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`SMR USA
`Exhibit 1041
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`US 8,591,047 B2
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`SMR USA
`Exhibit 1041
`Page 004
`
`

`

`

`

`

`

`

`

`U.S. Patent
`
`Nov. 26, 2013
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`Sheet 4 of 16
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`US 8,591,047 B2
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`FIG. 9
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`SMR USA
`Exhibit 1041
`Page 008
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`1
`EXTERIOR SIDEVIEW MIRROR ASSEMBLY
`
`2
`SUMMARY OF THE INVENTION
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`US 8,591,047 B2
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`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`The present application is a continuation of U.S. patent
`application Ser. No. 13/590,854, filed Aug. 21, 2012, 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 ofU.S. patent application Ser. No. 10/709,434, filed
`May 5, 2004, now U.S. Pat. No. 7,420,756, which claims the
`benefit of U.S. provisional application Ser. No. 60/471,872,
`filed May 20, 2003, which are hereby incorporated herein by
`reference in their entireties.
`
`FIELD OF THE INVENTION
`
`The present invention relates generally to rearview mirror
`elements for a rearview mirror assembly of a vehicle and,
`more particularly, to exterior rearview mirror elements com(cid:173)
`prising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`
`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. Poly(cid:173)
`meric 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 or wiping snow or condensation off the mirror
`element outer surface, such as during winter. A variety of hard 45
`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)
`inboard portion or surface at the inboard side of the reflective
`element (i.e., closer to the side body of the vehicle when the 55
`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 60
`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.
`
`The present invention provides a molded wide angle or
`multi-radius substrate for a reflective element. The molded
`5 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 sur(cid:173)
`face and a more curved outboard portion or surface. The
`molded substrate may have an anti-abrasion film or layer,
`10 such as an ultrathin glass film, applied over the exterior sur(cid:173)
`face 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
`15 film, laminated or adhered or otherwise applied thereto.
`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
`20 surface of the substrate has a less curved inboard portion or
`surface and a more curved outboard portion or surface. The
`substrate comprises a polymeric resin material. The glass film
`is adapted to substantially conform to the exterior surface of
`the wide angle substrate. The glass film comprises a glass
`25 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 com(cid:173)
`prises a substrate having an exterior surface, and an anti-
`30 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 pref(cid:173)
`erably comprises a glass material (such as a soda lime glass or
`a borosilicate or the like) and has a thickness of less than
`35 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 substrate material ( or less preferably, may be
`cut from an injected molded strip or sheet). The flexible glass
`40 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
`50 surface or side of the substrate or strip opposite the exterior
`surface. The reflective film may comprise a polymeric reflec(cid:173)
`tive 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
`65 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
`
`SMR USA
`Exhibit 1041
`Page 021
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`

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`US 8,591,047 B2
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`3
`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 poly(cid:173)
`meric resin. The functional film is preferably unrolled from a 5
`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 10
`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 15
`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.
`A reflective film, such as a polymeric reflective film or the 20
`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 reflec(cid:173)
`tive film as the film is generally continuously applied to the 25
`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 exte- 30
`rior 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 reflec(cid:173)
`tive 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.
`
`35
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`BRIEF DESCRIPTION OF THE DRAWINGS
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`4
`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 driv(cid:173)
`er's side exterior rearview mirror assembly of FIG. 9;
`FIG. 11 is an enlarged sectional view of a plano-multira(cid:173)
`dius 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
`ofFIG.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 divid(cid:173)
`ing wall in a backing plate element;
`FIG.14A is a cross-section taken along line XX ofFIG.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(cid:173)
`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 piano reflec(cid:173)
`tive element assembly of FIG. 16;
`FIG. 18 is an end view of the piano reflective element
`assemblyofFIG.16 as viewed from line XVIII-XVIII of FIG.
`16;
`FIG. 19 is a top view of the piano reflective element assem(cid:173)
`bly of FIG. 16 as viewed from line XIX-XIX of FIG. 16;
`FIG. 20 is a schematic representation of the piano reflective
`element assembly ofFIG.16 illustrating the orientation of the
`reflective element;
`FIG. 21 is another schematic representation of the orienta(cid:173)
`tion of the reflective elements of the piano reflective element
`40 in FIG. 16;
`FIG. 22 is a diagram illustrating the range of viewing of the
`reflective elements of the piano reflective element assembly
`of FIG. 16; and
`FIG. 23 is a perspective view of another embodiment of an
`45 exterior rearview mirror system of the present invention.
`
`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 accordance with the present invention;
`FIG. 3 is a sectional view of the wide angle or multi-radius
`reflective element taken along the line III-III in FIG. 2;
`FIG. 4 is a sectional view similar to FIG. 3, showing a wide
`angle or multi-radius reflective element in accordance with
`the present invention with a reflective film or layer applied to 50
`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 manufacturing a prismatic mirror reflec(cid:173)
`tive element in accordance with the present invention;
`FIG. SA is an elevation of the extruder of FIG. 5, showing
`the wedge shape of the extruded strip and reflective element
`substrate;
`FIG. 6 is a plan view of the extruded strip showing the cut
`out shapes of the reflective element cut from the extruded
`strip;
`FIG. 7 is a sectional view of the reflective element formed
`by the process shown in FIG. 5;
`FIG. 8 is a diagram showing an alternate process for manu(cid:173)
`facturing 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;
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawings and the illustrative embodi-
`ments depicted therein, an 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
`55 view or wide angle field of view to a driver or occupant of the
`vehicle and may comprise a single reflective element sub(cid:173)
`strate 18 having an inner surface 18a and an opposite exterior
`surface 18b (FIGS. 2 and 3). The exterior surface 18b com(cid:173)
`prises a less curved or substantially flat inboard portion or
`60 surface 18c and a more curved outboard portion or surface
`18d, as discussed below. The substrate 18 may have an anti(cid:173)
`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
`65 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
`
`SMR USA
`Exhibit 1041
`Page 022
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`

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`US 8,591,047 B2
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`5
`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(cid:173)
`radius or wide angle single element reflective element sub(cid:173)
`strate. 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.
`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 20
`portion of cabin 125. Automobile 110 further includes a
`driver-side exterior sideview mirror assembly 112 and a pas(cid:173)
`senger-side exterior sideview mirror assembly 114, each
`adapted for attachment to opposing sides of automobile body
`111, most preferably adjacent to the seating position of the 25
`driver seated in driver seat 129 for driver-side assembly 112
`and adjacent to the front passenger seat 121 for passenger(cid:173)
`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 30
`mirror assemblies. Driver-side exterior sideview mirror
`assembly 112 includes, as illustrated in FIG. 10, a plano(cid:173)
`multiradius exterior sideview reflective element assembly
`130. Plano-multiradius reflective element assembly 130 is
`mounted to a reflective element positioning actuator 136. The 35
`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 40
`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 45
`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 piano- 50
`multiradius reflective element assembly 130 to a pre-set ori(cid:173)
`entation 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, 60
`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 65
`mounted to surface 159 of, and are both supported by,