Method for manufacturing vehicle mirrors

• US 20070000771A1
• Filed: 06/26/2006
• Published: 01/04/2007
• Est. Priority Date: 07/01/2005
• Status: Abandoned Application

• Current Assignee: Lang-Mekra North America LLC
• Original Assignee: Lang-Mekra North America LLC
• Inventors: Lang, Werner, Bauer, Jochen, Felbinger, Willi, Mayer, Rudolf
• Application Number:
  US11/474,844
• Publication Number:
  US 20070000771A1
• Time in Patent Office: Days
• US Class Current: 204/192.270
• CPC Class Codes: C23C 14/025 Metallic sublayers
• CPC Class Codes: C23C 14/205 by cathodic sputtering
• CPC Class Codes: C23C 14/584 Non-reactive treatment
• CPC Class Codes: C23C 28/00 Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
• CPC Class Codes: C23C 28/021 including at least one metal alloy layer
• CPC Class Codes: C23C 28/023 only coatings of metal elements only

Abstract

Molding a carrier base from plastic having a curved base surface formed into a fixed shape prior to receiving a mirror coating. Sputtering a first mirror coating layer selected of chromium onto the curved base surface, wherein the first layer has a light reflectivity in the range of approximately 60% to 65% of visible electromagnetic radiation. Sputtering a second mirror coating layer of aluminum onto the first layer so that the second layer has a light reflectivity of at least about 80% of visible electromagnetic radiation and a maximum thickness of approximately 20% of the thickness of the first layer. The first and second mirror coating layers are applied to the curved base surface to have a combined layer thickness in the range of approximately 5 mm to 1 μm. Applying an anti-scratch coating onto the second mirror coating layer to resist damage to the first and second mirror coating layers.

Claims

1. A method for manufacturing a vehicle mirror having a curved mirror surface, particularly for use with commercial vehicles, comprising the steps of:

providing a carrier base having a curved base surface molded into a fixed shape during the original molding of the carrier base and prior to receiving a mirror coating; and

,

sputtering a mirror coating onto said curved base surface following molding of said curved base surface to provide a vehicle mirror with a reflective surface free of atomic diffusion and structural stratification as occurs when said mirror coating is applied to said carrier base prior to forming said curved base surface.

2. The method of claim 1 including the step of molding said carrier base from a thermoplastic polymer.

3. The method of claim 2 including the step of sputtering a mirror coating having a layer thickness in the range of approximately 5 mm to 1 μ

m onto said curved base surface of said carrier base.

4. The method of claim 3 wherein said mirror coating is constructed of materials selected from the group consisting of chromium, chromium alloy, aluminum, aluminum alloy, and combinations thereof.

5. The method of claim 4 including the step of forming said mirror coating by sputtering a first layer selected from one of a chromium and a chromium alloy onto said curved base surface of said carrier base.

6. The method of claim 5 including the step of forming said first layer with a light reflectivity in the range of approximately 60% to 65% of visible electromagnetic radiation.

7. The method of claim 5 including the step of sputtering a second layer selected from one of a aluminum and a aluminum alloy onto said first layer.

8. The method of claim 7 including the step of forming said second layer with a light reflectivity of at least about 80% of visible electromagnetic radiation.

9. The method of claim 7 including the step of forming said second layer thinner than said first layer.

10. The method of claim 7 including the step of forming said second layer with a thickness approximately 50% or less than the thickness of said first layer.

11. The method of claim 7 including the step of applying an anti-scratch coating onto said second layer.

12. A method for manufacturing a curved vehicle mirror comprising the steps of:

molding a carrier base from a thermoplastic polymer having a curved base surface being formed into a fixed shape prior to receiving a mirror coating;

sputtering a first mirror coating layer selected from one of a chromium and a chromium alloy onto said curved base surface of said carrier base, wherein said first mirror coating layer has a light reflectivity in the range of approximately 60% to 65% of visible electromagnetic radiation;

sputtering a second mirror coating layer selected from one of a aluminum and a aluminum alloy onto said first layer, wherein said second layer has a light reflectivity of at least about 80% of visible electromagnetic radiation; and

,

wherein said first and second mirror coatings are applied to said curved base surface to have a combined layer thickness in the range of approximately 5 mm to 1 μ

m.

13. The method of claim 12 including the step of forming said second layer thinner than said first layer.

14. The method of claim 13 including the step of forming said second layer with a maximum thickness of approximately 20% of the thickness of said first layer.

15. The method of claim 13 including the step of applying an anti-scratch coating onto said second layer.

16. A method for manufacturing a curved vehicle mirror comprising the steps of:

molding a carrier base from a thermoplastic polymer having a curved base surface being formed into a fixed shape prior to receiving a mirror coating;

sputtering a first mirror coating layer selected from one of a chromium and a chromium alloy onto said curved base surface of said carrier base, wherein said first mirror coating layer has a light reflectivity in the range of approximately 60% to 65% of visible electromagnetic radiation;

sputtering a second mirror coating layer selected from one of a aluminum and a aluminum alloy onto said first layer so that said second mirror coating layer has a light reflectivity of at least about 80% of visible electromagnetic radiation and a maximum thickness of approximately 20% of the thickness of said first layer, wherein said first and second mirror coating layers are applied to said curved base surface to have a combined layer thickness in the range of approximately 5 mm to 1 μ

m; and

,

applying an anti-scratch coating onto said second mirror coating layer to resist damage to said first and second mirror coating layers.