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`US007842154B2
`
`c12) United States Patent
`Lynam
`
`(IO) Patent No.:
`(45) Date of Patent:
`
`US 7,842,154 B2
`Nov. 30, 2010
`
`(54) MIRROR REFLECTIVE ELEMENT AND
`METHOD OF FORMING SAME
`
`(75)
`
`Inventor: Niall R. Lynam, Holland, MI (US)
`
`(73) Assignee: Donnelly Corporation, Holland, MI
`(US)
`
`( *) Notice:
`
`Subject to any disclaimer, the term ofthis
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 246 days.
`
`(21) Appl. No.: 12/197,666
`
`(22) Filed:
`
`Aug. 25, 2008
`
`(65)
`
`Prior Publication Data
`
`US 2008/0308219 Al
`
`Dec. 18, 2008
`
`Related U.S. Application Data
`
`(62) Division of application No. 10/709,434, filed on May
`5, 2004, now Pat. No. 7,420,756.
`
`(60) Provisional application No. 60/471,872, filed on May
`20, 2003.
`
`(51)
`
`Int. Cl.
`B29C 47102
`(2006.01)
`(52) U.S. Cl. ......................... 156/242; 156/99; 156/102;
`156/244.11; 264/1.6; 264/1.7; 264/1.9; 264/173.11
`( 58) Field of Classification Search . ... ... ... ... .. ... . 156/99,
`156/102, 242,244.11, 244.27; 264/1.6, 1.7,
`264/1.9, 173.11
`See application file for complete search history.
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`3,451,876 A * 6/1969 Edelmann et al ............ 428/163
`
`3,759,647 A
`9/1973 Schrenk et al.
`3,773,882 A
`11/1973 Schrenk
`3,884,606 A
`5/1975 Schrenk
`4,193,668 A
`3/1980 Skinner
`4,385,804 A
`5/1983 Tamura et al.
`4,666,264 A
`5/1987 Yamabe
`4/1988 Bahls
`4,737,188 A
`7/1990 Ichikawa
`4,944,581 A
`5,085,907 A
`2/1992 Smith
`5,262,894 A
`11/1993 Wheatley et al.
`11/1994 Schissel et al.
`5,361,172 A
`5,483,386 A
`1/1996 Carson
`5,690,768 A * 11/1997 Iwasa et al. ................. 156/108
`5,910,854 A * 6/1999 Varaprasad et al.
`......... 359/273
`6,030,084 A
`2/2000 Schmidt
`6,409,354 Bl
`6/2002 Richard
`6,522,451 Bl
`2/2003 Lynam
`6,709,119 B2
`3/2004 Gillich et al.
`7,420,756 B2
`9/2008 Lynam
`
`* cited by examiner
`
`Primary Examiner-Joseph S Del Sole
`Assistant Examiner-Timothy Kennedy
`(74) Attorney, Agent, or Firm-Van Dyke, Gardner, Linn &
`Burkhart, LLP
`
`(57)
`
`ABSTRACT
`
`A method for forming a reflective element substrate for a
`mirror assembly of a vehicle includes generally continuously
`forming an elongated sheet of substrate material and applying
`a substantially transparent functional film to a surface of the
`elongated sheet. The substantially transparent functional film
`is unrolled from a reel or roll of the film and the unrolled film
`is applied to the surface of the elongated sheet generally
`continuously as the sheet is formed or extruded or cast. Two
`or more mirror substrates are formed from the elongated sheet
`after the film is applied to the surface of the sheet.
`
`20 Claims, 3 Drawing Sheets
`
`2.0
`
`24
`
`SMR USA
`Exhibit 1015
`Page 001
`
`

`

`U.S. Patent
`
`Nov. 30, 2010
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`Exhibit 1015
`Page 003
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`Nov. 30, 2010
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`Page 004
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`

`

`US 7,842,154 B2
`
`1
`MIRROR REFLECTIVE ELEMENT AND
`METHOD OF FORMING SAME
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`The present application is a division of U.S. patent appli(cid:173)
`cation 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 is
`hereby incorporated herein by reference in its entirety.
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to rearview mirror
`elements for a rearview mirror assembly of a vehicle and,
`more particularly, to exterior rearview mirror elements com(cid:173)
`prising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`
`2
`molded substrate may have an anti-abrasion film or layer,
`such as an ultrathin glass film, applied over the exterior sur(cid:173)
`face or first surface to provide substantial protection against
`scratches occurring to the molded substrate. The inner surface
`5 or second surface of the reflective element substrate may have
`a reflective coating or layer, such as a polymeric reflective
`film, laminated or adhered or otherwise applied thereto.
`According to an aspect of the present invention, a wide
`angle reflective element for a mirror assembly for a vehicle
`10 includes a wide angle substrate having an exterior surface and
`a glass film disposed at the exterior surface. The exterior
`surface of the substrate has a less curved inboard portion or
`surface and a more curved outboard portion or surface. The
`substrate comprises a polymeric resin material. The glass film
`15 is adapted to substantially conform to the exterior surface of
`the wide angle substrate. The glass film comprises a glass
`material and has a thickness of less than approximately 0.8
`mm.
`According to another aspect of the present invention, a
`20 reflective element for a mirror assembly for a vehicle com(cid:173)
`prises a substrate having an exterior surface, and an anti(cid:173)
`abrasion film applied to the exterior surface. The substrate
`comprises a polymeric resin material, such as a transparent
`optical polymeric resin material. The anti-abrasion film pref-
`25 erably comprises a glass material (such as a soda lime glass or
`a borosilicate or the like) and has a thickness of less than
`approximately 0.8 mm, and is flexible to conform to the
`exterior surface.
`The substrate may be cut from a strip or sheet of molded or
`30 extruded or cast substrate material ( or less preferably, may be
`cut from an injected molded strip or sheet). The flexible glass
`film may be unrolled from a reel or roll and applied to the
`exterior surface of the elongated strip or sheet of substrate
`material. The substrate, including the glass film or layer, may
`35 then be cut or otherwise formed from the elongated strip or
`sheet.
`The substrate may comprise a wide angle substrate and/or
`may comprise a multi-radius exterior surface having a less
`curved inboard portion or surface and a more curved outboard
`portion or surface.
`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 reflec(cid:173)
`tive film laminated or otherwise adhered or applied to the
`inner side of the substrate or strip. The reflective film may
`comprise an all polymer-thin-film multilayer, high reflective
`mirror film comprising multiple coextrusion of many plastic
`layers to form a highly reflective mirror film.
`Optionally, a reflective film or layer may be applied to the
`exterior surface of the substrate or sheet or strip, and the glass
`film or layer or sheet may be applied over the reflective film
`layer. In such an application, the substrate acts as a support or
`backing plate for the reflective film or layer and the glass film
`or layer, whereby optical clarity/transparency of the substrate
`55 material is not necessary.
`According to another aspect of the present invention, a
`method for forming a reflective element substrate for a mirror
`assembly of a vehicle comprises generally continuously
`forming an elongated strip or sheet of substrate material and
`60 applying a substantially transparent functional film, such as
`an anti-abrasion film or a hydrophilic film or a hydrophobic
`film or the like, to a surface of the elongated strip sheet. The
`substrate material may comprise a transparent optical poly(cid:173)
`meric resin. The functional film is preferably unrolled from a
`65 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
`
`Typically, mirror reflective elements are formed of glass
`and have a reflective coating deposited thereon, such as via
`vacuum deposition or wet chemical silvering or the like, such
`as on a silver line, such as described in U.S. Pat. No. 4,737,
`188, which is hereby incorporated herein by reference. Poly(cid:173)
`meric reflective elements are also known, such as are
`described in U.S. Pat. Nos. 6,601,960; 6,409,354; 4,944,581;
`4,385,804; 4,193,668; 4,666,264; and 5,483,386, which are
`hereby incorporated herein by reference. For such polymeric
`mirror reflective elements, the need exists for a hard coat or
`surface on the first or outer or exterior surface of the element
`which is contacted by the exterior elements, such as rain, road
`debris, or the like, or contacted, for example, by a person
`scraping ice or wiping snow or condensation off the mirror
`element outer surface, such as during winter. A variety of hard
`coats have been proposed in the art, typically applied by dip
`coating or vacuum deposition techniques. However, a need
`exists for an automotive mirror reflective element which has
`the properties of plastic (i.e., a specific gravity roughly half 40
`that of glass), and which has a glass-like exterior surface.
`Also, exterior rearview mirror reflective elements may be
`aspheric or multi-radius, and may typically have a less curved
`or substantially flat ( around 2000 mm radius or thereabouts)
`inboard portion or surface at the inboard side of the reflective 45
`element (i.e., closer to the side body of the vehicle when the
`mirror assembly is mounted to the vehicle), and a more
`curved multi-radius portion or surface at the outboard side of
`the reflective element (i.e., further from the side body of the
`vehicle when the mirror assembly is mounted to the vehicle), 50
`in order to provide an extended field of view. It is typically
`desirable to have the reflective elements or substrates of such
`exterior mirror elements to be formed of a glass material
`because glass material typically provides an enhanced scratch
`resistance over conventional optical resins and the like.
`Therefore, there is a need in the art for a mirror reflective
`element that overcomes the shortcomings of the prior art
`elements and substrates.
`
`SUMMARY OF THE INVENTION
`
`The present invention provides a molded wide angle or
`multi-radius substrate for a reflective element. The molded
`substrate comprises a polymeric optical resin transparent
`material and has a curved exterior surface, which may have a
`less curved/flatter or substantially flat inboard portion or sur(cid:173)
`face and a more curved outboard portion or surface. The
`
`SMR USA
`Exhibit 1015
`Page 005
`
`

`

`US 7,842,154 B2
`
`3
`mirror element shapes or mirror element substrates may be
`cut or otherwise formed from the elongated sheet after the
`functional film is applied to the surface of the strip or sheet.
`The functional or anti-abrasion film may comprise an
`ultrathin glass material which is sufficiently flexible to be
`provided in a reel or roll ( or in a sheet that is flexible and
`conformable to a bent substrate). The substrates may be
`formed with a wide angle exterior surface or a multi-radius
`exterior surface. The anti-abrasion film may be sufficiently
`flexible to conform to the wide angle or multi-radius or
`curved exterior surface.
`A reflective film, such as a polymeric reflective film or the
`like, may be applied to the opposite surface of the substrate or
`sheet or strip. The reflective film may be sufficiently flexible
`to be provided in a reel or roll form ( or in a sheet that is flexible
`and conformable to a bent substrate) for unrolling the reflec(cid:173)
`tive film as the film is generally continuously applied to the
`surface of the generally continuously formed sheet or strip.
`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 exte(cid:173)
`rior surface of the substrate. The anti-abrasion film preferably
`comprises an ultrathin glass film or sheet to provide enhanced
`scratch resistance. The molded substrate may have a reflec(cid:173)
`tive film or layer laminated or applied to the inner surface
`opposite the exterior surface.
`These and other objects, advantages, purposes and features
`of the present invention will become apparent upon review of
`the following specification in conjunction with the drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a perspective view of an exterior rearview mirror
`assembly in accordance with the present invention;
`FIG. 2 is a perspective view of a wide angle or multi-radius
`reflective element in accordance with the present invention;
`FIG. 3 is a sectional view of the wide angle or multi-radius
`reflective element taken along the line III-III in FIG. 2;
`FIG. 4 is a sectional view similar to FIG. 3, showing a wide
`angle or multi-radius reflective element in accordance with
`the present invention with a reflective film or layer applied to
`the exterior surface of the element and an anti-abrasion film or
`layer applied over the reflective film or layer;
`FIG. 5 is a diagram showing the extruding, coating and
`cutting processes for manufacturing a prismatic mirror reflec(cid:173)
`tive element in accordance with the present invention;
`FIG. SA is an elevation of the extruder of FIG. 5, showing
`the wedge shape of the extruded strip and reflective element
`substrate;
`FIG. 6 is a plan view of the extruded strip showing the cut
`out 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. 5; and
`FIG. 8 is a diagram showing an alternate process for manu(cid:173)
`facturing a prismatic mirror reflective element in accordance
`with the present invention, where a strip of substrate material
`is cast and formed via a caster and float section.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawings and the illustrative embodi(cid:173)
`ments depicted therein, an exterior rearview mirror assembly
`10 includes a reflective element 12 mounted at a casing 14,
`which is mounted at an exterior portion of a vehicle 16 (FIG.
`
`4
`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 sub(cid:173)
`strate 18 having an inner surface 18a and an opposite exterior
`5 surface 18b (FIGS. 2 and 3). The exterior surface 18b com(cid:173)
`prises a less curved or substantially flat inboard portion or
`surface 18c and a more curved outboard portion or surface
`18d, as discussed below. The substrate 18 may have an anti(cid:173)
`abrasion coating or layer or film 20, such as an ultrathin glass
`10 coating or layer or film, laminated or deposited or otherwise
`applied to the exterior surface 18b, and may have a reflective
`coating or layer 22 laminated or applied to the inner surface
`18a, as also discussed below.Aspects of the reflective element
`of the present invention may be suitable for use in a reflective
`15 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(cid:173)
`radius or wide angle single element reflective element sub-
`20 strate. The reflective element 12 may provide a field of view
`similar to the piano-auxiliary reflective element assembly
`disclosed in U.S. Pat. Nos. 6,522,451 and 6,717,712, which
`are hereby incorporated herein by reference.
`The substrate 18 of the reflective element 12 of the present
`25 invention may be formed (such as by casting, extrusion or
`injection molding) of a polymeric optical resin material, such
`as an acrylic or polycarbonate resin, a polyolefin, a cyclic
`olefin copolymer, such as a COC resin known as "TOPAS"
`and available from Ticona of Summit, N.J. (such as a resin of
`30 the type described in U.S. patent application Ser. No. 09/946,
`228, filed Sep. 5, 2001 for IMPROVED PLASTIC SUB(cid:173)
`STRATE FOR INFORMATION DEVICE AND METHOD
`FOR MAKING SAME, which is hereby incorporated herein
`by reference) or the like. Because the substrate can be, for
`35 example, injection molded from an optical resin, the substrate
`may be molded or formed to a desired shape having a wide
`angle or multi-radius surface, which is typically challenging
`to accomplish with glass sheets. This is because any prescrip(cid:173)
`tion or form for the substrate can be established in an injection
`40 mold by machining, such that when the injection mold is
`filled with molten injected optical resin material, the optical
`resin material takes the shape of the mold. Thus, for example,
`a substrate having a substantially or fully flat inboard region
`for a multi-radius (often referred to as an aspheric) exterior
`45 mirror element is fully practical.
`As shown in FIGS. 1-3, inboard portion or surface 18c of
`exterior surface 18b is positioned at or toward the side of the
`reflective element that is toward the side body of the vehicle
`when the mirror assembly is mounted to or attached to the
`50 vehicle. The inboard portion 18c of surface 18b of substrate
`18 may comprise a substantially flat or slightly curved or less
`curved surface, such as a surface having a radius of curvature
`of preferably greater than at least approximately 4000 mm,
`more preferably greater than at least approximately 9000 mm,
`55 and most preferably greater than at least approximately
`12000 mm. The inboard surface 18c may provide a field of
`view of up to approximately 10 degrees, preferably up to
`approximately 15 degrees, and more preferably up to
`approximately 20 degrees.
`Outboard portion or surface 18d of exterior surface 18b of
`substrate 18 is positioned outward from inboard portion and is
`thus further away from the side body of the vehicle when the
`mirror assembly is mounted to or attached to the vehicle.
`Outboard portion 18d of exterior surface 18b may be a more
`65 convex or curved surface, such that the substrate comprises a
`wide angle or multi-radius exterior surface substrate. The
`more curved outboard surface 18d of the substrate may have
`
`60
`
`SMR USA
`Exhibit 1015
`Page 006
`
`

`

`US 7,842,154 B2
`
`5
`radii of curvature in the range of less than about 4000 mm to
`about 100 mm or lower. The more curved outboard portion or
`surface 18d may provide an extended field of view when
`combined with the less curved inboard portion or surface 18c.
`For example, the combined field of view of the mirror reflec(cid:173)
`tive element 12 may be preferably greater than at least
`approximately 25 degrees, more preferably greater than at
`least approximately 35 degrees, and most preferably greater
`than at least approximately 45 degrees. The substrate may be
`formed to have curves or shapes or to provide other field of
`views, without affecting the scope of the present invention.
`The exterior surface 18b of substrate 18 may be coated or
`covered with a substantially transparent functional film or
`layer 20, such as an anti-abrasion film or layer, such as an
`ultrathin glass film or layer or sheet having a thickness of
`preferably less than or equal to approximately 0.8 mm, more
`preferably less than or equal to approximately 0.5 mm, and
`most preferably less than or equal to approximately 0.3 mm.
`The ultrathin glass film or layer or sheet 20 provides a flexible
`glass film which can be conformed to the exterior surface of
`the molded substrate (for example, such as described in U.S.
`Pat. No. 5,085,907, which is hereby incorporated herein by
`reference) after the substrate is molded. The ultrathin glass
`film or layer may provide substantial protection against
`scratches on the outboard surface, such as may occur due to
`impact by debris at the outside of the vehicle (for exterior
`mirror assembly applications) or by use of ice scrapers and
`the like on the glass surface and the like. The ultrathin glass
`film or layer may be applied to a molded or extruded strip
`( such as described below with respect to FIGS. 5-8) or may be
`applied to the surface or surfaces of a formed or cut substrate,
`without affecting the scope of the present invention. The
`flexible ultrathin glass film or layer of the present invention
`allows the wide angle or multi-radius substrate to be molded
`in the desired shape out of a transparent acrylic resin material,
`yet may conform to the curved or multi-radius or aspheric
`shape and provide enhanced protection or scratch resistance
`to the substrate.
`It is envisioned that other functional films or hard coats or
`anti-abrasion films or the like may be applied to the exterior
`surface of the molded substrate, such as via adhering or
`applying a film to the exterior surface or via dip coating or
`vacuum deposition or the like. Optionally, a hydrophobic film
`or hydrophilic film or element or property may also or other(cid:173)
`wise be applied to the exterior surface 18b of the substrate.
`Optionally, the functional film may comprise a non-glass or
`polymeric film, such as a polymeric material that is a harder
`and/or different property material than the substrate itself.
`Optionally, the anti-abrasion film may be formed of the same
`resin material as the substrate to match the coefficients of
`thermal expansion and thus reduce thermal expansion/con(cid:173)
`traction mismatches between the materials.
`Optionally, the inner or rear surface 18a of the substrate 18
`may have a reflective layer or coating or film or sheet 22
`laminated or otherwise applied thereto. For example, the
`reflective layer or film 22 may comprise a polymeric reflec(cid:173)
`tive film 22 laminated or otherwise adhered or applied to the
`rear or inner surface 18a of a molded or extruded or cast strip
`(such as described below with respect to FIGS. 5-8) or of the
`molded or formed substrate 18. Reflective film 22 may com(cid:173)
`prise a polymeric reflective film, such as an all polymer-thin(cid:173)
`film multilayer, high reflective mirror film, such as a multi(cid:173)
`layer, non-metallic reflective film which may comprise
`multiple coextrusion of many plastic layers to form a highly
`reflective mirror film, such as described in U.S. Pat. Nos.
`3,773,882; 3,884,606; and 3,759,647, which are hereby
`incorporated herein by reference. Such a reflective film thus
`
`6
`may comprise multilayers of polymer materials to form a
`highly reflective mirror film, such as a Radiant Light Film, a
`Radiant Mirror Film or a Radiant Color Film, such as com(cid:173)
`mercially available from 3M of St. Paul, Minn., such as a
`5 Radiant Color Film CM590 or CM500. Also, a durable met(cid:173)
`allized polymeric mirror layer can be used, such as described
`in U.S. Pat. No. 5,361,172, which is hereby incorporated
`herein by reference.
`As shown in FIG. 4, it is envisioned that a substrate or
`10 substrate shape or sheet or strip of substrate material 118 may
`have a reflective film or layer 122 adhered or laminated or
`otherwise applied to the exterior surface 118b of the substrate
`material.An anti-abrasion film or layer 120 (which may com(cid:173)
`prise an ultrathin glass film or layer as described above) may
`15 be adhered or laminated or otherwise applied to the reflective
`film or layer 122. In such an application, with the reflective
`layer on the front or exterior surface of the substrate, the
`substrate material may be molded or formed of a polymeric
`material that does not provide optical clarity and need not be
`20 transparent. The substrate material may act only as a support
`or backing plate for the reflective film or layer and the anti(cid:173)
`abrasion film or layer and thus may be opaque or non-trans(cid:173)
`parent. The exterior surface 118b of substrate material 118
`may comprise a wide angle exterior surface or a multi-radius
`25 exterior surface having a less curved inboard portion or sur(cid:173)
`face 118c and a more curved outboard portion or surface
`118d, such as discussed above with respect to substrate 18.
`Optionally, and such as shown in FIGS. 5, 6 and 8, the
`optical resin material may be molded or extruded or cast into
`30 a generally continuous strip 19 having the desired curved or
`multi-radius surfaces, and may be cut to form the substrates.
`The substrates may be cut from the strip via any known
`cutting process, such as via a laser cutting process or a water(cid:173)
`jet cutting process or the like, without affecting the scope of
`35 the present invention.
`As shown in FIGS. 5-8, the molding processes and film or
`layer application processes of the present invention may be
`used to form a prismatic or wedge-shaped strip for forming
`prismatic or wedge-shaped substrates 18' (FIG. 7) for use in
`40 an interior rearview mirror assembly of a vehicle.
`As also shown in FIGS. 5-8, the substrate material or
`optical resin material may be extruded or cast to form the
`continuous strip or sheet 19. For example, and as shown in
`FIGS. 5 and SA, the strip 19 may be extruded by an extruder
`45 24, which, preferably continuously, extrudes the optical resin
`material through an extrusion nozzle 26. The extruded mate(cid:173)
`rial may be moved through an annealing lehr 28 to reduce or
`substantially eliminate birefringence, striation, stress and/or
`distortion in the strip or substrates. The coatings or layers or
`50 films 20 and/or 22 may be applied to one or both surfaces of
`the strip or substrate after the annealing process. The strip 19
`may then be cut, such as via laser cutting or water-jet cutting
`devices or processes 30, or via other forming processes, to
`form the substrates 18' after the films or coatings have been
`55 applied thereto.
`Optionally, and as shown in FIG. 8, the strip 19 of optical
`polymeric resin material may be cast by a caster 32, which
`deposits the molten polymer or resin material onto a float
`section 34, such as a heated plate or heated melt. The float
`60 section 34 may be angled to form the wedge-shaped strip as
`the strip or ribbon of cast molten polymer solidifies as it
`passes across the hot float section (it is also envisioned that the
`float may provide a curved surface to form the curved out(cid:173)
`board surface of the substrate). The coatings or layers or films
`65 20, 22 may be applied to the solidified strip and the strip may
`be cut to form the substrates after the coatings or layers or
`films have been applied thereto.
`
`SMR USA
`Exhibit 1015
`Page 007
`
`

`

`US 7,842,154 B2
`
`7
`Because the films or layers are flexible, it is envisioned that
`the anti-abrasion film or ultrathin glass film and/or the reflec(cid:173)
`tive polymeric film may be unwound or unrolled and applied
`along the generally continuously extruded or cast substrate
`material or strip 19. For example, and as shown in FIGS. 5-8,
`the ultrathin glass film (or other outer layer anti-abrasion
`coating or film) 20 may be provided in a reel or roll form or
`strip 20a and may be unwound or unrolled and laminated or
`otherwise adhered or applied along the exterior surface 19b of
`the extruded or cast strip 19 of substrate material. Likewise,
`the reflective polymeric film 22 may be provided in a reel or
`roll form or strip 22a and may be attached or applied to the
`inner surface 19a of the substrate material strip 19, such as via
`laminating or adhering or otherwise applying the film to the
`substrate material, such as by using optical adhesive and/or
`via rolling or ironing the film or sheet (preferably at an
`elevated temperature and with vacuum assist) onto the sub(cid:173)
`strate or strip surface, to secure the reflective film to the
`substrate or extruded or cast strip or sheet.
`Optionally, the glass film or layer or sheet ( or reel or roll of
`glass sheet or strip) may be coated with a highly reflective
`metallic layer, such as silver or aluminum or the like, depos(cid:173)
`ited on or applied to its inner surface (i.e., the surface which
`is adhered to or otherwise applied to the substrate or substrate
`sheet or strip). The reflective layer or coating may be applied
`to the glass film or layer with or without transparent over(cid:173)
`coats. The glass film thus may provide the reflective layer at
`the exterior surface of the substrate, such that the reflective
`layer provides the second layer or surface, with the substrate
`behind the reflective layer. The glass sheet or film may thus be
`provided with the reflective mirror coating already applied
`thereto. The glass layer with reflective layer or coating
`applied thereto may be provided in a reel or roll form for
`applying both the reflective layer and the anti-abrasion layer
`to the exterior surface of the substrate or substrate strip or
`sheet in one application process. In such an application, the
`substrate material need not comprise a transparent optical
`resin material, and a separate reflective layer or film or coat(cid:173)
`ing would not be necessary at the inner or rear surface of the
`substrate.
`It is envisioned that other hard coats or films or the like may
`be applied to one or more surfaces of the molded substrate
`strip or to the molded and cut substrates, such as via dip
`coating or vacuum deposition or the like, without affecting
`the scope of the present invention. The other hard coats or
`films may be substantially flexible and may be applied via
`unrolling of a reel of an anti-abrasion film or sheet and apply(cid:173)
`ing the film or sheet to a surface of an extruded or cast strip of
`transparent acrylic resin or the like, as discussed above.
`Optionally, a hydrophobic film or hydrophilic film or element 50
`or property may also or otherwise be applied to ( or sprayed
`on) one or both surfaces 18a, 18b of the substrate or strip or
`sheet. Optionally, one or both of the reflective polymeric film
`22 and the anti-abrasion film 20 may be formed of the same
`resin material as the substrate 18, 18' or substrate strip 19 to
`match the coefficients of thermal expansion and thus reduce
`thermal expansion/contraction mismatches between the
`materials.
`Optionally, it is envisioned that such ultrathin glass films,
`anti-abrasion films, reflective films or reflective systems may
`be used for electrochromic mirror reflective elements or cells
`as well. For example, the interior or exterior rearview mirror
`assembly of the present invention may comprise an electro(cid:173)
`chromic mirror, such as an electrochromic mirror assembly
`and electrochromic element utilizing principles disclosed in
`commonly assigned U.S. Pat. Nos. 5,140,455; 5,151,816;
`6,690,268; 6,178,034; 6,154,306; 6,002,544; 5,567,360;
`
`8
`5,525,264; 5,610,756; 5,406,414; 5,253,109; 5,076,673;
`5,073,012; 5,117,346; 5,724,187; 5,668,663; 5,910,854;
`5,142,407 and/or 4,712,879, which are hereby incorporated
`herein by reference, and/or as disclosed in the following
`5 publications: N. R. Lynam, "Electrochromic Automotive
`Day/Night Mirrors", SAE Technical Paper Series 870636
`(1987); N. R. Lynam, "Smart Windows for Automobiles",
`SAE Technical Paper Series 900419 (1990); N. R. Lynam and
`A. Agrawal, "Automotive Applications of Chromogenic
`10 Materials", Large Area Chromogenics: Materials and
`Devices for Transmittance Control, C. M. Lampert and C. G.
`Granquist, EDS., Optical Engineering Press, Wash. (1990),
`which are hereby incorporated by reference herein. The mir(cid:173)
`ror assembly may comprise an interior rearview mirror
`15 assembly, and may include an accessory module or may be
`mounted to an accessory module, such as an accessory mod(cid:173)
`ule of the types disclosed in U.S. patent application Ser. No.
`10/355,454, filed Jan. 31, 2003 for VEHICLE ACCESSORY
`MODULE, now U.S. Pat. No. 6,824,281, which is hereby
`20 incorporated herein by reference.
`Optionally, the mirror assembly may include one or more
`displays for displaying information to a driver of the vehicle
`at or through the reflective element of the mirror assembly.
`For example, the mirror assembly may include one or more
`25 displays of the types described in U.S. Pat. Nos. 6,329,925;
`6,501,387; 6,690,268; 5,910,854; 6,420,036; 5,668,663; and
`5,724,187, and/or in U.S. patent application Ser. No. 10/054,
`633, filed Jan. 22, 2002 by Lynam et al. for VEHICULAR
`LIGHTING SYSTEM, now U.S. Pat. No. 7,195,381; and Ser.
`30 No. 10/456,599, filed Jun.