DECLARATION (37 CFR 1.63) FOR UTILITY OR DESIGN APPLICATION USING AN
`APPLICATION DATA SHEET (37 CFR 1.76)
`
`Electronic Version v11
`Stylesheet Version v10
`
`Title of
`Invention MIRROR REFLECTIVE ELEMENT
`
`As the below named inventor, I declare that:
`
`This declaration is directed to the invention titled:" MIRROR REFLECTIVE ELEMENT"
`
`I believe that I am the original and first inventor of the subject matter which is claimed and for
`which a patent is sought;
`
`I have reviewed and understand the contents of the above-identified application, including the
`claims, as amended by any amendment specifically referred to above;
`
`I acknowledge the duty to disclose to the United States Patent and Trademark Office all
`information known to me to be material to patentability as defined in 37 CFR 1.56, including
`for continuation-in-part applications, material information which became available between the
`filing date of the prior application and the national or PCT International filing date of the
`continuation-in-part application.
`
`All statements made herein of my knowledge are true, all statements made herein on
`information and belief are believed to be true, and further that these statements were made
`with the knowledge that willful false statements and the like are punishable by fine or
`imprisonment, or both, under 18 U.S.C. 1001, and may jeopardize the validity of the
`application or any patent issuing thereon.
`
`FULL NAME OF INVENTOR:
`
`Inventor: Niall R. Lynam
`
`Signature :
`
`Inventor
`
`Citizen of : US
`
`SMR USA
`Exhibit 1028
`Page 001
`
`

`

`DONOl P-1152
`
`DECLARATION AND POWER OF ATTORNEY
`As a below named inventor, I hereby declare:
`My residence, post office address and citizenship are as stated below next to my name.
`I believe I am the original, first and sole inventor, if only one name is listed below, or an original, first
`and joint inventor, if plural names are listed below, of the subject matter which is claimed and for which a patent
`is sought on the invention entitled MIRROR REFLECTIVE ELEMENT, the specification of which is attached
`hereto.
`
`I have reviewed and understand the contents of the above-identified specification, including the claims,
`as amended by any amendment referred to above.
`
`I acknowledge the duty to disclose to the United States Patent and Trademark Office (the Office), all
`information which is known by me to be material to patentability as defined in Title 37, Code of Federal
`Regulations (C.F.R.), Section 1.56.
`
`CLAIM OF PRIORITY
`I hereby claim the benefit under Title 35, United States Code, § l 19(e) of any United States provisional
`application(s) listed below:
`
`U.S. Serial No. 60/471,872, filed on May 20, 2003.
`
`POWER OF ATTORNEY
`I hereby appoint the patent law firm of Van Dyke, Gardner, Linn & Burkhart, LLP, 2851 Charlevoix
`Drive, S.E., Suite 207, Grand Rapids, Michigan 49546, telephone number 616/975-5500, facsimile number
`616/975-5505, and the individual patent attorneys and patent agents at such patent law firm, namely, Daniel Van
`Dyke, Reg. No. 25 046; Donald S. Gardner, Reg. No. 25 975; Terence J. Linn, Reg. No. 30 283; Frederick S.
`Burkhart, Reg. No. 29 288; Catherine S. Collins, Reg. No. 37 599; Timothy A. Flory, Reg. No. 42 540; and Karl
`T. Ondersma, Reg. No. 55 894 my attorney(s) or agent(s) with full power of substitution and revocation, to
`prosecute this application and to transact all business in and to receive all correspondence from the Patent and
`Trademark Office connected therewith.
`
`All statements made herein of my own knowledge are true and all statements made on information and
`belief are believed to be true, and further, these statements are made with the knowledge that willful false
`statements and the like are punishable by fine or imprisonment, or both, under 18 U.S.C. § 1001, and that such
`willful false statements may jeopardize the validity of this application or any patent issued thereon.
`
`Sole inventor:
`
`Niall R. Lynam
`Citizenship: U.S.A.
`Residence:
`248 Foxdown
`Holland, Michigan 49424
`United States of America
`Post Office Address: Same as above.
`
`Date
`
`SMR USA
`Exhibit 1028
`Page 002
`
`

`

`FEE TRANSMITTAL
`
`Electronic Version v08
`Stylesheet Version v08.0
`
`Title of
`Invention
`
`MIRROR REFLECTIVE ELEMENT
`
`Application Number :
`
`Date:
`
`First Named Applicant:
`
`Attorney Docket Number:
`
`Niall R. Lynam
`
`DON01 P-1152
`
`TOT AL FEE AUTHORIZED $ 788
`
`Patent fees are subject to annual revisions on or about October 1st of each year.
`
`Filing as large entity
`
`BASIC FILING FEE
`
`Fee Description
`Utility Filing Fee
`
`EXTRA CLAIM FEES
`
`Fee Code
`1001
`
`I
`I
`
`Amount$
`
`I
`770
`7701
`Subtotal For Basic Filing Fees:$ 770
`
`Fee Paid$
`
`Fee Description
`Total Claims : 21
`Independent Claims: 2
`
`Extra Claim
`1
`0
`
`Fee Code
`1202
`1201
`
`Amount$
`
`Fee Paid$
`
`18
`18
`8E
`0
`Subtotal For Extra Claims Fees:$ 18
`
`AUTHORIZED BILLING INFORMATION
`The commissioner is hereby authorized to charge indicated fees and credit any
`overpayments to:
`
`Deposit account number:
`Access Code
`Deposit name:
`Deposit authorized name:
`Signature:
`Date (YYYYMMDD):
`
`220190
`****
`
`Van Dyke, Gardner, Linn and Burkhart, LLP
`Timothy A. Flory
`/taf/
`2004-05-05
`
`Charge Any Additional Fee Required Under 37 C.F.R. Sections 1.16 and 1.17.
`
`SMR USA
`Exhibit 1028
`Page 003
`
`

`

`APPLICATION DATA SHEET
`
`Electronic Version v14
`
`Stylesheet Version v14.0
`
`Title of Invention
`
`MIRROR REFLECTIVE ELEMENT
`
`Application Type :
`Attorney Docket Number:
`
`regular, utility
`D0N01 P-1152
`
`Correspondence address:
`Customer Number:
`
`28101
`
`Continuing Data:
`
`This is a Non-Provisional of US application number 60/471,872, filed 2003-05-20 , now pending.
`
`11111111111111111111111111111111111
`
`Inventor Information:
`
`Inventor 1:
`Applicant Authority Type:
`Citizenship:
`Given Name:
`Middle Name:
`Family Name:
`Residence:
`City of Residence:
`State of Residence:
`Country of Residence:
`Address-1 of Mailing Address:
`Address-2 of Mailing Address:
`City of Mailing Address:
`State of Mailing Address:
`Postal Code of Mailing Address:
`Country of Mailing Address:
`Phone:
`Fax:
`E-mail:
`
`Attorney Information:
`
`Inventor
`us
`Niall
`R.
`Lynam
`
`Holland
`Ml
`us
`248 Foxdown
`
`Holland
`Ml
`49424
`us
`
`SMR USA
`Exhibit 1028
`Page 004
`
`

`

`practitioner(s) at Customer Number:
`
`28101
`
`as my attorney(s) or agent(s) to prosecute the application identified above, and to transact all
`business in the United States Patent and Trademark Office connected therewith.
`
`11111111111111111111111111111111111
`
`Assignee 1:
`Organization Name:
`Address-1 of Mailing Address:
`Address-2 of Mailing Address:
`City of Mailing Address:
`State of Mailing Address:
`Postal Code of Mailing Address:
`Country of Mailing Address:
`Phone:
`Fax:
`E-mail:
`
`Donnelly Corporation
`414 East Fortieth Street
`
`Holland
`Ml
`49423-5368
`us
`
`SMR USA
`Exhibit 1028
`Page 005
`
`

`

`TRANSMITTAL
`
`Electronic Version v1 .1
`Stylesheet Version v1 .1.0
`
`MIRROR REFLECTIVE ELEMENT
`
`Title of
`Invention
`
`Application Number :
`
`Date:
`
`First Named Applicant:
`
`Niall R. Lynam
`
`Confirmation Number:
`
`Attorney Docket Number:
`
`DON01 P-1152
`
`I hereby certify that the use of this system is for OFFICIAL correspondence between patent
`applicants or their representatives and the USPTO. Fraudulent or other use besides the filing
`of official correspondence by authorized parties is strictly prohibited, and subject to a fine
`and/or imprisonment under applicable law.
`I , the undersigned, certify that I have viewed a display of document(s) being electronically
`submitted to the United States Patent and Trademark Office, using either the USPTO provided
`style sheet or software, and that this is the document(s) I intend for initiation or further
`prosecution of a patent application noted in the submission. This document(s) will become
`part of the official electronic record at the USPTO.
`
`Submitted By:
`Timothy A. Flory
`Registered Number: 42 540
`
`Elec. Sign.
`/taf/
`
`Sign. Capacity
`Attorney
`
`SMR USA
`Exhibit 1028
`Page 006
`
`

`

`Documents being submitted:
`
`Files
`
`us-declaration
`
`us-fee-sheet
`
`us-request
`
`application-body
`
`us-declaration
`Comments
`
`D0N01 P1152-usdecl.xml
`us-declaration .dtd
`us-declaration .xsl
`D0N01 P1152-usfees.xml
`us-fee-sheet.xsl
`us-fee-sheet.dtd
`D0N01 P1152-usrequ.xml
`us-request.dtd
`us-request.xsl
`SpecificationD0N01 P1152-trans.xml
`us-application-body .xsl
`application-body .dtd
`wipo.ent
`mathml2.dtd
`mathml2-qname-1.mod
`isoamsa.ent
`isoamsb.ent
`isoamsc.ent
`isoamsn.ent
`isoamso.ent
`isoamsr.ent
`isogrk3.ent
`isomfrk.ent
`isomopf.ent
`isomscr.ent
`isotech.ent
`isobox.ent
`isocyr1 .ent
`isocyr2.ent
`isodia.ent
`isolat1 .ent
`isolat2.ent
`isonum.ent
`isopub.ent
`mmlextra.ent
`mmlalias.ent
`soextblx.dtd
`FIG1 .tit
`FIG2.tif
`FIG3.tif
`Declaration POA.tif
`
`SMR USA
`Exhibit 1028
`Page 007
`
`

`

`Electronic Version
`
`Stylesheet Version vl.1.1
`
`Description
`
`MIRROR REFLECTIVE ELEMENT
`
`CROSS REFERENCE TO RELATED APPLICATIONS
`
`[0001] The present application claims the benefit of U.S. provi(cid:173)
`
`sional application, Ser. No. 60/471,872, filed May 20,
`
`2003 (Attorney Docket DONOl P-1092), which is hereby
`
`incorporated herein by reference in its entirety.
`
`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,
`
`SMR USA
`Exhibit 1028
`Page 008
`
`

`

`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 con(cid:173)
`
`tacted by the exterior elements, such as rain, road debris,
`
`or the like, or contacted, for example, by a person scrap(cid:173)
`
`ing ice or wiping snow or condensation off the mirror ele(cid:173)
`
`ment 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 ex(cid:173)
`
`terior 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 sur-
`
`SMR USA
`Exhibit 1028
`Page 009
`
`

`

`face 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 mir(cid:173)
`
`ror elements to be formed of a glass material because
`
`glass material typically provides an enhanced scratch re(cid:173)
`
`sistance over conventional optical resins and the like.
`
`[0005] 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 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 pro(cid:173)
`
`vide substantial protection against scratches occurring to
`
`the molded substrate. The inner surface or second surface
`
`SMR USA
`Exhibit 1028
`Page 010
`
`

`

`of the reflective element substrate may have a reflective
`
`coating or layer, such as a polymeric reflective film, lami(cid:173)
`
`nated 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 vehi(cid:173)
`
`cle 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 in(cid:173)
`
`board portion or surface and a more curved outboard
`
`portion or surface. The substrate comprises a polymeric
`
`resin material. The glass film is adapted to substantially
`
`conform to the exterior surface of the wide angle sub(cid:173)
`
`strate. 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(cid:173)
`
`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 flexi-
`
`SMR USA
`Exhibit 1028
`Page 011
`
`

`

`ble 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.
`
`[001 O] 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 sur(cid:173)
`
`face or side of the substrate or strip opposite the exterior
`
`surface. The reflective film may comprise a polymeric re(cid:173)
`
`flective 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
`
`SMR USA
`Exhibit 1028
`Page 012
`
`

`

`glass film or layer or sheet may be applied over the reflec(cid:173)
`
`tive 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/ trans(cid:173)
`
`parency 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 continu(cid:173)
`
`ously forming an elongated strip or sheet of substrate
`
`material and applying a substantially transparent func(cid:173)
`
`tional 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 com(cid:173)
`
`prise 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 gen(cid:173)
`
`erally continuously as the strip or sheet is formed or ex(cid:173)
`
`truded or cast or molded. Preferably, multiple mirror ele(cid:173)
`
`ment 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 ul-
`
`SMR USA
`Exhibit 1028
`Page 013
`
`

`

`trathin 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-ra(cid:173)
`
`dius exterior surface. The anti-abrasion film may be suffi(cid:173)
`
`ciently flexible to conform to the wide angle or multi-ra(cid:173)
`
`dius 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 sub(cid:173)
`
`strate or sheet or strip. The reflective film may be suffi(cid:173)
`
`ciently 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 con(cid:173)
`
`tinuously formed sheet or strip.
`
`[0016] Therefore, the present invention provides a molded wide
`
`angle or multi-radius single substrate for a rearview mir(cid:173)
`
`ror assembly which has an anti-abrasion or anti-scratch
`
`film or layer applied to the curved, wide angle or multi(cid:173)
`
`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 sub(cid:173)
`
`strate may have a reflective film or layer laminated or ap-
`
`SMR USA
`Exhibit 1028
`Page 014
`
`

`

`plied to the inner surface opposite the exterior surface.
`
`[0017] These and other objects, advantages, purposes and fea(cid:173)
`
`tures of the present invention will become apparent upon
`
`review of the following specification in conjunction with
`
`the drawings.
`
`BRIEF DESCRIPTION OF DRAWINGS
`
`[0018] FIG. 1 is a perspective view of an exterior rearview mirror
`
`assembly in accordance with the present invention;
`
`[0019] FIG. 2 is a perspective view of a wide angle or multi-ra(cid:173)
`
`dius reflective element in accordance with the present in(cid:173)
`
`vention;
`
`[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;
`
`[0021] 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(cid:173)
`
`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 inven(cid:173)
`
`tion;
`
`SMR USA
`Exhibit 1028
`Page 015
`
`

`

`[0023] FIG. SA is an elevation of the extruder of FIG. 5, showing
`
`the wedge shape of the extruded strip and reflective ele(cid:173)
`
`ment 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; and
`
`[0026] FIG. 8 is a diagram showing an alternate process for man(cid:173)
`
`ufacturing a prismatic mirror reflective element in accor(cid:173)
`
`dance with the present invention, where a strip of sub(cid:173)
`
`strate material is cast and formed via a caster and float
`
`section.
`
`DETAILED DESCRIPTION
`
`[0027] Referring now to the drawings and the illustrative embod(cid:173)
`
`iments depicted therein, an exterior rearview mirror as(cid:173)
`
`sembly 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 sin(cid:173)
`
`gle reflective element substrate 18 having an inner surface
`
`18a and an opposite exterior surface 18b (FIGS. 2 and 3).
`
`SMR USA
`Exhibit 1028
`Page 016
`
`

`

`The exterior surface 18b comprises a less curved or sub(cid:173)
`
`stantially flat inboard portion or surface 18c and a more
`
`curved outboard portion or surface 18d, as discussed be(cid:173)
`
`low. 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 sur(cid:173)
`
`face 18a, as also discussed below. Aspects of the reflec(cid:173)
`
`tive 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).
`
`[0028] Reflective element 12 may comprise an aspheric or multi(cid:173)
`
`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 as(cid:173)
`
`sembly disclosed in U.S. Pat. Nos. 6,522,451 and
`
`6,717,712, which are hereby incorporated herein by refer(cid:173)
`
`ence.
`
`[0029] The substrate 18 of the reflective element 12 of the
`
`present invention may be formed (such as by casting, ex(cid:173)
`
`trusion or injection molding) of a polymeric optical resin
`
`SMR USA
`Exhibit 1028
`Page 017
`
`

`

`material, such as an acrylic or polycarbonate resin, a poly(cid:173)
`
`olefin, a cyclic olefin copolymer, such as a COC resin
`
`known as "TOPAS" and available from Ticona of Summit,
`
`NJ (such as a resin of the type described in U.S. pat. appli(cid:173)
`
`cation, Ser. No. 09/946,228, filed Sep. 5, 2001 for IM(cid:173)
`
`PROVED PLASTIC SUBSTRATE FOR INFORMATION DEVICE
`
`AND METHOD FOR MAKING SAME (Attorney Docket
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`DON03 P-910), which is hereby incorporated herein by
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`reference) or the like. Because the substrate can be, for
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`example, injection molded from an optical resin, the sub(cid:173)
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`strate may be molded or formed to a desired shape having
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`a wide angle or multi-radius surface, which is typically
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`challenging to accomplish with glass sheets. This is be(cid:173)
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`cause any prescription or form for the substrate can be
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`established in an injection mold by machining, such that
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`when the injection mold is filled with molten injected op(cid:173)
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`tical resin material, the optical resin material takes the
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`shape of the mold. Thus, for example, a substrate having
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`a substantially or fully flat inboard region for a multi-ra(cid:173)
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`dius (often referred to as an aspheric) exterior mirror ele(cid:173)
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`ment is fully practical.
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`[0030] As shown in FIGS. 1-3, inboard portion or surface 18c of
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`exterior surface 18b is positioned at or toward the side of
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`SMR USA
`Exhibit 1028
`Page 018
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`the reflective element that is toward the side body of the
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`vehicle when the mirror assembly is mounted to or at(cid:173)
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`tached to the vehicle. The inboard portion 18c of surface
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`18b of substrate 18 may comprise a substantially flat or
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`slightly curved or less curved surface, such as a surface
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`having a radius of curvature of preferably greater than at
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`least approximately 4000 mm, more preferably greater
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`than at least approximately 9000 mm, and most prefer(cid:173)
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`ably greater than at least approximately 12000 mm. The
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`inboard surface 18c may provide a field of view of up to
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`approximately 10 degrees, preferably up to approximately
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`15 degrees, and more preferably up to approximately 20
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`degrees.
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`[0031] Outboard portion or surface 18d of exterior surface 18b
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`of substrate 18 is positioned outward from inboard por(cid:173)
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`tion and is thus further away from the side body of the
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`vehicle when the mirror assembly is mounted to or at(cid:173)
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`tached to the vehicle. Outboard portion 18d of exterior
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`surface 18b may be a more convex or curved surface,
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`such that the substrate comprises a wide angle or multi(cid:173)
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`radius exterior surface substrate. The more curved out(cid:173)
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`board surface 18d of the substrate may have radii of cur(cid:173)
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`vature in the range of less than about 4000 mm to about
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`SMR USA
`Exhibit 1028
`Page 019
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`100 mm or lower. The more curved outboard portion or
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`surface 18d may provide an extended field of view when
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`combined with the less curved inboard portion or surface
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`18c. For example, the combined field of view of the mirror
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`reflective element 12 may be preferably greater than at
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`least approximately 25 degrees, more preferably greater
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`than at least approximately 3 5 degrees, and most prefer(cid:173)
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`ably greater than at least approximately 45 degrees. The
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`substrate may be formed to have curves or shapes or to
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`provide other field of views, without affecting the scope of
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`the present invention.
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`[0032] The exterior surface 18b of substrate 18 may be coated or
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`covered with a substantially transparent functional film or
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`layer 20, such as an anti-abrasion film or layer, such as an
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`ultrathin glass film or layer or sheet having a thickness of
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`preferably less than or equal to approximately 0.8 mm,
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`more preferably less than or equal to approximately 0.5
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`mm, and most preferably less than or equal to approxi(cid:173)
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`mately 0.3 mm. The ultrathin glass film or layer or sheet
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`20 provides a flexible glass film which can be conformed
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`to the exterior surface of the molded substrate (for exam(cid:173)
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`ple, such as described in U.S. Pat. No. 5,085,907, which is
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`hereby incorporated herein by reference) after the sub-
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`SMR USA
`Exhibit 1028
`Page 020
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`strate is molded. The ultrathin glass film or layer may
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`provide substantial protection against scratches on the
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`outboard surface, such as may occur due to impact by de(cid:173)
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`bris at the outside of the vehicle (for exterior mirror as(cid:173)
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`sembly applications) or by use of ice scrapers and the like
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`on the glass surface and the like. The ultrathin glass film
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`or layer may be applied to a molded or extruded strip
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`(such as described below with respect to FIGS. 5-8) or
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`may be applied to the surface or surfaces of a formed or
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`cut substrate, without affecting the scope of the present
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`invention. The flexible ultrathin glass film or layer of the
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`present invention allows the wide angle or multi-radius
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`substrate to be molded in the desired shape out of a
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`transparent acrylic resin material, yet may conform to the
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`curved or multi-radius or aspheric shape and provide en(cid:173)
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`hanced protection or scratch resistance to the substrate.
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`[0033]
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`It is envisioned that other functional films or hard coats or
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`anti-abrasion films or the like may be applied to the exte(cid:173)
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`rior surface of the molded substrate, such as via adhering
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`or applying a film to the exterior surface or via dip coating
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`or vacuum deposition or the like. Optionally, a hydropho(cid:173)
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`bic film or hydrophilic film or element or property may
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`also or otherwise be applied to the exterior surface 18b of
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`SMR USA
`Exhibit 1028
`Page 021
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`

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`the substrate. Optionally, the functional film may com(cid:173)
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`prise a non-glass or polymeric film, such as a polymeric
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`material that is a harder and/or different property mate(cid:173)
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`rial than the substrate itself. Optionally, the anti-abrasion
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`film may be formed of the same resin material as the sub(cid:173)
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`strate to match the coefficients of thermal expansion and
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`thus reduce thermal expansion/contraction mismatches
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`between the materials.
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`[0034] Optionally, the inner or rear surface 18a of the substrate
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`18 may have a reflective layer or coating or film or sheet
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`22 laminated or otherwise applied thereto. For example,
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`the reflective layer or film 22 may comprise a polymeric
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`reflective film 22 laminated or otherwise adhered or ap(cid:173)
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`plied to the rear or inner surface 18a of a molded or ex(cid:173)
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`truded or cast strip (such as described below with respect
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`to FIGS. 5-8) or of the molded or formed substrate 18.
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`Reflective film 22 may comprise a polymeric reflective
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`film, such as an all polymer-thin-film multilayer, high re(cid:173)
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`flective mirror film, such as a multilayer, non-metallic re(cid:173)
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`flective film which may comprise multiple coextrusion of
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`many plastic layers to form a highly reflective mirror film,
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`such as described in U.S. Pat. Nos. 3,773,882; 3,884,606;
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`and 3,759,647, which are hereby incorporated herein by
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`SMR USA
`Exhibit 1028
`Page 022
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`reference. Such a reflective film thus may comprise multi(cid:173)
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`layers of polymer materials to form a highly reflective
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`mirror film, such as a Radiant Light Film, a Radiant Mirror
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`Film or a Radiant Color Film, such as commercially avail(cid:173)
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`able from 3M of St. Paul, Minn., such as a Radiant Color
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`Film CM590 or CMSOO. Also, a durable metallized poly(cid:173)
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`meric mirror layer can be used, such as described in U.S.
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`Pat. No. 5,361,172, which is hereby incorporated herein
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`by reference.
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`[0035] As shown in FIG. 4, it is envisioned that a substrate or
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`substrate shape or sheet or strip of substrate material 118
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`may have a reflective film or layer 122 adhered or lami(cid:173)
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`nated or otherwise applied to the exterior surface 118b of
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`the substrate material. An anti-abrasion film or layer 120
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`(which may comprise an ultrathin glass film or layer as
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`described above) may be adhered or laminated or other(cid:173)
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`wise applied to the reflective film or layer 122. In such an
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`application, with the reflective layer on the front or exte(cid:173)
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`rior surface of the substrate, the substrate material may
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`be molded or formed of a polymeric material that does
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`not provide optical clarity and need not be transparent.
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`The substrate material may act only as a support or back(cid:173)
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`ing plate for the reflective film or layer and the anti-
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`SMR USA
`Exhibit 1028
`Page 023
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`

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`abrasion film or layer and thus may be opaque or non(cid:173)
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`transparent. The exterior surface 118b of substrate mate(cid:173)
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`rial 118 may comprise a wide angle exterior surface or a
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`multi-radius exterior surface having a less curved inboard
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`portion or surface 118c and a more curved outboard por(cid:173)
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`tion or surface 118d, such as discussed above with re(cid:173)
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`spect to substrate 18.
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`[0036] Optionally, and such as shown in FIGS. 5, 6 and 8, the op(cid:173)
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`tical resin material may be molded or extruded or cast
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`into a generally continuous strip 19 having the desired
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`curved or multi-radius surfaces, and may be cut to form
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`the substrates. The substrates may be cut from the strip
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`via any known cutting process, such as via a laser cutting
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`process or a water-jet cutting process or the like, without
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`affecting the scope of the present invention.
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`[0037] As shown in FIGS. 5-8, the molding processes and film or
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`layer application processes of the present invention may
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`be used to form a prismatic or wedge-shaped strip for
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`forming prismatic or wedge-shaped substrates 18' (FIG. 7)
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`for use in an interior rearview mirror assembly of a vehi(cid:173)
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`cle.
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`[0038] As also shown in FIGS. 5-8, the substrate material or opti(cid:173)
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`cal resin material may be extruded or cast to form the
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`SMR USA
`Exhibit 1028
`Page 024
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`

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`continuous strip or sheet 19. For example, and as shown
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`in FIGS. 5 and SA, the strip 19 may be extruded by an ex(cid:173)
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`truder 24, which, preferably continuously, extrudes the
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`optical resin material through an extrusion nozzle 26. The
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`extruded material may be moved through an annealing
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`lehr 28 to reduce or substantially eliminate birefringence,
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`striation, stress and/or distortion in the strip or sub(cid:173)
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`strates. The coatings or layers or films 20 and/or 22 may
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`be app