Abstract:
The area of Concentrating Solar Power (CSP) and Concentrating Photovoltaics (CPV) require reliable, robust and durable reflectors capable of withstanding different environments, weather and transportation conditions. It is therefore important to use a method for fabricating a reflector which seals a reflector edge against moisture, corrosion and contaminants and protects the edge from cracks and damage. Embodiments of this method include depositing a clear sealant over the reflector edges, extending a reflective film over the edges of the reflector then sealing from the back and laminating a flexible strip of a clear polymer such as PVB and EVA around the top edge, a bottom edge, and all side edges of the reflector. Another embodiment includes performing hemming process on a front assembly of the reflector over the edges of a back assembly forming a sacrificial layer at the back of the reflector to prevent delamination.

Description:
TECHNICAL FIELD 
       [0001]    Embodiments of the subject matter described herein relate generally to solar reflectors. More particularly, embodiments of the present subject matter relate to reflector components, reflective films, reflector edge protection and methods for assembly. 
       BACKGROUND 
       [0002]    Glass mirrors and film-based reflectors are used in the area of Concentrating Solar Power (CSP) and Concentrating Photovoltaic (CPV) systems. Film-based reflectors typically include a reflective film adhered to a glass substrate or other suitable substrate. 
         [0003]    In some known arrangements, the edge of the reflective layer is exposed to the elements which risks damage that can destroy its reflective functionality. Moreover, when a reflective layer deteriorates due to exposure to air, moisture, or other damaging agents, the defect can propagate through the material and cause further damage inward from the edges. As a result, it can be advantageous to improve the sealing of reflective film edges in solar reflectors. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0004]    A more complete understanding of the subject matter can be derived by referring to the detailed description and claims when considered in conjunction with the following figures, wherein like reference numbers refer to similar elements throughout the figures. 
           [0005]      FIG. 1  is a schematic perspective view of a solar reflector fabricated in accordance with an embodiment; 
           [0006]      FIGS. 2-5  are schematic cross-sectional diagrams of a reflector in different states during fabrication, in accordance with an embodiment; 
           [0007]      FIGS. 6-11  are schematic cross-sectional diagrams of a reflector in different states during fabrication in accordance with another embodiment; 
           [0008]      FIGS. 12-15  are schematic cross-sectional diagrams of a reflector in different states during fabrication in accordance with yet another embodiment; 
           [0009]      FIG. 16  is an enlarged and partial cross-section view of an embodiment of an edge sealant dispenser adjacent an edge of a solar reflector; 
           [0010]      FIG. 17  is an enlarged and partial cross-sectional view of another embodiment of an edge sealant dispenser adjacent an edge of a solar reflector; 
           [0011]      FIGS. 18-22  are schematic cross-sectional diagrams of a reflector in different states of fabrication in accordance with yet another embodiment; 
           [0012]      FIGS. 23-25  are schematic cross-sectional diagrams of a reflector in different states of fabrication in accordance with still another embodiment; and 
           [0013]      FIGS. 26-30  are flow charts representing optional methods for fabricating reflectors. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    The following detailed description is merely illustrative in nature and is not intended to limit the embodiments of the subject matter or the application and uses of such embodiments. As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” Any implementation described herein as exemplary is not necessarily to be construed as preferred or advantageous over other implementations. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. 
         [0015]    Methods for sealing and protecting the edges of devices, such as reflectors, are disclosed herein. The methods described herein can be performed to make a reflector which includes a rigid substrate having a front side configured to face the sun during normal operation and a back side opposite the front side. The reflector can have a top edge, a bottom edge and two opposite side edges. The method can comprise adhering a reflective film to at least the front side of the rigid substrate to form a reflective upper surface. Further, a sealant can be deposited in a first state around the top edge, the bottom edge, and the side edges of the reflector. The method can further comprise curing the sealant to a second state. The first state can be a flowable state, and the second state can be a solid state. 
         [0016]    Another method for sealing and protecting the edge of a reflector can be performed to make a reflector which includes a rigid substrate having a front side configured to face the sun during normal operation and a back side opposite the front side. The reflector can have a top edge, a bottom edge and two opposite side edges. The method can comprise adhering a reflective film to at least the front side of the rigid substrate to form a reflective upper surface. A hollow mold can be coupled along the edges of the reflector, and the sealant can be dispensed into the mold along the edges of the reflector. Subsequent to dispensing the sealant into the mold, a curing step can be performed. Subsequent to the curing step, the mold can be removed from the edges of the reflector without removing the sealant to form a reflective upper surface. 
         [0017]    Still another method for sealing and protecting the edge of a reflector can be used to make a reflector which includes a rigid substrate having a front side configured to face the sun during normal operation and a back side opposite the front side. The method can comprise adhering a reflective film to at least the front side of the rigid substrate, extending over a top, bottom and side edges of the rigid substrate to form a reflective upper surface. A sealant can be applied at the back side of the reflector along the bottom edge. A curing process can be performed along the back side and the edges to melt the sealant into position. 
         [0018]    Yet another method for forming an assembled reflector can be used to make a reflector which includes a front assembly having a flange portion and a back assembly having an engagement flange. A reflective film can be adhered to at least the front assembly to form a reflective upper surface. The method can comprise coupling the front assembly to the back assembly, and securing the front assembly to the back assembly by folding the flange portion of the front assembly over and around edges of the back assembly to couple to the engagement flange. 
         [0019]      FIGS. 1-29  illustrate various embodiments for sealing and protecting the edges of a reflector. The various steps need not be performed in the order described below, and the disclosed methods can be incorporated into a more comprehensive procedure, process or fabrication technique having additional functionality not described in detail herein. 
         [0020]      FIGS. 1-3  illustrate different states of fabrication of an embodiment of a method for fabricating a reflector  100  which includes a rigid substrate  110  and a reflective film layer  122  that defines a reflective upper surface  120  of the reflector  100 .  FIGS. 1 and 3  illustrate the reflector  100  in an assembled state. 
         [0021]    The reflective film layer  122  can be mechanically coupled to the rigid substrate  110 . In some embodiments, the rigid substrate  110  can be a glass substrate, however, in other embodiments, other suitable substrates can be used. For example, in some arrangements, a metal (e.g., sheet metal and other types of formed metal) can be used as the rigid substrate  110 . In one embodiment, the rigid substrate  110  can be a plastic molded substrate. In another embodiment, the rigid substrate  110  can be a fiberglass substrate. In certain embodiments, the reflective film layer  122  can comprise an acrylic sublayer, silver sublayer and a copper sublayer. Moreover, the rigid substrate  110  can comprise, or can be mounted upon, a metal backing with ribs. In other embodiments, the rigid substrate  110  can comprise, or can be mounted upon, a front surface plate joined to a back surface plate that forms a composite backing structure. 
         [0022]    The rigid substrate  110  can have a front side  102  configured to face the sun during normal operation and a back side  103  opposite the front side  102 . The substrate  110  can also have lateral-facing side surfaces  111  extending along the top, bottom, and two opposite side edges of the substrate  110 . As illustrated in  FIG. 1 , the reflective upper surface  120  of the reflector  100  reflects incident light  140  to form reflected light  144 . 
         [0023]    While the reflector  100  shown in  FIGS. 1 and 3  is substantially planar, it should be appreciated that the reflector  100  can also be shaped three-dimensionally, for example, to form a concavity. In embodiments with a concave substrate  100 , the reflective film  122  can be attached to the concave surface of the substrate  110  to form a parabolic mirror for use in a solar reflection and/or concentration apparatus. Other substrate shapes can also be used. Also, although only one reflector  100  is illustrated herein, the reflector  100  can be used as one in an array of multiple reflectors within a solar collection system. 
         [0024]    As illustrated in  FIGS. 1-3 , the reflective film  122  can define the reflective upper surface  120  of the reflector  100 . The reflective film  122  can be rolled and laminated onto the front side  102  of the rigid substrate  110 , as shown in  FIG. 2 . In some embodiments, an adhesive material can be applied to the front side  102  of the rigid substrate  110  and/or the reflective film  122  in order to attach the reflective film  122  to the rigid substrate  110 . Excess reflective film  124  can either be removed or rolled over and around to protect and seal the edges of the rigid substrate  110 . The reflective film  122  can include a silver or aluminum film, although other reflective material combinations can also be used. In other embodiments, the reflective surface  120  can be formed on a glass substrate using a wet solution of silver and/or copper. 
         [0025]    With reference to  FIGS. 4-5 , further embodiments for sealing and protecting the edges of a reflector  100  are disclosed. As illustrated in  FIG. 4 , a sealant in a first state  130  can be dispensed on a first edge  104  and a second edge  106  of the reflector  100  to cover the edges of both the reflective film  122  and the rigid substrate  110 . Additionally, the rigid substrate  110  can comprise a sheet of glass. While  FIGS. 4 and 5  illustrate applying sealant to only two edges  104 ,  106 , it should be appreciated that the sealant can also be applied on the other two edges of the reflector  100 . 
         [0026]    Optionally, the sealant  130  can be applied in a manner so as to extend over the lateral-facing side surfaces  111  of the substrate  110 . For example, the sealant  130  can be applied such that the sealant  130  extends in a substantially continuously along the periphery of the film and laterally-facing side surfaces  111  of the top, bottom, and two opposite side edges of the substrate  110 . As used herein, “substantially continuously” can be considered to include gaps along the path of the sealant wherein the cumulative size of the all of the gaps total no more than about 5% of the length of the periphery of the substrate  110 . In some embodiments, the sealant  130  can extend continuously along the periphery of the reflector  100  without any gaps. 
         [0027]    The deposited sealant in a first state  130  can have a thickness of less than about 5 mm as measured from the laterally-facing side surfaces  111  of the rigid substrate  110  to along the two edges  104 ,  106 , of the reflector  100 . The sealant can also be applied on the other two edges of the reflector  100 . 
         [0028]    Further, in some embodiments, the sealant  130  can be applied so as to extend from the film  122 , downwardly onto the substrate  110 , over the laterally-facing side surfaces  111  of the substrate and onto the back side  103  of the substrate  110 . Additionally, similarly to that described above, the sealant  130  can extend substantially continuously along the periphery of film  122  and the back side  103 , or continuously without gaps. 
         [0029]    In some arrangements, it can be advantageous to employ an optically transparent sealant. As illustrated, a portion of the sealant can be applied to the reflective surface  120  of the reflector  100 . If a non-transparent sealant is used, then the sealant can block part of the reflecting surface of the reflector  100 , thereby decreasing the power efficiency of the system. In some embodiments, a sealant with a refractive index of about 1.5 can be used. In addition, the sealant can be selected such that it transmits at least about 50% of incident light to the underlying reflective surface  120  (e.g., for a spectral window for light transmission of at least about 50%). One suitable transparent sealant is silicone. Another suitable sealant is ethylene-vinyl acetate (EVA), however, other transparent sealants may be suitable if they sufficiently seal the edges of the solar reflector  100 . In the first state  130 , the sealant can be flowable so that it can be easily applied over the edges of the rigid substrate  110 . In some arrangements, the sealant in the first state  130  can be in a liquid or semi-liquid form. 
         [0030]    Turning to  FIG. 5 , a curing process can be performed along the edges of the reflector  100  to form a sealant in a second state  132 . In the second (e.g., cured) state  132 , the sealant can be hardened to form a solid edge seal for the reflector  100 . Curing the sealant to form the second state  132  can be advantageous in simultaneously sealing and protecting the reflector  100  edges. For example, the cured sealant can prevent moisture and other environmental contaminants from damaging the edge of the reflector  100  over time. In addition, the cured sealant can provide enhanced structural integrity for the reflector  100 , as the hardened sealant material can ensure a secure bonding or lamination between the reflective film and the rigid substrate. 
         [0031]    The curing process can comprise a thermal curing process in some embodiments. For example, in some embodiments, the sealant in the first state  130  can undergo a localized heating process to cure the sealant to the second state  132 . In some embodiments, thermal curing processes can be used, including, a batch heating process or selective heating. In other embodiments, an optical curing process, e.g., an ultraviolet (UV) curing process, or a thermal curing process can be employed to cure the sealant from the first state  130  to the second state  132 . In yet other embodiments, the sealant can be cured by exposing the sealant to the atmosphere to allow it to dry and harden. In one embodiment, a binary sealant material can be used. The binary sealant material can be composed of a sealant and a catalyst mixed with the sealant prior to dispensing. The catalyst can accelerate the curing rate of the sealant in the curing process. 
         [0032]      FIGS. 6-8  illustrate another embodiment for fabricating a reflector  200  comprising a rigid substrate  210  coupled to a reflective film  222 . Unless otherwise specified below, the numeric indicators used to refer to components in  FIGS. 1-5  are similar to the components in  FIGS. 6-8 , except that the index has been incremented by 100. 
         [0033]    As an alternative to dispensing a sealant directly to the reflector  200  edges (e.g., edges  204  and  206 ), a mold  260  can be attached over the edges of the reflector  200 , as illustrated in  FIG. 6 . In some arrangements, the mold  260  can be applied around the perimeter of the reflector  200 . The mold  260  can include first and second clamping portions  263 ,  264  that mechanically couple to the reflective surface  220  of the reflector and the back side  203  of the rigid substrate  210 , respectively. The mold  260  can couple to the reflector  200  by way of a mechanical clamping force such that the first clamping portion  263  presses the film  222  to the surface of the substrate  210  against the force of the second clamping portion  264  pressing against the back surface of the substrate  210 . 
         [0034]    The mold  260  can be configured to generate a desired clamping force in any known manner, such as, for example, but without limitation, springs, actuators, screws, robotic arms, manual positioning of the clamps including the use of elastic retention members, interlocking clamps which cooperate to provide the clamping force, gearsets, etc. Additionally, the clamping force can be provided by way of the construction of the mold  260 , such that in a relaxed state, the distance between the first and second clamping portions  263 ,  264  is less than a thickness of the substrate  210  and the film  222 . In such embodiments, the mold  260  can be configured to be elastically expandable and resilient such that the first and second clamping portions  263 ,  264  can be elastically spread apart from each other, placed over the substrate  210  and film  222 , then released so as to press against the substrate  210  and the film  222  as described above. In other embodiments, the first and second clamping portions  263 ,  264  of the mold  260  can be temporarily adhered to the reflector  200 . 
         [0035]    Upon coupling the mold  260  to the reflector  200 , a recess  261  can be formed between the mold  260  and the first and second edges  204 ,  206  of the reflector  200 . While the mold  260  illustrated in  FIGS. 6-8  is applied around all four edges of the reflector  200 , in other embodiments, the mold  260  may be applied around fewer than all the edges, e.g., one, two, or three edges of the reflector. In addition the mold  260  can be made from metal or plastic (which can be a reusable plastic). A skilled artisan will understand that other materials are suitable. 
         [0036]    Turning to  FIG. 7 , a sealant in a first state  230  can be caused to flow through the recess  261  of the mold  260  and onto the reflector edges (e.g., first and second edges  204  and  206 ). For example, sealant can flow from a sealant source (e.g., a tube, sack, or other reservoir filled with flowable sealant) through an aperture or opening in the mold  260 . The sealant in the first state  230  can be in a flowable state. In some arrangements, the sealant in the first state  230  can be in a liquid or semi-liquid form. As shown in  FIG. 8 , a curing step can be performed on the sealant in the first state  230  to form a sealant in a second state  232 . As in the embodiment of  FIGS. 4-5 , the sealant can be cured using a thermal, UV, or atmospheric curing process, or any other suitable curing procedure. As above, any suitable sealant can be used, including, e.g., silicone or EVA. The sealant in the second state  232  can be in a solid form, e.g., hardened as compared to the uncured sealant. The mold  260  can be removed, completing the combined edge sealing and protection process. 
         [0037]    With reference to  FIGS. 9-11 , another embodiment for fabricating a reflector  200  is shown. A laminate in a first state  234  can be adhered around the edges (e.g., first and second edges  204 ,  206 ) of the substrate. The laminate in a first state can be comprised of a flexible strip of a clear lamination polymer such as polyvinyl butyral (PVB) and EVA. Other suitable lamination materials are possible. In other embodiments, the laminate in the first state  234  can be a powder or resin applied around the edges of the reflector  200 . 
         [0038]    In  FIG. 10 , a laminating device  262  can be coupled to the edges of the substrate over the laminate in a first state  234 . The laminating device  262  can be configured to bond the transparent laminate to the edges of the reflector  200 . A lamination process can be performed to form a laminate in a second state  236 , as illustrated in  FIG. 11 . In some implementations, the laminating device  262  can be configured to provide heat and/or pressure to perform the lamination process. The laminate in a second state  236  can be in a solid form, e.g., hardened as compared to the laminate in the first state  234 . The laminating device  262  can be removed after completing the combined edge sealing and protection process. To conserve optical performance the sealant described in the embodiments above can comprise a clear sealant, e.g., having a refractive index of about 1.5. 
         [0039]    With reference to  FIGS. 12-15 , yet another embodiment for fabricating a reflector  300  is shown. An oversized reflective film  322  can be wrapped around the front side  302  and edges of the substrate to form a reflective upper surface  320  on top of the rigid substrate  310 , as shown in  FIG. 12 . As illustrated, a portion of the reflective film  322  can be attached to the back side  303  of the rigid substrate  310 . 
         [0040]    Turning to  FIG. 13 , a sealant in a first state  330  can be dispensed on the back side  303  of the reflector  300  and on portions of the reflective film  322  that attach to the back side  303  of the rigid substrate  310 . In some implementations, the sealant in the first state  330  can be applied to portions of the reflective film  322  that cover the edges (e.g., first and second edges  304 ,  306 ) of the reflector  300 . By applying the sealant to the back side  303  of the rigid substrate  310 , the front side  302  remains free of sealant. In some embodiments, the sealant in the first state  330  can be dispensed overlying the reflective film  323  and continuing onto the back side  303  of the rigid substrate  310 . 
         [0041]    A sealant-free front side  302  can be advantageous for various reasons. For example, applying the sealant to the back side  303  of the rigid substrate  310  can reduce any optical obstructions introduced by applying the sealant to the front side  302 . Moreover, since the sealant is dispensed on the back side  303  of the reflector  300 , the sealant need not be a transparent sealant. In addition, exposing the sealant to sunlight (e.g., by applying the sealant to a portion of the front side  302 ) can degrade the sealant over time in some cases. Applying the sealant to the back side  303  of the substrate  310  can therefore provide additional shielding of the sealant from direct sunlight and UV degradation. Such shielding can increase the reflector&#39;s overall durability. 
         [0042]    As illustrated in  FIG. 14 , a curing step can be performed on the sealant in a first state  330 . In some embodiments, such as in  FIG. 14 , heat  350  is applied to cure the sealant from the first state  330  to a second state  332 , as shown in  FIG. 15 . Other curing mechanisms, such as those described above, are also possible. As above, the sealant in the first state  330  can be in a flowable (e.g., liquid or semi-liquid) state. The sealant in the second state  332  can be a solid (e.g., hardened or cured) state. Any of the methods and materials described above can be employed in the embodiment of  FIGS. 12-15 . 
         [0043]      FIGS. 16 and 17  illustrate one way that the sealant can be dispensed on the back surface of the reflector  400  in the embodiment described by  FIGS. 12-15 . A print nozzle  470  can be placed at an angle (e.g., a 45 degree angle in  FIG. 16 ) to the back side  403  of the substrate  410  using a hotmelt printer as seen in  FIG. 16 . While a 45 degree angle is shown in  FIG. 16 , it should be appreciated that the print nozzle  470  can be placed at any other suitable angle with the back side  403  of the rigid substrate  410 . As above, the reflector  400  can comprise the rigid substrate  410 , the reflective film  422 , and the reflective upper surface  420 , in addition to any of the other material combinations described above. As  FIG. 17  illustrates, the print nozzle can also be perpendicular to the side edge (e.g., first edge  404 ) of the reflector  400 . While the print nozzle  470  has been described in relation to the embodiment of  FIGS. 12-15 , the print nozzle  470  can be used in other embodiments as well, including, e.g., the embodiments of  FIGS. 4-8 . 
         [0044]    With reference to  FIGS. 18-22 , still another embodiment for fabricating a reflector  500  is shown. The reflector  500  can comprise a reflective film  522  defining a reflective upper surface  520 , and a front assembly  510 . As seen in  FIG. 18 , the reflective film  522  can be rolled and laminated or adhered onto the front assembly  510 . The assembled reflector  500  is illustrated in  FIG. 19 . A back assembly  512  can be coupled to the back side  503  of the front assembly  510 . The coupling process can comprise the addition of an adhesive to strengthen the contact between both structures. The back assembly  512  can provide structural support for the reflector  500 . The back assembly  512  can also be configured to couple the reflector  500  to a larger system of solar reflectors, e.g., by coupling to an array of other reflectors (such as to an axis of the array). 
         [0045]    Turning to  FIGS. 20-22 , the front assembly  510  can be secured to the back assembly  512  by folding a flange portion  530  of the front assembly  510  over and around perimeter edges of the back assembly. To facilitate the folding process, the front assembly  510  can have an excess portion with a width range of 1 mm to 20 mm extending from the front assembly  510 . This excess material or sacrificial material acts also to protect the edge of the reflector  500  against delamination. In  FIG. 22 , the flange portion  530  of the front assembly  510  can be further folded over the back assembly  512  such that a portion of the back side  503  of the front assembly  510  contacts an engagement flange  532  of the back assembly  512 . The flange portion  530  can couple to the engagement flange  532  by mechanically clamping onto the engagement flange  532 . In some embodiments, an adhesive can optionally be used to assist in coupling the flange portion  530  to the engagement flange  532 . In some embodiments, the engagement flange  532  can be a structural extension of a portion of the back assembly  512 . In other embodiments, the engagement flange  532  can be formed from a back surface of the back assembly  512 . The folding process can be performed in a fold direction  540  as seen in  FIGS. 20 and 21 . During the process of coupling the front assembly  510  to the back assembly  512 , the sealant can optionally be applied over the engagement flange  532  and the flange portion  530  of the front assembly  510 . As above, the sealant can be applied in a first state (e.g., flowable) and cured to a second state (e.g., hardened or solid). 
         [0046]    With reference to  FIG. 23-25 , another embodiment for fabricating a reflector  600  comprising a reflective film  622  and a front assembly  610  is shown. Similar to the embodiment discussed above in  FIGS. 18-22 , a back assembly  612  can be coupled to the back side  603  of the front assembly  610 . The front assembly  610  can be secured to the back assembly  612  by folding a flange portion  630  of the front assembly  610  over and around perimeter edges of the back assembly to contact an engagement flange  632  of the back assembly  612 . The folding process can be done in a fold direction  640  as seen in  FIG. 24 . Both the front assembly  610  and the back assembly  612  can comprise a cross strut structure  650  for additional structural support. For enhanced structural integrity the cross strut structure  650  can further comprise stiffening ribs. The folding process discussed above can comprise a hemming process similar to those performed in car manufacturing or other industrial hemming processes. The hemming process also allows for forming a sacrificial layer at the back of the reflector to prevent delamination and provides an alternative to the edge protection processes previously described. 
         [0047]      FIG. 26  illustrates a flow chart of an embodiment for fabricating a reflector  100 . A first step  700  in the reflector fabrication method can comprise adhering a reflective film  122  to the front side  102  of a rigid substrate  110  to form a reflective upper surface  120 . Adhering a reflective film can comprise rolling the reflective film  122  on the front side  102  of the rigid substrate  110 . Adhering a reflective film  122  can also comprise rolling and subsequently laminating the reflective film  122  on the front side  102  of the rigid substrate  110 . A sealant in a first state  130  can be deposited around the top edge, bottom edge, and all side edges of the reflector  100  as described in the second step  702  of the flow chart. Depositing the sealant in a first state  130  can comprise depositing a sealant in a flowable state such as silicone or EVA. The sealant can be made of a material with an optical index of about 1.5 to allow light transmission through the sealant and allow unobstructed reflection from the reflective upper surface  120 . In other embodiments the sealant in a first state  130  can have at least 80% light transmission. A hotmelt printer can be used to deposit the sealant in a first state  130  along the edges of the reflector  100 . The sealant in a first state  130  can be cured to form a sealant in a second state  132  as described in the last step  704  of the flow chart. The sealant in a second state  132  can be in a solid state and can also have at least 80% light transmission. Other processes, materials, and structures, such as those used in  FIGS. 4-5 , can be used with the embodiment of  FIG. 26 . 
         [0048]      FIG. 27  illustrates a flow chart of another embodiment for fabricating a reflector  200 . Similar to the above, the first step  706  in the reflector fabrication method can comprise adhering a reflective film to the front side of the rigid substrate  210  to form a reflective upper surface  220 . A mold  260  can be coupled along the edges of the reflector  200  as shown in  FIG. 6  and described in the second step  708  of the flow chart. The mold  260  can be made of metal or comprise a metal hollow mold. The mold  260  can also comprise of a reusable hollow plastic mold which can be recycled for use with another reflector. Turning to block  710 , a sealant in a first state  230  can be dispensed into the mold  260 . In block  712 , a curing step can be performed to form a sealant in a second state  232 . In block  714 , the mold  260  can be removed from the edges of the reflector  200 . The sealant in a first state  230  can be in a flowable state while the sealant in a second state can be in a solid state  232 . In some embodiments, the mold  260  can be kept in contact with the reflector edge until the end of the fabrication process. In this embodiment, the mold  260  can provide additional structural support to the reflector  200  during succeeding reflector fabrication processes and removed after the fabrication process. In yet other embodiment, the mold  260  can be made of the same or similar material and optical properties of the sealant. This eliminates the requirement of removing the mold and sealant after the curing process, with no loss to the reflective properties of the reflector  200 . Other processes, materials, and structures, such as those employed in  FIGS. 6-8 , can be used in the embodiment of  FIG. 27 . 
         [0049]      FIG. 28  illustrates a flow chart of another embodiment for fabricating a reflector  200 . Similar to the discussion above, the first step  716  in the reflector fabrication method comprises adhering a reflective film to the front side of the rigid substrate  210  to form a reflective upper surface  220 . A second step  718  can be performed, which can comprise adhering a laminate in a first state  234  around the edges of the substrate. The laminate in a first state  234  can comprise a flexible strip of a clear lamination polymer such as PVB or EVA. In block  720 , a laminating device  262  can be coupled along the edges of the reflector  200  over the laminate in a first state  234 . Turning to block  722 , a lamination process can be performed to form a laminate in a second state  236 . The lamination device  262  can be removed once the lamination process is complete in block  724 . Other procedures, materials, and structures, similar to those described above with respect to  FIGS. 9-11 , can be employed in the embodiment of  FIG. 28 . 
         [0050]      FIG. 29  illustrates a flow chart of another embodiment for fabricating a reflector  300 . As discussed above, the first step  726  in the reflector fabrication method can comprise adhering a reflective film to the front side  302  of the rigid substrate  310  and extending the film over the top, side and bottom edges to form a reflective upper surface  320 . A second step  728  can be performed in which a sealant in a first state  330  can be applied at the back side  303  of the reflector  300  along the first and second edges  304 ,  306 . While  FIG. 13  illustrates applying sealant to only two edges  304 ,  306 , it should be appreciated that the sealant can also be applied on the other two edges of the reflector  300 . The sealant in a first state  330  can also be applied at a 45° angle at the back side  303  of the reflector  300  as shown in  FIG. 16 , which allows optimal coverage of the interface between the reflective film and the back surface of the rigid substrate  310 . Placing the sealant at the back side  303  of the reflector  300  has the advantage of shielding the sealant from direct sunlight and UV degradation, which would increase the overall durability of the reflector  300 . A curing process  350  can be performed on the sealant in a first state  330  along the back side of the reflector  300  and edges to form a sealant in a second state  332  as described in the last step  730  of the flow chart. Other curing mechanisms, such as those described above, are also possible. The sealant in a first state  330  can be in a flowable state while the sealant in a second state can be in a solid state  332 . Other procedures, materials, and structures, similar to those described above with respect to  FIGS. 12-15 , can be employed in the embodiment of  FIG. 29 . 
         [0051]      FIG. 30  illustrates a flow chart of yet another embodiment for fabricating a reflector  500  and  600 . Similar to that discussed above, the first step  732  in the reflector fabrication method can comprise adhering a reflective film  522  to at least the front assembly  510  to form a reflective upper surface  520 . A second step  734  can be performed; the front assembly  510  can be coupled to the back assembly  512  by applying a sealant or by welding the interface between the front assembly  510  and back assembly  512 . The front assembly  510  can be secured to the back assembly  512  by folding a flange portion  530  of the front assembly  510  in a folding direction  540  over and around perimeter edges to contact an engagement flange  532  of the back assembly  512 . The folding process comprises the last step  736  of the flow chart. The folding process can comprise a hemming process for sealing the edge of the reflector  500  similar to that performed in the automotive industry. In some embodiments, the front assembly  510  and the back assembly  512  can have a stamped cross strut structure  650  that provides additional structural support. This can be further secured using a similar folding process as described by  FIGS. 23-25 . Other procedures, materials, and structures, similar to those described above with respect to  FIGS. 18-25 , can be employed in the embodiment of  FIG. 30 . 
         [0052]    While at least one exemplary embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the claimed subject matter in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope defined by the claims, which includes known equivalents and foreseeable equivalents at the time of filing this patent application.