Thin film mirror
A thin film mirror, comprising: a mirror shell ( 605 ); a reflective film ( 601 ) stretched between forming structures ( 603 ) provided on said mirror shell and reflective film being arranged such that they form a chamber which is capable of being placed under at least partial vacuum; the mirror shell having an inner surface which forms an inner wail of said chamber, wherein the mirror shell is a moulded part where its inner surface is a controlled surface.
1. A thin film mirror, comprising:
a mirror shell;
a reflective film stretched between forming structures provided on said mirror shell and reflective film being arranged such that they form a chamber which is capable of being placed under at least partial vacuum;
the mirror shell having an inner surface which forms an inner wall of said chamber, wherein the mirror shell is a moulded part where its inner surface is a controlled surface.
2. A thin film mirror according to claim 1 , wherein the inner surface has at least one protrusion formed integral with the mirror shell during its moulding.
3. A thin film mirror according to claim 2 , wherein the protrusion provides at least one of the forming structures.
4. A thin film mirror according to claim 1 , wherein the mirror shell has the shape of a section of a substantially spherical shell or toroid.
5. A thin film mirror according to claim 1 , wherein the mirror shell has an upper edge part and a lower edge part, the upper and lower edge parts being formed along small circles, said small circles being formed in planes which are parallel to one another.
6. A thin film mirror according to claim 4 , wherein the mirror shell subtends through an angle of at least 180° .
7. A thin film mirror according to claim 6 , wherein the mirror shell comprises two sections joined together, wherein each section subtends through an angle of 180° or less.
8. A thin film mirror according to claim 1 , wherein the mirror shell comprises two sections, where one section is provided on top of the other section.
9. A thin film mirror according to claim 1 , further comprising at least one protrusion on its inner surface, said protrusion providing a forming structure for said reflective film which defines the lateral extent of the mirror, said forming structure being provided spaced in from a lateral edge of the mirror.
10. A thin film mirror according to claim 1 , further comprising a protrusion in the form of a ridge which is separated from the edges of the mirror, said ridge providing a secondary forming structure for said reflective film, said secondary forming structure being provided spaced apart from an edge of the mirror shell with a forming structure, said secondary forming structure contacting said reflective film.
11. A thin film mirror according to claim 10 , further comprising a tensioning mechanism configured to provide a force on a section of reflective material between the secondary forming structure and a forming structure at the nearest edge of the mirror to the secondary forming structure.
12. A thin film mirror according to claim 1 , wherein said mirror shell comprises a composite material.
13. A thin film mirror according to claim 12 , wherein said mirror shell comprises a composite with a foam core.
14. A thin film mirror, comprising:
a mirror shell;
a reflective film stretched between forming structures provided on said mirror shell and reflective film being arranged such that they form a chamber which is capable of being placed under at least partial vacuum;
the mirror shell having an inner surface which forms an inner wall of said chamber, wherein the mirror shell is a moulded part where its inner surface comprises one or more protrusions spaced in from an edge of said mirror shell.
15. A simulator comprising:
a thin film mirror;
a screen onto which an image is provided, said mirror being located such that a user sees the image projected onto the screen via the mirror; and
an image generator configured to control the image provided on the screen, wherein said thin film mirror is a mirror according to claim 1 .
16. A method of making a thin film mirror, said method comprising:
forming a mirror shell;
fixing a reflective film to said mirror shell, such that a chamber is formed between said reflective film and mirror shell, said chamber being capable of being placed under vacuum,
wherein forming said mirror shell comprises moulding said mirror shell using a male mould.
17. A method according to claim 16 , wherein said male mould has a part which is a substantially spherical section.
18. A method according to claim 16 , further comprising forming said mould.
19. A method according to claim 18 , wherein the mould is formed with at least one groove, such that at least one forming structure is formed on a surface of said mirror shell which is adjacent said mould.
20. A method according to claim 19 , wherein a groove is formed in said mould which is spaced apart from the edge of said mould, such that a secondary forming structure is provided on said mirror shell, said secondary forming structure being spaced apart from the edge of said mirror shell, such that the reflective film contacts the secondary forming structure.
21. A method according to claim 18 , wherein a plurality of grooves are formed in the mould, said grooves being positioned at different lateral positions of the mould.
22. A method according to claim 21 , further filling one or more of the grooves such that the innermost unfilled groove defines the lateral extent of the mirror to be formed.