Method of making reflector for solar collector or the like and corresponding product
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 member (e.g., thermoplastic or glass based) to the cold-bent glass substrate, the plate member for maintaining the coated glass substrate in a desired bent orientation. In certain example embodiments, the glass substrate supporting the reflective coating may be maintained in desired bent form by using another glass substrate and a glue layer provided between the another glass substrate and the glass substrate supporting the coating. The bent reflector (e.g., mirror) may be used in a solar collector, or in any other suitable application.
1 . A method of making a mirror, the method comprising:
providing a flat glass substrate;
forming a reflective coating on the flat glass substrate;
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 200 degrees C.;
maintaining the glass substrate and the coating thereon in substantially the desired bent shape by using a thermoplastic member that is attached to the glass substrate and/or the coating thereon; and
pre-heating the thermoplastic member to a temperature of from about 80-200 degrees C. prior to a bending of the thermoplastic member, wherein the thermoplastic member is bent along with the glass substrate supporting the reflective coating.
2 . The method of claim 1 , wherein said bending of the glass substrate 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 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 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 is performed when the glass substrate is at approximately room temperature.
6 . The method of claim 1 , wherein the thermoplastic member is attached to the glass substrate via one or both of: (a) an adhesive provided between the coating and the thermoplastic member, and/or (b) a plurality of fasteners.
7 . The method of claim 1 , wherein the thermoplastic member is attached to the glass substrate and/or coating, after the glass substrate has been bent; and wherein the glass substrate is from about 1.0 to 2.25 mm thick.
8 . The method of claim 1 , wherein the thermoplastic member is attached to the glass substrate and/or coating, before the glass substrate has been bent.
9 . (canceled)
10 . The method of claim 1 , wherein the coating comprises at least one reflective layer comprising Al, Ag and/or Cr.
11 . 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.
12 . A method of making a reflector, the method comprising:
providing a flat glass substrate;
forming a reflective coating on the flat glass substrate, the reflective coating for reflecting visible and/or IR radiation and comprising at least one reflective layer comprising one or more of Ag, Al and/or Cr;
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 200 degrees C.; and
maintaining the glass substrate and the coating thereon in substantially the desired bent shape by using a frame member; and
pre-heating the frame member to a temperature of from about 80-200 degrees C. prior to a bending of the frame member, wherein the frame member is bent either along with the glass substrate or prior to being coupled with the glass substrate.
13 . The method of claim 12 , wherein said bending of the glass substrate is performed when the glass substrate is at a temperature of no more than about 150 degrees C.
14 . The method of claim 12 , wherein said bending of the glass substrate is performed when the glass substrate is at a temperature of no more than about 100 degrees C.
15 . The method of claim 12 , wherein said bending of the glass substrate is performed when the glass substrate is at a temperature of no more than about 50 degrees C.
16 . The method of claim 12 , wherein said bending of the glass substrate is performed when the glass substrate is at approximately room temperature.
17 . The method of claim 12 , wherein the frame member comprises one of: (1) a thermoplastic member that is attached to the glass substrate via one or both of: (a) an adhesive provided between the coating and the thermoplastic member, and/or (b) a plurality of fasteners, or (2) another glass substrate with a glue layer being provided between the another glass substrate and the glass substrate supporting the reflective coating.
18 . (canceled)
19 . The method of claim 12 , wherein the reflector is used as a vehicle window or as a mirror in a solar collector.
20 . The method of claim 12 , wherein the glass substrate is from 1.0 to 2.25 mm thick
21 - 27 . (canceled)
28 . A method of making a mirror, the method comprising:
providing a flat glass substrate;
forming a reflective coating on the flat glass substrate;
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 200 degrees C.;
maintaining the glass substrate and the coating thereon in substantially the desired bent shape by using a thermoplastic member that is attached to the glass substrate and/or the coating thereon; and
wherein the thermoplastic member is attached to the glass substrate and/or coating, before the glass substrate has been bent.
29 . The method of claim 28 , wherein the thermoplastic member is attached to the glass substrate via one or both of: (a) an adhesive provided between the coating and the thermoplastic member, and/or (b) a plurality of fasteners.
30 . The method of claim 28 , wherein the bent shape comprises a substantially parabolic shape, and wherein the mirror is used as a mirror in a solar collector.
31 . The method of claim 28 , wherein said bending of the glass substrate is performed when the glass substrate is at a temperature of no more than about 100 degrees C.
32 . The method of claim 28 , wherein said bending of the glass substrate is performed when the glass substrate is at approximately room temperature.