(19) United States
`(12) Patent Application Publication (10) Pub. No.: US 2004/0264011 A1
`Lynam
`(43) Pub. Date:
`Dec. 30, 2004
`
`US 2004O264O11A1
`
`(54) MIRROR REFLECTIVE ELEMENT
`(75) Inventor: Niall R. Lynam, Holland, MI (US)
`Correspondence Address:
`VAN DYKE, GARDNER, LINNAND
`BURKHART, LLP
`2851 CHARLEVOIX DRIVE, S.E.
`P.O. BOX 888695
`GRAND RAPIDS, MI 49588-8695 (US)
`(73) Assignee: DONNELLY CORPORATION, Hol
`land, MI (US)
`(21) Appl. No.:
`10/709,434
`(22) Filed:
`May 5, 2004
`Related U.S. Application Data
`(60) Provisional application No. 60/471,872, filed on May
`20, 2003.
`
`Publication Classification
`
`(51) Int. Cl." ....................................................... GO2B 5/08
`(52) U.S. Cl. .............................................................. 359/866
`
`(57)
`
`ABSTRACT
`
`A reflective element for a mirror assembly for a vehicle
`includes a Substrate and a functional or anti-abrasion film
`applied to an exterior Surface of the Substrate. The Substrate
`comprises a polymeric resin material, Such as a transparent
`optical polymeric resin material. The functional or anti
`abrasion film may comprise a glass material and may have
`a thickness of less than approximately 0.8 mm. The anti
`abrasion film is flexible to conform to the exterior Surface of
`the substrate. The flexible film may be unrolled from a reel
`or roll and applied to the exterior Surface of an 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 sheet of molded or extruded or
`cast Substrate material.
`
`
`
`SMR USA
`Exhibit 1036
`Page 001
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 1 of 3
`
`US 2004/0264.011 A1
`
`
`
`
`
`©N,
`ÇXXXXXXXXXX?
`
`CXXXXXXXXXXX
`
`
`
`
`
`
`
`ZZZZZZZZZ
`
`SMR USA
`Exhibit 1036
`Page 002
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 2 of 3
`Fig. 3
`l6a
`
`&
`,
`l
`6
`
`18
`
`US 2004/0264.011 A1
`
`22
`2-1 18
`2O
`
`8
`
`| 9a
`
`22
`
`Ses-e-a-s-s-s-s-s-A
`Ele=-E-21
`S-
`
`2O
`
`182
`
`l8
`
`F 6. 2
`
`8c
`
`TTT
`
`| 8
`
`F.C. 1
`
`8o
`
`f
`184
`
`122
`
`3b V
`8e
`
`2O
`
`SMR USA
`Exhibit 1036
`Page 003
`
`

`

`Patent Application Publication Dec. 30, 2004 Sheet 3 of 3
`
`US 2004/0264.011 A1
`
`2: [
`
`XXXX&&&&
`
`××××××XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX2222222;
`
`zzZ ' ? ' +Tog!
`
`bl
`
`
`
`
`
`
`
`SMR USA
`Exhibit 1036
`Page 004
`
`

`

`US 2004/0264.011 A1
`
`Dec. 30, 2004
`
`MIRROR REFLECTIVE ELEMENT
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`0001. The present application claims the benefit of U.S.
`provisional application Ser. No. 60/471,872, filed May 20,
`2003 (Attorney Docket DONO1 P-1092), which is hereby
`incorporated herein by reference in its entirety.
`
`FIELD OF THE INVENTION
`0002 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
`comprising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`Typically, mirror reflective elements are formed of
`0.003
`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. Polymeric 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 refer
`ence. 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.
`0004. 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 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 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.
`0005 Therefore, there is a need in the art for a mirror
`reflective element that overcomes the shortcomings of the
`prior art elements and Substrates.
`
`SUMMARY OF INVENTION
`0006 The present invention provides a molded wide
`angle or multi-radius Substrate for a reflective element. The
`molded Substrate comprises a polymeric optical resin trans
`parent material and has a curved exterior Surface, which may
`have a less curved/flatter or substantially flat inboard portion
`
`or Surface 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 Surface or first Surface to provide Substantial pro
`tection 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.
`0007 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 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 the wide angle Substrate. The glass film
`comprises a glass material and has a thickness of less than
`approximately 0.8 mm.
`0008 According to another aspect of the present inven
`tion, a reflective element for a mirror assembly for a vehicle
`comprises a Substrate having an exterior Surface, and an
`anti-abrasion film applied to the exterior Surface. The Sub
`Strate comprises a polymeric resin material, Such as a
`transparent optical polymeric resin material. The anti-abra
`Sion film preferably 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.
`0009. The substrate may be cut from a strip or sheet of
`molded or 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 then be cut or otherwise formed
`from the elongated Strip or sheet.
`0010. 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.
`0011. 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 poly
`meric reflective 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 mul
`tilayer, high reflective mirror film comprising multiple coex
`trusion of many plastic layers to form a highly reflective
`mirror film.
`0012 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/transpar
`ency of the Substrate material is not necessary.
`0013. According to another aspect of the present inven
`tion, a method for forming a reflective element Substrate for
`a mirror assembly of a vehicle comprises generally continu
`
`SMR USA
`Exhibit 1036
`Page 005
`
`

`

`US 2004/0264.011 A1
`
`Dec. 30, 2004
`
`ously 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 Substrate material may comprise a transpar
`ent optical polymeric 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 ele
`ment 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.
`0.014. 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
`curved exterior Surface.
`0.015 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 and conformable to a bent substrate)
`for unrolling the reflective film as the film is generally
`continuously applied to the Surface of the generally continu
`ously formed sheet or Strip.
`0016. 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 exterior 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 reflective film or layer laminated or applied to
`the inner Surface opposite the exterior Surface.
`0.017. 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.
`BRIEF DESCRIPTION OF DRAWINGS
`FIG. 1 is a perspective view of an exterior rearview
`0.018
`mirror assembly in accordance with the present invention;
`0.019
`FIG. 2 is a perspective view of a wide angle or
`multi-radius reflective element in accordance with the
`present invention;
`0020 FIG. 3 is a sectional view of the wide angle or
`multi-radius reflective element taken along the line III-III in
`FIG. 2;
`0021 FIG. 4 is a sectional view similar to FIG. 3,
`showing a wide angle or multi-radius reflective element in
`accordance with the present invention with a reflective film
`or layer applied to the exterior Surface of the element and an
`anti-abrasion film or layer applied over the reflective film or
`layer;
`0022 FIG. 5 is a diagram showing the extruding, coating
`and cutting processes for manufacturing a prismatic mirror
`reflective element in accordance with the present invention;
`
`0023 FIG. 5A is an elevation of the extruder of FIG. 5,
`showing the wedge shape of the extruded Strip and reflective
`element Substrate;
`0024 FIG. 6 is a plan view of the extruded strip showing
`the cut out shapes of the reflective element cut from the
`extruded Strip;
`0025 FIG. 7 is a sectional view of the reflective element
`formed by the process shown in FIG. 5; and
`0026 FIG. 8 is a diagram showing an alternate process
`for manufacturing 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.
`
`DETAILED DESCRIPTION
`0027 Referring now to the drawings and the illustrative
`embodiments depicted therein, an exterior rearview mirror
`assembly 10 includes a reflective element 12 mounted at a
`casing 14, which is mounted at an exterior portion of a
`vehicle 16 (FIG. 1). Reflective element 12 may provide an
`enhanced field of view or wide angle field of view to a driver
`or occupant of the vehicle and may comprise a single
`reflective element substrate 18 having an inner Surface 18a
`and an opposite exterior surface 18b (FIGS. 2 and 3). The
`exterior surface 18b comprises a less curved or substantially
`flat inboard portion or surface 18c and a more curved
`outboard portion or Surface 18d, as discussed below. The
`Substrate 18 may have an anti-abrasion coating or layer or
`film 20, Such as an ultrathin glass coating or layer or film,
`laminated or deposited or otherwise applied to the exterior
`Surface 18b, and may have a reflective coating or layer 22
`laminated or applied to the inner Surface 18a, as also
`discussed below. Aspects of the reflective element of the
`present invention may be 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 rear
`view mirror assembly (not shown).
`0028 Reflective element 12 may comprise an aspheric or
`multi-radius or wide angle Single element reflective element
`substrate. The reflective element 12 may provide a field of
`View Similar to the plano-auxiliary reflective element assem
`bly disclosed in U.S. Pat. Nos. 6,522,451 and 6,717,712,
`which are hereby incorporated herein by reference.
`0029. The substrate 18 of the reflective element 12 of the
`present invention may be formed (Such as by casting,
`extrusion or injection molding) of a polymeric optical resin
`material, Such as an acrylic or polycarbonate resin, a poly
`olefin, a cyclic olefin copolymer, Such as a COC resin known
`as “TOPAS' and available from Ticona of Summit, N.J.
`(Such as a resin of the type described in U.S. pat. application,
`Ser. No. 09/946,228, filed Sep. 5, 2001 for IMPROVED
`PLASTIC SUBSTRATE FOR INFORMATION DEVICE
`AND METHOD FOR MAKING SAME (Attorney Docket
`DONO3 P-910), which is hereby incorporated herein by
`reference) or the like. Because the Substrate can be, for
`example, injection molded from an optical resin, the Sub
`Strate may be molded or formed to a desired shape having a
`wide angle or multi-radius Surface, which is typically chal
`lenging to accomplish with glass sheets. This is because any
`prescription or form for the Substrate can be established in
`an injection mold by machining, Such that when the injection
`
`SMR USA
`Exhibit 1036
`Page 006
`
`

`

`US 2004/0264.011 A1
`
`Dec. 30, 2004
`
`mold is filled with molten injected optical resin material, the
`optical resin material takes the shape of the mold. Thus, for
`example, a Substrate having a Substantially or fully flat
`inboard region for a multi-radius (often referred to as an
`aspheric) exterior mirror element is fully practical.
`0030. As shown in FIGS. 1-3, inboard portion or surface
`18c of exterior surface 18bis positioned at or toward the side
`of the reflective element that is toward the side body of the
`vehicle when the mirror assembly is mounted to or attached
`to the vehicle. The inboard portion 18c of Surface 18b of
`substrate 18 may comprise a substantially flat or slightly
`curved or less curved Surface, Such as a Surface having a
`radius of curvature of preferably greater than at least
`approximately 4000 mm, more preferably greater than at
`least approximately 9000 mm, and most preferably greater
`than at least approximately 12000 mm. The inboard surface
`18c may provide a field of view of up to approximately 10
`degrees, preferably up to approximately 15 degrees, and
`more preferably up to approximately 20 degrees.
`0.031
`Outboard portion or surface 18d of exterior surface
`18b of Substrate 18 is positioned outward from inboard
`portion and is thus further away from the side body of the
`vehicle when the mirror assembly is mounted to or attached
`to the vehicle. Outboard portion 18d of exterior surface 18b
`may be a more conveX or curved Surface, Such that the
`Substrate comprises a wide angle or multi-radius exterior
`Surface Substrate. The more curved outboard Surface 18d of
`the Substrate may have radii of curvature in the range of less
`than about 4000 mm to about 100 mm or lower. The more
`curved outboard portion or surface 18d may provide an
`extended field of view when combined with the less curved
`inboard portion or surface 18c. For example, the combined
`field of view of the mirror reflective element 12 may be
`preferably greater than at least approximately 25 degrees,
`more preferably greater than at least approximately 35
`degrees, and most preferably greater than at least approxi
`mately 45 degrees. The substrate may be formed to have
`curves or shapes or to provide other field of views, without
`affecting the Scope of the present invention.
`0032) The exterior surface 18b of substrate 18 may be
`coated or covered with a Substantially transparent functional
`film or layer 20, Such as an anti-abrasion film or layer, Such
`as an ultrathin glass film or layer or sheet having a thickneSS
`of preferably less than or equal to approximately 0.8 mm,
`more preferably less than or equal to approximately 0.5 mm,
`and most preferably less than or equal to approximately 0.3
`mm. The ultrathin glass film or layer or sheet 20 provides a
`flexible glass film which can be conformed to the exterior
`Surface of the molded Substrate (for example, Such as
`described in U.S. Pat. No. 5,085,907, which is hereby
`incorporated herein by reference) after the Substrate is
`molded. The ultrathin glass film or layer may provide
`Substantial protection against Scratches on the outboard
`Surface, Such as may occur due to impact by debris at the
`outside of the vehicle (for exterior mirror assembly appli
`cations) or by use of ice Scrapers and the like on the glass
`Surface and the like. The ultrathin glass film or layer may be
`applied to a molded or extruded Strip (Such as described
`below with respect to FIGS. 5-8) or may be applied to the
`Surface or Surfaces of a formed or cut Substrate, without
`affecting the scope of the present invention. The flexible
`ultrathin glass film or layer of the present invention allows
`the wide angle or multi-radius Substrate to be molded in the
`
`desired shape out of a transparent acrylic resin material, yet
`may conform to the curved or multi-radius or aspheric shape
`and provide enhanced protection or Scratch resistance to the
`Substrate.
`0033. It is envisioned that other functional films or hard
`coats or anti-abrasion films or the like may be applied to the
`exterior Surface of the molded Substrate, Such as via adher
`ing or applying a film to the exterior Surface or via dip
`coating or vacuum deposition or the like. Optionally, a
`hydrophobic film or hydrophilic film or element or property
`may also or otherwise be applied to the exterior surface 18b
`of the substrate. Optionally, the functional film may com
`prise a non-glass or polymeric film, Such as a polymeric
`material that is a harder and/or different property material
`than the substrate itself. Optionally, the anti-abrasion film
`may be formed of the same resin material as the Substrate to
`match the coefficients of thermal expansion and thus reduce
`thermal expansion/contraction mismatches between the
`materials.
`0034.
`Optionally, the inner or rear surface 18a of the
`substrate 18 may have a reflective layer or coating or film or
`sheet 22 laminated or otherwise applied thereto. For
`example, the reflective layer or film 22 may comprise a
`polymeric reflective film 22 laminated or otherwise adhered
`or applied to the rear or inner surface 18a of a molded or
`extruded or cast Strip (Such as described below with respect
`to FIGS. 5-8) or of the molded or formed substrate 18.
`Reflective film 22 may comprise a polymeric reflective film,
`Such as an all polymer-thin-film multilayer, high reflective
`mirror film, Such as a multilayer, non-metallic reflective film
`which may comprise multiple coextrusion of many plastic
`layers to form a highly reflective mirror film, Such as
`described in U.S. Pat. Nos. 3,773,882; 3,884,606; and 3,759,
`647, which are hereby incorporated herein by reference.
`Such a reflective film thus may comprise multilayers of
`polymer materials to form a highly reflective mirror film,
`such as a Radiant Light Film, a Radiant Mirror Film or a
`Radiant Color Film, such as commercially available from
`3M of St. Paul, Minn., Such as a Radiant Color Film CM590
`or CM500. Also, a durable metallized polymeric mirror
`layer can be used, such as described in U.S. Pat. No.
`5,361,172, which is hereby incorporated herein by reference.
`0035. As shown in FIG.4, it is envisioned that a substrate
`or substrate shape or sheet or strip of substrate material 118
`may have a reflective film or layer 122 adhered or laminated
`or otherwise applied to the exterior surface 118b of the
`substrate material. An anti-abrasion film or layer 120 (which
`may comprise an ultrathin glass film or layer as described
`above) may be adhered or laminated or otherwise applied to
`the reflective film or layer 122. In such an application, with
`the reflective layer on the front or exterior surface of the
`substrate, the substrate material may be molded or formed of
`a polymeric material that does not provide optical clarity and
`need not be transparent. The Substrate material may act only
`as a Support or backing plate for the reflective film or layer
`and the anti-abrasion film or layer and thus may be opaque
`or non-transparent. The exterior surface 118b of substrate
`material 118 may comprise a wide angle exterior Surface or
`a multi-radius exterior Surface having a less curved inboard
`portion or surface 118c and a more curved outboard portion
`or surface 118d, such as discussed above with respect to
`Substrate 18.
`
`SMR USA
`Exhibit 1036
`Page 007
`
`

`

`US 2004/0264.011 A1
`
`Dec. 30, 2004
`
`0036) Optionally, and such as shown in FIGS.5, 6 and 8,
`the optical resin material may be molded or extruded or cast
`into a generally continuous Strip 19 having the desired
`curved or multi-radius Surfaces, and may be cut to form the
`Substrates. The Substrates may be cut from the Strip via any
`known cutting process, Such as via a laser cutting proceSS or
`a water-jet cutting proceSS or the like, without affecting the
`Scope of the present invention.
`0037. As shown in FIGS. 5-8, the molding processes and
`film or layer application processes of the present invention
`may be used to form a prismatic or wedge-shaped Strip for
`forming prismatic or wedge-shaped substrates 18' (FIG. 7)
`for use in an interior rearview mirror assembly of a vehicle.
`0038. As also shown in FIGS. 5-8, the substrate material
`or optical resin material may be extruded or cast to form the
`continuous Strip or sheet 19. For example, and as shown in
`FIGS. 5 and 5A, the strip 19 may be extruded by an extruder
`24, which, preferably continuously, extrudes the optical
`resin material through an extrusion nozzle 26. The extruded
`material may be moved through an annealing lehr 28 to
`reduce or Substantially eliminate birefringence, striation,
`StreSS and/or distortion in the Strip or Substrates. The coat
`ings or layerS or films 20 and/or 22 may be applied to one
`or both Surfaces of the Strip or Substrate after the annealing
`process. The Strip 19 may then be cut, Such as via laser
`cutting or water-jet cutting devices or processes 30, or via
`other forming processes, to form the Substrates 18' after the
`films or coatings have been applied thereto.
`0039. Optionally, and as shown in FIG. 8, the strip 19 of
`optical polymeric resin material may be cast by a caster 32,
`which deposits the molten polymer or resin material onto a
`float Section 34, Such as a heated plate or heated melt. The
`float Section 34 may be angled to form the wedge-shaped
`Strip as the Strip or ribbon of cast molten polymer Solidifies
`as it passes across the hot float Section (it is also envisioned
`that the float may provide a curved surface to form the
`curved outboard Surface of the Substrate). The coatings or
`layers or films 20, 22 may be applied to the Solidified strip
`and the strip may be cut to form the substrates after the
`coatings or layers or films have been applied thereto.
`0040. Because the films or layers are flexible, it is envi
`Sioned that the anti-abrasion film or ultrathin glass film
`and/or the reflective polymeric film may be unwound or
`unrolled and applied along the generally continuously
`extruded or cast Substrate material or strip 19. For example,
`and as shown in FIGS. 5-8, the ultrathin glass film (or other
`outer layer anti-abrasion coating or film) 20 may be pro
`vided in a reel or roll form or strip 20a and may be unwound
`or unrolled and laminated or otherwise adhered or applied
`along the exterior surface 19b of the extruded or caststrip 19
`of Substrate material. Likewise, the reflective polymeric film
`22 may be provided in a reel or roll form or strip 22a and
`may be attached or applied to the inner surface 19a of the
`Substrate material Strip 19, Such as via laminating or adher
`ing or otherwise applying the film to the Substrate material,
`Such as by using optical adhesive and/or via rolling or
`ironing the film or sheet (preferably at an elevated tempera
`ture and with vacuum assist) onto the Substrate or Strip
`Surface, to Secure the reflective film to the Substrate or
`extruded or cast Strip or sheet.
`0041) Optionally, the glass film or layer or sheet (or reel
`or roll of glass sheet or strip) may be coated with a highly
`
`reflective metallic layer, Such as Silver or aluminum or the
`like, deposited on or applied to its inner Surface (i.e., the
`Surface which is adhered to or otherwise applied to the
`substrate or substrate sheet or strip). The reflective layer or
`coating may be applied to the glass film or layer with or
`without transparent overcoats. The glass film thus may
`provide the reflective layer at the exterior Surface of the
`Substrate, Such that the reflective layer provides the Second
`layer or surface, with the substrate behind the reflective
`layer. The glass sheet or film may thus be provided with the
`reflective mirror coating already applied thereto. The glass
`layer with reflective layer or coating applied thereto may be
`provided in a reel or roll form for applying both the
`reflective layer and the anti-abrasion layer to the exterior
`Surface of the Substrate or SubStrate Strip or sheet in one
`application process. In Such an application, the Substrate
`material need not comprise a transparent optical resin mate
`rial, and a separate reflective layer or film or coating would
`not be necessary at the inner or rear Surface of the Substrate.
`0042. It is envisioned that other hard coats or films or the
`like may be applied to one or more Surfaces of the molded
`Substrate Strip or to the molded and cut Substrates, Such as
`Via dip coating or vacuum deposition or the like, without
`affecting the Scope of the present invention. The other hard
`coats or films may be substantially flexible and may be
`applied via unrolling of a reel of an anti-abrasion film or
`sheet and applying the film or sheet to a Surface of an
`extruded or cast Strip of transparent acrylic resin or the like,
`as discussed above. Optionally, a hydrophobic film or hydro
`philic film or element or property may also or otherwise be
`applied to (or sprayed on) one or both surfaces 18a, 18b of
`the Substrate or strip or sheet. Optionally, one or both of the
`reflective polymeric film 22 and the anti-abrasion film 20
`may be formed of the same resin material as the Substrate 18,
`18" or substrate strip 19 to match the coefficients of thermal
`expansion and thus reduce thermal expansion/contraction
`mismatches between the materials.
`0043. Optionally, it is envisioned that such ultrathin glass
`films, anti-abrasion films, reflective films or reflective sys
`tems may be used for electrochromic mirror reflective
`elements or cells as well. For example, the interior or
`exterior rearview mirror assembly of the present invention
`may comprise an electrochromic mirror, Such as an electro
`chromic mirror assembly and electrochromic element uti
`lizing principles disclosed in commonly assigned U.S. Pat.
`Nos. 5,140.455; 5,151,816; 6,690,268; 6,178,034; 6,154,
`306; 6.002,544; 5,567,360; 5,525,264; 5,610,756; 5,406,
`414, 5,253,109; 5,076,673; 5,073,012; 5,117,346; 5,724,
`187; 5,668,663; 5,910,854; 5,142,407 and/or 4,712,879,
`which are hereby incorporated herein by reference, and/or as
`disclosed in the following publications: N. R. Lynam, “Elec
`trochromic Automotive Day/Night Mirrors”, SAE Technical
`Paper Series 870636 (1987); N. R. Lynam, “Smart Windows
`for Automobiles”, SAE Technical Paper Series 900419
`(1990); N. R. Lynam and A. Agrawal, “Automotive Appli
`cations of Chromogenic Materials, Large Area Chromoge
`nics: Materials and Devices for Transmittance Control, C.
`M. Lampert and C. G. Granquist, EDS., Optical Engineering
`Press, Wash. (1990), which are hereby incorporated by
`reference herein. The mirror assembly may comprise an
`interior rearview mirror assembly, and may include an
`accessory module or may be mounted to an accessory
`module, Such as an accessory module of the types disclosed
`in U.S. pat. application Ser. No. 10/355,454, filed Jan. 31,
`2003 for VEHICLE ACCESSORY MODULE (Attorney
`Docket DONO1 P-1050), which is hereby incorporated
`herein by reference.
`
`SMR USA
`Exhibit 1036
`Page 008
`
`

`

`US 2004/0264.011 A1
`
`Dec. 30, 2004
`
`0044 Optionally, the mirror assembly may include one or
`more displays for displaying information to a driver of the
`vehicle at or through the reflective element of the mirror
`assembly. For example, the mirror assembly may include
`one or more displays of the types described in U.S. Pat. Nos.
`6,329,925; 6,501,387; 6,690,268; 5,910,854; 6,420,036;
`5,668,663; and 5,724,187, and/or in U.S. pat. application
`Ser. No. 10/054,633, filed Jan. 22, 2002 by Lynam et al. for
`VEHICULAR LIGHTING SYSTEM (Attorney Docket
`DONO1 P-962); and Ser. No. 10/456,599, filed Jun. 6, 2003
`by Weller et al. for INTERIOR REARVIEW MIRROR
`SYSTEM WITH COMPASS (Attorney Docket DONO1
`P-1076), and/or in PCT Application No. PCT/US03/29776,
`filed Sep. 19, 2003 by Donnelly Corporation et al. for
`ELECTROCHROMIC MIRROR ASSEMBLY (Attorney
`Docket DONO1 FP-1109(PCT)); PCT Application No. PCT/
`US03/35381, filed Nov. 5, 2003 by Donnelly Corporation et
`a1 for ELECTRO-OPTIC REFLECTIVE ELEMENT
`ASSEMBLY (Attorney Docket DONO1 FP-1116(PCT));
`and/or PCT Application No. PCT/US03/40611, filed Dec.
`19, 2003 by Donnelly Corporation et al. for ACCESSORY
`SYSTEM FOR VEHICLE (Attorney Docket DONO1
`FP-1123(PCT)), and/or in U.S. provisional applications, Ser.
`No. 60/508,086, filed Oct. 2, 2003 by Schofield for MIR
`ROR REFLECTIVE ELEMENT ASSEMBLY INCLUD
`ING ELECTRONIC COMPONENT (Attorney Docket
`DONO1 P-1113); Ser. No. 60/525,952, filed Nov. 26, 2003
`by Lynam for MIRROR REFLECTIVE ELEMENT FOR A
`VEHICLE (Attorney Docket DONO1 P-1130); Ser. No.
`60/471.546, filed May 19, 2003 (Attorney Docket DONO1
`P-1093); Ser. No. 60/525,537, filed Nov. 26, 2003 (Attorney
`Docket DONO1 P-1129); and Ser. No. 60/556,259, filed Mar.
`25, 2004 (Attorney Docket DONO1 P-1147), which are all
`hereby incorporated herein by reference, without affecting
`the Scope of the present invention.
`0.045
`Optionally, the mirror assembl