US008550642B2
`
`(12) United States Patent
`US 8,550,642 B2
`(10) Patent N0.:
`
`(45) Date of Patent: *Oct. 8, 2013
`Lynam
`
`EXTERIOR REARVIEW MIRROR ASSEMBLY
`
`(54)
`
`(58) Field of Classification Search
`USPC .......................................................... 359/866
`
`(75)
`
`Inventor: Niall R. Lynam, Holland, MI (US)
`
`See application file for complete search history.
`
`(73)
`
`Assignee: Donnelly Corporation, Holland, MI
`(US)
`
`(56)
`
`References Cited
`U.S. PATENT DOCUMENTS
`
`(*)
`
`Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`This patent is subject to a terminal dis-
`claimer.
`
`(21)
`
`Appl. N0.: 13/590,854
`
`(22)
`
`Filed:
`
`Aug. 21, 2012
`
`(65)
`
`(60)
`
`(60)
`
`(51)
`
`(52)
`
`Prior Publication Data
`
`US 2012/0314316A1
`
`Dec. 13,2012
`
`Related US. Application Data
`
`Division of application No. 13/336,018, filed on Dec.
`23, 2011, now Pat. No. 8,267,534, which is a
`continuation of application No. 12/911,274, filed on
`Oct. 25, 2010, now Pat. No. 8,128,243, which is a
`continuation of application No. 12/851,045, filed on
`Aug. 5, 2010, now Pat. No. 7,934,843, which is a
`continuation of application No. 12/ 197,666, filed on
`Aug. 25, 2008, now Pat. No. 7,842,154, which is a
`division ofapplication No. 10/709,434, filed on May 5,
`2004, now Pat. No. 7,420,756.
`
`Provisional application No. 60/471 ,872, filed on May
`20, 2003.
`
`Int. Cl.
`G023 5/08
`US. Cl.
`USPC .......................................................... 359/866
`
`(2006.01)
`
`1,114,559 A
`1,672,559 A
`RE17,274 E
`2,135,262 A
`2,263,382 A
`2,279,751 A
`2,514,989 A
`2,580,014 A
`2,636,419 A
`2,778,273 A
`
`10/1914 Weed
`6/1928 Doble
`4/1929 Porter
`11/1938 Schumacher
`11/1941 Gotzinger
`4/1942 Elwood
`7/1950 Buren
`12/1951 Gazda
`4/1953 Kerr
`1/1957 Fellmeth
`
`(Continued)
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`
`2409748
`2550095
`
`9/1975
`5/1976
`
`(Continued)
`Primary Examiner 7 Alessandro Amari
`(74) Attorney, Agent, or Firm 7 Gardner, Linn, Burkhart &
`Flory, LLP
`
`ABSTRACT
`(57)
`An exterior rearview mirror assembly for a vehicle includes a
`bracket fixedly secured to the vehicle, a mirror casing secured
`to the bracket and defining a primary opening, and a primary
`mirror disposed within said primary opening for providing a
`view rearward of the motor vehicle through a primary field of
`view. The primary mirror defines a primary plane. A spotting
`mirror is spaced apart from the primary mirror and extends
`through a secondary plane different from the primary plane. A
`divider extends between the primary mirror and the spotting
`mirror to separate the primary and secondary mirrors visually.
`
`11 Claims, 16 Drawing Sheets
`
`135'
`
`\
`
`173"
`
`\
`
`174'
`
`180'
`
`Patent Owner Magna - Ex. 2015, p. 1
`
`Patent Owner Magna - Ex. 2015, p. 1
`
`

`

`US 8,550,642 B2
`
`Page 2
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`2,890,539
`2,911,177
`3,104,274
`3,131,250
`3,146,296
`3,170,985
`3,175,463
`3,266,016
`3,267,806
`3,280,701
`3,337,285
`3,338,655
`3,375,053
`3,389,952
`3,404,935
`3,408,136
`3,424,517
`3,563,638
`3,601,614
`3,610,739
`3,667,833
`3,708,222
`3,759,647
`3,764,201
`3,773,882
`3,806,232
`3,826,563
`3,881,811
`3,884,606
`3,909,117
`4,193,668
`4,200,359
`4,223,983
`4,258,979
`4,264,144
`4,268,120
`4,281,899
`4,293,191
`4,303,308
`4,306,770
`4,311,362
`4,311,363
`4,325,609
`4,331,382
`4,350,412
`4,385,804
`4,435,042
`4,436,371
`4,436,372
`4,439,013
`4,449,786
`4,470,665
`4,499,451
`4,526,446
`4,549,786
`4,555,166
`4,575,202
`4,588,267
`4,609,266
`4,623,222
`4,629,296
`4,630,904
`4,666,264
`4,674,849
`4,674,850
`4,678,294
`4,679,906
`4,712,879
`4,715,701
`4,721,364
`4,727,302
`4,733,336
`4,737,188
`4,770,522
`4,773,740
`
`>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
`
`6/1959
`11/1959
`9/1963
`4/1964
`8/1964
`2/1965
`3/1965
`8/1966
`8/1966
`10/1966
`8/1967
`8/1967
`3/1968
`6/1968
`10/1968
`10/1968
`1/1969
`2/1971
`8/1971
`10/1971
`6/1972
`1/1973
`9/1973
`10/1973
`11/1973
`4/1974
`7/1974
`5/1975
`5/1975
`9/1975
`3/1980
`4/1980
`9/1980
`3/1981
`4/1981
`5/1981
`8/1981
`10/1981
`12/1981
`12/1981
`1/1982
`1/1982
`4/1982
`5/1982
`9/1982
`5/1983
`3/1984
`3/1984
`3/1984
`3/1984
`5/1984
`9/1984
`2/1985
`7/1985
`10/1985
`11/1985
`3/1986
`5/1986
`9/1986
`11/1986
`12/1986
`12/1986
`5/1987
`6/1987
`6/1987
`7/1987
`7/1987
`12/1987
`12/1987
`1/1988
`2/1988
`3/1988
`4/1988
`9/1988
`9/1988
`
`Holt
`West
`King
`Ely
`Fischer
`Katulich
`Seashore
`Maruyama et al.
`Azegami
`Donnelly et a1.
`Travis
`Young
`Ward
`Tobin, Jr.
`Creager
`Travis
`Budreck
`Panozzo
`Platzer, Jr.
`Seashore
`Baldwin, Sr.
`Stern
`Schrenk et al.
`Haile
`Schrenk
`Gray
`Davis
`French
`Schrenk
`Takahashi et al.
`Skinner
`Lawson
`Bloom
`Mahin
`McCord
`Jitsumori
`Oskam
`Kim
`Kobrin
`Marhauer
`LaPorte
`Marsalka et a1.
`Alford
`Graff
`Steenblik et al.
`Tamura et a1.
`Wood et al.
`Wood et al.
`Schmidt et a1.
`Hagn et al.
`McCord
`Blom
`Suzuki et al.
`Adams
`Albers et al.
`Enomoto
`McGuire
`Pastore
`Blom
`Itoh et al.
`White
`Pastore
`Yamabe
`Stewart
`Blom
`Van No strand
`Brandenburg
`Lynam et al.
`Urban
`Itoh et al.
`Mizuta et al.
`Skogler et al.
`Bahls
`Alten
`Kawakami et al.
`
`S
`
`>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
`
`D297,926
`4,793,690
`4,799,768
`4,824,231
`4,826,289
`4,828,379
`4,853,283
`4,859,046
`4,882,466
`4,882,565
`4,906,075
`4,906,085
`4,913,542
`4,917,485
`4,929,074
`4,932,769
`4,932,770
`4,944,581
`4,948,242
`4,989,964
`5,005,962
`5,014,167
`5,022,747
`5,033,835
`5,044,739
`5,050,977
`5,052,792
`5,066,112
`5,073,012
`5,076,673
`5,078,480
`5,080,492
`5,085,907
`5,107,374
`5,115,346
`5,115,352
`5,117,346
`5,118,540
`5,140,455
`5,142,407
`5,151,816
`5,151,824
`5,166,833
`5,178,448
`5,179,471
`5,183,099
`5,189,537
`5,193,029
`5,207,492
`5,225,943
`5,233,461
`5,237,458
`5,237,459
`5,239,405
`5,247,395
`5,253,109
`5,262,894
`5,285,060
`5,295,021
`5,296,973
`5,313,335
`5,327,288
`5,354,965
`5,355,245
`5,361,172
`5,371,659
`5,406,414
`5,412,512
`5,424,875
`5,432,643
`5,437,931
`5,446,576
`5,481,409
`5,483,386
`5,497,305
`5,497,306
`5,509,606
`5,517,367
`5,523,877
`
`10/1988
`12/1988
`1/1989
`4/1989
`5/1989
`5/1989
`8/1989
`8/1989
`11/1989
`11/1989
`3/1990
`3/1990
`4/1990
`4/1990
`5/1990
`6/1990
`6/1990
`7/1990
`8/1990
`2/1991
`4/1991
`5/1991
`6/1991
`7/1991
`9/1991
`9/1991
`10/1991
`11/1991
`12/1991
`12/1991
`1/1992
`1/1992
`2/1992
`4/1992
`5/1992
`5/1992
`5/1992
`6/1992
`8/1992
`8/1992
`9/1992
`9/1992
`11/1992
`1/1993
`1/1993
`2/1993
`2/1993
`3/1993
`5/1993
`7/1993
`8/1993
`8/1993
`8/1993
`8/1993
`9/1993
`10/1993
`11/1993
`2/1994
`3/1994
`3/1994
`5/1994
`7/1994
`10/1994
`10/1994
`11/1994
`12/1994
`4/1995
`5/1995
`6/1995
`7/1995
`8/1995
`8/1995
`1/1996
`1/1996
`3/1996
`3/1996
`4/1996
`5/1996
`6/1996
`
`Kesler
`Gahan et al.
`Gahan
`Quintana
`Vandenbrink et a1.
`Parsons et a1.
`Skolnick
`Traynor et a1.
`Friel
`Gallmeyer
`Matsumiya
`Sugihara et al.
`Adolfsson
`Baldwin, Sr.
`Urban
`Goosen
`Caravaty
`Ichikawa
`Desmond et al.
`Mei se
`Edelman
`Roberts
`Polanyi et al.
`Platzer, Jr.
`do Espirito Santo
`Platzer, Jr.
`McDonough
`Lynam et al.
`Lynam
`Lynam et al.
`Warszawski
`Platzer, Jr.
`Smith
`Lupo et al.
`Lynam
`do Espirito Santo
`Gard
`Hutchison
`Varaprasad et al.
`Varaprasad et al.
`Varaprasad et al.
`O’Farrell
`Shyu
`Adams et al.
`Caskey et a1.
`Bechu
`O’Farrell
`Schofield et al.
`Roberts
`Lupo
`Dornan et al.
`Polanyi et al.
`Strauss
`Varaprasad et al.
`Martinez
`O’Farrell et al.
`Wheatley et a1.
`Larson et al.
`Swanson
`Burke
`Gray et al.
`Wellington et a1.
`Lee
`Lynam
`Schissel et a1.
`Pastrick et al.
`O’Farrell et al.
`Zebold et al.
`Davis, 11
`Huang
`Tsai et al.
`Lynam et al.
`Roberts
`Carson
`Pastrick et al.
`Pastrick
`Breithaupt et al.
`Kim et a1.
`Lynam
`
`Patent Owner Magna - EX. 2015, p. 2
`
`Patent Owner Magna - Ex. 2015, p. 2
`
`

`

`US 8,550,642 B2
`
`Page 3
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`5,525,264 A
`5,526,195 A
`5,530,588 A
`5,535,056 A
`5,550,677 A
`5,557,467 A
`5,559,640 A
`5,563,744 A
`5,567,360 A
`5,575,552 A
`5,579,133 A
`5,587,236 A
`5 587 699 A
`5:594’222 A
`5 594,593 A
`5:610:756 A
`5,621,569 A
`5,621,577 A
`5,644,442 A
`5,649,756 A
`5,668,663 A
`5,669,698 A
`5,669,699 A
`5,669,704 A
`5,669,705 A
`5,670,935 A
`5,689,370 A
`5,691,855 A
`5,715,093 A
`5 722 836 A
`5:724:187 A
`5,751,489 A
`5,760,962 A
`5,784,211 A
`5,786,772 A
`5 788 357 A
`5’790’298 A
`5:790’327 A
`5,793:542 A
`5,796,094 A
`5 796 532 A
`5:805’367 A
`5,808:777 A
`5,823,654 A
`5,825,527 A
`5,835,294 A
`5,838,505 A
`5,847,889 A
`5 863 116 A
`5:864:434 A
`5,877,897 A
`5,910,854 A
`5,922,176 A
`5,929,786 A
`5,938,320 A
`5,980,050 A
`6,001,486 A
`6,002,511 A
`6,005,511 A
`6,005,724 A
`6,007,207 A
`6,030,084 A
`6 032 323 A
`6:033’078 A
`6,065:840 A
`6,074,068 A
`6,097,023 A
`6,109,586 A
`6,111,684 A
`6,116,743 A
`6,124,647 A
`6,128,860 A
`6,154,306 A
`6,164,564 A
`6,172,613 B1
`
`6/1996 Cronin et al.
`6/1996 Thomas
`6/1996 Vivier
`7/1996 Caskey et a1.
`8/1996 Schofield et 31.
`9/1996 McColgan et a1.
`9/1996 Vachss et al.
`10/1996 Matsumiya
`10/1996 Varaprasad et a1.
`11/1996 Faloon et 31.
`11/1996 Black et al.
`12/1996 Agrawal et 31.
`12/1996 Faloon et 31.
`1/1997 Caldwell
`1/1997 Milner
`3/1997 Lynam et 31.
`4/1997 Schlenke
`4/1997 Lang et a1.
`7/1997 Lemere
`7/1997 Adams et 31.
`9/1997 Varaprasad et a1.
`9/1997 Veldman et 31.
`9/1997 Pastrick et al.
`9/1997 Pastrick
`9/1997 Pastrick et 31.
`9/1997 Schofield et 31.
`11/1997 Tonar et 31.
`“/1997 Lupkas
`2/1998 Schierbeek etal.
`3/1998 Younker
`3/1998 Vmpmsad et 31.
`5/1998 Caskey et 31.
`6/1998 Schofield et a1.
`7/1998 Mingledorff
`7/1998 Schofield et a1.
`8/1998 Muth et 31.
`8/1998 Tom
`8/1998 Lee em.
`8/1998 Kondo et 31.
`8/1998 Schofield et al.
`8/1998 Kanazawa
`9/1998 Kamzawa
`9/1998 Lynam et 31.
`10/1998 Pastrick et 31.
`10/1998 Forgette et 31.
`11/1998 Minegishi
`11/1998 Palathingal
`12/1998 Korniyama et 31.
`1/1999 Pastrick et 31.
`“1999 Taylor
`3/1999 Schofield et 31.
`6/1999 Varaprasad et a1.
`7/1999 Caskey
`7/1999 Schofield et a1.
`8/1999 Crandall
`11/1999 McCord
`12/1999 Varaprasad et a1.
`12/1999 Varaprasad et a1.
`12/1999 Young et 31.
`12/1999 Todd
`12/1999 Liu
`2/2000 Schmidt
`3/2000 Smith et 31.
`3/2000 Su et 31.
`5/2000 Caskey et 31.
`6/2000 Palathingal
`8/2000 Schofield et a1.
`8/2000 Hoek
`8/2000 Forgette et a1.
`9/2000 Hoek
`9/2000 Marcus et a1.
`10/2000 Repp
`11/2000 Varaprasad et a1.
`12/2000 Franco et a1.
`1/2001 DeLine et a1.
`
`1/2001 Pastrick et a1.
`6,176,602 B1
`1/2001 Allemand et a1.
`6,178,034 B1
`3/2001 Caskey et a1.
`6,196,688 B1
`3/2001 Schofield et a1.
`6,198,409 B1
`3/2001 M011
`6199993 Bl
`3/2001 B05
`6,201,642 B1
`3/2001 Varaprasad et a1.
`6,207,083 B1
`5/2001 Miller
`6,227,689 Bl
`6/2001 Varaprasad et a1.
`6,245,262 B1
`6/2001 Lynam
`6,250,148 Bl
`7/2001 TQdd etal~
`6257746 Bl
`7/2001 Klm
`6,260,608 B1
`8/2001 G001_Sby
`6,270,225 Bl
`8/2001 Pastrlck et a1.
`6,276,821 B1
`9/2001 Caskey etal~
`6286965 Bl
`9/2001 Schofield et a1.
`6,294,989 B1
`10/2001 Caldwell
`6,310,611 B1
`11/2001 Platzer, Jr.
`6,315,419 B1
`11/2001 Spooner et a1.
`6,318,870 B1
`11/2001 Caldwell
`6,320,282 B1
`12/2001 Skiver et a1.
`6,329,925 B1
`1/2002 Lynam
`6,341,523 B2
`2/2002 Smlth et a1.
`6,343,402 B1
`3/2002 Tonar et a1.
`6,356,376 B1
`5/2002 Palathmgal
`6,390,632 Bl
`5/2002 Bos et a1.
`6,396,397 B1
`6/2002 Chou
`6398377 Bl
`6/2002 RICth
`6,409,354 B1
`7/2002 Varaprasad et a1.
`6,420,036 B1
`8/2002 Hutzel et a1.
`6,428,172 B1
`8/2002 Chu et a1.
`6,441,964 B1
`9/2002 Schofield et a1.
`6,445,287 B1
`9/2002 Agrawal ML
`64495082 Bl
`10/2002 Schofield et a1.
`6,472,979 B2
`12/2002 Schofield et a1.
`6,498,620 B2
`12/2002 Skiver et a1.
`6,501,387 B2
`1/2003 Henlon etal~
`65115192 Bl
`1/2003 Tonar et a1.
`6,512,624 B2
`2/2003 Lynam
`6522451 Bl
`3/2003 Ohmorl et a1.
`6,537,138 B2
`6/2003 Miller
`6,582,109 B2
`7/2003 Hoekstra etal.
`6,595,649 B2
`9/2003 Franco et a1.
`6,615,438 B1
`66275918 32 WW GetZ_etal~
`6,642,851 B2
`11/2003 DeLlne et a1.
`6,648,477 B2
`11/2003 Hutzel et a1.
`6,669,109 B2
`12/2003 Ivanov et a1.
`6,690,268 B2
`2/2004 Schofield et a1.
`6,709,119 B2
`3/2004 Gillich et a1.
`6,717,610 B1
`4/2004 Bos et a1.
`6,717,712 B2
`4/2004 Lynam etal.
`6,719,215 B2
`4/2004 Droulllard
`6,731,205 B2
`5/2004 Schofield et a1.
`6,737,629 B2
`5/2004 Nixon et a1.
`6,742,904 B2
`6/2004 Bechtel et a1.
`6,757,109 132
`60004 1305
`D493,131 S
`7/2004 Lawlor et a1.
`D493a394 S
`7/2004 Lawloreta1~
`6,824,281 B2
`11/2004 Schofield et a1.
`6,831,268 B2
`12/2004 Bechtel et a1.
`6,882,287 132
`40005 Schofield
`6919796 132
`7/2005 Boddy etal.
`6,932,483 B2
`8/2005 Strumolo et a1.
`6,979,090 B1
`12/2005 Wnuk
`7,001,032 B2
`2/2006 L0
`7,005,974 B2
`2/2006 McMahon et a1.
`7,025,469 B1
`4/2006 Manfre‘ et a1.
`7,038,577 B2
`5/2006 Pawlicki et a1.
`7,097,312 B2
`8/2006 Platzer, Jr.
`7,106,392 B2
`9/2006 You
`7,126,456 B2
`10/2006 Boddy etal.
`7,167,294 B2
`1/2007 Lynam et a1.
`7,168,830 B2
`1/2007 Pastrick et a1.
`7,184,190 B2
`2/2007 McCabe et a1.
`7,195,381 B2
`3/2007 Lynam et a1.
`7,249,860 B2
`7/2007 Kulas et a1.
`7,255,451 B2
`8/2007 McCabe et a1.
`7,267,448 B2
`9/2007 Schmidt et a1.
`7,274,501 B2
`9/2007 McCabe et a1.
`
`Patent Owner Magna - EX. 2015, p. 3
`
`Patent Owner Magna - Ex. 2015, p. 3
`
`

`

`US 8,550,642 B2
`
`Page 4
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`3:33:33; 3%
`7,339,149 B1
`7 345 680 B2
`7370:983 B2
`7,377 675 B2
`7391:563 B2
`7:400,435 B2
`7 420 756 B2
`7:423:522 B2
`7,492,281 B2
`7,526,103 B2
`7,581,859 B2
`7,626,749 B2
`7,636,188 B2
`7,857,469 B2
`7,934,843 B2
`8,128,243 B2 *
`8,267,534 B2
`2002/0036828 A1
`2002/0048100 A1
`2002/0072026 A1*
`2002/0105741 A1
`2002/0159169 A1
`2002/0159270 A1
`2003/0026009 A1
`2003/0026012 A1
`2003/0031023 A1
`2003/0043589 A1
`2003/0117731 A1
`2004/0032638 A1
`2004/0032675 A1
`2004/0032676 A1
`2004/0114260 A1
`2004/0165291 A1
`2004/0257685 A1
`2004/0264011 A1
`2005/0078389 A1
`2005/0083577 A1
`2005/0099693 A1
`2005/0134983 A1
`2005/0232469 A1
`2005/0248859 A1
`2006/0050018 A1
`2006/0061008 A1
`2006/0125919 A1
`2006/0126150 A1
`2006/0171704 A1
`2006/0184297 A1
`2006/0268440 A1
`
`................... 432/77
`
`121388; Exist 31'
`3/2008 Schofield et al.
`3/2008 David
`5/2008 DeWind et £11.
`5/2008 Pastrick et al.
`6/2008 McCabe et £11.
`7/2008 Byers et £11.
`9/2008 Lynam
`9/2008 O’Brien et al.
`2/2009 Lynam et £11.
`4/2009 Schofield et al.
`9/2009 Lynam
`12/2009 Baur et al.
`12/2009 Baur et 31.
`12/2010 Sinelli et 31.
`5/2011 Lynam
`3/2012 Lynam .......................... 359/866
`9/2012 Lynam
`3/2002 Wong
`4/2002 Hoek
`6/2002 Lynam et al.
`8/2002 Platzer, Jr.
`10/2002 McCord
`10/2002 Lynam et 31.
`2/2003 Vandenbrink
`2/2003 Pavao
`2/2003 Hutzel
`3/2003 Blank
`6/2003 Platzer, Jr.
`2/2004 Tonar et 31.
`2/2004 Weller et 31.
`2/2004 Drummond et 31.
`6/2004 Bartnick
`8/2004 Platzer, Jr.
`12/2004 Minor et 31.
`12/2004 Lynam
`4/2005 Kulas et 31.
`4/2005 Varaprasad et al.
`5/2005 Schofield et 31.
`6/2005 Lynam
`10/2005 Schofield et al.
`11/2005 Platzer, Jr.
`3/2006 Hutzel et 31.
`3/2006 Karner et 31.
`6/2006 Camilleri et 31.
`6/2006 Tonar et 31.
`8/2006 Bingle et 31.
`8/2006 Higgins-Luthman
`11/2006 Platzer, Jr.
`
`2006/0279863 A1
`2007/0058257 A1
`2007/0285789 A1
`2008/0212189 A1
`2008/0225421 A1
`2008/0304170 A1
`2008/0308219 A1
`2009/0040306 A1
`2009/0115631 A1
`2009/0237820 A1
`2009/0268321 A1
`2010/0195228 A1
`2010/0296187 A1
`2011/0157732 A1
`2011/0170207 A1
`
`12/2006 Starbuck
`3/2007 Lynam
`12/2007 Lindahl et al.
`9/2008 Baur et al.
`9/2008 Platzer
`12/2008 Zhao
`”/2008 Lynam
`2/2009 F0016 et £11.
`5/2009 F0016 et 211.
`9/2009 MeCabe et al.
`10/2009 W115011
`8/2010 S1ne111 et £11.
`11/2010 Lynm
`6/2011 Henlon et 31.
`7/2011 Lynam
`
`FOREIGN PATENT DOCUMENTS
`
`DE
`DE
`DE
`DE
`DE
`DE
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`EP
`FR
`GB
`GB
`GB
`JP
`JP
`JP
`JP
`JP
`JP
`KR
`NL
`TW
`W0
`W0
`W0
`W0
`W0
`W0
`W0
`
`2647592
`2915521
`3302735
`3329998
`3620228
`4026578
`0210757
`0310261
`0356099
`0551802
`0728618
`0729864
`0791503
`0917987
`2628042
`1279158
`2048189
`2092534
`0051637
`55076721
`362075619
`62105103
`1186443
`1208245
`2002092059
`7908257
`424057
`W0 0181956
`WO 2004026633
`WO 2004047421
`WO 2004103772
`WO 2006124682
`WO 2007005942
`WO 2008051910
`
`* cited by examiner
`
`4/1978
`10/1980
`8/1984
`3/1985
`12/1987
`4/1992
`2/1987
`4/1989
`2/1990
`1/1992
`8/1996
`9/1996
`8/1997
`5/1999
`3/1988
`6/1972
`12/1980
`8/1982
`4/1980
`10/1980
`4/1987
`5/1987
`7/1989
`8/1989
`12/2002
`6/1981
`3/2001
`11/2001
`4/2004
`6/2004
`12/2004
`11/2006
`1/2007
`5/2008
`
`Patent Owner Magna - EX. 2015, p. 4
`
`Patent Owner Magna - Ex. 2015, p. 4
`
`

`

`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 1 of 16
`
`US 8,550,642 B2
`
`vaououououououonououaIVOoVQOCOOOOOOOOOOOOOO.
`
`N
`
`E
`
`2
`
`3
`
`§\\
`
`aa:
`
`Patent Owner Magna - EX. 2015, p. 5
`
`Patent Owner Magna - Ex. 2015, p. 5
`
`
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 2 of 16
`
`US 8,550,642 B2
`
` 18
`
`K
`
`186
`
`E
`
`18E:
`
`FIG. 2
`
`18::
`
`E
`
`“8
`«(\2
`
`FIG.4
`Ma
`
`122
`
`"853
`
`\
`
`/ %“8‘3
`
`120
`
`“8::
`
`Patent Owner Magna - EX. 2015, p. 6
`
`Patent Owner Magna - Ex. 2015, p. 6
`
`

`

`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 3 of 16
`
`US 8,550,642 B2
`
`0.0.0..4-.
`
`is...avuoukhhhha03¢....
`
`nowonoworwfiowouou.
`
`ON
`
`vn0MONOMONOMOMONOMOMONOMOMOMOMONONONQNONONONHOMOMONOMONOHOMONOMONONONONJ.WMOMOMOMOMOMOMON.
`
`NNmm:
`
`Patent Owner Magna - EX. 2015, p. 7
`
`Patent Owner Magna - Ex. 2015, p. 7
`
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 4 of 16
`
`US 8,550,642 B2
`
`
`
`Patent Owner Magna - EX. 2015, p. 8
`
`Patent Owner Magna - Ex. 2015, p. 8
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 5 of 16
`
`US 8,550,642 B2
`
`NM,
`
`—
`
`HG.10
`
`I36
`
`Patent Owner Magna - EX. 2015, p. 9
`
`Patent Owner Magna - Ex. 2015, p. 9
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 6 of 16
`
`US 8,550,642 B2
`
`130
`
`I65
`
`FIG.H
`
`Patent Owner Magna - EX. 2015, p. 10
`
`Patent Owner Magna - Ex. 2015, p. 10
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 7 of 16
`
`US 8,550,642 B2
`
`u;
`
`173
`
`170
`
`173'
`
`HG. 12
`
`Patent Owner Magna - EX. 2015, p. 11
`
`Patent Owner Magna - Ex. 2015, p. 11
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 8 of 16
`
`US 8,550,642 B2
`
`Multiradius
`
`Multiradius
`
`15501654165
`
`Multiradius
`
`Multiradius
`
`FIG 13A
`
`FIG 13C
`
`FIG i3D
`
`Patent Owner Magna - EX. 2015, p. 12
`
`Patent Owner Magna - Ex. 2015, p. 12
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 9 of 16
`
`US 8,550,642 B2
`
`.
`
`.
`
`155
`\
`
`165
`/
`
`Multlradlus ‘7
`
`FIG.13E
`
`a
`
`155
`
`FIG. 13F
`
`Multiradius
`
`1511;. 136
`150
`
`1511; 13H
`
`”8'”
`
`‘50
`
`150
`
`‘55
`
`Multiradius
`
`- 155
`
`150
`
`“5
`
`155 - Multiradius
`
`Patent Owner Magna - EX. 2015, p. 13
`
`Patent Owner Magna - Ex. 2015, p. 13
`
`

`

`U.S. Patent
`
`Oct. 8, 2013
`
`Sheet 10 of 16
`
`US 8,550,642 B2
`
`:m:
`
`a
`
`m:.2“.S
`
`bln
`
`MS
`
`he
`
`
`
` .E/fl,7
`
`<2«.2
`
`Patent Owner Magna - EX. 2015, p. 14
`
`Patent Owner Magna - Ex. 2015, p. 14
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 11 of 16
`
`US 8,550,642 B2
`
`230
`
`255
`
`FIG.15
`
`250
`
`265
`
`Patent Owner Magna - EX. 2015, p. 15
`
`Patent Owner Magna - Ex. 2015, p. 15
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 12 of 16
`
`US 8,550,642 B2
`
`
`412
`
`Patent Owner Magna - EX. 2015, p. 16
`
`Patent Owner Magna - Ex. 2015, p. 16
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 13 of 16
`
`US 8,550,642 B2
`
`314:3
`
`3‘75
`
`
`
`Patent Owner Magna - EX. 2015, p. 17
`
`Patent Owner Magna - Ex. 2015, p. 17
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 14 of 16
`
`US 8,550,642 B2
`
`316
`
` X
`
`___YJ
`
`|
`
`I !
`
`|I I
`
`321%
`
`/;//3“)
`
`,fiK/l316
`
`_
`
`xc
`
`330E
`
`______ _
`Y’
`
`332
`
`330
`
`Patent Owner Magna - EX. 2015, p. 18
`
`Patent Owner Magna - Ex. 2015, p. 18
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 15 of 16
`
`US 8,550,642 B2
`
`
`
`
`
`Patent Owner Magna - EX. 2015, p. 19
`
`Patent Owner Magna - Ex. 2015, p. 19
`
`

`

`US. Patent
`
`Oct. 8, 2013
`
`Sheet 16 of 16
`
`US 8,550,642 B2
`
`
`
`Patent Owner Magna - EX. 2015, p. 20
`
`Patent Owner Magna - Ex. 2015, p. 20
`
`

`

`US 8,550,642 B2
`
`1
`EXTERIOR REARVIEW MIRROR ASSEMBLY
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`The present application is a division of US. patent appli-
`cation Ser. No. 13/336,018, filed Dec. 23, 2011, which is a
`continuation of US. patent application Ser. No. 12/911,274,
`filed Oct. 25, 2010, now US. Pat. No. 8,128,243, which is a
`continuation of US. patent application Ser. No. 12/851,045,
`filed Aug. 5, 2010, now US. Pat. No. 7,934,843, which is a
`continuation of US. patent application Ser. No. 12/197,666,
`filed Aug. 25, 2008, now US. Pat. No. 7,842,154, which is a
`division of US. patent application Ser. No. 10/709,434, filed
`May 5, 2004, now US. Pat. No. 7,420,756, which claims the
`benefit of US. 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-
`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 US. Pat. No. 4,737,
`188, which is hereby incorporated herein by reference. Poly-
`meric reflective elements are also known, such as are
`described in US. 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 ofhard
`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
`mirror assembly is mounted to the vehicle), and a more
`curved multi-radius portion or surface at the outboard side of
`the reflective element (i.e., further from the side body of the
`vehicle when the mirror assembly is mounted to the vehicle),
`in order to provide an extended field of view. It is typically
`desirable to have the reflective elements or substrates of such
`
`exterior mirror elements to be formed of a glass material
`because glass material typically provides an enhanced scratch
`resistance over conventional optical resins and the like.
`Therefore, there is a need in the art for a mirror reflective
`element that overcomes the shortcomings of the prior art
`elements and substrates.
`
`SUMMARY OF THE INVENTION
`
`The present invention provides a molded wide angle or
`multi-radius substrate for a reflective element. The molded
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`
`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-
`face 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 sur-
`face or first surface to provide substantial protection against
`scratches occurring to the molded substrate. The inner surface
`or second surface ofthe reflective element substrate may have
`a reflective coating or layer, such as a polymeric reflective
`film, laminated or adhered or otherwise applied thereto.
`According to an aspect of the present invention, a wide
`angle reflective element for a mirror assembly for a vehicle
`includes a wide angle substrate having an exterior surface and
`a glass film disposed at the exterior surface. The exterior
`surface of the substrate has a less curved inboard portion or
`surface and a more curved outboard portion or surface. The
`substrate comprises a polymeric resin material. The glass film
`is adapted to substantially conform to the exterior surface of
`the wide angle substrate. The glass film comprises a glass
`material and has a thickness of less than approximately 0.8
`mm.
`
`According to another aspect of the present invention, a
`reflective element for a mirror assembly for a vehicle com-
`prises a substrate having an exterior surface, and an anti-
`abrasion film applied to the exterior surface. The substrate
`comprises a polymeric resin material, such as a transparent
`optical polymeric resin material. The anti-abrasion film pref-
`erably comprises a glass material (such as a soda lime glass or
`a borosilicate or the like) and has a thickness of less than
`approximately 0.8 mm, and is flexible to conform to the
`exterior surface.
`
`The substrate may be cut from a strip or sheet of molded or
`extruded or cast substrate material (or less preferably, may be
`cut from an injected molded strip or sheet). The flexible glass
`film may be unrolled from a reel or roll and applied to the
`exterior surface of the elongated strip or sheet of substrate
`material. The substrate, including the glass film or layer, may
`then be cut or otherwise formed from the elongated strip or
`sheet.
`
`The substrate may comprise a wide angle substrate and/or
`may comprise a multi-radius exterior surface having a less
`curved inboard portion or surface and a more curved outboard
`portion or surface.
`A reflective film or layer may be applied to the inner
`surface or side of the substrate or strip opposite the exterior
`surface. The reflective film may comprise a polymeric reflec-
`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 ofthe 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 ofthe substrate
`material is not necessary.
`According to another aspect of the present invention, a
`method for forming a reflective element substrate for a mirror
`assembly of a vehicle comprises generally continuously
`forming an elongated strip or sheet of substrate material and
`applying a substantially transparent functional film, such as
`an anti-abrasion film or a hydrophilic film or a hydrophobic
`film or the like, to a surface of the elongated strip sheet. The
`substrate material may comprise a transparent optical poly-
`
`Patent Owner Magna - Ex. 2015, p. 21
`
`Patent Owner Magna - Ex. 2015, p. 21
`
`

`

`US 8,550,642 B2
`
`3
`meric resin. The functional film is preferably unrolled from a
`reel or roll of film and applied to the surface of the elongated
`strip or sheet generally continuously as the strip or sheet is
`formed or extruded or cast or molded. Preferably, multiple
`mirror element shapes or mirror element substrates may be
`cut or otherwise formed from the elongated sheet after the
`functional film is applied to the surface of the strip or sheet.
`The functional or anti-abrasion film may comprise an
`ultrathin glass material which is sufficiently flexible to be
`provided in a reel or roll (or in a sheet that is flexible and
`conformable to a bent substrate). The substrates may be
`formed with a wide angle exterior surface or a multi-radius
`exterior surface. The anti-abrasion film may be sufficiently
`flexible to conform to the wide angle or multi-radius or
`curved exterior surface.
`
`A reflective film, such as a polymeric reflective film or the
`like, may be applied to the opposite surface ofthe substrate or
`sheet or strip. The reflective film may be sufliciently 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-
`tive film as the film is generally continuously applied to the
`surface of the generally continuously formed sheet or strip.
`Therefore, the present invention provides a molded wide
`angle or multi-radius single substrate for a rearview mirror
`assembly which has an anti-abrasion or anti-scratch film or
`layer applied to the curved, wide angle or multi-radius exte-
`rior surface ofthe 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-
`tive film or layer laminated or applied to the inner surface
`opposite the exterior surface.
`These and other objects, advantages, purposes and features
`ofthe present invention will become apparent upon review of
`the following specification in conjunction with the drawings.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`FIG. 1 is a perspective view of an exterior rearview mirror
`assembly in accordance with the present invention;
`FIG. 2 is a perspective view of a wide angle or multi-radius
`reflective element in 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
`the exterior surface ofthe 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-
`tive element in accordance with the present invention;
`FIG. 5A 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-
`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;
`FIG. 9 is a perspective view of an automobile equipped
`with exterior sideview mirror assemblies according to this
`present invention;
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`
`FIG. 10 is a top plan partial fragmentary view of the driv-
`er’s side exterior rearview mirror assembly of FIG. 9;
`FIG. 11 is an enlarged sectional view of a plano-multira-
`dius reflective element assembly of the mirror assembly in
`FIG. 10;
`FIG. 12 is an enlarged sectional view of a demarcation
`element ofthe plano-multiradius reflective element assembly
`of FIG. 11;
`FIGS. 13A-13H illustrate views of various locations for a
`
`plano reflective element and an auxiliary reflective element
`according to this present invention;
`FIG. 14 is a sectional view of a second embodiment of a
`
`plano reflective element assembly according to the present
`invention including a demarcation element formed as a divid-
`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 plano-
`auxiliary reflective element assembly according to this
`present invention;
`FIG. 16 is a front elevation view of another embodiment of
`
`a plano reflective element assembly according to the present
`invention;
`FIG. 17 is an exploded perspective view ofthe plano reflec-
`tive element assembly of FIG. 16;
`FIG. 18 is an end view of the plano reflective element
`assembly ofFIG. 16 as viewed from line XVIII-XVIII of FIG.
`16;
`FIG. 19 is a top view ofthe plano reflective element assem-
`bly of FIG. 16 as viewed from line XIX-XIX of FIG. 16;
`FIG. 20 is a schematic representation ofthe plano reflective
`element assembly ofFIG. 16 illustrating the orientation ofthe
`reflective element;
`FIG. 21 is another schematic representation of the orienta-
`tion of the reflective elements of the plano reflective element
`in FIG. 16;
`FIG. 22 is a diagram illustrating the range ofviewing ofthe
`reflective elements of the plano reflective element assembly
`of FIG. 16; and
`FIG. 23 is a perspective view of another embodiment of an
`exterior rearview mirror system of the present invention.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawings and the illustrative 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
`view or wide angle field ofview to a driver or occupant ofthe
`vehicle and may comprise a single reflective element sub-
`strate 18 having an inner surface 18a and an opposite exterior
`surface 18b (FIGS. 2 and 3). The exterior surface 18b com-
`prises a less curved or substantially flat inboard portion or
`surface 180 and a more curved outboard portion or surface
`18d, as discussed below. The substrate 18 may have an anti-
`abrasion coating or layer or film 20, such as an ultrathin glass
`coating or layer or film, laminated or deposited or otherwise
`applied to the exterior surface 18b, and may have a reflective
`coating or layer 22 laminated or applied to the inner surface
`18a, as also discussedbelow. Aspects ofthe reflective element
`ofthe present invention may be suitable