`DON09 P-2048
`
`EXTERIOR SIDEVIEW MIRROR ASSEMBLY
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`CROSS REFERENCE TO RELATED APPLICATIONS
`
`[00011
`
`The present application is a continuation of U.S. patent application Ser. No.
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`13/590,854, filed Aug. 21, 2012 (Attorney Docket DON09 P-1852), which is a division of
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`U.S. patent application Ser. No. 13/336,018, filed Dec. 23, 2011, now U.S. Pat. No.
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`8,267,534, which is a continuation of U.S. patent application Ser. No. 12/911,274, filed
`
`Oct. 25, 2010, now U.S. Pat. No. 8,128,243, which is a continuation of U.S. patent
`
`application Ser. No. 12/851,045, filed Aug. 5, 2010, now U.S. Pat. No. 7,934,843, which is
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`a continuation of U.S. patent application Ser. No. 12/197,666, filed Aug. 25, 2008, now
`
`U.S. Pat. No. 7,842,154, which is a division of U.S. patent application Ser. No. 10/709,434,
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`filed May 5, 2004, now U.S. Pat. No. 7,420,756, which claims the benefit of U.S.
`
`provisional application, Ser. No. 60/471,872, filed May 20, 2003, which are hereby
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`incorporated herein by reference in their entireties.
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`FIELD OF THE INVENTION
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`[0002]
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`The present invention relates generally to rearview mirror elements for a rearview
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`mirror assembly of a vehicle and, more particularly, to exterior rearview mirror elements
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`comprising multi-radius reflective elements.
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`BACKGROUND OF THE INVENTION
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`[0003]
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`Typically, mirror reflective elements are formed of glass and have a reflective
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`coating deposited thereon, such as via vacuum deposition or wet chemical silvering or the
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`like, such as on a silver line, such as described in U.S. Pat. No. 4,737,188, which is hereby
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`incorporated herein by reference. Polymeric reflective elements are also known, such as
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`are described in U.S. Pat. Nos. 6,601,960; 6,409,354; 4,944,581; 4,385,804; 4,193,668;
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`4,666,264; and 5,483,386, which are hereby incorporated herein by reference. For such
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`polymeric mirror reflective elements, the need exists for a hard coat or surface on the first
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`or outer or exterior surface of the element which is contacted by the exterior elements,
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`such as rain, road debris, or the like, or contacted, for example, by a person scraping ice
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`or wiping snow or condensation off the mirror element outer surface, such as during winter.
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`A variety of hard coats have been proposed in the art, typically applied by dip coating or
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`vacuum deposition techniques. However, a need exists for an automotive mirror reflective
`
`1
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`SMR USA
`Exhibit 1025
`Page 001
`
`
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`element which has the properties of plastic (i.e., a specific gravity roughly half that of
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`glass), and which has a glass-like exterior surface.
`
`[0004]
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`Also, exterior rearview mirror reflective elements may be aspheric or multi-radius,
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`and may typically have a less curved or substantially flat (around 2000 mm radius or
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`thereabouts) inboard portion or surface at the inboard side of the reflective element (i.e.,
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`closer to the side body of the vehicle when the mirror assembly is mounted to the vehicle),
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`and a more curved multi-radius portion or surface at the outboard side of the reflective
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`element (i.e., further from the side body of the vehicle when the mirror assembly is
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`mounted to the vehicle), in order to provide an extended field of view. It is typically
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`desirable to have the reflective elements or substrates of such exterior mirror elements to
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`be formed of a glass material because glass material typically provides an enhanced
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`scratch resistance over conventional optical resins and the like.
`
`[OOOS]
`
`Therefore, there is a need in the art for a mirror reflective element that overcomes
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`the shortcomings of the prior art elements and substrates.
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`SUMMARY OF THE INVENTION
`
`[0006]
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`The present invention provides a molded wide angle or multi-radius substrate for a
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`reflective element. The molded substrate comprises a polymeric optical resin transparent
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`material and has a curved exterior surface, which may have a less curved/flatter or
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`substantially flat inboard portion or surface and a more curved outboard portion or surface.
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`The molded substrate may have an anti-abrasion film or layer, such as an ultrathin glass
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`film, applied over the exterior surface or first surface to provide substantial protection
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`against scratches occurring to the molded substrate. The inner surface or second surface
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`of the reflective element substrate may have a reflective coating or layer, such as a
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`polymeric reflective film, laminated or adhered or otherwise applied thereto.
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`[0007]
`
`According to an aspect of the present invention, a wide angle reflective element for
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`a mirror assembly for a vehicle includes a wide angle substrate having an exterior surface
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`and a glass film disposed at the exterior surface. The exterior surface of the substrate has
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`a less curved inboard portion or surface and a more curved outboard portion or surface.
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`The substrate comprises a polymeric resin material. The glass film is adapted to
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`substantially conform to the exterior surface of the wide angle substrate. The glass film
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`comprises a glass material and has a thickness of less than approximately 0.8 mm.
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`2
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`SMR USA
`Exhibit 1025
`Page 002
`
`
`
`[0008]
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`According to another aspect of the present invention, a reflective element for a
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`mirror assembly for a vehicle comprises a substrate having an exterior surface, and an
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`anti-abrasion film applied to the exterior surface. The substrate comprises a polymeric
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`resin material, such as a transparent optical polymeric resin material. The anti-abrasion
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`film preferably comprises a glass material (such as a soda lime glass or a borosilicate or
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`the like) and has a thickness of less than approximately 0.8 mm, and is flexible to conform
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`to the exterior surface.
`
`[0009]
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`The substrate may be cut from a strip or sheet of molded or extruded or cast
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`substrate material (or less preferably, may be cut from an injected molded strip or sheet).
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`The flexible glass film may be unrolled from a reel or roll and applied to the exterior surface
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`of the elongated strip or sheet of substrate material. The substrate, including the glass film
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`or layer, may then be cut or otherwise formed from the elongated strip or sheet.
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`[0010]
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`The substrate may comprise a wide angle substrate and/or may comprise a multi-
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`radius exterior surface having a less curved inboard portion or surface and a more curved
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`outboard portion or surface.
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`[0011]
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`A reflective film or layer may be applied to the inner surface or side of the substrate
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`or strip opposite the exterior surface. The reflective film may comprise a polymeric
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`reflective film laminated or otherwise adhered or applied to the inner side of the substrate
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`or strip. The reflective film may comprise an all polymer-thin-film multilayer, high reflective
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`mirror film comprising multiple coextrusion of many plastic layers to form a highly reflective
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`mirror film.
`
`[00121
`
`Optionally, a reflective film or layer may be applied to the exterior surface of the
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`substrate or sheet or strip, and the glass film or layer or sheet may be applied over the
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`reflective film layer. In such an application, the substrate acts as a support or backing
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`plate for the reflective film or layer and the glass film or layer, whereby optical clarity/
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`transparency of the substrate material is not necessary.
`
`[0013]
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`According to another aspect of the present invention, a method for forming a
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`reflective element substrate for a mirror assembly of a vehicle comprises generally
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`continuously forming an elongated strip or sheet of substrate material and applying a
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`substantially transparent functional film, such as an anti-abrasion film or a hydrophilic film
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`or a hydrophobic film or the like, to a surface of the elongated strip sheet. The substrate
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`material may comprise a transparent optical polymeric resin. The functional film is
`
`3
`
`SMR USA
`Exhibit 1025
`Page 003
`
`
`
`preferably unrolled from a reel or roll of film and applied to the surface of the elongated
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`strip or sheet generally continuously as the strip or sheet is formed or extruded or cast or
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`molded. Preferably, multiple mirror element shapes or mirror element substrates may be
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`cut or otherwise formed from the elongated sheet after the functional film is applied to the
`
`surface of the strip or sheet.
`
`[0014]
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`The functional or anti-abrasion film may comprise an ultrathin glass material which
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`is sufficiently flexible to be provided in a reel or roll (or in a sheet that is flexible and
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`conformable to a bent substrate). The substrates may be formed with a wide angle
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`exterior surface or a multi-radius exterior surface. The anti-abrasion film may be
`
`sufficiently flexible to conform to the wide angle or multi-radius or curved exterior surface.
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`[0015]
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`A reflective film, such as a polymeric reflective film or the like, may be applied to the
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`opposite surface of the substrate or sheet or strip. The reflective film may be sufficiently
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`flexible to be provided in a reel or roll form (or in a sheet that is flexible and conformable to
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`a bent substrate) for unrolling the reflective film as the film is generally continuously
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`applied to the surface of the generally continuously formed sheet or strip.
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`[0016]
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`Therefore, the present invention provides a molded wide angle or multi-radius single
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`substrate for a rearview mirror assembly which has an anti-abrasion or anti-scratch film or
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`layer applied to the curved, wide angle or multi-radius exterior surface of the substrate.
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`The anti-abrasion film preferably comprises an ultrathin glass film or sheet to provide
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`enhanced scratch resistance. The molded substrate may have a reflective film or layer
`
`laminated or applied to the inner surface opposite the exterior surface.
`
`[0017]
`
`These and other objects, advantages, purposes and features of the present
`
`invention will become apparent upon review of the following specification in conjunction
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`with the drawings.
`
`[0018]
`
`FIG. 1 is a perspective view of an exterior rearview mirror assembly in accordance
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`with the present invention;
`
`[0019]
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`FIG. 2 is a perspective view of a wide angle or multi-radius reflective element in
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`accordance with the present invention;
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`[0020]
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`FIG. 3 is a sectional view of the wide angle or multi-radius reflective element taken
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`along the line 111-111 in FIG. 2;
`
`4
`
`SMR USA
`Exhibit 1025
`Page 004
`
`
`
`[00211
`
`FIG. 4 is a sectional view similar to FIG. 3, showing a wide angle or multi-radius
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`reflective element in accordance with the present invention with a reflective film or layer
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`applied to the exterior surface of the element and an anti-abrasion film or layer applied
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`over the reflective film or layer;
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`[0022]
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`FIG. 5 is a diagram showing the extruding, coating and cutting processes for
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`manufacturing a prismatic mirror reflective element in accordance with the present
`
`invention;
`
`[0023]
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`FIG. 5A is an elevation of the extruder of FIG. 5, showing the wedge shape of the
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`extruded strip and reflective element substrate;
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`[0024]
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`FIG. 6 is a plan view of the extruded strip showing the cut out shapes of the
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`reflective element cut from the extruded strip;
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`[0025]
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`FIG. 7 is a sectional view of the reflective element formed by the process shown in
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`FIG. 5;
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`[0026]
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`FIG. 8 is a diagram showing an alternate process for manufacturing a prismatic
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`mirror reflective element in accordance with the present invention, where a strip of
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`substrate material is cast and formed via a caster and float section;
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`[0027]
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`FIG. 9 is a perspective view of an automobile equipped with exterior sideview mirror
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`assemblies according to this present invention;
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`[0028]
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`FIG. 10 is a top plan partial fragmentary view of the driver's side exterior rearview
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`mirror assembly of FIG. 9;
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`[0029]
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`FIG. 11 is an enlarged sectional view of a plano-multiradius reflective element
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`assembly of the mirror assembly in FIG. 1 O;
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`[0030]
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`FIG. 12 is an enlarged sectional view of a demarcation element of the plano-
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`multiradius reflective element assembly of FIG. 11;
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`[0031]
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`FIGS. 13A-13H illustrate views of various locations for a piano reflective element
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`and an auxiliary reflective element according to this present invention;
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`[0032]
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`FIG. 14 is a sectional view of a second embodiment of a piano reflective element
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`assembly according to the present invention including a demarcation element formed as a
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`dividing wall in a backing plate element;
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`[0033]
`
`[0034]
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`FIG. 14A is a cross-section taken along line XX of FIG. 14;
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`FIG. 14B is a cross-sectional view taken along line YY of FIG. 14;
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`5
`
`SMR USA
`Exhibit 1025
`Page 005
`
`
`
`[0035]
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`FIG. 15 is a schematic of a third embodiment of a piano-auxiliary reflective element
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`assembly according to this present invention;
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`[0036]
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`FIG. 16 is a front elevation view of another embodiment of a piano reflective
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`element assembly according to the present invention;
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`[0037]
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`FIG. 17 is an exploded perspective view of the piano reflective element assembly of
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`FIG. 16;
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`[0038]
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`FIG. 18 is an end view of the piano reflective element assembly of FIG. 16 as
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`viewed from line XVIII--XVIII of FIG. 16;
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`[0039]
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`FIG. 19 is a top view of the piano reflective element assembly of FIG. 16 as viewed
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`from line XIX--XIX of FIG. 16;
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`[0040]
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`FIG. 20 is a schematic representation of the piano reflective element assembly of
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`FIG. 16 illustrating the orientation of the reflective element;
`
`[0041]
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`FIG. 21 is another schematic representation of the orientation of the reflective
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`elements of the piano reflective element in FIG. 16;
`
`[0042]
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`FIG. 22 is a diagram illustrating the range of viewing of the reflective elements of
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`the piano reflective element assembly of FIG. 16; and
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`[0043]
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`FIG. 23 is a perspective view of another embodiment of an exterior rearview mirror
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`system of the present invention.
`
`[0044]
`
`Referring now to the drawings and the illustrative embodiments depicted therein, an
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`DESCRIPTION OF THE PREFERRED EMBODIMENTS
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`exterior rearview mirror assembly 10 includes a reflective element 12 mounted at a casing
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`14, which is mounted at an exterior portion of a vehicle 16 (FIG. 1 ). Reflective element 12
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`may provide an enhanced field of view or wide angle field of view to a driver or occupant of
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`the vehicle and may comprise a single reflective element substrate 18 having an inner
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`surface 18a and an opposite exterior surface 18b (FIGS. 2 and 3). The exterior surface
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`18b comprises a less curved or substantially flat inboard portion or surface 18c and a more
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`curved outboard portion or surface 18d, as discussed below. The substrate 18 may have
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`an anti-abrasion coating or layer or film 20, such as an ultrathin glass coating or layer or
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`film, laminated or deposited or otherwise applied to the exterior surface 18b, and may have
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`a reflective coating or layer 22 laminated or applied to the inner surface 18a, as also
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`discussed below. Aspects of the reflective element of the present invention may be
`
`6
`
`SMR USA
`Exhibit 1025
`Page 006
`
`
`
`suitable for use in a reflective element for an exterior rearview mirror assembly (as shown
`
`in FIG. 1) and/or a reflective element for an interior rearview mirror assembly (not shown).
`
`[0045]
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`Reflective element 12 may comprise an aspheric or multi-radius or wide angle
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`single element reflective element substrate. The reflective element 12 may provide a field
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`of view similar to the piano-auxiliary reflective element assembly disclosed in U.S. Pat.
`
`Nos. 6,522,451 and 6,717,712, which are hereby incorporated herein by reference.
`
`[0046]
`
`As illustrated in FIG. 9 from U.S. Pat. No. 6,717,712, incorporated above,
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`passenger automobile 110 (which may be a sedan, a station-wagon, a sports car, a
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`convertible, a minivan, a sports utility vehicle, a pick-up truck or a similar passenger
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`carrying non-commercial, personal transportation automobile) includes an interior rearview
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`mirror assembly 127 positioned within interior vehicle cabin 125. Interior vehicle cabin 125
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`further includes a steering wheel 116, a driver seat 129 positioned at steering wheel 116, a
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`front passenger seat 121 adjacent to driver seat 129 in the front portion of cabin 125, and
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`a rear passenger seat 123 in the rear portion of cabin 125. Automobile 110 further
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`includes a driver-side exterior sideview mirror assembly 112 and a passenger-side exterior
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`sideview mirror assembly 114, each adapted for attachment to opposing sides of
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`automobile body 111, most preferably adjacent to the seating position of the driver seated
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`in driver seat 129 for driver-side assembly 112 and adjacent to the front passenger seat
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`121 for passenger-side assembly 114. Exterior sideview mirrors, mounted as shown in
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`FIG. 9 close to the driver seating location, are commonly referred to as door-mounted
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`exterior sideview mirror assemblies. Driver-side exterior sideview mirror assembly 112
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`includes, as illustrated in FIG. 10, a plano-multiradius exterior sideview reflective element
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`assembly 130. Plano-multiradius reflective element assembly 130 is mounted to a
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`reflective element positioning actuator 136. The orientation of plano-multiradius reflective
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`element assembly 130, and hence its rearward field of view, is adjustable by actuator 136
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`in response to control 137. Control 137 can comprise a handset control that allows the
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`driver manually move the orientation of plano-multiradius reflective element assembly 130
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`within exterior mirror housing 140 (such as by a lever control or by a cable control) and
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`hence reposition the rearward field of view of plano-multiradius reflective element
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`assembly 130. Alternately, when actuator 136 comprises an electrically actuated actuator
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`that is electrically operable incorporating at least one motor, control 137 can comprise a
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`switch (which, preferably, is operable under control of the driver seated in cabin 125) or
`
`7
`
`SMR USA
`Exhibit 1025
`Page 007
`
`
`
`control 137 can comprise a memory controller, as known in the automotive mirror art, that
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`controls actuator 136 to move the position of plano-multiradius reflective element assembly
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`130 to a pre-set orientation that suits the rearward field of view preference of an individual
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`driver. Actuator 136 is mounted to bracket 138 which attaches to vehicle body side 111.
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`Plano-multiradius reflective element assembly 130 is positionable by actuator 136 within
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`exterior mirror housing 140.
`
`[0047]
`
`Plano-multiradius reflective element assembly 130, as shown in FIG. 11, comprises
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`a piano element 150 and a separate multiradius element 155. Preferably, piano element
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`150 is adjacent to multiradius element at a joint. At their joint, piano element 150 and
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`separate multiradius element 155 can touch leaving substantially no gap or space
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`therebetween, or piano element 150 and separate multiradius element 155 can be spaced
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`apart at their joint by a space or gap, as in FIG. 11. Plano element 150 and multiradius
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`element 155 are both mounted to surface 159 of, and are both supported by, a single
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`backing plate element 160. Plano element 150 and multiradius element 155 are
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`demarcated apart by demarcation element 165. Surface 161 of backing plate element 160
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`is preferably adapted to attach, such as by attachment member 164, to actuator 136 when
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`plano-multiradius reflective element assembly 130 is mounted in driver-side exterior
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`sideview mirror assembly 112 (and/or in passenger-side exterior side view mirror assembly
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`114) such that piano element 150 and multiradius element 155 are adjusted and
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`positioned in tandem and simultaneously when the driver (or alternatively, when a mirror
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`memory system, as is conventional in the rearview mirror arts) activates actuator 136 to
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`reposition the rearward field of view of plano-multiradius reflective element assembly 130.
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`Thus, since elements 150, 155 are part of plano-multiradius reflective element assembly
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`130, movement of plano-multiradius reflective element assembly 130 by actuator 136
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`simultaneously and similarly moves piano element 150 and multiradius element 155.
`
`[0048]
`
`Plano element 150 preferably comprises a flat reflector-coated glass substrate
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`having unit magnification, and comprises a reflective surface through which the angular
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`height and width of the image of an object is equal to the angular height and width of the
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`object when viewed at the same distance (except for flaws that do not exceed normal
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`manufacturing tolerances). Plano element 150 may comprise a conventional fixed
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`reflectance mirror reflector or it may comprise a variable reflectance mirror reflector whose
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`reflectivity is electrically adjustable. For example, piano element 150 may comprise a flat
`
`8
`
`SMR USA
`Exhibit 1025
`Page 008
`
`
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`glass substrate coated with a metallic reflector coating such as a chromium coating, a
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`titanium coating, a rhodium coating, a metal alloy coating, a nickel-alloy coating, a silver
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`coating, an aluminum coating (or any alloy or combination of these metal reflectors). The
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`metal reflector coating of piano element 150 may be a first surface coating (such as on
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`surface 166) or a second surface coating (such as on surface 167), as such terms are
`
`known in the mirror art. The reflector coating on piano element 150 may also comprise a
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`dielectric coating, or a multilayer of dielectric coatings, or a combination of a metal layer
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`and a dielectric layer to form automotive mirror reflectors as known in the automotive
`
`mirror art. If a variable reflectance reflector element, piano element 150 preferably
`
`comprises an electro-optic reflector element and, most preferably, an electrochromic
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`reflector element.
`
`[0049]
`
`When mounted into exterior side view mirror assembly 112 and/or 114, plano-
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`multiradius reflective element assembly 130 is preferably orientated so that at least a
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`portion of (more preferably a substantial portion of) the reflector surface of piano element
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`150 is positioned closer to the vehicle body (and hence to the driver) than any portion of
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`the reflector surface of multiradius element 155. Thus, and referring to FIG. 11, side A of
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`piano element 150 of plano-multiradius reflective element assembly 130 is positioned
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`closer to the driver than side D of multiradius element 155 when plano-multiradius
`
`reflective element assembly 130 is mounted on an automobile. Also, when mounted into
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`exterior side view mirror assembly 112 and/or 114, surfaces 166, 168 of plano-multiradius
`
`reflective element assembly 130 face rearwardly in terms of the direction of vehicle travel.
`
`[OOSO]
`
`Multiradius element 155 of plano-multiradius reflective element assembly 130
`
`preferably comprises a curved/bent mirrored glass substrate. The degree of curvature
`
`preferably increases (and hence the local radius of curvature decreases) across the
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`surface of multiradius element 155 with the least curvature (largest radius of curvature)
`
`occurring at the side of multiradius element 155 (side C in FIG. 11) positioned adjacent its
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`joint to piano element 150 when both are mounted on backing plate element 160. Thus,
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`and referring to FIG. 11, the local radius of curvature at side C of multiradius element 155,
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`when mounted on backing plate element 160, is larger than at side D. Also, the local
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`radius of curvature preferably progressively decreases across multiradius element 155
`
`from side C to side D. Preferably, the local radius of curvature at side C of multiradius
`
`element 155 is at least about 1000 mm; more preferably is at least about 2000 mm and
`
`9
`
`SMR USA
`Exhibit 1025
`Page 009
`
`
`
`most preferably is at least about 3000 mm whereas the local radius of curvature at side D
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`of multiradius element 155 is, preferably, less than about 750 mm, more preferably less
`
`than about 350 mm; most preferably less than about 150 mm. Preferably, multiradius
`
`element 155 comprises a bent glass substrate with radii of curvature in the range of from
`
`about 4000 mm to about 50 mm. The multiradius prescription for the multiradius element
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`to be used in a particular exterior mirror assembly can vary according to the specific field
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`of view needs on a specific automobile model.
`
`[0051]
`
`The total field of view rearwardly of the automobile of the piano-auxiliary reflective
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`element assembly (which is a combination of the field of view of the piano reflective
`
`element and of the auxiliary reflective element) preferably generally subtends an angle of
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`at least about 20 degrees (and more preferably, generally subtends an angle of at least
`
`about 25 degrees and most preferably, generally subtends an angle of at least about 30
`
`degrees) with respect to the side of an automobile to which is attached an exterior
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`sideview mirror assembly equipped with the piano-auxiliary reflective element assembly.
`
`[0052]
`
`Multiradius element 155 may comprise a conventional fixed reflectance mirror
`
`reflector or it may comprise a variable reflectance mirror reflector whose reflectivity is
`
`electrically adjustable. For example, multiradius element 155 may comprise a flat glass
`
`substrate coated with a metallic reflector coating such as a chromium coating, a titanium
`
`coating, a rhodium coating, a metal alloy coating, a nickel-alloy coating, a silver coating, an
`
`aluminum coating (or any alloy or combination of these metal reflectors). The metal
`
`reflector coating of multiradius element 155 may be a first surface coating (such as on
`
`surface 168) or a second surface coating (such as on surface 169), as such terms are
`
`known in the mirror art. The reflector coating on multiradius element 155 may also
`
`comprise a dielectric coating, or a multilayer of dielectric coatings, or a combination of a
`
`metal layer and a dielectric layer to form automotive mirror reflectors as known in the
`
`automotive mirror art. If a variable reflectance reflector element, multiradius element 155
`
`preferably comprises an electro-optic reflector element and, most preferably, an
`
`electrochromic reflector element.
`
`[0053]
`
`Also, it is preferable that the thickness of piano element 150 and multiradius
`
`element 155 be substantially the same in dimension so that their respective outer surfaces,
`
`166 and 168, are substantially coplanar so that a driver can readily view images in either
`
`or both elements. The thickness dimension of elements 150, 155 is determined by the
`
`10
`
`SMR USA
`Exhibit 1025
`Page 010
`
`
`
`thickness of the substrate (or in the case of laminate-type electrochromic reflective
`
`elements, the thickness of the two substrates between which the electrochromic medium is
`
`disposed). For example, piano element 150 and/or multiradius element 155 can comprise
`
`a reflector coated glass substrate or panel of thickness preferably equal to or less than
`
`about 2.3 mm, more preferably equal to or less than about 1.6 mm, most preferably equal
`
`to or less than about 1.1 mm. Use of a thinner substrate is beneficial in terms of improving
`
`the overall stability/vibration performance of the image seen in plano-multiradius reflective
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`element assembly 130 when mounted to an automobile.
`
`[0054]
`
`The reflector area of piano element 150 is preferably larger than that of multiradius
`
`element 155. Preferably, the width dimension of piano element 150 is larger than the
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`width dimension of multiradius element 155 (both width dimensions measured at their
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`respective widest dimension and with the width of the respective element being gauged
`
`with the respective element oriented as it would be orientated when mounted on the
`
`automobile). Thus, and referring to FIG. 11, the distance from side A to side B of piano
`
`element 150 is larger than the distance from side C to side D of multiradius element 155.
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`Thus, the ratio of the width of piano element 150 to the width of multiradius element 155 is
`
`preferably greater than 1; more preferably greater than 1.5; most preferably greater than
`
`2.5 in order to provide a large, unit magnification piano element 150 as the principal rear
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`viewing portion of plano-multiradius reflective element assembly 130 and providing
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`multiradius element 155 as a smaller, auxiliary, separate, wide-angle viewing portion of
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`plano-multiradius reflective element assembly 130. For plano-multiradius reflective
`
`element assemblies to be mounted to the exterior sideview assemblies of passenger
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`automobiles used non-commercially and for non-towing purpose, the width of piano
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`element 150 (at its widest dimension) is preferably in the range of from about 50 mm to
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`about 225 mm; more preferably in the range of from about 75 mm to about 175 mm; most
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`preferably in the range of from about 100 mm to about 150 mm.
`
`[0055]
`
`Backing plate element 160 is preferably a rigid polymeric substrate capable of
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`supporting piano element 50 and multiradius element 155. Backing plate element 160
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`comprises a flat portion (generally between E and Fas shown in FIG. 11) that corresponds
`
`to and is aligned with piano element 150. Backing plate element 60 also comprises a
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`curved portion (generally between G and H as shown in FIG. 11) that corresponds to and
`
`is aligned with multiradius element 155. Preferably, curved portion G-H of multiradius
`
`11
`
`SMR USA
`Exhibit 1025
`Page 011
`
`
`
`element 155 is fabricated with a multiradius prescription that is substantially the same as
`
`the multiradius prescription of multiradius element 155. Backing plate element 160 is
`
`formed as a single element to which elements 150 and 155 are separately attached.
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`Preferably, backing plate element 160 is formed by injection molding of a thermoplastic or
`
`a thermosetting polymer resin. Materials suitable to use for backing plate element 160
`
`include unfilled or filled polymeric materials such as glass and/or mineral filled nylon or
`
`glass and/or mineral filled polypropylene, ABS, polyurethane and similar polymeric
`
`materials. For example, backing plate element 160 can be formed of ABS in an injection
`
`molding operation. Plano element 150 can be cut from a stock lite of flat chromium mirror(cid:173)
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`coated 1.6 mm thick glass. Multiradius element 155 can be cut from a stock lite of
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`multiradiusly-bent chromium mirror-coated 1 .6 mm thick glass. Plano element 150 and
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`multiradius element 155 can then be attached (such as by an adhesive attachment such
`
`as an adhesive pad or by mechanical attachment such by clips, fasteners or the like) to the
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`already molded backing plate element 160. Alternatively, piano element 150 and
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`multiradius element 155 can each by individually loaded into an injection molding tool.
`
`Once loaded, a polymeric resin (or the monomers to form a polymeric resin) can be
`
`injected into the mold in order to integrally form backing plate element 160 with elements
`
`150, 155 integrally molded thereto. Integral molding of the backing plate element to piano
`
`element 150 and multiradius element 155 (along with any other elements such as the
`
`demarcation element 165) in a single integral molding operation, is a preferred fabrication
`
`process for plano-multiradius reflective element assembly 130.
`
`[0056]
`
`Plano-multiradius reflective element assembly 130 further preferably includes
`
`demarcation element 165 that functions to delineate and demarcate the piano region of the
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`assembly from the wide-angle, multiradius region and also preferably functions to prevent
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`ingress of debris, dirt, water and similar contaminants (such as road splash, car wash
`
`spray, rain, snow, ice, leaves, bugs and similar items that plano-multiradius reflective
`
`element assembly 130 would be subject to when mounted and used on an automobile)
`
`into any gap between piano element 150 and multiradius element 155 when both are
`
`attached to backing plate element 160. Optionally, at least a portion of demarcation
`
`element 165 can be disposed in any gap between piano element 150 and multiradius
`
`element 155 at their joint on backing plate element 160. Preferably, demarcation element
`
`165 is formed of a polymeric material that is dark colored (such as black or dark blue or
`
`12
`
`SMR USA
`Exhibit 1025
`Page 012
`
`
`
`dark brown or dark grey or a similar dark color) such as a dark colored polypropylene resin
`
`or a dark colored nylon resin or a dark colored polyurethane resin or a dark colored
`
`polyvinyl chloride resin or a dark colored silicone material. Most preferably demarcation
`
`element 165 is formed of an at least partially elastomeric material (such as silicone, or
`
`EPDM, or plasticized PVC or the like) in order to provide a degree of