WO 2006/124682
`
`PCT/US2006/018567
`
`viewing area for viewing the blind spot area at the side and rearward of the vehicle, while the
`
`primary or central region of the reflective element provides a generally planar reflective
`
`surface for viewing rearward and sideward of the vehicle mirror.
`
`[00132}
`
`The reflective element 31 O' includes a perimeter band 3261 around the perimeter of the
`
`reflective element and a perimeter band portion 326a1 inboard of a wide angle area or region
`
`352 at the reflective element and around an inboard perimeter region of the wide angle
`
`reflector 350. The perimeter band thus separates and/or demarcates the wide angle reflective
`
`portion from the generally planar reflective portion of the reflective element, and may
`
`conceal or hide the edges of the wide angle reflector. As can be seen with reference to FIG.
`
`13, the perimeter band 326' is disposed on the second surface 312a of the front substrate 312
`
`and generally at or along the perimeter seal 322 of the reflective element 310', while the
`
`perimeter band portion 326a' is disposed on the second surface 312a and inboard of the seal
`
`322 to generally outline/demarcate an inner perimeter of the wide angle reflector 350. The
`
`perimeter band portion 326a' may have generally the same width as the perimeter band 326',
`
`or may have a reduced width or narrow width to reduce the effect on the viewing area of the
`
`reflective element.
`
`[00133]
`
`Wide angle reflector 350 is positioned at the rear (or fourth) surface 314b of rear
`
`substrate 314 and may be adhered to rear surface 314b and generally behind the wide angle
`
`area 352 defined by the perimeter band 326' and perimeter band portion 326a'. In the
`
`illustrated embodiment, wide· angle reflector 350 comprises a substantially clear, transparent
`
`optical plastic member 354 {such as, for example, an acrylic or polycarbonate or COC or
`
`CR39 or the like) and a reflective coating or layer or adhesive or film 356. Optical plastic
`
`men:iber 354 has a substantially flat mating surface 354a and a curved face 354b opposite to
`
`the mating face 354a. Reflective ~lm 356 maybe adhered or otherwise attached to curved
`
`face 354b so as to establish a curved reflective surface 356a. Wide angle reflector 350 may
`
`be adhered to or otherwise attached to rear surface 314b of rear substrate 314, such as via an
`
`optical adhesive 358, such as an optical epoxy or acrylic material. The optical adhesive may
`
`be substantially optically matched to the reflective element substrates, so that the refractive
`
`index of the optical adhesive is substantially similar to the refractive index of the glass
`
`substrate (such as at about 1.52 refractive index), such as by utilizing aspects of the reflective
`
`element described in U.S. pat. application, Ser. No. 10/993,302, filed Nov. 19, 2004
`
`(Attorney Docket DONO! P-1186), which is hereby iµcorporated herein by referenc~ in its
`
`entirety.
`
`-44-
`
`SMR USA
`Exhibit 1006
`Page 0860
`
`

`

`WO 2006/124682
`
`PCT /US2006/018567
`
`[00134]
`
`Thus, the wide angle reflector may be positioned at the rear surface of the reflective
`
`element and may reflect light from a wide angle view to the driver of the vehicle to assist the
`
`driver in viewing the blind spot area at the side of the vehicle. The reflective element may
`
`comprise an electro-optic reflective element with a transparent conductive coating or layer
`
`318 at the rear surface 312a of the front substrate 312 and a third surface reflective coating or
`
`layer (or layers) 320b at the front surface 314a of the rear substrate 314, and with an electro(cid:173)
`
`optic or electrochromic medium 316 disposed therebetween. As can be seen in FIG. 13, the
`
`third surface reflective coating or layer 320b (such as a layer of chromium or ruthenium or
`
`rhodium or ruthenium/chromium or rhodium/chromium or other suitable layer or coating)
`
`may be removed or not established at the wide angle reflector area, and a transparent
`
`conductive coating or layer 320a may be disposed over the third surface, including the wide
`
`angle reflector area, so that the electro-optic feature may function in that area. A window or
`
`port or non-reflective region 321 thus may be formed in the third surface reflector (so as to
`
`provide a window or area that is substantially devoid of the reflective coating or coatings) to
`
`enhance the light transmissivity therethrough (such as by ablating or masking the area to
`
`remove or not establish the reflective coating or coatings at the wide angle reflector area).
`
`The front surface of the rear substrate thus may have the transparent conductive coating 320a
`
`over its entire surface, with the wide angle reflector area being masked during the deposition
`
`or coating of the third surface reflective coating or coatings so that the reflective coatings are
`
`not deposited or established at the wide angle viewing area ( or the reflective coatings may be ·
`
`removed or ablated after the coating process). The wide angle reflector thus may be disposed
`
`behind the electro-optic medium so as to provide the wide angle reflective field of view
`
`through the electro-optic medium.
`
`[00135]
`
`Optionally, the perimeter seal may be disposed around the perimeter of the reflective
`
`element and along the wide, angle perimeter band portion 326a' so that the wide angle area
`
`3 52 is devoid of the electro-optic medium ( and may be d~void of the third surface reflector
`
`layers or coatings in that area as well) to enhance light transmissivity through the reflective
`
`element in the wide angle viewing area. In such an application, the transparent conductive
`
`coating may also be removed from the wide angle reflector area, such that the coatings or
`
`layers in that area may be readily removed or not established, such as by laser ablating or
`
`masking or the like.
`
`[00136]
`
`Optionally, the perimeter band (and/or any indicia or display elements or the like as
`
`described above) may be established at a rear surface of a curved or bent substrate, such as
`
`for a passenger-side exterior mirror of a vehicle. For example, and with reference to FIG. 14,
`-45-
`
`SMR USA
`Exhibit 1006
`Page 0861
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`a curved reflective element 410 includes a bent or curved substrate 412 (such as a convex or
`
`aspheric substrate) and a reflective· coating or layer 418 disposed or established at the rear
`
`surface 412a of substrate 412. A perimeter border or band 426 (such as chromium or other
`
`suitable material) may be disposed around the perimeter region of the reflective element, such
`
`as directly on the rear surface of the substrate 412 (as shown in FIG. 14) or over the reflective
`
`coating at the perimeter region (so that the reflective coating is between the perimeter band
`
`and the rear surface of the substrate), such as described above.
`
`[00137]
`
`The reflective coating or layer may comprise a metallic reflective material or may
`
`comprise transflective materials, such as a silicon or indium/silver material or an interference
`stack, such as an Si02/Ti02/Si02 stack oflayers or the like (such as by utilizing aspects of the
`reflective elements described in PCT Application No. PCT/US03/29776, filed Sep. 9, 2003
`
`by Donnelly Corp. et al. for MIRROR REFLECTIVE ELEMENT ASSEMBLY (Attorney
`
`Docket DONOi FP-1109(PCT)); and/or PCT Application No. PCT/US03/35381, filed Nov.
`
`5, 2003 by Donnelly Corp. et al. for ELECTRO-OPTIC REFLECTIVE ELEMENT
`
`ASSEMBLY (Attorney Docket DONOl FP-1116(PCT)); and/or U.S. pat. applications, Ser.
`
`No. 11/021,065, filed Dec. 23, 2004 by McCabe et al. for ELECTRO-OPTIC MIRROR
`
`CELL (Attorney Docket DONOl P-1193); Ser. No. 10/528,269, filed Mar. 17, 2005
`
`(Attorney Docket DONOl P-1109); Ser. No. 10/533,762, filed May 4, 2005 (Attorney Docket
`
`DONOl P-1116); Ser. No. 10/993,302, filed Nov. 19, 2004 (Attorney Docket DONOl P-
`
`1186), which are hereby incorporated herein by reference in their entireties). As shown in
`
`FIG. 13, a protective coating 438 (such as a lacquer or paint, which may be substantially
`
`transparent if the reflective element is'a transflective reflective element) may be disposed
`
`over the reflective coating 418 to protect the reflective coating.
`
`[00138)
`
`Typically, it is desired that the appearance of the mirror reflective elements of the
`
`exterior rearview mirrors of a vehicle match or substantially match between the driver-side
`
`and passenger-side rearview mirrors of a vehicle, so that, for example, for a vehicle with a
`
`driver-side electro-optic reflective element and a passenger-side non-electro-optic reflective
`
`element, the bleached ( or non-colored or non-darkened) appearance of the driver-side mirror
`
`reflector matches or substantially matches the appearance of the non-electro-optic passenger(cid:173)
`
`side mirror·reflector. A person viewing the vehicle, such as in a vehicle showroom or at a
`
`parking lot or the like, or while the vehicle is being driven along a road;thus may view and
`
`discern that that the mirror reflector at the driver-side mirror matches or substantially matches
`
`the mirror reflector at the passenger-side mirror.
`
`-46-
`
`SMR USA
`Exhibit 1006
`Page 0862
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`[00139]
`
`When both the driver and passenger-side rearview mirrors are selected to have the
`
`same type ofreflective element (such as a frameless electro-optic reflective element using a
`
`border, non-dimming metallic reflective band, such as, for example, a frameless
`
`electrochromic reflective element as described above), such symmetry of appearance is
`
`readily achieved. However, it is not unusual, for economy purposes, to provide an electro(cid:173)
`
`optic reflective element at the driver-side exterior rearview mirror and a non-electro-optic
`
`reflective mirror at the passenger-side exterior rearview mirror. When an electro-optic
`
`driver-side exterior rearview mirror is implemented on a vehicle with a non-electro-optic
`
`passenger-side exterior rearview mirror ( as is often selected to reduce costs associated with
`
`the mirror assemblies of the vehicle), it is still typically desired that the reflective elements of
`
`the side rearview mirrors substantially or fully match in appearance to provide a similar
`
`appearance or style at the mirror at both sides of the vehicle, such as for aesthetic purposes.
`
`Thus, it is desired that the appearance of the non-electro-optic reflective element of the
`passenger-side rearview mirror substantially or fully match the appearance of the electro(cid:173)
`
`optic reflective element of the driver-side rearview mirror, such as when the electro-optic
`reflective element is in its bleached or non-powered or non-darkened state ( such as during
`
`high ambient lighting or daytime lighting conditions).
`
`[001401
`
`The perimeter band material thus may be selected to substantially match the
`
`appearances between the driver-side exterior mirror (which may comprise an electrochromic
`mirror with a perimeter band around the perimeter to conceal the perimeter seal of the
`reflective element) and the passenger-side exterior mirror (which may comprise a non(cid:173)
`
`electrochromic mirror), so that both mirrors provide a similar appearance to the perimeter
`
`band and reflective element. For applications where the perimeter band material of the
`
`electrochromic or driver-side mirror is selected to be the same as the third surface reflector
`
`material, the optical.match (as viewed by a person viewing the reflective element) between
`
`the perimeter band and the third surface reflector is sufficient so that the perimeter band is not
`readily discernible at the mirror reflector. Thus, in such applications, it may not be necessary
`
`to provide a perimeter band on the corresponding conventional (such as chrome or titanium
`
`or "Blue" coated), non-EC passenger-side exterior mirror reflective element.
`
`(00141]
`
`However, even in such applications, the perimeter band at the driver-side mirror may.
`
`be discernible to a person viewing the exterior mirror, even when the perimeter band is
`
`substantially optically matched with the central reflector region of the reflective element.
`
`Thus, in order to at least substantially match the passenger-side non-electro-optic reflective
`
`element with the electro-optic reflective element at the driver-side mirror, a perimeter band or
`-47-
`
`SMR USA
`Exhibit 1006
`Page 0863
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`coating (for example, a layer of chromium or of rhodium or of rhodium/chromium) may be
`
`disposed around the perimeter edge or region of the non-electro-optic reflective element, such
`
`as a curved single substrate reflective element or the like. Thus, when one exterior side
`
`rearview mirror has an electro-optic reflective element (as is typically located at the driver(cid:173)
`
`side of the vehicle) and the other exterior side rearview mirror has a curved reflective element
`
`or non-electro-optic reflective element ( as may be provided at the passenger-side of the
`
`vehicle), a matching perimeter band may be disposed around the non-electro-optic reflective
`
`element so that the perimeter band of the passenger-side mirror matches or substantially
`
`matches the perimeter band of the driver-side mirror (such as by utilizing aspects described in.
`
`U.S. patent application Ser. No. 11/226,628, filed Sep. 14, 2005 (Attorney Docket DONOl P-
`
`1236), which is hereby incorporated herein by reference in its entirety).
`
`[00142]
`
`Such a matching appearance of the non-electro-optic reflective element with the
`
`frameless electro-optic reflective element (with perimeter band as described above) may be
`
`achieved via various processes. For example (and such as described above and shown in
`
`FIG. 14), a perimeter reflective border may comprise a first metallic reflective layer (such as
`
`a metallic border or band, such as a ruthenium metal or the like) and may be disposed around
`
`the perimeter region of the second surface of the curved glass substrate ( such as by sputter
`
`deposition or the like of the border material over the second surface of the substrate while the
`
`central region or primary viewing area of the second surface of the substrate is masked). A
`
`reflective layer or coating of a second metal reflector material ( such as chromium or the like)
`
`may be disposed over the second surface and over the perimeter border or band to provide the
`
`central reflective region with a reflective perimeter border or band for a frameless non(cid:173)
`
`electro-optic reflective element (such as by utilizing aspects described in U.S. patent
`
`applications, Ser. No. 11/226,628, filed Sep. 14, 2005 (Attorney Docket DONOl p:..1236);
`
`Ser. No. 10/533,762, filed May 4, 2005 (Attorney DocketDONOl P-1116); and/or Ser. No.
`
`11/021,065, filed Dec. 23, 2004 (Attorney Docket DONOl P-1193), and/or U.S. provisional
`
`applications, Ser. No. 60/681,250, filed May 16, 2005 (Attorney Docket DONOl P-1221);
`
`Ser. No. 60/690,400, filed Jun. 14, 2005 (Attorney Docket DONOl P-1225); Ser. No.
`
`60/695,149, filed Jun. 29, 2005 (Attorney Docket DONOl P-1227); Ser. No. 60/730,334, filed
`
`Oct. 26, 2005 (Attorney Docket DONOl P-1250); and Ser. No. 60/750,199, filed Dec. 14,
`
`2005 (Attorney Docket DONOl P-1260), which are hereby incorporated herein by reference
`
`in their entireties. Optionally, and desirably, the percent reflectivity of the second metallic
`
`· reflective layer is less than the percent reflectivity of the first metallic reflective layer.
`
`Optionally, the reflective material and thickness of the material layer at the perimeter or
`-48-
`
`SMR USA
`Exhibit 1006
`Page 0864
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`border region of the reflective element may be selected to provide a desired spectral
`
`reflectivity so as to match or substantially match the spectral reflectivity an4 appearance of
`
`the central region or main reflective region or dimming region of the electro-optic reflective
`
`element when the electro-optic reflective element is in its bleached or non-powered or non(cid:173)
`
`darkened/non-colored state.
`
`[00143]
`
`Optionally, the appearance of a matching perimeter band (that matches a perimeter
`
`band of an electro-optic reflective element, such as a perimeter band that substantially
`
`matches the color or tint of the central reflective region of the electro-optic reflective element
`
`when bleached) may be achieved by establishing a demarcation line along and through the
`
`reflective coating of a single substrate, so that the demarcation line appears to be an inward
`
`perimeter edge of a reflective perimeter band or border. For example, and as shown in FIGS.
`
`15A and 15B, a reflective element 510, such as a generally planar reflective element or a
`
`curved reflective element for an exterior rearview mirror, includes a substrate 512 (such as a
`
`glass substrate, such as a generally flat substrate or a bent or curved substrate, such as a
`
`convex or aspheric substrate) and a reflective coating or layer 518 ( such as a mirror reflector
`
`coating or coatings comprising, for example, chromium or titanium or silver or aluminum or
`
`silver alloy or aluminum alloy or a stack oflayers, such as an ITO/silver/ITO stack of layers,
`
`or like) disposed or established at the second or rear surface 512b of substrate 512 ( opposite
`
`the first or front or viewable surface 512a of the substrate 512), such as by sputter deposition
`
`in a vacuum deposition chamber, such as is known in the coating arts. As shown in FIG.
`
`15B, a perimeter or border reflector region 526 may be outlined or demarcated or defined by
`
`a demarcation line 526a established (such as by laser etching or the like) through the
`
`reflective coating or layer 518 at the perimeter region. The reflective element 510 thus has a
`
`central main reflector region 524 and the perimeter or border reflector region 526 separated
`
`or defined or circumscribed by demarcation line 526a.
`
`[00144]
`
`Thus, a mirror substrate or shape (such as a glass substrate or shape) may be cut from
`
`a sheet of glass to the desired mirror shape. The mirror substrate may be uniformly coated
`
`(with no masking) over at least substantially or entirely the second or rear surface of the
`
`substrate to provide a substantially uniform reflective coating or layer at the second surface of
`
`the substrate. Optionally, a sheet of glass or the like may be substantially uniformly coated
`
`over a surface of the sheet, and one ~r more coated mirror substrates or shapes may b~ cut
`
`from the coated glass sheet to provide the mirror substrate with the reflective coating or l~yer
`
`at the second-surface of the substrate. The demarcation line then m~y be established (such as
`
`via laser etching or the like) around the perimeter of the cut and coated substrate so as to
`-49-
`
`SMR USA
`Exhibit 1006
`Page 0865
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`circumscribe and run around substantially or wholly the perimeter region of the cut substrate
`
`or shape. The demarcation line and perimeter or border reflector region and central main
`
`reflector region of the reflective element thus may be established via a single, unmasked
`
`coating process. The demarcation line may be established at a range of about 2 mm to about
`
`5 mm (or more or less) inward from the perimeter cut edge of the substrate, whereby the
`
`width of the demarcation line may be selected to match or substantially match the border or
`
`perimeter band on the electro-optic reflective element at the driver-side mirror.
`
`[00145]
`
`As shown in FIG. lSB, a coating or layer or overcoating 538 (such as a lacquer or
`
`paint or frit or tape or applique or coating) may be disposed over the reflective coating 518 to
`
`cover or coat the rear surface of the reflective element. The coating or layer may be painted
`
`or pad printed or screened or inked or otherwise applied or disposed or established at the rear
`
`surface of the reflective element. Optionally, the coating or layer 538 may be disposed over
`
`the entire rear surface (whereby the coating may provide environmental protection if needed
`
`or desired at and over the metallic layer materials ( such as aluminum or gold or the like) of
`
`the reflective layer or coating, or may be disposed along the demarcation line 526a to
`
`substantially fill in the demarcation line 526a.
`
`[00146]
`
`The paint or coating or layer may be selected to be any desired color or tint so as to
`
`provide the desired edge demarcation of the perimeter or border reflector region 526. For
`
`example, the coating or layer 538 may comprise a dark color, such as black or the like, or
`
`may comprise a light grey or other color or tint, depending on the particular application and,
`
`more particularly, on the color or visibility or viewability of the perimeter band on the
`
`electro-optic reflective element at the driver-side rearview mirror. For example, the darker
`
`the color of the coating or layer or paint, the more readily viewable or discernible the
`
`demarcation line 526a may be to a person viewing the exterior rearview mirror. Thus, it may
`
`be desirable to provide a light grey (or similar or selected pale color or the like) demarcation
`
`line so that·the demarcation line is readily viewable/discernible, but not overly apparent or
`
`dominant at the reflective element.
`
`{00147)
`
`The -viewable width of the demarcation line (the dimension across the demarcation
`
`line when viewed at the reflective element by a person viewing the exterior rearview mirror)
`
`may be selected to provide the desired degree of viewability or discernibility of the
`
`· demarcation.line, so as to give the appearance of an edge of a perimeter band or border
`
`coating. Optionally~ for example, the demarcation line may have a width of preferably less
`
`than approximately 350 microns (one micron being equal to one millionth of a meter), more
`
`preferably less than approximately 250 microns and more preferably less than approximately
`-50-
`
`SMR USA
`Exhibit 1006
`Page 0866
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`1 75 microns. Also, for example, the demarcation line may have a width of preferably greater
`
`than approximately 50 microns, more preferably greater than approximately 75 microns and
`
`more preferably greater than approximately 100 microns. The demarcation line through the
`
`reflective coating at the rear surface of the reflective element thus functions to demarcate a
`
`perimeter border or band so as to provide the appearance of a perimeter band at the border
`
`region of the reflective element that substantially optically matches the central main reflector
`
`region of the reflective element.
`
`[00148]
`
`Although shown and described as a substantially continuous or uninterrupted
`
`demarcation line that circumscribes the perimeter region of the reflective element substrate,
`
`the demarcation line may be formed to only partially circumscribe the perimeter region of the
`
`reflective element substrate, without affecting the scope of the present invention. For
`
`example, the demarcation line may be a line segment around a portion of the perimeter region
`
`of the substrate or the demarcation line may comprise a non-continuous or interrupted
`
`demarcation line (such as a plurality ofline segments or dashes or the like) that extends
`
`partially or entirely around the perimeter region of the mirror substrate.
`
`[00149]
`
`Optionally, and as shown in FIG. 16, a mirror reflective element 510' may have a
`
`mirror reflective coating or reflector 518 and a perimeter or border reflector region 526' and
`
`central main reflector region 524', and a demarcation line 526a', such as described above.
`
`Mirror reflective element 51 O' includes a second demarcation line 526b' established or
`
`formed (such as by laser etching or the like) in and through the reflective coating 518, such as
`
`in a similar manner as described above with respect to demarcation line 526a of reflective
`element 510. In the illustrated embodiment, the second demarcation line 526b' extends along
`the lower perimeter region of the mirror substrate and curves downward_ to the perimeter edge
`
`of the reflective element 510'. Such a second demarcation line may be desirable for a
`
`passenger-side non-electro-optic mirror reflective element so that the non-electro-optic
`
`passenger-side mirror reflective element matches or substantially matches an electro-optic
`
`driver-side mirror reflective element, such as, for example, the driver-side mirror reflective
`
`element supplied by Gentex Corp. of Zeeland, MI for a model year 2006 Audi vehicle. The
`
`mirror reflective element 510' may be otherwise substantially similar to the mirror reflective
`
`element 510 described above, such that a detailed discussion of the mirror reflective elements·
`
`will not be repeated herein.
`
`[00150]
`
`Although shown and described as having the central main reflector region and the
`
`border reflector region (as either defined by a demarcation line.through the reflector coating
`
`or by a separate layer or coating around a perimeter region of the reflective element) at the
`-51-
`
`SMR USA
`Exhibit 1006
`Page 0867
`
`

`

`WO 2006/124682
`
`PCT/US2006/018567
`
`same surface of the electro-optic or non-electro-optic reflective element, it is envisioned that
`
`the border reflector band may be formed or established on the second or rear surface of the
`
`substrate while the central or main reflector coating may be established on the first or front
`
`surface of the substrate (in such an application, masking may be required to form the coatings
`
`at one or both sides of the substrate). Alternately, and optionally, the border reflector band
`
`may be established on the first surface of the substrate while the central or main reflector
`
`coating may be established on the second surface of the substrate (in such an application,
`
`masking may be required to form the coatings at one or both sides of the substrate).
`
`Optionally, the border and central reflector coatings may both be on the first or front surface
`
`of the reflective element, depending on the particular application of the reflective element and
`
`mirror assembly.
`
`[00151)
`
`The substrate or substrates of the reflective element may comprise any type of
`
`suitable substrate, such as a single glass substrate or the like. For example, the substrate may
`
`comprise a glass substrate having a thickness of at least about 1.6 mm, more preferably a
`
`thickness of at least about 1.8 mm and more preferably a thickness of at least about 2 mm, but
`
`could have a greater thickness or a reduced thickness without affecting the scope of the
`
`present invention. The substrate may comprise a substantially flat or planar substrate or may
`
`comprise a curved substrate depending on the particular application of the reflective element.
`
`[00152]
`
`Optionally, and with reference to FIGS. 17-21, a reflective element assembly 610 for
`
`an exteriorrearview mirror assembly includes a front substrate 612 (FIG. 21) and a rear
`
`substrate 614 spaced from front reflective element substrate 612, with an electro-optic
`
`medium 616 (preferably an electrochromic medium) sandwiched therebetween. The front
`
`substrate 612 has.a transparent conductive coating or layer 618 (such as an ITO layer, such as
`a Yz wave ITO layer or a doped tin oxide layer or a doped zinc oxide layer or the like)
`disposed on its rear surface 612a (typically referred to as the second surface of the laminate
`
`reflective element assembly) and the rear substrate 614 has a ihird surface mirror reflector
`
`620 (FIGS. 20 and 21) coated thereon (the mirror reflector may comprise a layer or stack of
`
`layers of metals or a metal or stack of metals with at least one conductive oxide layer, such as
`
`ITO, or the like as discussed below). The third surface mirror reflector covers the central
`
`region or EC-active or viewing region of the front surface 614a (typically referred to as the
`
`third surface of the reflective·eiement assembly) of the rear substrate 614 (but does not
`
`extend or cover fully to the perimeter edge of the substrate), and the mirror reflector coating
`
`620 overlaps a.tab-out or edge wraparound coating or coatings 636 (that extends substantially
`
`or fully to a perimeter edge of the substrate, and preferably, if in a "flush" electrochromic
`-52-
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`SMR USA
`Exhibit 1006
`Page 0868
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`

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`WO 2006/124682
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`PCT /US2006/018567
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`mirror element construction, wraps around the cut edge of the substrate) as discussed below.
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`An epoxy seal material 622 (FIG. 21) or the like, is applied between the substrates to define
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`the cavity for the electrochromic medium and to adhere the substrates together. The epoxy
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`seal 622 overlaps and seals an overlap region 621 where the third surface mirror reflector 620
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`overlaps the wraparound coating 636 to environmentally protect the third surface mirror
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`reflector 620, as also discussed below.
`
`[00153]
`
`Because an exterior rearview mirror is located at the exterior of a vehicle, the mirror
`
`reflective element is typically exposed to a hostile environment and may be exposed to
`humidity, rain, snow, ice, dirt, salt, debris and the like. In typical laminate electrochromic
`reflective element assemblies, any portion of the mirror reflector layer or layers that extend
`
`beyond the perimeter seal toward the outer edge of the rear substrate (for purposes of
`
`electrical contact) are particularly vulnerable. Thus, it is desirable to provide a robust
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`reflective element, such .as a mirror reflective element having environmentally stable coatings
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`or layers on the surfaces of the reflective element substrates that can be exposed to the hostile
`
`environment. Although such environmentally stable or robust coatings, as discussed below,
`
`are desirable and suited for exterior mirror applications, aspects of such coatings and the
`
`constructions herein are equally suited for interior mirror applications as well.
`
`[00154]
`
`As shown in FIG. 18, the rear substrate 614 of reflective element 610 includes a third
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`surface conductor or coating 636 that is disposed over the uncoated glass substrate and along
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`a portion (such as an uncoated perimeter region or perimeter glass surface) of the third
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`surface 614a of rear substrate 614. The third surface coating 636 includes a third surface
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`conductor portion or tab-out portion 636a (disposed at the perimeter region of the third
`
`surface 614a) and a wrap-around portion or coating 636b that wraps around and over a
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`perimeter edge or cut edge 614c of rear substrate 614. Third surface coating 636 may
`
`comprise an environmentally stable metallic layer or material, such as chromium or rhodium
`
`or ruthenium or platinum or the like, or a stack of, for example, _of chromium/ruthenium or
`
`chromium/rhodium or chromium/platinum or the like, and thus provides an environmentally
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`stable or robust wraparound coating at the perimeter region of the front surface 614a of the
`
`rear substrate 614.
`
`[00155]
`
`As shown in FIGS. 17 and 19, rear substrate 614 also includes a fourth surface
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`conductor or coating 638 disposed over the glass substrate and along a portion.(such as an
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`uncoated perimeter region or perimeter glass surface) of the fourth surface 614b of rear
`
`substrate 614. Fourth surface coating 638 includes a fourth surface conductor portion or
`
`electrical contact portion 638a and a ·wrap-around portion or coating 638b that wraps around
`-53-
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`SMR USA
`Exhibit 1006
`Page 0869
`
`

`

`WO 2006/124682
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`PCT /US2006/018567
`
`and over perimeter edge or cut edge 614c of rear substrate 614 onto the cut edge of the
`
`substrate and contacting third surface conductor coating 636 (and may be disposed at or over
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`or under wrap-around portion 636b at perimeter edge 614c, as shown in FIG. 19), in order to
`
`provide electrical conductivity between the fourth surface conductor 63 8a and the third
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`surface conductor 636 and the third surface mirror reflector coating 620, as discussed below.
`
`The fourth surface conductor 63 8a and wrap-around coating 63 8b may comprise the same
`
`material as the third surface conductor 636a and wrap-around coating 636b (such as
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`chromium or molybdenum or tungsten or Hastelloy or ruthenium or rhodium or platinum, or
`
`a stack of, for example, of chromium/ruthenium or chromium/rhodium or chromium/platinum
`
`or the like, or other suitable environmentally stable conductive material). Alternately, the
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`fourth surface coating 63 8 may comprise a different material than the third surface coating
`
`636, with both coatings or layers being selected to be substantially environmentally stable or
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`robust.
`
`[00156]
`
`The third and fourth surface conductors 636, 638 may