PATENT
`DON09 P-2194
`
`EXTENDED FIELD OF VIEW EXTERIOR MIRROR ELEMENT FOR VEHICLE
`
`CROSS REFERENCE TO RELATED APPLICATIONS
`
`[00011
`
`The present application is a continuation of U.S. patent application Ser. No.
`
`13/776,247, filed Feb. 25, 2013, now U.S. Pat. No. 8,562,157, which is a continuation of
`
`U.S. patent application Ser. No. 13/776,091, filed Feb. 25, 2013 (Attorney Docket DON09
`
`P-2048), which is a continuation of U.S. patent application Ser. No. 13/590,854, filed Aug.
`
`21, 2012, now U.S. Pat. No. 8,550,642, which is a division of U.S. patent application Ser.
`
`No. 13/336,018, filed Dec. 23, 2011, now U.S. Pat. No. 8,267,534, which is a continuation
`
`of U.S. patent application Ser. No. 12/911,274, filed Oct. 25, 2010, now U.S. Pat. No.
`
`8,128,243, which is a continuation of U.S. patent application Ser. No. 12/851,045, filed
`
`Aug. 5, 2010, now U.S. Pat. No. 7,934,843, which is a continuation of U.S. patent
`
`application Ser. No. 12/197,666, filed Aug. 25, 2008, now U.S. Pat. No. 7,842,154, 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 are hereby incorporated herein by reference in their
`
`entireties.
`
`FIELD OF THE INVENTION
`
`[0002]
`
`The present invention relates generally to rearview mirror elements for a rearview
`
`mirror assembly of a vehicle and, more particularly, to exterior rearview mirror elements
`
`comprising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`
`[0003]
`
`Typically, mirror reflective elements are formed of glass and have a reflective
`
`coating deposited thereon, such as via vacuum deposition or wet chemical silvering or the
`
`like, such as on a silver line, such as described in U.S. Pat. No. 4,737,188, which is hereby
`
`incorporated herein by reference. Polymeric reflective elements are also known, such as
`
`are described in U.S. Pat. Nos. 6,601,960; 6,409,354; 4,944,581; 4,385,804; 4,193,668;
`
`4,666,264; and 5,483,386, which are hereby incorporated herein by reference. For such
`
`polymeric mirror reflective elements, the need exists for a hard coat or surface on the first
`
`or outer or exterior surface of the element which is contacted by the exterior elements,
`
`such as rain, road debris, or the like, or contacted, for example, by a person scraping ice
`
`1
`
`SMR USA
`Exhibit 1026
`Page 001
`
`

`

`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.
`
`[0004]
`
`Also, exterior rearview mirror reflective elements may be aspheric or multi-radius,
`
`and may typically have a less curved or substantially flat (around 2000 mm radius or
`
`thereabouts) inboard portion or surface at the inboard side of the reflective element (i.e.,
`
`closer to the side body of the vehicle when the mirror assembly is mounted to the vehicle),
`
`and a more curved multi-radius portion or surface at the outboard side of the reflective
`
`element (i.e., further from the side body of the vehicle when the mirror assembly is
`
`mounted to the vehicle), in order to provide an extended field of view. It is typically
`
`desirable to have the reflective elements or substrates of such exterior mirror elements to
`
`be formed of a glass material because glass material typically provides an enhanced
`
`scratch resistance over conventional optical resins and the like.
`
`[OOOS]
`
`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
`
`[0006]
`
`The present invention provides a molded wide angle or multi-radius substrate for a
`
`reflective element. The molded substrate comprises a polymeric optical resin transparent
`
`material and has a curved exterior surface, which may have a less curved/flatter or
`
`substantially flat inboard portion or surface and a more curved outboard portion or surface.
`
`The molded substrate may have an anti-abrasion film or layer, such as an ultrathin glass
`
`film, applied over the exterior surface or first surface to provide substantial protection
`
`against scratches occurring to the molded substrate. The inner surface or second surface
`
`of the reflective element substrate may have a reflective coating or layer, such as a
`
`polymeric reflective film, laminated or adhered or otherwise applied thereto.
`
`[0007]
`
`According to an aspect of the present invention, a wide angle reflective element for
`
`a mirror 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
`
`2
`
`SMR USA
`Exhibit 1026
`Page 002
`
`

`

`substantially conform to the exterior surface of the wide angle substrate. The glass film
`
`comprises a glass material and has a thickness of less than approximately 0.8 mm.
`
`[0008]
`
`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 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.
`
`[0009]
`
`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.
`
`[0010]
`
`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.
`
`[0011]
`
`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.
`
`[00121
`
`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.
`
`[0013]
`
`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
`
`3
`
`SMR USA
`Exhibit 1026
`Page 003
`
`

`

`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.
`
`[0014]
`
`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.
`
`[0015]
`
`A reflective film, such as a polymeric reflective film or the like, may be applied to the
`
`opposite surface of the substrate or sheet or strip. The reflective film may be sufficiently
`
`flexible to be provided in a reel or roll form (or in a sheet that is flexible and conformable to
`
`a bent substrate) for unrolling the reflective film as the film is generally continuously
`
`applied to the surface of the generally continuously formed sheet or strip.
`
`[0016]
`
`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.
`
`[0017]
`
`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.
`
`[0018]
`
`FIG. 1 is a perspective view of an exterior rearview mirror assembly in accordance
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`with the present invention;
`
`[0019]
`
`FIG. 2 is a perspective view of a wide angle or multi-radius reflective element in
`
`accordance with the present invention;
`
`4
`
`SMR USA
`Exhibit 1026
`Page 004
`
`

`

`[0020]
`
`FIG. 3 is a sectional view of the wide angle or multi-radius reflective element taken
`
`along the line 111-111 in FIG. 2;
`
`[00211
`
`FIG. 4 is a sectional view similar to FIG. 3, showing a wide angle or multi-radius
`
`reflective element in accordance with the present invention with a reflective film or layer
`
`applied to the exterior surface of the element and an anti-abrasion film or layer applied
`
`over the reflective film or layer;
`
`[0022]
`
`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;
`
`[0023]
`
`FIG. 5A is an elevation of the extruder of FIG. 5, showing the wedge shape of the
`
`extruded strip and reflective element substrate;
`
`[0024]
`
`FIG. 6 is a plan view of the extruded strip showing the cut out shapes of the
`
`reflective element cut from the extruded strip;
`
`[0025]
`
`FIG. 7 is a sectional view of the reflective element formed by the process shown in
`
`FIG. 5;
`
`[0026]
`
`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;
`
`[0027]
`
`FIG. 9 is a perspective view of an automobile equipped with exterior sideview mirror
`
`assemblies according to this present invention;
`
`[0028]
`
`FIG. 10 is a top plan partial fragmentary view of the driver's side exterior rearview
`
`mirror assembly of FIG. 9;
`
`[0029]
`
`FIG. 11 is an enlarged sectional view of a plano-multiradius reflective element
`
`assembly of the mirror assembly in FIG. 1 O;
`
`[0030]
`
`FIG. 12 is an enlarged sectional view of a demarcation element of the plano-
`
`multiradius reflective element assembly of FIG. 11;
`
`[0031]
`
`FIGS. 13A-13H illustrate views of various locations for a piano reflective element
`
`and an auxiliary reflective element according to this present invention;
`
`[0032]
`
`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;
`
`[0033]
`
`FIG. 14A is a cross-section taken along line XX of FIG. 14;
`
`5
`
`SMR USA
`Exhibit 1026
`Page 005
`
`

`

`[0034]
`
`[0035]
`
`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;
`
`[0036]
`
`FIG. 16 is a front elevation view of another embodiment of a piano reflective
`
`element assembly according to the present invention;
`
`[0037]
`
`FIG. 17 is an exploded perspective view of the piano reflective element assembly of
`
`FIG. 16;
`
`[0038]
`
`FIG. 18 is an end view of the piano reflective element assembly of FIG. 16 as
`
`viewed from line XVIII--XVIII of FIG. 16;
`
`[0039]
`
`FIG. 19 is a top view of the piano reflective element assembly of FIG. 16 as viewed
`
`from line XIX--XIX of FIG. 16;
`
`[0040]
`
`FIG. 20 is a schematic representation of the piano reflective element assembly of
`
`FIG. 16 illustrating the orientation of the reflective element;
`
`[0041]
`
`FIG. 21 is another schematic representation of the orientation of the reflective
`
`elements of the piano reflective element in FIG. 16;
`
`[0042]
`
`FIG. 22 is a diagram illustrating the range of viewing of the reflective elements of
`
`the piano reflective element assembly of FIG. 16;
`
`[0043]
`
`FIG. 23 is a perspective view of another embodiment of an exterior rearview mirror
`
`system of the present invention;
`
`[0044]
`
`FIG. 24 depicts a cross-sectional view of another electrochromic mirror construction
`
`according to the present invention, and in this construction, a secondary weather barrier
`
`412 has been applied to the joint at which sealing means 405 joins substrates 402, 403;
`
`[0045]
`
`FIGS. 25A, 25B and 25C depict the orientation of the substrates in different
`
`constructions of the electrochromic mirrors and electrochromic devices of the present
`
`invention, with FIG. 25A depicting a perpendicular displacement of the first substrate and
`
`the second substrate, FIG. 25B depicting a lateral displacement and a perpendicular
`
`displacement of the first substrate and the second substrate, and FIG. 25C depicting an
`
`arrangement of the first substrate and the second substrate, wherein the dimensions of the
`
`length and width of the first substrate are slightly greater than those of the second
`
`substrate, and in this arrangement, the peripheral edge of the first substrate extends
`
`beyond the peripheral edge of the second substrate; and
`
`6
`
`SMR USA
`Exhibit 1026
`Page 006
`
`

`

`[0046]
`
`FIGS. 26A and 26B depict cross-sectional views of electrochromic devices, which
`
`illustrate different seal constructions that may be employed in accordance with the present
`
`invention.
`
`[0047]
`
`Referring now to the drawings and the illustrative embodiments depicted therein, an
`
`DESCRIPTION OF THE PREFERRED EMBODIMENTS
`
`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).
`
`[0048]
`
`Reflective element 12 may comprise an aspheric or multi-radius or wide angle
`
`single element reflective element substrate. The reflective element 12 may provide a field
`
`of view similar to the piano-auxiliary reflective element assembly disclosed in U.S. Pat.
`
`Nos. 6,522,451 and 6,717,712, which are hereby incorporated herein by reference.
`
`[0049]
`
`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 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 opposing sides of
`
`7
`
`SMR USA
`Exhibit 1026
`Page 007
`
`

`

`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 plano-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 plano-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 plano-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.
`
`[OOSO]
`
`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
`
`8
`
`SMR USA
`Exhibit 1026
`Page 008
`
`

`

`plano-multiradius reflective element 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.
`
`[0051]
`
`Plano element 150 preferably comprises a flat reflector-coated glass 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 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, piano 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 piano 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.
`
`[0052]
`
`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 of piano 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
`
`9
`
`SMR USA
`Exhibit 1026
`Page 009
`
`

`

`piano element 150 of plano-multiradius reflective element assembly 130 is positioned
`
`closer to the 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.
`
`[0053]
`
`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 piano 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.
`
`[0054]
`
`The total field of view rearwardly of the automobile of the piano-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 piano-auxiliary reflective element assembly.
`
`[0055]
`
`Multiradius element 155 may comprise a conventional fixed reflectance mirror
`
`reflector or it may comprise a variable reflectance mirror reflector whose reflectivity is
`
`10
`
`SMR USA
`Exhibit 1026
`Page 010
`
`

`

`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 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.
`
`[0056]
`
`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, piano 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 plano-multiradius reflective
`
`element assembly 130 when mounted to an automobile.
`
`[0057]
`
`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
`
`11
`
`SMR USA
`Exhibit 1026
`Page 011
`
`

`

`preferably greater than 1; more preferably greater than 1.5; most preferably greater than
`
`2.5 in order to provide a large, unit magnification piano 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 plano-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
`
`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.
`
`[0058]
`
`Backing plate element 160 is preferably a rigid polymeric substrate capable of
`
`supporting piano element 50 and multiradius element 155. Backing plate element 160
`
`comprises a flat portion (generally between E and Fas 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
`
`materials. For example, backing plate element 160 can be formed of ABS in an injection
`
`molding operation. Plano element 150 can be cut from a stock lite of flat chromium mirror(cid:173)
`
`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, piano element 150 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
`
`12
`
`SMR USA
`Exhibit 1026
`Page 012
`
`

`

`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 element to piano
`
`element 150 and multiradius element 155 (along with any other elements such as the
`
`demarcation element 165) in a single integral