`
`
`
`MOTHERSON
`MOTHERSON
`EXHIBIT 1004
`EXHIBIT 1004
`
`

`

`US007255451B2
`
`(12) United States Patent
`McCabe et al.
`
`(10) Patent No.:
`(45) Date of Patent:
`
`US 7.255.451 B2
`Aug. 14, 2007
`
`(54) ELECTRO-OPTIC MIRROR CELL
`(75) Inventors: Ian A. McCabe, Holland, MI (US);
`Hamid Habibi, Holland, MI (US);
`Niall R. Lynam, Holland, MI (US);
`Donald L. Bareman, Zeeland, MI (US)
`(73) Assignee: Donnelly Corporation, Holland, MI
`(US)
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 263 days.
`(21) Appl. No.: 11/021,065
`
`(*) Notice:
`
`(22) Filed:
`
`Dec. 23, 2004
`
`(65)
`
`Prior Publication Data
`US 2005/O195488 A1
`Sep. 8, 2005
`
`Related U.S. Application Data
`(63) Continuation-in-part of application No. PCT/US03/
`35381, filed on Nov. 5, 2003, application No. 11/021,
`065, and a continuation-in-part of application No.
`PCT/US03/29776, filed on Sep. 19, 2003.
`(60) Provisional application No. 60/629,926, filed on Nov.
`22, 2004, provisional application No. 60/563,342,
`filed on Apr. 19, 2004, provisional application No.
`60/553.842, filed on Mar. 17, 2004, provisional appli
`cation No. 60/531,838, filed on Dec. 23, 2003, pro
`visional application No. 60/490,111, filed on Jul. 25,
`2003, provisional application No. 60/489,816, filed
`on Jul. 24, 2003, provisional application No. 60/424,
`116, filed on Nov. 5, 2002, provisional application
`No. 60/423,903, filed on Nov. 5, 2002, provisional
`application No. 60/412.275, filed on Sep. 20, 2002.
`
`(51) Int. Cl.
`(2006.01)
`GO2B 5/08
`(52) U.S. Cl. ....................................... 359/605; 359/265
`(58) Field of Classification Search ..................... None
`See application file for complete search history.
`
`
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`2,263,382 A 11/1941 Gotzinger
`2,580,014 A 12/1951 Gazda
`3.266,016 A
`8/1966 Maruyama et al.
`3,280,701 A 10/1966 Donnelly et al.
`
`(Continued)
`FOREIGN PATENT DOCUMENTS
`
`EP
`
`O356099 A2
`
`2, 1990
`
`(Continued)
`Primary Examiner Stephone B. Allen
`Assistant Examiner Derek S. Chapel
`(74) Attorney, Agent, or Firm Van Dyke, Gardner, Linn &
`Burkhart, LLP
`
`(57)
`
`ABSTRACT
`
`A reflective element assembly for a variable reflectance
`vehicular mirror includes a front Substrate having a trans
`parent conductive coating disposed on a second Surface, and
`a rear Substrate having a third Surface conductive coating
`disposed on its third surface and preferably, a fourth surface
`conductive coating disposed on its fourth Surface. At least a
`portion of the third Surface conductive coating may wrap
`around an edge portion of the rear Substrate and at least a
`portion of the fourth Surface conductive coating may wrap
`around at least a second portion of the perimeter edge so as
`to establish electrical continuity between the fourth surface
`conductive coating on the fourth surface and the third
`Surface conductive coating on the third Surface. The rear
`Substrate may have a smaller dimension than the front
`Substrate so as to provide an overhang region, preferably at
`the wraparound region.
`
`19 Claims, 49 Drawing Sheets
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 1
`
`

`

`US 7.255.451 B2
`Page 2
`
`U.S. PATENT DOCUMENTS
`
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`8, 1990 Desmond et al.
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`5, 1991 Roberts
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`5,076,673 A 12/1991 Lynam et al.
`5,078.480 A
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`5/1992 Lynam
`5,117,346 A
`5, 1992 Gard
`5,140,455 A
`8/1992 Varaprasad et al.
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`5,151,816 A
`9/1992 Varaprasad et al.
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`9, 1992 O’Farrell
`5,178.448 A
`1/1993 Adams et al.
`5,179,471 A
`1/1993 Caskey et al.
`5, 183,099 A
`2f1993 Bechu
`5,189,537 A
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`5, 193,029 A
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`5,253,109 A 10/1993 O'Farrell et al.
`5,285,060 A
`2, 1994 Larson et al.
`5,313,335 A
`5/1994 Gray et al.
`5,327.288 A
`7/1994 Wellington et al.
`5,354,965 A 10/1994 Lee
`5,355.245 A 10/1994 Lynam
`5,406,414 A
`4/1995 O’Farrell et al.
`5.437,931 A
`8, 1995 Tsai et al.
`5,446,576 A
`8/1995 Lynam et al.
`5,481,409 A
`1/1996 Roberts
`5,509,606 A
`4/1996 Breithaupt et al.
`5,523,877 A
`6/1996 Lynam
`5,525,264 A
`6, 1996 Cronin et al.
`5,535,056 A
`7/1996 Caskey et al.
`5,550,677 A
`8, 1996 Schofield et al.
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`5,587,699 A 12/1996 Faloon et al.
`5,594,222 A
`1/1997 Caldwell
`5,610,756 A
`3/1997 Lynam et al.
`5,649,756 A
`7, 1997 Adams et al.
`5,668,663 A
`9/1997 Varaprasad et al.
`5,669,698 A
`9, 1997 Veldman et al.
`5,689,370 A 1 1/1997 Tonar et al.
`5,724, 187 A
`3/1998 Varaprasad et al.
`5,751,489 A
`5/1998 Caskey et al.
`5,786,772 A
`7, 1998 Schofield et al.
`5,788,357 A
`8, 1998 Muth et al.
`
`8, 1998 Tonar
`5,790,298 A
`9/1998 Lynam et al.
`5,808,777 A
`3, 1999 Schofield et al.
`5,877,897 A
`6/1999 Varaprasad et al.
`5,910,854 A
`7/1999 Caskey
`5,922, 176 A
`8, 1999 Crandall
`5,938,320 A
`6,001.486 A 12/1999 Varaprasad et al.
`6,002,544 A 12, 1999 Yatsu
`6,005,724 A 12, 1999 Todd
`6,065,840 A
`5/2000 Caskey et al.
`6,111,684 A
`8/2000 Forgette et al.
`6,154.306 A
`1 1/2000 Varaprasad et al.
`6,164,564. A 12/2000 Franco et al.
`6,172,613 B1
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`6,178,034 B1
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`6,196,688 B1
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`6,207,083 B1
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`6.245,262 B1
`6/2001 Varaprased et al.
`6,257,746 B1
`7/2001 Todd et al.
`6,260,608 B1
`7, 2001 Kim
`6.286,965 B1
`9/2001 Caskey et al.
`6,310,611 B1
`10/2001 Caldwell
`6,318,870 B1
`11/2001 Spooner et al.
`6,320,282 B1
`1 1/2001 Caldwell
`6,329,925 B1
`12/2001 Skiver et al.
`6,356,376 B1
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`6.420,036 B1
`7/2002 Varaprasad et al.
`6,428,172 B1
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`6,449,082 B1
`9/2002 Agrawal et al.
`6,501,387 B2 12/2002 Skiver et al.
`6,512,624 B2
`1/2003 Tonar et al.
`6,595,649 B2
`7/2003 Hoekstra et al.
`6,615.438 B1
`9/2003 Franco et al.
`6,627,918 B2
`9/2003 Getz et al.
`6,642,851 B2 11/2003 DeLine et al.
`6,648,477 B2 11/2003 Hutzel et al.
`6,669,109 B2 12/2003 Ivanov et al.
`6,690,268 B2
`2/2004 Schofield et al.
`6,719,215 B2
`4/2004 Drouillard
`6,737,629 B2
`5/2004 Nixon et al.
`6,742,904 B2
`6/2004 Bechtel et al.
`D493,131 S
`7/2004 Lawlor et al.
`D493,394 S
`7/2004 Lawlor et al.
`6,824,281 B2 11/2004 Schofield et al.
`6,831,268 B2 12/2004 Bechtel et al.
`2002/0159270 A1 10/2002 Lynam et al.
`2003.0043589 A1
`3, 2003 Blank
`2003/0101749 A1
`6/2003 Lingle et al.
`2004/0032638 A1
`2/2004 Tonar et al.
`2004/0032675 A1
`2/2004 Weller et al.
`2004/0032676 A1
`2/2004 Drummond et al.
`2004/0264.011 A1 12/2004 Lynam
`2005, 0078389 A1
`4, 2005 Kulas et al.
`2005.0099693 A1
`5.2005 Schofield et al.
`2005/0134983 A1
`6/2005 Lynam
`
`FOREIGN PATENT DOCUMENTS
`
`4f1987
`362O75619 A
`JP
`4, 2004
`WO WO 2004/026633 A2
`5, 2004
`WO WO 2004/042457 A3
`7, 2004
`WO WO 2004/058540 A3
`WO WO 2004,103772 A3 12/2004
`WO WO 2005062966 A2 * 7, 2005
`
`* cited by examiner
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 2
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
`
`Sheet 1 of 49
`
`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 3
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
`
`Sheet 2 of 49
`
`US 7.255.451 B2
`
`
`
`30b ---
`
`-3ob
`
`FIG.2
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 4
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
`
`Sheet 3 of 49
`
`US 7.255.451 B2
`
`
`
`FIG 3
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 5
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
`
`Sheet 4 of 49
`
`US 7.255.451 B2
`
`
`
`SN Sartrirt. It ritztry. It
`
`Irrizzzzz trade
`
`4.
`
`FIG.4
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 6
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
`
`Sheet 5 of 49
`
`US 7.255.451 B2
`
`
`
`FIG5
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 7
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
`
`Sheet 6 of 49
`
`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 8
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`

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`U.S. Patent
`
`Aug. 14, 2007
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`Sheet 7 of 49
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 9
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`

`

`U.S. Patent
`
`
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 10
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 9 of 49
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 11
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 10 of 49
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 12
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 11 of 49
`
`US 7.255.451 B2
`
`
`
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 13
`
`

`

`U.S. Patent
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`Aug. 14, 2007
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`Sheet 12 of 49
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`US 7.255.451 B2
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 14
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
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`Sheet 13 of 49
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`US 7.255.451 B2
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 15
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
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`Sheet 14 of 49
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 16
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 15 Of 49
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`US 7.255.451 B2
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 17
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`

`

`U.S. Patent
`
`Aug. 14, 2007
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`Sheet 16 of 49
`
`US 7.255.451 B2
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 18
`
`

`

`U.S. Patent
`
`Aug. 14, 2007
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`Sheet 17 Of 49
`
`US 7.255.451 B2
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`
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`28
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 19
`
`

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`U.S. Patent
`
`Aug. 14, 2007
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`Sheet 18 of 49
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 20
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 19 Of 49
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`US 7.255.451 B2
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`
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 21
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`

`

`U.S. Patent
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`Aug. 14, 2007
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`Sheet 20 of 49
`
`US 7.255.451 B2
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`20 N
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 22
`
`

`

`U.S. Patent
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`Aug. 14, 2007
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`Sheet 21 of 49
`
`US 7.255.451 B2
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 23
`
`

`

`U.S. Patent
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`Aug. 14, 2007
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`Sheet 22 of 49
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`US 7.255.451 B2
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 24
`
`

`

`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 25
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 24 of 49
`
`US 7.255.451 B2
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`42d
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 26
`
`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 25 of 49
`
`US 7.255.451 B2
`
`s:
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 27
`
`

`

`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 28
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 27 Of 49
`
`US 7.255.451 B2
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`525
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 29
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`

`

`U.S. Patent
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`Aug. 14, 2007
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`Sheet 28 of 49
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`US 7.255.451 B2
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`A HEA
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 30
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 29 Of 49
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`US 7.255.451 B2
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`525
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 31
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 30 of 49
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`US 7.255.451 B2
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`522
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 32
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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 31 of 49
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`US 7.255.451 B2
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`540
`
`PROCUREFLAT CLEAR GLASS SHEETS
`
`545
`
`BEND CLEAR GLASSSHEETS
`
`
`
`
`
`CUT CLEAR FRONT SHAPE
`
`(UTCLEAR REAR SHAPE
`
`
`
`
`
`MASKALONGPORTION OF
`EDGE PERMETERREGION
`
`MASKALONGPORTION OF
`EDGE PERMETERREGION
`
`565
`
`575
`
`DEPOST TO WITH
`WRAP-AROUND ONTO EDGES
`NOMASKED
`
`
`
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`WITH WRAP-AROUND ONTO
`EDGES NOT MASKED
`
`
`
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`
`FIG. 36
`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 33
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`

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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 32 of 49
`
`US 7.255.451 B2
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`629 629b 632
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`
`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 34
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`

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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 35
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`U.S. Patent
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`Aug. 14, 2007
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`Sheet 34 of 49
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 36
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`US 7.255.451 B2
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 37
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 38
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 39
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`Aug. 14, 2007
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 44
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`Aug. 14, 2007
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 45
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`Aug. 14, 2007
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`Sheet 44 of 49
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 46
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`Aug. 14, 2007
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 47
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`Aug. 14, 2007
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`Motherson Exhibit 1004, Page 48
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`Motherson Exhibit 1004, Page 49
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`Aug. 14, 2007
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`Motherson Innovations v. Magna Mirrors
`Motherson Exhibit 1004, Page 51
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`

`

`1.
`ELECTRO-OPTC MIRROR CELL
`
`US 7.255.451 B2
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`2
`the first cut shape by the applied perimeter material. The
`uncured adhesive material is then cured. Such as by heating,
`to adhere the shapes or Substrates together and to space the
`Substrates apart a desired amount to define an appropriate
`interpane cavity spacing. The Substrates, so adhered together
`and interspaced apart, form an empty cell with an interpane
`cavity between the substrates and bounded by the perimeter
`seal. Next, an electrolyte or monomer composition is filled
`into the cavity via an aperture (commonly known as a fill
`port or plug hole) provided in the perimeter material or seal,
`Such as via a vacuum fill process. However, until Such time
`as the interpane cavity is formed by the juxtapositioning and
`Superimposing of the respective front and rear shapes or
`Substrates of the electrochromic cell, dirt or glass chips or
`dust or skin flakes or other debris or contaminants or the like
`may fall onto or contact the pristine Surface of any one of the
`Substrates (the pristine Surfaces are the opposing Surfaces of
`the front and rear Substrates that oppose one another when
`the substrates are held together and that are contacted by the
`electrolyte or monomer composition or electrochromic
`medium in the interpane cavity). Such contaminants
`(whether contacting the Surfaces before or after coating)
`may interfere with the coloration/bleach mechanism and/or
`the coating durability/adhesion (such that Voids may exist in
`the coating due to glass chips or the like), as well as affect
`the perimeter seal adhesion, and thus often result in a flawed
`cell exhibiting cosmetic defects that is often discarded or
`scrapped.
`In order for the completed mirror reflective element
`assembly or cell to avoid such flaws, the pristine surfaces
`(that will oppose one another when the substrates are
`adhered together and that have the semiconductive or con
`ductive layers applied thereto) of the substrates preferably
`must be kept clean and untouched throughout the coating,
`conveying, adhering and assembly processes. Difficulties in
`keeping the Surfaces pristine are often encountered because
`the individual cut shape substrates are often handled and
`conveyed as they are moved from one process or station to
`the next. Often, the individual cut shape substrates are
`cleaned, such as via an ultrasonic cleaner or scrubber to
`remove any such debris or the like. However, the individual
`cut shape Substrates may be conveyed along a conveyor and
`held down via rollers during the scrubbing process, where
`the rollers often encroach and so touch the pristine surface
`of the substrate that will be the inner surface of the cavity.
`If any marks or debris are left by the rollers, they may be
`visible in the finished product and may result in the cell
`being scrapped.
`It is also known to provide display windows in the
`reflective coating or layer of a reflective element assembly,
`Such that a display device or illumination source may be
`viewable through the display window. Typically, for fourth
`surface reflective element assemblies (where the metallic
`reflective coating or layer is applied to the fourth or rear
`surface of the reflective element assembly), such display
`windows may be formed in the reflective coating of the
`Substrate via laser ablating or etching or sand blasting the
`reflective coating from the window area of the fourth surface
`(i.e., the rear surface of the rear substrate) after the reflective
`mirror coating (typically a silver mirror reflector layer
`overcoated with a copper layer and protected by a paint
`overcoat) is applied over substantially the entire fourth
`surface. The reflective coating is removed from the desired
`window area such that the glass or Substrate Surface is
`exposed on the fourth surface in the window area.
`However, such an approach does not readily apply to
`forming windows through the metallic reflective coating of
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`10
`
`The present application claims benefit of U.S. provisional
`applications, Ser. No. 60/531,838, filed Dec. 23, 2003: Ser.
`No. 60/553,842, filed Mar. 17, 2004; Ser. No. 60/563,342,
`filed Apr. 19, 2004; and Ser. No. 60/629,926, filed Nov. 22,
`2004, and is a continuation-in-part of PCT Application No.
`PCT/US03/35381, filed Nov. 5, 2003 by Donnelly Corp. et
`a1 for ELECTRO-OPTIC REFLECTIVE ELEMENT
`ASSEMBLY, which claims benefit of U.S. provisional appli
`cations, Ser. No. 60/490,111, filed Jul. 25, 2003 by McCabe
`et al. for FLUSH ELECTROCHROMIC CELL; and Ser.
`15
`No. 60/423.903, filed Nov. 5, 2002 by McCabe for ONE
`SIDED FLUSH ELECTROCHROMIC CELL, and is a
`continuation-in-part of PCT Application No. PCT/US03/
`29776, filed Sep. 19, 2003 by Donnelly Corp. et al. for
`ELECTROCHROMIC MIRROR ASSEMBLY, which
`claims benefit of U.S. provisional applications, Ser. No.
`60/412,275, filed Sep. 20, 2002 by McCabe for ELECTRO
`CHROMIC MIRROR ASSEMBLY: Ser. No. 60/424,116,
`filed Nov. 5, 2002 by McCabe for ELECTROCHROMIC
`MIRROR ASSEMBLY; and Ser. No. 60/489,816, filed Jul.
`25
`24, 2003 by McCabe for ELECTROCHROMIC MIRROR
`ASSEMBLY, which are all hereby incorporated herein by
`reference in their entireties.
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to reflective ele
`ment assemblies for rearview mirrors of vehicles and, more
`particularly, to electro-optic or electrochromic reflective
`element assemblies and a method for manufacturing electro
`optic or electrochromic reflective element assemblies.
`
`BACKGROUND OF THE INVENTION
`
`30
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`35
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`40
`
`Automotive electrochromic mirror reflective element cell
`assemblies typically include a front Substrate and a rear
`Substrate and an electrochromic medium sandwiched ther
`ebetween and contained within an interpane cavity. The
`Substrates are shaped as desired by the automobile manu
`facturer for a particular mirror design or application. For
`45
`example, an interior rearview mirror reflective element may
`have substrates that are generally oval or trapezoidal in
`shape and are formed to be approximately 20-26 cm long
`and 5-8 cm tall or wide. Exterior mirror reflective element
`assemblies are shaped differently and may have sharper radii
`at the corners and may be flat or convex or aspheric,
`depending on the particular application. The size of the
`substrates for the exterior reflective element assemblies may
`vary from about 7 cm by 7 cm to about 10 cm by 18 cm or
`larger.
`During manufacture and assembly of the reflective cell
`element assembly, the respective front and rear Substrates
`are often cut or broken out as cut shapes from larger flat or
`curved lites, typically glass sheets or lites. The individual
`front and rear cut shapes or substrates are cleaned and then
`coated with a conductive or semiconductive coating or
`coatings that are reflective or transparent. After they are
`coated, an uncured adhesive material, typically an uncured
`epoxy material (often containing spacer beads, such as glass
`beads or the like), is applied around the perimeter of one of
`the cut shapes or Substrates, and the other cut shape or
`Substrate is Superimposed thereupon and spaced apart from
`
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`US 7.255.451 B2
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`3
`third surface reflective element assemblies (i.e., a reflective
`element assembly that has the metallic reflective coating on
`the third surface (the front surface of the rear substrate) of
`the reflective element assembly). In order to properly darken
`or color the electrochromic medium disposed between the
`substrates, the opposed surfaces of the substrates (the front
`surface of the rear substrate and the rear surface of the front
`substrate) are coated substantially over their entire surfaces
`with a conductive coating. Typically, the second Surface (the
`rear surface of the front substrate) is coated with a trans
`parent electrically conductive coating, Such as an indium tin
`oxide (ITO), while the third surface (the front surface of the
`rear Substrate) is coated with a transparent electrically
`conductive coating, and is further coated with a metallic
`reflective conductive coating over the transparent coating.
`When it is desired to form a window in the metallic
`reflective conductive coating on the third surface, it is
`desirable that the window on the third surface still have the
`transparent electrically conductive coating over its surface
`area, in order to provide for appropriate darkening or col
`oring of the electrochromic medium at the window area. If
`the transparent electrically conductive coating is also
`removed from the third surface in the window area, the
`electrochromic medium may not darken or color uniformly
`across the reflective element assembly, particularly in the
`window area versus the rest of the reflective element assem
`bly. However, it may be difficult to laser ablate or etch only
`the metallic reflective coating from the third surface while
`leaving the transparent electrically conductive coating intact
`on the surface of the substrate at the window area. Such
`precise control of the depth of the ablation or etching may
`be difficult to achieve.
`Therefore, there is a need in the art for an improved
`process for manufacturing electro-optic mirror reflective
`element assemblies, such as electrochromic mirror reflective
`element assemblies, that overcomes the shortcomings of the
`prior art.
`
`10
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`15
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`25
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`30
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`35
`
`4
`The method of making or forming the reflective element
`assemblies includes providing a sheet of clear glass (sized to
`be greater than at least two intended mirror shapes) that will
`form the rear or second substrate of the mirror element cell
`(the rear substrate has the reflective conductive coating on
`its front surface, which will be the third surface of the
`reflective element assembly when it is assembled), and
`cleaning and coating (with a metallic electrically conductive
`layer or layers, such as silver, silver alloy, aluminum,
`aluminum alloy, or the like, such as described below) the
`surface of the sheet. The coating may be selectively removed
`from the surface of the sheet in the outline shapes of at least
`two desired mirror substrates, and more preferably multiple,
`Such as four or six or more, Substrates. Uncured adhesive
`material. Such as an uncured epoxy material may be applied
`to the surface of the sheet along the removed outlines to
`form the desired mirror shapes. The front cut shape or
`Substrate or sheet is Superimposed upon the rear sheet and
`spaced therefrom by the applied uncured material. The
`uncured adhesive material is then cured. Such as by heating,
`to adhere the shapes or Substrates together and to space the
`glass sheets apart a desired amount to define multiple
`appropriate interpane cavities or spacings. The sheets, so
`adhered together and interspaced apart, form multiple empty
`cells with interpane cavities between the rear sheet and the
`front sheet or substrates and bounded by the perimeter seal.
`An electrolyte or monomer composition is then filled into
`the cavities via a respective aperture provided in the perim
`eter material or seal. Such as via a vacuum fill process. The
`sheets may then be scribed and cut or broken to separate the
`individual shapes or cells from the sheets. Alternately, and
`optionally, the sheets may be scribed and cut or broken to
`form multiple empty cells prior to the filling process,
`whereby each individual shape or cell is filled after it is cut
`or separated from the sheets.
`Optionally, a single front sheet (that may eventually form
`at least two front substrates, and more preferably multiple,
`Such as four or six or more, Substrates) may be adhered to
`the rear sheet. The front sheet may be coated on its opposing
`surface (the surface that opposes the rear sheet when the
`sheets are sandwiched together) with a transparent electri
`cally conductive or semiconductive layer or coating. Such as
`an indium tin oxide (ITO) or the like. The front mirror
`shapes or Substrates may be scribed and broken and/or cut
`from the front sheet to form the cells after the sheets have
`been adhered together as described above. Optionally, the
`front substrates (with the transparent semi-conductive layer
`or coating applied to the Surface thereof) may be pre-cut or
`formed and the individual coated mirror shapes or substrates
`may be applied to the appropriate locations at the epoxy
`seals on the rear sheet. The rear sheet may then be scribed
`and broken and/or cut to form the mirror cells.
`The sheet or sheets thus may form at least two reflective
`element assemblies or cells. Because the sheet is large
`enough to have two or more mirror shapes defined thereon,
`the sheet may be handled along its edges by the conveyor
`and/or operators and, thus, may be handled in an area that is
`outside of the pristine cell surfaces within the epoxy seals/
`mirror shapes. The handling or conveying of the sheet thus
`does not encroach the pristine Surfaces and thus does not
`damage or harm the pristine Surfaces during the manufac
`turing and assembling of the cells. The method of the present
`invention thus provides an enhanced manufacturing process
`that limits or Substantially precludes touching or harming of
`the pristine Surfaces of the mirror shapes during the clean
`ing, coating, conveying and adhering processes. Also,
`because the sheets are larger than the individual Substrates,
`
`SUMMARY OF THE INVENTION
`
`40
`
`The present invention provides a method of making
`automotive electrochromic reflective cell element assem
`blies for automotive rearview mirror assemblies by first
`forming multiple interpane cavities on one or two sheets of
`glass and, thereafter, after the multiple electrochromic cell
`45
`cavities have been formed, cutting out individual electro
`chromic mirror cells that are shaped appropriate for utiliza
`tion in a complete automotive electrochromic rearview
`mirror assembly, such as the types described in U.S. Pat.
`Nos. 6,595,649; 6,648,477; 6,154,306; 5,610,756; 5,406,
`414; and/or 5.253,109, which are hereby incorporated herein
`by reference. Typically, the material for the substrates is
`glass, such as Soda-lime glass or the like, but other materials,
`Such as polycarbonate or other polymeric materials may be
`utilized without affecting the scope of the present invention.
`The completed mirror cells or reflective element assemblies
`include a front substrate and a rear substrate. The rear
`Substrate may have a reflective coating on its front Surface
`(toward the front substrate when the substrates are sand
`wiched together, and typically referred to as the third surface
`of the mirror reflective element assembly), while the front
`Substrate may have a transparent semiconductive coating,
`Such as a coating of indium tin oxide (ITO) or doped indium
`tin oxide or the like, on its rear surface (toward the rear
`Substrate when the Substrates are sandwiched together, and
`typically referred to as the second surface of the mirror
`reflective element assembly).
`
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`Motherson Exhibit 1004, Page 53
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`

`

`5
`economies in the coating process may be realized, since
`multiple mirror shapes may be coated during one coating
`process and without individual fixturing of the mirror
`shapes.
`The present invention also provides a means for masking
`a Substrate during the coating process to provide a window
`in the metallic reflective coating on a third surface of a
`reflective element assembly. The mask may be retained in
`the appropriate position via magnetic attraction to a mag
`10
`ne