`US008550642B2
`
`c12) United States Patent
`Lynam
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 8,550,642 B2
`*Oct. 8, 2013
`
`(54) EXTERIOR REARVIEW MIRROR ASSEMBLY
`
`(75)
`
`Inventor: Niall R. Lynam, Holland, MI (US)
`
`(73) Assignee: Donnelly Corporation, Holland, MI
`(US)
`
`(58) Field of Classification Search
`USPC .......................................................... 359/866
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`
`This patent is subject to a terminal dis(cid:173)
`claimer.
`
`(21) Appl. No.: 13/590,854
`
`(22) Filed:
`
`Aug. 21, 2012
`
`(65)
`
`Prior Publication Data
`
`US 2012/0314316Al
`
`Dec. 13, 2012
`
`Related U.S. Application Data
`
`(60) Division of application No. 13/336,018, filed on Dec.
`23, 2011, now Pat. No. 8,267,534, which is a
`continuation of application No. 12/911,274, filed on
`Oct. 25, 2010, now Pat. No. 8,128,243, which is a
`continuation of application No. 12/851,045, filed on
`Aug. 5, 2010, now Pat. No. 7,934,843, which is a
`continuation of application No. 12/197,666, filed on
`Aug. 25, 2008, now Pat. No. 7,842,154, which is a
`divisionofapplication No. 10/709,434, filed on May 5,
`2004, now Pat. No. 7,420,756.
`
`(60) Provisional application No. 60/471,872, filed on May
`20, 2003.
`
`(51)
`
`Int. Cl.
`G02B 5/08
`(52) U.S. Cl.
`USPC . ... ... ... .. ... ... ... ... ... .. ... ... ... ... ... .. ... ... ... ... 359/866
`
`(2006.01)
`
`185'
`
`174'
`
`1,114,559 A
`1,672,559 A
`RE17,274 E
`2,135,262 A
`2,263,382 A
`2,279,751 A
`2,514,989 A
`2,580,014 A
`2,636,419 A
`2,778,273 A
`
`10/1914 Weed
`6/1928 Doble
`4/1929 Porter
`11/1938 Schumacher
`11/1941 Gotzinger
`4/1942 Elwood
`7/1950 Buren
`12/1951 Gazda
`4/1953 Kerr
`1/1957 Fellmeth
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`
`9/1975
`2409748
`5/1976
`2550095
`(Continued)
`Primary Examiner - Alessandro Amari
`(74) Attorney, Agent, or Firm - Gardner, Linn, Burkhart &
`Flory, LLP
`
`ABSTRACT
`(57)
`An exterior rearview mirror assembly for a vehicle includes a
`bracket fixedly secured to the vehicle, a mirror casing secured
`to the bracket and defining a primary opening, and a primary
`mirror disposed within said primary opening for providing a
`view rearward of the motor vehicle through a primary field of
`view. The primary mirror defines a primary plane. A spotting
`mirror is spaced apart from the primary mirror and extends
`through a secondary plane different from the primary plane. A
`divider extends between the primary mirror and the spotting
`mirror to separate the primary and secondary mirrors visually.
`
`11 Claims, 16 Drawing Sheets
`
`173"
`
`~ \ '
`
`~ \
`
`180'
`
`SMR USA
`Exhibit 1001
`Page 001
`
`
`
`(56)
`
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`SMR USA
`Exhibit 1001
`Page 002
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`SMR USA
`Exhibit 1001
`Page 003
`
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`US 8,550,642 B2
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`
`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`DE
`DE
`DE
`DE
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`FR
`GB
`GB
`GB
`JP
`JP
`JP
`JP
`JP
`JP
`KR
`NL
`TW
`WO
`WO
`WO
`WO
`WO
`WO
`WO
`
`2647592
`2915521
`3302735
`3329998
`3620228
`4026578
`0210757
`0310261
`0356099
`0551802
`0728618
`0729864
`0791503
`0917987
`2628042
`1279158
`2048189
`2092534
`0051637
`55076721
`362075619
`62105103
`1186443
`1208245
`2002092059
`7908257
`424057
`WO 0181956
`WO 2004026633
`WO 2004047421
`WO 2004103772
`WO 2006124682
`WO 2007005942
`WO 2008051910
`
`* cited by examiner
`
`4/1978
`10/1980
`8/1984
`3/1985
`12/1987
`4/1992
`2/1987
`4/1989
`2/1990
`1/1992
`8/1996
`9/1996
`8/1997
`5/1999
`3/1988
`6/1972
`12/1980
`8/1982
`4/1980
`10/1980
`4/1987
`5/1987
`7 /1989
`8/1989
`12/2002
`6/1981
`3/2001
`11/2001
`4/2004
`6/2004
`12/2004
`11/2006
`1/2007
`5/2008
`
`SMR USA
`Exhibit 1001
`Page 004
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 1 of 16
`
`US 8,550,642 B2
`
`SMR USA
`Exhibit 1001
`Page 005
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 2 of 16
`
`US 8,550,642 B2
`
`FIG. 3
`
`22
`
`20
`
`--+-18c
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`m
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`118
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`118c
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`SMR USA
`Exhibit 1001
`Page 006
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 3 of 16
`
`US 8,550,642 B2
`
`C)
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`f.ti
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`SMR USA
`Exhibit 1001
`Page 007
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 4 of 16
`
`US 8,550,642 B2
`
`111
`
`116
`
`125
`
`127
`
`123
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`M
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`FIG. 9
`
`SMR USA
`Exhibit 1001
`Page 008
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 5 of 16
`
`US 8,550,642 B2
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`---
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`......
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`
`SMR USA
`Exhibit 1001
`Page 009
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 6 of 16
`
`US 8,550,642 B2
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`..:::c
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`SMR USA
`Exhibit 1001
`Page 010
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 7 of 16
`
`US 8,550,642 B2
`
`165
`
`171
`
`173'
`
`173
`
`170
`
`FIG. 12
`
`SMR USA
`Exhibit 1001
`Page 011
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 8 of 16
`
`US 8,550,642 B2
`
`155
`
`165
`
`Multiradius
`
`A
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`Plano
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`Multiradius
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`155
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`B
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`165
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`165 ~-----------------------~
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`SMR USA
`Exhibit 1001
`Page 012
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 9 of 16
`
`US 8,550,642 B2
`
`Multiradius
`
`FIG.13E
`
`FIG. 13F
`155
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`150
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`Multiradius
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`Plano
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`165
`
`150
`
`165
`
`Multi radius
`
`SMR USA
`Exhibit 1001
`Page 013
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 10 of 16
`
`US 8,550,642 B2
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`'c,..i
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`SMR USA
`Exhibit 1001
`Page 014
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`
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`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 11 of 16
`
`US 8,550,642 B2
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`~I
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`SMR USA
`Exhibit 1001
`Page 015
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 12 of 16
`
`US 8,550,642 B2
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`350
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`SMR USA
`Exhibit 1001
`Page 016
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`
`
`Oct. 8, 2013
`
`Sheet 13 of 16
`
`314
`
`Vs 8,SS0,642 B2
`
`U.s. Patent
`
`318
`
`317
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`324a
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`SMR USA
`Exhibit 1001
`Page 017
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 14 of 16
`
`US 8,550,642 B2
`
`316
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`SMR USA
`Exhibit 1001
`Page 018
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 15 of 16
`
`US 8,550,642 B2
`
`314
`
`312
`
`X-AXIS
`
`FIG.20
`
`314
`
`312
`
`Y-AXIS
`
`FIG. 21
`
`SMR USA
`Exhibit 1001
`Page 019
`
`
`
`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 16 of 16
`
`US 8,550,642 B2
`
`I .. ••t----- ~ --~-...cl
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`SMR USA
`Exhibit 1001
`Page 020
`
`
`
`US 8,550,642 B2
`
`1
`EXTERIOR REARVIEW MIRROR ASSEMBLY
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`The present application is a division of U.S. patent appli(cid:173)
`cation Ser. No. 13/336,018, filed Dec. 23, 2011, 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 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 ofU.S. patent application Ser. No. 10/709,434, 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 incorporated herein by
`reference in their entireties.
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to rearview mirror
`elements for a rearview mirror assembly of a vehicle and,
`more particularly, to exterior rearview mirror elements com(cid:173)
`prising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`
`2
`substrate comprises a polymeric optical resin transparent
`material and has a curved exterior surface, which may have a
`less curved/flatter or substantially flat inboard portion or sur(cid:173)
`face and a more curved outboard portion or surface. The
`5 molded substrate may have an anti-abrasion film or layer,
`such as an ultrathin glass film, applied over the exterior sur(cid:173)
`face or first surface to provide substantial protection against
`scratches occurring to the molded substrate. The inner surface
`or second surface of the reflective element substrate may have
`10 a reflective coating or layer, such as a polymeric reflective
`film, laminated or adhered or otherwise applied thereto.
`According to an aspect of the present invention, a wide
`angle reflective element for a mirror assembly for a vehicle
`includes a wide angle substrate having an exterior surface and
`15 a glass film disposed at the exterior surface. The exterior
`surface of the substrate has a less curved inboard portion or
`surface and a more curved outboard portion or surface. The
`substrate comprises a polymeric resin material. The glass film
`is adapted to substantially conform to the exterior surface of
`20 the wide angle substrate. The glass film comprises a glass
`material and has a thickness of less than approximately 0.8
`mm.
`According to another aspect of the present invention, a
`reflective element for a mirror assembly for a vehicle com-
`25 prises a substrate having an exterior surface, and an anti(cid:173)
`abrasion film applied to the exterior surface. The substrate
`comprises a polymeric resin material, such as a transparent
`optical polymeric resin material. The anti-abrasion film pref(cid:173)
`erably comprises a glass material (such as a soda lime glass or
`30 a borosilicate or the like) and has a thickness of less than
`approximately 0.8 mm, and is flexible to conform to the
`exterior surface.
`The substrate may be cut from a strip or sheet of molded or
`extruded or cast substrate material ( or less preferably, may be
`35 cut from an injected molded strip or sheet). The flexible glass
`film may be unrolled from a reel or roll and applied to the
`exterior surface of the elongated strip or sheet of substrate
`material. The substrate, including the glass film or layer, may
`then be cut or otherwise formed from the elongated strip or
`40 sheet.
`The substrate may comprise a wide angle substrate and/or
`may comprise a multi-radius exterior surface having a less
`curved inboard portion or surface and a more curved outboard
`portion or surface.
`A reflective film or layer may be applied to the inner
`surface or side of the substrate or strip opposite the exterior
`surface. The reflective film may comprise a polymeric reflec(cid:173)
`tive film laminated or otherwise adhered or applied to the
`inner side of the substrate or strip. The reflective film may
`comprise an all polymer-thin-film multilayer, high reflective
`mirror film comprising multiple coextrusion of many plastic
`layers to form a highly reflective mirror film.
`Optionally, a reflective film or layer may be applied to the
`exterior surface of the substrate or sheet or strip, and the glass
`film or layer or sheet may be applied over the reflective film
`layer. In such an application, the substrate acts as a support or
`backing plate for the reflective film or layer and the glass film
`or layer, whereby optical clarity/transparency of the substrate
`material is not necessary.
`According to another aspect of the present invention, a
`method for forming a reflective element substrate for a mirror
`assembly of a vehicle comprises generally continuously
`forming an elongated strip or sheet of substrate material and
`applying a substantially transparent functional film, such as
`65 an anti-abrasion film or a hydrophilic film or a hydrophobic
`film or the like, to a surface of the elongated strip sheet. The
`substrate material may comprise a transparent optical poly-
`
`Typically, mirror reflective elements are formed of glass
`and have a reflective coating deposited thereon, such as via
`vacuum deposition or wet chemical silvering or the like, such
`as on a silver line, such as described in U.S. Pat. No. 4,737,
`188, which is hereby incorporated herein by reference. Poly(cid:173)
`meric reflective elements are also known, such as are
`described in U.S. Pat. Nos. 6,601,960; 6,409,354; 4,944,581;
`4,385,804; 4,193,668; 4,666,264; and 5,483,386, which are
`hereby incorporated herein by reference. For such polymeric
`mirror reflective elements, the need exists for a hard coat or
`surface on the first or outer or exterior surface of the element
`which is contacted by the exterior elements, such as rain, road
`debris, or the like, or contacted, for example, by a person
`scraping ice or wiping snow or condensation off the mirror
`element outer surface, such as during winter. A variety of hard
`coats have been proposed in the art, typically applied by dip
`coating or vacuum deposition techniques. However, a need
`exists for an automotive mirror reflective element which has
`the properties of plastic (i.e., a specific gravity roughly half
`that of glass), and which has a glass-like exterior surface.
`Also, exterior rearview mirror reflective elements may be
`aspheric or multi-radius, and may typically have a less curved
`or substantially flat ( around 2000 mm radius or thereabouts)
`inboard portion or surface at the inboard side of the reflective
`element (i.e., closer to the side body of the vehicle when the 50
`mirror assembly is mounted to the vehicle), and a more
`curved multi-radius portion or surface at the outboard side of
`the reflective element (i.e., further from the side body of the
`vehicle when the mirror assembly is mounted to the vehicle),
`in order to provide an extended field of view. It is typically 55
`desirable to have the reflective elements or substrates of such
`exterior mirror elements to be formed of a glass material
`because glass material typically provides an enhanced scratch
`resistance over conventional optical resins and the like.
`Therefore, there is a need in the art for a mirror reflective 60
`element that overcomes the shortcomings of the prior art
`elements and substrates.
`
`45
`
`SUMMARY OF THE INVENTION
`
`The present invention provides a molded wide angle or
`multi-radius substrate for a reflective element. The molded
`
`SMR USA
`Exhibit 1001
`Page 021
`
`
`
`US 8,550,642 B2
`
`3
`meric resin. The functional film is preferably unrolled from a
`reel or roll of film and applied to the surface of the elongated
`strip or sheet generally continuously as the strip or sheet is
`formed or extruded or cast or molded. Preferably, multiple
`mirror element shapes or mirror element substrates may be
`cut or otherwise formed from the elongated sheet after the
`functional film is applied to the surface of the strip or sheet.
`The functional or anti-abrasion film may comprise an
`ultrathin glass material which is sufficiently flexible to be
`provided in a reel or roll ( or in a sheet that is flexible and
`conformable to a bent substrate). The substrates may be
`formed with a wide angle 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 15
`curved exterior surface.
`A reflective film, such as a polymeric reflective film or the
`like, may be applied to the opposite surface of the substrate or
`sheet or strip. The reflective film may be sufficiently flexible
`to be provided in a reel or roll form ( or in a sheet that is flexible 20
`and conformable to a bent substrate) for unrolling the reflec(cid:173)
`tive film as the film is generally continuously applied to the
`surface of the generally continuously formed sheet or strip.
`Therefore, the present invention provides a molded wide
`angle or multi-radius single substrate for a rearview mirror 25
`assembly which has an anti-abrasion or anti-scratch film or
`layer applied to the curved, wide angle or multi-radius exte(cid:173)
`rior surface of the substrate. The anti-abrasion film preferably
`comprises an ultrathin glass film or sheet to provide enhanced
`scratch resistance. The molded substrate may have a reflec- 30
`tive film or layer laminated or applied to the inner surface
`opposite the exterior surface.
`These and other objects, advantages, purposes and features
`of the present invention will become apparent upon review of
`the following specification in conjunction with the drawings. 35
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`4
`FIG. 10 is a top plan partial fragmentary view of the driv(cid:173)
`er's side exterior rearview mirror assembly of FIG. 9;
`FIG. 11 is an enlarged sectional view of a plano-multira(cid:173)
`dius reflective element assembly of the mirror assembly in
`5 FIG. 10;
`FIG. 12 is an enlarged sectional view of a demarcation
`element of the plano-multiradius reflective element assembly
`ofFIG.11;
`FIGS. 13A-13H illustrate views of various locations for a
`10 piano reflective element and an auxiliary reflective element
`according to this present invention;
`FIG. 14 is a sectional view of a second embodiment of a
`piano reflective element assembly according to the present
`invention including a demarcation element formed as a divid(cid:173)
`ing wall in a backing plate element;
`FIG.14A is a cross-section taken along line XX ofFIG.14;
`FIG. 14B is a cross-sectional view taken along line YY of
`FIG. 14;
`FIG. 15 is a schematic of a third embodiment of a piano(cid:173)
`auxiliary reflective element assembly according to this
`present invention;
`FIG. 16 is a front elevation view of another embodiment of
`a piano reflective element assembly according to the present
`invention;
`FIG.17 is an exploded perspective view of the piano reflec(cid:173)
`tive element assembly of FIG. 16;
`FIG. 18 is an end view of the piano reflective element
`assemblyofFIG.16 as viewed from line XVIII-XVIII of FIG.
`16;
`FIG. 19 is a top view of the piano reflective element assem(cid:173)
`bly of FIG. 16 as viewed from line XIX-XIX of FIG. 16;
`FIG. 20 is a schematic representation of the piano reflective
`element assembly ofFIG.16 illustrating the orientation of the
`reflective element;
`FIG. 21 is another schematic representation of the orienta(cid:173)
`tion of the reflective elements of the piano reflective element
`inFIG.16;
`FIG. 22 is a diagram illustrating the range of viewing of the
`reflective elements of the piano reflective element assembly
`40 of FIG. 16; and
`FIG. 23 is a perspective view of another embodiment of an
`exterior rearview mirror system of the present invention.
`
`FIG. 1 is a perspective view of an exterior rearview mirror
`assembly in accordance with the present invention;
`FIG. 2 is a perspective view of a wide angle or multi-radius
`reflective element in accordance with the present invention;
`FIG. 3 is a sectional view of the wide angle or multi-radius
`reflective element taken along the line III-III in FIG. 2;
`FIG. 4 is a sectional view similar to FIG. 3, showing a wide 45
`angle or multi-radius reflective element in accordance with
`the present invention with a reflective film or layer applied to
`the