`US008783882B2
`
`c12) United States Patent
`Lynam
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 8,783,882 B2
`Jul. 22, 2014
`
`(54) EXTENDED FIELD OF VIEW EXTERIOR
`MIRROR ELEMENT FOR VEHICLE
`
`(71) Applicant: Donnelly Corporation, Holland, MI
`(US)
`
`(72)
`
`Inventor: Niall R. Lynam, Holland, MI (US)
`
`(73) Assignee: Donnelly Corporation, Holland, MI
`(US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by O days.
`
`(56)
`
`References Cited
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`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`
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`2409748
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`2550095
`(Continued)
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`(21) Appl. No.: 14/054,004
`
`(22) Filed:
`
`Oct. 15, 2013
`
`(65)
`
`Prior Publication Data
`
`Feb. 13, 2014
`US 2014/0043706 Al
`Related U.S. Application Data
`
`(60)
`
`Continuation of application No. 13/776,247, filed on
`Feb. 25, 2013, now Pat. No. 8,562,157, and a
`
`(Continued)
`
`(51)
`
`(52)
`
`(58)
`
`(2006.01)
`(2006.01)
`(2006.01)
`
`Int. Cl.
`G02B 5/10
`G02B 71182
`B60R 1/08
`U.S. Cl.
`CPC ................. B60R 1/082 (2013.01); B60R 1/088
`(2013.01); B60R 1/08 (2013.01)
`USPC ........................................... 359/864; 359/872
`Field of Classification Search
`USPC ......... 359/838, 850, 864, 868-869, 871-878,
`359/881-884; 248/466-498
`See application file for complete search history.
`
`Primary Examiner - Stephane B Allen
`Assistant Examiner - Kimberly N Kakalec
`(74) Attorney, Agent, or Firm - Gardner, Linn, Burkhart &
`Flory, LLP
`
`(57)
`
`ABSTRACT
`
`A vehicular exterior sideview mirror assembly includes a
`main piano mirror element fixedly disposed at a first portion
`of a mirror backing plate element and an auxiliary non-piano
`curved mirror element fixedly disposed at a second portion of
`the backing plate element. The main piano mirror element
`and the auxiliary non-piano curved mirror element are adja(cid:173)
`cently disposed at the backing plate element in a side-by-side
`relationship. The field of view of the main piano mirror ele(cid:173)
`ment overlaps the field of view of the non-piano curved mirror
`element. The overall rearward field of view of the main piano
`mirror element and auxiliary non-piano curved mirror ele(cid:173)
`ment is at least about 25 degrees relative to the side of the
`vehicle. The overall rearward field of view of the main piano
`mirror element and auxiliary non-piano curved mirror ele(cid:173)
`ment is less than about 50 degrees relative to the side of the
`vehicle.
`
`20 Claims, 19 Drawing Sheets
`
`165
`
`D
`
`SMR USA
`Exhibit 1022
`Page 001
`
`
`
`US 8,783,882 B2
`Page 2
`
`Related U.S. Application Data
`
`continuation of application No. 13/776,091, filed on
`Feb. 25, 2013, now Pat. No. 8,591,047, which is a
`continuation of application No. 13/590,854, filed on
`Aug. 21, 2012, now Pat. No. 8,550,642, which is a
`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.
`
`(56)
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`SMR USA
`Exhibit 1022
`Page 002
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`Page 3
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`SMR USA
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`4/2009 Schofield et al.
`9/2009 Lynam
`12/2009 Baur et al.
`12/2009 Baur et al.
`12/2010 Sinelli et al.
`5/2011 Lynam
`9/2012 Lynam
`10/2013 Lynam
`3/2002 Wong
`4/2002 Hoek
`6/2002 Lynam et al.
`8/2002 Platzer, Jr.
`10/2002 McCord
`10/2002 Lynam et al.
`2/2003 Vandenbrink
`2/2003 Pavao
`2/2003 Hutzel
`3/2003 Blank
`6/2003 Platzer, Jr.
`2/2004 Tonar et al.
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`2/2004 Drummond et al.
`6/2004 Bartnick
`8/2004 Platzer, Jr.
`12/2004 Minor et al.
`
`US 8,783,882 B2
`Page 4
`
`2004/0264011 Al
`2005/0078389 Al
`2005/0083577 Al
`2005/0099693 Al
`2005/0134983 Al
`2005/0232469 Al
`2005/0248859 Al
`2006/0050018 Al
`2006/0061008 Al
`2006/0125919 Al
`2006/0126150 Al
`2006/0171704 Al
`2006/0184297 Al
`2006/0268440 Al
`2006/0279863 Al
`2007/0058257 Al
`2007 /0285789 Al
`2008/0212189 Al
`2008/0225421 Al
`2008/0304170 Al
`2008/0308219 Al
`2009/0040306 Al
`2009/0115631 Al
`2009/0237820 Al
`2009/0268321 Al
`2010/0195228 Al
`2010/0296187 Al
`2011/0157732 Al
`2011/0170207 Al
`2012/0314316 Al
`2013/0188237 Al
`2013/0188269 Al
`
`12/2004 Lynam
`4/2005 Kulas et al.
`4/2005 Varaprasad et al.
`5/2005 Schofield et al.
`6/2005 Lynam
`10/2005 Schofield et al.
`11/2005 Platzer, Jr.
`3/2006 Hutzel et al.
`3/2006 Karner et al.
`6/2006 Camilleri et al.
`6/2006 Tonar et al.
`8/2006 Bingle et al.
`8/2006 Higgins-Luthrnan
`11/2006 Platzer, Jr.
`12/2006 Starbuck
`3/2007 Lynam
`12/2007 Lindahl et al.
`9/2008 Baur et al.
`9/2008 Platzer
`12/2008 Zhao
`12/2008 Lynam
`2/2009 Foote et al.
`5/2009 Foote et al.
`9/2009 McCabe eta!.
`10/2009 Wilson
`8/2010 Sinelli et al.
`11/2010 Lynam
`6/2011 Henion et al.
`7/2011 Lynam
`12/2012 Lynam
`7/2013 Lynam
`7/2013 Lynam
`
`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
`
`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 1022
`Page 004
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 1 of 19
`
`US 8, 783,882 B2
`
`-
`
`SMR USA
`Exhibit 1022
`Page 005
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 2 of 19
`
`US 8,783,882 B2
`
`FIG. 3
`
`22
`
`20
`
`--+-18c
`
`m
`
`18d
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`m
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`
`18b
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`FIG.2
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`FIG.4
`118
`~)
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`118d
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`'122
`
`118b
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`~
`\ \120
`118c
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`SMR USA
`Exhibit 1022
`Page 006
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 3 of 19
`
`US 8,783,882 B2
`
`c:,
`
`CW') [J
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`c:,
`c-,,.i
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`SMR USA
`Exhibit 1022
`Page 007
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 4 of 19
`
`US 8,783,882 B2
`
`FIG. 9
`
`SMR USA
`Exhibit 1022
`Page 008
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 5 of 19
`
`US 8,783,882 B2
`
`---
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`SMR USA
`Exhibit 1022
`Page 009
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 6 of 19
`
`US 8,783,882 B2
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`~I
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`SMR USA
`Exhibit 1022
`Page 010
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 7 of 19
`
`US 8,783,882 B2
`
`165
`
`171
`
`173'
`
`173
`
`170
`
`------- - - -
`/
`CCC
`
`FIG. 12
`
`SMR USA
`Exhibit 1022
`Page 011
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 8 of 19
`
`US 8,783,882 B2
`
`155
`
`165
`
`Multiradius
`
`A
`
`Plano
`
`Multiradius
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`155
`
`Plano
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`Plano
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`Plano
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`165
`
`155
`
`C
`
`D
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`150
`
`FIG.13A
`
`150
`
`FIG.138
`
`150
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`FIG.13(
`
`165
`
`150
`FIG 13D
`
`SMR USA
`Exhibit 1022
`Page 012
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 9 of 19
`
`US 8, 783,882 B2
`
`Multiradius
`
`FIG.13E
`
`165
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`FIG. 13F
`155
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`Multiradius
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`FIG.136
`150
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`FIG.13H
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`155
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`Plano
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`Plano
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`150
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`150
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`155
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`Plano
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`Multiradius
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`Plano
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`165
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`150
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`165
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`Multi radius
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`SMR USA
`Exhibit 1022
`Page 013
`
`
`
`19~{)
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`170'
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`/LI.'!,
`~XI J'>...I
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`SMR USA
`Exhibit 1022
`Page 014
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 11 of 19
`
`US 8,783,882 B2
`
`~I
`
`SMR USA
`Exhibit 1022
`Page 015
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 12 of 19
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`US 8,783,882 B2
`
`350
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`355
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`332
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`417
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`FIG. 16
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`FIG.23
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`SMR USA
`Exhibit 1022
`Page 016
`
`
`
`U.s. Patent
`
`Ju]. 22, 2014
`
`Sheet 13 of 19
`
`Vs 8, 783,882 B2
`
`314
`
`317
`
`324a
`
`FIG. /J
`
`SMR USA
`Exhibit 1022
`Page 017
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 14 of 19
`
`US 8, 783,882 B2
`
`316
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`)
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`332
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`
`SMR USA
`Exhibit 1022
`Page 018
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 15 of 19
`
`US 8, 783,882 B2
`
`312
`
`X-AXIS
`
`FIG.20
`
`314
`
`312
`
`Y-AXIS
`
`FIG. 21
`
`SMR USA
`Exhibit 1022
`Page 019
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 16 of 19
`
`US 8,783,882 B2
`
`, ..... .__ ___ ~--~--..ii
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`er
`w
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`SMR USA
`Exhibit 1022
`Page 020
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 17 of 19
`
`US 8,783,882 B2
`
`\ \
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`SMR USA
`Exhibit 1022
`Page 021
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 18 of 19
`
`US 8,783,882 B2
`
`FIG. 25A
`
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`FIG. 25C
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`SMR USA
`Exhibit 1022
`Page 022
`
`
`
`U.S. Patent
`
`Jul. 22, 2014
`
`Sheet 19 of 19
`
`US 8,783,882 B2
`
`FIG.26A
`
`FIG. 268
`
`550A
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`590
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`...-'530'
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`SMR USA
`Exhibit 1022
`Page 023
`
`
`
`US 8,783,882 B2
`
`1
`EXTENDED FIELD OF VIEW EXTERIOR
`MIRROR ELEMENT FOR VEHICLE
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`2
`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
`element that overcomes the shortcomings of the prior art
`5 elements and substrates.
`
`SUMMARY OF THE INVENTION
`
`The present invention provides a molded wide angle or
`10 multi-radius substrate for a reflective element. The molded
`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-
`face and a more curved outboard portion or surface. The
`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
`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
`25 includes a wide angle substrate having an exterior surface and
`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
`30 is adapted to substantially conform to the exterior surface of
`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
`35 reflective element for a mirror assembly for a vehicle com(cid:173)
`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-
`40 erably comprises a glass material (such as a soda lime glass or
`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
`45 extruded or cast substrate material ( or less preferably, may be
`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
`50 then be cut or otherwise formed from the elongated strip or
`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
`55 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
`
`The present application is a continuation of U.S. patent
`application Ser. No. 13/776,247, filed Feb. 25, 2013, now
`U.S. Pat. No. 8,562,157, which is a continuation of U.S.
`patent application Ser. No. 13/776,091, filed Feb. 25, 2013,
`which is a continuation of U.S. patent application Ser. No.
`13/590,854, filed Aug. 21, 2012, now U.S. Pat. No. 8,550,
`642, which is a division of U.S. patent application Ser. No.
`13/336,018, filed Dec. 23, 2011, now U.S. Pat. No. 8,267,534,
`which is a continuation of U.S. patent application Ser. No. 15
`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, filedAug. 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, 20
`154, which is a division of U.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 incor(cid:173)
`porated 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
`
`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 60
`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 65
`desirable to have the reflective elements or substrates of such
`exterior mirror elements to be formed of a glass material
`
`SMR USA
`Exhibit 1022
`Page 024
`
`
`
`US 8,783,882 B2
`
`3
`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 5
`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
`an anti-abrasion film or a hydrophilic film or a hydrophobic
`film or the like, to a surface of the elongated strip sheet. The 10
`substrate material may comprise a transparent optical poly(cid:173)
`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 15
`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 20
`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 25
`flexible to conform to the wide angle or multi-radius or
`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 30
`to be provided in a reel or roll form ( or in a sheet that is flexible
`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
`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 40
`comprises an ultrathin glass film or sheet to provide enhanced
`scratch resistance. The molded substrate may have a reflec(cid:173)
`tive film or layer laminated or applied to the inner surface
`opposite the exterior surface.
`These and other objects, advantages, purposes and features 45
`of the present invention will become apparent upon review of
`the following specification in conjunction with the drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`4
`FIG. 6 is a plan view of the extruded strip showing the cut
`out shapes of the reflective element cut from the extruded
`strip;
`FIG. 7 is a sectional view of the reflective element formed
`by the process shown in FIG. 5;
`FIG. 8 is a diagram showing an alternate process for manu(cid:173)
`facturing a prismatic mirror reflective element in accordance
`with the present invention, where a strip of substrate material
`is cast and formed via a caster and float section;
`FIG. 9 is a perspective view of an automobile equipp