PATENT
`DONOD9 P-1624
`
`[0001]
`
`[0002]
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`[0003]
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`[0004]
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`EXTERIOR SIDEVIEW MIRROR SYSTEM
`CROSS REFERENCE TO RELATED APPLICATIONS
`The present application is a continuation of U.S. patent application Ser. No. 12/197,666,
`filed Aug. 25, 2008 (Attorney Docket DONO9 P-1462), which is a division ofU.S. patent
`.
`application Ser, No. 10/709,434, filed May 5, 2004, now U.S. Pat. No. 7,420,756, which claims
`the benefit of U.S, provisional application, Ser. No. 60/471,872,filed May 20, 2003, which are
`
`hereby incorporated herein by reference in their entireties.
`_ FIELD OF THE INVENTION
`The present invention relates generally to rearview mizror 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
`Typically, mirror reflective elements are formed of glassand have a reflective coating
`deposited thereon, such as via vacuum deposition or wet chemical silvering or the like, such as
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`on a silver line, such as described in U.S. Pat. No. 4,737,188, which is hereby incorporated
`herein by reference. Polymeric reflective elements are also known, such as are described in U.S.
`Pat. Nos. 6,601,960; 6,409,354; 4,944,581; 4,385,804; 4,193,668; 4,666,264; and 5,483,386,
`which are hereby incorporated herein by reference. For such polymeric mirrorreflective
`elements, the need exists for-a hard coat or surface on the first or outer or exterior surface ofthe
`element which is contacted by the exterior elements, such as rain, road debris, orthe 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 ofhard coats have been proposedin the
`art, typically applied by dip coating or vacuum deposition techniques. However, a need exists
`for an automotive mirrorreflective element which has the properties of plastic (.e., a specific
`
`gravity roughly half that of glass), and which hasa glass-like exterior surface.
`Also, exterior rearview mirrorreflective elements may beaspheric or multi-radius, and .
`maytypically have a less curved or substantially flat (around 2000 mm radius or thereabouts)
`inboard portion or surface at the inboard side ofthe reflective element (i.e., closer to the side
`bodyofthe vehicle when the mirror assembly is mounted to the vehicle), and a more curved |
`multi-radius portion or surface at the outboardsideofthe reflective element (i.e., further from
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`il
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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 ofview. It is typically desirable tohavethe 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 overconyentional optical resins and
`the like,
`|
`Therefore, there is a need in the art for a mirrorreflective element that overcomes the
`shortcomings of the prior art elements and substrates,
`SUMMARYOF 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
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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 havea reflective coating or layer, such as a polymericreflective film, laminated or adhered
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`
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`SMR USA
`Exhibit 1007
`Page 002
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`[0007]
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`[0008]
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`-or otherwise applied thereto.
`According to an aspect ofthe present invention, a wide angle reflective elementfora
`mitror assembly for a vehicle 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 is adapted to substantially conform to the
`oxterior surfaceofthe wide angle substrate. The glass film comprises a glass material and has a
`thickness ofless than approximately 0.8 mm.
`|
`.
`According to another aspect of the present invention, a reflective element for a mirror
`assembly for a vchiclc compriscs 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 polymericresin material. The anti-abrasion film preferably comprises a glass
`material (such as a soda limeglass or a borosilicate or the like) and has a thickness of less than
`approximately 0,8 mm,andis flexible to conform to the exterior surface.
`[0009]
`The substrate may be cut fromastrip 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
`2
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`SMR USA
`Exhibit 1007
`Page 002
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`

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`[0010]
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`[0011]
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`[0012]
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`glass film may be unrolled from a reel or roll and applied to the exterior-surface of the elongated
`stripor sheet of substrate material. The substrate, including the glass film or layer, may 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 reflectivefilm or layer may be appliedto 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
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`reflective film may comprise an all polymer-thin-film multilayer, high reflective mirror film
`comprising multiple coextrusion ofmany plastic layers to form a highly reflective mirror film.
`Optionally, a reflective film or layer may be applied to the exterior surface ofthe
`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
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`reflective film or layer and the glass film or layer, whereby optical clarity / transparency of the
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`substrate material is not necessary.
`
`[0013]
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`According to another aspect of the present invention, a method for forming a reflective
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`clement substrate for a mirror assembly of a vehicle comprises generally continuously forming
`an elongated strip or sheet of substrate material and 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 polymeric resin. The functional film is preferably unrolled from a reelorroll of film and
`applied to the surface of the elongated strip or sheet generally continuously as the strip or sheetis
`formed or extruded or cast or molded. Preferably, multiple mirror element shapes or mirror
`element substrates may be cut or otherwise formed from the elongated sheet after the functional
`
`|
`
`[0014]
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`film is applied to the surface ofthe strip or sheet.
`. The functional or anti-abrasion film may comprise an ultrathin glass material which is
`sufficiently flexible to be provided ina reel or roll (or in asheetthat 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.
`
`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 polymericreflective film or the like, may be applied to the
`opposite surface ofthe substrate or sheetor strip. The reflective film may be sufficiently flcxible
`to be provided in.a reel or roll form (or in a sheetthat 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-
`abrasionfilm preferably comprises an ultrathin glass film or sheet to provide enhanced scratch
`
`'
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`resistance, The molded substrate may havea reflective film or layer laminated or applied to the
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`inner surface opposite the exterior surface,
`
`These and other objects, advantages, purposes and features of the present invention will
`become apparent upon review ofthe 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 vicw of a wide angle or multi-radius reflective element in
`accordance with the present invention;
`FIG.3 is a sectional view ofthe wide angleor multi-radius reflective element taken along
`the line III-IH in FIG. 2;
`
`FIG.4 is a sectional view similar to FIG. 3, showing a wide angle or multi-radius
`reflective element in accordancewith the present invention with a reflective film or layer applied
`to the exterior surface ofthe element and ananti-abrasionfilm or layer applied over the
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`reflective film or layer;
`
`FIG. 5 is a diagram showing the extruding, coating and cutting processesfor
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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 ofthe
`extruded strip and reflective element substrate;
`.
`|
`FIG. 6 is a plan view of the extruded strip showing the cut out shapes ofthe reflective
`element cut from the extruded strip;
`FIG.7 is a sectional view ofthe reflective element formed by the process shownin FIG.
`
`[0016]
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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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`3;
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`SMR USA
`Exhibit 1007
`Page 004
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`SMR USA
`Exhibit 1007
`Page 004
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`

`

`
`
`[0026]
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`[0027]
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`[0028]
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`[0029]
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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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`[0036]
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`-
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`10037]
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`[0038]
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`[0039]
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`[0040]
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`[0041]
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`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;
`.
`
`FIG. 9 is a perspective view of an automobile equipped with exterior sideview mirror
`assemblics according to this present invention;
`.
`FIG. 10 is a top plan partial fragmentary view ofthe driver's side exterior rearview mirror
`
`_ assembly of FIG, 9;
`FIG, 11 is an enlarged sectional view ofa plano-multiradius reflective element assembly
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`ofthe mirror assembly in FIG.10,
`
`FIG. 12 is an enlarged sectional view of a demarcation element of the plano-multiradius
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`reflective element assembly of FIG. 11;
`FIGS. 13A-13Hillustrate views ofvarious locations fora plano reflective element and an
`auxiliary reflective element according to this present invention;
`FIG. 14 is a sectional view ofa second embodimentof a plano reflective element
`assembly according to the present invention including a demarcation element formed as a
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`dividing wall in a backing plate element;
`FIG, 144Ais a cross-section taken along line XXofFIG. 14;
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`FIG. 14Bis a cross-sectional view taken along line YY of FIG, 14;
`
`FIG, 15 is a schematic. of a third embodiment of a plano-auxiliary reflective clement
`assembly according to this present invention;
`.
`FIG. 16 is a front elevation view of another embodiment of a plano reflective element
`assembly according to the present invention;
`FIG. 17 is an exploded perspective view ofthe plano reflective element assembly of FIG.
`
`~ 16;
`
`FIG. 18 is an end view of the plano reflective element assembly of FIG, 16 as viewed -
`from line XVIJI--XVII of FIG. 16;
`FIG. 19 is a top view of the planoreflective clement assembly of FIG. 16 as viewed from
`line XIX--XIX of FIG.16;
`FIG. 20 is a schematic representation of the plano reflective element assembly. of FIG. 16
`illustrating the orientation ofthe reflective element;
`.
`- FIG. 21-is another schematic representationofthe orientation ofthe reflective elements
`ofthe plano reflective element in FIG. 16;
`
`SMR USA
`Exhibit 1007
`Page 005
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`SMR USA
`Exhibit 1007
`Page 005
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`

`

`[0042]
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`[0043]
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`[0044]
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`[0045]
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`[0046]
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`,
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`FIG.22 is a diagram illustrating the range of viewing ofthe reflective elements of the
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`planoreflective element assembly of FIG. 16; and
`FIG. 23 is a perspective view of another embodiment ofan exterior rearview mirror |
`system ofthe present invention.
`. DESCRIPTION OF THE PREFERRED EMBODIMENTS
`
`Referring now to the drawingsandthe illustrative embodiments depicted therein, an
`exterior rearview mirror assembly 10 includesa 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 ofthe
`vehicle and may comprise a single reflective element substrate 18 having an inner surface 18a
`and an opposite exterior surface 18b (FIGS. 2 and 3). The exterior surface 18b comprisesa less
`curvedor 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 layeror 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 ofthe reflective element of
`the present invention may be suitable for use in a reflective element for an exterior rearview
`mirror assembly (as shownin FIG.1) and/or a reflective element for an interior rearview mitror
`assembly (not shown).
`|
`Reflective clement 12 may comprise an aspheric or multi-radius or wide angle single
`elementreflective element substrate. The reflective element 12 may providea field of view
`similar to the plano-auxiliary reflective element assembly disclosed inUS. Pat. Nos. 6,522,451
`and 6,717,712, which are hereby incorporated herein by reference.
`As illustrated in FIG. 9 from U.S.Pat. No. 6,717,712, incorporated above, passenger
`automobile 110 (which may be a sedan, a station-wagon, a sports car, a convertible, a minivan,a
`sports utility vehicle, a pick-up.truck or a similar passenger carrying non-commercial, personal
`transportation automobile) includes an interior rearview mirror assembly 127positioned 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
`scat 129 in thefront portion of cabin 125, and a rear passenger seat 123 in the rear portion of
`cabin 125. Automobile 110 fartherincludes a driver-side exterior sideview mirror assembly 112
`and a passenger-side exterior sideview mirror assembly 114, each adapted for attachmentto
`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. 11 , most preferably adjacent to the seating position of the
`driver seated in driverseat 129 for driver-side assembly 112 and adjacentto the front passenger
`
`seat 121 for passenger-side assembly 114. Exterior sideview mirrors, mounted as shownin FIG,
`9 close to the driver seating location,are commonly referred to as door-mounted exterior
`sideview mirror assemblies. Driver-side exterior sideview mirror assembly 112 includes,as
`illustrated in FIG. 10, a plano-multiradius exterior sideview reflective clement assembly 130.
`Plano-multiradius reflective element assembly 130 is mountedto a reflective elementpositioning
`actuator 136. The orientation ofplano-multiradius reflective element assembly 130, and hence
`its rearward field ofview, is adjustable by actuator 136 in response to control 137. Control 137
`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 hencereposition the rearward field of view ofplano-
`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
`cabin 125) or control 137 can comprise a memory controller, as knownin the automotive mirror
`art, that controls actuator 136 to move the position of plano-multiradius reflective element
`assembly 130 to a pre-set orientation that suits the rearward field of view preference of an
`individual driver, Actuator 136 is mountedto bracket 138 which attaches to vehicle bodyside
`111. Plano-multiradius reflective element assembly 130 is positionable by actuator 136 within
`
`_
`exterior mirror housing 140.
`Plano-multiradius reflective element assembly 130, as shownin FIG. 11, comprises a
`plano element 150 and a separate multiradius element 155. Preferably, plano element 150 is
`adjacent-to multiradius element at a joint. At their joint, plano eloment 150 andseparate
`multiradius cloment 155 can touch leaving substantially no gap or space therebetween, or plano
`element 150 andseparate multiradius element 155 can be spaced apart at their joint by a space or
`gap, as in FIG. 11. Plano element 150 andmultiradius element 155 ate both mounted to surface
`159 of, and are both supportedby,a single backingplate element 160. Plano element 150 and
`multiradius element 155 are demarcated apart by demarcation element 165. 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 asscmbly 130 is mounted in driver-side
`exterior sideview mirror assembly 112 (and/or in passenger-side exterior side view mitror
`
`7
`
`[0047]
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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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`nickel-alloy coating, a silver coating, an aluminum coating (or any alloy or combination of these
`metal reflectors). The metal reflector coating ofplano element 150 maybeafirst surface coating
`(such as on surface 166) or a second surface coating (such as on surface 167), as such terms are
`
`
`
`
`
`[0043]
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`assembly 114) such that plano element 150 and multiradius element 155 are adjusted and
`
`positioned in tandem and simultaneously when the driver (or alternatively, when a mirror
`memory system, as is conventional in the rearview mirrorarts) activates actuator 136 to
`reposition the rearward field ofview ofplano-multiradius reflective element assembly 130.
`Thus, since elements 150, 155 are part of plano-multiradius reflective element assembly 130,
`
`movement of plano-multiradius reflective element assembly 130 by actuator 136 simultancously
`and similarly moves plano element 150 and multiradius element 155.
`Plano element 150 preferably comprises a flat reflector-coatedglass substrate having unit
`magnification, and comprises a reflective surface through which the angular height and width of
`the image of an object is equal to the angular height and width ofthe object when viewed at the
`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 whosereflectivity is electrically adjustable. For example,
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`plano element 150 may comprisea 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
`
`[0049]
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`known in the mirror art. The reflector coating on plano element 150 may also comprise a
`dielectric coating, or a multilayer ofdielectric coatings, or a combination of a metal layer and a
`dielectric layer to form automotive mirror reflectors as knownin the automotive mirrorart. Ifa
`variablereflectance reflector element, plano clement 150 preferably comprises an. electro-optic
`reflector element and, most preferably, an electrochromic reflector element.
`When mounted into exterior side view mirror assembly 112 and/or 114, plano-
`multiradius reflective element assembly 130 is preferably orientated so that at least a portion of
`(more preferably a substantial portion of) the reflector surface ofplano element 150 is positioned
`closer to the vehicle body (and henceto the driver) than any portion of the reflector surface of
`multiradius element 155. Thus, and referring to FIG. 11, side A of plano element 150 ofplano-
`multiradius reflective element assembly 130 is positioned closer to the driver than side D of
`raultiradius element 155 when plano-multiradiusreflective element assembly 130 is mounted on
`an automobile. Also, when mounted into exterior side view mirror assembly 112 and/or 114,
`
`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.
`
`[0050]
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`Multiradius element 155 of plano-multiradius reflective element assermbly 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
`. with the least curvature (largest radius of curvature) occurring at the side of multiradius element
`155 (side C in FIG. 11) positioned adjacentits joint to plano element 150 when both are mounted
`on backing plate element 160. Thus, and referring to FIG. 11, the local radius of curvature at
`sidc C of multiradius element 155, when mounted on backing plate element 160, is larger than at
`side D. Also, the local radius of curvature preferably progressively decreases across multiradius
`element 155 from side C to side D. Preferably, the local radius of curvature at side C of
`
`multiradius element -155 is at least about 1000 mm; more preferably is at least about 2000 mm
`and most preferably is at least about 3000 mm whereasthe local radius of curvature at side D of
`‘multiradius element 155 is, preferably, less than about 750 mm, more preferably less than about
`350 mm; most preferably less than about 150 mm. Preferably, multiradius element 155
`comprises a bent glass substrate with radii of curvature in the range of from about 4000 mm to
`about 50 mm. The multiradius prescription for the multiradius element to be used in a particular
`exterior mirror assembly can vary according to the specific field of view needs on a specific
`
`[0051]
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`automobile model.
`Thetotal field of view rearwardly ofthe automobile of the plano-auxiliary reflective
`element asscmbly (which is a. combination of the field of view of the plano reflective element
`
`[0052]
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`and of the auxiliary reflective element) preferably generally subtends an angle ofat least about
`20 degrees (and more preferably, generally subtends an angle ofat least about 25 degrees. and
`most preferably, generally subtends an angle ofat least about 30 degrees) with respect to the side
`of an automobile to whichis attached an exterior sideview mirror assembly equipped with the-
`plano-auxiliary reflective element assembly.
`.
`Multiradius element 155 may comprise a conventional fixed reflectance mirror reflector
`or it may comprise a variable reflectance mirror reflector whose reflectivity is electrically
`adjustable. For example, multiradius element 155 may comprise a flat glass substrate coated
`with a metallic reflector coating such as a chromium coating, a titanium coating, a rhodium
`
`coating, a metal alloy coating, a nickel-alloy coating, a silver coating, an aluminum coating (or
`any alloy or combination of these metal reflectors). The metal reflector coating ofmultiradius
`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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`

`

`
`
`[0053]
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`[0054]
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`element 155 may be a first surface coating (such as on surface 168) or a second surface coating
`(such as on surface 169), as such terms are known in the mirror art. The reflector coating on
`multiradius element 155 may also comprise a dielectric coating, or a multilayer of dielectric
`coatings, or a combination of a metal layer and a dielectric layer to form automotive mirror
`
`reflectors as known in the automotive mirrorart. If a variable reflectance reflector element,
`multiradius element 155 preferably comprises an electro-optic reflector element and, most
`preferably, an electrochromic reflector element.
`Also,it is preferable that the thickness ofplano clement 150 and multiradius element 155
`be substantially the same in dimension so that their respective outer surfaces, 166 and 168, are
`substantially coplanar so that a driver can readily view images ineither or both elements. The
`thickness dimensionofelements 150, 155 is determined bythe thickness of the substrate (or in
`the case of laminate-type electrochromicreflective elements, the thickness of the two substrates
`between which the electrochromic medium is disposed). For example, plano element 150 and/or
`multiradius element 155 can comprise a reflector coated glass substrate or panel ofthickness
`preferably equal to or less than about 2.3 mm, morepreferably equal to or less than about 1.6
`mm, mostpreferably equalto orless than about 1.1 mm. Use ofa thinner substrate is beneficial
`in terms of improving the overall stability/vibration performanceof the image seenin plano-
`multiradius reflective element assembly 130 when mounted to an automobile.
`Thereflector area ofplano clement150is preferably larger than that of multiradius
`~ element 155. Preferably, the width dimension ofplano element 150 is larger than the width
`dimension of multiradius element 155 (both width dimensions measuredat their respective
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`widest dimension and with the width of the respective element being gauged with the respective
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`element oriented as it would be orientated when mounted on the automobilc). Thus, and
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`referring to FIG, 11, the distance from side A to side Bofplano element 150 is larger than the
`distance from side C to side D ofmultiradius element 155. Thus, the ratio ofthe 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 ofplano-multiradiusreflective element
`assembly 130 and providing multiradius element 155 as a smaller, auxiliary, separate, wide-
`angle viewing portion of plano-multiradius reflective element assembly 130. For plano-
`multiradius reflective element assemblies to be mountedto the exterior sideview assemblies of
`passenger automobiles used non-commercially and for non-towing purpose, the width ofplano
`10
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`SMR USA
`Exhibit 1007
`Page 010
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`SMR USA
`Exhibit 1007
`Page 010
`
`

`

`[0055]
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`element 150 (at its widest dimension)is preferably in the range of from about 50 mm to about
`225 mm; morepreferably 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.
`Backingplate element 160 is preferably a rigid polymeric substrate capable of supporting
`plano element 50 and multiradius element 155. Backingplate element 160 comprisesa flat.
`portion (generally between E and F as shown in FIG. 11) that corresponds to and is aligned with
`plano element 150. Backing plate element 60 also comprises a curved portion (generally
`between G and H as shownin FIG. 11) that correspondsto andis aligned with multiradius
`element 155. Preferably, curved portion G-H of multiradius element 155 is fabricated with a
`
`multiradius prescription that is substantially the same as the multiradius prescription of
`
`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 molding of a thermoplastic or a thermosetting polymer resin. Materials suitable to
`use for backing plate element 160 include unfilled or filled polymeric materials such as glass
`and/or mineralfilled nylon or glass and/or mineralfilled polypropylene, ABS, polyurethane and
`similar polymeric materials. For example, backing plate element 160 can be formed ofABS in
`an injection molding operation. Plano element 150 can be.cut from a stock lite of flat chromium
`mirror-coated 1.6 mm thick glass. Multiradius element-155 can be cut from a stock lite of
`
`multiradiusly-bent chromium mirror-coated 1.6 mm thick glass. Plano element 150 and
`multiradius element 155 can then be attached (such as by an adhesive attachment such as an
`adhesive pad or by mechanical attachment such by clips, fasteners or the like) to the already
`molded backing plate element 160, Alternatively, plano element150 and multiradius element
`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
`integrally form backing plate element 160 with elements 150, 155 integrally molded thereto.
`Integral molding of the backing plate elementto plano element 150 and multiradius element 155
`(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 thatfunctionsto delineate and demarcatethe plano region ofthe
`assembly from the wide-angle, multiradius region and also preferably functions to prevent
`iL
`
`
`
`
`SMR USA
`Exhibit 1007
`Page 011
`
`SMR USA
`Exhibit 1007
`Page 011
`
`

`

`ingress of debris, dirt, water and similar contaminants (suchas toad splash, car wash spray,rain,
`snow, ice, leaves, bugs and similar items that plano-multiradiusreflective element assembly 130
`
`would be subject to when mounted and used on an automobile) into any gap between plano
`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
`
`plano element 150 and multiradius element 155 at their joint on backing 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 nylonresin or a dark colored polyurethaneresin 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 (suchas silicone,
`or EPDM,orplasticized 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 ofless than about 4 mm, more preferably less than
`about 3 mm and, most preferably less than about 2 mm. Crown portion 170 preferably is
`dimensioned to not protrude substantially beyond surfaces 166, 168 of elements 150, 155 when
`demarcation element 165 is installed between elements 150 and 155. Also, wings 173, 173' are
`preferably dimensioned to protrude (most preferablyslightly) onto surfaces 166, 168 of elements
`150, 155 when demarcation element 165 is installed between elements 150 and 155 in orderto
`provide a weatherbarrier seal and/orto at least partially accommodate any dimensional
`tolerances of elements 150, 155 that could lead to variation in the inter-element gap between .
`sides C and B. While the demarcation element shown in FIG. 12 is one embodiment, other
`
`construc