Reflector and methods of fabrication thereof

Patent metadata

Field	Value
Publication number	US-2016258596-A1
Application number	US-201514634911-A
Country	US
Kind code	A1
Filing date	Mar 2, 2015
Priority date	Mar 2, 2015
Publication date	Sep 8, 2016
Grant date	—

Abstract

A reflector that includes a substrate and a film disposed onto the substrate is provided. The film may include gas barrier layers configured to protect a reflective layer included in the film by blocking gas molecules from the top of the reflective layer and gas molecules originating from the bottom of the reflective layer.

First claim

What is claimed is:

1 . A reflector, comprising:
a substrate; a multilayer film disposed onto the substrate; wherein the multilayer film includes (i) gas barrier layers configured to protect a reflective layer included in the film by blocking gas molecules originating from the top of the reflective layer and gas molecules originating from the bottom of the reflective layer; and (ii) a top layer configured to protect the reflective layer against mechanical tearing.

2 . The reflector of claim 1 , wherein the multilayer film comprises a porcelain enamel layer in contact with the substrate.

3 . The reflector of claim 1 , wherein at least one of the gas barrier layers is a silicon sub-oxide.

4 . The reflector of claim 1 , wherein the reflective layer substantially comprises silver.

5 . The reflector of claim 1 , wherein the top layer is an anti-scratching layer.

6 . A reflector, comprising:
a substrate having an interior surface; a reflective surface supported by the substrate; a levelling layer intermediate the interior surface and the reflective surface, the levelling layer comprising a porcelain enamel; a gas barrier layer disposed on top of the reflective surface; and a protective layer disposed on top of the gas barrier layer.

7 . The reflector of claim 6 , further comprising another gas barrier layer disposed on top of the levelling layer.

8 . The reflector of claim 6 , wherein the porcelain enamel comprises a fused mixture of one or more oxides.

9 . The reflector of claim 6 , wherein the substrate is a metallic substrate.

10 . The reflector of claim 6 , wherein all the layers comprised therein are made of inorganic compounds.

11 . The reflector of claim 6 , wherein all the layers comprised therein include inorganic compounds.

12 . The reflector of claim 6 , wherein at least one layer includes an organic material.

13 . The reflector of claim 12 , wherein the at least one layer is a polymeric material.

14 . The reflector of claim 13 , wherein the polymeric material has inorganic particulates embedded therein.

15 . A method of fabricating a reflector, comprising:
forming a substrate; and disposing a film onto the substrate, the film comprising a levelling layer in contact with the substrate, and the film comprising a reflective layer; wherein the film further comprises gas barrier layers configured to protect the reflective film from diffusive and reactive species and an anti-scratching layer configured to protect the reflective layer from mechanical tearing.

16 . The method of claim 15 , wherein the substrate is a metallic substrate.

17 . The method of claim 15 , wherein the levelling layer is a porcelain enamel.

18 . The method of claim 15 , wherein the reflective layer is substantially made of silver.

19 . The method of claim 15 , wherein one of the gas barrier layers is a based on a silicon oxide.

20 . The method of claim 15 , wherein the film further comprises an anti-scratching layer.

Assignees

• Ge Lighting Solutions Llc

Inventors

• Cai Dengke
• Zhao Tianji
• Mayer Mark J
• Saha Koushik
• Ward Benjamin James

Classifications

• G02B1/14

  Protective coatings, e.g. hard coatings · CPC title

• F21V7/10

  Construction · CPC title

• G02B5/0808

  having a single reflecting layer (G02B5/0883, G02B5/0891 take precedence) · CPC title

• F21Y2115/10

  Light-emitting diodes [LED] · CPC title

• F21V7/22 Primary

  characterised by materials, surface treatments or coatings, e.g. dichroic reflectors · CPC title