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`Approved for use through10/31/2002. OMB 65 —0032
`U.S. Patent and Trademark Office; U.S. DEPARTMENT OF C MMERCE
`Under the Paperwork Reduction Act of 1995, no persons are required to respond to a collection of information unless it displays a valid OMB control number.
`PROVISIONAL APPLICATION FOR PATENT COVER SHEET
`his is a re- uest for film . a PROVISIONAL APPLICATION FOR PATENT under 37 CFR 1.53 c .
`
`
`
`Express Mail Label No.
`
`EV353872042US
`
`Given Name (first and middle [if any])
`
`Family Name or Surname
`
`Niall R.
`
`(City and either State or Foreign Country)
`
`
`
`0
`
`Holland, Michigan
`
`Residence
`
`separately numbered sheets attached hereto
`El Additional inventors are being named on the
`TITLE OF THE INVENTION (500 characters max)
`
`1
`
`Fl
`n.
`0).—
`
`
`MIRROR REFLECTIVE ELEMENT
`
`
`CORRESPONDENCE ADDRESS
` Direct all correspondence to:
`
`Place Customer Number
`‘
`Bar Code Label here
`
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`Customer Number
`
`281 01
`
`__>
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`OR
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`ll]
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`Type Customer Number here
`Firm or
`
`Individual Name
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`Fax—
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`Specification Number of Pages
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`Applicant claims small entity status. See 37 CFR 1.27.
`A check or money order is enclosed to cover the filing fees
`The Commissioner is hereby authorized to charge filing
`
`fees or credit any overpayment to Deposit Account Number:
`
`Payment by credit card. Form PTO-2038 is attached.
` The invention was made by an agency of the United States Government or under a contract with an agency of the
`United States Government.
`
`22-0190
`
`$16000
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`Drawing(s) Numberof Sheets
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`FILING FEE
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`E No.
`D Yes. the name of the U.S. Government agency and the Government contract number are:
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`Respectfully submitted,
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`SIGNATURE
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`TYPED or PRINTED NAME
`im°th A‘ Flo
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`TELEPHONE (616) 975-5500
`USE ONLY FOR FILING A PROVISIONAL APPLICATION FOR PA TENT
`This collection of information is required by 37 CFR 1.51. The information is used b the public to file (and by the PTO to process) a
`provisional application. Confidentiality is governed by 35 U.S.C. 122 and 37 CFR 1. 4. This collection IS estimated to take 8 hours to
`complete, including gathering. preparing; and submitting the complete provisional application to the PTO. Time will vary depending u on
`the individual case.
`ny comments on t 9 amount of time you require to complete t us form and/or suggestions for reducin this bur en,
`should be sent to the Chief Information Officer, U.S. Patent and Trademark Office, U.S. Department of Commerce, Was ington, D.C.
`20231. DO NOT SEND FEES OR COMPLETED FORMS TO THIS ADDRESS. SEND TO: Box Provisional Application, Assistant
`Commissioner for Patents, Washington, D.C. 20231.
`
`Date 05/20/2003
`
`REGISTRATION NO.
`(ifappropfiate)
`Docket Number:
`
`42 540
`
`7
`DON01 P-1092
`
`Patent Owner Magna - EX. 2010, p. 1
`
`Patent Owner Magna - Ex. 2010, p. 1
`
`

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`
`
`PATENT
`
`DONO 1 P— l 092
`
`Express Mail N0. EV3 53 872042US
`
`IN TIIE UNITED STATES PATENT AND TRADEMARK OFFICE
`
`Applicant
`
`: Niall R. Lynani
`
`For
`
`: MIRROR REFLECTIVE ELEMENT
`
`MS-Provisional Patent Application
`Commissioner for Patents
`P.O. Box 1450
`
`Alexandria, VA 22313-1450
`
`Dear Sir:
`
`CERTIFICATE OF MAILING BY EXPRESS MAIL
`
`I certify that the attached return postcard; a check in the amount of $160.00 for
`
`the filing fee; Provisional Application For Patent Cover Sheet (1 page, in duplicate); Patent
`
`Application Bibliographic Data Sheet (1 page); 13 pages of specification; and 3 sheets of
`
`drawings are being deposited with the United States Postal Service as Express Mail in an
`
`envelope having Express Mail Label Number EV353872042US addressed to:
`
`MS-Provisional Patent Application
`Commissioner for Patents
`PO. Box 1450
`
`Alexandria, VA 22313—1450
`
`on May 20, 2003.
`
`TAF/slg
`Enclosures
`
`Juan g. 21%
`
`Susan L. Gasper
`Van Dyke, Gardner, Linn & Burkhart, LLP
`2851 Charlevoix Drive, SE.
`PO. Box 888695
`
`Grand Rapids, MI 49588-8695
`(616) 975-5500
`
`Patent Owner Magna - EX. 2010, p. 2
`
`Patent Owner Magna - Ex. 2010, p. 2
`
`

`

`INVENTOR INFORMATION
`
`Inventor One Given Name:: Niall R
`
`Family Name:: Lynam
`Postal Address Line One:: 248 Foxdown
`
`Cityzz Holland
`State or Province:: Michigan
`Country:: USA
`Postal or Zip Code:: 49424
`City of Residence:: Holland
`State or Province of Residence:: Michigan
`Country of Residence:: USA
`Citizenship Country:: US
`
`CORRESPONDENCE INFORMATION
`
`Correspondence Customer Number:: 28101
`Fax One::
`(616) 975—5505
`Electronic Mail Onez:
`flory@vglb.com
`
`APPLICATION INFORMATION
`
`Title Line Onezz MIRROR REFLECTIVE ELEMENT
`
`Total Drawing Sheets::
`Formal Drawings?:: No
`Application Type:: Provisional
`Docket Number:: DONOl P—lO92
`
`3
`
`Secrecy Order in Parent Appl.?:: No
`
`REPRESENTATIVE INFORMATION
`
`Representative Customer Number:: 28101
`
`Source::
`
`PrintEFS Version 1.0.1
`
`Patent Owner Magna - EX. 2010, p. 3
`
`Patent Owner Magna - Ex. 2010, p. 3
`
`

`

` all???» in "iii“? -353; M 373’“ 3555???
`
`PROVISIONAL
`DONOl P—1092
`
`Express Mail No. EV3 53 872042US
`
`MIRROR REFLECTIVE ELEMENT
`
`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
`
`comprising multi—radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`
`10
`
`15
`
`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. Polymeric reflective elements are also known, such as are described in
`
`U.S. Pat. Nos. 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
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`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 that of glass), and which has a glass—like
`
`20
`
`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 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), 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.
`
`25
`
`30
`
`Patent Owner Magna - Ex. 2010, p. 4
`
`Patent Owner Magna - Ex. 2010, p. 4
`
`

`

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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.
`
`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 surface and a more curved outboard portion or surface.
`
`The molded substrate may have an anti—abrasion film or layer, such as an ultrathin glass film,
`
`applied over the exterior surface or first surface to provide substantial protection against
`
`scratches occurring to the molded substrate. The inner surface 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 reflective element for a mirror
`
`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 transparent optical polymeric resin material. The anti-abrasion film preferably 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 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 then be cut 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
`
`reflective 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 rellective 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
`2
`.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`Patent Owner Magna - Ex. 2010, p. 5
`
`Patent Owner Magna - Ex. 2010, p. 5
`
`

`

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`
`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 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 applying an anti-
`abrasion coating or film to a surface of the elongated strip sheet. The substrate material may
`comprise a transparent optical polymeric resin. The anti-abrasion film is preferably unrolled
`from a reel or roll of film and applied to the surface of the elongated strip or sheet generally
`
`continuously as the strip or sheet is formed or extruded or cast or molded. Preferably,
`multiple mirror element shapes or mirror element substrates may be cut from the elongated
`shcct after the anti—abrasion film is applied to the surface of the strip or sheet.
`
`The 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 reflective 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 exterior 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 reflective film or layer laminated or
`
`10
`
`15
`
`20
`
`25
`
`applied to the inner surface opposite the exterior surface.
`These and other objects, advantages, purposes and features of the present invention
`
`3O
`
`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;
`
`Patent Owner Magna - Ex. 2010, p. 6
`
`Patent Owner Magna - Ex. 2010, p. 6
`
`

`

`
`
` iifffn fififii-iixiii'ufiiiy. .. “7
`
`LA
`
`10
`
`15
`
`20
`
`25
`
`30
`
`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 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;
`
`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 manufacturing 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 embodiments 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. 1). Reflective element 12 may
`provide an enhanced field of view or wide angle field of view to a driver or occupant of the
`
`vehicle and may comprise a single reflective element substrate 18 having an inner surface
`
`surface 18a and an opposite exterior surface 18b (FIGS. 2 and 3). The exterior surface 18b
`
`comprises 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-
`
`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 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 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).
`4
`
`Patent Owner Magna - Ex. 2010, p. 7
`
`Patent Owner Magna - Ex. 2010, p. 7
`
`

`

` 311:}: 43.33 "=13" w“ .43.. 42:31, A 11"”
`
`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 plano-auxiliary reflective element assembly disclosed in US. Pat. No.
`
`6,522,451, and in US. pat. application, Ser. No. 09/745,172, filed Dec. 20, 2000 for
`
`EXTERIOR MIRROR PLANO-AUXILIARY REFLECTIVE ELEMENT ASSEMBLY
`
`(Attorney Docket DONOl P—842), which are hereby incorporated herein by reference.
`
`The substrate 18 of the reflective element 12 of the present invention may be formed
`(such as by casting, extrusion or injection molding) ofa 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, NJ (such as a resin of
`
`the type described in US. pat. application, Ser. No. 09/946,228, filed Sep. 5. 2001 for
`
`IMPROVED PLASTIC SUBSTRATE FOR INFORMATION DEVICE AND METHOD
`
`FOR MAKING SAME (Attorney Docket DON03 P—910), which is hereby incorporated
`
`herein by reference) or the like. Because the substrate can be, for 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 prescription or form for the substrate can be established in an
`
`injection 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 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 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, 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 convex or curved surface, such that the substrate
`5
`
`10
`
`15
`
`20
`
`25
`
`30
`
`Patent Owner Magna - Ex. 2010, p. 8
`
`Patent Owner Magna - Ex. 2010, p. 8
`
`

`

`
`
`comprises a wide angle or multi—radius exterior surface substrate. The more curved outboard
`
`surface 18d of the substrate may have 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 reflective 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 an anti-
`
`abrasion film or layer 20, 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
`
`US. 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 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 may also or otherwise be applied to the exterior surface
`
`18b of the substrate. 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/contraction mismatches between the materials.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`Patent Owner Magna - Ex. 2010, p. 9
`
`Patent Owner Magna - Ex. 2010, p. 9
`
`

`

`
`
`WM, 1 11 w '
`
`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 reflective 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 comprise a polymeric reflective film, such as an all
`
`polymer—thin-film multilayer, high reflective mirror film, such as a multilayer, non—metallic
`
`reflective film which may comprise multiple coextrusion of many plastic layers to form a
`
`highly reflective mirror film, such as described in US. Pat. Nos. 3,773,882; 3,884,606; and
`
`3,759,647, which are hereby incorporated herein by reference. Such a reflective film thus
`
`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
`
`commercially available from 3M of St. Paul, Minn, such as a Radiant Color Film CM59O or
`
`CM500. Also, a durable metallized polymeric mirror layer can be used, such as described in
`
`US. Pat. No. 5,361,172, which is hereby incorporated herein by reference.
`
`As shown in FIG. 4, it is envisioned that a substrate or 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 comprise an ultrathin glass film or layer as described above) may 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 transparent. The substrate material may act only as a support
`
`or backing plate for the reflective film or layer and the anti-abrasion film or layer and thus
`
`may be opaque or non—transparent. The exterior surface 118b of substrate material 118 may
`
`comprise a wide angle exterior surface or a multi-radius exterior surface having a less curved
`
`inboard portion or surface 1 180 and a more curved outboard portion or surface 118d, such as
`
`10
`
`15
`
`20
`
`25
`
`discussed above with respect to substrate 18.
`
`Optionally, and such as shown in FIGS. 5, 6 and 8, the optical resin material may be
`
`30
`
`molded or extruded or cast into 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-jet
`
`cutting process or the like, without affecting the scope of the present invention. .
`
`7
`
`Patent Owner Magna - Ex. 2010, p. 10
`
`Patent Owner Magna - Ex. 2010, p. 10
`
`

`

`51:1:51'5L;.-i!~"t'h"if an. 1133:
`
`_.
`
`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 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 5A, the strip 19 may be extruded by an extruder 24, which, preferably
`
`continuously, extrudes the optical resin material through an extrusion nozzle 26. The
`
`extruded material 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 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, to form the substrates 18' after the films or
`
`coatings have been 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 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 outboard surface of the substrate). The coatings or layers or films 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.
`
`Because the films or layers are flexible, it is envisioned that the anti—abrasion film or
`
`ultrathin glass film and/or the reflective 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
`
`10
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`15
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`20
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`25
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`3O
`
`Patent Owner Magna - Ex. 2010, p. 11
`
`Patent Owner Magna - Ex. 2010, p. 11
`
`

`

`..,- Am}: :1. nun-1“ “3.1:, gm, =rfl;_:
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`and with vacuum assist) onto the substrate 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,
`
`deposited 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 overcoats. 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
`
`rcsin material, and a separate reflective layer or film or coating would not be necessary at the
`
`inner or rear surface of the substrate.
`
`J
`
`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 applying 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 may also or otherwise be applied to 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,
`
`10
`
`15
`
`20
`
`25
`
`reflective films or reflective systems may be used for electrochromic mirror reflective
`
`30
`
`elements or cells as well. For example, the interior rearview mirror assembly of the present
`
`invention may comprise an electrochromic mirror, such as an electrochromic mirror assembly
`
`and electrochromic element utilizing principles disclosed in commonly assigned US. Pat.
`
`Nos. 5,140,455; 5,151,816; 6,178,034; 6,154,306; 6,002,544; 5,567,360; 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;
`9
`
`Patent Owner Magna - Ex. 2010, p. 12
`
`Patent Owner Magna - Ex. 2010, p. 12
`
`

`

`q: “gunman nur-
`1322211 11.51! "”il".n‘
`
`sf; 3...“,
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`41'“4.93:2: ,.“'
`
`
`
`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 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 Materials”, Large Area
`
`Chromogenics: Materials and Devices for Transmittance Control, C.M. Lampert and CG.
`
`Grandquist, EDS., Optical Engineering Press, Wash. (1990), which are hereby incorporated
`
`by reference herein, and/or as disclosed in US. pat. application, Ser. No. 09/792,002, filed
`
`Feb. 26, 2001 by Schofield et al. for VIDEO MIRROR SYSTEMS INCORPORATTNG AN
`
`ACCESSORY MODULE (Attorney Docket