Mirror reflective element and method of forming same

  • US 7,842,154 B2
  • Filed: 08/25/2008
  • Issued: 11/30/2010
  • Est. Priority Date: 05/20/2003
  • Status: Active Grant
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First Claim
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1. 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, wherein said functional film comprises an ultrathin glass material which is sufficiently flexible to be provided in a reel or roll;

    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.

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