5,724,187
`
`37
`A driver textural warming 23. such as the conventional
`textural warning “objects in mirror are closer than they
`appear”, may be included in the outermost more curved
`partion 55 of an electrochromic mutlti-radius exterior mirror
`according to this invention. (See FIG. 13.) Alternatively, a
`driver textural warning may be included in the innermost
`less curved region 65. Heretofore. such warnings have been
`established through sandblasting or as described in
`O'Farrell. Alternatively, textural warnings may be applied
`by silscreening onto a surface of one of the substrates 23
`of the mirror assembly or by other suitable techniques. such
`as laser ciching. onlo the reflective clement of the micror
`which is coated onto a surface of substrate 3.
`On demand displays 14 may be positioned behind the
`reficctive clement of the mirror (sce FIGS. 9 and 16) and
`become activated by user input of by input from a scascr,
`
`38
`overcoat layers likepaints. lacquers. of other oxide coatings.
`Nevertheless, such overcoat layers may. of course. be used_
`Also, a high reflector such as silver or alumiotim may’ be
`used, if desired. The window 13. now being only partially
`3 opagne in light transmissivity, is substantially light reflect-
`
`This partially transmitting/substantially reflecting win-
`dow may be established through cvaporating or sputtering
`(using vacuum
`techniques) chrorsium metal over
`10. the wiodow to a thickness of up 10 about 750 A. By so doing.
`light transmittance within the range of about 1% to about
`10% may be achieved, while also achicving light reflectance
`within the range of about 40% to about 65%. This method,
`however, [nirodnces increased manufacturing costs (¢.g.. by
`line-costed rearmost
`15 first creating the window in the silver li
`surface of substrate 3 and then vacuum
`iting
`thereover
`the thin film of chromium). Also, the differences in refiec-
`tivity between the higher reflectance off the silver reflective
`element and the lower refiectance off the partially
`
`po:
`detector, hazard detector of the like, In addition, a vehicle
`function (such as a turn signal. hand brake. foot brake, high
`An alternative method involves the use of a partially
`beam selection. gear change, memory feature selection and
`transmitting (Le.. light transmission within the range of at
`the like) may ectivate the on demand
`, The on
`least about 1% to about 20%). substantially reflecting (ic.
`display.
`demand display may also be activated by a function such as 25 light reflectance within the range of 10 Jeast about 40% to
`greater than about 70%) metal foil or reflector-coated poly-
`a compess. clock, a message cenier. s specdometer, an
`enginerevolution per unil meter and the like. In the context
`of their use in conjunction with rearvicw mirrors for motor
`vehicles. an on demand display, when not active or
`activaled, should desirably remain af least
`unobservable or undetectable by the driver and/or passon-
`gers. Similarly. in other applications with which these on
`demand displays may be desivubly used. they should remain
`at least substantially unobservable or ondetectable when not
`activated.
`On demand displays 14 should be an emitting electronic
`display, such as a vacuum fluorescent display. = light cmit-
`ting diode, a gas discharge display, a plasms display, a
`cathode ray tube. an electroluminescent display and the like.
`Conventionally. the reflective clement ip electrochromic
`mirrors is constructed by coating the rearmost (noo-inward)
`Surface of the second subswate 3, with a refiective element
`using a wet chemical silver line mirror coating. This rear-
`most surface is typically coated with a layer of silver 8, and
`then protected with a thin film layer of copper 19 which
`itselfis overcoated with & protective material 2, typically =
`paint such as « lead-based paint In this construction, the
`light
`transmissivity through the misror is substantially
`opaque—ie.. substantially less then about 0.01%. To place
`8 display, camera. sensor or the liice behind such a conven-
`tional mirror, a “window™ 13 through which light may pass
`must be created as described hercinafter.
`With reference to FIGS. 8. 9 and 10. it may be seen that
`on demand display capability may be introduced to 4 mirror
`through the window 13 that has been previously aeated
`therein (typically. by sand blasting, mechanical erosion (e.g.
`with a
`spinning
`rubber). leser etching. chemical etching and
`the like) by coating a layer of reflective material, such as a
`thin film of a metal 16 (e.g.. a medium reflector. such as
`chromium. titanium. stainless steel and the like. having a
`thickness preferably Jess than about 750 A). onto the rear-
`most (nop-inward) surface of substrate 3 at the portion of the
`substrate where the window 13 cxists. (See FIG. 14.) It may
`be preferable to use a medium reflector, such as chromium,
`titanium. stainless stee] and the like, because such medium
`reflectors are durable. seratch resistant and resistant
`to
`environmental degradation without the néed for additional
`
`polyester
`“MYLAR” film (commercially available from Du
`30 Pont). Such a foil, or sheet or film 15, reflector coated with
`a thin film of metal 16 may be contacted with. or adhered to
`using an optical adhesive 18, preferably an index matching
`adbesive such as described hereinafter. the window 13 in the
`Layer of reflective material on subsuate 3.
`Likewise. an appropriately sized glass cover sheet 15 (or
`a polymer cover sheet) which is coated with a thin film of
`metal 16 that is partially light transmitting (preferably, about
`1% tw about 20%), and yet substantially light reflecting
`(preferably, at least about 40% to greater than about 70%)
`40 may be contacted with, or adhered to using an optical
`adhesive 18 as described herein. the window 13 in the layer
`of reflective material on substrate 3. (See FIG. 9.)The glass
`cover sheet 15 may be any desired shape and should be
`sufficicntly large to at Jeast cover the cotire window 13
`45 created jn the silver-comed. rearmost surface of substrare 3
`(which may be suitable to accommodate. for cxampilc.
`compass displays, like the compass displays described in
`O'Farrell and Larson).
`it may be convenient to coat glass lites with a high
`$0 refiector, such as 4 thin film coating of aluminum or silver.
`to a thickwess that achieves the desired partial light trans-
`mittance and substantial Night reflectance. Alternatively, a
`medium reflector, such as a thin film coating of chromium.
`Stainless steel, titanium or the like. may be used to coat the
`55 glass lites.
`An inorganic oxide coating. such as silicon dioxide,
`Utanium dioxide, zinc oxide or the like, may also be over-
`conted onto the thin film metal reflector coating to impart
`resilience, resitance against environmental degradation.
`60 enhance scratch resistance and enhance opticalperformance.
`Likewise. a thin film of magnesium fluoride. or a combina-
`Gon of thin films of diclecttic materials such as described
`supra, may be used to overcoal the thin film metal reflector
`coating. A clear coat of a lacquer. such as an acrylic- or a
`65 urethanc-based lacquer of the like,
`is still another choice
`which may be used to overcoat the thin film metal reflector
`coating.
`
`Copy provided by USPTO from the CSIR Image Database on 06-26-2000
`
`~
`
`a
`
`SMR USA
`Exhibit 1029
`Page 181
`
`SMR USA
`Exhibit 1029
`Page 181
`
`

`

`5.724, 187
`
`40
`a thickness of sbourt 3 mm, and substrate 2 is fabricated from
`soda-lime glass (coated with HW-ITO baving a sheet resis-
`tance of about 12 ohms per square a5 a substantially trans-
`parent conductive electrode costing 4), with a thickness of
`about 0.043", In this construction. the fluorine-doped tin
`
`may also be used as a reflective clemeat $ conted onto cither
`surface or the inward surface of
`
`39
`Once formed. the partially transmitting/substantally
`reficcting giass lites may be subdivided into a multitude of
`smaller sized cover sheets to cover the window in the
`reflectoron the reammost (non-loward) surface of substrate 3.
`More specifically. a equare. circle or rectangle may be cut to
`dimensions of about 1 to about 6 mm or lerger than the
`dimensions of the window for the display. ‘The square- or
`rectangular-shaped glass cover shecis may then becontacted
`with, or adlcred to, the rearmost (non-inward) surface of
`substrate 3 to cover the previously established window for
`the display.
`An optical adhesive 18 that is index matched to the
`refractive index of glass (ic. about 1.52) may be used to
`adhere the glass cover sheet 15 to the reanmost (non-inward)
`surface of substratc 3. Such optical adhesives maximize
`patenl application
`commonly assigned co-pending
`optical quality and optical index matching. and minimize
`No. 07/700.760. filed May 15, 1991 (“the "760
`interfacial reflection, and include plasticized polyvinyl
`application”), the disclosure of which is hereby incorporated
`butyral, various silicones. polyurethanes such as “NOR-
`herein by reference, Where it is desired that the high
`LAND NOA 65° and “NORLAND NOA 68",and acrylics
`reflectance off the elemental semiconductor reflector be
`such es “DYMAX LIGHT-WELD 478". The giass cover
`within the range of at least about 60% to greater than about
`sheet 15 may be positioned with its semitransparent metal
`70%. an undercoat of = thin film Layer of silicon dioxide
`reflector costing 16 closest to the rearmost (non-ioward)
`surface of substrate 3 so that the micros construction com-
`between a thin film layer of silicon and the surface of the
`substrate onto which it is coated may be used to cnhance
`prises an assembled stack of the glass cover shect
`reflectivity performance [seec.g...te 760 application. and
`15/semitransparent reflector metal coating 16/optical adhe-
`U.S. Pat. No. 4.377,613 (Gardon) and U.S. Pat. No. 4.419.
`sive 18/rearmost (non-inward) surface of substrate 3. In this
`386 (Gordon), the disclosures of esch of which arc hereby
`construction. the optical adhesive is usedas both an arlhesive
`incorporated herein by reference}.
`and a5 a protectant for the semitransparent metal reflector-
`In addition, the layer of silicon and/or an undercoat of
`costing 16 of the glass cover sheet 15. Such a use of
`silicon dioxide may be deposited using techniques soch as
`semitransparent reflector-coated glass cover sheets 15/16
`lends itself to cconomical and automated mssembty. Also, the
`vacuum
`spray
`CVD.pyrolysis aad
`the like, For
`in-line
`ona float gizss linc.
`cover shect may be made from glass that is coated with a
`dichroic mirror or made from polymer reflector material
`(“PRM”). as described hereinafter.
`As an alternative to localized reflector coating with a thin
`metal film as shown in FIG. 10. or localized use of cover
`sheets, foils, films, and the like as shown in FIG, 9. at the
`non-inward surface of substrate 3 at window 13, similar
`localized reflector means can be
`at the inward
`facing surface of substrale 3 at the location of window 14.
`An emitting display 14 may also be positioned behind the
`rearmost (non-inward) surface of the glass cover sheet 15
`(which itself is positioned behind substrate 3 of the electro-
`chromic mizror assembly). In this regard. it may be desirable
`to use a thin glass for the cover sheet 15 to minimize
`multiple imaging and/or double imaging. The thickness of
`the cover sheet need not be thicker than about 0.063", with
`sultable thicknesses being about0.063"; about 0.043"; about
`0.028"; abour 0.016" and about 0.008". However. if desired
`the thickness of the cover sheet 15 may be greater than about
`0.063".
`Again with reference to FIG. 5. where the layer of
`refiective material is costed onto the inward surface of
`substrate 3. improved optical performance may be observed
`without reducing the thickness of substrate 3. In such
`constructions. a relatively thick glass (having a thickness of
`greater than about 0.063") may be used for substrate 3 with
`a thin glass (having a thickness of about 0.063" or less) used
`for substrate 2 while maintaining good mechanical
`=
`tics due to the relatively greater stiffness of substrate 3.
`Improved optical performance may also be observed dueto
`the relative closeness of the layer of reflective material
`(coated onto the inward surface of substrate 3) and the
`fronemost (non-inward) surface of substrate 2.
`An illustration of this aspect of the present invention may
`be seen where substrate 3 is fabricated from “TEC 10” glass
`(havinga sheet resistance of about 10 ohms per square). with
`
`be employed to deposit
`dioxide thin filmstacks onto float glass to provide a reflector
`for substrate 3 that is both highly reflecting and partially
`transmiiting. A further advantage of these clemental semi-
`conductor coatings is that they are bendable.
`For example, a glass coated with 2 reflective clement may
`be constructed by depositing omto a glass substrate a first
`of elemental silicon at an optical thickmess of about
`
`35
`
`45
`
`é
`74% after heating and bending. A substantially transparent
`conductive electrode coating. such 2s doped tin oxide (e.g.
`fluocine-doped tin oxide) and the like. may be coated over
`the third layer of elemental silicon to construct a highly
`reflecting, electrically conducting glass substrate suitable for
`use in electrochromic mirrors and electrochromic devices
`
`propertics.
`Preferably, refiectar-coated substrates constructed using
`multi-layer stacks. such as a glass/silicon/silicon dioxide/
`silicon stack (with or without additional undercoating or
`overcoating stack Layers). may be deposited in-bath. on-line
`onto glass being manufactured on a float glass line.
`It may also be advantageous to employ bendable
`reflector-coated substrates and techniques for manufacturing
`the same as taught by and described in the "760 application.
`and rowlti-layer stacks. such as the glass/silicon/silicon
`dioxide/silicon stack as described supra. with oc without an
`additional overcoating of a substantially transparent conduc-
`
`=n nrow
`
`SPTO
`
`irom the
`
`Cs
`
`had Ee OP
`
`SMR USA
`Exhibit 1029
`Page 182
`
`SMR USA
`Exhibit 1029
`Page 182
`
`

`

`5,724,187
`
`41
`tive electrode coating such as fluorine-doped tin oxide and
`the like. Bendable coatings may be advantageous in mini-
`mizing manufachiring requirements since depositing a thin
`film of metal generally requires the steps of first bending the
`non-reflector costed substrate and then coating the bent
`substrate with the layer of reflective material.
`As described supra. it may be advantageous to construct
`electrochromic mirrors whose reflective element 9 is located
`within the laminate assembly. This may be achieved by
`coating the imward surface of substrate 3 with a layer of
`effective ousterial &. such as silver. so that the ailver coating
`(along with any adhesion promoter Isyers 11) is protected
`from the ouwide environment For example, a layer of
`reflective material 8 may be vacuum deposited onto the
`inward surface of substrate 3 in one and the same process
`step as the subsequent deposition ofthe electrochromic solid
`film 7 onto substrate 3. This construction and process for
`coonomical
`
`a3
`
`42
`displays (along with any other components. circuitry. back-
`ing members, case structures. wiring and Lhe like) are pot
`substantially distinguishable or visible to the dover and
`vehicle cocupants,
`With reference to FIGS. 9 and 16. emitting displays 14.
`such as vacuurn fluorescent displays. light cmitting diodes.
`gas discharge displays. plasma displays, cathode ray tubes.
`clectroluminesceat displays and the like may also be placed
`in contact with, or adhered to using an adhesive 17. 18 such
`as an cpozy. the rear of substrate 3, Generally. such emitting
`displays may only be observable when powered so as to emit
`light
`A variety of emitting displays 14 may be used in this
`connection Including, but not limited to, double heterajuac-
`tion AlGaAs very high intensity red LED lamps, such as
`releceapertomrrina rela atesafepamherssuber
`double heterojunction AVGaAs/GaAs material technology
`iconeeunecioy available from Hewlett Packard Corporation.
`Palo Alto. Colif. under the designation “T-134 (5 mm)
`HLMP-4100-4101"}.
`Alternatively, vacuum fluorescent displays, such as 12V
`battery driven high luminance color vacuum fluorescent
`designations S-2425G. SIAC. 525900 ood
`§2397G]- It may also be advantageous to use displays 14
`that operate edficiently at about 12V or lower since these
`
`ri
`
`35
`
`45
`
`uniformity
`performance
`Optical
`the entire surface area of the mirror is enhanced. The thin
`film stack [which comprises the electrochromic solid film 7
`(e.g.. tungsten oxide), the layer of reflective material 8 (e.g...
`silver of aluminum) aod any ondercoat layers between the
`layer ofreflective material & and substrate 3} should have a
`fight reficctance within the range of at Ieast about 70% to
`greater than about 80%. with a light transmission within the
`range of about 1% to about 20%. Preferably. the light
`tansmission is within the
`of about 3% to about 20%,
`and more preferably within the range of sbout 4% to about
`8%. with a light reflectance greater than about 60%. The
`inward facing surface of substrate 3 may be coated with a
`foulti-layer partially transmitting/substantially reflecting
`conductor comprising a partially
`(preferably, in
`from NEC Electronics Incorporated. Mountain View. Calif..
`the range of about 1% to xbout 20%Wsubstantially reflecting
`such as under the designation Part No. FIP2OM&S.
`(preferably, greater than about 70% reflectance. and more
`Tt may also be desirable. particularly where the reflective
`preferably, greater than about 80% reflectance) metallayer
`clement is at least partially light transmitting,to use a light
`absorbing mezus, such as a biack-. brown- or blue-colored
`Darronbo hakretuitycoembacsingsthorcencoceenans
`or other suitably colored absorbing costing. tape, paint,
`with an at jesst partially conducting transparent conductor
`Jacquer and the like, on portions of the rearmost (non-
`ee eat ordeat tities cee
`inward) surface of substrate 3 where displays are not
`layer. 2 doped or undoped indium oxide lsyer (sich as
`indium tis oxide) or the Hike]. Opcionally. an undercosting
`mounted. It may be desirable to use substantially opague,
`and preferably dark colored tape or plastic film and the like.
`metal oxide (or another at least partially transmitting metal
`compound Isyer, such as a metal nitrideHe titanium nitride)
`across the sutface of substrate 3. such as by adhering to
`may be included in the sack which comprises the muiti-
`protective material 20. preferably across substantially the
`layer conductor. This multi-leyer conductor functions as
`entire rear surface. except where any displays are to be
`reflective clement 8, and can be overcoated with electro-
`Ee eyeeeee or sestheti-
`cally non-sppealing mirror Gael Shimsinakiowdats Ser anny
`chromic solid film 7 during fabrication of an electrochromic
`mirror incorporating on demand displays. Alternatively. the
`light emittance from the display may be reduced
`Piacement of apertures or cutouts in 2 tape or film backing
`multi-layer conducter described supra may be used on the
`inwant surface of substrate 3. with the electrochromic solid
`may expedite the assembly of such mirrors by guiding the
`film 7 coated onto the inward surface of substrate 2
`assembler to the point where the desired display or displays
`A light reflectance of at least 70% (preferably. at least
`is to be mounted. The tape or film backing may also serve
`80%) for the reflective clement to be used in an electrochre-
`Bs an anti-scatter means to enhance safety and prevent injury
`nic mirror incorporating on d=mand displays is desirable so
`by retaining amy giass shards which may result due to mizror
`breakage. for example caused by impact frora on accident.
`that the bleached (uspowered) refiectivity of the electro~
`chromic mirror can beaf Jeast 55% (preferably. at least 65%)
`Suitably colored paints, inks, plastic films or the jike may
`as measured using SAE J964a. which is the recommended
`be applied to the surface of substrate 3 where the display 14
`procedure for measuring reflectivity of rearview micros for
`is to be placed to change or effect the color of the display.
`automobiles. Likewise, a transmission through the reflective
`Also. the display 14 may be adhered to a surface of the
`clemeot of. preferably, between about 1% to 20%
`substrate using an adhesive 18, such as an index matching
`fansmission. but not much more than about 30% tansmis-
`adbesive 17. 18. that may be dyed to effect color and/or
`sion (measured using Iuminant A. a photopic detector. and
`contrast cnhancement in the display (see ¢.g.. Larson. the
`at near normal incidence) is desirable so thet emithng
`disclosure of which is hereby incorporated herein by
`reference],
`displays disposed behind the reflective clement of the elec-
`techromic mirror are adequately visible when powered
`Generally. and particularly when the electrochromic ele-
`even by day but when unpowered and not emitting. the
`ment is in its bleached, uncolored stale, it may be desirable
`
`60
`
`65
`
`Opy prov
`
`7
`
`aqe Da
`
`eon
`
`SMR USA
`Exhibit 1029
`Page 183
`
`SMR USA
`Exhibit 1029
`Page 183
`
`

`

`5,724,187
`
`.
`43
`for the image of the display—e.g., an information display.
`auch as a compass display, a clock display, a hazard warning
`display or thelike—to have a Inminance within the range of
`at least about 30 foot lamberts to about 80 foot lamberts
`, Within the range of af
`least about 40 foot
`lamberts to about 60 foot lamberts), as measured with the
`display placed behind. and emitting through, the electro-
`chromic mirror and with the electrochromic element in its
`fully transmitting, bleached state. With this level of
`luminance, sach a display may be read easily even with
`bright ambient levels of light. Also, the clectronic circuitry
`taught by and deseribed in Larson may be used to appro-
`peiately dim the display to suit nighttime driving conditions
`and/or to compensatefor any dimming ofthe electrochromic
`element. Generally, at night the luminance of the display is
`about 15-40%. preferably about 20-35%. that of the day-
`time value.
`During daytime lighting conditions. drivers of motar
`vehicles mounted with an clecrochromic mirror (interior.
`exterior of both) benefir from relatively high reflectance (at
`jeast about 55%. with st Jeast about 65% typically being
`pacferred) when im the bleached “day” state. Any display
`positioned behind the electrochromic miror should have «
`sufficiently high luminance topermit the display (which may
`i
`or combinations thereof) to
`
`10
`
`2
`
`25
`
`a4,
`HU75218.08L also is 2 0.125" thick sheeting. made from
`multiple polymer layers (c.g. 1305 layers). with # light
`reflectance of about 58%. However, this PRM has
`CAP Isyers which results in a transmission
`which has a distinctlyred tint. Ar such, it may beparticularly
`well-suited for use in conjunction with the mirrors of the
`present invention that employ in their construction red light
`emitting diodes. such as those typically employed in hazard
`warning devices.
`An say of light emitting diodes may be positioncd
`behind « window 13 in 2 mirror with ao appropriately sized
`piece of PRM positioned between the emitting displays 14
`and the rearmost (non-inward) surface ofthe substrate 3. By
`choosing a PRM with a selective transmissionwhichpermits
`the passage of the bandwidth of light cmitted by the emitter
`but that substantially mttenusics other wavelengths not
`within that bandpass of light. optical efficiency may be
`enhanced. Indeed, PRM itself may be an appropriate refiec-
`tive element behind which display emitters may be disposed.
`While PRM may be vulnerable to scratching and
`vo degradation from environmental exposure, substrates 2.3
`offer desirable
`from such damage. Use of PRM
`where the piece of PRM is larger than amd covers the
`window created in the reflective element on substrate 3 (but
`is smaller than the entire surface area of substrate 3) is
`
`a motor vehicle (ar outside. where electrochromic exterior
`rearview mirrors are used of where the
`interior rearview mirror is mounted in a convertible with it
`top down) are bright, such as midday on a runny. cloudless
`day. The mirrors of the present invention may achieve a light
`reflectance of at least about 55% for the high reflectance
`state where a high reflector in the form of a thin film metal
`costing is used with a sufficient thickness to allow for light
`to transmit through the electrochromic clement 1, preferably
`within the range of about 1% to about 15% transmission. but
`not exceeding about 30% (as measured using Mluminent A
`and a photopic detector. with near nomnal incidence). More
`. Where silver is used as o high reflector, the
`mirrors of the
`invention may achieve 2 light reflec-
`tance ofat Jeast about 65% for thehigh reficctance state with
`
`40
`
`supra). The thin film metal costing
`within the range of about200 A to about 1.500 A, preferably
`within the range of about 200 A to about 750 A.
`Tt may also be desirable. particularly when used in con-
`junction with highly
`selective light emitting
`diodes and the like, to usePRM as a reflectorplaced between
`the display 14 and the rearmost (non-inward) surface of
`substrate 3. PRM is a spectrally selective, substantially
`reflecting (greater than sbout 50%) and significantly tran:-
`parent polymer reflector material [see T. Alfrey. Jr ct al.
`“Physical Optics of Iridescent Mi
`Plastic Films”.
`Polym. Eng’g. & Sci. 46). 400-04 (1969); W. Schrenk et
`al.. “Coextruded Hlastomeric Optical Interference Film",
`ANTEC °88. 1703-07 (1988); and see generally U.S. Pat
`No. 3.711.176 (Alfrey. Ix); U.S. Pat, No, 3.557.265
`(Chisolm) and U.S. Pat. No. 3.565.985 (Schrenk). PRM is
`commercially available from Dow Chemical Co., Midland.
`Mich. such as under the designation PRM HU75218.03L.
`which is a 0.125" thick shesting made of multiple polymer
`layers (e.g.. 1305 layers), having differing refractive indices
`and transparenVtransparent CAP layers. This PRM exhibits
`a light reficctancs ofabout $8% and a generally neutral light
`transmittance. Another PRM. designated as PRM
`
`a
`
`65
`
`(commercially
`Labs, Santa Rosa. Calif.)) as the reflective element because
`of economic benefits.
`Should it be desirable to use a PRM/emitting display. =
`substrate with or without a thin film of metal refiector
`coating that is substantially transmitting may be positioned
`in front of the PRM. Suitable optical adhesives. preferably
`adhesives as described supra, may be used
`ight
`emitting element
`which emits light through a sheet of PRM. which is posi-
`tioned behind 2 glass substrate through which the emitted
`Light also passes. Such a mirror would
`reflective
`when the light emitting element (¢.g.. a red LED such as
`described supra) is unpowered, yet would efficiently display
`ing
`i
`ii
`fight emitting clement is
`powered. strobed of flashed. Also. PRM being 2 polymer
`material is relatively casily formed by molding, slumping.
`bending and similar polymer forming methods, so conform-
`ance to a compound curvature or convex curvature is
`facilitated.
`In that aspect of the present invention directed to exterior
`rearview mirrors for motorvehicles it may be advantageous
`to use in conjunction therewith signal lights. security lights.
`flood lights. remote actuation and combimstions thereof as
`taught by and described in commonly assigned co-pending
`U.S. patent
`io Ser. No. 08/011.947. filed Feb. 1.
`1993 (“the "947 application”). the disclosure of which is
`hereby incorporated herein by reference.
`The electrochromic mirrors of the present invention may
`also include an anti-reflective means. such as an anti-
`reficctive costing, on the front (non-inward) surface of the
`outermost or frontmost substrate as viewed by an observer
`(see e&g.. Lynam V); an anti-static means. such as a con-
`ductive coating. particularly a substantially transparent con-
`ductive coating.ITO. tis IMO. tin oxide and the like; index
`matching means to reduce internal and interfacial
`reflections, such as thia films of an appropriately selected
`optical path length: and/or light absorbing glass. such as
`glass tinted to a neutral density. such as
`gray
`tinted glass (commercially available from Pitsburgh Plate
`
`rom
`we
`San BP
`Qe aieiintetiteete
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`mans Matnhoce an
`
`38.07
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`SMR USA
`Exhibit 1029
`Page 184
`
`SMR USA
`Exhibit 1029
`Page 184
`
`

`

`5.724.187
`
`45
`Giass Industries) and “SUNGLAS” gray tinted glass
`(commercially available from Ford Glass Co., Detroit.
`Mich.). which assists in sugmenting contrast enhancement.
`Moreover, polymer interlayers, which may be tinted gray.
`such as those used in electrochromic devices as taught by
`and described in Lynam 1 may be incorporated into the
`electrochromic micrors described herein.
`The mirrors of this present invention. particularly rear-
`iew mirrors intended for use on the exterior motor vehicles,
`may also benefit from an mrtiliary beating rocans used in
`Connection therewith such as those taught by and described
`in U.S. Pat No. §.151,824 (O'Farrell) and U.S. pateot
`application Ser. No. 07/971,676, filed Nov. 4. 1992 (“the
`
`polymer or blend within which is
`filler like carbon black. graphite. a metal and a metal oxide,
`{see c.g.. U.S. Pat. No. 4.882.466 (Fricl)]. The heater pads
`exhibit 2 positive ltemperamre coefficient; that is, their
`resistance increases when the
`temperature
`increases. Thus. the heater pads may be used as a self-
`regulating heating element.
`As an alternative to a heater pad. a heater means, such as
`a resistance layer or heating film, may be deposited (such as
`through vacuum deposition. thick film printing, screen
`Printing. dispensing. contact printing, Sow coating and the
`like) onto the outward facing surface of substrate3 (Le.. onto
`the rearmost surface of an electrochromic minror assembly).
`Suiteble beater means include a PTC moterial. a metal thin
`film layer (such, chromitim. molybdenum, a nickel-based
`alloy like Inconeland Hastelloy. stainiess steel, titanium and
`the like), and 2 transparent conductor thin filrm (such as tin
`oxide (doped or undoped) andindiurntin oxide). Such beater
`means are disclosed in the "676 application.
`The heater means referred to above function both to
`assure rapid coloration and bleaching of an electrochromic
`searview mirror when operated at Jow temperatures, and to
`remove any frost or dew which may accumulate on the
`outward facing surface of subswrate 2 (i¢.. the outermost
`surface of the rearview mirror that is contacted by outdoor
`elements like rain, snow. dew and the like), Por example. 2
`convex or multi-radius electrochromic outside mirror for an
`automobile may be fabricated by forming substrarc 3
`through bending a fuori
`tin oxide coated glass
`substrate (such as a “TEC-Glass” product like “TEC 20°,
`“TEC 12" ao “TEC 10”) so that the transparent conductor
`doped tin oxide thin film coating is located on the concave
`surface of substrate 3. The opposite, convex surface of
`substrate 3 is coated with a metal reflector layer (such as
`silver. optionally being undercoated with a chromium adhe-
`sion promoter layer) and the reflector in tum is contacted
`with an electrochromic layer. such as tungsten oxide, This
`convex surface reflector coated/concave surface transparent
`conductor coated substrate 3 is then mated with an cquiva-
`lently bent substrate 2 that is coated on its concave (inward
`facing) surface with a transparest condactor (such as fluo-
`rine doped tin oxide), and with an electrolyte between the
`mated substrates to forma an electrochromic exterior rear
`view mirror. Next, bus bars (c.g... a conductive frit, solder or
`the fike) are formed on opposing sides of the transparent
`conductor thin film heater on the rearmost. concave surface
`of substrate 3. When connecied to the 12 volt battery/
`ignition electrical supply of 4 vehicle. the transparent con-
`
`&
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`35
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`45
`
`sO
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`58
`
`6
`
`4%
`ductor thin film beater on the rcarmost, concave surface of
`substrate 3 heats the electrochromic medium and defrosts
`the front, outermost. concave surface of substrate 2.
`¥f a display fs to be mounted behind the reflective element.
`an appropriately sized and shaped aperture through the
`auxiliary beating means ahould be used fo accommodate the
`display but not leave portions of the mirror unheated for
`de-icing or de-misting purposes. Likewise. should » heat
`distribution pad be used. suchas an aluminumor copper foil
`es described in the "676
`an eppropiiately sized
`and shaped aperture should also be provided therein to
`accommodate such displays. Where apertures are to be
`included in 2 PTC heater pad. a pattern of resistive cloc-
`trodes which contact the conductive polymer, which may
`typically be applied by a silk-screening process as described
`in FricL. should be designed to accommodate the apertures in
`the ped In addition, such a pattern may also be useful to
`thermally compensate for the apertures in the pad.
`Altematively,
`the resistive electrode/conductive polymer
`combination may be applied. for example. directly onto the
`rearmost (non-iowsrd) surface of substrate 3, or onto # heat
`dist