4eo/oe/soHa
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`
`
`
`
`Given Name(first and middle[if any])
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`Family Name or Surname
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`Residence
`(City and either State or Foreign Country)
`
`separately numbered sheets attached hereto
`[| Additional inventors are being named on the
`TITLE OF THE INVENTION(500 characters max)
`
`ct
`
`a.
`ar
`
`—_—_>
`
`
`
`
`iataes
`
`
`lk eS abet
`PHB) HBEy%0 )
`
`Approvedfor use through10/31/2002. OMB 0651-0032
`U.S. Patent and Trademark Office; U.S. DEPARTMENT OF COMMERCE
`Under the Paperwork Reduction Act of 1995, no personsare required to respondto a collection of information unless it displays a valid OMB control number.
`PROVISIONAL APPLICATION FOR PATENT COVER SHEET
`This is a requestfor filing a PROVISIONAL APPLICATION EOR PATENT under 37 GER 1.53(¢).
`Express Mail Label No.
`EV353872042US
`
`ld‘s'nc6eof
`
`
`
`
`
`
`
`
`
` Holland, Michigan
`05/20/03 “te,
`~
`MIRROR REFLECTIVE ELEMENT
`
`
`
`
`
`Direct all correspondenceto:
`CORRESPONDENCE ADDRESS
`
`Place Customer Number
`Customer Number
`28101
`:
`Bar Code Label here
`OR
`Type Customer Number here
`
`
`Firm or
` (J
`Individual Name
`
`Address
`
`
`Address
`
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`
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` FILING FEE
`
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`Applicant claims small entity status. See 37 CFR 1.27.
`AMOUNT($)
`Accheck or moneyorderis enclosed to coverthe filing fees
`
`The Commissioner is hereby authorized to chargefiling
`fees or credit any overpayment to Deposit Account Number:
`
`Paymentbycredit card. Form PTO-2038is attached.
` The invention was made by an agencyof the United States Governmentor undera contract with an agency of the
`United States Government.
`
`No.
`
`Specification Number of Pages
`
`Drawing(s) Number of Sheets
`
`22-0190
`
`$160.00
`
`CI Yes, the nameof the U.S. Government agency and the Governmentcontract numberare:
`
`
`
`Respectfully submitted,
`
`
`Date
`
`{05/20/2003
`
`
`SIGNATURE
`TYPEDor PRINTED NAME
`imothy A. Flory
`reLEPHONE (816) 975-5500
`USE ONLY FORFILING A PROVISIONAL APPLICATION FOR PATENT
`This collection of information is required by 37 CFR 1.51. The information is used by
`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 1.14. This collection is estimated to take 8 hours to
`complete, including gathering, preparing, and submitting the complete provisional application to the PTO. Timewill vary depending upon
`the individual case.
`Any comments on the amountof time you require to complete this form and/or suggestions for reducing this burden,
`should be sent to the Chief Information Officer, U.S. Patent and Trademark Office, U.S. Department of Commerce, Washington,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.
`
`REGISTRATION NO.
`(if appropriate)
`Docket Number:
`
`42 540
`
`DONO1 P-1092
`
`Patent Owner Magna- Ex. 2010,p. 1
`
`Patent Owner Magna - Ex. 2010, p. 1
`
`

`

`val AMO OSE gah em, een
`settee,
`LB a ag Ha
`
`PATENT
`DONO1 P-1092
`Express Mail No. EV353872042US
`
`IN THE UNITED STATES PATENT AND TRADEMARK OFFICE
`
`Applicant
`
`: Niall R. Lynam
`
`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 EV353872042USaddressedto:
`
`MS-Provisional Patent Application
`Commissioner for Patents
`P.O. Box 1450
`Alexandria, VA 22313-1450
`
`on May 20, 2003.
`
`TAF/slg
`Enclosures
`
`Xvoen 2 Looper
`
`Susan L. Gasper
`Van Dyke, Gardner, Linn & Burkhart, LLP
`2851 Charlevoix Drive, S.E.
`P.O. 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
`City:: Holland
`State or Province:: Michigan
`Country:: USA
`Postal or 4Gip 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:r:
`(616) 975-5505
`Electronic Mail One::
`flory@vglb.com
`
`APPLICATION INFORMATION
`
`Title Line One:: MIRROR REFLECTIVE ELEMENT
`Total Drawing Sheets::
`3
`Formal Drawings?:: No
`Application Type:: Provisional
`Docket Number:: DONO1 P-1092
`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
`
`

`

`Jaeoe Shaaee a ES
`
`PROVISIONAL
`DONO1 P-1092
`Express Mail No. EV353872042US
`
`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.
`
`BACKGROUNDOF THE INVENTION
`
`Typically, mirror reflective elements are formed of glass and havea reflective coating
`deposited thereon, such as via vacuum deposition or wet chemicalsilvering or the like, such
`as onasilver 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, suchas are described in
`USS. 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 clements,
`the need exists for a hard coat or surface on thefirst 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
`
`15
`
`mirror element outer surface, such as during winter. A variety of hard coats have been
`
`- proposedin the art, typicallyapplied 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,
`
`25
`
`and maytypically 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.c.,
`closer to the side body of the vehicle when the mirror assembly is mountedto 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 extendedfield of view. It is typically desirable to have
`the reflective elements or substrates of such exterior mirror elements to be formed ofa glass
`
`material because glass material typically provides an enhancedscratch resistance over
`
`30
`
`conventional optical resins and the like.
`
`Patent Owner Magna- Ex. 2010, p. 4
`
`Patent Owner Magna - Ex. 2010, p. 4
`
`

`

`anteety, si
`catty ab at “ty gah
`wath
`ge
`SAPa Be at
`
`Therefore, there is a need in theart for a mirrorreflective element that overcomesthe
`
`shortcomings of the prior art elements and substrates.
`SUMMARYOF THE INVENTION
`
`The present invention provides a molded wide angle or multi-radius substrate fora
`reflective element. The molded substrate comprises a polymeric optical resin transparent
`
`material and has a curved exterior surface, which may havea 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 surfaceorfirst surface to provide substantial protection against
`scratches occurring to the molded substrate. The inner surface or second surface ofthe
`reflective element substrate may havea 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 limeglass or a borosilicate or the like) and hasa thickness of
`less than approximately 0.8 mm,andis 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 reelor roll and applied to the exterior surface of the
`elongatedstrip or sheet of substrate material. The substrate, includingthe 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 ofthe 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 orstrip, and the glass film or layer or sheet may be applied over the
`2
`
`Patent Owner Magna- Ex. 2010, p. 5
`
`20
`
`25
`
`30
`
`Patent Owner Magna - Ex. 2010, p. 5
`
`

`

`
`wei ABA PREYSeshSoHE Hest,
`stig, ayer tte,
`fey aeSe a
`
`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 orfilm to a surface of the elongated strip sheet. The substrate material may
`comprise a transparent optical polymericresin. The anti-abrasion film is preferably unrolled
`fromareelor roll of film and applied to the surface of the elongatedstrip or sheet generally
`continuously as the strip or sheet is formed or extrudedor castor molded. Preferably,
`10
`multiple mirror element shapes or mirror element substrates may be cut from the elongated
`shect after the anti-abrasion film is applied to the surface of the strip or sheet.
`The anti-abrasion film may comprisean ultrathin glass material whichis sufficiently
`flexible to be provided in a reelor 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 conformto the wide
`angle or multi-radius or curved exterior surface.
`A reflective film, such as a polymeric reflective film orthe 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 sheetorstrip.
`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 extcrior 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 havea reflective 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 ofthe following specification in conjunction with the
`drawings.
`
`20
`
`25
`
`30
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. | 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
`
`

`

` SiaeSE oe
`
`FIG. 2 is a perspective view of a wide angle or multi-radius reflective element in
`
`accordancewith 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 orlayer;
`
`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 ofthe
`
`extruded strip and reflective element substrate;
`FIG. 6 is a plan view ofthe extrudedstrip showing the cut out shapes ofthe reflective
`
`element cut from the extrudedstrip;
`
`FIG. 7 is a sectional view ofthe reflective element formed by the process shown in
`
`FIG. 5; and
`
`FIG. 8 is a diagram showingan alternate process for manufacturing a prismatic mirror
`
`reflective element in accordance with the present invention, where a strip of substrate
`
`material is cast and formedvia a caster and float section.
`
`DESCRIPTION OF THE PREFERRED EMBODIMENTS
`
`Referring now to the drawings andtheillustrative embodiments depicted therein, an
`exterior rearview mirror assembly 10 includesa reflective element 12 mountedat 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 comprisea 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 18¢c 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 ofthe 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
`
`20
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`25
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`Patent Owner Magna - Ex. 2010, p. 7
`
`

`

` Beepe ah a RB ag ae
`
`Reflective element 12 may comprise an aspheric or multi-radius or wide angle single
`
`elementreflective element substrate. The reflective element 12 may provide a field of view
`
`similar to the plano-auxiliary reflective element assembly disclosed in U.S. Pat. No.
`6,522,451, and in U.S. pat. application, Ser. No. 09/745,172,filed Dec. 20, 2000 for
`
`EXTERIOR MIRROR PLANO-AUXILIARY REFLECTIVE ELEMENT ASSEMBLY
`
`(Attorney Docket DONO1 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
`COCresin known as "TOPAS"and available from Ticona of Summit, NJ (such as a resin of
`
`the type described in U.S. 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 DONO3 P-910), whichis 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 whenthe injection moldis 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 elementis fully practical.
`As shown in FIGS. 1-3, inboard portion or surface 18c of exterior surface 18b is
`positioned at or towardtheside of the reflective elementthat is toward the side body of the
`vehicle when the mirror assembly is mountedto 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 ofcurvature of preferably greater
`than at lcast approximately 4000 mm, morepreferably greater than at least approximately
`9000 mm,and mostpreferably 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 andis 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
`
`Patent Owner Magna- Ex. 2010,p. 8
`
`20
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`25
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`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 haveradii 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 combinedfield of view of the mirror reflective element 12
`may bepreferably 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 shapesor 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 providesa flexible glass film which can be
`conformedto 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 andthelike
`on the glass surface and thelike. The ultrathin glass film or layer may be applied to a molded
`or extrudedstrip (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
`enhancedprotection 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.
`
`20
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`25
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`30
`
`Patent Owner Magna- Ex. 2010, p. 9
`
`Patent Owner Magna - Ex. 2010, p. 9
`
`

`

`BSE gs0STEEE
`
`
`head ALD td
`Aaa oPa EO Ea
`
`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 polymericreflective 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 asan all
`polymer-thin-film multilayer, high reflective mirrorfilm, such as a multilayer, non-metallic
`reflective film which may comprise multiple coextrusion of manyplastic 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 hercin 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 CM590 or
`CMS500. Also, a durable metallized 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 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 ofthe 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 appliedto 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 backingplate for the reflective film or layer and the anti-abrasion film or layer and thus
`maybe opaque or non-transparent. The exterior surface 1 18b 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 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 and8, the optical resin material may be
`molded or extruded orcast into a generally continuous strip 19 having the desired curved or
`multi-radius surfaces, and may be cut to form the substrates. The substrates maybe cut from
`the strip via any knowncutting process, such as via a laser cutting process or a water-jet
`cutting processor the like, without affecting the scope ofthe present invention.
`
`20
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`7
`
`Patent Owner Magna- Ex. 2010, p. 10
`
`Patent Owner Magna - Ex. 2010, p. 10
`
`

`

`Reg hdd at ah RE
`
`As shownin FIGS. 5-8, the molding processes and film or layer application processes
`
`of the present invention may be used to forma 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 continuousstrip or sheet 19. For example, and as shownin
`
`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 ofthe 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 polymeror 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-shapedstrip as the strip or ribbon of cast molten polymersolidifies 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
`maybe 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.
`Becausethe films or layers are flexible, it is envisioned that the anti-abrasion film or
`ultrathin glass film and/orthe reflective polymeric film may be unwoundor unrolled and
`applied along the generally continuously extruded or cast substrate material or strip 19. For
`example, and as shownin FIGS. 5-8, the ultrathin glass film (or other outer layer anti-
`abrasion coating or film) 20 maybe providedin a reel orroll form orstrip 20a and may be
`unwoundor unrolled and laminated or otherwise adhered or applied along the exterior
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`surface 19b of the extruded orcast strip 19 of substrate material. Likewise, the reflective
`polymeric film 22 may be providedin a rcel or roll form orstrip 22a and maybeattached 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/orvia rolling or ironing the film or sheet (preferably at an elevated temperature
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`Patent Owner Magna- Ex. 2010, p. 11
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`Patent Owner Magna - Ex. 2010, p. 11
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`and with vacuum assist) onto the substrate or strip surface, to secure the reflective film to the
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`substrate or extruded orcast 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 aluminumorthe like,
`deposited on orapplied 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 providethe reflective layer at the exterior surface of the substrate, such that the
`reflective layer provides the second layeror 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 shcet 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 coating would not be necessaryat the
`inner or rear surface of the substrate.
`°
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`It is envisioned that other hard coats or films or the like may be applied to one or
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`more surfaces of the molded substrate strip or to the molded and cut substrates, suchas via
`dip coating or vacuum depositionor 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 extrudedorcast strip of transparentacrylic resin orthe like, as discussed above.
`Optionally, a hydrophobic film or hydrophilic film may also or otherwise be applied to onc or
`both surfaces 18a, 18b ofthe substrate or strip or sheet. Optionally, one or both ofthe
`reflective polymeric film 22 and the anti-abrasion film 20 may be formed of the sameresin
`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 mirrorreflective
`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 elementutilizing 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
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`Patent Owner Magna- Ex. 2010, p. 12
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`Patent Owner Magna - Ex. 2010, p. 12
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`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
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`Windowsfor Automobiles”, SAE Technical Paper Series 900419 (1990); N. R. Lynam and
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`A. Agrawal, “Automotive Applications of Chromogenic Materials”, Large Area
`
`Chromogenics: Materials and Devices for Transmittance Control, C.M. Lampert and C.G.
`
`Grandquist, EDS., Optical Engineering Press, Wash. (1990), which are hereby incorporated
`
`by reference herein, and/or as disclosed in U.S. pat. application, Ser. No. 09/792,002, filed
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`Feb. 26, 2001 by Schofield et al. for VIDEO MIRROR SYSTEMS INCORPORATING AN
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`ACCESSORY MODULE(Attorney Docket DONO1 P-869), which is hereby incorporated
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`herein by reference. The mirror assembly may comprise an interior rearview mirror
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`assembly, and may include an accessory module or may be mounted to an accessory module,
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`such as an accessory module of the types disclosed in U.S. pat. application, Ser. No.
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`10/355,454,filed Jan. 31, 2003 for VEHICLE ACCESSORY MODULE(Attorney Docket
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`DONO1 P-1050), which is hereby incorporated herein by reference.
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`Therefore, the present invention provides a wide angle or mulli-radius single substrate
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`or reflective element which may provide an enhancedfield of view for an interior or exterior
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`rearview mirror assembly. The wide angle or multi-radius single element reflector may have
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`an anti-abrasion coating or ultrathin glass film conformed to and applied to the exterior