US008550642B2
`
`a2) United States Patent
`US 8,550,642 B2
`(0) Patent No.:
`*Oct. 8, 2013
`(45) Date of Patent:
`Lynam
`
`(54)
`
`EXTERIOR REARVIEW MIRROR ASSEMBLY
`
`(58) Field of Classification Search
`USPC wiecesssesctesseseseseecssseecsnecensensseseeansentes 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 ofthis
`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. No.: 13/590,854
`
`(22)
`
`Filed:
`
`Aug. 21, 2012
`
`(65)
`
`(60)
`
`(60)
`
`(51)
`
`(52)
`
`Prior Publication Data
`
`US 2012/0314316 Al
`
`Dec. 13, 2012
`
`Related U.S. 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 May5,
`2004, now Pat. No. 7,420,756.
`
`Provisional application No. 60/471,872, filed on May
`20, 2003.
`
`Int. Cl.
`GO02B 5/08
`US. Cl.
`USPC voce cess neenecn ener creer entenensenees 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 — Alessandro Amari
`(74) Attorney, Agent, or Firm — Gardner, Linn, Burkhart &
`Flory, LLP
`
`ABSTRACT
`(57)
`An exterior rearview mirror assemblyfor a vehicle includes a
`bracketfixedly 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 mirrorsvisually.
`
`11 Claims, 16 Drawing Sheets
`
`185'
`
`\
`
`173”
`
`\
`
`174
`
`180
`
`Patent Owner Magna- Ex. 2015, p. 1
`
`Patent Owner Magna - Ex. 2015, p. 1
`
`

`

`US 8,550,642 B2
`
`Page 2
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`PPPPrSPPEEEEEPEPEEPPSESEPEEPSEEEEELSPEEPSPEESPPEESEPEEEPSPSESPESEPPSPrereerPPS
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`(56)
`
`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
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`4,733,336
`4,737,188
`4,770,522
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`
`Patent Owner Magna- Ex. 2015, p. 2
`
`Patent Owner Magna - Ex. 2015, p. 2
`
`

`

`US 8,550,642 B2
`
`Page 3
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`(56)
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`Patent Owner Magna- Ex. 2015, p. 3
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`Patent Owner Magna - Ex. 2015, p. 3
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`US 8,550,642 B2
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`Page 4
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`Patent Owner Magna- Ex. 2015, p. 4
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`Patent Owner Magna - Ex. 2015, p. 4
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`

`

`U.S. Patent
`
`Oct. 8, 2013
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`Sheet 1 of 16
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`US 8,550,642 B2
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`
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`EXXKRXRXRG\eryewy3y—|
`Parara
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`Patent Owner Magna- Ex. 2015, p. 5
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`Patent Owner Magna - Ex. 2015, p. 5
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`

`

`U.S. Patent
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`Oct. 8, 2013
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`Sheet 2 of 16
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`US 8,550,642 B2
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`FIG. 3
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`Patent Owner Magna- Ex. 2015, p. 6
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`Patent Owner Magna - Ex. 2015, p. 6
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`

`

`U.S. Patent
`
`Oct. 8, 2013
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`Sheet 3 of 16
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`US 8,550,642 B2
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`BOOOOoS
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`Patent Owner Magna- Ex. 2015, p. 7
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`Patent Owner Magna - Ex. 2015, p. 7
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`

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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 4 of 16
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`US 8,550,642 B2
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`Patent Owner Magna- Ex. 2015, p. 8
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`Patent Owner Magna - Ex. 2015, p. 8
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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 5 of 16
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`US 8,550,642 B2
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`FG.10
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`Patent Owner Magna- Ex. 2015, p. 9
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`Patent Owner Magna - Ex. 2015, p. 9
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`U.S. Patent
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`130
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`US 8,550,642 B2
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`FG.I]
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`Oct. 8, 2013
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`Sheet6 of 16
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`165
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`Patent Owner Magna- Ex. 2015, p. 10
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`Patent Owner Magna - Ex. 2015, p. 10
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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 7 of 16
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`US 8,550,642 B2
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`165
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`
`
`FIG. 12
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`Patent Owner Magna- Ex. 2015, p. 11
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`Patent Owner Magna - Ex. 2015, p. 11
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`

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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 8 of 16
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`US 8,550,642 B2
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`155
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`165
`
`7
`
`150
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`Multiradius
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`Patent Owner Magna- Ex. 2015, p. 12
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`Patent Owner Magna - Ex. 2015, p. 12
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`

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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 9 of 16
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`US 8,550,642 B2
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`155
`\
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`Multiradius ani
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`165
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`Patent Owner Magna- Ex. 2015, p. 13
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`Patent Owner Magna - Ex. 2015, p. 13
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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 10 of 16
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`US 8,550,642 B2
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`Patent Owner Magna- Ex. 2015, p. 14
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`Patent Owner Magna - Ex. 2015, p. 14
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`

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`U.S. Patent
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`Oct. 8, 2013
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`US 8,550,642 B2
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`230
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`255
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`265
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`Patent Owner Magna- Ex. 2015, p. 15
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`Patent Owner Magna - Ex. 2015, p. 15
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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 12 of 16
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`US 8,550,642 B2
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`Patent Owner Magna- Ex. 2015, p. 16
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`Patent Owner Magna - Ex. 2015, p. 16
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`U.S. Patent
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`Oct. 8, 2013
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`US 8,550,642 B2
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`3140
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`37
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`Patent Owner Magna- Ex. 2015, p. 17
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`Patent Owner Magna - Ex. 2015, p. 17
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`U.S. Patent
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`Oct. 8, 2013
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`US 8,550,642 B2
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`316
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`Patent Owner Magna- Ex. 2015, p. 18
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`Patent Owner Magna - Ex. 2015, p. 18
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`U.S. Patent
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`Oct. 8, 2013
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`US 8,550,642 B2
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`Patent Owner Magna- Ex. 2015, p. 19
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`Patent Owner Magna - Ex. 2015, p. 19
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`U.S. Patent
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`Oct. 8, 2013
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`Sheet 16 of 16
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`US 8,550,642 B2
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`Patent Owner Magna- Ex. 2015, p. 20
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`Patent Owner Magna - Ex. 2015, p. 20
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`

`

`US 8,550,642 B2
`
`1
`EXTERIOR REARVIEW MIRROR ASSEMBLY
`
`CROSS REFERENCE TO RELATED
`APPLICATIONS
`
`The present application is a division of U.S. patent appli-
`cation Ser. No. 13/336,018, filed Dec. 23, 2011, 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 US. Pat. No. 7,842,154, which is a
`division of U.S. patent application Ser. No. 10/709,434, filed
`May5, 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,
`moreparticularly, to exterior rearview mirror elements com-
`prising multi-radius reflective elements.
`
`BACKGROUND OF THE INVENTION
`
`Typically, mirror reflective elements are formed of glass
`and havea reflective coating deposited thereon, such as via
`vacuum deposition or wet chemicalsilveringor 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-
`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 onthefirst or outer or exterior surface of the element
`whichis contacted bythe 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
`elementouter surface, such as during winter. A variety ofhard
`coats have been proposedin 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 (1.e., a specific gravity roughly half
`that of glass), and which hasa glass-like exterior surface.
`Also, exterior rearview mirrorreflective 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 inboardside ofthereflective
`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 mountedto the vehicle),
`in order to provide an extendedfield 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 andthelike.
`Therefore, there is a need in the art for a mirror reflective
`element that overcomes the shortcomings of the prior art
`elements and substrates.
`
`SUMMARYOF THE INVENTION
`
`The present invention provides a molded wide angle or
`multi-radius substrate for a reflective element. The molded
`
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`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 secondsurface ofthe reflective element substrate may have
`a reflective coating or layer, such as a polymeric reflective
`film, laminated or adhered or otherwise appliedthereto.
`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. Theglass 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
`extrudedor cast substrate material (or less preferably, may be
`cut from an injected moldedstrip 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 anda 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. Thereflective film may comprise a polymericreflec-
`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 manyplastic
`layers to form a highly reflective mirrorfilm.
`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 thereflective film
`layer. In such an application, the substrate acts as a support or
`backingplatefor the reflectivefilm 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
`methodfor forming a reflective element substrate for a mirror
`assembly of a vehicle comprises generally continuously
`forming an elongatedstrip 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
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`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 polymericreflective film or the
`like, may be applied to the opposite surface ofthe substrate or
`sheetor strip. Thereflective film may be sufficiently flexible
`to be provided in a reel or roll form (or in a sheetthatis 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 sheetorstrip.
`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 havea 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 II-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 elementandan anti-abrasionfilm or
`layer applied overthe reflective film or layer;
`FIG. 5 is a diagram showing the extruding, coating and
`cutting processes for manufacturing a prismatic mirrorreflec-
`tive element in accordance with the present invention;
`FIG.5A is an elevation of the extruder of FIG. 5, showing
`the wedge shapeofthe extrudedstrip 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 ofthe reflective element formed
`
`by the process shownin FIG.5;
`FIG. 8 is a diagram showingan alternate process for manu-
`facturing a prismatic mirrorreflective element in accordance
`with the present invention, wherea strip of substrate material
`is cast and formedvia 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;
`
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`60
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`65
`
`4
`FIG. 10 is a top plan partial fragmentary view ofthe 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-multiradiusreflective 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 embodimentof 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. 14Ais across-section taken along line XX of FIG. 14;
`FIG. 14Bis a cross-sectional view taken along line YY of
`FIG.14;
`FIG. 15 is a schematic of a third embodimentof 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 explodedperspective view ofthe planoreflec-
`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 planoreflective
`element assembly ofFIG.16 illustratingthe orientation ofthe
`reflective element;
`FIG.21 is another schematic representation ofthe orienta-
`tion ofthe reflective elements of the planoreflective 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 embodimentof an
`exterior rearview mirror system of the present invention.
`
`DESCRIPTION OF THE PREFERRED
`EMBODIMENTS
`
`Referring now to the drawingsandtheillustrative embodi-
`ments depicted therein, an exterior rearview mirror assembly
`10 includes a reflective element 12 mounted at a casing 14,
`which is mountedat an exterior portion of a vehicle 16 (FIG.
`1). Reflective element 12 may provide an enhancedfield 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 185 (FIGS. 2 and 3). The exterior surface 185 com-
`prises a less curved or substantially flat inboard portion or
`surface 18c and a more curved outboard portion or surface
`18d, as discussed below. The substrate 18 may have an anti-
`abrasion coating or layeror film 20, such as an ultrathin glass
`coating orlayeror film, laminated or deposited or otherwise
`applied to the exterior surface 185, and may havea reflective
`coating or layer 22 laminated or applied to the inner surface
`18a, as also discussed below. Aspects ofthe reflective element
`ofthe present invention maybesuitablefor use in a reflective
`elementfor an exterior rearview mirror assembly (as shown in
`FIG. 1) and/or a reflective element for an interior rearview
`mirror assembly (not shown).
`Patent Owner Magna- Ex. 2015, p. 22
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`Patent Owner Magna - Ex. 2015, p. 22
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`

`

`US 8,550,642 B2
`
`6
`to actuator 136 when plano-multiradius reflective element
`assembly 130 is mounted in driver-side exterior sideview
`mirror assembly 112 (and/or in passenger-side exterior side
`view mirror assembly 11