`
`
`PATENT
`DON09 P-14621624
`
`EXTERIOR SIDEVIEW MIRROR
`REFLECTIVE ELEMENT AND METHOD OF
`FORMING SAMESYSTEM CROSS REFERENCE
`TO RELATED APPLICATIONS
`The present application is a continuation of U.S. patent application Ser. No.
`[0001]00011
`
`12/197,666, filed Aug. 25, 2008 (Attorney Docket DON09 P-1462), which is a division of
`U.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 isare hereby incorporated herein by reference in its entiretytheir entireties.
`
`FIELD OF THE INVENTION
`The present invention relates generally to rearview mirror elements for a rearview
`[0002]100021
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`mirror assembly of a vehicle and, more particularly, to exterior rearview mirror elements
`comprising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`Typically, mirrorminor reflective elements are formed of glass and have a reflective
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`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. 6,601,960; 6,409,354; 4,944,581; 4,385,804; 4,193,668; 4,666,264;
`and 5,483,386, which are hereby incorporated herein by reference. For such polymeric mirror
`reflective elements, the need exists forfor- a hard coat or surface on the first or outer or exterior
`surface of the element which is contacted by the exterior elements, such as rain, road debris, or
`the like, or contacted, for example, by a person scraping ice or wiping snow or condensation off
`the mirror element outer surface, such as during winter. A variety of hard coats have been
`proposed in the art, typically applied by dip coating or vacuum deposition techniques. However,
`a need exists for an automotive mirror reflective element which has the properties of plastic (i.e.,
`a specific gravity roughly half that of glass), and which has a glass-like exterior surface.
`
`Also, exterior rearview mirror reflective elements may be aspheric or multi-radius, and
`may typically have a less curved or substantially flat (around 2000 mm radius or thereabouts)
`
`1
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`[0003]
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`[0004]
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`SMR USA
`Exhibit 1020
`Page 001
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`

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`[0005]
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`[0006]
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`[0007]
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`[0008]
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`inboard portion or surface at the inboard side of the reflective element (i.e., closer to the side
`body of the vehicle when the mirror assembly is mounted to the vehicle), and a more curved
`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.
`
`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
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`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 wide angle reflective element for a mirror
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`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 conformconfotin to the
`exterior surface of the wide angle substrate. The glass film comprises a glass material and has a
`thickness of less than approximately 0.8 mm.
`According to another aspect of the present invention, a 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
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`2
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`SMR USA
`Exhibit 1020
`Page 002
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`

`

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`
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`[0009]
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`[0010]
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`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
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`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 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.
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`3
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`SMR USA
`Exhibit 1020
`Page 003
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`[0009]
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`[0010]
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`[0011]
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`[0012]
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`[0013]
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`[0014]
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`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 or otherwise formed from the elongated strip or sheet.
`The substrate may comprise a wide angle substrate and/or may comprise a multi-
`radius exterior surface having a less curved inboard portion or surface and a more
`curved outboard portion or surface.
`A reflective film or layer may be applied to the inner surface or side of the substrate
`or strip opposite the exterior surface. The reflective film may comprise a polymeric
`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 reflective film or layer may be applied to the exterior surface of the
`substrate or sheet or strip, and the glass film or layer or sheet may be applied over the
`reflective film layer. In such an application, the substrate acts as a support or backing plate
`for the reflective film or layer and the glass film or layer, whereby optical clarity /
`transparency of the substrate 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 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 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
`or otherwise formed from the elongated sheet after the functional film is applied to the
`surface of the strip or sheet.
`The functional or anti-abrasion film may comprise an ultrathin glass material which
`is sufficiently flexible to be provided in a reel or roll (or in a sheet that is flexible and
`conformable to a bent substrate). The substrates may be formed with a wide angle exterior
`surface or a multi-
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`4
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`SMR USA
`Exhibit 1020
`Page 004
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`

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`[0013]
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`Loon] 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.
`[0012] Optionally, a reflective film or layer may be applied to the exterior surface of the substrate
`or sheet or strip, and the glass film or layer or sheet may be applied over the reflective film
`layer. In such an application, the substrate acts as a support or backing plate for the
`reflective film or layer and the glass film or layer, whereby optical clarity / transparency
`of the substrate 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 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 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 or otherwise formed from the elongated sheet after the functional film is applied to the
`surface of the strip or sheet.
`The functional or anti-abrasion film may comprise an ultrathin glass material which is
`
`sufficiently flexible to be provided in a reel or roll (or in a sheet that is flexible and
`conformable to a bent substrate). The substrates may be formed with a wide angle exterior
`surface or a multi-radius exterior surface. The anti-abrasion film may be sufficiently
`flexible to conform to the wide angle or multi-radius or curved exterior surface.
`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
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`opposite surface of the substrate or sheet or strip. The reflective film may be sufficiently flexible
`
`[0014]
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`[0015]
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`5
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`SMR USA
`Exhibit 1020
`Page 005
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`

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`[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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`[0026]
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`to be provided in a reel or roll form (or in a sheet that is flexible and conformable to a bent
`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 applied to the
`inner surface opposite the exterior surface.
`These and other objects, advantages, purposes and features of the present invention
`will become apparent upon review of the following specification in conjunction
`with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS
`FIG. 1 is a perspective view of an exterior rearview mirror assembly in accordance with
`
`the present invention;
`FIG. 2 is a perspective view of a wide angle or multi-radius reflective element in
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`accordance with the present invention;
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`FIG. 3 is a sectional view of the wide angle or multi-radius reflective element taken along
`the line
`in FIG. 2;
`FIG. 4 is a sectional view similar to FIG. 3, showing a wide angle or multi-radius reflective
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`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
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`manufacturing a prismatic mirror reflective element in accordance with the present invention;
`FIG. 5A is an elevation of the extruder of FIG. 5, showing the wedge shape of the
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`extruded strip and reflective element substrate;
`FIG. 6 is a plan view of the extruded strip showing the cut out shapes of the reflective
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`element cut from the extruded strip;
`FIG. 7 is a sectional view of the reflective element formed by the process shown in FIG. 5;
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`and
`FIG, 8 is a diagram showing an alternate process for manufacturing a prismatic
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`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.
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`6
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`SMR USA
`Exhibit 1020
`Page 006
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`

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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]
`[0035]
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`[0036]
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`[0037]
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`[0038]
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`[0039]
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`[0040]
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`[0041]
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`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
`assemblies according to this present invention;
`FIG. 10 is a top plan partial fragmentary view of the driver's side exterior rearview mirror
`assembly of FIG. 9;
`FIG. 11 is an enlarged sectional view of a plano-multiradius reflective element assembly
`of the mirror assembly in FIG. 10;
`FIG. 12 is an enlarged sectional view of a demarcation element of the plano-multiradius
`reflective element assembly of FIG. 11;
`FIGS. 13A-13H illustrate views of various locations for a piano reflective element and an
`auxiliary reflective element according to this present invention;
`FIG. 14 is a sectional view of a second embodiment of a piano reflective element
`assembly according to the present invention including a demarcation element
`formed as a dividing wall in a backing plate element;
`
`FIG. 14A is a cross-section taken along line XX of FIG. 14;
`FIG. 14B is a cross-sectional view taken along line YY of FIG. 14;
`FIG. 15 is a schematic of a third embodiment of a piano-auxiliary reflective element
`assembly according to this present invention;
`FIG. 16 is a front elevation view of another embodiment of a piano reflective element
`assembly according to the present invention;
`FIG. 17 is an exploded perspective view of the plano reflective element assembly of FIG.
`16;
`
`FIG. 18 is an end view of the piano reflective element assembly of FIG. 16 as viewed
`from line
`of FIG. 16;
`FIG. 19 is a top view of the piano reflective element assembly of FIG. 16 as viewed from
`line XIX--XIX of FIG. 16;
`FIG. 20 is a schematic representation of the piano reflective element assembly of FIG. 16
`illustrating the orientation of the reflective element;
`FIG. 21 is another schematic representation of the orientation of the reflective elements
`of the piano reflective element in FIG. 16;
`
`SMR USA
`Exhibit 1020
`Page 007
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`

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`[0042]
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`FIG, 22 is a diagram illustrating the range of viewing of the reflective elements of
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`the piano reflective element assembly of FIG. 16; and
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`[0043]
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`FIG. 23 is a perspective view of another embodiment of an exterior rearview mirror
`system of the present invention.
`DESCRIPTION OF THE PREFERRED EMBODIMENTS
`Referring now to the drawings and the illustrative embodiments depicted therein, an
`[00270044]
`
`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 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).
`Reflective element 12 may comprise an aspheric or multi-radius or wide angle
`[00280045]
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`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 U.S. 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
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`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 127 positioned within interior vehicle cabin 125. Interior vehicle cabin 125 further
`includes a steering wheel 116, a driver seat 129 positioned at steering wheel 116, a front
`passenger seat 121 adjacent to driver seat 129 in the front portion of cabin 125, and a rear
`passenger seat 123 in the rear portion of cabin 125. Automobile 110 further includes a
`driver-side exterior sideview mirror assembly 112 and a passenger-side exterior sideview
`mirror assembly 114, each adapted for attachment to
`
`[0046]
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`8
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`SMR USA
`Exhibit 1020
`Page 008
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`

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`[0047]
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`opposing sides of automobile body 111, most preferably adjacent to the seating position of
`the driver seated in driver seat 129 for driver-side assembly 112 and adjacent to the front
`passenger seat 121 for passenger-side assembly 114. Exterior sideview mirrors, mounted as
`shown in 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 piano-multiradius exterior sideview
`reflective element assembly 130. Plano-multiradius reflective element assembly 130 is
`mounted to a reflective element positioning actuator 136. The orientation of plano-
`multiradius reflective element assembly 130, and hence its rearward field of view, is
`adjustable by actuator 136 in response to control 137. Control 137 can comprise a handset
`control that allows the driver manually move the orientation of piano-multiradius
`reflective element assembly 130 within exterior mirror housing 140 (such as by a lever
`control or by a cable control) and hence reposition the rearward field of view of piano-
`multiradius reflective element assembly 130. Alternately, when actuator 136 comprises an
`electrically actuated actuator that is electrically operable incorporating at least one motor,
`control 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 known in
`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 mounted to bracket 138
`which attaches to vehicle body side 111. Plano-multiradius reflective element assembly 130
`is positionable by actuator 136 within exterior mirror housing 140.
`Plano-multiradius reflective element assembly 130, as shown in FIG. 11, comprises a
`
`piano element 150 and a separate multiradius element 155. Preferably, piano element 150 is
`adjacent to multiradius element at a joint. At their joint, piano element 150 and separate
`multiradius element 155 can touch leaving substantially no gap or space therebetween, or
`piano element 150 and separate multiradius element 155 can be spaced apart at their joint
`by a space or gap, as in FIG. 11. Plano element 150 and multiradius element 155 are both
`mounted to surface 159 of, and are both supported by, a single backing plate 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
`
`
`
`9
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`SMR USA
`Exhibit 1020
`Page 009
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`

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`[0048]
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`[0049]
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`assembly 130 is mounted in driver-side exterior sideview mirror assembly 112 (and/or in
`passenger-side exterior side view mirror assembly 114) such that piano 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 mirror arts) activates actuator 136 to reposition the rearward field of view of
`plano-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 simultaneously and similarly moves piano
`element 150 and multiradius element 155.
`Plano element 150 preferably comprises a flat reflector-coated glass substrate having
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`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 of the object when
`viewed at the same distance (except for flaws that do not exceed normal manufacturing
`tolerances). Plano element 150 may comprise a conventional fixed reflectance mirror
`reflector or it may comprise a variable reflectance mirror reflector whose reflectivity is
`electrically adjustable. For example, plano element 150 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
`of plano element 150 may be a first surface coating (such as on surface 166) or a second
`surface coating (such as on surface 167), as such terms are known in the mirror art. The
`reflector coating on piano element 150 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 mirror art. If a variable
`reflectance reflector element, piano element 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, piano-
`multiradius reflective element assembly 130 is preferably orientated so that at least a
`portion of (more preferably a substantial portion of) the reflector surface of plano element
`150 is positioned closer to the vehicle body (and hence to the driver) than any portion of the
`reflector surface of multiradius element 155. Thus, and referring to FIG. 11, side A of piano
`element 150 of piano-multiradius reflective element assembly 130 is positioned closer to the
`
`
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`1 0
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`SMR USA
`Exhibit 1020
`Page 010
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`

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`[0050]
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`[0051]
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`[00521
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`
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`driver than side D of multiradius element 155 when plano-multiradius reflective element
`assembly 130 is mounted on an automobile. Also, when mounted into exterior side view
`mirror assembly 112 and/or 114, surfaces 166, 168 of plano-multiradius reflective element
`assembly 130 face rearwardly in terms of the direction of vehicle travel.
` Multiradius element 155 of plano-multiradius reflective element assembly 130
`preferably comprises a curved/bent mirrored glass substrate. The degree of curvature
`preferably increases (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 adjacent its 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 side 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 whereas the local radius of curvature at side D of multiradius
`element 155 is, preferably, less than about 750 mm, more preferably less than about 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 automobile model.
`The total field of view rearwardly of the automobile of the plano-auxiliary reflective
`
`element assembly (which is a combination of the field of view of the piano reflective
`element and of the auxiliary reflective element) preferably generally subtends an angle of
`at least about 20 degrees (and more preferably, generally subtends an angle of at least
`about 25 degrees and most preferably, generally subtends an angle of at least about 30
`degrees) with respect to the side of an automobile to which is attached an exterior sideview
`mirror assembly equipped with the 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
`
`1 1
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`SMR USA
`Exhibit 1020
`Page 011
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`

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`[0053]
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`[0054]
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`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 of multiradius 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 mirror art. 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 of piano element 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 in either or both
`elements. The thickness dimension of elements 150, 155 is determined by the thickness of
`the substrate (or in the case of laminate-type electrochromic reflective elements, the
`thickness of the two substrates 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 of thickness preferably equal to or less than about 2.3 mm,
`more preferably equal to or less than about 1.6 mm, most preferably equal to or less than
`about 1.1 mm. Use of a thinner substrate is beneficial in terms of improving the overall
`stability/vibration performance of the image seen in piano-multiradius reflective element
`assembly 130 when mounted to an automobile.
`The reflector area of piano element 150 is preferably larger than that of multiradius
`
`element 155. Preferably, the width dimension of piano element 150 is larger than the width
`dimension of multiradius element 155 (both width dimensions measured at their respective
`widest dimension and with the width of the respective element being gauged with the
`respective element oriented as it would be orientated when mounted on the automobile).
`Thus, and referring to FIG. 11, the distance from side A to side B of piano element 150 is
`larger than the distance from side C to side D of multiradius element 155. Thus, the ratio of
`the width of piano element 150 to the width of multiradius element 155 is preferably greater
`than 1; more preferably greater than 1.5; most preferably greater than 2.5 in order to
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`1 2
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`SMR USA
`Exhibit 1020
`Page 012
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`[0055]
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`provide a large, unit magnification plano element 150 as the principal rear viewing portion
`of plano-multiradius reflective 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 piano-multiradius reflective element assemblies to be mounted to
`the exterior sideview assemblies of passenger automobiles used non-commercially and for
`non-towing purpose, the width of piano
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`element 150 (at its widest dimension) is preferably in the range of from about 50 mm to
`about 225 mm; more preferably in the range of from about 75 mm to about 175 mm; most
`preferably in the range of from about 100 mm to about 150 mm.
`Backing plate element 160 is preferably a rigid polymeric substrate capable of
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`supporting plano element 50 and multiradius element 155. Backing plate element 160
`comprises a flat portion (generally between E and F as shown in FIG. 11) that corresponds
`to and is aligned with piano element 150. Backing plate element 60 also comprises a
`curved portion (generally between G and H as shown in FIG. 11) that corresponds to and
`is aligned with multiradius 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 mineral filled nylon or
`glass and/or mineral filled polypropylene, ABS, polyurethane and similar polymeric
`materi