PATENT
`DON09 P-1696
`
`EXTERIOR SIDEVIEW MIRROR SYSTEM
`
`CROSS REFERENCE TO RELATED APPLICATIONS
`
`[0001]
`
`The present application is a divisional of U.S. patent application Ser. No. 12/851,045,
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`filed Aug. 5, 2010 (Attorney Docket DON09 P-1624), which is a continuation of U.S. patent
`
`application Ser. No. 12/197,666, filed Aug. 25, 2008, now U.S. Pat. No. 7,842,154, which is a
`
`division of U.S. patent application Ser. No. 10/709,434, filed May 5, 2004, now U.S. Pat. No.
`
`7,420,756, which claims the benefit of U.S. provisional application, Ser. No. 60/471,872, filed
`
`May 20, 2003, which are hereby incorporated herein by reference in their entireties.
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`FIELD OF THE INVENTION
`
`[0002]
`
`The present invention relates generally to rearview mirror elements for a rearview mirror
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`assembly of a vehicle and, more particularly, to exterior rearview mirror elements comprising
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`multi-radius reflective elements.
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`BACKGROUND OF THE INVENTION
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`[0003]
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`Typically, mirror reflective elements are formed of glass and have a reflective coating
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`deposited thereon, such as via vacuum deposition or wet chemical silvering or the like, such as
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`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,
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`which are hereby incorporated herein by reference. For such polymeric mirror reflective
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`elements, the need exists for a hard coat or surface on the first or outer or exterior surface of the
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`element which is contacted by the exterior elements, such as rain, road debris, or the like, or
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`contacted, for example, by a person scraping ice or wiping snow or condensation off the mirror
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`element outer surface, such as during winter. A variety of hard coats have been proposed in the
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`art, typically applied by dip coating or vacuum deposition techniques. However, a need exists
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`for an automotive mirror reflective element which has the properties of plastic (i.e., a specific
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`gravity roughly half that of glass), and which has a glass-like exterior surface.
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`[0004]
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`Also, exterior rearview mirror reflective elements may be aspheric or multi-radius, and
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`may typically have a less curved or substantially flat (around 2000 mm radius or thereabouts)
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`inboard portion or surface at the inboard side of the reflective element (i.e., closer to the side
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`body of the vehicle when the mirror assembly is mounted to the vehicle), and a more curved
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`1
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`SMR USA
`Exhibit 1007
`Page 001
`
`

`

`multi-radius portion or surface at the outboard side of the reflective element (i.e., further from
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`the side body of the vehicle when the mirror assembly is mounted to the vehicle), in order to
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`provide an extended field of view. It is typically desirable to have the reflective elements or
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`substrates of such exterior mirror elements to be formed of a glass material because glass
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`material typically provides an enhanced scratch resistance over conventional optical resins and
`
`the like.
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`[0005]
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`Therefore, there is a need in the art for a mirror reflective element that overcomes the
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`shortcomings of the prior art elements and substrates.
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`SUMMARY OF THE INVENTION
`
`[00061
`
`The present invention provides a molded wide angle or multi-radius substrate for a
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`reflective element. The molded substrate comprises a polymeric optical resin transparent
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`material and has a curved exterior surface, which may have a less curved/flatter or substantially
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`flat inboard portion or surface and a more curved outboard portion or surface. The molded
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`substrate may have an anti-abrasion film or layer, such as an ultrathin glass film, applied over the
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`exterior surface or first surface to provide substantial protection against scratches occurring to
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`the molded substrate. The inner surface or second surface of the reflective element substrate
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`may have a reflective coating or layer, such as a polymeric reflective film, laminated or adhered
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`or otherwise applied thereto.
`
`[0007]
`
`According to an aspect of the present invention, a wide angle reflective element for a
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`mirror assembly for a vehicle includes a wide angle substrate having an exterior surface and a
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`glass film disposed at the exterior surface. The exterior surface of the substrate has a less curved
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`inboard portion or surface and a more curved outboard po1iion or surface. The substrate
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`comprises a polymeric resin material. The glass film is adapted to substantially confonn to the
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`exterior surface of the wide angle substrate. The glass film comprises a glass material and has a
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`thickness ofless than approximately 0.8 mm.
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`[0008]
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`According to another aspect of the present invention, a reflective element for a mirror
`
`assembly for a vehicle comprises a substrate having an exterior surface, and an anti-abrasion film
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`applied to the exterior surface. The substrate comprises a polymeric resin material, such as a
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`transparent optical polymeric resin material. The anti-abrasion film preferably comprises a glass
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`material (such as a soda lime glass or a borosilicate or the like) and has a thickness ofless than
`
`approximately 0.8 mm, and is flexible to conform to the exterior surface.
`
`2
`
`SMR USA
`Exhibit 1007
`Page 002
`
`

`

`(0009]
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`The substrate may be cut from a strip or sheet of molded or extruded or cast substrate
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`material ( or less preferably, may be cut from an injected molded strip or sheet). The flexible
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`glass film may be unrolled from a reel or roll and applied to the exterior surface of the elongated
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`strip or sheet of substrate material. The substrate, including the glass film or layer, may then be
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`cut or otherwise formed from the elongated strip or sheet.
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`(0010]
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`The substrate may comprise a wide angle substrate and/or may comprise a multi-radius
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`exterior surface having a less curved inboard portion or smface and a more curved outboard
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`portion or surface.
`
`[00111
`
`A reflective film or layer may be applied to the inner surface or side of the substrate or
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`strip opposite the exterior surface. The reflective film may comprise a polymeric reflective film
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`laminated or otherwise adhered or applied to the inner side of the substrate or strip. The
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`reflective film may comprise an all polymer-thin-film multilayer, high reflective mirror film
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`comprising multiple coextrusion of many plastic layers to form a highly reflective mirror film.
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`[0012]
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`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
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`film layer. In such an application, the substrate acts as a support or backing plate for the
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`reflective film or layer and the glass film or layer, whereby optical clarity/ transparency of the
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`substrate material is not necessary.
`
`(0013]
`
`According to another aspect of the present invention, a method for forming a reflective
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`element substrate for a min-or assembly of a vehicle comprises generally continuously forming
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`an elongated strip or sheet of substrate material and applying a substantially transparent
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`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 transparent
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`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
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`element substrates may be cut or otherwise formed from the elongated sheet after the functional
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`film is applied to the surface of the strip or sheet.
`
`(0014]
`
`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
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`to a bent substrate). The substrates may be formed with a wide angle exterior surface or a multi-
`
`3
`
`SMR USA
`Exhibit 1007
`Page 003
`
`

`

`radius exterior surface. The anti-abrasion film may be sufficiently flexible to conform to the
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`wide angle or multi-radius or curved exterior surface.
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`[0015]
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`A reflective film, such as a polymeric reflective film or the like, may be applied to the
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`opposite surface of the substrate or sheet or strip. The reflective film may be sufficiently flexible
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`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 continuously fonned 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(cid:173)
`
`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.
`
`[0017]
`
`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.
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`BRIEF DESCRIPTION OF THE DRAWINGS
`
`[0018]
`
`FIG. 1 is a perspective view of an exterior rearview mirror assembly in accordance with
`
`the present invention;
`
`[0019]
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`FIG. 2 is a perspective view of a wide angle or multi-radius reflective element in
`
`accordance with the present invention;
`
`[0020]
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`FIG. 3 is a sectional view of the wide angle or multi-radius reflective element taken along
`
`the line III-III in FIG. 2;
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`[0021]
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`FIG. 4 is a sectional view similar to FIG. 3, showing a wide angle or multi--radius
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`reflective element in accordance with the present invention with a reflective film or layer applied
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`to the exterior surface of the element and an anti-abrasion film or layer applied over the
`
`reflective film or layer;
`
`[0022]
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`FIG. 5 is a diagram showing the extruding, coating and cutting processes for
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`manufacturing a prismatic mirror reflective element in accordance with the present invention;
`
`[0023]
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`FIG. 5A is an elevation of the extruder of FIG. 5, showing the wedge shape of the
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`extruded strip and,reflective element substrate;
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`[0024]
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`FIG. 6 is a plan view of the extrnded strip showing the cut out shapes of the reflective
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`element cut from the extruded strip;
`
`4
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`SMR USA
`Exhibit 1007
`Page 004
`
`

`

`(0025]
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`FIG. 7 is a sectional view of the reflective element fonned by the process shown in FIG.
`
`5·
`'
`
`[0026]
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`FIG. 8 is a diagram showing an alternate process for manufacturing a prismatic mirror
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`reflective element in accordance with the present invention, where a strip of substrate material is
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`cast and formed via a caster and float section;
`
`(0027]
`
`FIG. 9 is a perspective view of an automobile equipped with exterior sideview mirror
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`assemblies according to this present invention;
`
`[0028]
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`FIG. 10 is a top plan partial fragmentary view of the driver's side exterior rearview mirror
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`assembly of FIG. 9;
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`[0029]
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`FIG. 11 is an enlarged sectional view of a plano-multiradius reflective element assembly
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`of the mirror assembly in FIG. 10;
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`[0030]
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`FIG. 12 is an enlarged sectional view of a demarcation element of the plano-multiradius
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`reflective element assembly of FIG. 11;
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`[0031]
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`FIGS. 13A-13H illustrate views of various locations for a piano reflective element and an
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`auxiliary reflective element according to this present invention;
`
`[0032]
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`FIG. 14 is a sectional view of a second embodiment of a plano reflective element
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`assembly according to the present invention including a demarcation element formed as a
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`[0033]
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`[0034]
`
`[0035]
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`dividing wall in a backing plate element;
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`FIG. 14A is a cross-section taken along line XX of FIG. 14;
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`FIG. 14B is a cross-sectional view taken along line YY of FIG. 14;
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`FIG. 15 is a schematic of a third embodiment of a plano--auxiliary reflective element
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`assembly according to this present invention;
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`[0036]
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`FIG. 16 is a front elevation view of another embodiment of a plano reflective element
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`assembly according to the present invention;
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`[0037]
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`FIG. 17 is an exploded perspective view of the piano reflective element assembly of PIG.
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`16;
`
`[0038]
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`FIG. 18 is an end view of the piano reflective element assembly of FIG. 16 as viewed
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`from line XVIII--XVIII of PIG. 16;
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`(0039]
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`FIG. 19 is a top view of the piano reflective element assembly of FIG. 16 as viewed from
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`line XIX--XIX of PIG. 16;
`
`(0040]
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`FIG. 20 is a schematic representation of the plano reflective element assembly of FIG. 16
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`illustrating the orientation of the reflective element;
`
`5
`
`SMR USA
`Exhibit 1007
`Page 005
`
`

`

`[0041]
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`FIG. 21 is another schematic representation of the orientation of the reflective elements
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`of the piano reflective element in FIG. 16;
`
`[0042]
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`FIG. 22 is a diagram illustrating the range of viewing of the reflective elements of the
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`piano reflective element assembly of FIG. 16; and
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`[0043]
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`FIG. 23 is a perspective view of another embodiment of an exterior rearview mirror
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`system of the present invention.
`
`[0044]
`
`Referring now to the drawings and the illustrative embodiments depicted therein, an
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`DESCRIPTION OF THE PREFERRED EMBODIMENTS
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`exterior rearview mirror assembly 10 includes a reflective element 12 mounted at a casing 14,
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`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
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`and an opposite exterior surface 18b (FIGS. 2 and 3). The exterior surface 18b comprises a less
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`curved or substantially flat inboard portion or surface 18c and a more curved outboard portion or
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`surface 18d, as discussed below. The substrate 18 may have an anti-abrasion coating or layer or
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`film 20, such as an ultrathin glass coating or layer or film, laminated or deposited or otherwise
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`applied to the exterior surface 18b, and may have a reflective coating or layer 22 laminated or
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`applied to the inner surface 18a, as also discussed below. Aspects of the reflective element of
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`the present invention may be suitable for use in a reflective element for an exterior rearview
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`mirror assembly (as shown in FIG. 1) and/or a reflective element for an interior rcarview mirror
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`assembly (not shown).
`
`[0045]
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`Reflective element 12 may comprise an aspheric or multi-radius or wide angle single
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`element reflective element substrate. The reflective element 12 may provide a field of view
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`similar to the piano-auxiliary reflective element assembly disclosed in U.S. Pat. Nos. 6,522,451
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`and 6,717,712, which are hereby incorporated herein by reference.
`
`[0046]
`
`As illustrated in FIG. 9 from U.S. Pat. No. 6,717,712, incorporated above, passenger
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`automobile 110 (which may be a sedan, a station-wagon, a sports car, a convertible, a minivan, a
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`sports utility vehicle, a pick-up truck or a similar passenger carrying non-commercial, personal
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`transportation automobile) includes an interior rearview mirror assembly 127 positioned within
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`interior vehicle cabin 125. Interior vehicle cabin 125 further includes a steering wheel 116, a
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`driver seat 129 positioned at slee11.ng wheel 116, a front passenger seat 121 adjacent to driver
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`seat 129 in the front portion of cabin 125, and a rear passenger seat 123 in the rear portion of
`
`6
`
`SMR USA
`Exhibit 1007
`Page 006
`
`

`

`cabin 125. Automobile 110 further includes a driver-side exterior sidevicw mirror assembly.112
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`and a passenger-side exterior sideview mirror assembly 114, each adapted for attachment to
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`opposing sides of automobile body 111, most preferably adjacent to the seating position of the
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`driver seated in driver seat 129 for driver-side assembly 112 and adjacent to the front passenger
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`seat 121 for passenger-side assembly 114. Exterior sideview mirrors, mounted as shown in FIG.
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`9 close to the driver seating location, are commonly referred to as door-mounted exterior
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`sideview mirror assemblies. Driver-side exterior sideview mirror assembly 112 includes, as
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`illustrated in FIG. 10, a plano-multiradius exterior sideview reflective element assembly 130.
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`Plano-multiradius reflective element assembly 130 is mounted to a reflective element positioning
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`actuator 136. The orientation of plano-multiradius reflective element assembly 130, and hence
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`its rearward field of view, is adjustable by actuator 136 in response to control 137. Control 137
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`can comprise a handset control that allows the driver manually move the orientation of plano(cid:173)
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`multiradius reflective element assembly 130 within exterior mirror housing 140 (such as by a
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`lever control or by a cable control) and hence reposition the rearward field of view of plano(cid:173)
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`multiradius reflective element assembly 130. Alternately, when actuator 136 comprises an
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`electrically actuated actuator that is electrically operable incorporating at least one motor, control
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`137 can comprise a switch (which, preferably, is operable under control of the driver seated in
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`cabin 125) or control 137 can comprise a memory controller, as known in the automotive mirror
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`art, that controls actuator 136 to move the position of plano-multiradius reflective element
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`assembly 130 to a pre-set orientation that suits the rearward field of view preference of an
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`individual driver. Actuator 136 is mounted to bracket 138 which attaches to vehicle body side
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`111. Plano-multiradius reflective element assembly 130 is positionable by actuator 136 within
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`exterior mirror housing 140.
`
`[0047)
`
`Plano-multiradius reflective element assembly 130, as shown in FIG. 11, comprises a
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`piano element 150 and a separate multiradius element 155. Preferably, plano element 150 is
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`adjacent to multiradius element at a joint. At their joint, plano element 150 and separate
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`multiradius element 155 can touch leaving substantially no gap or space therebetween, or piano
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`element 150 and separate multiradius element 155 can be spaced apart at their joint by a space or
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`gap, as in FIG. 11. Plano element 150 and multiradius element 155 are both mounted to surface
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`159 o±: and are both supported by, a single backing plate element 160. Plano element 150 and
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`multiradius element 155 are demarcated apaii by demarcation element 165. Surface 161 of
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`backing plate element 160 is preferably adapted to attach, such as by attachment member 164, to
`
`7
`
`SMR USA
`Exhibit 1007
`Page 007
`
`

`

`actuator 136 when plano-multiradius reflective element assembly 130 is mounted in driver-side
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`exterior sideview mirror assembly 112 (and/or in passenger-side exterior side view mirror
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`assembly 114) such that plano element 150 and multiradius element 155 are adjusted and
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`positioned in tandem and simultaneously when the driver (or alternatively, when a mirror
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`memory system, as is conventional in the rearview mirror arts) activates actuator 136 to
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`reposition the remward field of view ofplano-multiradius reflective element assembly 130.
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`Thus, since elements 150, 155 are part of plano-multiradius reflective element assembly 130,
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`movement of plano-multiradius reflective element assembly 130 by actuator 136 simultaneously
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`and similarly moves plano element 150 and multiraclius element 155.
`
`[0048]
`
`Plano element 150 preferably comprises a flat reflector-coated glass substrate having unit
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`magnification, and comprises a reflective surface through which the angular height and width of
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`the image of an object is equal to the angular height and width of the object when viewed at the
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`same distance (except for flaws that do not exceed normal manufacturing tolerances). Plano
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`element 150 may comprise a conventional fixed reflectance mirror reflector or it may comprise a
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`variable reflectance mirror reflector whose reflectivity is electrically adjustable. For example,
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`plano element 150 may comprise a flat glass substrate coated with a metallic reflector coating
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`such as a chromium coating, a titanium coating, a rhodium coating, a metal alloy coating, a
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`nickel-alloy coating, a silver coating, an aluminum coating (or any alloy or combination of these
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`metal reflectors). The metal reflector coating ofplano element 150 may be a first surface coating
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`(such as on surface 166) or a second surface coating (such as on surface 167), as such terms are
`
`known in the mirror art. The reflector coating on plano element 150 may also comprise a
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`dielectric coating, or a multilayer of dielectric coatings, or a combination of a metal layer and a
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`dielectric layer to form automotive mirror reflectors as known in the automotive mirror art. If a
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`variable reflectance reflector element, plano element 150 preferably comprises an electro-optic
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`reflector element and, most preferably, an electrochromic reflector element.
`
`[0049]
`
`When mounted into exterior side view mirror assembly 112 and/or 114, plano-
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`multiradius reflective element assembly 130 is preferably orientated so that at least a portion of
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`(more preferably a substantial portion of) the reflector surface of plano element 150 is positioned
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`closer to the vehicle body (and hence to the driver) than any potiion of the reflector surface of
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`multiradius element 155. Thus, and refen-ing to FIG. 11, side A of plano element 150 of plano(cid:173)
`
`multiradius reflective clement assembly 130 is positioned closer to the driver than side D of
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`multiradius element 155 when plano-multiradius reflective element assembly 130 is mounted on
`
`8
`
`SMR USA
`Exhibit 1007
`Page 008
`
`

`

`an automobile. Also, when mounted into exterior side view mirror assembly 112 and/or 114,
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`surfaces 166, 168 ofplano-multiradius reflective element assembly 130 face rearwardly in terms
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`of the direction of vehicle travel.
`
`[0050]
`
`Multiradius element 155 of plano-multiradius reflective element assembly 130 preferably
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`comprises a curved/bent mirrored glass substrate. The degree of curvature preferably increases
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`(and hence the local radius of curvature decreases) across the surface ofmultiradius element 155
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`with the least curvature (largest radius of curvature) occurring at the side of multiradius element
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`155 (side C in FIG. 11) positioned adjacent its joint to piano element 150 when both are mounted
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`on backing plate element 160. Thus, and referring to FIG. 11, the local radius of curvature at
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`side C of multiraclius element 155, when mounted on backing plate element 160, is larger than at
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`side D. Also, the local radius of curvature preferably progressively decreases across multiradius
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`element 155 from side C to side D. Preferably, the local radius of curvature at side C of
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`multiradius element 155 is at least about 1000 mm; more preferably is at least about 2000 mm
`
`and most preferably is at least about 3000 mm whereas the local radius of curvature at side D of
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`multiradius element 155 is, preferably, less than about 750 mm, more preferably less than about
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`350 mm; most preferably less than about 150 mm. Preferably, multiradius element 155
`
`comprises a bent glass substrate with radii of curvature in the range of from about 4000 mm to
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`about 50 mm. The multi.radius prescription for the multiradius element to be used in a particular
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`exterior mirror assembly can vary according to the specific field of view needs on a specific
`
`automobile model.
`
`[0051]
`
`The total field of view rearwardly of the automobile of the piano-auxiliary reflective
`
`element assembly (which is a combination of the field of view of the piano reflective element
`
`and of the auxiliary reflective element) preferably generally subtends an angle of at least about
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`20 degrees (and more preferably, generally subtends an angle of at least about 25 degrees and
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`most preferably, generally subtends an angle of at least about 30 degrees) with respect to the side
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`of an automobile to which is attached an exterior sideview mirror assembly equipped with the
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`piano-auxiliary reflective element assembly.
`
`[0052]
`
`Multiradius element 155 may comprise a conventional fixed reflectance mirror reflector
`
`or it may comprise a variable reflectance mirror reflector whose reflectivity is electrically
`
`adjustable. For example, multiradius element 155 may comprise a flat glass substrate coated
`
`with a metallic reflector coating such as a chromium coating, a titanium coating, a rhodium
`
`coating, a metal alloy coating, a nickel-alloy coating, a silver coating, an aluminum coating ( or
`
`9
`
`SMR USA
`Exhibit 1007
`Page 009
`
`

`

`any alloy or combination of these metal reflectors). The metal reflector coating ofmultiradius
`
`element 155 may be a first surface coating (such as on surface 168) or a second surface coating
`
`(such as on surface 169), as such terms are known in the mirror art. The reflector coating on
`
`multiradius element 155 may also comprise a dielectric coating, or a multilayer of dielectric
`
`coatings, or a combination of a metal layer and a dielectric layer to form automotive mirror
`
`reflectors as known in the automotive mirror art. If a variable reflectance reflector element,
`
`multiradius element 155 preferably comprises an electro-optic reflector element and, most
`
`preferably, an electrochromic reflector element.
`
`[0053]
`
`Also, it is preferable that the thickness ofplano element 150 and multiraclius element 155
`
`be substantially the same in dimension so that their respective outer surfaces, 166 and 168, are
`
`substantially coplanar so that a driver can readily view images in either or both elements. The
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`thickness dimension of elements 150, 155 is detennined by the thickness of the substrate ( or in
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`the case of laminate-type electro chromic reflective elements, the thickness of the two substrates
`
`between which the electrochromic medium is disposed). For example, plano element 150 and/or
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`multiradius element 155 can comprise a reflector coated glass substrate or panel of thickness
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`preferably equal to or less than about 2.3 mm, more preferably equal to or less than about 1.6
`
`mm, most preferably equal to or less than about 1.1 mm. Use of a thinner substrate is beneficial
`
`in terms of improving the overall stability/vibration performance of the image seen in plano(cid:173)
`
`multiradius reflective element assembly 130 when mounted to an automobile.
`
`[0054]
`
`The reflector area of plano element 150 is preferably larger than that of multiradius
`
`element 155. Preferably, the width dimension of plano element 150 is larger than the width
`
`dimension ofmultiradius element 155 (both width dimensions measured at their respective
`
`widest dimension and with the width of the respective element being gauged with the respective
`
`element oriented as it would be orientated when mounted on the automobile). Thus, and
`
`referring to FIG. 11, the distance from side A to side B of plano element 150 is larger than the
`
`distance from side C to side D ofmultiradius element 155. Thus, the ratio of the width ofplano
`
`element 150 to the width of multiradius element 155 is preferably greater than 1; more preferably
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`greater than 1.5; most preferably greater than 2.5 in order to provide a large, unit magnification
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`plano element 150 as the principal rear viewing portion of plano-multiradius reflective element
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`assembly 130 and providing multiradius element 155 as a smaller, auxiliary, separate, wide(cid:173)
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`angle viewing portion of plano-multiradius reflective element assembly 130. For plano(cid:173)
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`multiradius reflective element assemblies to be mounted to the exterior sideview assemblies of
`
`10
`
`SMR USA
`Exhibit 1007
`Page 010
`
`

`

`passenger automobiles used non-commercially and for non-towing purpose, the width of plano
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`element 150 (at its widest dimension) is preferably in the range of from about 50 mm to about
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`225 mm; more preferably in the range of from about 75 mm to about 175 mm; most preferably in ·
`
`. the range of from about 100 mm to about 150 mm.
`
`[0055]
`
`Backing plate element 160 is preferably a rigid polymeric substrate capable of supporting
`
`plano element 50 and multiradius element 155. Backing plate element 160 comprises a flat
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`portion (generally between E and Fas shown in FIG. 11) that corresponds to and is aligned with
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`plano element 150. Backing plate element 60 also comprises a curved portion (generally
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`between G and Has shown in FIG. 11) that corresponds to and is aligned with multiradius
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`element 155. Preferably, curved portion G-H ofmultiradius element 155 is fabricated with a
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`multiradius prescription that is substantially the same as the multiradius prescription of
`
`multiraclius element 15 5. Backing plate element 160 is formed as a single element to which
`
`elements 150 and 155 are separately attached. Preferably, backing plate element 160 is formed
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`by injection molding of a thermoplastic or a thermosetting polymer resin. Materials suitable to
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`use for backing plate element 160 include unfilled or filled polymeric materials such as glass
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`and/or mineral filled nylon or glass and/or mineral filled polypropylene, ABS, polyurethane and
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`similar polymeric materials. For example, backing plate element 160 can be formed of ABS in
`
`an injection molding operation. Plano element 150 can be cut from a stock lite of flat chromium
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`mirror-coated 1.6 mm thick glass. Multiradius element 155 can be cut from a stock lite of
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`multiradiusly-bent chromium mirror-coated 1.6 mm thick glass. Plano element 150 and
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`multiradius clement 155 can then be attached (such as by an adhesive attachment such as an
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`adhesive pad or by mechanical attachment such by clips, fasteners or the like) to the already
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`molded backing plate element 160. Alternatively, plano element 150 and multiradius element
`
`155 can each by individually loaded into an injection molding tool. Once loaded, a polymeric
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`resin (or the monomers to form a polymeric resin) can be injected into the mold in order to
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`integrally form backing plate element 160 with elements 150, 155 integrally molded thereto.
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`Integral molding of the backing plate element to piano element 150 and multiradius element 155
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`(along with any other elements such as the demarcation element 165) in a single integral molding
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`operation, is a preferred fabrication process for plano-multirndius reflective element assembly
`
`130.
`
`[00561
`
`Plano-multiradius reflective element assembly 130 further preferably includes
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`demarcation element 165 that functions to delineate and demarcate the plano region of the
`
`11
`
`SMR USA
`Exhibit 1007
`Page 011
`
`

`

`assembly from the wide-angle, multiradius region and also preferably functions to prevent
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`ingress of debris, dirt, water and similar contaminants (such as road splash, car wash spray, rain,
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`snow, ice, leaves, bugs and similar items that plano-multiradius reflective element assembly 130
`
`would be subject to when mounted and used on an automobile) into any gap between plano
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`element 150 and multiradius element 155 when both are attached to backing plate element 160.
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`Optionally, at least a portion of demarcation element 165 can be disposed in any gap between
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`plano element 150 and multiradius element 155 at their joint on backing plate element 160.
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`Preferably, demarcation element 165 is fanned of a polymeric material that is dark colored (such
`
`as black or dark blue or dark brown or dark grey or a similar dark color) such as a dark colored
`
`polypropylene resin or a dark colored nylon resin or a dark colored polyurethane resin or a dark
`
`colored polyvinyl chloride resin or a dark colored silicone material. Most preferably
`
`demarcation element 165 is fonned of an at least partially elastomeric material (such as silicone,
`
`or EPDM, or plasticized PVC or the like) in order to provide a degree of vibration dampening for
`
`elements 150, 155. As shown in FIG. 12, demarcation element 165 optionally includes a crown
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`portion 170 that includes wing portions 173, 173' and a stem portion 171. Stem portion 171
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`preferably has a cross-sectional width CCC ofless than about 4 mm, more preferably less than
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`about 3 nun and, most preferably less than about 2 mm. Crown portion 170 preferably is
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`dim