Curved reflective mirror and manufacturing method thereof
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Solution Overview
Problem
Existing curved reflective mirrors for solar energy applications have poor light concentrating performance, low reflection precision, and short service life due to manual gluing methods, high manufacturing costs, and inconsistent thermal expansion coefficients, making them unsuitable for large-scale production.
Innovation Solution
A curved reflective mirror is manufactured using a flat glass structure, an intermediate adhesive layer, and a flat glass mirror, which are curved and deformed mechanically with a mold, then solidified and bonded together using heating or UV radiation, eliminating the need for hot bending technology and ensuring consistent thermal expansion coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual gluing method is used to stick multiple small glass lenses to curved glass, then the curved mirror can be manufactured, but the mirror surface has poor light concentrating performance and low reflection precision
Solution Approach 1:
The patent divides the curved mirror manufacturing into two separate stages: first manufacturing a flat glass mirror with high precision reflecting surface, then bending the entire mirror to form the curved shape. This segmentation allows each stage to optimize for its specific requirement - flat polishing for reflection precision and bending for curvature formation.
Solution Approach 2:
The patent performs the critical flat glass mirror polishing and reflecting surface coating as a preliminary action before bending. This ensures that the high-precision optical surface is created when the glass is still flat and easier to work with, before the complex curvature is introduced.
2Shape
If high-temperature thermal deformation manufacturing method is used, then curved glass can be formed, but the manufacturing cost is quite high
Solution Approach 1:
The patent replaces the thermal deformation process with a mechanical bending process. Instead of heating glass to softening temperature to form curves, the patent uses mechanical force to bend the already-manufactured flat glass mirror into the desired curved shape, significantly reducing energy consumption and manufacturing cost.
3Ease of manufacture
If mechanical cold deformation manufacturing method is used, then the manufacturing cost is lower, but the mirror holder and curved reflective mirror have inconsistent temperature expansion coefficients causing corrosion
Solution Approach 1:
The patent achieves homogeneity by making the entire curved reflective mirror from a single piece of glass through bending, eliminating the need for separate mirror holder components made from different materials. This single-material construction ensures consistent thermal expansion coefficients throughout the structure.
Solution Approach 2:
The patent creates a composite structure where the curved glass mirror itself serves as both the reflective surface and the structural support, integrating functions that would otherwise require separate components with different material properties.
4Ease of manufacture
If mechanical cold deformation method is used with adhesive fixing, then manufacturing cost is lower, but the protective paint on the back of the mirror is exposed to air causing reflecting layer corrosion
Solution Approach 1:
The patent introduces a protective film or coating on the back surface of the bent glass mirror to seal and protect the reflecting layer from environmental exposure, while maintaining the mechanical bending process for cost-effectiveness.
5Adaptability or versatility
If flat glass mirror is cut into multiple small pieces and stuck to curved glass, then the curved mirror can be assembled, but it involves many complicated procedures requiring much labor and time
Solution Approach 1:
The patent segments the manufacturing process into flat mirror production and bending operations, but keeps the mirror as a single piece throughout, avoiding the segmentation of cutting and reassembly that reduces productivity.
Solution Approach 2:
The patent changes the physical state and shape parameters of the glass mirror through controlled bending, transforming a flat mirror into a curved mirror without changing the material composition or requiring disassembly and reassembly operations.
6Manufacturing precision
If uniform glue application is not achieved, then the surface appearance of the reflective mirror may be bad and reflection precision may become low
Solution Approach 1:
The patent performs the critical optical surface preparation and reflecting surface creation as preliminary actions on the flat glass mirror before bending, ensuring high reflection precision is achieved when the glass is still flat and easier to work with, eliminating the need for precise glue application on curved surfaces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a reflective mirror with excellent light concentrating performance, high reflection precision, improved mechanical strength, and extended service life, facilitating large-scale production and ensuring stability and durability for outdoor use.
Implementation Method 1
the curved and deformed flat glass structure, intermediate adhesive layer, and flat glass mirror are solidified and bonded together in a heating and/or ultraviolet (UV) light radiation and/or room temperature solidification manner
Implementation Method 2
the curved and deformed flat glass structure, intermediate adhesive layer, and flat glass mirror are solidified and bonded together in a heating and/or ultraviolet (UV) light radiation and/or room temperature solidification manner
Implementation Method 3
the flat glass structure, the intermediate adhesive layer, and the flat glass mirror are curved and deformed in a mechanical manner with the support of a mold
Data Source
AI summary
A curved reflective mirror includes a flat glass structure, an intermediate adhesive layer, and a flat glass mirror. The intermediate adhesive layer is positioned between the flat glass structure and the flat glass mirror. The flat glass structure, the intermediate adhesive layer, and the flat glass mirror are curved and deformed in a mechanical manner with the support of a mold. The curved and deformed flat glass structure, intermediate adhesive layer, and flat glass mirror are solidified and bonded together in a heating and/or ultraviolet (UV) light radiation and/or room temperature solidification manner to form a composite curved structure. Also provided is a method for manufacturing a curved reflective mirror. The curved reflective mirror can be widely applied in the fields of solar thermal collection and concentration and solar thermal power generation.