Curved reflective mirror and manufacturing method thereof

• US 9,541,683 B2
• Filed: 10/12/2011
• Issued: 01/10/2017
• Est. Priority Date: 12/17/2010
• Status: Active Grant

• Current Assignee: Terasolar Photothermal Technology Co., Ltd
• Original Assignee: Terasolar Photothermal Technology Co., Ltd
• Inventors: Liu, Yang
• Primary Examiner(s): Collins, Darryl J
• Assistant Examiner(s): Tallman, Robert E
• Application Number:
  US13/995,029
• Publication Number:
  US 20130265667A1
• Time in Patent Office: 1,917 Days
• Field of Search: 359/838, 359846-849, 359850-853, 359/867, 359871-877, 359/883, 359/884
• US Class Current: 1/1
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/1022 Metallic coatings
• CPC Class Codes: B32B 17/10706 being photo-polymerized
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10788 containing ethylene vinylacetate
• CPC Class Codes: B32B 38/0012 Mechanical treatment, e.g. roughening, deforming, stretching
• CPC Class Codes: C03C 27/10 with the aid of adhesive specially adapted for that purpose
• CPC Class Codes: F24S 2025/601 by bonding, e.g. by using adhesives
• CPC Class Codes: F24S 23/74 with trough-shaped or cylindro-parabolic reflective surfaces
• CPC Class Codes: F24S 23/82 characterised by the material or the construction of the reflector
• CPC Class Codes: G02B 5/10 with curved faces
• CPC Class Codes: Y02E 10/40 Solar thermal energy, e.g. solar towers
• CPC Class Codes: Y02E 10/52 PV systems with concentrators
• CPC Class Codes: Y10T 156/1048 to form dished or receptacle-like product

Abstract

A curved reflective mirror includes a flat glass structure, an intermediate adhesive layer, and a flat glass mirror. The intermediate adhesive layer is positioned between the flat glass structure and the flat glass mirror. The flat glass structure, the intermediate adhesive layer, and the flat glass mirror are curved and deformed in a mechanical manner with the support of a mold. The curved and deformed flat glass structure, intermediate adhesive layer, and flat glass mirror are solidified and bonded together in a heating and/or ultraviolet (UV) light radiation and/or room temperature solidification manner to form a composite curved structure. Also provided is a method for manufacturing a curved reflective mirror. The curved reflective mirror can be widely applied in the fields of solar thermal collection and concentration and solar thermal power generation.

Claims

1. A curved reflective mirror, comprising a flat glass structure, an intermediate adhesive layer, and a flat glass mirror,

wherein the intermediate adhesive layer is positioned between the flat glass structure and the flat glass mirror, so that the flat glass structure, the intermediate adhesive layer, and the flat glass mirror are curved and deformed in a mechanical manner with support of a mold, and the curved and deformed flat glass structure, intermediate adhesive layer, and flat glass mirror are solidified and bonded together in a heating and/or ultraviolet (UV) light radiation and/or room temperature solidification manner to form a composite curved surface structure,

wherein the intermediate adhesive layer comprises an adhesive and a reinforcement shaper, and

wherein the reinforcement shaper reduces liquidity of the adhesive, and causes the adhesive to be uniformly distributed between the flat glass structure and the flat glass mirror.

2. The curved reflective mirror according to claim 1, wherein the UV light radiation manner is a UV lamp radiation or outdoor sunshine radiation manner.

3. The curved reflective mirror according to claim 1, wherein the intermediate adhesive layer is a hot melt glue sheet.

4. The curved reflective mirror according to claim 3, wherein the hot melt glue sheet is ethylene-vinyl acetate copolymer (EVA) or polyvinyl butyral (PVB).

5. The curved reflective mirror according to claim 1, wherein the intermediate adhesive layer comprises a hot melt glue sheet and the reinforcement shaper, and the hot melt glue sheet is positioned on the reinforcement shaper.

6. The curved reflective mirror according to claim 1, wherein the intermediate adhesive layer comprises liquid light solidification glue and the reinforcement shaper, and the liquid light solidification glue is coated on the reinforcement shaper.

7. The curved reflective mirror according to claim 6, wherein the liquid light solidification glue is a UV binder.

8. The curved reflective mirror according to claim 1, wherein the intermediate adhesive layer comprises an ordinary chemical adhesive.

9. The curved reflective mirror according to claim 8, wherein the ordinary chemical adhesive is a single-component, two-component, or multi-component adhesive.

10. The curved reflective mirror according to claim 1, wherein the intermediate adhesive layer comprises an ordinary chemical adhesive and the reinforcement shaper, and the chemical adhesive is coated on the reinforcement shaper.

11. The curved reflective mirror according to claim 1, wherein the reinforcement shaper is glass fiber fabric or non-woven fabric.

12. The curved reflective mirror according to claim 1, wherein an end edge of the curved reflective mirror or the entire curved reflective mirror is placed on a mirror holder and the mirror holder is used for fixing the curved reflective mirror.

13. The curved reflective mirror according to claim 1, wherein the flat glass structure is toughened glass, and the flat glass mirror is a toughened glass mirror.

14. The curved reflective mirror according to claim 1, wherein the flat glass structure is non-toughened glass, and the flat glass mirror is a non-toughened glass mirror.

15. The curved reflective mirror according to claim 14, wherein the intermediate adhesive layer is 0.1 millimeters to 2 millimeters thick.

16. The curved reflective mirror according to claim 1, wherein the flat glass structure is 2 millimeters to 5 millimeters thick, and the flat glass mirror is 0.5 millimeters to 3.2 millimeters thick.

17. The curved reflective mirror according to claim 1, wherein the curved reflective mirror is a concave mirror or a convex mirror.

18. The curved reflective mirror according to claim 1, wherein the flat glass structure is multi-layer flat glass, and the multiple layers of the flat glass are molded and fixed through a continuous adhesive layer of a large size.

19. The curved reflective mirror according to claim 1, wherein the flat glass structure is two-layer flat glass, first flat glass is close to the flat glass mirror, and second flat glass arranged at the bottom is greater than the first flat glass in size.

20. The curved reflective mirror according to claim 1, wherein the flat glass mirror and first flat glass are arranged in a misaligned manner on second flat glass along an axial direction to form a large-sized curved reflective mirror.

21. The curved reflective mirror according to claim 1, wherein second flat glass, first flat glass, and the flat glass mirror are consistent in size, and are arranged in a staggered manner along an axial direction and are molded through solidification.

22. The curved reflective mirror according to claim 1, wherein the intermediate adhesive layer comprises an adhesive layer and the reinforcement shaper in direct contact with the adhesive layer.

23. A curved reflective mirror according to claim 1, wherein the reinforcement shaper comprises a fabric support structure that supports the adhesive between the flat glass structure and the flat glass mirror.

24. A method of manufacturing a curved reflective mirror, comprising:

arranging a flat glass mirror, an intermediate adhesive layer, and a flat glass structure in sequence on a curved surface supporting apparatus, wherein the intermediate adhesive layer comprises an adhesive and a reinforcement shaper;

curving and deforming the flat glass mirror, the intermediate adhesive layer, and the flat glass structure in a mechanical manner with the support of a mold; and

solidifying and pressing together the curved and deformed flat glass structure, intermediate adhesive layer, and flat glass mirror in a heating and/or ultraviolet (UV) light radiation and/or room temperature solidification manner to form a composite curved reflective mirror,

wherein the reinforcement shaper reduces liquidity of the adhesive, and causes the adhesive to be uniformly distributed between the flat glass structure and the flat glass mirror.

25. The method of manufacturing a curved reflective mirror according to claim 24, wherein before the solidification and pressing step, the method comprises a step of preliminarily pressing the flat glass mirror and the flat glass structure onto the curved surface supporting apparatus by using the elasticity of the flat glass mirror.

26. The method of manufacturing a curved reflective mirror according to claim 24, wherein before the step of arranging the flat glass mirror, the intermediate adhesive layer, and the flat glass structure in sequence on the curved surface supporting apparatus, the method comprises a step of manufacturing the curved surface supporting apparatus.

27. The method of manufacturing a curved reflective mirror according to claim 26, wherein the curved surface supporting apparatus comprises a base and a curved surface supporting member, curvature of the curved surface supporting member is greater than that of the demanded curved reflective mirror, so as to compensate for a recurrent magnitude of the finished curved reflective mirror.

28. The method of manufacturing a curved reflective mirror according to claim 24, wherein after the solidification and pressing step, the method comprises a step of trimming and detecting the composite curved reflective mirror.

29. The method of manufacturing a curved reflective mirror according to claim 28, wherein after the trimming and detecting step, the method comprises a step of fixing the formed curved reflective mirror on a mirror holder.

30. The method of manufacturing a curved reflective mirror according to claim 28, wherein the mechanical manner is to vacuumize the mold or impose pressure on the flat glass structure, the intermediate adhesive layer, and the flat glass mirror in the mold.

31. The method of manufacturing a curved reflective mirror according to claim 24, wherein the curving and deforming the flat glass mirror, the intermediate adhesive layer, and the flat glass structure is done in a cold-bend technique of less than 100 degrees C., while the adhesive is heated.