MIRROR REFLECTIVE ELEMENT

• US 20040264011A1
• Filed: 05/05/2004
• Published: 12/30/2004
• Est. Priority Date: 05/20/2003
• Status: Active Grant

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Lynam, Niall R.
• Granted Patent: US 7,420,756 B2
• Time in Patent Office: Days
• US Class Current: 359/866
• CPC Class Codes: B60R 1/0602 comprising means for cleaning or deicing
• CPC Class Codes: B60R 1/072 for adjusting the mirror relative to its housing
• CPC Class Codes: B60R 1/08 involving special optical features, e.g. avoiding blind spots , e.g. convex mirrors; Side-by-side associations of rear-view and other mirrors B60R1/025, B60R1/10 take precedence
• CPC Class Codes: B60R 1/082 using a single wide field mirror or an association of rigidly connected mirrors
• CPC Class Codes: B60R 1/088 using a cell of electrically changeable optical characteristic, e.g. liquid-crystal or electrochromic mirrors
• CPC Class Codes: G02B 27/0006 with means to keep optical surfaces clean, e.g. by preventing or removing dirt, stains, contamination, condensation G02B1/18 takes precedence; cleaning in general B08B
• CPC Class Codes: G02B 7/182 for mirrors
• CPC Class Codes: G02F 1/157 Structural association of cells with optical devices, e.g. reflectors or illuminating devices
• CPC Class Codes: G02F 1/161 Gaskets; Spacers; Sealing of cells; Filling or closing of cells

Abstract

A reflective element for a mirror assembly for a vehicle includes a substrate and a functional or anti-abrasion film applied to an exterior surface of the substrate. The substrate comprises a polymeric resin material, such as a transparent optical polymeric resin material. The functional or anti-abrasion film may comprise a glass material and may have a thickness of less than approximately 0.8 mm. The anti-abrasion film is flexible to conform to the exterior surface of the substrate. The flexible film may be unrolled from a reel or roll and applied to the exterior surface of an 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 of molded or extruded or cast substrate material.

Claims

1. A wide angle reflective element for a mirror assembly for a vehicle comprising:

a wide angle substrate having an exterior surface comprising a less curved inboard portion or surface and a more curved outboard portion or surface, said substrate comprising a polymeric resin material; and

a glass film disposed at said exterior surface, said glass film adapted to substantially conform to said exterior surface of said wide angle substrate, said glass film comprising a glass material and having a thickness of less than approximately 0.8 mm.

2. The wide angle reflective element of claim 1, wherein said glass film comprises a flexible glass film.

3. The wide angle reflective element of claim 1, wherein said substrate is cut from a molded or extruded or cast strip or sheet, said glass film being applied to said strip or sheet, at least two substrates being cut from said strip or sheet.

4. The wide angle reflective element of claim 3 including a reflective film applied to said strip or sheet on an inner surface of said substrates opposite said exterior surface.

5. The wide angle reflective element of claim 1 including a reflective film applied to an inner surface of said substrate opposite said exterior surface.

6. The wide angle reflective element of claim 5, wherein said reflective film comprises a polymeric reflective film laminated or otherwise adhered or applied to said inner surface of said substrate.

7. The wide angle reflective element of claim 6, wherein said reflective film comprises an all polymer-thin-film multilayer, high reflective mirror film comprising multiple coextrusion of many plastic layers to form a highly reflective mirror film.

8. The wide angle reflective element of claim 1 including a reflective film applied to said exterior surface of said substrate, said glass film being applied to an exterior surface of said reflective film.

9. The wide angle reflective element of claim 8, wherein said reflective film comprises a polymeric reflective film laminated or adhered or otherwise applied to said exterior surface of said substrate.

10. The wide angle reflective element of claim 9, wherein said reflective film comprises an all polymer-thin-film multilayer, high reflective mirror film comprising multiple coextrusion of many plastic layers to form a highly reflective mirror film.

11. The wide angle reflective element of claim 1, wherein said reflective element is adapted for one of an interior rearview mirror assembly and an exterior rearview mirror assembly.

12. A method for forming a reflective element substrate for a mirror assembly of a vehicle comprising:

generally continuously forming an elongated sheet of substrate material, said substrate material comprising a polymeric resin material;

applying a substantially transparent functional film to a surface of said elongated sheet;

unrolling said substantially transparent functional film from a reel or roll of said film and applying said unrolled film to said surface of said elongated sheet generally continuously as said sheet is formed or extruded or cast; and

forming two or more mirror substrates from said elongated sheet after said film is applied to said surface of said sheet.

13. The method of claim 12, wherein said substantially transparent functional film provides an anti-abrasion function.

14. The method of claim 12, wherein said substantially transparent functional film provides a hydrophobic function or a hydrophilic function.

15. The method of claim 12, wherein said functional film comprises an ultrathin glass material which is sufficiently flexible to be provided in a reel or roll.

16. The method of claim 12, wherein said substrates are formed with a wide angle or multi-radius exterior surface, said functional film being sufficiently flexible to conform to said wide angle or multi-radius curved surface.

17. The method of claim 12 including applying a reflective film, such as a polymeric reflective film or the like, to an opposite surface of said sheet.

18. The method of claim 17, wherein said reflective film is sufficiently flexible to be provided in a reel or roll form, said method including unrolling said reflective film and generally continuously applying said reflective film to said opposite surface of said generally continuously formed sheet.

19. The method of claim 12 including applying a reflective film, such as a polymeric reflective film or the like, to said surface of said sheet, wherein applying said functional film comprises applying said functional film to said reflective film.

20. The method of claim 19, wherein said reflective film is sufficiently flexible to be provided in a reel or roll form, said method including unrolling said reflective film and generally continuously applying said reflective film to said surface of said generally continuously formed sheet.

21. The method of claim 12 including forming a vehicle mirror assembly with one of said two or more mirror substrates.