Lightweight rigid mirror and method for manufacturing the same

Abstract

To provide a mirror body, a mirror array, and a method of producing a mirror and a mirror array.SOLUTION: The mirror body can be formed of a rigid foam and has a front surface with a shape adapted to reflect light that originates in a projector of a simulator. A block of the rigid foam may be machined to form the mirror body. A reflective material is positioned over the front surface to reflect light from the projector. In embodiments, the reflective material is a sheet of a metalized film. In embodiments, the reflective material is applied to the front surface in a first state and subsequently changes to a second state. The mirror array may be formed of two or more mirror bodies. In embodiments, a seam between adjacent mirror bodies is covered with the reflective material.SELECTED DRAWING: None

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application No. 63 / 185,497, filed May 7, 2021, which is incorporated herein by reference in its entirety.

[0002] (Field) FIELD OF THE DISCLOSURE The present disclosure relates generally to mirrors and mirror arrays used in simulators and methods for manufacturing the mirrors. [Background technology]

[0003] (background) Advanced simulators (e.g., flight simulators) used to train users to operate vehicles typically display images to the user to depict the environment around the vehicle. The realism of the image is achieved by collimating the light (and thus the image) to the user, creating an afocal image. Mirrors are used to collimate the light from the screen. The choice of mirror can vary greatly depending on the field of view and other requirements of the simulator. One known type of mirror is a rigid mirror formed from glass. Another known mirror is a vacuum-formed (or "stretched film") mirror. Several challenges exist with these types of mirrors.

[0004] Rigid glass mirrors are relatively heavy and difficult to transport. The simulator must be designed to support the weight of the glass mirror and its supporting frame. For full-motion simulators, the motion platform must be strong and rigid enough to support the mirror and frame, which increases the cost of the simulator.

[0005] Simulators utilizing rigid mirrors often contain three to seven or more glass mirrors to achieve the required field of view. Gaps or seams exist between the glass mirrors to allow for mirror expansion or movement. Although the gaps may only be about six-hundredths of an inch (1.524 mm) wide, they do not reflect image light and appear to the user as dark lines. Such lines can be distracting to the user and reduce the realism and effectiveness of the training simulator.

[0006] Another challenge is that manufacturing glass mirrors is time-consuming and expensive. The front reflective surface of a glass mirror is difficult to manufacture and maintain. Its front surface must be ground, polished, and dimensioned to a predetermined shape. The glass mirror is then placed in a vacuum chamber, and a mirror coating is simultaneously applied to the front surface. The reflective coating is fragile and easily damaged, but difficult to repair.

[0007] Yet another limitation of glass mirrors is that they are most economically formed into a spherical shape by the random action of two components acting against each other using an abrasive medium. Vacuum-formed film mirrors, when formed, also approximate a spherical shape. However, for some applications, the ideal shape for a mirror to collimate light is a parabola, and glass mirrors with a parabolic shape require expensive processes to create. Vacuum-formed film mirrors with a parabolic shape are also difficult to fabricate. Therefore, a spherical shape is typically used for glass and vacuum-formed mirrors to approximate the central portion of a large parabola, and the resulting optical properties are a compromise between the ideal mirror shape and the economics of large-scale manufacturing.

[0008] Vacuum-formed mirrors are formed by placing a reflective material, such as Mylar®, in a frame with a hollow interior. The edges of the frame are fashioned to create the correct initial geometry for the mirror. The reflective material is attached to the frame edges in such a way that it forms an airtight seal. A vacuum is then applied to the hollow interior, and sensors inside the chamber are used to draw the reflective material into an approximate spherical shape to achieve the proper depth of draw. Unfortunately, the vacuum must be applied continuously. Unless a constant vacuum is maintained, the reflective surface will not have the required optical properties. The pumps required to create a constant vacuum consume electricity and generate a significant amount of distracting noise.

[0009] Also, vacuum-formed mirrors are easily damaged. For example, the reflective material is easily punctured and torn. If the reflective material is punctured, the vacuum will tear the reflective material and the vacuum will not be able to be maintained. The reflective surface then loses its shape and optical properties and must be replaced. Replacing the reflective material is difficult and frequently requires disassembly of parts of the simulator and frame.

[0010] Vacuum-formed mirrors are also less precise than glass mirrors and, for several reasons, conform poorly to the desired spherical shape of an ideal mirror. As the reflective material is drawn inward into the hollow interior of the frame, it has a steeper curve near the pinned edges and a flatter curve near the center, resulting in a "catenary" shape. The overall uniformity of the curve is highly dependent on the skill of the operator in manually pinning the edges of the reflective material to the frame with the correct amount of tension. The result is often slightly uneven and astigmatic, causing image distortion or "swimming" as objects are seen moving across the mirror.

[0011] Therefore, there is a need for new mirror bodies and mirror arrays for simulators, as well as new methods of forming mirror bodies and mirror arrays. Summary of the Invention [Means for solving the problem]

[0012] (summary) One aspect of the present disclosure is a mirror body formed from a lightweight substrate. The lightweight substrate has a density much lower than the glass typically used to form mirrors. In one specific example, the lightweight substrate has a density of about 12 lbs / ft 3 (192 kg / m 3 In another embodiment, the density of the lightweight substrate is about 60 lbs / ft 3 (961 kg / m 3 In contrast, float glass, which is typically used to make glass mirrors, has a resistance of about 160 lbs / ft 3 (2563 kg / m 3 ) density.

[0013] In one embodiment, the lightweight substrate is foam. Additionally or alternatively, the lightweight substrate may comprise one or more of plastic, fiberglass, metal, rubber, and wood.

[0014] Support elements are optionally provided to stiffen and / or support the mirror body. In one embodiment, the support elements include stringers such as wire, tubing, wire, cable, or angle irons. The support elements can be formed from any suitable material, including wood, plastic, glass, and metal. The support elements can be located on one or more exterior surfaces of the mirror body. Additionally or alternatively, the support elements can be located at least partially or completely within the mirror body.

[0015] The mirror body has a front surface with a shape suitable for reflecting light from a light source, such as a projector, LED panel, or OLED screen. In one embodiment, the shape is suitable for collimating light scattered from a diffusing screen illuminated by the light source. Alternatively, the light source directly illuminates the front surface of the mirror body.

[0016] The front surface of the mirror body is coated with a reflective material.

[0017] In one embodiment, the reflective material is a sheet, which may be a metallized film.

[0018] Alternatively, in another embodiment, the reflective material is applied to the front surface in a liquid state and subsequently changes to a solid state. In one embodiment, the reflective material is a paint having reflective properties.

[0019] If desired, the reflective material is applied to the front surface of the mirror body by a physical vapor deposition method, in this embodiment the reflective material may comprise a metal such as aluminum.

[0020] Another aspect of the present disclosure is a mirror array for a simulator. The mirror array includes two or more mirror bodies formed from a lightweight substrate, which can be foam.

[0021] The front surface of the mirror body is coated with a reflective material, and in at least one embodiment, the seam between two adjacent mirror bodies is coated with a reflective material.

[0022] The reflective material may be a sheet, which may be a metallized film.

[0023] In another embodiment, the reflective material comprises a metal applied to the front surface of the mirror body by physical vapor deposition.

[0024] Alternatively, the reflective material is a paint. The paint is applied to the front surface in a first state. The paint then transforms into a second state that is dimensionally stable. In the second state, the paint contains suitable reflective properties. In some embodiments, the paint is cured after being applied to the front surface.

[0025] Yet another aspect of the present disclosure is a method of forming a mirror body for a mirror array. The method includes forming a substrate into a mirror body. In at least one embodiment, the substrate is a foam.

[0026] The mirror body may be formed by casting the substrate in a mold or by use of a form. In other embodiments, the substrate is subjected to an additive manufacturing process to form the mirror body.

[0027] In some embodiments, the mirror body is formed by mechanically removing material from a block of substrate. Optionally, a CNC machine is used to remove material from the block to form the mirror body. Alternatively, the mirror body may be formed by a combination of two or more of these methods.

[0028] The mirror body is optionally formed from two or more substrates. In at least one embodiment, the mirror body is formed from a first material and a second material having different material properties than the first material.

[0029] In some embodiments, the first material is a first foam. The first foam has a first density.

[0030] The second material can be a second foam having a second density higher than the first density, hi another embodiment, the second material is glass.

[0031] In some embodiments, the first portion of the mirror body is formed from the first foam by any suitable method, including casting, additive manufacturing, removing a portion of a block formed from the first foam, or any other method. The surface of the first portion of the mirror body, such as the front surface, can be reshaped by removing some of the first foam by any suitable method, including sanding, grinding, cutting, heating, etc.

[0032] A second material is then used to form a second portion of the mirror body, such as the front surface of the mirror body. In one embodiment, the second portion is formed from a second foam. Optionally, the second foam is cast onto the front surface of the first portion of the mirror body.

[0033] Alternatively, the second portion is an insert formed from the second material and including a front surface having a predetermined shape. The insert is then joined to the first portion by any method known to those skilled in the art to form the mirror body. In some embodiments, the second portion is adhered or glued to the first portion. Additionally or alternatively, a mechanical fastener can be used to interconnect the second portion to the first portion.

[0034] In at least one embodiment, the second portion is formed from a second foam. Alternatively, the second portion is formed from glass. In some embodiments, the second portion includes a reflective material applied to the front surface by physical vapor deposition.

[0035] Although only two materials are described in this example, any number of materials may be combined to form the mirror body of the present disclosure.

[0036] The method includes disposing a reflective material on the front surface of the mirror body. The reflective material may be applied to the front surface in a liquid state. Alternatively, the reflective material is a sheet.

[0037] One aspect of the present disclosure is a mirror substantially as described herein.

[0038] Another aspect is a mirror array for a simulator including at least one mirror substantially as described herein.

[0039] Another aspect of the present disclosure is a method of forming a mirror body substantially as described herein.

[0040] Yet another aspect is a method of forming a mirror array including at least one mirror substantially as described herein.

[0041] One aspect of the present disclosure is a mirror for a simulator that includes: (1) a body formed from rigid foam and including a front surface, a rear surface, a top surface, a bottom surface, a first side surface, and a second side surface, wherein the front surface has a shape suitable for reflecting light originating from a projector of the simulator; and (2) a reflective material coating the front surface to reflect light from the projector.

[0042] The front surface of the mirror body is configured to reflect light to a user of the simulator.

[0043] In some embodiments, the reflective material conforms to the shape of the front surface.

[0044] In some embodiments, the reflective material is attached (or affixed) to the body with a chemical fastener, such as an adhesive.

[0045] Additionally or alternatively, the reflective material may be attached to the body with mechanical fasteners such as clips, staples, nails and screws.

[0046] In at least one embodiment, the reflective material is held in place against the front surface by static electricity.

[0047] In one or more embodiments, the reflective material is held in place against the front surface by suction.

[0048] In at least one embodiment, one or more of the rear surface, top surface, bottom surface, first side surface, and second side surface are coated with a material to maintain suction and prevent airflow through the coated surface.

[0049] In some embodiments, the body is formed by one or more of: (i) machining a block of rigid foam; (ii) casting a material that hardens to form rigid foam; (iii) using an additive manufacturing process; and (iv) an injection molding process.

[0050] Additionally or alternatively, the mirror includes one or more of the above embodiments and, optionally, the following: (a) the rigid foam defines a first portion of the body; and (b) the second portion of the body is defined by an insert formed from a second material, the insert defining a front surface of the body.

[0051] In some embodiments, the mirror includes one or more of the preceding embodiments, wherein the rigid foam includes one or more of: (a) polyurethane foam; (b) polyethylene foam; (c) polystyrene foam; (d) polyisocyanurate foam; (e) thermosetting polymer (or plastic); (f) metal foam; (g) syntactic foam; (h) cellulose foam; and (i) high-density urethane foam.

[0052] In at least one embodiment, the mirror includes one or more of the preceding embodiments, wherein the reflective material is one or more of: (a) a metallized film; (b) biaxially oriented polyethylene terephthalate (BoPET); (c) a polyester film made from oriented polyethylene terephthalate (PET); (d) a metallized PET (polyester) film; (e) a vacuum-metallized high-gloss PET film; (f) an aluminized polyester (or aluminum-deposited polyester) film; (f) a metal-coated polymer film; (g) a material applied to the front surface by physical vapor deposition, and (h) a material applied to the front surface in a first state, which subsequently changes to a solid state.

[0053] In some embodiments, the mirror comprises one or more of the previous embodiments, with the shape of the front surface adapted to collimate light scattered from a diffusing screen illuminated by a projector.

[0054] In one or more embodiments, the mirror includes one or more of the preceding embodiments, wherein the shape of the front surface of the mirror body includes at least portions (or sections) of a circle, a sphere, a parabolic shape, an ellipse, a flat shape, a freeform shape, and combinations thereof.

[0055] In some embodiments, the mirror includes one or more of the previous embodiments, wherein the body is formed from a rigid foam that is at least partially porous.

[0056] Additionally or alternatively, in one or more embodiments, at least a portion of the body is adapted to facilitate drawing air through the front surface, hi some embodiments, at least the front surface has a plurality of apertures configured to facilitate airflow.

[0057] The mirror optionally comprises one or more of the above embodiments, wherein a reflective material is applied to the front surface in a first state and subsequently transformed into a solid state.

[0058] In some embodiments, the reflective material comprises a paint having reflective properties.

[0059] Alternatively, in at least one embodiment, the reflective material is applied to the front surface by physical vapor deposition, during which the reflective material is in a gas (or vapor) phase. Thus, the first state of the reflective material may be described as a vapor or gas state or phase.

[0060] Another embodiment is a mirror for a simulator, comprising: (1) a body formed from rigid foam and including a front surface, a rear surface, a top surface, a bottom surface, a first side surface, and a second side surface, the front surface having a shape suitable for reflecting light originating from a projector of the simulator; and (2) a reflective material coating the front surface to reflect light from the projector, the reflective material being applied to the front surface in a first state and subsequently changing to a solid.

[0061] In some embodiments, the reflective material comprises a paint having reflective properties.

[0062] In other embodiments, the paint contains pigments (or dyes) that reflect light.

[0063] In one or more embodiments, the reflective material is applied to the front surface by physical vapor deposition, during which the first state of the reflective material is in a vapor or gaseous phase or state.

[0064] In at least one embodiment, the mirror includes one or more of the preceding embodiments, and optionally, the body is formed by one or more of: (i) machining a block of rigid foam; (ii) casting a material that hardens to form rigid foam; (iii) using an additive manufacturing process; and (iv) an injection molding process.

[0065] Additionally or alternatively, the mirror may include one or more of the preceding embodiments, and optionally include one or more of: (a) the rigid foam defines a first portion of the body; and (b) the second portion of the body is defined by an insert formed from a second material, the insert defining a front surface of the body.

[0066] In some embodiments, the mirror comprises one or more of the preceding embodiments, wherein the rigid foam optionally comprises one or more of: (a) polyurethane foam; (b) polyethylene foam; (c) polystyrene foam; (d) polyisocyanurate foam; (e) thermosetting polymer (or plastic); (f) metal foam; (g) syntactic foam; (h) cellulose foam; and (i) high density urethane foam.

[0067] In some embodiments, the mirror comprises one or more of the previous embodiments, optionally with a shape of the front surface of the mirror body suitable for collimating light scattered from a diffusing screen illuminated by a projector.

[0068] In other embodiments, the mirror includes one or more of the previous embodiments, and the shape of the front surface of the mirror body optionally includes at least a portion of a circle, a sphere, a parabolic shape, an ellipse, a flat shape, a freeform shape, and combinations thereof.

[0069] Another aspect of the present disclosure is a mirror array for a simulator that includes: (1) a first mirror body positioned adjacent to a second mirror body, the mirror body formed from foam; and (2) a reflective material covering a front surface of the mirror body such that the reflective material covers a seam between the first and second mirror bodies.

[0070] In some embodiments, the foam is one or more of: (a) polyurethane foam; (b) polyethylene foam; (c) polystyrene foam; (d) polyisocyanurate foam; (e) thermosetting polymer (or plastic); (f) metal foam; (g) syntactic foam; (h) cellulose foam; and (i) high density urethane foam.

[0071] In at least one embodiment, the reflective material is one or more sheets of (a) metallized film; (b) biaxially oriented polyethylene terephthalate (BoPET); (c) polyester film made from oriented polyethylene terephthalate (PET); (d) metallized PET (polyester) film; (e) vacuum-metallized high-gloss PET film; (f) aluminized polyester film; and (g) metal-coated polymer film.

[0072] In some embodiments, the mirror array includes one or more of the previous embodiments, and optionally, a reflective material is applied to the front surface in a first state and subsequently transformed into a solid state.

[0073] In other embodiments, the mirror array includes one or more of the previous embodiments, and the reflective material optionally includes paint containing pigments that reflect light.

[0074] In at least one embodiment, one or more of the first and second mirror bodies includes: (a) a first portion formed from a rigid foam; and (b) a second portion defined by an insert formed from a second material, the insert defining a front surface of the mirror body.

[0075] In some embodiments, the reflective material conforms to the shape of the front surface.

[0076] In one or more embodiments, the reflective material is attached to at least one of the first and second mirror bodies with a chemical fastener, such as an adhesive.

[0077] In at least some embodiments, the reflective material is attached to at least one of the first and second mirror bodies with mechanical fasteners such as clips, staples, nails, and screws.

[0078] Additionally or alternatively, the mirror array may include one or more of the above embodiments, optionally with the reflective material held in place against the front surface by electrostatic charges.

[0079] In some embodiments, the reflective material is held in place against the front surface by suction.

[0080] In at least one embodiment, one or more of the rear surface, top surface, bottom surface, first side surface, and second side surface are coated with a material to maintain suction and prevent airflow through the coated surface.

[0081] In some embodiments, the mirror array comprises one or more of the previous embodiments, and the front surface may optionally have a shape suitable for collimating light scattered from a diffusing screen illuminated by the simulator's projector.

[0082] In at least one embodiment, the mirror array includes one or more of the preceding embodiments, wherein the front surfaces of the first and second mirror bodies have a shape that includes at least portions of a circle, a sphere, a parabolic shape, an ellipse, a flat shape, a freeform shape, and combinations thereof.

[0083] In at least some embodiments, the mirror array includes one or more of the preceding embodiments, wherein one or more of the first and second mirror bodies are formed from a rigid foam. Optionally, the rigid foam is at least partially porous.

[0084] Additionally or alternatively, in one or more embodiments, at least a portion of one or more of the mirror bodies of the mirror array is adapted to facilitate drawing air through the front surface, hi some embodiments, at least the front surface has a plurality of openings formed therein to facilitate airflow.

[0085] Another embodiment is a method of forming a mirror body for a simulator, comprising: (1) fabricating a substrate into a mirror body including a front surface having a geometry suitable for reflecting light originating from a projector of the simulator; and (2) coating the front surface with a reflective material to reflect light from the projector.

[0086] In one or more embodiments, the mirror body is rigid.

[0087] In some embodiments, the substrate is selected from the group consisting of: (a) polyurethane foam; (b) polyethylene foam; (c) polystyrene foam; (d) polyisocyanurate foam; (e) thermosetting polymers (or plastics); (f) metal foams; (g) syntactic foams; (h) cellulose foams; (i) high density urethane foams; (j) glass; (k) plastics; (l) fiberglass; (m) metals; (n) rubber; and (o) wood.

[0088] In some embodiments, the substrate comprises a rigid foam. Optionally, the rigid foam is at least partially porous.

[0089] In at least one embodiment, creating the substrate includes milling a block of substrate into the mirror body.

[0090] In several embodiments, creating the substrate includes one or more of: (i) machining a block of rigid foam; (ii) casting a material that hardens to form rigid foam; (iii) using an additive manufacturing process; and (iv) using an injection molding process.

[0091] In some embodiments, the method includes one or more of the preceding embodiments, further including smoothing the geometry of the front surface to an average surface roughness of about 0.23 μm to about 0.10 μm.

[0092] In some embodiments, the reflective material is one or more sheets of (a) metallized film; (b) biaxially oriented polyethylene terephthalate (BoPET); (c) polyester film made from oriented polyethylene terephthalate (PET); (d) metallized PET (polyester) film; (e) vacuum-metallized high-gloss PET film; (f) aluminized polyester film; and (g) metal-coated polymer film.

[0093] In some embodiments, coating the front surface with reflective material includes cutting a sheet to fit the front surface.

[0094] Additionally or alternatively, in one or more embodiments, coating the front surface with a reflective material includes attaching the reflective material to the mirror body with a chemical fastener.

[0095] The method may include one or more of the preceding embodiments, and optionally, in at least one embodiment, coating the front surface with a reflective material includes attaching the reflective material to the mirror body with mechanical fasteners.

[0096] In some embodiments, the mechanical fastener is one or more of a clip, staple, nail, and screw.

[0097] In some embodiments, the reflective material is held in place against the front surface by static electricity.

[0098] The method optionally further includes applying an electrostatic charge to one or more of the front surface and the reflective material.

[0099] Additionally or alternatively, in at least one embodiment, the reflective material is held in place against the front surface by suction.

[0100] In some embodiments, the method further includes drawing air through the front surface to create suction.

[0101] In some embodiments, the method may include one or more of the preceding embodiments and may include coating one or more of the rear surface, top surface, bottom surface, first side surface, and second side surface of the mirror body with a material to maintain suction through the front surface and prevent airflow through the coated surfaces.

[0102] In certain embodiments, the method includes one or more of the preceding embodiments, further including connecting a fitting for a hose to the mirror body.

[0103] In at least one embodiment, the method includes one or more of the preceding embodiments, further including connecting a hose of a vacuum pump to the fitting.

[0104] In some embodiments, the method includes one or more of the preceding embodiments, wherein coating the front surface further includes applying a reflective material to the front surface in a first state, wherein the reflective material subsequently changes to a solid state.

[0105] The method may include any one or more of the preceding embodiments, and optionally, the first state of the reflective material is a vapor or gaseous phase or state.

[0106] In some embodiments, the method includes one or more of the preceding embodiments, further including curing the reflective material.

[0107] In at least one embodiment, the method includes one or more of the preceding embodiments, wherein coating the front surface further includes applying a reflective material on the front surface in the first state.

[0108] In some embodiments, the reflective material is sprayed onto the front surface in the first state.

[0109] In one or more embodiments, the reflective material includes a paint having reflective properties.

[0110] In some embodiments, the paint includes pigments that reflect light.

[0111] In some embodiments, the method includes one or more of the preceding embodiments, wherein coating the front surface further includes applying the reflective material to the front surface by physical vapor deposition, during which the reflective material is in a gas phase.

[0112] In at least one embodiment, the method includes one or more of the preceding embodiments, wherein preparing the substrate further includes: (a) forming the substrate into a first portion of the mirror body; and (b) forming the second substrate into an insert that defines a second portion of the mirror body, the insert defining a front surface of the mirror body.

[0113] In some embodiments, the method includes one or more of the preceding embodiments, wherein coating the front surface further includes placing the insert in a vacuum chamber and transferring the reflective material to the front surface using physical vapor deposition.

[0114] In some embodiments, the method includes one or more of the preceding embodiments, wherein creating the substrate further includes creating a front surface geometry to collimate scattered light from a diffusion screen illuminated by a projector of the simulator.

[0115] In some embodiments, the method includes one or more of the preceding embodiments, wherein creating the substrate further includes creating the geometry of the front surface to include at least one of a circular, spherical, parabolic, elliptical, planar, freeform, and combinations thereof.

[0116] In some embodiments, the method includes one or more of the preceding embodiments, wherein preparing the substrate further includes adapting the mirror body to facilitate drawing air through the front surface. In some embodiments, the method further includes forming a plurality of openings through at least the front surface to facilitate airflow.

[0117] The Abstract is neither intended nor should be construed as being representative of the full extent and scope of the present disclosure. The present disclosure is described in various levels of detail in the Abstract, as well as in the accompanying Figures and Detailed Description, and no limitation on the scope of the disclosure is intended by either the inclusion or non-inclusion of elements, components, etc. in this Abstract. Further aspects of the present disclosure will become more apparent from the Detailed Description, particularly when taken in conjunction with the Figures.

[0118] As used herein, the phrases "at least one," "one or more," and "and / or" are open-ended expressions that are both conjunctive and separable in operation. For example, "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and / or C" mean A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B, and C together.

[0119] As used herein, "a" or "an" entity refers to one or more of that entity. Thus, "a" (or "an"), "one or more," and "at least one" can be used interchangeably herein.

[0120] Unless otherwise specified, all numbers expressing quantities, dimensions, conditions, ratios, ranges, and the like used in the specification and claims should be understood to be modified in all instances by the term "about" or "approximately." Thus, unless otherwise specified, all numbers expressing quantities, dimensions, conditions, ratios, ranges, and the like used in the specification and claims may be increased or decreased by about 5% to achieve satisfactory results. Additionally, if the meaning of the term "about" or "approximately" as used herein is not clear to persons of ordinary skill in the art, the term "about" or "approximately" should be interpreted to mean within plus or minus 5% of the stated value.

[0121] All ranges described herein may be modified to any subrange or portion of the range, or to any value within the range, without departing from the invention. For example, the range "5 to 55" includes, but is not limited to, the subranges "5 to 20" and "17 to 54."

[0122] As used herein, the terms "including," "comprising," or "having," and variations thereof, are meant to encompass the subsequently listed items and equivalents thereof, as well as additional items. Thus, the terms "including," "comprising," or "having," and variations thereof, can be used interchangeably herein.

[0123] As used herein, the term "means" should be understood to be accorded its broadest interpretation pursuant to 35 U.S.C. §112(f). Accordingly, any claim incorporating the term "means" will cover all structure, material, or acts described herein, and all equivalents thereof. Furthermore, structures, materials, or acts, and equivalents thereof, will include all that are described in the Abstract, Brief Description of the Drawings, Detailed Description, Abstract, and the claims themselves.

[0124] BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the disclosed systems and, together with the general description of the disclosure given above and the detailed description of the drawings below, serve to explain the principles of the disclosed systems and devices. [Brief explanation of the drawings]

[0125] [Figure 1] FIG. 1 is a schematic cross-sectional side elevation view of a simulator having a lightweight rigid mirror according to an embodiment of the present disclosure. [Figure 2] FIG. 2 is a front perspective view of the mirror array of the simulator of FIG. [Figure 3] FIG. 3 is a right side elevation view of the mirror array of FIG. [Figure 4] FIG. 4 is a plan view of the mirror array of FIG. [Figure 5] FIG. 5 is a front elevation view of the mirror array of FIG. [Figure 6] FIG. 6 is a perspective view of a mirror body of the mirror array of FIG. 2 according to an embodiment of the present disclosure. [Figure 7] 7 is a right side elevational view of the mirror body of FIG. 6. FIG. [Figure 8] FIG. 8 is a front elevational view of the mirror body of FIG. [Figure 9] FIG. 9 is a perspective view of a block of substrate used to form the mirror body. [Figure 10] FIG. 10 is another perspective view of the block of FIG. 9, showing the mirror body shown in hidden lines within the block. [Figure 11] FIG. 11 is a right side elevation view of a mirror body formed from two materials according to an embodiment of the present disclosure. [Figure 12] FIG. 12 is a flow chart illustrating a method for forming a mirror body according to an embodiment of the present disclosure. [Figure 13]FIG. 13 is a flow chart showing one example of a method for forming a mirror array for a simulator.

[0126] The drawings may not necessarily be to scale. In certain instances, details that are not necessary for an understanding of the present disclosure or that obscure other details may be omitted. Of course, it should be understood that the present disclosure is not necessarily limited to the specific examples shown herein. As will be recognized, other examples are possible using one or more of the features described above or below, alone or in combination. For example, it is contemplated that various features and devices shown and / or described with respect to one example example can be combined with, or substituted for, features or devices of other examples, regardless of whether such combination or substitution is specifically shown or described herein.

[0127] Below is a list of components according to various embodiments of the present disclosure and shown in the drawings. Number Component 2 Simulator 4 users 6. Light source (e.g., projector) 8 images 10 Collimated beam 12 screens 14 Mirror Array 16 Reflective surface (or reflective surface) 18 seams 20 Mirror body 22 Front 24 Rear 26 Top surface 28 bottom 30 First Aspect 32 The Second Aspect 34 Recessed part on the side of the mirror 36 Protrusion on the side of the mirror 38 Mount Points 40 reflective material 42 Sheets of reflective material 44 first edge of reflective material 46 Second edge of reflective material 48 Pump 50 Fitting 52 Conduit 54 blocks 56 Insert 60. Method for forming mirror body 62 Provision of substrate 64 Formation of substrate on mirror body 66 Finishing of mirror body surface as desired 68 Mirror surface coating 70 Connecting the fitting to the mirror body 72 Attaching hard points to the mirror body 74 Placement of reflective material on the front surface 80 Method for forming a mirror array 82 Provision of mirror body 84 Mirror body placement 86 Filling the seams between mirror bodies 88 Placement of reflective material on the mirror body DETAILED DESCRIPTION OF THE INVENTION Detailed Description of the Invention

[0128] 1, a simulator 2 according to an embodiment of the present disclosure will be generally described. The simulator 2 generally includes a projector 6, a screen 12, and a mirror array 14 facing the screen 12. A reflective surface 16 is formed on the mirror array. The reflective surface 16 is oriented toward the screen.

[0129] In use, projector 6 projects image 8 onto screen 12. Image 8 is viewed by user 4 as a reflection off mirror array 14. In an embodiment of the present disclosure, mirror array 14 is configured so that image 8 appears to user 4 as collimated light beams 10, viewed at a distant focus without distortion to the image. Collimated light beams 10 are substantially parallel to one another. This is achieved by projecting image 8 onto screen 12 by projector 6, with image 8 then reflecting off mirror array 14 and viewed by user 4.

[0130] 1, as will be appreciated by those skilled in the art, image 8 is back-projected onto the concave surface of screen 12 by projector 6. Projector 6 is positioned facing the concave surface of the screen. Also, in such an embodiment, image 8 is viewable on the opposing concave surface of screen 12 and is then reflected onto mirror array 14. In this embodiment, the concave surface of screen 12 has a diffusion coating or is treated to scatter light from projector 6. However, it will be understood by those skilled in the art that any arrangement of projector 6, screen 12, and mirror array 14 is within the scope of this disclosure. Furthermore, in some embodiments, mirror array 14 is configured to reflect light from projector 6 directly without first passing through screen 12.

[0131] When used in conjunction with a flight simulator 2, the image 8 visible to the user 4 may depict the external environment of an airplane or helicopter cockpit. The flight simulator 2 may include a control system having a processor and memory that stores flight simulation software that generates the image 8.

[0132] Although the mirror array 14 of the present disclosure is described with respect to a flight simulator 2, it will be appreciated that the mirror array can be used with any type of simulator, including, for example, simulators for mobile equipment and vehicles of all sizes and types, such as automobiles, trucks, trains, rail vehicles (e.g., tanks or construction vehicles), ships, and spacecraft. The mirror array can also be used with games or other simulation systems, as well as in theaters.

[0133] The mirror array 14 can have any size and geometry necessary to meet one or more of the collimation, geometric distortion, field of view, and other requirements of the simulator 2. In some embodiments, the mirror array 14 has one mirror body 20. However, in some embodiments, the mirror array includes at least two mirror bodies 20 with a gap or seam 18 between adjacent mirror bodies. The seam 18 is shown with a dashed line in FIG. 1 for illustrative purposes only. In the mirror arrays 14 of some embodiments of the present disclosure, the seams 18 are not visible to the user 4 because they are coated with the reflective material 40 described herein.

[0134] Any number of mirror bodies 20 can be a mirror array. Although only three mirror bodies 20A, 20B, and 20C are shown, with two seams 18A, 18B indicated by dashed lines, the mirror array 14 shown in FIG. 1 includes five mirror bodies. In other embodiments, the simulator 2 of the present disclosure can have a mirror array 14 that includes one mirror body with no seam, two mirror bodies and one seam, three mirror bodies and two seams, four mirror bodies and three seams, or six mirror bodies and five seams.

[0135] 2-8 , each mirror body 20 of the mirror array 14 is formed from a lightweight substrate. The mirror body 20 generally includes a front surface 22 opposing a rear surface 24, a top surface 26 opposing a bottom surface 28, and a first side surface 30 opposing a second side surface 32. The front surface 22 is fabricated (or shaped) to reflect light from the light source 6. More specifically, the front surface 22 has a shape to reflect the image 8 produced by the light source 6 from the screen 12 to the user 4.

[0136] The mirror body 20 may optionally include mounting points or hardpoints 38 for securing the mirror body to the frame of the simulator 2 and / or adjacent mirror bodies. The hardpoints 38 are shown schematically in Figures 6-8, although other positions and arrangements of hardpoints are contemplated. The hardpoints 38 may extend outward from the mirror body. Some hardpoints may be at least partially recessed into the mirror body.

[0137] In some embodiments, the front surface 22 may have any predetermined shape suitable for collimating light from the projector 6 to the user 4. Each mirror body 20 of the mirror array 14 may be curved or flat. The mirror array 14 may include a combination of mirror bodies 20 and front surfaces that are curved or flat.

[0138] In some embodiments, the front surface 22 is curved. For example, the front surface 22 can be generally concave, as shown in Figures 6-8. In another embodiment, the front surface 22 is convex. The front surface can have any desired shape selected to reflect light from the light source 6, including spherical, elliptical, freeform, flat, and other geometries known to those skilled in the art. In some embodiments, the front surface 22 of the mirror body 20 has a shape that includes at least one portion of a circle, a sphere, a parabolic shape, an elliptical shape, a flat, a freeform, and combinations thereof.

[0139] The front surface 22 of the mirror body, whether convex or concave, can have any desired radius of curvature. In some embodiments, the front surface 22 has a radius of curvature between about 9 feet and about 12 feet. Optionally, the radius of curvature is about 9.25 feet, about 10 feet, or about 11 feet. In other embodiments, the radius of curvature can be less than 9 feet or greater than 12 feet.

[0140] As generally shown in Figures 6-8, in some embodiments, the first and second sides 30, 32 of the mirror body 20 are generally oriented perpendicularly. In some embodiments, the first side 30 is a mirror image of (or coincides with) the second side 32. In addition, the sides 30, 32 are optionally planar. The sides 30, 32 may also be described as having a radial shape that is aligned with the center of curvature of the mirror array 14 such that the sides of adjacent mirror bodies 20 coincide with one another.

[0141] The radial sides 30, 32 may be approximately perpendicular to the front surface 22 or may be "plumb" to the front surface 22. Alternatively, the radial sides 30, 32 may be oriented at an oblique angle to the front surface 22, with the first side 30 oriented to the second side 32 at a complementary angle.

[0142] In another embodiment, the first and second side surfaces 30, 32 can have various shapes. For example, the first side surface 30 of the first mirror body can be fabricated to ensure a predetermined alignment with the second side surface 32 of the second mirror body. If desired, the adjacent side surfaces 30, 32 of the first and second mirror bodies can overlap in a manner similar to a "lap joint." Additionally or alternatively, the adjacent side surfaces 30, 32 of the mirror bodies can be fabricated to form a tongue and groove joint, a mortise and tenon joint, a dovetail joint, or other joints known to those skilled in the art.

[0143] In some embodiments, a dowel, pin, or other mechanical fastener may be used to join the first side 30 of the first mirror body to the second side 32 of the second mirror body. For example, a pocket may be formed in each mirror body adjacent the first and second sides. A mechanical fastener may then extend from the first pocket in the first mirror body to the second pocket in the second mirror body.

[0144] Additionally or alternatively, a protrusion (e.g., a flange or bracket) may extend from the rear surface 24 of each mirror body adjacent the first side 30 and / or the second side 32. Mechanical fasteners may then extend through the first protrusion of the first mirror body and through the second protrusion of the second mirror body.

[0145] In some embodiments, the first side 30 is adapted to lock with the second side. Specifically, in some embodiments, the first side has a shape or includes a feature configured to frictionally engage a feature on the second side.

[0146] Optionally, first side 30 may include a first bevel oriented at a first angle relative to front surface 22. Second side 32 of the second mirror may have a second bevel oriented at a second angle relative to the front surface. The first and second angles may be complementary angles.

[0147] Additionally or alternatively, in some embodiments, the first and second sides of adjacent mirror bodies 20 may be keyed to one another. For example, referring now to FIG. 8 , one of the first and second sides of the first mirror body 20 may include a recess 34 for receiving a protrusion 36 on the other of the first and second sides of the second mirror body. The recess 34 and protrusion 36 may have any shape, size, and orientation. In some embodiments, the recess is generally cylindrical, and the protrusion has a corresponding cylindrical shape. Additionally or alternatively, the recess may be a groove, and the protrusion is a corresponding tongue.

[0148] In another embodiment, the first side optionally includes a pin and the second side optionally includes a corresponding protrusion or "tail" similar to a dovetail. Other arrangements of the first and second sides of the mirror body are contemplated.

[0149] 2-5, in some embodiments, the mirror array 14 includes a first mirror body 20A having a first side 30A disposed adjacent to a second side 32B of a second mirror body 20B. A first seam 18A exists between the first and second mirror bodies.

[0150] 2-5 as being oriented substantially vertically, other arrangements and orientations of the seam 18 are contemplated. For example, in some embodiments, the mirror body 20 is stacked with a first mirror body at the bottom and a second mirror body disposed on top of the first mirror body. In this embodiment, the first seam 18 may be oriented substantially horizontally.

[0151] The first and second mirror bodies 20A, 20B may be bonded together as desired by any suitable method known to those skilled in the art. In some embodiments, the first mirror body is bonded to the second mirror body by chemical means, such as an adhesive or glue. Additionally or alternatively, the first and second mirror bodies may be interconnected using mechanical means, such as fasteners. In another embodiment, the first mirror body 20A is welded to the second mirror body 20B.

[0152] Optionally, the simulator includes a frame (not shown). The mirror bodies 20 of the mirror array may be interconnected to the frame such that adjacent mirror bodies are held at a predetermined orientation relative to one another. Other systems and methods for interconnecting and / or aligning adjacent mirror bodies 20 are contemplated.

[0153] The front surface 22 of the mirror body 20 is optionally treated to achieve a desired surface quality or precision. For example, the front surface may be mechanically prepared to a predetermined finish. The mechanical preparation may remove at least some material from the front surface.

[0154] In at least one embodiment, the front surface is polished (or sanded) to a predetermined finish. In some embodiments, the front surface 22 is polished with an abrasive material having a predetermined grit selected to achieve a desired average surface roughness Ra. In some embodiments, the abrasive material is 400-grit to 1,000-grit sandpaper to achieve an Ra of about 0.23 μm to about 0.10 μm.

[0155] Additionally or alternatively, a filler material may be applied to the front surface to modify the shape of the front surface 22. The filler material may be used to fill depressions or scratches in the front surface. In some embodiments, the filler material is a non-shrinkable polyester bulk filler such as Bond-O. Any suitable filler material known to those skilled in the art may be applied to the front surface of the mirror array.

[0156] Filler material may also be applied to fill the seam 18 between adjacent mirror bodies 20 to create a continuous, smooth surface. In some embodiments, the filler material is pressed into the seam 18 and assembled so that it is raised onto the front faces of the adjacent mirror bodies. Then, when the filler material hardens, it can be sanded down level with the front faces of the mirror bodies so that the filler material in the seam is smooth and in contact with the rest of the front faces. If necessary, this process can be repeated two or three times until the surface is substantially smooth to the desired surface quality or precision.

[0157] The front surfaces 22 of the mirror bodies 20 of the mirror array are coated with a reflective material 40 to reflect the image 8 from the projector 6. In this manner, the user 4 uses the reflective surfaces 16 of the mirror array 14 to view the image 8 (formed by the projector 6).

[0158] 5, a reflective material 40 is generally shown disposed on a mirror array 14 according to an embodiment of the present disclosure. In this embodiment, the reflective material 40 covers the seams 18 (shown in FIGS. 2-4) that would be present if the mirror array included two or more mirror bodies 20. In this manner, the reflective material 40 provides a reflective surface 16 for the mirror array without seams that would obstruct the image 8 produced by the projector 6.

[0159] Any suitable reflective material 40 may be used with the simulator of the present disclosure. The reflective material 40 may include a material that conforms to the shape of the front surface 22 of the mirror body 20.

[0160] In some embodiments, the reflective material is rigid. Alternatively, the reflective material 40 is flexible.

[0161] In some embodiments, the reflective material 40 is applied to the front surface in a first state (e.g., a liquid or gas state). After application to the front surface of the mirror body, the reflective material changes from the first state to a second state that is different from the first state. In the second state, the reflective material is dimensionally stable and includes suitable reflective properties. For example, the reflective material 40 can be a paste, gel coat, or paint that has reflective properties. The reflective material can include a pigment that reflects light. In some embodiments, the reflective material is cured to change from the first state to the second state.

[0162] The reflective material 40 may optionally be applied to the front surface of the mirror body by physical vapor deposition. In some embodiments, the front surface 22 of the mirror body may be treated to the desired smoothness by any suitable method known to those skilled in the art (e.g., by polishing and / or applying a filler material). The mirror body is then placed in a vacuum chamber with the reflective material in a cohesive state. The reflective material may include an aluminum alloy or another suitable metal in either a solid or liquid state.

[0163] The reflective material is then processed to convert it to a gas phase. While in the gas phase, the reflective material collects on the front surface (and on any coating on the first surface). The reflective material then returns to a condensed state as a thin film on the front surface of mirror body 20. One suitable physical vapor deposition method that can be used to apply the reflective material to front surface 22 is evaporative physical vapor deposition, although other suitable physical vapor deposition methods can be used.

[0164] In some embodiments, the reflective material 40 is a sheet 42 having a reflective surface. The sheet 42 has a width between a first edge 44 and a second edge 46. The first and second edges may be approximately parallel. However, the sheet may have any shape or geometric profile selected to cover the front surface 22 of one or more mirror bodies 20. In some embodiments, the sheet is cut into an irregular shape for placement on the front surface of the mirror body 20.

[0165] The sheet can have any desired thickness. In some embodiments, the sheet 42 has a thickness of about 0.1 mil (0.00254 mm) to about 30 mils (0.762 mm). In another embodiment, the thickness of the sheet 42 is about 1 mil (0.0254 mm) to about 3 mils (0.0762 mm).

[0166] Sheet 42 can be of any thickness, but mirror body front surface 22 may require different finishing based on thickness. For example, if sheet 42 is less than about 3 mils (0.0762 mm) thick, front surface 22 may need to be smoothed to reduce the surface roughness of the mirror body to a greater extent than for thicker sheets. Optionally, a coating or fill material is applied to the front surface if sheet 42 is less than a predetermined thickness.

[0167] Any sheet 42 having a suitable reflective surface may be used with the mirror arrays of the present disclosure. Examples of suitable materials that may be used to form the sheet 42 of reflective material 40 include, but are not limited to, metallized films, biaxially oriented polyethylene terephthalate (BoPET), polyester films made from oriented polyethylene terephthalate (PET), metallized PET (polyester) films, vacuum-metallized high-gloss PET films, aluminized polyester films, and metal-coated polymer films. One example of a sheet 42 is Mylar®. Other materials having a reflective surface of suitable optical quality may be used to form the sheet 42.

[0168] In some embodiments, one sheet 42 of reflective material 40 is disposed on the front surface 22 of the mirror body 20 to define the reflective surface 16 of the mirror array 14. The sheet 42 may be stretched if necessary to reduce or remove wrinkles or bubbles. For example, stretching or other mechanical means may be used to draw the sheet 42 tightly into alignment with the front surface.

[0169] In some embodiments, the frame is formed with a surface having a shape that is the negative of the front surface 22 of the mirror array. The reflective surface of the reflective material 40 is placed against the fabricated surface of the frame. The frame with the reflective material is then placed in a predetermined alignment with the front surface 22, and subsequently the frame is removed and the reflective material is placed in position over the mirror array 14.

[0170] Alternatively, two or more sheets 42 of reflective material may be used to cover the front surface 22. If desired, the two or more sheets 42 are bonded together by any suitable method.

[0171] In some embodiments, the first edge 44 of the first sheet 42 is positioned proximate to the second edge 46 of the adjacent second sheet 42. The first edge 44 is optionally positioned less than 0.125 inches (3.175 mm) from the second edge 46. For example, the first edge can be less than about 0.060 inches (1.524 mm) or less than about 0.015 inches (0.381 mm) from the second edge. In some embodiments, the first edge is between about 0.005 inches (0.127 mm) and about 0.125 inches (3.175 mm) from the second edge. Optionally, at least a portion of the first edge abuts or is adjacent to the second edge 46.

[0172] Additionally or alternatively, a portion of the first sheet 42 may overlap and cover the adjacent second sheet. In some embodiments, a portion of the front surface 22 of one or more mirror bodies 20 may be removed below the overlapping portion of the two sheets 42 to ensure that no extraneous sheet protrudes above the designed shape of the front surface. More specifically, material of the mirror body 20 may be removed from the front surface 22 to occupy twice the thickness of the overlapping portion of the two sheets 42 to maintain the surface precision of the mirror array 14. In some embodiments, sand may be abraded or otherwise mechanically worked against the portion of the front surface below the two overlapping sheets 42 to remove material to a depth equal to the thickness of one sheet 42 of reflective material.

[0173] Additionally or alternatively, if two sheets 42 overlap, the sheets may be cut at the overlapping portion. The cut ends of the sheets may then be removed, leaving an adjacent seam (or joint) between the two sheets 42.

[0174] If the sheets 42 are too thick, the overlap of two sheets 42 of reflective material 40 may cause distortion visible to a user. Therefore, for thicker sheets, it may be beneficial to position the first and second edges 44, 46 of two adjacent sheets 42 adjacent to one another without overlapping to prevent distortion in the reflective surface 16 caused by overlapping edges. However, if the sheets 42 are less than about 5 mils (0.127 mm), or less than about 3 mils (0.0762 mm), the overlapping edges 44 and 46 of adjacent sheets 42 and the resulting doubling of the thickness of the sheets is not expected to cause distortion visible to a user 4.

[0175] The distance that the first edge 44 of the first sheet 42 extends beyond the second edge 46 of the second adjacent sheet 42 is optionally limited to a predetermined amount to reduce the area that may cause distortion visible to the user. For example, the distance that the first sheet overlaps the second sheet may be limited to less than about 5 mm. In some embodiments, the first edge 44 of the first sheet 42 overlaps the second edge 46 of the second adjacent sheet by about 0.1 mm to about 5 mm.

[0176] The sheets 42 can be positioned on the mirror array 14 in any orientation. Each sheet 42 can cover one or more portions of the mirror body 20. Optionally, the sheets 42 are oriented generally horizontally, as shown generally in FIG. 5. In some embodiments, each sheet extends from a first side to a second side of the mirror array. In another embodiment, the sheets 42 are oriented generally vertically. Thus, the sheet of reflective material can span from the bottom to the top of the front surface 22. In another embodiment, the sheet of reflective material can have a diagonal orientation.

[0177] Edges 44, 46 of sheet 42 are shown with dashed lines in Figure 5 for clarity, however, as will be appreciated by those skilled in the art, after the sheet is placed on the mirror array, the edges will not be visible to user 4 as generally shown in Figures 2 and 4.

[0178] The reflective material 40 is disposed on the front surface 22 of the mirror body 20 in any suitable manner. In some embodiments, the reflective material is attached to a portion of the mirror body. Optionally, an adhesive may be used to attach the reflective material to the mirror body. For example, an adhesive may be applied to the front surface 22 of the mirror body 20, and the sheet 42 may be attached to the front surface.

[0179] Additionally or alternatively, fasteners may be used to attach the sheet 42 to the mirror body 20. Any suitable fasteners known to those skilled in the art may be used. Thus, pins, fasteners, such as clips, staples, straps, thread, tape, nails, and screws may be used to attach the sheet 42 of reflective material 40 to the mirror body.

[0180] Optionally, electrostatic charges may additionally (or alternatively) be used to hold the sheet of reflective material 40 in place against the mirror body front surface 22. In some embodiments, an electrostatic charge is applied to one or more of the mirror array 14 and the sheet 42 to help hold the sheet in place against the mirror body front surface 22. In some embodiments, during installation of the reflective material 40, an electrostatic charge is applied to the sheet by any means known to those skilled in the art. For example, an operator may rub the sheet with an appropriate material to induce an electrostatic charge.

[0181] Additionally or alternatively, the sheet 42 of reflective material is held in place against the front surface 22 by suction. In this embodiment, a pump 48 is used to draw air through the front surface 22 of the mirror array and mirror bodies. The pump can be configured to apply any suitable amount of suction below atmospheric pressure. In some embodiments, a suction of between about 1 kPa and about 35 kPa below atmospheric pressure is used to hold the sheet in place.

[0182] In some embodiments, the mirror body 20 is formed from a material that is at least partially porous. In another embodiment, the material used to form the mirror body has a density that is less than the glass used to form prior art mirrors.

[0183] The material used to form the mirror body 20 can be a rigid foam. The rigid foam can have an open cell structure. Alternatively, the rigid foam has a closed cell structure. In some embodiments, the rigid foam is substantially dimensionally stable. As used herein, substantially dimensionally stable means that the material used to form the mirror body 20 can expand or contract by about 0.01% to about 0.5%, or less than about 0.1%.

[0184] Any suitable foam known to those skilled in the art may be used to form the mirror body 20. The mirror body 20 may include one or more of: (a) polyurethane foam; (b) polyethylene foam; (c) polystyrene foam; (d) polyisocyanurate foam; (e) thermosetting polymer (or plastic); (f) metal foam (e.g., aluminum foam); (g) syntactic foam including a composite of a first material (e.g., a metal, polymer, or ceramic matrix) and a second material (which may be one or more of hollow spheres and solid spheres); (h) cellulose foam; and (i) high-density urethane foam. In some embodiments, the mirror body 20 is formed from a tooling foam known to those skilled in the art.

[0185] The foam of the mirror body can have any desired density. In some embodiments, the foam has a density of about 3 lbs / ft 3 (48kg / m 3 ) ~ approx. 40 lbs / ft 3 (641 kg / m 3 ) or approximately 12 lbs / ft 3 (192 kg / m 3 )

[0186] If desired, mirror body 20 is adapted to facilitate drawing air through the front surface to create suction for sheet 42. For example, a plurality of perforations or openings may be formed through front surface 22 to facilitate airflow therethrough.

[0187] In some embodiments, at least a portion of the exterior surface of mirror body 20 is treated to prevent airflow therethrough. In this manner, suction is maintained (or concentrated) through front surface 22.

[0188] In some embodiments, one or more of the rear surface, top surface, bottom surface, first side surface, and second side surface are treated to prevent airflow. Any suitable method for preventing airflow may be used. The treatment may include applying a non-porous material to the exterior of the mirror body. In some embodiments, the non-porous material is metal, plastic, or wood.

[0189] Additionally or alternatively, the non-porous material can be a coating. In some embodiments, the coating is a paint or sealant that is applied to selected portions of the mirror body to prevent airflow therethrough.

[0190] Also, referring back to FIG. 1, the mirror body may include a valve or fitting 50 for connection to a conduit 52. The conduit 52 is connectable to a pump 48 that draws air through the mirror body 20. Although the fitting 50 is shown adjacent the rear surface 24 of the mirror body 20, air may be drawn from the mirror body through any of the rear, top, and bottom surfaces. For example, FIG. 7 shows an embodiment of a mirror body 20 having a fitting 50 for a pump 48 located on the bottom surface 28.

[0191] In operation, pump 48 draws through conduit 52 to create suction adjacent front surface 22. In some embodiments, pump 48 is operated substantially continuously. Alternatively, pump 48 may be operated only to initially position sheet 42 on mirror array 14. Thus, in some embodiments, pump 48 is not used during operation of simulator 2.

[0192] The mirror body 20 of the present disclosure may be formed by any means known to those skilled in the art. In some embodiments, the mirror body 20 is cast so that the front surface 22 has a predetermined shape. Alternatively, in another embodiment, the mirror body 20 is formed by an additive manufacturing process. In another embodiment, the mirror body 20 is formed by injection molding a plastic or rubber material.

[0193] 9-10, in an embodiment of the present disclosure, the mirror body 20 is formed by carving or machining a block 54 of suitable material. The block 54 can be of any size and shape.

[0194] In some embodiments, the blocks are formed from rigid foams, which may include, but are not limited to, one or more of polyurethane foam, polyethylene foam, polystyrene foam, polyisocyanurate foam, thermosetting polymer (or plastic), metal foam (e.g., aluminum foam), syntactic foam, cellulose foam, and high-density urethane foam.

[0195] Any suitable method of fabricating the mirror body 20 from the block 54 may be used. Optionally, the block 54 may be cut to form the mirror body. Additionally or alternatively, the block may be milled to remove material. In another embodiment, a laser is used to burn or cut material from the block.

[0196] In some embodiments, a computer numerically controlled (CNC) mill or similar device is used to remove material from block 54 to form mirror body 20. As will be appreciated by those skilled in the art, the surface of mirror body 20 may require additional processing after initial formation by a CNC mill or other tool. For example, front surface 22 may be polished or smoothed to mechanically remove some of the material of mirror body 20. In some embodiments, front surface 22 may be ground after initial formation. Additionally or alternatively, coatings or fillers may be applied to the front surface described herein.

[0197] 11, a mirror body 20' according to some embodiments of the present disclosure is generally shown. The mirror body 20' is formed from two or more different materials. For example, in some embodiments, a block 54 of a first material is formed as described herein. The first material is optionally a first foam. Portions of the block 54 are removed to form a first portion of the mirror body 20' having a top surface 26, a bottom surface 28, a first side surface 32, and a second side surface 32.

[0198] The second portion of the mirror body 20' is defined by an insert 56 formed from a second material. The insert 56 includes a front surface 22 having a predetermined shape.

[0199] The second material is different from the first material. Optionally, the second material has different material properties than the first material.

[0200] The second material can be a second foam. Additionally or alternatively, insert 56 can include one or more of a second foam, plastic, glass, or metal. In some embodiments, the first foam has a first density and the second foam has a second density that is higher than the first density.

[0201] Insert 56 may be formed by any suitable method, including one or more of casting, additive manufacturing, or any other method described herein. In some embodiments, portions of insert 56, such as front surface 22, are reconstructed by removing material by any suitable method, including grinding, milling, cutting, heating, etc.

[0202] In some embodiments, the insert 56 is cast onto the front surface of the block 54 to form the mirror body 20'. Alternatively, in another embodiment, the insert 56 is formed separately from the block 54. The insert is then bonded to the block 54 by any method known to those skilled in the art to form the mirror body 20'. In some embodiments, the insert 56 is attached or adhered to the block 54. Additionally or alternatively, mechanical fasteners can be used to interconnect the insert to the block.

[0203] Reflective material 40 is applied to the front surface 22 of insert 56 either before or after the insert is attached to block 54. Reflective material 40 can be any reflective material described herein or later developed.

[0204] In some embodiments, the reflective material 40 is a sheet 42. Alternatively, the reflective material is applied to the front surface by physical vapor deposition. In this embodiment, the reflective material may include a metal.

[0205] Forming the mirror body 20' from at least two materials offers several advantages. The first and second materials can be selected based on beneficial material properties. For example, the first material may be selected based on its suitability for a finishing method (e.g., machining or sanding). The first material may also be selected to provide a desired stiffness, smoothness, density, or porosity. Similarly, the second material may be selected to facilitate a fabrication method (e.g., casting).

[0206] In some embodiments, the second material is a foam selected to be cast to form the insert 56 with a front surface 22 that has a smoothness that requires little or no additional finishing. For example, the second material may not require polishing or coating to achieve the desired smoothness. Alternatively, the second material is glass or plastic.

[0207] Referring now to FIG. 12 , a method 60 of forming mirror bodies 20 for mirror array 14 of simulator 2 according to an embodiment of the present invention is generally illustrated. While the general order of operations of method 60 is shown in FIG. 12 , it will be understood by those skilled in the art that the operations of the method can be arranged and performed differently than that shown in FIG. 12 . Furthermore, while the operations of the method may be described sequentially, in fact many of the operations may be performed in parallel or simultaneously. Furthermore, some of the operations are optional and may not be performed. The operations of method 60 will be described with reference to the components described in conjunction with FIGS. 1-11 .

[0208] In operation 62, a substrate is provided that will form the mirror body 20. The substrate can be any suitable material that is substantially dimensionally stable after the mirror body is formed.

[0209] The substrate can be a liquid that is substantially rigid when set or cured. Alternatively, the substrate can be a solid. In some embodiments, the substrate is a porous material.

[0210] In some embodiments, the substrate is a foam. Any suitable foam may be used. For example, the substrate may include one or more of polyurethane foam, polyethylene foam, polystyrene foam, polyisocyanurate foam, thermosetting polymer (or plastic), metal foam, syntactic foam, cellulose foam, and high-density urethane foam.

[0211] If desired, two or more substrates may be used to form the mirror body 20'. In some embodiments, a first portion of the mirror body 20' is formed from a first material (or first substrate) and a second portion of the mirror body is formed from a different second material (or second substrate). A second substrate may be used to form the front surface 22 of the mirror body. The first substrate may be a first foam. The second substrate may include one or more of a second foam, plastic, glass, or metal.

[0212] In operation 64, the mirror body 20 is fabricated or formed from the substrate. Any suitable means may be used to form the mirror body 20 from the substrate. In some embodiments, the substrate is used in an additive manufacturing process to form the mirror body.

[0213] Additionally or alternatively, the mirror body 20 (or a portion of the mirror body) is cast from a substrate such that the front surface 22 has a predetermined shape. A mold or form may be used to cast the substrate into the mirror body. In some embodiments, after a first portion of the mirror body 20′ is formed from a first substrate, a second portion of the mirror body is formed by casting a second substrate over the first mirror body portion. In another embodiment, the second portion of the mirror body 20′ includes an insert 56 having a front surface 22 of a predetermined shape that bonds to the first mirror body portion.

[0214] In another embodiment, the substrate is a plastic or rubber material. In this embodiment, operation 64 includes molding the plastic or rubber substrate into mirror body 20. If desired, an injection molding process can be used to form the plastic or rubber substrate mirror body.

[0215] Additionally or alternatively, operation 64 may include forming the mirror body 20 by mechanically removing material. For example, a block 54 of substrate may be cut or milled to form the mirror body. The substrate may be any one or more of the forms described herein. If desired, a CNC machine or similar device may be used to form the mirror body from the block 54. Additionally or alternatively, a laser may be used to cut the block 54. A combination of two or more methods of forming the substrate described herein may be performed in any order or sequence to form the mirror body.

[0216] When forming the mirror body in operation 64, the front surface 22 of the mirror body 20 is formed to have a shape suitable for reflecting light from a light source 6, such as a projector, an LED panel, or an OLED screen. In some embodiments, the front surface 22 has a shape suitable for collimating light scattered from the diffusing screen 12 illuminated by the light source 6 of the simulator 2. Alternatively, the front surface can have a shape that reflects light when illuminated directly by the light source 6.

[0217] The front surface 22 can have any desired shape and geometry. For example, the front surface can have any combination of convex, concave, flat, and freeform shapes known to those skilled in the art. In some embodiments, the front surface 22 can have a shape that includes at least one portion of a circle, a sphere, a parabolic shape, an ellipse, a flat shape, a freeform shape, and combinations thereof.

[0218] Method 60 may include an optional operation 66 in which the surface of the mirror body is finished, which may include modifying the front surface 22 of the mirror body to obtain a desired surface quality.

[0219] In some embodiments, finishing operation 66 includes sanding the front surface. Any suitable abrasive material or product (e.g., sandpaper, grinding block, file, etc.) may be used. The abrasive material may optionally have a grit of about 400 to about 1,000. In another embodiment, the front surface may be treated with heat or a flame.

[0220] In optional operation 68, a coating may be applied to a surface of the mirror body. For example, a filler material may be applied to the front surface. The filler material may be a polyester body filler.

[0221] Additionally or alternatively, operation 68 may include applying a coating to one or more of the rear surface, top surface, bottom surface, first side surface, and second side surface of mirror body 20 to prevent airflow therethrough, in this manner preventing loss of suction through the front surface if a reflective material is placed on the front surface using a vacuum force, as described herein.

[0222] In some embodiments, the method 60 includes, in optional operation 70, connecting a fitting 50 to the mirror body. The fitting 50 is adapted to connect to a conduit 52 of a vacuum pump 48. In this manner, the vacuum pump 48 can draw air through the mirror body 20 to create a vacuum adjacent the front surface 22.

[0223] Operation 70 may also include perforating the mirror body 20 to create a vacuum adjacent to the front surface to facilitate airflow therethrough. More specifically, if the substrate used to form the mirror body 20 is not sufficiently porous, or if the coating or filler material applied to the front surface 22 is not porous, openings or perforations may be formed to facilitate airflow through the mirror body. In some embodiments, when the mirror body 20' is formed from two different substrates (e.g., a first substrate having a low density and a second substrate having a higher density), the perforations may be formed through at least the second substrate, such as an insert 56, bonded to a first portion of the mirror body.

[0224] The perforations may be formed by any suitable method, for example, they may be made mechanically (with a drill bit in a mill), with a laser, or with a fluid (e.g., a water jet or gas at high pressure).

[0225] Method 60 may optionally include operation 72, which includes attaching hardpoints 38 to the mirror body. Subsequently, hardpoints 38 may be used to connect the mirror body to a second mirror body. Additionally or alternatively, the hardpoints may be connected to a frame or support of the simulator.

[0226] Operation 74 includes disposing reflective material 40 on the front surface 22 of the mirror body 20. In some embodiments, the reflective material is disposed on the front surface before the mirror body 20 is positioned adjacent to a second mirror body in the mirror array 14. Alternatively, the reflective material 40 is disposed on the front surface after the mirror body is positioned adjacent to the second mirror body.

[0227] In some embodiments, the reflective material 40 is in a first state (e.g., a liquid or paste) when applied to the front surface 22 of the mirror body 20. Subsequently, the reflective material 40 transforms into a solid after being applied to the front surface.

[0228] Alternatively, the reflective material 40 is a sheet 42 having a reflective surface. The method includes cutting the sheet 42 to fit the front surface, if desired.

[0229] In some embodiments, the method includes bonding a first sheet of reflective material to a second sheet of reflective material. Any suitable means may be used to bond the first and second sheets.

[0230] The first edge of the first sheet may be disposed adjacent to the second edge of the second sheet. Optionally, the first edge of the first sheet overlaps the second sheet.

[0231] In some embodiments, adhesive is used to hold the reflective material 40 in a predetermined orientation against the front surface 22. Additionally or alternatively, mechanical fasteners are used to position the reflective material against the front surface. In at least some embodiments, static electricity is used to hold the reflective material on the front surface. In yet another embodiment, a vacuum is used to hold the reflective material against the front surface.

[0232] In some embodiments, operation 74 includes disposing a reflective material 40 on the insert 56. The reflective material can be a sheet 42 applied to the insert. Alternatively, the reflective material is applied to the front surface 22 of the insert 56 by physical vapor deposition. Any reflective material suitable for use in physical vapor deposition may be used. In some embodiments, the reflective material 40 is metal. The reflective material may be disposed on the insert 56 before or after the insert is attached to the first portion of the mirror body 20'.

[0233] Referring now to FIG. 13 , a method 80 of forming a mirror array 14 of a simulator 2 according to an embodiment of the present invention is generally illustrated. While the general order of operations of method 80 is shown in FIG. 13 , it will be understood by those skilled in the art that the operations of the method may be arranged and performed differently than that shown in FIG. 13 . Furthermore, while the operations of the method may be described sequentially, in fact many of the operations may be performed in parallel or simultaneously. Furthermore, some of the operations are optional and may not be performed. The operations of method 80 will be described with reference to the components described in conjunction with FIGS. 1-12 .

[0234] Operation 82 includes providing one or more mirror bodies 20. The mirror bodies are at least partially formed from a lightweight substrate as described herein. In some embodiments, the lightweight substrate is foam. Optionally, two or more substrates are used to form the mirror body 20'. The mirror bodies may be formed by method 60.

[0235] In operation 84, a first mirror body is positioned adjacent to a second mirror body. The mirror bodies are positioned in a predetermined orientation. If desired, the first and second mirror bodies 20 are interconnected or bonded together in any suitable manner. Additionally or alternatively, the mirror bodies may be interconnected to the frame of the simulator.

[0236] In optional operation 86, the seam 18 between adjacent mirror bodies may be filled. Any suitable filler material may be used to fill the seam. In some embodiments, operation 86 includes grinding the filler material after it has set so that it is substantially even with the front surfaces of adjacent mirror bodies 20.

[0237] Operation 88 includes disposing a reflective material on the front surface 22 of the mirror bodies 20. The reflective material covers the seams 18 between adjacent mirror bodies 20.

[0238] The reflective material 40 may be a liquid or a paste when applied to the front surface 22 of the mirror body 20. The liquid or paste then hardens to a solid state.

[0239] Alternatively, the reflective material 40 is a sheet 42 having a reflective surface. The method may include cutting a sheet of reflective material. Optionally, two or more sheets of reflective material are used to cover the front surface. In some embodiments, the method includes bonding a first sheet of reflective material to a second sheet.

[0240] In some embodiments, a chemical fastener is used to hold the reflective material in a predetermined orientation relative to the front surface. The chemical fastener may be an adhesive.

[0241] Additionally or alternatively, the reflective material is positioned against the front surface using mechanical fasteners, which may be clips, staples, nails and screws or any other mechanical fastener known to one skilled in the art.

[0242] In some embodiments, static electricity is used to hold the reflective material on the front surface, and in still other embodiments, a vacuum is used to attract the reflective material to the front surface.

[0243] In another embodiment, operation 88 includes attaching an insert 56 to a first portion of the mirror body 20'. The insert 56 may include a reflective material 40 disposed on the first surface 22 of the insert before the insert is attached to the first portion of the mirror body. In some embodiments, the insert 56 is formed from glass or plastic. Alternatively, the insert 56 is formed from foam. The front surface 22 of the insert may be coated with the reflective material 40 by any suitable means. In some embodiments, the reflective material includes a metal, such as aluminum, applied to the front surface by physical vapor deposition.

[0244] The mirror array 14 of the present disclosure offers numerous advantages over prior art mirror arrays. For example, the mirror array 14 of all embodiments of the present disclosure will have significantly less distortion across the reflective surface 16 than a vacuum-formed mirror due to the rigid backing provided by the front surface 22 of the mirror body 20. Specifically, the front surface 22 provides support to the reflective material 40 so as to maintain the shape of the reflective surface 16 all the way to the edges of the mirror array 14. In contrast, the reflective surface of a vacuum-formed mirror is distorted because the reflective material is sucked into the hollow interior of the frame.

[0245] Vacuum-formed mirrors are also prone to tears (or rips) or sudden decompression "popping" events. These tears can cause catastrophic failure of the vacuum-formed mirror and require significant time to repair. In contrast, the mirror array 14 of the present disclosure is much more durable because there is no vacuum required to create the mirror. For example, a tool dropped on the mirror array 14 can cause a small divot in the mirror body 20. However, this damage can be repaired with a filler such as Bond-O or a similar material.

[0246] Additionally, the mirror array 14 of the present disclosure is easier to repair than vacuum-formed mirrors. Specifically, the reflective surface 16 of the mirror array 14 can be repaired or replaced without disassembly or removal of the structural components of the mirror array and / or the simulator's motion platform. This is beneficial because if the reflective surface 16 degrades due to dust accumulation, handprints, scratches, etc., the reflective material 40 can be removed and replaced, akin to wallpapering a room, without significant disassembly of the simulator 2 or mirror array 14.

[0247] Another benefit is that the mirror array 14 of the present disclosure is significantly lighter than prior art mirror arrays of similar dimensions formed from rigid glass mirrors. The mirror body 20 of the present disclosure can be formed from a material having a density that is less than the density of the glass substrate and supporting metal frame used to form the rigid glass mirror. As will be appreciated by those skilled in the art, the supporting metal frame of a rigid glass mirror can be more than half the total weight of the mirror array for the rigid glass mirror. In some embodiments, the mirror array of the present disclosure weighs less than half the weight of a similarly classified rigid glass mirror array. The reduced weight of the mirror array of the present disclosure reduces shipping and handling costs, reduces the cost of simulator construction, and reduces maintenance costs.

[0248] Additionally, the mirror array 14 of the present disclosure requires significantly less manufacturing time and cost than prior art mirror arrays having rigid glass mirrors of similar size and geometry. Specifically, the mirror array 14 described herein eliminates the glass mirror grinding, polishing, dimensioning, mirror frame mounting, and vacuum chamber coating required to manufacture prior art mirror arrays.

[0249] Compared to the rigid glass mirrors of prior art mirror arrays, the mirror array 14 of the present disclosure will have a very low risk of shipping damage because the mirror bodies 20 can be shipped separately and without painting with reflective material. The mirror bodies 20 can be assembled to form the mirror array 14 at the site, and then the reflective material 40 can be "skinned." Thus, the reflective surface 16 of the mirror array will not be damaged during shipping of the mirror bodies. Any incidental scratches to the fabricated front surface 22 of the mirror body 20 can be repaired with filler and then polished, if necessary, to match the original shape.

[0250] In some embodiments, a sheet 42 of reflective material 40 can be pre-cut to the geometry required to cover the front surface 22 of the mirror body 20. The pre-cut sheet 42 can then be transported to a protected installation location inside a shipping tube. In this way, the reflective surface of the sheet 42 is protected from incidental damage and dust.

[0251] Another benefit of the mirror array 14 of some embodiments of the present disclosure may be the absence of visible seams between adjacent mirror bodies 20. In contrast, prior art mirror arrays with rigid glass mirrors have visible seams due to air gaps between the glass mirror segments. Some prior art rigid glass mirror arrays have seam gaps of at least 0.06 inches (1.524 mm) between the glass mirror segments. These seams create visible lines that interfere with the image reflected from the mirror array. In some embodiments of the present disclosure, the seams between adjacent mirror bodies 20 are less than 0.06 inches (1.524 mm). For example, in embodiments of the present disclosure, the seams between adjacent mirror bodies may be between about 0.01 inches (0.254 mm) and about 0.06 inches (1.524 mm), or about 0.03 inches (0.762 mm).

[0252] Another benefit of the present disclosure is the ability to create collimating mirrors for the simulator 2 that are non-spherical, which is not possible using conventional methods of vacuum-formed film mirrors or glass substrate mirrors. When using a spherical concave mirror as the collimating mirror, the vertical field of view is limited to just above 60° because the optical layout is a compromise between unobstructed field of view, proper collimation, and acceptable distortion. However, collimated light is best created when the mirror is parabolic, like the mirrors in searchlights and lighthouses. When creating mirrors for collimated viewing using the present disclosure, the shape can be spherical, or the shape can be any combination of parabolic, elliptical, or freeform, which results in a larger field of view than is possible with a spherical mirror, or has better collimation and distortion performance for the same field of view.

[0253] While various embodiments of the systems and methods have been described in detail, it will be apparent that variations and modifications of these embodiments will occur to those skilled in the art. It is to be clearly understood that such variations and modifications are within the scope and spirit of the present disclosure. Furthermore, it is to be understood that the phraseology and terminology used herein is for descriptive purposes and should not be regarded as limiting. As used herein, the words "including," "comprising," "having," and variations thereof are meant to encompass the items listed thereafter and equivalents thereof, as well as additional items. Furthermore, it is to be understood that the claims are not necessarily limited to the specific features or steps described herein. Rather, the specific features and steps are disclosed as example forms of implementing the claimed systems and methods.

[0254] It should be recognized that any feature described herein may be claimed in combination with other features described herein, regardless of whether the features are from the same described embodiment. Specifically, features of one aspect or embodiment of the present disclosure may be combined with other aspects or embodiments disclosed herein. Thus, it is contemplated that various aspects, features, and devices shown and / or described with respect to one embodiment may be combined with (or substituted for) aspects, features, or devices of the other embodiments, whether or not such combination or substitution is specifically shown or described herein.

[0255] To provide additional background, context, and to further satisfy the written description requirements of 35 U.S.C. § 112, the following references are hereby incorporated by reference in their entireties: U.S. Patent No. 3,549,803; U.S. Patent No. 6,176,588; U.S. Patent No. 6,206,531; U.S. Patent No. 7,708,561; U.S. Patent No. 10,422,933; U.S. Patent Application Publication No. 2004 / 0121193; U.S. Patent Application Publication No. 2006 / 0012895; U.S. Patent Application Publication No. 2008 / 0043352; U.S. Patent Application Publication No. 2015 / 0378128; U.S. Patent Application Publication No. 2022 / 0011480.

Claims

1. A projector; a diffusion screen; and a mirror array having a reflective surface oriented in the direction of the diffusing screen, wherein the projector is configured to project an image onto the diffusing screen, the image being viewable by a user as a reflection on the reflective surface of the mirror array; Including, the mirror array further comprises: a first mirror body; a second mirror body disposed adjacent to the first mirror body; wherein each of the first and second mirror bodies is formed from a rigid foam and includes a front surface, a rear surface, a top surface, a bottom surface, a first side surface, and a second side surface, and the shape of the front surface of each mirror body is suitable for collimating light scattered from the diffusing screen when illuminated by the projector; and a reflective material forming the reflective surface of the mirror array; wherein the reflective material extends beyond a first side of the first mirror body onto the second mirror body, the reflective material coats the front surfaces of the first and second mirror bodies, the reflective material coats a seam between the first and second mirror bodies, and the reflective material is one or more of: (a) a metallized film; (b) biaxially oriented polyethylene terephthalate (BoPET); (c) a polyester film made from stretched polyethylene terephthalate (PET); (d) a metallized PET (polyester) film; (e) a vacuum metallized high gloss PET film; (f) an aluminized polyester film; or (f) a metal coated polymer film; A simulator having a mirror array, wherein the reflective material is attached to a first mirror body and a front surface of the first mirror body with a chemical fastener such that the reflective material conforms to the shape of each front surface.

2. The simulator of claim 1 , wherein the chemical fastener is an adhesive.

3. The simulator of claim 1 , wherein the reflective material has a thickness of about 0.00254 mm to about 0.762 mm.

4. A simulator as described in claim 1, wherein the front surfaces of the first and second mirror bodies have an average surface roughness of approximately 0.23 μm to approximately 0.10 μm.

5. The simulator of claim 1 , wherein the rear surfaces of the first and second mirror bodies are formed from rigid foam.

6. A simulator as described in claim 1, wherein the front surfaces of the first and second mirror bodies include a coating of filler material configured to smooth the front surfaces, and the filler material is positioned between each front surface and a reflective material.

7. The simulator of claim 6 , wherein the filler material is a non-shrink polyester material.

8. 10. The simulator of claim 1, wherein the rigid foam is one or more of polyethylene foam, polystyrene foam, polyisocyanurate foam, thermosetting polymer (or plastic), metal foam, syntactic foam, cellulose foam, and high density urethane foam.

Images