The values of desired reflectance level may be established, by way of example, from the respective light levels sensed bylight sensors20,22 as well as the configuration of the vehicle as set forth in commonly assigned provisional patent application Ser. No. 60/117,633, filed by Kenneth Schofield et al. on Jan. 28, 1999, the disclosure of which is hereby incorporated herein by reference. The microcomputer controller then selects a duty cycle for the PWM signal supplied atoutput34 to transistor Q₁. The selected duty cycle may take into account, by way of example, the voltage across masterelectrochromic cell24 as monitored byinput38 from line44 and the degree of change in reflectance level desired. The PWM signal supplied atoutput34 produces a voltage level atline32 which is monitored by the microcomputer atinput38. Ifmaster electrochromic element24 is being switched to a substantially lower transmissivity, it may be desirable to momentarily increase the voltage supplied to the master electrochromic cell in order to rapidly modify the transmissivity of the cell. During such transitions,microcomputer38 may more frequently monitor the voltage at line44 in order to ensure that any temporary over voltage condition ofmaster electrochromic element24 is kept within a prescribed maximum voltage level. Values of maximum voltage level, as well as PWM duty cycles, may be selected according to the principles disclosed in commonly assigned application Ser. No. 08/832,380, entitled DIGITAL ELECTROCHROMIC MIRROR SYSTEM, filed on Apr. 2, 1997, by Kenneth L. Schierbeek, the disclosure of which is hereby incorporated herein by reference. Ifmicrocomputer controller26 determines that the reflectance level ofmaster electrochromic element24 should be substantially increased, then the PWM signal would be disconnected fromoutput34 andoutput36 energized in order to place transistor Q₂in a saturated condition. This will rapidly dissipate charge onmaster electrochromic element24 to increase the transmissivity thereof.
• [0045]Microcomputer controller26 additionally selects a duty cycle for a PWM signal supplied atoutput46. The PWM signal will be selected at least as a function of the desired reflectance level for slaveelectrochromic element18. The selected duty cycle may take into account the current reflectance level ofmaster electrochromic element24 represented at least in part by the voltage across slaveelectrochromic element18 online48, as monitored byinput52 to the microcomputer. Once a duty cycle is selected,microcomputer26 produces a PWM signal atoutput46.Microcomputer26 may choose to dwell on a particular duty cycle atoutput46 unless the calculated duty cycle change is more than a given percent. In the illustrated embodiment, the duty cycle is not changed bymicrocomputer26 unless the calculated duty cycle change is at least 5 percent, more preferably at least 10 percent and most preferably at least 15 percent. If the calculated duty cycle of slave electrochromicreflective element18 results in a substantial increase in the transmissivity ofreflective element18, then microcomputer26 removes the PWM signal fromoutput46 and supplies an output at 50 to cause transistor Q₄to enter a saturated mode which quickly dissipates any charge fromline48 thereby rapidly increasing the transmissivity of slaveelectrochromic element18.
• [0046]Drive signal48 applied to interior electrochromicreflective element18 is compensated for the thermal environment of interiorelectrochromic mirror assembly11 as well as the surface area, present reflectance level, and the like, of interior electrochromicreflective element18. This is accomplished bydrive circuit13′ monitoring voltage across electrochromicreflective element18 as supplied to input52 ofmicrocomputer26. Drivesignal32 applied to exterior electrochromicreflective element24 is compensated for the thermal environment of exteriorelectrochromic mirror assembly19, as well as the surface area, present reflectance level, and the like, of exterior electrochromicreflective element24. This is accomplished bydrive circuit13′ monitoring voltage across electrochromicreflective element24 as supplied to input38 ofmicrocomputer26. In this manner, drivecircuit13 can compensate for different thermal environments of interior and exteriorelectrochromic mirror assemblies11,19. Additionally,microcomputer26 may receive temperature sensor inputs for any of the interior and/or electrochromic exterior rearview mirror assemblies to further compensate for different thermal environments. This additional input or inputs may assistmicrocomputer26 in reducing effects created by non-linearity in the relationship between voltage across the electrochromic reflective element and its reflectance level for different temperatures.
• Although transistor Q[0047]₃is illustrated as operated in a saturated mode at a particular PWM, the slave drive could alternatively be a transistor drive in a non-saturated state either continuously or at a PWM.
• The present invention, although illustrated with one master electrochromic reflective element and one slave electrochromic reflective element, could be utilized with two master drive circuits to drive two electrochromic reflective elements, such as for two exterior rearview mirror assemblies and one slave electrochromic element which is slave to one of the master drive circuits. Alternatively, an electrochromic mirror system may utilize one master electrochromic element to drive one exterior electrochromic rearview mirror and two slave electrochromic elements, each driven to an independently or tandemly controlled partial reflectance level that is higher than the partial reflectance level of the master rearview assembly. Other variations may suggest themselves to the skilled artisan.[0048]
• In yet a further embodiment, a[0049]drive circuit13′ utilizes a transistor Q₆to replace both the functions of diode D₁and bleaching transistor Q₂(FIG. 10). As will be observed from FIG. 10,microcontroller26 includes asingle output34 which is supplied to the base of a transistor Q₅whose collector is connected to ajunction100 which is supplied through aresistor102 to the base of transistor Q₁and toresistors104 and106 to the base of transistor Q₆. Whenmicrocomputer26 drives transistor Q₅into saturation, transistor Q₁is switched into saturation, and Q₆is cut off. During such portion of the cycle, energy is stored in inductor L₂and a current is forced through electrochromicreflective element24. Whenmicrocomputer controller26 switches transistor Q₅into an open circuit condition, transistor Q₁is switched into an open circuit condition and transistor Q₆is switched into saturation. This causes a current to continue to flow through inductor L₂and electrochromicreflective element24 as the energy from inductor L₂is dissipated. Asmicrocomputer controller26 switches transistor Q₅according to a rectangular wave, electrochromicreflective element24 is provided with a drive signal whose voltage is proportional to the duty cycle of such rectangular wave. If it is decided bymicrocomputer controller26 to rapidly increase the reflectivity of electrochromicreflective element24 by rapidly dissipating the charge accumulated thereon,microcomputer26 holdsoutput34 in a low state which causes transistor Q₅to be open-circuited and transistor Q₆to be driven to saturation. This rapidly dissipates any charge on electrochromicreflective element24. Whenmicrocomputer controller26 once again determines the need to decrease the reflectivity of electrochromicreflective element24, it applies a rectangular waveform to itsoutput34, thereby applying a drive signal as previously described. By suitable circuit modifications, transistors Q₅and Q₆can each be bipolar transistors, N channel field effect transistors, P channel field effect transistors, or the like.
• The functions performed by[0050]microcomputer26 could be implemented by any circuit capable of generating a digital signal including a programmable computer, a dedicated digital logic circuit, or the like. Preferably, the components making upelectronic control13,13′,13″ are commonly mounted inhousing14 of interiorelectrochromic mirror assembly11 as disclosed in commonly assigned U.S. Pat. No. 5,424,898, the disclosure of which is hereby incorporated herein by reference. However, it should be understood that the components could alternatively be located in exteriorelectrochromic mirror assembly19 or in a location separate from the mirror assemblies as disclosed in commonly assigned U. S. Pat. No. 5,659,423, the disclosure of which is hereby incorporated herein by reference.
• Changes and modifications in the specifically described embodiments can be carried out without departing from the principles of the invention which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.[0051]

Claims (62)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. A vehicular electrochromic rearview mirror system, comprising:

at least one electrochromic rearview mirror assembly having an electrochromic reflective element, said electrochromic reflective element assuming a partial reflectance level in response to a signal applied thereto;

a drive circuit applying a drive signal to said electrochromic reflective element establishing a partial reflectance level thereof, said drive circuit including a digital controller and a switching power supply controlled by said digital controller producing said drive signal.

2. The vehicular electrochromic rearview mirror system inclaim 1 wherein said switching power supply comprises a switching step-down converter.

3. The vehicular electrochromic rearview mirror system inclaim 2 wherein said switching power supply comprises a buck converter.

4. The vehicular electrochromic rearview mirror system inclaim 3 wherein said switching power supply comprises an impedance device and at least one electronic switch in series electrical connection between said electrochromic reflective element and a voltage potential.

5. The vehicular electrochromic rearview mirror system inclaim 4 wherein said impedance device has energy storing capability.

6. The vehicular electrochromic rearview mirror system inclaim 4 wherein said impedance device comprises an inductor.

7. The vehicular electrochromic rearview mirror system inclaim 4 wherein said voltage potential is in the range from 5 volts DC to 16 volts DC.

8. The vehicular electrochromic rearview mirror system inclaim 7 wherein said voltage potential is approximately 8 volts DC.

9. The vehicular electrochromic rearview mirror system inclaim 4 wherein said at least one electronic switch is operated in a saturated mode.

10. The vehicular electrochromic rearview mirror system inclaim 4 wherein said at least one electronic switch is operated during steady-state reflectance levels at a duty cycle less than or equal to 65%.

11. The vehicular electrochromic rearview mirror system inclaim 10 wherein said at least one electronic switch is operated during steady-state reflectance levels at a duty cycle that operates in a range of 0% to 50%.

12. The vehicular electrochromic rearview mirror system inclaim 4 wherein said at least one electronic switch is one of a bipolar transistor and a field effect transistor.

13. The vehicular electrochromic rearview mirror system inclaim 4 wherein said at least one electronic switch comprises a bipolar transistor.

14. The vehicular electrochromic rearview mirror system inclaim 4 wherein said drive circuit monitors voltage across said electrochromic reflective element and controls said at least one electronic switch at least in part as a function of the monitored voltage.

15. The vehicular electrochromic rearview mirror system inclaim 14 wherein said drive circuit periodically monitors voltage across said electrochromic reflective element at a same general time relative to operation of said switch.

16. The vehicular electrochromic rearview mirror system inclaim 15 wherein said drive circuit periodically monitors voltage across said electrochromic reflective element when said at least one electronic switch is open.

17. The vehicular electrochromic rearview mirror system inclaim 4 including another impedance device in series electrical connection with said at least one electronic switch and said impedance device to limit voltage across said electrochromic cell should said at least one electronic switch remain in a closed state.

18. The vehicular electrochromic rearview mirror system inclaim 4 including another electronic switch between said impedance device and another voltage potential to conduct current in said impedance device when said at least one electronic switch is not conducting.

19. The vehicular electrochromic rearview mirror system inclaim 18 wherein said another switch comprises one of a diode, a bipolar transistor and a field effect transistor.

20. The vehicular electrochromic rearview mirror system inclaim 18 wherein said another switch comprises a diode.

21. The vehicular electrochromic rearview mirror system inclaim 18 wherein said another switch comprises a bipolar transistor.

22. The vehicular electrochromic rearview mirror system inclaim 1 wherein said digital controller comprises a microcomputer.

23. A vehicular electrochromic rearview mirror system, comprising:

a plurality of electrochromic rearview mirror assemblies and a plurality of electrochromic reflective elements, each associated with one of said electrochromic rearview mirror assemblies, wherein each of said electrochromic reflective elements assumes a partial reflectance level in response to a signal applied thereto;

a drive circuit applying a drive signal to each of said electrochromic reflective elements, said drive circuit comprising a digital controller, a master drive circuit responsive to said digital controller to apply a first drive signal to one of said electrochromic reflective elements, and a slave drive circuit responsive to said digital controller to apply a second drive signal to a second of said electrochromic reflective elements, said second drive signal derived from said first drive signal.

24. The vehicular electrochromic rearview mirror system inclaim 23 wherein said master drive circuit comprises a switching power supply.

25. The vehicular electrochromic rearview mirror system inclaim 23 wherein said slave drive circuit comprises a proportional controller.

26. The vehicular electrochromic rearview mirror system inclaim 23 wherein said master drive circuit comprises a first electronic switch and said slave drive circuit comprises a second electronic switch.

27. The vehicular electrochromic rearview mirror system inclaim 26 wherein said controller operates said first electronic switch at a first repetition rate and said second electronic switch at a second repetition rate, one said repetition rate at a high end of human hearing frequencies and another said repetition rate at a low end of human hearing frequencies.

28. The vehicular electrochromic rearview mirror system inclaim 27 wherein said first repetition rate is at a high end of human hearing frequencies and said second repetition rate is at a low end of human hearing frequencies.

29. The vehicular electrochromic rearview mirror system inclaim 26 wherein said controller operates said first electronic switch during steady-state reflectance levels at a duty cycle of less than or equal to 65%.

30. The vehicular electrochromic rearview mirror system inclaim 29 wherein said controller operates said second electronic switch during steady-state reflectance levels at a duty cycle greater than or equal to 65%.

31. The vehicular electrochromic rearview mirror system inclaim 30 wherein said controller operates said first electronic switch during steady-state reflectance levels at a duty cycle in a range of between 0% and 50%.

32. The vehicular electrochromic rearview mirror system inclaim 31 wherein said controller operates said second electronic switch during steady-state reflectance levels at a duty cycle in a range of between 75% and 100%.

33. The vehicular electrochromic rearview mirror system inclaim 23 wherein said switching power supply comprises a buck converter.

34. The vehicular electrochromic rearview mirror system inclaim 33 wherein said switching power supply comprises an impedance device and an electronic switch in series electrical connection between said electrochromic reflective element and a voltage potential.

35. The vehicular electrochromic rearview mirror system inclaim 34 wherein said impedance device has energy storing capability.

36. The vehicular electrochromic rearview mirror system inclaim 34 wherein said impedance device comprises an inductor.

37. The vehicular electrochromic rearview mirror system inclaim 34 wherein said voltage potential is in the range from 5 volts DC to 16 volts DC.

38. The vehicular electrochromic rearview mirror system inclaim 37 wherein said voltage potential is approximately 8 volts DC.

39. The vehicular electrochromic rearview mirror system inclaim 26 wherein said first and second electronic switches are comprised of transistors.

40. The vehicular electrochromic rearview mirror system inclaim 39 wherein said first and second electronic switches comprise one of a bipolar transistor and a field-effect transistor.

41. The vehicular electrochromic rearview mirror system inclaim 26 wherein said first and second electronic switches are operated in saturated modes.

42. The vehicular electrochromic rearview mirror system inclaim 26 wherein said drive circuit monitors voltage across at least one of said reflective elements and controls at least one of said first and second switches at least in part as a function of monitored voltage.

43. The vehicular electrochromic rearview mirror system inclaim 26 wherein said drive circuit monitors voltage across said one of said electrochromic reflective elements and controls said first electronic switch at least in part as a function of the monitored voltage.

44. The vehicular electrochromic rearview mirror system inclaim 43 wherein said drive circuit monitors voltage across said second of said electrochromic reflective elements and controls said second electronic switch at least in part as a function of the monitored voltage.

45. The vehicular electrochromic rearview mirror system inclaim 26 wherein said drive circuit monitors voltage across said second of said electrochromic reflective elements and controls said second electronic switch at least in part as a function of the monitored voltage.

46. The vehicular electrochromic rearview mirror system inclaim 23 wherein said one of said electrochromic reflective elements is associated with an exterior electrochromic rearview mirror assembly.

47. The vehicular electrochromic rearview mirror system inclaim 46 wherein said second of said electrochromic reflective elements is associated with an interior electrochromic rearview mirror assembly.

48. The vehicular electrochromic rearview mirror system inclaim 46 wherein said second of said electrochromic reflective elements is associated with another exterior electrochromic rearview mirror assembly.

49. The vehicular electrochromic rearview mirror system inclaim 23 wherein said one of said electrochromic reflective elements is associated with an interior electrochromic rearview mirror assembly.

50. A vehicular electrochromic rearview mirror system, comprising:

at least one electrochromic rearview mirror assembly having an electrochromic reflective element, said electrochromic reflective element assuming a partial reflectance level in response to a signal applied thereto;

a drive circuit applying a drive signal to said electrochromic reflective element, said drive circuit comprising an impedance device, at least one first electronic switch electrically series connecting said impedance device and said electrochromic reflective element with a first voltage potential and at least one second electronic switch electrically series connecting said impedance device and said electrochromic reflective element with a second voltage potential, said at least one first electronic switch and said at least one second electronic switch alternatingly operated to apply a drive current through said impedance device and said at least one electrochromic reflective element.

51. The vehicular electrochromic rearview mirror system inclaim 50 wherein said impedance device has energy storing capability.

52. The vehicular electrochromic rearview mirror system inclaim 51 wherein said impedance device comprises an inductor.

53. The vehicular electrochromic rearview mirror system inclaim 50 wherein said at least one second electronic switch comprises one second electronic switch that is operated according to a PWM sequence with said at least one first electronic switch to supply charge to the at least one electrochromic reflective element and another second electronic switch that is operated to drain current from said at least one electrochromic reflective element.

54. The vehicular electrochromic rearview mirror system inclaim 50 wherein said at least one second electronic switch comprises a second electronic switch that both is operated according to a PWM sequence with said at least one first electronic switch to supply charge to the at least one electrochromic reflective element and is operated by itself to drain current from said at least one electrochromic reflective element.

55. The vehicular electrochromic rearview mirror system inclaim 50 including a digital control operating said at least one first electronic switch and said at least one second electronic switch.

56. The vehicular electrochromic rearview mirror system inclaim 50 wherein said first voltage potential is on an order of magnitude of vehicle ignition voltage.

57. The vehicular electrochromic rearview mirror system inclaim 56 wherein said drive signal is on an order of magnitude of less than vehicle ignition voltage.

58. The vehicular electrochromic rearview mirror system inclaim 56 wherein said second voltage potential is vehicle chassis potential.

59. The vehicular electrochromic rearview mirror system inclaim 50 wherein said at least one first electronic switch comprises one of a bipolar transistor and a field effect transistor.

60. The vehicular electrochromic rearview mirror system inclaim 50 wherein said at least one second electronic switch comprises one of a diode, a bipolar transistor and a field effect transistor.

61. The vehicular electrochromic rearview mirror system in claim60 wherein said at least one second electronic switch comprises a diode.

62. The vehicular electrochromic rearview mirror system in claim60 wherein said at least one second electronic switch comprises a bipolar transistor.

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