CN101042443A - 一种用于制造车辆后视镜的方法 - Google Patents
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Abstract
利用塑料来模制承载基底,所述承载基底具有弯曲的基底表面,在接纳后视镜覆层之前,基底表面形成为固定的形状。将铬制的第一后视镜涂覆层溅镀到弯曲的基底表面上,其中第一层对于可见电磁辐射的光反射率在大约60%到65%的范围中。将铝制的第二后视镜涂覆层溅镀到第一层上,从而第二层对可见电磁辐射的光反射率至少约为80%,并且第二层的最大厚度大约为第一层的厚度的20%。第一和第二后视镜涂覆层被施加到弯曲的基底表面以具有在大约5毫米到1微米的范围中的总的层厚度。将防划覆层施加到第二后视镜涂覆层上以防止对第一和第二后视镜涂覆层的损伤。
Description
技术领域
本发明涉及车辆的后视镜,并且更特别的是涉及一种用于制造具有提高的反射特性的弯曲的塑料的车辆后视镜的方法。
背景技术
车辆的后视镜通过某种工艺大规模地生产,其中薄的铬层、铝层、银层或另一种类似的轻质反射性金属以及通常的粘合剂由此从汽化状态沉积在金属或玻璃的主体上,所述主体起着承载基底的作用。不利的是,起着承载板的作用的金属或玻璃主体重量大,并且对于最终制成的后视镜会使得制造成本昂贵。另外,由金属或玻璃物质制成的承载板例如在碰撞中不具有弹性变形的能力。
由于这些限制,已知有利的是使用具有由轻质塑料制成的承载基底的后视镜。然而,下面的事实立刻变得显而易见:通过已知的电镀方法利用铬涂覆塑料承载基底会导致易碎的铬层。后视镜的弹性变形在安装过程中经常发生,并且会造成后视镜覆层中的微小裂纹,这会导致后视镜的总体反射中的模糊不清。
DE 697,08,926 T2提出:一种扁平的热塑性的基底,例如PMMA(聚甲基丙烯酸甲酯),可以通过将反射性的铌层溅镀到塑料基底上从而被涂覆。重要的是,接纳覆层的基底具有扁平的接纳表面以保持适合的反射特性。然而,经常出现这样的情况:将反射覆层施加到基底之后,后视镜被热处理以成形为适合的后视镜形状,所述形状通常是弯曲的表面。由于施加覆层的溅镀工艺,当基底在施加反射覆层之后被成形时,后续的热成形造成覆层中发生原子扩散和结构分层。最终的弯曲的后视镜的所得到的反射特性被不利地改变从而降低后视镜的反射质量。
考虑上述参考文献DE 697,08,962 T2中的特征,本发明的目的是提供一种利用塑料的承载基底制造弯曲的后视镜的制造方法,所述后视镜具有较好的光学特性,在这些特性中,有利的是反射质量得到显著的提高,同时避免了与基底的涂覆之后的热处理相关的问题。
发明内容
上述目标通过一种用于制造具有弯曲的后视镜表面的车辆后视镜的方法实现,所述后视镜特别用于商务车辆,所述方法包括下列步骤:提供承载基底,所述基底具有弯曲的基底表面,在最初的承载基底的模制过程中并且在接纳后视镜覆层之前,所述基底表面被模制为固定的形状;以及在模制所述弯曲的基底表面之后,将后视镜覆层溅镀到所述弯曲的基底表面上,以为车辆后视镜提供不包括原子扩散和结构分层的反射表面,当所述后视镜覆层在形成所述弯曲的基底表面之前被施加到所述承载基底时会发生原子扩散和结构分层。因此,车辆后视镜以这样一种方式制造,首先塑料承载基底被制成它的最终的弯曲形状,并且之后,薄的后视镜覆层通过溅镀被施加在一侧上。
令人惊奇的是,结果是具有它们最终形状而非扁平的这种承载基底能够被溅镀。因此,之前使用的通过热处理进行后续的成形被省略,连同消除了它对光学特性特别是反射质量的固有的损害。
与通过按照上述的技术的方法制造的后视镜相反,根据本发明的方法因此提供了具有提高的光学特性的后视镜。
与在本说明书开始部分描述的具有金属或玻璃承载基底的车辆后视镜对比,根据本发明制造的后视镜本质上更轻,并且在它的功能方面更为优秀。它还具有能够弹性地弯曲变形而不会断裂的能力,它或者具有能够如同在金属后视镜或玻璃后视镜中那样永久变形的能力。另外,塑料减弱了在车辆的操作中常见的振动,从而反射的图像显得更加稳定。有利的是,下面的事实已经变得显而易见:通过避免在将反射层施加到基底之后的热成形,根据本发明的方法制成的后视镜能够防止反射图形质量的降低,所述反射图形质量的降低是由于后视镜反射涂覆层的经常的弹性变形造成的。
有利的是,薄的后视镜覆层包括5毫米到1微米的层厚度。这种覆层厚度确保了后视镜覆层到承载基底的充分的附着,即使在基底的弹性变形的情况中,并且提供适合的光学特性,特别是提高的反射率。
有利的是,薄的后视镜覆层包括铬或者铬合金制成的第一层,并且优选包括铝或者铝合金制成的第二层,所述第二层设置在第一层的远离承载基底的那一侧上。
有利的是,由于第二层的反射率至少为80%,因此第二层比第一层薄许多,第一层的反射率大约为60%到65%。有利的是,第二层的厚度至多为第一层厚度的50%,但特别优选的是最大厚度为第一层的厚度的20%。
有利的是,如在液晶显示器中公知的,“防划”覆层可施加在薄的后视镜覆层上。
有利的是,后视镜覆层设置在后视镜的前侧上。在这种情况中,承载基底不需要是透明的。
在从属权利要求和下面的说明性的实施例中可以发现本发明的另外的目的、特征和优点。
附图说明
下面将与其它特征一起描述设计成实施本发明的结构。通过阅读下面的说明书和参考附图,本发明将易于理解,其中附图形成说明书的一部分,其中示出了本发明的实例,附图中:
图1示出了车辆后视镜的横截面视图,该后视镜按照根据本发明的方法制造,和;
图2示出了在根据本发明的制造后视镜的方法中各种步骤的流程图。
具体实施方式
下面将参考图1和图2更详细地描述本发明。
根据本发明的一个实施例,第一步骤是:承载基底1利用具有弯曲的基底表面6的塑料制造,所述基底表面6用于接纳后视镜覆层。如步骤10所示,这可以通过模制实现,可以通过喷射、注射或浇铸热塑性的聚合物、或者使泡沫塑料硬化而实现。之后,如步骤12所示,在将后视镜覆层施加到弯曲的基底表面6之前,承载基底1仍然可以通过研磨、修整等再加工成最终的形式。
一旦承载基底1被构造并且被设置成它的最终的形式,可以通过溅镀施加方法将后视镜覆层沉积到承载基底上。如步骤14所示,为了沉积薄的第一层铬层2,电压以已知的方式施加在充满惰性气体的容器中,从而被惰性气体离子驱使出铬靶13之外的铬原子被朝着承载基底1加速,并且沉积在其上以通过凝结形成第一层2。适当的溅镀设备例如可以从具有竖直传送件和竖直磁电管的InllineSputter Equipment A1250V中找到。美国专利4,166,018同样描述了一种优选的溅镀装置,并且其内容在此整体引为参考,从而本公开可应用到这些情况。
施加第一层2之后,利用铝靶15执行相同的过程,以将第二层铝层3溅镀到第一层铬层2上,如步骤16所示。通过缩短施加时间,可以为第二层3提供较薄的层厚度。在一个优选实施例中,由于较高的反射率,第二层3施加的厚度可以小于第一层2的厚度。铝覆层反射大约80%的可见的电磁辐射,与之不同,第一层铬层2的反射率大约为60%到65%。有利的是,第二层3的厚度至多为第一层2的厚度的50%。在一个优选实施例中,第二层3的最大厚度为第一层2的厚度的20%。
优选的是,结合的后视镜覆层的层厚度为5毫米到1微米。这种覆层厚度确保了后视镜覆层到承载基底的充分的附着,即使在承载基底的弹性变形的情况中,并且提供了适合的光学特征,特别是提高的反射率。
有利的是,在施加第二层3之后,例如可以通过喷镀透明的塑料或树脂覆层4以进一步在后视镜上增设防划覆层,如步骤18所示。
后视镜然后处于完工的状态,并且不需要进一步的后续加工,特别是热处理重新成形,这会破坏结构,并且会破坏已经溅镀到其上的层的吸持力。
虽然使用特定的术语描述了本发明的优选实施例,但是这种描述仅是示意性的,并且在不脱离权利要求的实质和范围的情况下,可以作出各种修改和变型。
在图1中,箭头“A”表示观察后视镜的人的观察方向,即后视镜覆层2、3设置在后视镜的前侧上。因此,承载基底1可以由透明的材料制成。
Claims (14)
1.一种用于制造具有弯曲的后视镜表面的车辆后视镜的方法,所述后视镜特别用于商务车辆,所述方法包括下列步骤:
提供承载基底,所述基底具有弯曲的基底表面,在最初的承载基底的模制过程中并且在接纳后视镜覆层之前,所述基底表面被模制为固定的形状;和
在模制所述弯曲的基底表面之后,将后视镜覆层溅镀到所述弯曲的基底表面上,以为车辆后视镜提供不包括原子扩散和结构分层的反射表面,当所述后视镜覆层在形成所述弯曲的基底表面之前被施加到所述承载基底时会发生原子扩散和结构分层。
2.如权利要求1所述的方法,其特征在于,包括利用热塑性聚合物模制所述承载基底的步骤。
3.如权利要求1或2所述的方法,其特征在于,包括下面的步骤:将具有在大约5毫米到1微米的范围中的层厚度的后视镜覆层溅镀到所述承载基底的所述弯曲的基底表面上。
4.如上述权利要求中任一项所述的方法,其特征在于,所述后视镜覆层利用从包括下列材料的组中选择的材料构造:铬,铬合金,铝,铝合金及其组合物。
5.如上述权利要求中任一项所述的方法,其特征在于,包括下面的步骤:通过将从铬和铬合金之一选择的第一层溅镀到所述承载基底的所述弯曲的基底表面上形成所述后视镜覆层。
6.如权利要求5所述的方法,其特征在于,包括下面的步骤:形成具有对可见电磁辐射的光反射率在大约60%到65%的范围中的所述第一层。
7.如权利要求5或6所述的方法,其特征在于,包括下面的步骤:将从铝和铝合金之一选择的第二层溅镀到所述第一层上。
8.如权利要求7所述的方法,其特征在于,包括下面的步骤:形成具有对可见的电磁辐射的光反射率至少大约为80%的所述第二层。
9.如权利要求7或8所述的方法,其特征在于,包括形成比所述第一层更薄的所述第二层的步骤。
10.如权利要求7到9中任一项所述的方法,其特征在于,包括下面的步骤:形成其厚度为所述第一层的厚度的大约50%或者更小的所述第二层。
11.如权利要求10所述的方法,其特征在于,包括下面的步骤:形成其最大厚度为所述第一层的厚度的大约20%的所述第二层。
12.如权利要求7到11中任一项所述的方法,其特征在于,包括将防划覆层施加到所述第二层上的步骤。
13.如上述权利要求中任一项所述的方法,其特征在于,后视镜覆层设置在后视镜的前侧上。
14.一种利用根据上述权利要求中任一项所述的方法制造的特别用于商用车辆的车辆后视镜。
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DE102005030900.3 | 2005-07-01 | ||
DE102005030900A DE102005030900A1 (de) | 2005-07-01 | 2005-07-01 | Verfahren zur Herstellung eines Fahrzeugspiegels |
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CN101042443A true CN101042443A (zh) | 2007-09-26 |
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CNA2006100958694A Pending CN101042443A (zh) | 2005-07-01 | 2006-06-30 | 一种用于制造车辆后视镜的方法 |
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US (1) | US20070000771A1 (zh) |
EP (1) | EP1739205A3 (zh) |
JP (1) | JP2007011365A (zh) |
KR (1) | KR20070003686A (zh) |
CN (1) | CN101042443A (zh) |
DE (1) | DE102005030900A1 (zh) |
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DE102005030900A1 (de) * | 2005-07-01 | 2007-01-11 | Mekra Lang Gmbh & Co. Kg | Verfahren zur Herstellung eines Fahrzeugspiegels |
KR101364724B1 (ko) * | 2012-06-20 | 2014-02-20 | 주식회사 에스엘미러텍 | 차량용 미러 어셈블리 및 그 제조 방법 |
DE102014208687B3 (de) * | 2014-05-08 | 2015-10-08 | Mekra Lang Gmbh & Co. Kg | Aussenrückspiegel für ein Fahrzeug, insbesondere Nutzfahrzeug |
JP6270767B2 (ja) * | 2015-03-30 | 2018-01-31 | ニチハ株式会社 | 建材 |
KR101629147B1 (ko) * | 2015-04-24 | 2016-06-10 | 고려대학교 산학협력단 | 입자형 곡면 거울 장치 및 이의 제조 방법 |
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CH400714A (de) * | 1960-05-21 | 1965-10-15 | Bosch Gmbh Robert | Oberflächenspiegel mit metallischer Spiegelschicht und anorganischer Schutzschicht |
US4166018A (en) * | 1974-01-31 | 1979-08-28 | Airco, Inc. | Sputtering process and apparatus |
DE3333334A1 (de) * | 1983-09-15 | 1985-03-28 | Robert Bosch Gmbh, 7000 Stuttgart | Verfahren zum herstellen einer spiegelschicht, insbesondere fuer scheinwerferreflektoren |
DE4223590A1 (de) * | 1992-07-17 | 1994-01-20 | Leybold Ag | Spiegel und Verfahren zu seiner Herstellung |
DE9212080U1 (de) * | 1992-09-08 | 1992-12-10 | Schlenke, Hubert, 5778 Meschede | Kraftfahrzeug-Innenrückblickspiegel |
IL110443A0 (en) * | 1993-07-29 | 1994-10-21 | Hughes Aircraft Co | Reflective plastic optics with improved optical properties |
US6086210A (en) * | 1995-06-29 | 2000-07-11 | Cardinal Ig Company | Bendable mirrors and method of manufacture |
US6356376B1 (en) * | 1997-04-02 | 2002-03-12 | Gentex Corporation | Electrochromic rearview mirror incorporating a third surface metal reflector and a display/signal light |
US20020187350A1 (en) * | 2001-01-29 | 2002-12-12 | Honeywell International Inc. | Robust highly reflective optical construction |
JP4266108B2 (ja) * | 2002-09-30 | 2009-05-20 | 株式会社小糸製作所 | 車両用灯具 |
DE102005030900A1 (de) * | 2005-07-01 | 2007-01-11 | Mekra Lang Gmbh & Co. Kg | Verfahren zur Herstellung eines Fahrzeugspiegels |
-
2005
- 2005-07-01 DE DE102005030900A patent/DE102005030900A1/de not_active Withdrawn
-
2006
- 2006-06-26 US US11/474,844 patent/US20070000771A1/en not_active Abandoned
- 2006-06-29 JP JP2006179082A patent/JP2007011365A/ja active Pending
- 2006-06-30 KR KR1020060060738A patent/KR20070003686A/ko not_active Application Discontinuation
- 2006-06-30 EP EP06013643A patent/EP1739205A3/en not_active Ceased
- 2006-06-30 CN CNA2006100958694A patent/CN101042443A/zh active Pending
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JP2007011365A (ja) | 2007-01-18 |
DE102005030900A1 (de) | 2007-01-11 |
EP1739205A2 (en) | 2007-01-03 |
EP1739205A3 (en) | 2007-12-26 |
US20070000771A1 (en) | 2007-01-04 |
KR20070003686A (ko) | 2007-01-05 |
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