PATENT
`DO},l 09 P—1624
`
`EXTERIOR SIDEVIEW MIRROR SYSTEM
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`CROSS REFERENCE TO RELATED APPLICATIONS
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`[0001]
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`The present application is a continuation of U.S. patent application Ser. No. 12/197,666,
`filed Aug. 25, 2008 (Attorney Docket DON09 P—1462), whichis a division of US. patent
`'
`application Ser. No 10/709434, filed May 5, 2004 now U.S. Pat. No. 7,420,756, which claims
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`the benefit of U.S. provisional application, Ser. No. 60/471,872, filed May 20, 2003, which are
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`hereby incorporated herein by reference in their entireties.
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`‘
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`. FIELD OF THE INVENTION
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`[0002]
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`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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`,
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`BACKGROUND OF THE INVENTION
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`[0003]
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`Typically, mirror reflective elements are formed of glassand 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
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`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
`element outer surface, such as during winter. A variety of hard coats have been proposed in the
`art, typically applied by dip coating or vacuum deposition techniques. However, a need exists
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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.
`Also, exterior rearview mirror reflective elements may be aspheric or multi—radius, and ’
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`[0004]
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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
`body of the vehicle when the mirror assembly is mounted to the vehicle), and a more curved V
`multi-radius portion or surface at the outboard side ofthe reflective element (i.e., further from
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`,
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`1
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`SMR USA
`Exhibit 1007
`Page 001
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`SMR USA
`Exhibit 1007
`Page 001
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`

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`[0005]
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`[0006]
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`the side body of the vehicle when the mirror assembly is mounted to the vehicle), in order to
`provide an extended field of view. It is typically desirable to'have the reflective elements or
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`substrates of such exterior mirror elements to he formed of a glass material because glass
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`material typically provides an enhanced scratch resistance over conventional optical resins and
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`the like.
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`Therefore, there is a need in the art for a mirror reflective element that overcomes the
`shortcomings of the prior art elements and substrates.
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`SUMMARY OF THE INVENTION
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`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.
`According to an aspect of the present invention, a Wide angle reflective element for a
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`[0007]
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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 portion or surface. The substrate
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`comprises apolymeric resin material. The glass film is adapted to substantially conform to the
`exterior surface’ofthe Wide angle substrate. The glass film comprises a glass material and has a.
`thickness of less than approximately 0.8 mm.
`‘
`1
`According to another aspect of the present invention, a reflective element for a mirror
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`'
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`[0008]
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`assembly for a vehicle comprises a substrate having an exterior surface, and an anti—abrasion film
`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 of less than
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`approximately 0.8 mm, and is flexible to conform to the exterior surface.
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`{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
`2
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`SMR USA
`Exhibit 1007
`Page 002
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`SMR USA
`Exhibit 1007
`Page 002
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`

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`glass film may be unrolled from a reel or roll and applied to the exterior surface of the elongated
`stripcr 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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`I
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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 surface and a more curved outboard
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`[0011]
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`portion or surface.
`A reflective film or layer may be applied to the inner surface or side of the substrate or
`strip opposite the exterior surface. The reflective film may comprise a 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
`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.
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`[0013]
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`According to another aspect of the present invention, a method for forming a reflective
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`element substrate for a mirror 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
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`like, to a surface of the elongated strip sheet. The substrate material may comprise a transparent
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`7 optical polymeric resin. The functional film is preferably unrolled from a reel or roll of film and
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`applied to the surface of the elongated strip or sheet generally continuously as the strip or sheet is
`formed or extruded or east or molded. Preferably, multiple mirror element shapes or mirror
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`1
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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.
`7 The functional or anti-abrasion film may comprise an ultrathin glass material which is
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`[0014]
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`sufficiently flexible to be provided in a reel or roll (or in asheet 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-
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`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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`SMR USA
`Exhibit 1007
`Page 003
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`SMR USA
`Exhibit 1007
`Page 003
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`

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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
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`substrate) for unrolling the reflective film as the film is generally continuously applied to the
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`surface of the generally continuously formed sheet or strip.
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`[0016]
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`‘
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`Therefore, the present invention provides a molded wide angle or multi-radius single
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`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-
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`abrasion film preferably comprises an ultrathin glass film or sheet to provide enhanced scratch
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`‘
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`resistance. The molded substrate may have a reflective film or layer laminated or applied to the
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`inner surface opposite the exterior surface.
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`These and other objects, advantages, purposes and features of the present invention will
`become apparent upon review of the following specification in conjunctibn with the drawings.
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`FIG. 1 is a perspective View of an exterior rearview mirror assembly in accordance with
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`the present invention;
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`FIG. 2 is a perspective View of a wide angle or multi—radius reflective element in
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`accordance with the present invention;
`FIG. 3 is a sectional view of the wide angle. or multi-radius reflective element taken along
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`the line III—III in FIG. 2;
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`FIG. 4 is a sectional View similar to FIG. 3, showing a wide angle or multi-radius
`reflective element in accordance with the present invention with a reflective film or layer applied '
`to the exterior surface of the element and an anti-abrasion film or layer applied over the
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`reflective film or layer;
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`7
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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;
`FIG. 5A is an elevation of the extruder of FIG. 5, showing the wedge shape of the
`extruded strip and reflective element substrate;
`V
`2
`I
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`FIG. 6 is a plan view of the extruded strip showing the cutout shapes 'of the reflective
`element cut from the extruded strip;
`
`FIG. 7 is a sectional View of the reflective element formed by the process shown in FIG.
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`[0017]
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`[0018]
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`[0019]
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`[0020]
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`[0021]
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`[0022]
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`[0023]
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`[0024]
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`[0025]
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`5;
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`SMR USA
`Exhibit 1007
`Page 004
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`SMR USA
`Exhibit 1007
`Page 004
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`

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`[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;
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`[0027]
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`[[0028]
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`FIG. 9 is a perspective View of an automobile equipped with exterior sideview mirror
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`assemblies according to this present invention;
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`1
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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 ofa plano—multiradius reflective element assembly
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`[0030]
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`[0031]
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`[0032]
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`[0033]
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`[0034]
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`[0035]
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`of the mirror assembly in FIG. 10;
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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. 1 1;
`FIGS. l3A-13H illustrate views ofvarious locations for a plano reflective element and an
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`auxiliary reflective element according to this present invention;
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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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`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 clement
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`assembly according to this present invention;
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`V
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`[0036]
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`,
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`FIG. 16 is a fiont elevation view of another embodiment of a plano reflective element
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`[0037]
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`[0038]
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`[0039]
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`[0040]
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`[0041]
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`assembly according to the present invention;
`FIG. 17 is an exploded perspective view of the piano reflective element assembly of FIG.
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`’ 16;
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`FIG. 18 is an end view of the plane reflective element assembly of FIG. 16 as Viewed *
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`from line XVIII-~XVIII of FIG. 16 ;
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`FIG. 19 is a top View of the piano reflective element assembly of FIG. 16 as viewed fiom
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`line XIXnXIX of FIG. 16;
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`FIG. 20 is a schematic representation of the plano reflective element assembly of FIG. 16'
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`I
`illustrating the orientation of the reflective element;
`~ FIG. 21 is another Schematic representationof the orientation ofthe reflective elements
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`of the plano reflective element in FIG. 16;
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`SMR USA
`Exhibit 1007
`Page 005
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`SMR USA
`Exhibit 1007
`Page 005
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`

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`[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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`plane reflective element assembly of FIG. 16; and
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`[00431
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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.
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`DESCRIPTION OF THE PREFERRED EMBODIMENTS
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`[0044]
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`Referring now to the drawings and the illustrative embodiments depicted therein, an
`exterior rearview mirror assembly 10 includes a reflective element 12 mounted at a casing 14,
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`which is mounted at an exterior portion of a vehicle 16.(FIG. 1). Reflective element 12 may
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`provide an enhanced field of View or wide angle field of View to a driver or occupant of the
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`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 180 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
`film 20, such as an ultrathin glass coating or layer or film, laminated or deposited or otherwise
`applied to the exterior surface 18b, and may have a reflective coating or layer 22 laminated or
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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
`mirror assembly (as shown in FIG. 1) and/or a reflective element for an interior rearview mirror
`assembly (not shown).
`‘
`Reflective element 12 may comprise an aspheric or multi-radius or wide angle single
`element reflective element substrate. The reflective element 12 may provide a field of view"
`similar to the plane—auxiliary reflective element assembly disclosed in US Pat. Nos. 6,522,451
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`and 6,717,712, which are hereby incorporated herein by reference.
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`.
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`[0045]
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`‘ [0046]
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`As illustrated in FIG. 9 from US. 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—uptruek or a similar passenger carrying non—commercial, personal
`transportation automobile) includes an interior r'earview mirror assembly 127vpositio'ned within -
`interior vehicle cabin 125. Interior vehicle cabin 125 further includes a steering wheel 116, a
`driver seat 129 positioned at steering Wheel 116, a front passenger seat 121 adjacent to driver
`seat 129 in the front portion of cabin 125, and a rear passenger seat 123 in the rear portion of
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`cabin 125. Automobile 110 furtherincludes a driver—side exterior sideview mirror assembly 112
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`and a passenger—side exterior sideView mirror assembly 114, each adapted for attachment to
`6
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`SMR USA
`Exhibit 1007
`Page 006
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`SMR USA
`Exhibit 1007
`Page 006
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`

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`opposing sides of automobile body 111, most preferably adjacent to the seating positionof 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
`illustrated in FIG. 10, a plane—multiradius exterior sideview reflective element assembly 13 0.
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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
`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—
`multiradius reflective element assembly 130 within exterior mirror housing 140 (such as by a
`lever control or by a cable control) and hence reposition the rearward field of View of plane-
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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 plane-multiradius reflective element
`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.
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`V
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`[0047]
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`Plano-multiradius reflective element assembly 130, as shown in FIG. 11, comprises a
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`plano element 150 and a Separate multiradius element 155. Preferably, plano element 150 is
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`adj acent-to multiradius element at a joint. At their joint, plano element 150 and separate
`multiradius element 155 can touch leaving substantially no gap or space therebetween, or plane
`element 150 and separate multiradius element 155 can be spaced apart at their joint by a space or
`gap, as in FIG. 11. Plano element 150 and‘multiradius element 155 are both-mounted to surface
`159 of, and are both supported by, a single backingplate element 160. Plano element 150 and
`multiradius element 155 are demarcated apart by demarcation element 165.7 Surface 161 of
`backing plate element 160 is preferably adapted to attach, such as by attachment member 164, to
`actuator 136 when plano—multiradius reflective element assembly 13f) is mounted in driver-side
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`exterior sideview mirror assembly 112 (and/or in passenger-side exterior side view mirror
`
`7
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`SMR USA
`Exhibit 1007
`Page 007
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`SMR USA
`Exhibit 1007
`Page 007
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`

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`assembly 114) such that plane 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
`memory. system, as is conventional in the rearview mirror arts) activates actuator 136 to
`reposition the rearward field ofView ofplane-multiradius reflective element assembly 130.
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`Thus, since elements 150, 155 are part of plane-multiradius reflective element assembly 130,
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`movement of plane-multiradius reflective element assembly 130 by actuator 136 simultaneously
`I and similarly moves plane element 150 and multiradius element 155.
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`[0048]
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`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
`the image Of an ebj ect 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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`plane 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-alley coating, a silver coating, an aluminum coating (or any'alloy or combination of these
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`metal reflectors). The metal reflector coating efplano 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
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`known in the mirror art. The reflector coating on plane element 150 may also comprise a
`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
`variablereflectance reflector element, plane element 150 preferably comprises an electre—eptie
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`reflector element and, most preferably, an electrochromic reflector element.
`When mounted into exterior side view mirror assembly 112 and/or 114, plane-
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`[0049]
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`multiradius reflective element assembly 130 is preferably orientated so that at least a portion of
`(more preferably a substantial portion of) the reflector surface ofplane element 150 is positioned
`closer to the vehicle body (and hence to the driver) than any portion of the reflector surface of
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`multiradius element 155. Thus, and referring to FIG. 11, side A of plane element 150 of plane—
`multiradius reflective element assembly 130 is positioned closer to the driver than side D of
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`multiradius element 155 when plane-multiradius reflective element assembly 130 is mounted on
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`an automobile. Also, when mounted into exterior side view mirror assembly 112 and/or 114,
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`SMR USA
`Exhibit 1007
`Page 008
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`SMR USA
`Exhibit 1007
`Page 008
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`

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`surfaces 166, 168 of plano-multiradius reflective element assembly 130 face rearwardly in terms
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`of the direction of vehicle travel.
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`[0050]
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`Multiradius element 155 of piano—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 of multiradius element 155
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`. with the least curvature (largest radius of curvature) occurring at the side of multiradius element
`155 (side C in FIG. 11) positioned adjacent its joint to plane element 150 When both are mounted
`on backing plate element 160. Thus, and referring to FIG. 11, the local radius of curvature at
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`side C of multiradius 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 7155 is at least about 1000 mm; more preferably is at least about 2000 mm
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`and most preferably is at least about 3000 mm whereas the local radius of curvature at side D of
`‘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
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`comprises a bent glass substrate with radii of curvature in the range of firom about 4000 mm to
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`about 50 mm. The multiradius 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
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`automobile model.
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`[0051]
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`The total field of view rearwardly of the automobile of the plane-auxiliary reflective
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`element assembly (which is a combination of the field of view of the pl ano reflective element
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`and of the auxiliary reflective element) preferably generally subtends an angle of at least about
`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
`of an automobile to which is attached an exterior sideview mirror assembly equipped with the -
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`plano-auxiliary reflective element assembly.
`
`7
`
`[0052]
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`Multiradius element 155 may comprise a conventional fixed reflectance mirror reflector
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`or it may comprise a variable reflectance mirror reflector whose reflectivity is electrically
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`adjustable. For example, multiradius element 155 may comprise a flat glass substrate coated
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`with a metallic reflector coating such as a chromium coating, a titanium coating, a rhodium
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`coating, a metal alloy coating, a nickel-alloy coating, a silver coating, an aluminum coating (or
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`any alloy or combination of these metal reflectors). The metal reflector coating of multiradius
`9
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`SMR USA
`Exhibit 1007
`Page 009
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`SMR USA
`Exhibit 1007
`Page 009
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`

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`element 155 may be a first surface coating (such as on surface 168) or a second surface coating
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`(such as on surface 169), as such terms are known in the mirror art. The reflector coating on
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`multiradius element 15 5 may also comprise a dielectric coating, or a multilayer of dielectric
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`coatings, or a combination of a metal layer and a dielectric layer to form automotive mirror
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`reflectors as known in the automotive mirror art. If a variable reflectance reflector element,
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`multiradius element 155 preferably comprises an electro—optic reflector element and, most
`
`[0053]
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`preferably, an electrochromic reflector element.
`Also, it is preferable that the thickness of plano element 150 and multiradius element 155
`be substantially the same in dimension so that their respective outer surfaces, 166 and 168, are
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`substantially coplanar so that a driver can readily View images in either or both elements. The
`thickness dimension of elements 150, 155 is determined by the thickness of the substrate (or- in
`the case of laminate-type electrochromic reflective elements, the thickness of the two substrates
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`between which the electrochrornic 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
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`mm, most preferably equal to or less than about 1.1 mm. Use of a thinner substrate is beneficial
`in tenns of improving the overall stability/vibration performance of the image seenin plano—
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`multiradius reflective element assembly 130 when mounted to an automobile.
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`[0054]
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`The reflector area of plano element 150 is preferably larger than that of multiradius
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`' element 155. Preferably, the width dimension of plano element 150 is larger than the width
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`dimension of multiradius element 1 55 (both width dimensions measured at their respective
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`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 ofmultiradius element 155 is preferably greater than 1; more preferably
`greater than 1.5; most preferably greater than 2.5 in order to provide a large, unit magnification
`
`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-
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`angle Viewing portion of plano-multiradius reflective element assembly 130. For plano-
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`multiradius reflective element assemblies to be mounted to the exterior sideview assemblies of
`passenger automobiles used non-commercially and for non—towing purpose, the width of plano
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`SMR USA
`Exhibit 1007
`Page 010
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`SMR USA
`Exhibit 1007
`Page 010
`
`

`

`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
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`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.
`
`portion (generally between E and F as shown in FIG. 11) that corresponds to and is aligned with
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`piano element 150. Backing plate element 60 also comprises a curved portion (generally
`
`between G and H as shown in FIG. 11) that corresponds to and is aligned with multiradius
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`element 155. Preferably, curved portion G—H of multiradius element 155 is fabricated with a
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`multiradius prescription that is substantially the same as the multiradius prescription of
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`multiradius element 155. 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
`
`by injection melding 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
`similar polymeric materials. For example, backing plate element 160 can be formed of ABS in
`
`an injection molding operation. Plano element 150 can becut from a stock lite of flat chromium
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`mirror—coated 1.6 mm thick glass. Multiradius element4155 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 element 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
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`155 can each by individually loaded into an injection molding tool. Once loaded, a polymeric
`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.
`
`Integral molding of the backing plate element to plano element 150 and multiradius element 15 5
`
`(along with any other elements such as the demarcation element 165) in a single integral molding
`
`operation, is a preferred fabrication process for plano-multiradius reflective element assembly
`
`.130.
`
`[0056]
`
`Plano-multiradius reflective element assembly 130 further preferably includes
`
`demarcation element 165 that functions to delineate and demarcate the plano region of the
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`assembly from the wide-angle, multiradius region and also preferably functions to prevent
`11
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`SMR USA
`Exhibit 1007
`Page 011
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`SMR USA
`Exhibit 1007
`Page 011
`
`

`

`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.
`
`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 backng plate element 160.
`
`Preferably, demarcation element 165 is formed 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 formed 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
`
`portion 170 that includes wing portions 173, 173’ and a stem portion 171. Stem portion 171
`
`preferably has a cross-sectional width CCC of less than about 4 mm, more preferably less than
`
`about 3 mm and, most prcfcrably less than about 2 mm. Crown portion 170 preferably is
`
`dimensioned to not protrude substantially beyond surfaces 166, 168 of elements 150, 155 when
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`demarcation element 165 is installed between elements 150 and 155. Also, wings 173, 173' are
`preferably dimensioned to p