Method for manufacturing vehicle mirrors
First Claim
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.
1 Assignment
0 Petitions
Accused Products
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.
7 Citations
16 Claims
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1. A method for manufacturing a vehicle mirror having a curved mirror surface, particularly for use with commercial vehicles, comprising the steps of:
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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. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11)
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12. A method for manufacturing a curved vehicle mirror comprising the steps of:
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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. - View Dependent Claims (13, 14, 15)
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16. A method for manufacturing a curved vehicle mirror comprising the steps of:
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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.
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Specification