US4465734A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Composite mirror panels
Assignee: AGC Glass Europe SA
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Filing: 1982-05-04
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Granted: 1984-08-14
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Expires: 2002-05-04
Abstract
Abstract A method of manufacturing a composite which includes a mirror panel comprising the steps of water-tightly bonding a first backing sheet made of waterproof material to the rear side of a mirror including a vitreous sheet bearing a radiation-reflecting coating on its rear side, thereby forming a mirror/backing sheet laminate; locating the laminate and a second backing sheet between a pair of dies with the laminate and the second backing positioned in spaced relationship; injecting the space between the laminate and the second backing sheet with a foamable plastic material; allowing or causing the foamable plastic material to foam and thereby press the laminate and the second backing sheet into close conformity with the respective die faces and, allowing or causing the foam to set and adhere to each backing sheet while the laminate and second backing sheet are pressed against the die faces to form a substantially rigid composite sandwich structure.
Inventors
- 👤 Pierre Laroche
- 👤 Francois Toussaint
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-25 23:43
CPC Classifications
B; B32; B32B; B32B5/00; B32B5/18; B32B5/20; B29; B29C; B29C44/00; B29C44/02; B29C44/12; B29C44/1228; B29C44/1233; B29C44/14; B29C44/16; B29D; B29D11/00; B29D11/00596; B32B15/00; B32B15/04; B32B15/046; B32B15/18; B32B17/00; B32B17/06; B32B17/061; B32B17/10; B32B17/10005; B32B17/10165; B32B17/10174; B32B17/10807; B32B17/10889; F; F24; F24S; F24S23/00; F24S23/70; F24S23/82; B32B2266/00; B32B2266/02; B32B2266/0214; B32B2266/0278; B32B2266/08; B32B2551/00; B32B2551/08; Y; Y02; Y02E; Y02E10/00; Y02E10/40; Y10; Y10T; Y10T156/00; Y10T156/10; Y10T156/1002; Y10T156/1043; Y10T156/1044; Y10T428/00; Y10T428/24; Y10T428/24008; Y10T428/24942; Y10T428/2495; Y10T428/24967; Y10T428/249921; Y10T428/249953; Y10T428/249982; Y10T428/249987
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
145 words
A method of manufacturing a composite mirror panel comprising the steps of: water-tightly bonding a first backing sheet made of waterproof material to the rear side of a mirror including a vitreous sheet bearing radiation-reflecting coating on its rear side, thereby forming a mirror/backing sheet laminate; locating the laminate and a second backing sheet between a pair of dies with the laminate and the second backing sheet positioned in spaced relationship; injecting the space between the laminate and the second backing sheet with a foamable plastic material; allowing the foamable plastic material to foam and thereby press the laminate and the second backing sheet into close conformity with the respective die faces and, allowing the foam to set and adhere to each backing sheet while the laminate and second backing sheet are pressed against the die faces to form a substantially rigid composite sandwich structure.
Claim 2
Independent Claim
145 words
A method of manufacturing a composite mirror panel comprising the steps of: water-tightly bonding a first backing sheet made of waterproof material to the rear side of a mirror including a vitreous sheet bearing radiation-reflecting coating on its rear side, thereby forming a mirror/backing sheet laminate; locating the laminate and a second backing sheet between a pair of dies with the laminate and the second backing sheet positioned in spaced relationship; injecting the space between the laminate and the second backing sheet with a foamable plastic material; allowing the foamable plastic material to foam and thereby press the laminate and the second backing sheet into close conformity with the respective die faces and, allowing the foam to set and adhere to each backing sheet while the laminate and second backing sheet are pressed against the die faces to form a substantially rigid composite sandwich structure.
Claim 3
Dependent Claim
18 words
The method according to claim 1, wherein said vitreous sheet has a thickness no greater than 1.5 mm.
Claim 4
Dependent Claim
25 words
The method according to claim 1, wherein each of the backing sheets has a Young's modulus of elasticity of at least 10 GN/m 2 .
Claim 5
Dependent Claim
15 words
The method according to claim 3, wherein at least the first backing sheet is metal.
Claim 6
Dependent Claim
16 words
The method according to claim 4, wherein at least one of the backing sheets is steel.
Claim 7
Dependent Claim
23 words
The method according to claim 4 or 5, wherein the first backing sheet has a thickness in the range 0.5 to 1.0 mm.
Claim 8
Dependent Claim
23 words
The method according to claim 1, wherein the vitreous sheet and the first backing sheet are bonded together to form a flat laminate.
Claim 9
Dependent Claim
54 words
The method according to claim 7, wherein the first backing sheet and the vitreous sheet are bonded together to form a flexible laminate having a neutral bending surface lying outside the thickness of the vitreous sheet when the laminate is flexed within the elastic limit of its component sheets to form a concave reflector.
Claim 10
Dependent Claim
37 words
The method according to claim 8 wherein: one die face is convexly curved; the laminate is placed against the convexly curved die face and is forced into conformity therewith by the pressure generated during the foaming process.
Claim 11
Dependent Claim
16 words
The method according to claim 1, wherein the foamable material will generate a closed cell foam.
Claim 12
Dependent Claim
15 words
The method according to claim 1, wherein the foamable material will generate a polyurethane foam.
Claim 13
Dependent Claim
22 words
The method according to claim 1, wherein the density of the foam layer formed is between 50 and 80 kg/m 3 .
Claim 14
Dependent Claim
25 words
The method according to claim 1, wherein the foam when set has a compressive strength at 10% deflection of at least 50 N/cm 2 .
Claim 15
Dependent Claim
25 words
The method according to claim 1, wherein the foam when set has a compressive strength at 10% deflection of at most 200 N/cm 2 .
Claim 16
Dependent Claim
20 words
The method according to claim 1, wherein the thickness of the foam layer formed is between 30 and 55 mm.
Claim 17
Dependent Claim
37 words
The method according to claim 1, further including the step of priming at least one of the backing sheets prior to the step of injecting the foamable plastic material to promote adhesion of the foam plastic material.
Claim 18
Dependent Claim
29 words
The method according to claim 1, including maintaining the backing sheets in spaced relation, prior to the injection of said foam, by one or more spacer members disposed therebetween.
Claim 19
Dependent Claim
40 words
The method according to claim 1, further including: prior to injection of the foamable material, maintaining the laminate and the second backing sheet in spaced apart relationship by projections formed at edges of at least one of the backing sheets.
Claim 20
Dependent Claim
16 words
The method according to claim 18, wherein the backing sheets and projections form a box structure.
Claim 21
Dependent Claim
23 words
The method according to claim 1, further including attaching a means for mounting the panel to a support to the second backing sheet.
Claim 22
Dependent Claim
35 words
The method according to claim 1, further including embedding a means for mounting the panel to a support in the foam so that the means bears on the front face of the second backing sheet.
Claim 23
Dependent Claim
10 words
A panel made by the method according to claim 1.
Claim 24
Dependent Claim
19 words
A panel made by the method according to claim 9 wherein the mirror of the panel is concavely curved.
Claim 25
Dependent Claim
25 words
The method according to claim 1, wherein each of the backing sheets has a Young's modulus of elasticity of at least 50 GN/m 2 .
Claim 26
Dependent Claim
17 words
The method according to claim 3, wherein at least one of the backing sheets is galvanised steel.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-08-14 | 1988-02-13 | 1988-08-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-08-14 | 1992-02-13 | 1992-08-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-08-14 | 1996-02-13 | 1996-08-14 | $7700.00 | Window Closed / Lapsed |