(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2004/0164228 A1
`Aug. 26, 2004
`Fogg et al.
`(43) Pub. Date:
`
`US 20040164228A1
`
`(54) AUTOMATIC VEHICLE EXTERIOR LIGHT
`CONTROL SYSTEM ASSEMBLIES
`
`(22) Filed:
`
`Feb. 20, 2004
`
`(76) Inventors: Jeremy A. Fogg, Holland, MI (US);
`Gregory M. Ejsmont, Grand Rapids,
`MI (US); Darin D. Tuttle, Byron
`Center, MI (US); Joseph S. Stam,
`Holland, MI (US)
`
`Correspondence Address:
`PRICE, HENEVELD, COOPER, DEWITT, &
`LITTON,
`LLP/GENTEX CORPORATION
`695 KENMOOR, S.E.
`P O BOX 2567
`GRAND RAPIDS, MI 49501 (US)
`
`(21) Appl. No.:
`
`10/783,273
`
`Related US. Application Data
`
`(60) Provisional application No. 60/448,793, ?led on Feb.
`21, 2003.
`
`Publication Classi?cation
`
`.
`(51) Int.Cl.7
`(52) Us. 01. ........................................................ ..250/208.1
`
`(57)
`
`ABSTRACT
`
`The present invention relates to various improvements relat
`ing to automatic vehicle equipment control systems.
`
`106
`
`107
`
`VALEO EX. 1011
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`Patent Application Publication Aug. 26,2004 Sheet 21 of 23
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`Patent Application Publication Aug. 26,2004 Sheet 22 of 23
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`Patent Application Publication Aug. 26,2004 Sheet 23 of 23
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`Fig. 21
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`

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`Aug. 26,2004
`
`AUTOMATIC VEHICLE EXTERIOR LIGHT
`CONTROL SYSTEM ASSEMBLIES
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`[0001] The present application claims priority, under 35
`U.S.C. §119(e), to U.S. provisional patent application serial
`No. 601448,793, filed on Feb. 21, 2003. The disclosure of
`this provisional patent application is incorporated herein in
`its entirety by reference.
`
`BACKGROUND OF THE INVENTION
`
`[0002] Automatic vehicle exterior light control systems
`provide a significant convenience function for drivers by
`alleviating the burden of manually switching between high
`and low beam headlights in response to changing traffic
`conditions. It is known that drivers, on average, do not
`utilize their high beam headlights as often as is appropriate.
`High beam headlights can provide from two to four, or more,
`times the visibility distance at night as compared to low
`beam headlights. Thereby, a driver of a controlled vehicle is
`enabled to detect an obstacle or pedestrian at night earlier
`than otherwise would be the case. There is a safety benefit
`during night time driving introduced by automating the
`beam switching task and increasing the average utilization
`of high beam headlights.
`
`[0003] Known systems designed to automatically control
`vehicle exterior lights utilize a forward looking digital
`imaging system to acquire images of the scene generally in
`front of the controlled vehicle, to analyze the images and to
`detect headlights of oncoming vehicles and taillights of
`leading vehicles. It has become apparent that repeatable and
`predictable vehicle to vehicle system operation suffers when
`misalignment
`is present in the corresponding imaging
`assemblies.
`
`[0004] What are needed are automatic vehicle exterior
`light control systems that provide improved features to
`accurately detect related images generally forward of a
`controlled vehicle. Systems configured to automatically
`account for minor imager assembly misalignments are also
`needed.
`
`SUMMARY OF THE INVENTION
`
`[0005] The present invention provides automatic vehicle
`exterior light control systems that provide improved features
`to accurately detect related images generally forward of a
`controlled vehicle. Systems configured to automatically
`account for minor imager assembly misalignments are also
`provided.
`
`[0006] In at least one embodiment, an imager assembly
`mounting means is provide that insures accurate alignment
`of an imager assembly with respect to the desired field of
`view. In a related embodiment, an imager assembly mount-
`ing means provides for quick installation within an associ-
`ated controlled vehicle.
`
`[0007] In at least one embodiment, features are provided
`within the imager assembly mounting means that insure
`proper selection for the specific controlled vehicle require-
`ments. In a related embodiment, incorrect assembly is
`prevented.
`
`[0008] In at least one embodiment, an imager assembly
`mounting means is provided that exploits use of snap
`together components for quick and efficient manufacturing.
`In a related embodiment, a minimum of tools are required
`for assembling the imager assembly mounting means.
`[0009] In at least one embodiment, various improvements
`of the present invention are integrated with other vehicular
`systems. In at least one related embodiment, the various
`integrated systems are configured to share components for
`improved operation and, or, to lower associated costs.
`[0010] Other advantages of the present invention will
`become apparent when reading the following detail descrip-
`tion in light of the figures, examples and appended claims.
`
`BRIEF DESCRIPTION OF THE FIGURES
`
`[0011] FIG. 1 depicts a controlled vehicle relative to the
`taillights of a leading vehicle and the headlights of an
`oncoming vehicle;
`[0012] FIG. 2 depicts a controlled vehicle;
`[0013] FIG. 3a depicts a perspective view of an interior
`rearview mirror assembly;
`[0014] FIG. 3b depicts a second perspective view of the
`mirror assembly of FIG. 3;
`[0015] FIG. 4 depicts a perspective view of an exploded
`stationary assembly;
`[0016] FIG. 5 depicts a second perspective view of the
`stationary assembly of FIG. 4;
`[0017] FIG. 6 depicts a perspective view of an attachment
`member;
`[0018] FIG. 7 depicts a second perspective of the attach-
`ment member of FIG. 6;
`[0019] FIG. 8 depicts a perspective view of a carrier1
`baffle;
`[0020] FIG. 9 depicts a perspective view of an exploded
`rearview mirror assembly;
`[0021] FIG. 10 depicts a second perspective view of the
`mirror assembly of FIG. 9;
`[0022] FIG. 11 depicts a perspective view of a second
`exploded stationary assembly;
`[0023] FIG. 12 depicts a second perspective view of the
`stationary assembly of FIG. 11
`[0024] FIG. 13 depicts a perspective view of a third
`exploded stationary assembly;
`[0025] FIG. 14 depicts a second perspective view of the
`stationary assembly of FIG. 13;
`[0026] FIG. 15 depicts a perspective view of an exploded
`front housing;
`[0027] FIGS. 16a and 16b depict actual image sensor
`alignment values;
`[0028] FIG. 17 depicts image sensor field of view versus
`alignment;
`[0029] FIG. 18 depicts actual taillight count versus image
`position;
`
`

`

`Aug. 26,2004
`
`[0030] FIG. 19 depicts actual headlamp count versus
`image position;
`
`[0031] FIG. 20 is a pictorial representation of the data of
`Table 5; and
`
`[0032] FIG. 21 is a pictorial representation of the data of
`Table 6.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`
`[0033] Referring initially to FIG. 1, for illustrative pur-
`poses, an automatic vehicle exterior light control system 106
`is shown to be installed within a controlled vehicle 105.
`Although the control system 106 is depicted to be integral
`with the interior rearview mirror assembly, it should be
`understood that the control system, or any of the individual
`components thereof, may be mounted in any suitable loca-
`tion within the interior, or on the exterior, of the controlled
`vehicle 105. The term "controlled vehicle" is used herein
`with reference to a vehicle comprising an automatic vehicle
`exterior light control system. Suitable locations for mount-
`ing the associated image sensor are those locations that
`provide an unobstructed view of the scene generally forward
`of the controlled vehicle 105 and allow for detection of
`headlights 116 of oncoming vehicles 115 and taillights 111
`of leading vehicles 110 within the glare zone 108 associated
`with the controlled vehicle.
`
`[0034] FIG. 2 depicts a controlled vehicle 205 comprising
`an interior rearview mirror assembly 206 incorporating an
`automatic vehicle exterior light control system. The pro-
`cessing and control system functions to send configuration
`data to the imager, receive image data from the imager, to
`process the images and to generate exterior light control
`signals. Detailed descriptions of such automatic vehicle
`exterior light control systems are contained in commonly
`assigned U.S. Pat. Nos. 5,837,994, 5,990,469, 6,008,486,
`6,130,448, 6,130,421, 6,049,171, 6,465,963, 6,403,942,
`6,587,573, 6,611,610, 6,621,616, 6,631,316 and U.S. patent
`application Ser. Nos. 101208,142, 091799,310, 601404,879,
`601394,583, 101235,476 and 091800,460 and Attorney
`docket numbers AUTO 211US1 and AUTO 211US2; the
`disclosures of which are incorporated herein in their entire-
`ties by reference. The controlled vehicle is also depicted to
`include a driver's side outside rearview mirror assemblv
`210a, a passenger's side outside rearview mirror assembly
`210b, a center high mounted stop light (CHMSL) 245,
`A-pillars 250a, 250b, B-pillars 255a, 255b and C-pillars
`260a, 260b; it should be understood that any of these
`locations may provide alternate locations for an image
`sensor, image sensors or related processing and, or, control
`components. It should be understood that any, or all, of the
`rearview mirrors may be automatic dimming electro-optic
`mirrors. The controlled vehicle is depicted to include a host
`of exterior lights including headlights 220a, 220b, foul
`weather lights 230a, 230b, front turn indicatorlhazard lights
`235a, 235b, tail lights 225a, 225b, rear turn indicator lights
`226a, 226b, rear hazard lights 227a, 227b and backup lights
`240a, 240b. It should be understood that additional exterior
`lights may be provided, such as, separate low beam and high
`beam headlights, integrated lights that comprise multipur-
`
`pose lighting, etc. It should also be understood that any of
`the exterior lights may be provided with positioners (not
`shown) to adjust the associated optical axis of the given
`exterior light. It should be understood that the controlled
`vehicle of FIG. 2 is generally for illustrative purposes and
`that suitable automatic vehicle exterior light control sys-
`tems, such as those disclosed in the patents and patent
`applications incorporated herein by reference, may be
`employed along with other features described herein and
`within disclosures incorporated herein by reference.
`
`[0035] Turning now to FIGS. 3a and 3b, an embodiment
`of an interior rearview mirror assembly 300a, 300b is
`shown. The mirror assembly includes a stationary accessory
`assembly enclosed within a front housing 385a, 385b and a
`rear housing 390a, 390b. The front housing comprises an
`aperture 386b defining an image sensor visual opening. The
`stationary accessory assembly along with a rearview mirror
`are carried by an attachment member 355a, 355b. The
`rearview mirror comprises a mirror housing 360a, 360b, a
`bezel 361a, 361b and a mirror element 362a. A wire cover
`394a, 394b is included to conceal related wiring 315b. The
`rearview mirror assembly 300a, 300b also incorporates an
`ambient light sensor 365b, at least one microphone 366b, a
`glare light sensor 365a, operator interfaces 363a, indicators
`364a and at least one information display 370.
`
`[0036] When viewed from an image sensor's perspective,
`and as used herein, the x-axis is a longitudinal axis associ-
`ated with a controlled vehicle (i.e. the optical axis of the
`image sensor), the y-axis is a cross-car axis associated with
`a controlled vehicle (i.e. horizontal axis of the image sensor)
`and the z-axis is a vertical axis of an associated controlled
`vehicle (i.e. vertical axis of the image sensor). Vertical
`rotation of the image sensor refers to rotation about the
`y-axis, defined in terms of upldown angular motion. Hori-
`zontal rotation of the image sensor refers to rotation about
`the z-axis, defined in terms of leftlright angular motion.
`Skew rotation of the image sensor refers to rotation about the
`x-axis. Angular variation of an imager board installed in a
`controlled vehicle has a direct effect on the optical axis of
`the image sensor. Angular rotation shifts the "sweet spot"
`and the field of view causing increased field limit in one
`direction and decreased field limit in another direction.
`Positional variation of an imager board installed in a con-
`trolled vehicle has minimal effect on verformance of an
`associated automatic vehicle exterior light control system.
`Millimeters of positional movement, which is a typical
`tolerance, causes little angular variation of the optical axis
`(i.e. typically less than 0.001 degree) at distances of 300
`meters or greater. Apreferred nominal image sensor field of
`view when incorporated in an automatic vehicle exterior
`light control system is approximately 15 degrees left,
`approximately 15 degrees right, approximately 4 degrees up
`and approximately 4 degrees down with respect to the
`optical axis.
`
`[0037] Associated mechanical variations may be due to
`anyone, or a combination, of: 1) carrierbaffle tolerance,
`board surface; 2) carrierbaffle tolerance, registration por-
`tions; 3) attachment member, carrierbaffle mounting sur-
`face; 4) attachment member, button receptacle and 5) imager
`board thickness. Table 1 summarizes angular variations.
`
`

`

`Aug. 26,2004
`
`TABLE 1
`
`Angular Variation Study
`
`Source of Variation
`
`Preferred Max UpIDown
`
`RightlLeft
`
`[0040]
`
`TABLE 4
`
`Angular Variation Study
`
`0.2 mm Surf
`
`0.2 mm Surf
`
`CarrierlBaffle - imager
`board mounting
`Carrierbaffle -
`registration portions
`Attachment member - 0.13 mm Surf
`carrierbaffle
`Attachment member -
`button recepticle
`Imager board thickness +/-0.005"
`
`0.1 mm Surf
`
`Total
`
`+I-0.401 deg
`
`+I-0.316 deg
`
`+I-0.318 deg
`
`+/-0.249 deg
`
`+I-0.207 deg
`
`+I-0.162 deg
`
`+I-0.215 deg
`
`+I-0.316 deg
`
`+/-0.260 deg
`
`+/-0.140 deg
`
`+I-1.401
`
`+I-1.183 deg
`
`[0038] Expected controlled vehicle level variations may
`include anyone or combinations of: 1) windshield form, sag
`tolerance; 2) sheet metal variation; 3) windshield adhesive
`thickness; 4) windshield position; 5) button position; 6)
`button rotation; 7) "Bigfoot" button; 8) button adhesive; 9)
`vehicle attitude build variation and 10) vehicle load. Tables
`2 through 4 contain summaries of data related to vehicle
`level variations.
`
`Prefered
`Mechanical Variables Maximum
`
`0.2 mm Surf
`
`0.2 mm Surf
`
`CarriedBaffle - Imager
`Board
`CarriedBaffle -
`registration portion
`surface
`Attachment member - 0.13 mm Surf
`CarriedBaffle
`Attachment member -
`Button recepticle
`Imager Board
`Thickness
`
`0.1 mm Surf
`
`+I-0.005"
`
`UpIDown
`
`RightlLeft
`
`+I-0.401 deg
`
`+/-0.316 deg
`
`+I-0.318 deg
`
`+I-0.249 deg
`
`+I-0.207 deg
`
`+I-0.162 deg
`
`+I-0.215 deg
`
`+I-0.316 deg
`
`+I-0.260 deg
`
`+I-0.140 deg
`
`Total
`
`+I-1.401
`
`+I-1.183 deg
`
`Vehicle Variables
`
`Spec
`
`UpIDown
`
`RightlLeft
`
`Windshield Sag
`
`sheet ~
`
`~t~variation
`
`Adhesive Thickness
`
`+I-3.5 mm
`l
`
`+I-3 mm
`+I-3.5 mm
`
`+I-0.615 deg
`+1-0.24 deg
`+I-0.52 deg
`
`+I-0.006 deg
`+1-0.24 deg
`+I-0.26 deg
`
`TABLE 2
`
`Image Sensor Optical Axis Angular Variation versus Windshield Angle and Button Rotation
`
`Wind-
`shield
`
`1 degree button rotation
`
`2 degree button rotation
`
`3 degree button rotation
`
`4 degree button rotation
`
`Angle
`
`H
`
`V
`
`S
`
`H
`
`V
`
`S
`
`H
`
`V
`
`S
`
`H
`
`V
`
`S
`
`UpIDown
`
`RightlLeft
`
`Total
`
`[0039]
`
`TABLE 3
`
`Angular Variation Study
`
`Preferred
`maximum
`
`+I-3.5 mm
`+I-3 mm
`+I-3.5 mm
`+IF3 mm
`+IF6 mm
`+I-1.5 deg
`
`Windshield Sag
`Sheet Metal Variation
`Adhesive Thickness
`Windshield Position
`Button Position
`Button Rotation
`
`Total
`Bigfoot Button
`Vehicle Build Variation
`Vehicle Load Study
`
`+/-0.006 deg
`+I-0.24 deg
`+I-0.26 deg
`+I-0.08 deg
`+/-0.13 deg
`+I-1.34 deg
`
`+I-2.056 deg
`+I-0.35 deg
`
`+I-0.615 deg
`+I-0.24 deg
`+/-0.52 deg
`+I-0.03 deg
`+I-0.09 deg
`+I-0.003 deg
`
`+I-1.498 deg
`+I-0.38 deg
`+I-0.8 deg
`+I-0.7 deg
`
`TABLE 4-continued
`
`Angular Variation Study
`
`Windshield Position
`Button Position
`Button Rotation
`
`+I-3 mm
`+IF6 mm
`+I-1.5 deg
`
`+/-0.03 deg
`+I-0.09 deg
`+I-0.003 deg
`
`+/-0.08 deg
`+/-0.13 deg
`+I-1.34 deg
`
`Total Mechanical and
`Vehicle Variables
`Statistically Probable
`Variation (30)
`SPV with Veh Load,
`Build and Bigfoot (30)
`SPV with 0.75 Degree
`Button Rot (30)
`SPV with 3.0 Degree
`Button Rot (30)
`SPV with 5.0 Degree
`Button Rot (30)
`
`+I-1.498 deg
`
`+/-2.056 deg
`
`+I-2.899 deg
`
`+I-3.239 deg
`
`+I-1.065 deg
`
`+I-1.501 deg
`
`+I-1.552 deg
`
`+I-1.501 deg
`
`+I-1.065 deg
`
`+I-0.95 deg
`
`+I-1.065 deg
`
`+I-2.76 deg
`
`+I-1.065 deg
`
`+I-4.51 deg
`
`[0041] Turning now to FIGS. 4 and 5, there are shown
`exploded, perspective, views of an accessory and rearview
`mirror mount assembly 405, 505. In a preferred embodi-
`
`

`

`Aug. 26,2004
`
`ment, the accessory and rearview mirror mount assembly
`provides a rigid structure for mounting a repositionably
`mounted interior rearview mirror along with a stationarily
`mounted image sensor. As will be described in detail herein,
`the preferred accessory and rearview mirror mount assembly
`facilitates ease of assembly as well as provides for repeat-
`able, reliable and precise alignment of the related compo-
`nents. In at least one embodiment, the associated imager is
`used for automatic exterior vehicle light control or which
`precision alignment of the image sensor is preferred.
`
`[0042] Imager board 410, 510 is provided with an image
`sensor with lens 411. In a preferred embodiment, the imager
`board will also include an image sensor control logic and
`timing circuit, communication line drivers and wire harness
`receptacle 413. Optionally, the imager board may comprise
`a processor for receiving and, at least partially, processing
`images obtained from the image sensor. In a preferred
`embodiment, the image sensor and at least one other device
`selected from the group comprising; 1) an image sensor
`control logic; 2) an A/D converter; 3) a low voltage differ-
`ential signal line driver; 4) a temperature sensor; 5) a control
`output; 6) a voltage regulator; 7) a second image sensor; 8)
`a microprocessor; 9) a moisture sensor and 10) a compass
`are integrated in a common ASIC, most preferably on a
`common silicon wafer. Preferably, the image sensor with
`lens 411 includes lens cover snap portions 412 for engaging
`lens cover 420, 520 snap clips 421. The lens cover has an
`aperture 422 for alignment with the optical axis of the image
`sensor and lens. Various suitable optical systems, such as
`those depicted and described in commonly assigned U.S.
`Pat. Nos. 5,990,469; 6,008,486; 6,130,421; 6,130,448;
`6,049,171; and 6,403,942 and U.S. Patent Application Attor-
`ney Docket number AUTO 318V1; the disclosures of which
`are incorporated herein in their entireties by reference; may
`be employed.
`
`[0043] An imager board wiring harness (not shown) is
`preferably provided with plugs on either end thereof. The
`imager board is preferably provided with a male receptacle
`413 for receiving one of the plugs of the imager board wiring
`harness (not shown).
`
`[0044] With additional reference to FIG. 5, a lens cover
`420,520 is snapped onto the lens and then the imager board
`is placed on the carrierbaffle 430, 530 such that the align-
`ment pins 531, 831 are received within the alignment holes
`514 such that the image sensor with lens 411 and lens cover
`are aligned with the baffle aperture 832. Preferably, the
`alignment pins and, or, holes are slightly tapered such that
`the pins are initially freely received within the alignment
`holes then become snug once the imager board is pressed
`into place upon the carrierbaffle. Preferably, the lens cover
`is further secured in place by the lens cover retainers 833. It
`should be understood that the baffle may be a separate part
`that snaps in place on a separate carrier.
`
`[0045] Once the imager board is in place upon the carrier1
`baffle, the imager board retainer 445,545 is placed such that
`the imager board is retained upon the carrierbaffle. Prefer-
`ably, the imager board retainer comprises hinge portions 446
`that are received within the hinge receptacles 534, 834 with
`the imager board retainer substantially perpendicular to the
`carrierbaffle. The imager board retainer is preferably then
`pivoted around the hinge portions such that the clip portions
`447 are received within clip receptacles 535, 835 and
`
`retained therein via interlocking clips. It should be under-
`stood that the imager board retainer may be configured to
`snap in place at three, four or more points in lieu of the hinge
`portions on one end.
`
`[0046] A far field baffle 450, 550 is snapped onto the
`carrierbaffle such that the aperture 452,552 is aligned with
`the baffle aperture 832 and such that the far field baffle snap
`clips 451, 551 are engaged with far field snap portions 443
`on either side of the baffle. The far field baffle, in part,
`defines the field of view of the associated image sensor.
`
`[0047] The carrierbaffle 430,530 is placed proximate the
`attachment member 455, 555, 655, 755 such that the regis-
`tration portions 837 are received within the registration
`receptacles 456, 556, 656. Four fasteners 475, 575 are
`placed through fastener slots 457, 557, 657, 757 and
`received within fastener receptacles 841 to secure the car-
`rierbaffle to the attachment member. Alternatively, an align-
`ment shim assembly 458 may be provided with individually
`removable alignment shims 459. Each alignment shim is
`provided with at least a first graduation 459a and, preferably,
`with second and third graduations 459b, 459c, respectively.
`The alignment shims may provide a means for expanding
`the applicability of any one accessory and rearview mirror
`mount assembly 405,505 to a broader array of vehicles and
`windshield configurations. Preferably, the fasteners are
`threaded screws and the fastener receptacles are provided
`with mating threads. Optionally, the fasteners and fastener
`receptacles may be configured with interference fit function-
`ality such that the fasteners are pressed into the fastener
`receptacles. It should be understood that the carrierbaffle
`may be configured to snap onto the attachment member in
`lieu of using fasteners.
`
`[0048] The transparent cover 480, 580 is attached to the
`front housing 485, 585 such that the transparent cover is
`fixed to the front housing to close the aperture 486. The
`transparent cover may be assembled with a spring clip 481
`using housing interlocks 481a, 481b and spring clip inter-
`locks (shown as elements 1589a, 1589b in FIG. 15). Pref-
`erably, the transparent cover is substantially transparent to
`light rays in the visible spectrum, however, incorporates an
`infrared and, or, ultra violet spectral filter characteristic.
`Thereby, substantially blocking infrared and, or, ultra violet
`light rays from impinging upon the image sensor. Front
`housing 485, 585 is preferably provided with a recessed
`periphery with snap interlock 487, 587 to engage an inner
`perimeter with snap interlock 493, of a rear housing 490,
`590. The front housing and rear housing combine to define
`an enclosure.
`
`[0049] With further reference to FIG. 8, the carrierbaffle
`is preferably provided with a part match pin 844 that is
`located on an opposite side from a part match pin on the
`front or rear housing such that a particular carrierbaffle will
`only allow assembly with an appropriate housing. The part
`match pin is provided to allow for sure assembly of match-
`ing parts because it is envisioned that the carrierbaffle will
`be configured to match a specific vehicle windshield angle
`and wire cover. For example, a carrierbaffle for a 24.3
`degree angle windshield vehicle that has a rear housing 490,
`590 with a first wire cover will not work with a rear housing
`490,590 that does not have a wire cover (i.e. the part match
`pins will be aligned, thereby, prohibiting assembly). When
`the correct carrierbaffle is mated with the correspondingly
`
`

`

`Aug. 26,2004
`
`correct rear housing, the part match pins will not be aligned
`and assembly will be impeded.
`
`[0050] As further shown in FIG. 8, the carrierbaffle is
`provided with upper standoffs 838 and lower standoffs 840
`which, in part, define the angle at which the associated
`image sensor board and compass sensors are placed with
`respect to an associated vehicle windshield. In a preferred
`embodiment, the angle may be selected by providing a
`predetermined upper and lower standoff length. In a pre-
`ferred embodiment, the angle of the imager with respect to
`the windshield will range from approximately 20 to approxi-
`mately 35 degrees, more preferably from approximately
`24.3 to approximately 30 degrees. The preferred accessory
`and rearview mirror mount assembly will provide for this
`range with only changing the upper andlor lower standoff
`lengths. To further expand the accommodated windshield
`angles, the attachment member will be altered as described
`elsewhere herein.
`
`[0051] With additional reference to FIGS. 6 and 7, the
`attachment member 455, 555, 655, 755 are depicted in
`greater detail. The attachment member is configured to
`slidably engage a vehicle mounting button (not shown) in
`button receptacle 666 and to receive a rearview mirror on
`ball 662, 762. A lower portion of the attachment member is
`defined by the lower periphery 670, lower chamber 672 and
`lower cavity 673. The ribs 671 are provided to allow the
`attachment member to function as a substitute for the
`retainer 445, 545 when combined with an appropriately
`designed interposing member such as a piece of substan-
`tially elastic sheet. An upper portion is defined by the button
`receptacles 666, the accessory mount 665, an upper chamber
`669, a threaded set screw hole 668 and an upper cavity 667.
`The upper and lower portions are preferably configured as
`shown in FIGS. 6 and 7 to maximize the strength while
`minimizing the resulting attachment member thickness in
`any given location. The thickness is desirably minimized to
`conserve material and to reduce associated shrinkage and
`warpage during manufacturing. Preferably, the attachment
`member is manufactured from an injection molded zinc
`process. Preferably, a mold is provided with a cavity that
`separates at least into four sections (a cover half, ejector half,
`and two slides) such that the, at least partially, solidified
`attachment member is ejected by applying force to the
`ejection pins 660, 760 and ejection point 761. When so
`ejected, the attachment member is provided with a clean
`mold separation line 763 on, at least, the ball 662, 762.
`Preferably, molten zinc is injected into a mold via apertures
`in the mold corresponding to mold fill locations 764. It
`should be understood that the associated mold may have
`more or less sections depending on the desired material and
`ability to reuse. It should be understood that inserts may be
`provided for the mold section portion that defines the upper
`andlor lower standoff lengths. Thereby, the same mold
`section may be used to produce various angle parts.
`
`[0052]
`In a preferred embodiment, the attachment member
`is provided with stiffeners 759 located proximate the fas-
`tener slots 457, 657, 757. Most preferably, the attachment
`member is provided with a ground connector feature 758 for
`facilitating connection of the ground connector (shown as
`element 1417 in FIG. 14) along with at least one of the
`fasteners. It should be understood that alternate ground
`connector features may be provided.
`
`*
`
`
`
`*
`
`.
`
`[0053] As can be seen from FIGS. 4, 5, 6 and 7, the
`attachment member. in vart. defines the relationshiv which
`the image sensor defines with respect to an associated field
`of view. The corresponding angle may be altered by chang-
`ing the angle at which the upper portion of the attachment
`member defines with respect to the lower portion, varying
`the length of the registration portions of the carrierbaffle,
`providing shims of differing thicknesses, or any combination
`thereof. It should be apparent that other modifications may
`be made to vary the resulting imager aim. A windshield
`sealing boot (shown as element 1389,1489 in FIGS. 13 and
`14, respectively) may be provided to impede nuisance
`buildup on the transparent cover, such as, dust, windshield
`cleaner spray, moisture and the like.
`[0054]
`It should be understood that materials other than
`zinc may be used for the attachment member such as steel,
`steel alloys, aluminum, aluminum alloy, rigid plastics, poly-
`mers, magnesium, magnesium alloys and the like. It is
`within the scope of the present invention to use composite
`materials such as fiber glass, fiber reinforced plastics, etc.
`[0055] Turning now to FIGS. 9 and 10, there are shown
`exploded, perspective, views of a rearview mirror assembly
`900, 1000. In a preferred embodiment, the rearview mirror
`assembly provides a rigid structure for mounting an interior
`rearview mirror along with an imager board. As will be
`described herein, the preferred accessory and rearview mir-
`ror mount assembly facilitates ease of assembly as well as
`provides for repeatable, reliable and precise alignment of the
`related components. In at least one embodiment, the asso-
`ciated imager is used for automatic exterior vehicle light
`control for which precision alignment of the imager is
`preferred.
`[0056]
`Imager board 910,1010 is provided with an image
`sensor with lens. In a preferred embodiment, the imager
`board will also include an image sensor control logic and
`timing circuit, communication line drivers and wire harness
`receptacle 913. Optionally, the imager board may comprise
`a processor for receiving and, at least partially, processing
`images obtained from the image sensor. In a preferred
`embodiment, the image sensor and at least one other device
`selected from the group comprising; 1) an image sensor
`control logic; 2) an A/D converter; 3) a low voltage differ-
`ential signal line driver; 4) a temperature sensor; 5) a control
`output; 6) a voltage regulator; 7) a second image sensor; 8 )
`a microprocessor; 9) a moisture sensor and 10) a compass
`are integrated in a common ASIC, most preferably on a
`common silicon wafer. Preferably, the image sensor with
`lens includes lens cover snap portions for engaging lens
`cover 920, 1020 snap clips. The lens cover has an aperture
`for alignment with the image sensor and lens.
`
`[0057] An imager board wiring harness (not shown) is
`preferably provided with plugs on either end thereof. The
`imager board is preferably provided with a male receptacle
`913 for receiving one of the plugs of the imager board wiring
`harness.
`[0058]
`In a preferred assembly method, an imager board
`and an imager board wiring harness are provided and the
`wiring harness is plugged into the associated receptacle 913.
`The lens cover is snapped onto the lens and the imager board
`is placed on the carrierbaffle such tha