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

• Current Assignee: Donnelly Corporation (Magna International Incorporated)
• Original Assignee: Donnelly Corporation (Magna International Incorporated)
• Inventors: Lynam, Niall R.
• Primary Examiner(s): Del Sole; Joseph S
• Assistant Examiner(s): KENNEDY, TIMOTHY J
• APPLICATION: US 20080308219A1
• Time in patent office: 827 Days
• Field of Search: 156/99, 156/102, 156/242, 156/244.11, 156/244.27, 264/1.6, 264/1.7, 264/1.9, 264/173.11
• US Class Current: 156/242
• 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 G02B7/181 takes precedence; mounting of MEMS mirrors, e.g. DMDs, G02B26/0833 ; optical devices or arrangements using movable or deformable optical elements for controlling the intensity, colour, phase, polarisation or direction of light G02B26/00 ; mirror arrangements in vehicles B60R1/02
• 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 method for forming a reflective element substrate for a mirror assembly of a vehicle includes generally continuously forming an elongated sheet of substrate material and applying a substantially transparent functional film to a surface of the elongated sheet. The substantially transparent functional film is unrolled from a reel or roll of the film and the unrolled film is applied to the surface of the elongated sheet generally continuously as the sheet is formed or extruded or cast. Two or more mirror substrates are formed from the elongated sheet after the film is applied to the surface of the sheet.

Claims

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.

2. The method of claim 1, wherein said substantially transparent functional film provides an anti-abrasion function.

3. The method of claim 1, wherein said substantially transparent functional film provides a hydrophobic function.

17. The method of claim 1, wherein said substantially transparent functional film provides a hydrophilic function.

4. 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, 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.

5. The method of claim 4 including applying a reflective film to an opposite surface of said sheet.

6. The method of claim 5, 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.

7. The method of claim 4 including applying a reflective film to said surface of said sheet, wherein applying said functional film comprises applying said functional film to said reflective film.

8. The method of claim 7, wherein said reflective film is sufficiently flexible to be provided in a reel or roll than, said method including unrolling said reflective film and generally continuously applying said reflective film to said surface of said generally continuously formed sheet.

18. The method of claim 4, wherein said substantially transparent functional film provides an anti-abrasion function.

19. The method of claim 5, wherein applying a reflective film comprises applying a polymeric reflective film to an opposite surface of said sheet.

20. The method of claim 8, wherein applying a reflective film comprises applying a polymeric reflective film to said surface of said sheet.

9. 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;

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

forming a vehicle mirror assembly with one of said two or more mirror substrates.

10. The method of claim 9 including applying a reflective film to an opposite surface of said sheet.

11. The method of claim 10, 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.

12. The method of claim 9 including applying a reflective film to said surface of said sheet, wherein applying said functional film comprises applying said functional film to said reflective film.

13. The method of claim 12, 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.

14. The method of claim 9, wherein said substantially transparent functional film provides a hydrophilic function.

15. The method of claim 9, wherein said substantially transparent functional film provides a hydrophobic function.

16. The method of claim 9, wherein said substantially transparent functional film provides an anti-abrasion function.