Method of making reflector for solar collector or the like, and corresponding product, including reflective coating designed for improved adherence to laminating layer
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.
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 PdCl 2 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.