Abstract:
A light reflective film with structural support. The structural support is a layer of adhesive applied to a reflective film, a polyester film attached to the applied adhesive layer, a second adhesive layer applied to the other side of the polyester film, and a fiber layer applied to the second layer of adhesive. A UV light blocker may be sprayed onto the fiber layer. Such reflective surface being ideal for use in tension member solar collection systems.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    Not Applicable. 
       APPENDIX 
       [0003]    Not Applicable. 
       BACKGROUND OF THE INVENTION 
       [0004]    1. Field of the Invention 
         [0005]    The present invention relates to reflective surface and, more particularly to a mirrored surface with structural support for preventing creep when under long-term tension. 
         [0006]    2. Related Art 
         [0007]    There are many different reflective film products that are commercially available from various manufacturers. For example, one manufacturer is ReflecTech, Inc., and another is The 3M Company. An example of a reflective film product that is commercially available may consist of five layers: an acrylic layer for protection from the physical environment, a silver layer for reflectance, a copper layer for strength, an adhesive layer to assist in applying the film to a solid object (these four layers collectively referred to as “reflective film”), and a polyester film for peeling off and the preventing of premature contact with an unintended solid object. In use, the polyester film is peeled off, and the reflective film is applied to a solid object such as sheet metal. Other commercially available reflective film products may use a different number of layers, and may use a metal other than silver for reflectance (such aluminum) sandwiched between various polymer layers, which may or may not include UV light inhibiting or UV light blocking layers. Common to all reflective film products is that the product is in the form of a sheet roll that is glued to a solid such as sheet metal or glass. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention is a reflective film with structural support. The structural support is a layer of adhesive applied to a reflective film, a polymer film attached to the applied adhesive layer, a second adhesive layer applied to the other side of the polymer film, and a fiber layer applied to the second layer of adhesive. A UV light blocker may be sprayed onto the fiber layer. 
         [0009]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0011]      FIG. 1  illustrates an elevated view of the prior art. 
           [0012]      FIG. 2  illustrates an elevated view of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0013]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0014]      FIG. 1  illustrates an elevated view of a prior art product. Reflective product, shown generally at  10 , comprises an external acrylic layer  12 , a reflective layer  14 , a foundation layer  16 , an adhesive layer  18 , and a polymer layer  20 . Layers  12 ,  14 ,  16 , and  18  are collectively referred to hereinafter as “reflective film  22 ”. It should be understood that there are many different ways to layer materials to produce a reflective film. The layering shown in  FIG. 1  is simply one example of layering, but a reflective film may be produced using a different number of layers, a different material selection for each layer, a different ordering of layers, and a different number of layers. Generally, a “reflective film” is a flexible sheet with multiple layers where one side of the sheet has a high reflectance, and does not have the rigidity to maintain a planar surface when extended an unsupported distance of twelve inches. 
         [0015]    Polymer layer  20  is used to protect the adhesive layer  18  before the intended use of reflective film  22 . In use, polymer layer  20  is peeled away from reflective film  22 . Then, reflective film  22  is applied to a solid object such as sheet metal, by placing newly exposed adhesive layer  18  in physical contact with the solid object. 
         [0016]      FIG. 2  illustrates an elevated view of the reflective product or reflective device  10 ′ of the present invention. In the present invention, reflective product  10 ′ comprises a reflective film layer  22 ′, an adhesive layer  18 ′, a polymer layer  20 ′, a second adhesive layer  24 , and a fiber layer  26 . Reflective film layer  22 ′ is a flexible sheet with multiple layers where one side of the sheet has a high reflectance, and does not have the rigidity to maintain a planar surface when extended an unsupported distance of twelve inches. 
         [0017]    The adhesive layer  18 ′ is different from the adhesive layer  18  of the prior art. Adhesive layer  18 ′ permanently bonds reflective film layer  22 ′ to polymer layer  20 ′ such that polymer layer  20 ′ cannot be peeled or separated from reflective film layer  22 ′. It is important that polymer layer  20 ′ remain bonded. The difference between polymer layer  20  ( FIG. 1 ) and polymer layer  20 ′ ( FIG. 2 ) is that the polymer of polymer layer  20  is selected to separate easily from or detach easily from reflective film  22 , whereas the polymer of polymer layer  20 ′ is selected prevent separation from or detachment from (to enhance fixation with) reflective film  22 ′. When reflective product  10 ′ of the present invention is placed under tension, polymer layer  20 ′ prevents the texture of fiber layer  26  from visibly pressing through reflective film layer  22 ′, and therefore allows reflective film layer  22 ′ to remain a smooth surface. Adhesive layer  18  is preferably an adhesive that retains adhesion under tension, and that will stretch as the other layers of reflective product  10 ′ stretch when placed under tension. 
         [0018]    It is possible that if the commercial product is initially used, in an alternative embodiment of the present invention, another adhesive layer  18 ′ may be applied over the existing adhesive layer  18 . In such a situation, reflective product  10 ′ of the alternative embodiment of the present invention has two adhesive layers,  18  and  18 ′ instead of a single adhesive layer  18 ′ as shown in  FIG. 2 . 
         [0019]    Fiber layer  26  is any fiber material that resists creep (permanent stretch) under long-term tension. Therefore, cloths made from materials such as cotton, fiberglass, or nylon are suitable. In addition, newer engineered materials such as fiber-reinforced composites (E-glass, glass, carbon fiber, Kevlar carbon, basalt fiber, etc.) are also suitable. At present, the preference is for cloths made from long fibers that run parallel to the direction of the intended applied tension. As a result, the most preferred embodiment at present is a unidirectional fiberglass cloth. A unidirectional fiberglass cloth allows some elastic stretch, but resists creep. This allows the resulting reflective product  10 ′ to hold a tension stretch without significant permanent lengthening. As shown in  FIG. 2 , the ends of various filaments comprising fiber layer  26  are shown. 
         [0020]    Further shown in  FIG. 2  is an optional UV coating layer  26 . This UV coating layer  26  may be sprayed onto fiber layer  26 . UV coating layer  26  prevents or blocks UV light from penetrating through fiber layer  26  and reaching polyester layer  20 . Polyester material is known to break down over time when exposed to UV light. UV coating layer  26  is preferably composed of any substance that inhibits the penetration of UV light, such as zinc oxide. 
         [0021]    The resulting reflective product  10 ′ of the present invention is flexible, but strong enough to be placed under tension. In use, the reflective product  10 ′ of the present invention may be used in tension about a structural frame, and still retain film-like flexibility for wrapping or bending about a structural frame, without need of any continuous sheet metal support. The prior art reflective product  10  shown in  FIG. 1  cannot be placed in tension about a structural frame without attachment to a further surface such as sheet metal. 
         [0022]    As various modifications could be made to the exemplary embodiments, as described above with reference to the corresponding illustrations, without departing from the scope of the invention, it is intended that all matter contained in the foregoing description and shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims appended hereto and their equivalents.