Method of making reflector for solar collector or the like, and corresponding product, including reflective coating designed for improved adherence to laminating layer

• US 20070291384A1
• Filed: 06/14/2006
• Published: 12/20/2007
• Est. Priority Date: 06/14/2006
• Status: Abandoned Application

• Current Assignee: Guardian Glass LLC (KOCH Industries Incorporated)
• Original Assignee: Guardian Industries Corporation (KOCH Industries Incorporated)
• Inventors: Wang, Yei-Ping (Mimi) H.
• Application Number:
  US11/452,418
• Publication Number:
  US 20070291384A1
• Time in Patent Office: Days
• US Class Current: 359/883
• CPC Class Codes: B32B 17/10036 comprising two outer glass sheets
• CPC Class Codes: B32B 17/1022 Metallic coatings
• CPC Class Codes: B32B 17/10761 containing vinyl acetal
• CPC Class Codes: B32B 17/10889 shaping the sheets, e.g. by using a mould B32B17/10816 takes precedence
• CPC Class Codes: F24S 23/82 characterised by the material or the construction of the reflector
• CPC Class Codes: G02B 5/0841 comprising organic materials, e.g. polymers
• CPC Class Codes: Y02E 10/40 Solar thermal energy, e.g. solar towers

Abstract

A reflector (e.g., mirror) for use in a solar collector or the like is provided. In certain example embodiments of this invention, a reflector is made performing at least the following steps: (a) forming a reflective coating on a flat glass substrate, (b) cold-bending the glass substrate with the reflective coating thereon; and (c) applying a plate or frame member (e.g., another glass sheet/substrate, or alternatively a thermoplastic member) to the cold-bent glass substrate, the plate or frame member for maintaining the coated glass substrate in a desired bent orientation. In certain example embodiments, the reflective coating is a mirror coating and includes a passivating film including tin oxide and/or silane(s) for better adhering to the polymer based glue/adhesive/laminating layer which may be made of polyvinyl butyral (PVB) or the like.

Claims

1. A method of making a mirror, the method comprising:

providing a flat glass substrate;

forming a mirror coating on the flat glass substrate, the mirror coating including a reflective layer and an uppermost film comprising tin oxide and/or silane(s);

after the mirror coating has been formed on the flat glass substrate, bending the glass substrate together with the coating thereon into a desired bent shape, the bending being performed when the glass substrate is at a temperature of no more than about 200 degrees C.; and

maintaining the glass substrate and the coating thereon in substantially the desired bent shape by using a plate that is laminated to the glass substrate using a polymer based glue layer, so that the polymer based glue layer directly contacts the uppermost film of the mirror coating which comprises tin oxide and/or silane(s).

2. The method of claim 1, wherein said bending of the glass substrate with the coating thereon is performed when the glass substrate is at a temperature of no more than about 150 degrees C.

3. The method of claim 1, wherein said bending of the glass substrate with the coating thereon is performed when the glass substrate is at a temperature of no more than about 100 degrees C.

4. The method of claim 1, wherein said bending of the glass substrate with the coating thereon is performed when the glass substrate is at a temperature of no more than about 50 degrees C.

5. The method of claim 1, wherein said bending of the glass substrate with the coating thereon is performed when the glass substrate is at approximately room temperature.

6. The method of claim 1, wherein said plate is a glass sheet.

7. The method of claim 1, wherein said plate is a glass sheet that is pre-bent before being laminated to the glass substrate.

8. The method of claim 1, wherein the glass substrate is from about 1.0 to 2.25 mm thick.

9. The method of claim 1, wherein the polymer based glue layer comprises polyvinyl butyral.

10. The method of claim 1, wherein the reflective layer of the mirror coating comprises silver.

11. The method of claim 1, wherein in making the mirror coating, a solution comprising PdCl₂ is sprayed toward the glass substrate prior to forming of the reflective layer.

12. The method of claim 1, wherein the bent shape comprises a substantially parabolic shape, and wherein the mirror is used as a mirror in a solar collector.

13. The method of claim 1, wherein the uppermost film of the mirror coating comprises tin oxide.

14. The method of claim 1, wherein the uppermost film of the mirror coating comprises at least one silane.

15. A method of making a mirror, the method comprising:

providing a flat glass substrate;

forming a reflective coating on the flat glass substrate, the reflective coating including a reflective layer and an uppermost film comprising metal oxide and/or silane(s);

after the reflective coating has been formed on the flat glass substrate, bending the glass substrate together with the coating thereon into a desired bent shape, the bending being performed when the glass substrate is at a temperature of no more than about 250 degrees C.; and

maintaining the glass substrate and the coating thereon in substantially the desired bent shape by using a plate that is laminated to the glass substrate using a polymer based laminating layer, so that the polymer based laminating layer directly contacts the uppermost film of the reflective coating which comprises metal oxide and/or silane(s).

16. A mirror, comprising:

a first bent glass substrate with a mirror coating formed thereon, wherein the mirror coating comprises a reflective layer and an uppermost film comprising metal oxide and/or silane(s);

a second bent glass substrate laminated to the first bent glass substrate using a polymer based glue layer, and wherein the polymer based glue layer directly contacts the uppermost film of the mirror coating which comprises metal oxide and/or silane(s).

17. The mirror of claim 16, wherein the uppermost film of the mirror coating comprises tin oxide.

18. The mirror of claim 16, wherein the uppermost film of the mirror coating comprises at least one silane.