Energy absorbing rearview mirror assembly

Claim 2

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case at a position to the rear of said rear surface of said mirror element and between said actuator and said rear surface of said anti-scatter layer, said actuator and support arm being spaced to the rear of said plate, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle,

Claim 3

The mirror assembly of claim 1 wherein said plate is adhered to said anti-scatter layer on said mirror element.

Claim 4

The mirror assembly of claim 2 wherein said plate is adhered by a layer of material having opposed adhesive surfaces.

Claim 5

The mirror assembly of claim 3 wherein said adhering layer is a tackified acrylic laminating adhesive.

Claim 6

The mirror assembly of claim 2 wherein said plate is made of polymeric plastics or metals.

Claim 7

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being adhered to said anti-scatter layer on said mirror element, and being made of polymeric plastics or metals; said said polymeric plastic or metals consist of nylon, glass-filled polybutylene terephthalate, aluminum, steel, stainless steel, titanium, or metal alloys.

Claim 8

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being adhered to said anti-scatter layer on said mirror element, and being made of polymeric plastics or metals; said said polymeric plastic or metals consist of nylon, glass-filled polybutylene terephthalate, aluminum, steel, stainless steel, titanium, or metal alloys.

Claim 9

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being adhered to said anti-scatter layer on said mirror element, and being selected from the group of materials consisting of polymeric plastics and metals; said plate being metal and including a pacifying, non-conductive coating thereon.

Claim 10

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being adhered to said anti-scatter layer on said mirror element, and being selected from the group of materials consisting of polymeric plastics and metals; said plate being metal and including a pacifying, non-conductive coating thereon.

Claim 11

The mirror assembly of claim 7 wherein said plate is aluminum having an epoxy coating thereon.

Claim 12

The mirror assembly of claim 2 wherein said plate is metal having a pacifying, non-conductive coating thereon.

Claim 13

The mirror assembly of claim 1 wherein said rear surface of said mirror element has a predetermined peripheral configuration, said plate having a configuration smaller than said predetermined peripheral configuration.

Claim 14

The mirror assembly of claim 1 wherein said plate is smaller than said mirror element and is sufficiently large to cover the area intermediate said actuator and said mirror element.

Claim 15

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing, the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being mounted within said mirror case and spaced rearwardly of said rear surface of said mirror element.

Claim 16

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing, the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being mounted within said mirror case and spaced rearwardly of said rear surface of said mirror element.

Claim 17

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element: a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said anti-scatter layer being selected from the group consisting essentially of a hot-melt polymeric coating, a plastisol, a tape, a film, a tape having opposed adhesive surfaces, a film having opposed adhesive surfaces, and a flexible, resilient polymeric material having opposed adhesive surfaces.

Claim 18

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element: a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said anti-scatter layer being selected from the group consisting essentially of a hot-melt polymeric coating, a plastisol, a tape, a film, a tape having opposed adhesive surfaces, a film having opposed adhesive surfaces, and a flexible, resilient polymeric material having opposed adhesive surfaces.

Claim 19

The mirror assembly of claim 1 wherein said mirror case is molded from a polymeric material and includes a peripheral wall having said rim thereon, and a rear wall spaced behind said rim to define a hollow interior within said case; said actuator being pivotally mounted within said hollow interior adjacent to said plate.

Claim 20

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi.

Claim 21

An energy absorbing, prismatic rearview mirror assembly for use on the interior of a vehicle of the type equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case having a peripheral rim defining an opening in said case; a prismatic, glass mirror element mounted within said mirror case, said mirror element having a front surface adjacent said rim and a rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted within said mirror case adjacent said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an anti-scatter layer on said rear surface of said mirror element; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said anti-scatter layer, said plate selected to have a sufficient thickness, stiffness and resistance to cracking and permanent deformation to absorb/disperse energy in the event an impact from the direction of said front surface of said mirror element by a deployed air bag within the vehicle causes fracture of said mirror element by said actuator when said assembly is mounted in a vehicle; said plate being selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi.

Claim 22

The mirror assembly of claim 15 wherein said resistance to cracking and permanent deformation of said plate is a Notched Izod impact of at least about 1.0 ft lb/in.

Claim 23

The mirror assembly of claim 15 wherein said resistance to cracking and permanent deformation of said plate is a yield strength of at least about 21,000 psi.

Claim 24

The mirror assembly of claim 17 wherein said yield strength is at least about 32,000 psi.

Claim 25

The mirror assembly of claim 15 wherein said plate thickness is within the range of between about 0.020 and 0.125 inches.

Claim 26

The mirror assembly of claim 19 wherein said plate thickness is within the range of between about 0.025 and 0.050 inches.

Claim 27

The mirror assembly of claim 20 wherein said elastic modulus of said plate is at least 1×10 6 psi.

Claim 28

The mirror assembly of claim 15 wherein said elastic modulus of said plate is at least 1×10 6 psi.

Claim 29

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case at a position to the rear of said rear surface of said mirror element and between said actuator and said rear surface of said mirror element, said actuator and support arm being spaced to the rear of said plate, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi.

Claim 30

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case at a position to the rear of said rear surface of said mirror element and between said actuator and said rear surface of said mirror element, said actuator and support arm being spaced to the rear of said plate, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi.

Claim 31

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate being adhered to said mirror element rear surface over said reflective layer.

Claim 32

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate being adhered to said mirror element rear surface over said reflective layer.

Claim 33

The mirror assembly of claim 24 wherein said plate is adhered by a layer of material having opposed adhesive surfaces.

Claim 34

The mirror assembly of claim 25 wherein said mirror element is glass; said adhering layer being a tackified acrylic laminating adhesive.

Claim 35

The mirror assembly of claim 24 wherein said plate is made of polymeric plastics or metals.

Claim 36

The mirror assembly of claim 27 wherein said polymeric plastic or metals consist of nylon, glass-filled polybutylene terephthalate, aluminum, steel, stainless steel, titanium, or alloys thereof.

Claim 37

The mirror assembly of claim 27 wherein said plate is aluminum having an epoxy coating thereon.

Claim 38

The mirror assembly of claim 27 wherein said plate is metal having a pacifying, non-conductive coating thereon.

Claim 39

The mirror assembly of claim 24 wherein said rear surface of said mirror element has a predetermined peripheral configuration, said plate having a configuration smaller than said predetermined peripheral configuration.

Claim 40

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate being mounted within said mirror case and spaced rearwardly of said rear surface of said mirror element.

Claim 41

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate being mounted within said mirror case and spaced rearwardly of said rear surface of said mirror element.

Claim 42

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surface, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, and an anti-scatter layer on said rear surface of said mirror element between said plate and said reflective layer.

Claim 43

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surface, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, and an anti-scatter layer on said rear surface of said mirror element between said plate and said reflective layer.

Claim 44

The mirror assembly of claim 33 wherein said mirror element is glass; said anti-scatter layer being selected from the group consisting essentially of a hot-melt polymeric coating, a plastisol, a tape, a film, a tape having opposed adhesive surfaces, a film having opposed adhesive surfaces, and a flexible, resilient polymeric material having opposed adhesive surfaces.

Claim 45

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle: an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate being smaller than said mirror element and sufficiently large to cover the area intermediate said actuator and said mirror element.

Claim 46

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle: an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate being smaller than said mirror element and sufficiently large to cover the area intermediate said actuator and said mirror element.

Claim 47

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate thickness being within the range of between about 0.020 and 0.125 inches.

Claim 48

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said plate thickness being within the range of between about 0.020 and 0.125 inches.

Claim 49

The mirror assembly of claim 36 wherein said plate thickness is within the range of between about 0.025 and 0.050 inches.

Claim 50

The mirror assembly of claim 37 wherein said elastic modulus of said plate is at least 1×10 6 psi.

Claim 51

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support and mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, said elastic modulus of said plate being at least 1×10 6 psi.

Claim 52

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support and mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, said elastic modulus of said plate being at least 1×10 6 psi.

Claim 53

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, said resistance to cracking and permanent deformation of said plate being a Notched Izod impact of at least about 1.0 ft lb/in.

Claim 54

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, said resistance to cracking and permanent deformation of said plate being a Notched Izod impact of at least about 1.0 ft lb/in.

Claim 55

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, said resistance to cracking and permanent deformation of said plate being a yield strength of at least about 21,000 psi.

Claim 56

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi, said resistance to cracking and permanent deformation of said plate being a yield strength of at least about 21,000 psi.

Claim 57

The mirror assembly of claim 41 wherein said yield strength is at least about 32,000 psi.

Claim 58

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said mirror case being molded from a polymeric material and including a peripheral wall having a rim defining an opening in said case, and a rear wall spaced behind said rim to define a hollow interior within said case; said actuator being pivotally mounted within said hollow interior adjacent to and spaced to the rear of said plate to move said mirror case and mirror element between said day and night positions; said mirror element being glass.

Claim 59

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate selected to have a thickness within the range of between about 0.015 and 0.250 inches, an elastic modulus of at least about 250,000 psi, and a resistance to cracking and permanent deformation of at least one of a Notched Izod impact of at least about 0.5 ft lb/in and a yield strength of at least about 10,000 psi; said mirror case being molded from a polymeric material and including a peripheral wall having a rim defining an opening in said case, and a rear wall spaced behind said rim to define a hollow interior within said case; said actuator being pivotally mounted within said hollow interior adjacent to and spaced to the rear of said plate to move said mirror case and mirror element between said day and night positions; said mirror element being glass.

Claim 60

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case at a position to the rear of said rear surface of said mirror element and between said actuator and said rear surface of said mirror element, said actuator and support arm being spaced to the rear of said plate, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches.

Claim 61

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case at a position to the rear of said rear surface of said mirror element and between said actuator and said rear surface of said mirror element, said actuator and support arm being spaced to the rear of said plate, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches.

Claim 62

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches, said plate being adhered to said mirror element rear surface over said reflective layer, said mirror element being glass.

Claim 63

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches, said plate being adhered to said mirror element rear surface over said reflective layer, said mirror element being glass.

Claim 64

The mirror assembly of claim 45 wherein said plate is adhered by a layer of material having opposed adhesive surfaces.

Claim 65

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches; and an anti-scatter layer on said rear surface of said mirror element between said plate and said reflective layer, said mirror element being glass.

Claim 66

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches; and an anti-scatter layer on said rear surface of said mirror element between said plate and said reflective layer, said mirror element being glass.

Claim 67

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case: a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer: a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches, said plate being glass-filled polybutylene terephthalate having a thickness of between about 0.025 and 0.050 inches and a flexural modulus of at least about 1×10 6 psi.

Claim 68

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case: a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer: a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches, said plate being glass-filled polybutylene terephthalate having a thickness of between about 0.025 and 0.050 inches and a flexural modulus of at least about 1×10 6 psi.

Claim 69

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches; said plate being mounted within said mirror case and spaced rearwardly of said rear surface of said mirror element.

Claim 70

An energy absorbing, inside rearview mirror assembly for use on a vehicle equipped with an air bag/supplemental occupant restraint system, said assembly comprising: a mirror case; a mirror element mounted within said case, being of the type which is fracturable upon impact, and having front and rear surfaces, said rear surface facing the interior of said mirror case; a light reflective layer on said rear surface of said mirror element; a day/night actuator mounted for movement in said mirror case behind said rear surface of said mirror element, said actuator being movable to move said mirror element between a day position in which light is reflected from said reflective layer to a viewer and a night position in which a reduced amount of light is reflected from said front surface of said mirror element to a viewer; a support arm mounted on said actuator to support said assembly on the vehicle; and an energy absorbing plate for protecting said mirror element in the event of contact by said actuator caused by deployment of an air bag within the vehicle, said plate being located within said mirror case between said actuator and said rear surface of said mirror element, said plate being formed from a polymeric material having a flexural modulus of at least about 250,000 psi, a Notched Izod impact of at least about 0.5 ft lb/in, and a thickness within the range of between about 0.015 and 0.250 inches; said plate being mounted within said mirror case and spaced rearwardly of said rear surface of said mirror element.