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`US 20020072026141
`
`(19) United States
`([2) Patent Application Publication (IO) l’ub. N0.: US 2002/0072026 A1
`(43) Pub. Date:
`Jun. 13, 2002
`Lynam et al.
`
`(54) EXTERIOR MIRROR PIANO-AUXILMRY
`REFLECTIVE ELEM ENT ASSEMBLY
`
`Publication Classification
`
`(76)
`
`Inventors: Niall R. Lynam, Holland, M] (US);
`John O. Llnduhl. liruitport, Ml (US);
`Hahns Y. Fuchs. Dorl‘lmmltcn (DE)
`
`Correspondence Address:
`Catherine S. Collins
`Van Dyke, Gardner, Linn 8; Burkhart, LLP
`2851 Charlct'oix l)r., S.E., Ste. 207
`RU. Box 888695
`Grand Rapids, Ml 49588-8695 (US)
`
`(21) Appl.No.:
`
`o9;74s,172
`
`(22
`
`Filed:
`
`Dec. 20, 2000
`
`Related U.S. Application Data
`
`(63] Continuation~in—part of application No. (l9t478.3|5.
`tiled on Jan. 5, 2000.
`
`Int. CL" ............
`(51)
`(52) U.S. Cl.
`............
`
`...... F1271) 15,?02
`
`..... 4-32,:f 77
`
`(S?)
`
`ABS'I‘RAC'I'
`
`This invention provides a reflective clement assembly suit-
`able for use in an exterior sideview mirror assembly
`mounted to the side body of an automobile. The reflective
`element assembly includes a first rollectivc element and a
`second reflective element. The second rollectivc element is
`angled downwardly and forwardly with respect to the first
`reflective clement when the mirror assembly is mounted to
`a side ol‘an automobile to provide an increased field olVicw.
`In one form. both reflective eiemems are commonly sup-
`ported on a heml. which is mounted to the mirror assembly
`casing. In another form,
`the reflective elements are sepa-
`rately mounted. with the second reflective element fixedly
`mounted to the casing and the lirst rcllectivo element mov—
`ably supported in the mirror casing, for example‘ on an
`actuator
`
`12
`
`11
`
`
`
`Patent Owner Magna - Ex. 2012, p. 1
`Patent Owner Magna - Ex. 2012, p. 1
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`

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`latent Application Publication
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`Jun. 13, 2002 Sheet 1 of 14
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`Patent Owner Magna - Ex. 2012, p. 2
`Patent Owner Magna - Ex. 2012, p. 2
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`Patent Application Publication
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`Jun. 13, 2002 Sheet 2 of 14
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`US 2002/0072026 A1
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`Figure2
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`Patent Owner Magna - Ex. 2012, p. 3
`Patent Owner Magna - EX. 2012, p. 3
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`Patent Application Publication
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`Jun. 13, 2002 Sheet 3 0f 14
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`Patent Owner Magna - Ex. 2012, p. 4
`Patent Owner Magna - Ex. 2012, p. 4
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`Patent Application Publication
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`Patent Owner Magna - Ex. 2012, p. 5
`Patent Owner Magna - EX. 2012, p. 5
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`Patent Owner Magna - Ex. 2012, p. 8
`Patent Owner Magna - EX. 2012, p. 8
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`Patent Application Publication
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`Jun. 13, 2002 Sheet 8 of 14
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`Patent Owner Magna - Ex. 2012, p. 9
`Patent Owner Magna - EX. 2012, p. 9
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`Patent Application Publication
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`

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`Patent Application Publication
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`Jun. 13, 2002 Sheet 11 of 14
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`Patent Owner Magna - Ex. 2012, p. 12
`Patent Owner Magna - Ex. 2012, p. 12
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`

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`Patent Application Publication
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`Jun. 13, 2002 Sheet 12 of 14
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`US 20030072026 Al
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`Patent Owner Magna - Ex. 2012, p. 13
`Patent Owner Magna - Ex. 2012, p. 13
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`

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`Patent Application Publication
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`Jun. 13, 2002 Sheet 13 of 14
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`US 2002/0072026 A1
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`Patent Owner Magna - Ex. 2012, p. 14
`Patent Owner Magna - Ex. 2012, p. 14
`
`

`

`Patent Application Publication
`
`Jun. 13, 2002 Sheet 14 of 14
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`US 2002/0072026 A1
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`Patent Owner Magna - Ex. 2012, p. 15
`atent Owner Magna - Ex. 2012, p. 15
`
`

`

`US 20(l2iOO72026 Al
`
`Jun. 13, 2002
`
`EXTERIOR MIRROR PIANO-AUXILIARY
`REFLECTIVE ELEMENT ASSEMBLY
`
`[0001] This is a continuation-impart of US. patent appli-
`cation Ser. No.
`(ӣ478,315,
`filed Jan. 6,2000, entitled
`“EXTERIOR MIRROR PLANO-AUXILIARY REFLEC-
`TIVE ELEMENT ASSEMBLY", which is incorporated by
`reference herein in its entirety.
`
`TECHNICAL FIELD AND BACKGROUND OF
`THE INVENTION
`
`[0002] The present invention relates to exterior sideview
`mirror assemblies suitable for use on an automobile, and
`more specifically,
`to piano-auxiliary reflective element
`assemblies for use in automobile exterior sideview mirror
`assemblies.
`
`[0003] Automobiles are typically equipped with an inte-
`rior rearview mirror assembly (adapted for providing a
`rearward field of view immediately rearward ofthe vehicle,
`typically principally in the road lane the vehicle is traveling
`in) and at
`least one exterior sideview mirror assembly
`attached to the side of the vehicle (typically adjacent a front
`side window portion). The exterior side view mirror assem-
`bly typically comprises a reflective element adapted to
`provide a rearward field of view of the side lane adjacent the
`vehicle so as to allow the driver see whether a side approach»
`ing vehicle is present when the driver is contemplating a lane
`change. Conventionally, automobiles are equipped with a
`driver-side exterior mirror assembly and, very often, with a
`passengerside exterior sideview mirror assembly mounted
`to the side of the automobile body opposite to that of the
`driver-side ammbly. While the combination of an interior
`rearview mirror with a driver-side exterior mirror (and
`especially in a three—mirror system comprising an interior
`rearview minor with a driver-side exterior mirror and a
`passengerside exterior mirror) works well in many driving
`situations, rear vision blind spots present a potential safety
`hazard while driving. A rear vision blind spot is an area
`adjacent the side of an automobile where a view of another
`vehicle (overtaking on that side) is not captured in the
`rearward field of view of the exterior mirror reflector on that
`side. This presents a potential safety hazard as the driver,
`upon checking the view in the exterior sideview mirror and
`seeing no overtaking vehicle therein, may deem it safe to
`initiate a
`lane change, unaware that
`there is a vehicle
`immediately adjacent in a blind-spot of the exterior mirror
`reflector.
`
`[0004] Various attempts have been made conventionally to
`minimize andfor eliminate exterior mirror blind-spots on
`vehicles. One approach is to make the exterior mirror
`reflector larger, and particularly wider with respect to the
`vehicle body. By increasing the width of the exterior mirror
`reflector, it has a wider field of view rearwards, and hence
`the reflector blindspot
`is reduced. While use of a wide
`exterior mirror reflector is an option for trucks, buses and
`commercial vehicles, increasing the width of the reflector
`used in an exterior sideview mirror assembly mounted on
`automobiles (such as sedans, station wagons, sports cars,
`convertibles, minivans, sports utility vehicles, pick~up
`trudts and similar passenger carrying automobiles) is often
`not an option. In such domestic automobiles, increasing the
`width of the exterior mirror reflector increases the size of the
`exterior sideview mirror assembly with a concomitant
`
`increase in aerodynamic drag, increase in fuel consumption,
`increased difliculty in parking in tight parking spaces, and
`increased reflector vibration. Use of a non-flat, curved
`exterior mirror reflector is commonly used to increase
`rearward field of view without increasing reflector size.
`
`[0005] While working well to increase field ofview, use of
`a curved reflector (such as a convex, sphericallycurved
`reflector) has disadvantages. The field of view rearward
`increases as the degree of curvature of the bent substrate
`increases (i.e., the field of view rearward increases as the
`radius of curvature of the bent substrate decreases). How-
`ever, such wide~angle mirrors have non-unit magnification
`and distance perception rearward is distorted. For this rea-
`son, convex (spherically-bent) exterior mirror reflectors are
`required in some countries (such as the United States) to
`carry a safety warning “OBJECTS 1N MIRROR ARE
`CLOSER THAN THEY APPEAR". Distance perception is
`particularly important for a driver-side exterior mirror.
`indeed, Federal Vehicle Safety Standard No: 111 in the
`United States (the entire disclosure of which is hereby
`incorporated by reference herein) requires that the driver-
`side exterior mirror reflector exhibit unit magnification, and
`places restrictions on the radius of curvature allowed for any
`bent passenger-side mirror as well as requiring a safety
`warning be placed thereon. As an improvement over spheri-
`cally benticonvex mirror reflectors. aspherical or multiradius
`mirror reflectors (such as are disclosed in US. Pat. Nos.
`4,449,786 and 5,724,187, the entire disciosures of which are
`hereby incorporated by reference herein) have been devel-
`oped. Such mirrors are widely used in Europe and Asia for
`both driver-side exterior mirror reflectors and for passenger-
`side exterior mirror reflectors. The aspherical or multiradius
`mirror reflectors typically have a less curved (larger radius
`of curvature) reflective region that is inboard or closest to the
`driver when mounted on a vehicle and, usually separated by
`a demarcation line or the like, have a more curved (smaller
`radius of curvature) region that is outboard or farthest from
`the driver when mounted on a vehicle. However, such
`aspherical or multiradius reflectors do not have unit magni-
`fication and so cannot be used when unit magnification is
`mandated (such as by FMVSS 111, referenced above).
`
`[0006] To supplement a flat driver-side exterior mirror
`reflector, an auxiliary and separate bent reflector is some-
`times incorporated into the driver-side exterior sideview
`mirror assembly. However, this is often not suitable for
`passenger automobiles because of the extra space required in
`the sideview mirror assembly to accommodate an auxiliary
`reflector element. Also, in most passenger automobiles, the
`position of the side view mirror reflector is adjustable by the
`driver {such as by a hand-adjust, or by a manually adjustable
`cable such as a Bowden cable or by an electrically operable
`actuator, as known in the art) in order to provide to that
`driver his or her desired rearward field of view, which
`ill-suits use of a separate, auxiliary reflector. Likewise,
`addition of stick-on blindwspot mirror reflectors (such as are
`commonly sold in automotive parts stores and the like) onto
`an automobile exterior sideview mirror reflector has disad-
`vantages, including obscuring field of view of the automo-
`bile mirror reflector and adding to mirror element vibration.
`
`[0007] There is thus a need to provide an automobile
`exterior sideview reflective element, and particularly a
`driver-side automobile exterior sideview reflective element,
`that overcomes the disadvantages above and that provides
`
`Patent Owner Magna - Ex. 2012, p. 16
`Patent Owner Magna - Ex. 2012, p. 16
`
`

`

`US 20020072026 Al
`
`Jun. 13, 2002
`
`
`
`SUMMARY OF THE INVENTION
`
`[0008] According to the present invention, an automobile
`exterior sideview mirror system includes an exterior side-
`view mirror assembly having a reflective element assembly.
`The reflective element assembly includes a first reflective
`element and a second reflective element, which together
`provide an increased field of view for the exterior side mirror
`assembly.
`
`in one form of the invention, an automobile exte-
`[0009]
`rior side mirror system includes an exterior side mirror
`assembly, which is adapted for attachment to a side of an
`automobile. The exterior sideview mirror assembly includes
`a reflective element assembly having a plane reflective
`element, which forms a first
`reflective element, and a
`multiradiused reflective element which forms a second
`reflective element. The reflective element assembly is
`mounted to an actuator, which moves the reflective element
`assembly to position the rearward field of view of the
`reflective element assembly. The reflective element assem-
`bly further includes a frame element assembly to which the
`lirst and second reflective elements are mounted and which
`orients the second reflective element such that
`it has a
`viewing range which spans outwardly and downwardly with
`respect to the first reflective element to thereby provide an
`increased field of view for the exterior sideview mirror
`assembly.
`
`in one aspect, the first reflective element and the
`[0010]
`second reflective element are adjacently attached to the
`frame element assembly at a joint. The reflective element
`assembly further includes a demarcation element disposed at
`its joint to form a demarcation between the first and second
`reflective elements that is visible to the driver. In a further
`aspect, the frame element assembly includes a bezel portion
`which extends around the first reflective element, with the
`demarcation clement comprising a segment of the first berel
`portion.
`
`the second reflective element
`In another aspect,
`[0011]
`comprises a bent glass substrate with radii of curvature in the
`range of about 4000 mm to about 100 mm.
`
`in yet another aspect, the frame element assembly
`[0012]
`includes a frame, with the first and second reflective ele-
`ments being mounted in the frame. The multiradiused reflec—
`tive element is mounted to the frame at an outboard position,
`with the plane reflective element being positioned adjacent
`the multiradiused reflective element and at an inboard posi-
`tion with respect
`to the multiradiused reflective element
`when the exterior side mirror assembly is mounted to an
`automobile. In a further aspect, the plano reflective element
`is mounted to the frame by a backing plate, which is
`preferably adapted to mount to the actuator.
`
`element
`reflective
`first
`the
`In other aspects,
`[0013]
`includes a rearward field of view having a principal axis,
`
`which is dilIerent from and angled to a principal axis of the
`reanvard field of view of the second reflective element when
`the reflective element assembly is mounted in the exterior
`sideview mirror assembly. The principal axis of the rearward
`field of view of the second reflective element is directed
`generally outwardly and downwardly with respect
`to a
`longitudinal axis of the automobile when the exterior side
`mirror system is mounted to an automobile. For example,
`the principal axis of the rearward field of view of the second
`reflective element may form a downward angle with respect
`to the principal axis of the rearward field of view of the first
`reflective element in the range from about 035° to about 5°,
`or in a range of about l.5° to about 35°, in a range of about
`2° to about 3°.
`
`In other aspects, the principal axis of the second
`[0014]
`reflective element forms an outward angle with respect to
`the principal axis of the rearward field of view of the first
`reflective element in a range of about 075° to about 5°, or
`in a range of about 1° to about 3°, or in a range of about
`1.250 to about 25°,
`
`[0015] According to another form of the invention, an
`automobile exterior side mirror system includes an exterior
`side mirror assembly, which is adapted for attachment to a
`side of an automobile. The exterior side mirror assembly
`includes a mirror easing. a reflective element assembly, and
`an actuator. The reflective element assembly includes a
`frame element assembly, a first reflective element having a
`unit magnification, and a second reflective element having a
`multiradiused curvature. The frame element assembly
`mounts the first reflective element and the second reflective
`element in the mirror casing and is adapted to mount to the
`actuator, which adjusts the orientation of the reflective
`element assembly. The first reflective element has a first
`rearward field of view with a first principal axis, and the
`second reflective elenteut has a second rearward field of
`view with a second principal axis, with the second principal
`axis being angled outwardly and downwardly with respect to
`the first principal axis.
`
`In one aspect, the second principal axis is angled
`[0016]
`outwardly from the first principal axis at an angle in a range
`of about (L'I'Su to about 5°, or in a range of approximately 1°
`to about 3°, or at an angle in a range of about 125° to about
`25°.
`
`the second principal axis is
`In another aspect,
`[0017]
`angled downwardly from the first principal axis at an angle
`in a range of approximately 0.75" to about 5", or in a range
`of about 15° to about 35°, or at an angle in a range of about
`2" to about 3".
`
`the frame includes a support
`In another aspect,
`[0018]
`surface for the second reflective element, with the support
`surface angling the second principal axis of the second
`reflective clement.
`
`In yet another form of the invention, an automobile
`[0019]
`exterior sidcview mirror system includes an exterior side—
`view mirror assembly, which is adapted for attachment to a
`side of an automobile. The mirror assembly includes an
`actuator and a reflective element assembly. The reflective
`element assembly includes a frame element assembly, a first
`reflective elentent, and a second reflective element. The
`frame element assembly is adapted to mount to the actuator
`and includes a frame and a support surface for the second
`
`Patent Owner Magna - Ex. 2012, p. 17
`Patent Owner Magna - Ex. 2012, p. 17
`
`

`

`US 20030072026 Al
`
`Jun. 13, 2002
`
`'4.)
`
`reflective element. The actuator adjusts the posilion of the
`reflective element assembly to thereby adjust the viewing
`angle of the sideview mirror system. The support surface
`angles the second reflective element downwardly and for-
`wardly of the first
`reflective element when the mirror
`assembly is mounted to an automobile whereby the second
`reflective element provides a viewing range which spans
`outwardly and downwardly with respect to the automobile to
`thereby provide an increased field of view for the exterior
`side-view mirror assembly.
`
`In one aspect, the support surface is provided by a
`[0020]
`plate element,
`for example a solid plate element or a
`l'oraminous plate element.
`[It other aspects,
`the support
`surface is provided by a frame.
`
`In further aspects, the frame includes a lirst bezel
`[0021]
`portion and a second bezel portion. with the first bezel
`portion extending around the lirsl reflective element, and the
`seeond bevel portion extending around [he semnd reflective
`element. In one form, the second bezel portion is angled
`forwardly with respect to the first bezel portion when said
`exterior sideview mirror assembly is mounted to a side of an
`automobile.
`
`[0022]
`In another aspect, the second reflective element is
`located outboard of the first reflective element.
`
`
`
`
`
`[0033] FIG. 8 is a front elevation view of another embodi-
`ment ofa piano reflective element assembly according to the
`present invention;
`
`[0034] FIG. 9 is an exploded perspective view of the
`piano reflective element assembly of FIG. 8;
`
`[0035] FIG. 10 is an end view of the plano reflective
`element assembly of FIG. 8 as viewed from line X—X of
`FIG. 8;
`
`[0036] FIG. 11 is a top view of the plano reflective
`element assembly of FIG. 8 as viewed from fine XI-XI of
`FIG. 8;
`
`[0037] FIG. 12 is a schematic representation of the plano
`reflective element assembly of FIG. 8 illustrating the ori-
`entation of the reflective element;
`
`[0038] FIG. 13 is another schematic representation of the
`orientation of the reflective elements of the plano reflective
`element in FIG. 8;
`
`[0039] FIG. 14 is a diagram illustrating the range of
`viewing of the reflective elements of the plano reflective
`element assembly of FIG. 8; and
`
`[0040] FIG. 15 is a perspective View of another embodi-
`ment of an exterior rearview mirror system of the present
`invention.
`
`
`
`Patent Owner Magna - Ex. 2012, p. 18
`Patent Owner Magna - Ex. 2012, p. 18
`
`

`

`US 20020072026 Al
`
`Jun. 13, 2002
`
`comprise a memory controller, as known in the automotive
`mirror art, that controis actuator 36 to move the position of
`plano~multiradius reflective element assembly 30 to a pre-
`set orientation that suits the rearward field of view prefer-
`ence of an individual driver. Actuator 36 is mounted to
`bracket 38 which attaches to vehicle body side 11. Plano-
`multiradius reflective element assembly 30 is positionable
`by actuator 36 within exterior mirror housing 40.
`
`Plano—multiradius reflective element assembly 30.
`[0042]
`as shown in FIG. 3, comprises a plane element 50 and a
`separate multiradius element 55. Preferably, plano element
`50 is adjacent to multiradius element at a joint. At theirjoint,
`plano element 50 and separate multiradius element 55 can
`touch ieaving substantially no gap or space therebetween, or
`plano element 50 and separate multiradius element 55 can be
`spaced apart at their joint by a space or gap, as in FIG. 3.
`Plano element 50 and multiradius element 55 are both
`mounted to surface 59 of, and are both supported by, a single
`backing plate element 60. Plano element 50 and multiradius
`element 55 are demarcated apart by demarcation element 65.
`Surface 61 ofbacking plate element 60 is preferably adapted
`to attach, such as by attachment member 64, to actuator 36
`when plane-multiradius reflective element assembly 30 is
`mounted in driver-side exterior sideview mirror assembly 12
`(anchor in passenger-side exterior side view mirror assembly
`14) such that piano element 50 and multiradius element 55
`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 36 to reposition the rearward field of view
`of plano-multiradius reflective element assembly 30. Thus,
`since elements 50, 55 are part ofplano-multiradius reflective
`element assembly 30, movement of plano~multiradius
`reflective element assembly 30 by actuator 36 simulta-
`neously and similarly moves plano element 50 and multi-
`radius element 55.
`
`[0043] Plano element 50 preferably comprises a flat reflec-
`tor-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 50 may comprise
`a conventional fixed reflectance mirror reflector or it may
`comprise a variable reflectance mirror reflector whose
`reflectivity is electrically adjustable. For example, plano
`element 50 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 alioy or combination of these metal reflectors). The
`metal reflector coating of plane element 50 may be a first
`surface coating (such as on surface 66) or a second surface
`coating (such as on surface 67), as such terms are known in
`the mirror art. The reflector coating on plano element 50 may
`also comprise a dielectric coating, or a multilayer cf dielec»
`tric coatings, or a combination of a metal
`layer and a
`dielectric layer to form automotive mirror reflectors as
`known in the automotive mirror art. Ifa variable reflectance
`reflector element, piano element 50 preferably comprises an
`electro~optic reflector element and, most preferably, an
`electrochrcmic reflector element.
`
`[0044] When mounted into exterior side view mirror
`assembly 12 andior 14, plano-rnultiradius reflective element
`assembly 30 is preferably orientated so that at least a portion
`of (more preferably a substantial portion of) the reflector
`surface of plane element 50 is positioned closer to the
`vehicle body (and hence to the driver) than any portion of
`the reflector surface of muitiradius element 55. Thus, and
`referring to FIG. 3, side A of plane element 50 of plane-
`multiradius reflective element assembly 30 is positioned
`closer to the driver than side D of multiradius element 55
`when plano-multiradius reflective element assembly 30 is
`mounted on an automobile. Also, when mounted into exte-
`rior side view mirror assembly 12 andr‘or l4, surfaces 66. 68
`of piano-multiradius reflective element assembly 30 face
`rearwardly in terms of the direction of vehicle travel.
`
`[0045] Multiradius element 55 of plano~multiradius
`reflective element assembly 30 preferany comprises a
`curvedfbent mirrored glass substrate. The degree of corva~
`ture preferably increases (and hence the local radius of
`curvature decreases) across the surface of multiradius ele-
`ment 55 with the least curvature (largest radius of curvature)
`occurring at the side of multiradius element 55 (side C in
`FIG. 3) positioned adjacent its joint to plano element 50
`when both are mounted on backing plate element 60. Thus,
`and referring to FIG. 3, the local radius of curvature at side
`C of multiradius element 55, when mounted on backing
`plate element 60, is larger than at side D. Also, the local
`radius of curvature preferably progressively decreases
`across multiradius element 55 from side C to side D.
`Preferably, the local radius of curvature at side C of multi-
`radius element 55 is at least about 3000 mm; more prefer-
`ably 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 55 is, preferably, less than about
`750 mm, more preferably less than about 350 mm; most
`preferably less than about 150 mm. Preferably, multiradius
`element 55 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 ele-
`ment to be used in a particular exterior mirror assembly can
`vary according to the specific field of view needs on a
`specific automobile model.
`
`[0046] The total field of view rearwardly of the automo»
`bile of the plane-auxiliary reflective element assembly
`(which is a combination of the field of view of the plano
`reflective element and of the auxiliary reflective element)
`preferably generally subtends an angle of at least about 20°
`(and more preferably, generally subtends an angle of at least
`about 25° and most preferably, generally subtends an angle
`of at least about 30°) with respect to the side of an auto-
`mobile to which is attached an exterior sideview mirror
`assembly equipped with the plano~auxiliary reflective ele-
`ment assembly.
`
`[0047] Multiradius element 55 may comprise a conven-
`tional fixed reflectance mirror reflector or it may comprise a
`variable reflectance mirror reflector whose reflectivity is
`electrically adjustable. For example, multiradius element 55
`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 nickei»
`alloy coating, a silver coating, an aluminum coating (or any
`alloy or combination of these metal reflectors). The metal
`reflector coating of multiradius element 55 may be a first
`
`Patent Owner Magna - Ex. 2012, p. 19
`Patent Owner Magna - Ex. 2012, p. 19
`
`

`

`US 20020072026 Al
`
`Jun. 13, 2002
`
`surface coating (such as on surface 68) or a second surface
`coating (such as on surface 69), as such terms are known in
`the mirror art. The reflector coating on multiradius element
`55 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 55 preferably com-
`prises an eiectro—optic reflector element and, most prefer-
`ably, an electrochromic reflector element.
`
`[0048] Also, it is preferable that the thiclo'tess of plano
`element 50 and multiradius element 55 be substantially the
`same in dimension so that their respective outer surfaces, 66
`and 68, are substantially coplanar so that a driver can readily
`view images in either or both elements. The thickness
`dimension of elements 50, 55 is determined by the thickness
`of the substrate (or in the case of laminate-type electrochro-
`mic reflective elements, the thickness of the two substrates
`between which the electrochromic medium is disposed). For
`example, plano element 50 audior muitiradius element 55
`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 stabilityr'vibration performance of the image seen in
`plano-multiradius reflective element assembly 30 when
`mounted to an automobile.
`
`[0049] The reflector area of plano element 50 is preferably
`larger than that of multiradius element 55. Preferably, the
`width dimension of plano element 50 is larger than the width
`dimension of multiradius element 55 (both width dimen»
`sions 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 refen'ing to
`FIG. 3, the distance from side Ato side 13 of piano element
`50 is larger than the distance from side C to side D of
`multiradius element 55. Thus, the ratio of the width of plano
`element 50 to the width of multiradius element 55 is
`preferably greater than 1; more preferably greater than 1.5;
`most preferably greater than 2.5 in order to provide a large,
`unit magnification plano element 50 as the principal rear
`viewing portion of plano-multiradius reflective element
`assembly 30 and providing multiradius element 55 as a
`smaller, auxiliary, separate, wide-angle viewing portion of
`plano-multiradius reflective element assembly 30. For
`plano~multiradius
`reflective element assemblies
`to be
`mounted to the exterior sideview assemblies of passenger
`automobiles used noncommercially and for non»towir|g
`purpose,
`the width of piano element 50 (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 17'5 mm; most preferably in the range of
`from about 100 mm to about 150 mm.
`
`[0050] Backing plate element 60 is preferably a rigid
`polymeric substrate capable of supporting plano element 50
`and multiradius element 55. Backing plate element 60
`comprises a flat portion (generally between E and F as
`shown in FIG. 3) that corresponds to and is aligned with
`plano element 50. Backing plate element 60 also comprises
`a curved portion (generally between G and H as shown in
`FIG. 3) that corresponds to and is aligned with multiradius
`
`element 55. Preferably, curved portion G-H of multiradius
`element 55 is fabricated with a multiradius prescription that
`is substantially the same as the multiradius prescription of
`multiradius element 55. Backing plate element 60 is formed
`as a single element
`to which elements 50 and 55 are
`separately attached. Preferably, backing plate element 60 is
`formed by injection molding of a thermoplastic or a ther-
`mosetting polymer resin. Materials suitable to use for back-
`ing plate element 60 include unfilled or filled polymeric
`materials such as glass andior mineral filled nylon or glass
`andt'or mineral filled polypropylene, ABS, polyurethane and
`similar polymeric materials. For example, backing plate
`element 60 can be formed of ABS in an injection molding
`operation. Plano element 50 can be cut from a stock lite of
`flat chromium mirror-coated 1.6 mm thick glass. Multiradius
`element 55 can be cut from a stock lite of multiradiusly-bent
`chromium mirror-coated 1.6 mm thick glass. Plano element
`50 and multiradius element 55 can then be attached (such as
`by an adhesive attachment such as an adhesive pad or by
`mechanical attachment suc