U.S. patent number 3,790,748 [Application Number 05/261,420] was granted by the patent office on 1974-02-05 for mirror having electrical heating means.
This patent grant is currently assigned to Glaverbel. Invention is credited to Pol Baudin, Jean-Claude Hoyois, Robert Van Laethem.
United States Patent |
3,790,748 |
Van Laethem , et
al. |
February 5, 1974 |
MIRROR HAVING ELECTRICAL HEATING MEANS
Abstract
A mirror comprising a sheet of chemically tempered glass has a
light reflecting coating on one face thereof and an electrically
conductive heating element positioned either on the other face of
the glass or on a face of a second glass sheet. A layer of
electrically insulating material is positioned between the heating
element and light reflecting coating and this layer may constitute
the sheet of glass, a sheet of plastic, or a space having a gaseous
medium therein. The heating element is connectable to a source of
electricity and generates heat by the Joule effect. The heating
element is in heating relationship to the mirror so that this
generated heat is transmitted to the mirror.
Inventors: |
Van Laethem; Robert (Loverval,
BE), Baudin; Pol (Ransart, BE), Hoyois;
Jean-Claude (Gilly, BE) |
Assignee: |
Glaverbel (Watermael-Boitsfort,
BE)
|
Family
ID: |
10134344 |
Appl.
No.: |
05/261,420 |
Filed: |
June 9, 1972 |
Foreign Application Priority Data
|
|
|
|
|
Jun 9, 1971 [GB] |
|
|
19736/71 |
|
Current U.S.
Class: |
219/219;
219/543 |
Current CPC
Class: |
A47G
1/02 (20130101); B32B 17/10761 (20130101); F24D
13/022 (20130101); H05B 3/845 (20130101); B32B
17/10055 (20130101); F24D 13/02 (20130101); B32B
17/10174 (20130101); G02B 7/1815 (20130101); B32B
17/10036 (20130101); Y02B 30/00 (20130101); Y02B
30/26 (20130101) |
Current International
Class: |
A47G
1/02 (20060101); A47G 1/00 (20060101); F24D
13/02 (20060101); G02B 7/18 (20060101); H05B
3/84 (20060101); H05b 001/00 () |
Field of
Search: |
;219/219,543 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
Corning Glass Works Product Information, "Pyrex Brand E-C Heated
Mirror" Bulletin IC-7, Nov, 2, 1959.
|
Primary Examiner: Albritton; C. L.
Attorney, Agent or Firm: Jaskiewicz; Edmund M.
Claims
1. A mirror comprising a support sheet of glass, a light reflecting
coating on a face of said support sheet, a second sheet of glass,
an electrically conductive heating element disposed on said second
glass sheet in heating relationship to said support sheet, means
for connecting said heating element to a source of electricity so
that heat is generated by the Joule effect in said heating element,
there being a layer of electrically insulating material between
said light reflecting coating and said
2. A mirror as claimed in claim 1 wherein said layer of
electrically
3. A mirror as claimed in claim 1 wherein said layer of
electrically
4. A mirror as claimed in claim 3 wherein said polymeric material
comprises
5. A mirror as claimed in claim 1 wherein said support and said
second
6. A mirror as claimed in claim 1 wherein said electrically
conductive heating element is positioned between said support sheet
and said second
7. A mirror as claimed in claim 1 wherein said electrically
conductive heating element is on the face of said second sheet away
from said support
8. A mirror as claimed in claim 7 and comprising a protective layer
over
9. A mirror as claimed in claim 8 wherein said protective layer
comprises a coating of at least one of SiO.sub.2 and a sheet of a
polymeric material
10. A mirror as claimed in claim 1 wherein said light reflecting
coating is
11. A mirror as claimed in claim 10 and comprising an opaque layer
between
12. A mirror as claimed in claim 1 wherein said support sheet and
the light
13. A mirror as claimed in claim 1 wherein said support sheet and
said second sheet with their respective light reflecting coating
and heating element being spaced, and a gaseous medium in the space
between said
14. A mirror as claimed in claim 13 and comprising means
permanently securing said support sheet and said second sheet
together along their
15. A mirror as claimed in claim 14 wherein said securing means
comprises a
16. A mirror as claimed in claim 13 wherein said securing means
comprises a
17. A mirror as claimed in claim 1 and comprising removeable means
around the edtes of said support sheet and said second sheet for
binding said sheets together in face-to-face relationship whereby
said sheets can be
18. A mirror as claimed in claim 1 wherein said support sheet
comprises a sheet of tempered glass having the light reflecting
coating on one face thereof, a protective coating overlying said
light reflecting coating, a second sheet of glass with said layer
of electrically conductive heating element being on a face thereof,
and a sheet of plastic material uniting said support sheet and said
second sheet between said heating element
19. A mirror as claimed in claim 1 wherein said support is of
chemically
20. A mirror as claimed in claim 1 wherein said electrically
conductive heating element comprises a coating of one selected from
the group of gold, copper, silver, aluminum, chromium, SnO.sub.2,
In.sub.2 O.sub.3 and graphite.
Description
The conventional mirror which comprises a sheet of glass having a
silver coating on a face thereof is susceptible to fogging or
misting from the moisture condensed from the atmosphere. In order
to prevent this fogging of the mirror it has been proposed to pass
electric current through the silver coating. It was contemplated to
develop heat by the Joule effect in the optical or light reflecting
layer so that this heat will be transmitted to the glass sheet by
virtue of the intimate contact between the silver coating and the
glass. THe conduction of heat from the silver layer to the glass
would heat the glass sufficiently to raise the temperature of the
surface of the glass above the dew point of the atmosphere in
contact with the mirror.
This proposed heating of the mirror had several disadvantages. It
was not possible to manufacture the mirror in accordance with high
safety standards required for those mirrors which were to be
installed in bathrooms where the air humidity is high. Further, the
higher the humidity of the atmosphere in which the mirror is to be
used, the greater must be the electrical heating current in order
to heat sufficiently the mirror to raise its temperature above the
dew point of the atmosphere. A further problem was that the
requirement for the light reflecting coating to also perform a
heating function imposed additional restrictions on the
specifications to which this light reflecting coating must be made
and applied.
It is therefore the principal object of the present invention to
provide a novel and improved mirror having an electrical heating
element.
It is another object of the present invention to provide a mirror
whose temperature can be safely raised by means of an electrical
heating element associated therewith, which is simple in
construction and safe in operation.
It is an additional object of the present invention to provide a
novel and improved manner of mounting an electrically conductive
heating element in heat relationship to a mirror.
The objects of the present invention are achieved and the
disadvantages of the prior art as described above are eliminated by
the present invention. The present invention essentially discloses
a mirror having a support sheet with a light reflecting coating on
one side thereof. The mirror is also provided with electrically
conductive material constituting a heating element or heating
elements which can be connected to a source of electrical energy
for generating heat by the Joule effect. THe electrically
conductive heating element is electrically insulated from the light
reflecting coating completely or partially by at least one
intervening layer of electrically insulating material which
intervening layer or one of the intervening layers, if there is
more than one layer, may be constituted by the support sheet.
The insulating layer may comprise a layer of organic material
between the heating element and light reflecting coating or a sheet
of organic polymeric material between these coatings. The heating
element may be in the form of an electrically conductive coating on
the support sheet. This coating may be transparent and thus can be
applied to the front face of the mirror in front of the light
reflecting coating.
There may also be provided a second sheet upon which is applied the
heating element in the form of an electrically conductive material.
This second sheet may be spaced from the support sheet and
separated therefrom by an air gap, by electrically insulated
material or by a sheet of plastic.
The mirrors constructed according to the present invention provide
several significant advantages. Since the heating and optical or
light reflecting functions are performed by different components of
the mirror the thickness and chemical composition of the light
reflecting coating can be selected independently of any
considerations of the heating function. This represents a
significant improvement over known mirrors wherein a high degree of
light reflectivity must be provided by a coating or layer which
must also function as a resistance heating element. Secondly, an
important safety factor is obtained by providing an electrical
insulation of the heating element from the sheet of glass coated
with the light reflecting layer. It may appear that the electrical
insulation of the heating elements from the mirror glass is a
disadvantage since this glass is the structure which must be
heated. In actual practice, however, the increase in the safety of
the mirror more than compensates for any slight additional heating
current which may be required because of the presence of the
electrical insulation. A further advantage obtained by providing an
electrical insulation between the heating element and the light
reflecting coating is that it is now possible to construct a mirror
in which sufficient heat can be generated so that the mirror can
function as a heating source or a space heater.
Various insulating materials can be employed to form at least one
insulating layer between the electrical heating element and the
light reflecting coating. Materials can also be used which form an
insulating layer in the form of a coating.
Other objects and advantages of the present invention will be
apparent upon reference to the accompanying description when taken
in conjunction with the following drawings, which are exemplary,
wherein;
FIG. 1 is a cross-sectional view of an electrically heated mirror
incorporating the present invention;
FIG. 2 is a front elevational view of a glass support sheet upon
which the electrically conductive material is applied in a
plurality of spaced zones;
FIGS. 3 and 4 are cross-sectional views of two modifications of
electrically heated mirrors according to this invention;
FIGS. 5 and 6 are cross-sectional views of two further
modifications wherein the sheets are in spaced relationship;
FIGS. 7, 8 and 9 are cross-sectional views of additional
modifications wherein the mirror comprises a plurality of layers or
sheets; and
FIG. 10 is a cross-sectional view of another modification of the
invention wherein the mirror comprises a single coated sheet.
Proceeding next to the drawings wherein like reference symbols
indicate the same parts throughout the various views a specific
embodiment and modifications of the present invention will be
described in detail.
The mirror illustrated in FIG. 1 comprises a transparent sheet 1 of
chemically tempered float glass having on one face a highly visible
light reflecting coating 2 of metallic silver, a coating layer 3 of
copper to protect the silver coating, and a coating 4 of protecting
paint or varnish. These elements correspond with the components of
a conventional mirror.
The mirror of FIG. 1 further comprises a second sheet 5 of
chemically tempered glass precoated with a layer 6 of metallic gold
to define an electrically conductive element. This layer 6 is
connected to a source of electricity by means of electrical
conductors or wires, not shown in the drawing, which are soldered
to the heating element 6. These wires may be soldered to opposite
edges of the sheet 5 to function as electrical contacts on the
completed mirror.
The sheet 5 with its coating 6 is secured to the sheet 1 by an
intervening layer 7 of polyvinylbutyral foil which is softened in
situ by subjecting the assembly to heat and pressure. The heating
element 6 may comprise an all-over coating of electrically
conductive material or this element may comprise an electrically
conductive coating applied to one or more band-like zones on the
surface of sheet 5.
The heating efficiency of the mirror of FIG. 1 is very high because
the resistance heating element 6 is enclosed between glass sheets
and the heat generated as a result of electric current flowing
through the layer 6 is used predominantly to increase the
temperature of the laminate in order to keep the mirror free of
condensed moisture. The heating effect is considerably greater than
it would be if heat were generated by passing electric current
through the silver layer 2 since the layer 2 must be appreciably
thicker than the gold layer 6 in order to assure the necessary high
degree of light reflection.
According to the present invention it is preferred that the heating
element is in the form of an electrically conductive coating on the
support sheet. By utilizing the heating element in the form of a
coating the assembly of the components of the mirror are
facilitated and there is achieved a very good heat distribution
over the area of the mirror. The electrically conductive coating
can be transparent for certain applications. It is therefore
possible for the electrically conductive coating through which the
heating current is passed to be positioned on the mirror in front
of the light reflecting coating. While this particular arrangement
is not preferred it is particularly adaptable for mirrors in which
a high degree of safety is not a prime consideration but in which
it is desired to provide in front of the light reflecting coating a
transparent coating which can impart color by reflecting light in a
particular part of the visible spectrum. The chemical composition
of the electrically conductive coating or coatings can thus be
selected to achieve the required selective light reflection.
Where the electrically conductive coating is positioned behind the
light reflecting coating the electrically conductive coating can
then be either transparent or opaque.
Instead of the above described electrically conductive coating
there may be provided an electrical resistance element in the form
of a wire or wires. The wires can project from the margins of the
mirror to function as integral contacts connectable to a voltage
source. This arrangement of the wires avoids the necessity for
terminals to be soldered to the mirror.
The heating element in the form of a conductive coating may extend
over at least the greater portion of the area of the mirror. This
will enable a uniform heat distribution to be achieved over the
entire mirror or at least over the most important portion
thereof.
By positioning the silver layer 2 and gold layer 6 between the
glass sheets as described above these layers are effectively
protected against abrasion and corrosion. Under certain
circumstances it may be desirable to apply a further coating onto
the gold layer 6 in order to prevent adhesion to the
polyvinylbutyral foil 7. Such a layer may comprise Bi.sub.2
O.sub.3.
In another embodiment (No. 2) of the mirror shown in FIG. 1 sheets
1 and 5 were of ordinary soda-lime glass of the following
composition by weight: 72% SiO.sub.2, 12.5% Na.sub.2 O, 0.09%
K.sub.2 O, 9.4% CaO, 3% MgO, 3% Al.sub.2 O.sub.3, 0.01% Fe.sub.2
O.sub.3. The sheets were 3 mm. in thickness and each measured 62.5
cm .times. 45 cm.
The sheet 1 was coated with a layer of silver 2, a protective layer
of copper 3 and a layer 4 of paint or varnish to protect the silver
layer. The layers 2, 3 and 4 were of the conventional thicknesses
used in the manufacture of mirrors and known in the art.
On sheet 5 there was applied a coating 6 of bismuth oxide, a layer
of gold and a further layer of bismuth oxide. The optical
thicknesses of the first and second bismuth oxide layers were 50
and 150 A, whereas the gold layer had an optical thickness of 100
A.
The intervening sheet 7 comprised a sheet of polyvinylbutyral 0.4
mm. in thickness.
The gold layer was connected to a source of electrical current
having a potential of 30 volts. The power consumption of the mirror
was 65 watts which was sufficient to keep the mirror free from
misting under the high humidity conditions such as would by
encountered in a bathroom. The connection from the gold layer to
the source of electric current was made by conductor wires which
were electrically connected to the gold layer at the opposed
shorter sides of the mirror by electrodes formed by band-like
deposits of copper applied by flame-spraying. The width of the
electrodes was about 5 mm.
The electrical power which is supplied to the electrical heating
element depends upon the utilisation of the article. In general, a
power of 250 watts/m.sup.2 suffices to maintain the temperature of
the mirror sufficiently high to prevent misting. A higher
electrical power, e.g. of the order of 1,000 Watts/m.sup.2, will
normally be appropriate in the case that the mirror has also to
serve as a heating panel, i.e. as a space heater.
In a modification of the above described Embodiment No. 2
constructed as shown in FIG. 2, the gold layer was replaced by a
heating element consisting of an electrically conductive coating
applied along seven spaced parallel bands or strips on the sheet 5
and along marginal end zones to form electrodes which were
connected to a source of electric current at 220 volts. With this
heating element the voltage of the electric current source was
increased even though the optical thickness of the electrically
conductive coating forming the heating element remained the same,
namely, 100 A. As a result, the temperature of the mirror was
maintained considerably higher than when an all-over gold layer was
used as the heating element.
In an embodiment (No. 3) of a mirror constructed as shown in FIG. 2
an electrically conductive coating was applied on the surface of an
ordinary glass sheet 8 measuring 102 cm .times. 78 cm to form
seventeen spaced parallel conductive threads or bands joined by
marginal end electrodes 10. Each of these strips 9 was one meter in
length and 0.6-0.7 mm. in width with the thickness of each strip
being 10 to 15 microns. The strips were spaced a distance of 43 mm.
apart. The conductive strips 9 were formed of an aluminum alloy
comprising 95 percent by weight of aluminum and 5 percent by weight
of antimony. The strips were formed by abrasion transfer wherein a
rotating disc composed of the alloy was guided along the surface of
the glass sheet 8 in frictional contact therewith.
The electrodes 10 and 11 were formed by flame-spraying copper onto
the surface of the glass sheet. The electrodes were connected to an
8 volt source of electrical current. The power consumption of the
mirror was 240 watts which was sufficient to maintain the mirror
free from misting in conditions of high atmospheric humidity.
In another embodiment (No. 4) of the invention similar to
Embodiment No. 2 the heating element comprised a layer of
SnO.sub.2. This layer was deposited chemically on a glass sheet 5
measuring 45 cm .times. 60 cm and the layer had a thickness of
1,000 A. The layer was connected to a source of electrical current
at 220 volts at which the power consumption of the mirror was about
70 watts.
In accordance with the teaching of this invention the mirror
disclosed herein can also function as a space heater in the room in
which it is installed, usually a bathroom. In a further embodiment
(No. 5) such a mirror has the general construction of the mirror
shown in FIG. 1 and comprises a glas sheet 5 of thermally tempered
glass having a thickness of 5 mm. The sheet 1 was a sheet of
ordinary soda glass manufactured by the float process in which the
molten glass was applied on the surface of a bath of molten tin.
The thickness of sheet 1 was 6.35 mm. The sheet was subjected to a
chemical tempering treatment which involved immersing the sheet in
a bath of molten potassium nitrate at a temperature of
470.degree.C. During the period of immersion, sodium ions contained
in surface layers of the sheet were replaced by potassium ions
deriving from the bath of molten potassium nitrate. Since the
potassium ions were of a greater diameter than the sodium ions
which they replaced, the ion exchange set up compressive surface
stresses in the glass sheet while the internal layers of the glass
were in tension. The planeity of the faces of the sheet was
excellent.
The heating element 6 was formed by depositing on the sheet 5 a
layer of bismuth oxide (Bi.sub.2 O.sub.3), layer of gold, and then
a further layer of bismuth oxide. These three layers had optical
thicknesses of 50 A, 100 A and 150 A respectively. These layers
were applied onto an area of the sheet 5 measuring 60 cm .times. 45
cm. Copper electrodes were deposited in contact with the gold layer
at the extremities of the shorter side of the coated area.
The use of tempered glass sheets enabled a higher electrical power
input to be used than was possible with the mirrors of the
preceding embodiment (No. 4). The electrodes were connected to a
source of electrical current at 70 watts under which conditions the
power consumption was 1,400 watts/m.sup.2 and the mirror was
maintained at a sufficiently high temperature to serve as an
effective space heater.
In a further modification the heating layer comprised layers of
gold applied along three bands running parallel with the longer
dimension of the sheet and along transverse zones electrically
connecting the three bands in series. With this heating element it
was possible to use an input voltage of 220 volts.
Still another embodiment (No. 6) of an electrically heated mirror,
serving also as a space heater, was made in the general form
illustrated in FIG. 1. The sheet 1 was a sheet of soda-lime glass
of ordinary composition (as described in Embodiment No. 2) 3 mm. in
thickness. On this sheet 1 a light reflecting layer of silver was
deposited and this layer was protected by a copper layer 3 and a
paint layer 4. The thicknesses of the layers 2, 3 and 4 were 100
m.mu. 200 m.mu. and 0.3 mm.
The heating panel component comprised a sheet 5 of thermally
tempered glass 4 mm. in thickness, on which electrically conductive
strips 9 (FIG. 2) composed of an aluminium alloy, the number and
dimensions and spacing of the threads, and the composition of the
aluminium alloy being as specified in Embodiment No. 3, were formed
by abrasion transfer. The threads were connected in parallel by end
electrodes 10, 11 (FIG. 2) formed by deposited copper, also as
specified in above.
The mirror and heating panel components were secured together as a
laminate by means of an interposed sheet 7 of polyvinylbutyral 0.38
mm. in thickness.
Bonding these sheets of coated glass by a sheet of plastic material
is advantageous since it provides a high resistance to damage of
the coatings and a secure bonding of the coated sheets by means of
the intervening plastics sheet. The components of the mirror can be
readily united under heat and pressure to cause the plastic sheet
to serve as a bonding medium with or without the interposition of
additional adhesive.
The mirror was connected to a source of electric current at 10
Volts, under which conditions the power consumption was of the
order of 700 Watts which was sufficient for heating a room of small
dimensions.
A still further embodiment (No. 7) of an electrically heated mirror
of the form shown in FIG. 1 was made in the manner described in
Embodiment No. 5 with however the modification that the sheet 5 was
replaced by a sheet of thermally tempered glass and the heating
element was composed of a layer of SnO.sub.2, 200 A in optical
thickness. The mirror was connected to a source of electric current
at 220 Volts under which conditions the power consumption was 1,400
Watts/m.sup.2.
Another embodiment (No. 8) of an electrically heated mirror of the
form shown in FIG. 3 was made, incorporating a mirror component,
comprising the sheet 12 and the coating 13, 14 and 15, which was of
conventional construction e.g. as described in Embodiment No. 2. As
indicated in FIG. 3 the coatings did not extend to the margins of
the sheet 12. The heating component comprised a layer 17 of
In.sub.2 O.sub.3 deposited on a sheet of glass 16 of ordinary
composition. A peripheral marginal zone of the sheet 16 was left
uncoated. The mirror and heating panel components were secured to
an intervening peripheral spacer 18 made of silicone which was
glued to the uncoated margins of the sheets 12 and 16, and forms an
endless joint between them to seal the interior space 19.
The dimensions of the mirror were 62 cm .times. 45 cm.
The layer 17 of In.sub.2 O.sub.3 was formed by chemical deposition
in situ and had an optical thickness of about 800 A.
The heating element was connected to a source of electric current
at 200 Volts under which conditions the power consumption was of
the order of 250 Watts/m.sup.2.
Another embodiment (No. 9) of an electrically heated mirror was
made which was similar to that described in Embodiment No. 8 but
wherein the heating element was constituted by strips of copper
applied along spaced parallel bands, and along transverse
connecting zones, so that the heating element was of the kind shown
in FIG. 2. In use, the electric current flows through strips 9 in
parallel. An electrically conductive coating or coatings on spaced
parallel zones is favourable for achieving a relatively high
density of the heating current for a given applied voltage. In
cases in which the electrically conductive coating or coatings is
or are present in front of the light reflecting coating responsible
for the mirror effect, the degree of light transparency of the
electrically conductive coating or coatings is not so critical in
the case that the coating or coatings is or are on spaced zones of
the substrate.
There were ten parallel copper strips, equally spaced across the
width of the sheet 16 and having a length of 58 cm, a width of 0.5
cm and a thickness of 0.01 mm. The copper strips were glued onto
the surface of the sheet 16 by means of a layer of polyvinylbutyral
0.4 mm. in thickness.
The heating element was connected to a source of electric current
at 1.2 Volts, under which conditions the power consumption was 75
Watts which was sufficient to keep the mirror free from misting in
an atmosphere of high relative humidity.
In certain embodiments of the invention the heating element is
located between the support sheet and a second sheet. By
sandwiching the heating element between component sheets of the
mirror, electrical energy saving is promoted due to a reduction in
the amount of heat which is dissipated without heating the mirror.
The shielding of the heating element is also beneficial from the
point of view of safety and for protecting the heating element from
damage.
In Embodiment No. 10, a mirror having the general form shown in
FIG. 4 was made, using for the mirror component a sheet 20 of
thermally tempered glass, 6 mm. in thickness, having a layer 21 of
silver, a layer 22 of copper and a layer of paint 23 of
conventional thicknesses.
The heating panel component is of laminated structure and comprised
sheets 24 and 25 of ordinary glass, 2.5 mm. and 3 mm. in thickness,
respectively, the sheets having been subjected to a chemical
tempering treatment of the kind described in Embodiment No. 5. The
sheet 24 was coated on one side with a layer 26 of copper, 100
m.mu. thickness, by evaporation in vacuo. The coated sheet 24 was
united with the sheet 25 by a sheet 27 of polyvinylbutyral 0.3 mm.
in thickness, to form a laminate. Constructing of the mirror as a
laminate is advantageous because the all-over bonding of the
several layers renders the mirror resistant to any penetration of
air or moisture between the layers, and these layers are securely
held in their proper relationship during all normal handling in the
course of transportation or otherwise.
The heating panel component thus formed was joined to the mirror
component by a spacer comprising a peripheral layer 28 of a
silicone, 2 mm. in thickness to seal the interior space 30.
The use of a bonding medium between the margins of the coated
sheets significantly facilitates the assembly of the components of
the mirror.
Another embodiment (No. 11) of an electrically heated mirror of the
form shown in FIG. 4 was made in the same way as the mirror
described in Embodiment No. 10 with, however, the modification that
the heating element 26 was constituted by a layer of
polyvinylbutyral covered by a thin film or pellicule of graphite.
Electrically conductive contacts or electrodes were connected to
the graphite coating before laminating the coated sheet 24 with the
sheet 25 by means of the polyvinylbutyral sheet 27. THe electrodes
were connected to a source of electric current at a voltage
sufficient to keep the temperature of the mirror sufficiently high
to prevent condensation of moisture on the face of the mirror when
it was installed in conditions of high relative humidity.
Another embodiment (No. 12) concerns a mirror of the form shown in
FIG. 5 and adapted to serve as a heating radiator.
The mirror comprised two sheets 31 and 34 of ordinary tempered
glass measuring 60 cm .times. 45 cm.
The sheet 31 was chemically tempered using a technique similar to
that described in Embodiment No. 5, and the sheet 34 was thermally
tempered.
The chemically tempered glass sheet 31 was coated with a layer 32
of silver 100 m.mu. in thickness, the peripheral margin of the
sheet 31 being, however, left uncoated. The silver layer was
covered by a chromium oxide layer 33, 200 m.mu. in thickness which
was applied by means of a conventional low frequency cathodic
sputtering in vacuo, as well known per se. The chromium oxide layer
completely covered the silver layer and extended onto the marginal
zone of the sheet 31 so as to ensure that the silver layer was
effectively protected from chemical corrosion and was effectively
electrically insulated.
The thermally tempered glass sheet 34 was coated with a layer 35 of
tin oxide (SnO.sub.2), serving as heating element. The tin oxide
layer was built up by successive chemical depositions of tin oxide
to achieve a total layer thickness sufficient to obtain a power
distribution of 275 Watts/m.sup.2 under a voltage input of 220
Volts. It was found that it was suitable for the tin oxide layer to
have a thickness of 850 A for this purpose.
In a modification, a layer of In.sub.2 O.sub.3, of the same
thickness, was used in place of the layer of tin oxide.
The sheets 31 and 34, coated as above described, were held in
spaced relation by two frame members 36 made of copper and having
tinned inner faces, the said frame members being fitted along
opposed margins of the sheets 31 and 34. The tinned inner faces of
the frame members 36 made contact with the tin oxide coating 35
constituting the heating element. The frame members 36 were
connected to the opposed poles of a source of electric current to
serve as electrodes. For safety reasons, the frame members 36 were
covered on the outside by electrically insulating members or
material (not shown). The frame members also protect the edges of
the sheets.
Because of the presence of the electrically insulating layer 33,
the frame members 36 were insulated from the silver layer 32 so
that when the unit was in use no electric current passed through
the silver layer.
When the unit is installed so that the frame members 36 are
vertical the heat generated in the unit maintains a convection
current of air through the space 37 between the coated sheets.
In a modification, the margins of the coated sheets 31 and 34 were
held in a frame which comprised, in addition to the frame members
36, two further frame members which extended along the other
opposed margins of the sheets. The coated sheets were thus held in
a complete rectangular frame. In this case it was necessary to
ensure that the additional frame members were electrically
insulating or were electrically insulated from the members 36 in
order not to short-circuit the electrical system. In such a
modification, it is possible to provide one or more holes in each
of two opposed frame members, e.g. in the frame members 36, in
order to ensure equalisation of pressure between the interior space
37 and the surrounding atmosphere.
A mirror substantially the same as that described in Embodiment No.
12 was made, with however the difference that the heating element
35 was constituted by spaced electrically conductive bands to
provide a better distribution of the electrical heating current.
The electrically conductive bands were also composed of SnO.sub.2
formed by chemical deposition in situ. The bands had a length of 73
cm and a width of 1 cm, and were spaced apart by 0.5 cm. The
thickness of the deposited bands resulted in a power consumption of
375 Watts under an alternating applied voltage of 220 Volts.
Another embodiment (No. 14) comprised a mirror of the general form
shown in FIG. 6. This mirror employed sheets 38 and 41 of ordinary
glass, 3 mm. in thickness, which had been subjected to a chemical
tempering treatment of the kind described in Embodiment No. 5.
The sheets 38 and 41 were coated, sheet 38 with a gold layer 39,
150 A in thickness and with an electrically insulating layer 40
composed of SiO.sub.2, 150 A in thickness, and the sheet 41 with an
electrically conductive layer 42 of silver.
The coated sheets 38 and 41 were held in spaced relation by a frame
comprising two opposed members 43 made of a refractory material,
and two brass components (not shown) serving as electrodes in
contact with the electrically conductive layer 39. The brass
components are formed so that they did not make contact with the
silver layer 42.
The mirror and heating panel components and the frame members were
assembled so that, in the finished product, the interior space 44
was hermetically sealed. Prior to being sealed, this space was
filled with a dehydrated gas at a reduced pressure. Under these
circumstances the silver layer 42 was not subject to oxidation.
When such unit is heated, the temperature of the gas in the space
44 rises and the gas consequently expands. The pressure in the
space 44 when the unit is in unheated condition is such that the
sheets 38 and 41 are brought into substantially flat condition by
the higher pressure which prevails in the space 44 when the unit is
heated. The appropriate pressure can be determined experimentally,
the voltage applied to the heating element being carefully and very
gradually increased towards the required operative value in
successive tests.
In a modification, sheets 38 and 41 were of different thicknesses.
The sheet 41 which bore the silver layer was of substantially
greater thickness, e.g. 8 mm., and the sheet 38 was a thinner
sheet, e.g. 2 mm. in thickness. In this modification, the sheet 41
remained flat at all times, whereas the sheet 38, which is hidden
from view behind the mirror when the unit is in use, flexes so as
to preserve a pressure substantially equal to atmospheric pressure
in the space 44.
Another embodiment (No. 15) related to a mirror having
substantially the structure shown in FIG. 7. The mirror comprised a
sheet of ordinary glass 45, bearing a silver layer 46 and a
protective silicone layer 47, and a sheet 48 of ordinary glass
bearing a heating element 49 composed of a layer of
polyvinylbutyral impregnated with graphite, and a sheet of "Mylar"
50 to protect the graphite conductive layer.
The coated sheets 45 and 48 and the "Mylar" sheet 50, which are
shown spaced apart in the drawing in the interest of clarity, were
held together by pieces of adhesive tape which were bound around or
applied across margins of the sheet assembly.
A further embodiment (No. 16) of a mirror was made from components
which are shown in FIG. 8. These components include a heating panel
component comprising a sheet 53 of thermally tempered glass of
ordinary composition, bearing a silver laYer 54, and a protective
thermally insulating top layer 55 made of "Teflon." The second
component is the mirror component which comprises a sheet 51, which
is also a sheet of thermally tempered ordinary glass and which
bears a conductive layer of aluminium 52. Electrodes (not shown)
are connected to opposed margins of this layer.
This protective coating 55 constitutes an electrically insulating
layer between the conductive coating 54 and the light reflecting
coating 52 when the different components are brought together in
face-to-face contact or when the components are connected in spaced
relationship, in which latter case the space 56 between the coated
sheets may be very much narrower than that shown in the drawing.
The coated sheets 51, 53 may for example be held together by
adhesive material applied between the margins of the coated
sheets.
The two coated sheets, which are shown spaced apart in the interest
of clarity, were held together in face-to-face contact by steel
clamping members of U-section which were fitted over margins of the
assembled sheets.
Another embodiment (No. 17) relates to a mirror having components
as shown in FIG. 9. The mirror comprises sheets of ordinary glass
57 and 59. The sheet 57 bears a light reflecting layer 58 of
silver, and the sheet 59 bears an electrically conductive layer 60
composed of tin oxide (SnO.sub.2) to which electrodes (not shown)
are connected. The coated sheets were clamped together by a
suitable adhesive so that the silver layer 58 was directly
contacted by the uncoated face of the glass sheet 59. The sheets
can also be clamped in spaced relation to leave a space 61
therebetween.
As an illustration of specific possible modifications of the mirror
described with reference to FIG. 9, it can be modified in any one
or more of the following ways:
a. by interposing a plastics sheet between the sheets 57 and
59;
b. by uniting the sheets in the alternative relationship i.e. so
that the glass sheet 57 contacts the layer 60;
c. by covering the layer 60 by a protective sheet of plastics
material;
d. by adopting features a and c in combination.
Positioning the heating element on the side of the second sheet
away from the support sheet is advantageous, particularly in
mirrors which do not have to comply with high safety standards and
in which it is desirable for an appreciable amount of generated
heat to be radiated from the mirror to enable the mirror to serve
as a space heater. When the heating element is on the outer face of
the second sheet a protective layer may cover the heating element,
particularly in those cases where the heating element is
constituted by a coating of electrically conductive material.
A further embodiment (No. 18) of a mirror in accordance with FIG.
10 was made by applying to one face of a sheet 62 of thermally
tempered ordinary glass, a light reflective silver layer 63 and by
applying to the other face of the said glass sheet a transparent
electrically conductive layer 64 of gold.
This mirror had a golden hue, viewed by reflected light.
The mirror described with reference to FIG. 10 can, for example, be
modified by:
a. covering the layer 63 and/or the layer 64 by a protective sheet
of plastics material;
b. covering the layer 63 and/or the layer 64 by a sheet of
transparent glass.
Various insulating materials can be used for forming at least one
insulating layer between the electrical heating element or elements
and the light reflecting coating. Examples of insulating materials
which are useful in various cases are: TiO.sub.2, ZrO.sub.2,
Cr.sub.2 O.sub.3, and Fe.sub.2 O.sub.3. These materials can be used
to form an insulating layer in the form of a coating.
In the most preferred embodiments of the invention the mirror
includes, in addition to said support sheet, a second sheet which
bears a coating or coatings constituting said heating element or
elements.
Such a construction feature affords important advantages. In
particular, the mirror components can very easily be assembled
because what is involved in this operation is the bringing together
of two pre-coated sheets and the preparation of the sheets is
relatively simple because they can be independently processed in
ways which are most suited to the particular coating compositions
employed.
The invention includes mirrors in which there is the support sheet
and a second sheet bearing an electrically conductive coating, and
in which both sheets are substantially rigid. The assembly of the
component sheets is easier when the main components are rigid
sheets than when one or each of them is flimsy. In preferred
embodiments of the invention, each of said support sheet and said
second sheet is a sheet of glass. The use of glass for both sheets
is particularly desirable because glass is a very satisfactory
substrate material for bearing the electrically conductive coating
as well as the light reflecting coating and because mirror
production usually proceeds in a flat-glass production factory.
The heating element is constituted by an electrically conductive
coating or coatings selected from: Au, Cu, Ag, Al, Cr, SnO.sub.2,
In.sub.2 O.sub.3 and graphite. For the support sheet and the second
sheet preferance is given to the use of glass sheets but sheets of
other material can be used. Examples of suitable sheets are ceramic
sheets, sheets of vitrocrystalline or vitroceramic material and
sheets of plastics, a sheet of wired glass, also sheets comprising
a combination of two or more of such materials, with the proviso
that sheets which are not transparent cannot be used in front of
the light reflecting coating. The plastic material should be
capable of withstanding the temperature to which it is raised by
the heat generated in the heating element.
The use of sheets of thermally or chemically tempered glass is
preferred because tempered glass can have a very high tensile
strength and its use is therefore an advantage for the strength of
the article. Chemically tempered glass is especially recommended
because of its ability to withstand substantial strains imposed by
substantial temperature variations.
Various methods may be employed in constructing a mirror according
to the invention, for coating the support sheet and the said second
sheet. By way of example, a light reflecting layer composed of
gold, copper, silver or aluminium can be formed by evaporation in
vacuo. High frequency sputtering can be used for applying a coating
of gold, copper, silver or aluminium whereas a low frequency
sputtering technique may be used for deposition layers of gold,
silver, copper, bismuth oxide, chromium oxide and cadmium oxide.
Layers of SnO.sub.2 and In.sub.2 O.sub.3 and various other coating
substances can be applied by chemical deposition.
In order to improve the adhesion of a given coating substance to a
substrate, the latter may be precoated with a snubbing or attaching
layer. For example, a sheet of glass which is to serve as a support
sheet can be coated with chromium preparatory to the application of
a gold coating so as to improve the gripping of the gold layer.
Various materials suitable for forming a solid insulating layer
have already been referred to in the course of the foregoing
description. Other insulating materials which can be used include
TiO.sub.2, AnO.sub.2, Sr.sub.2 O.sub.3, CoO and Fe.sub.2
O.sub.3.
The front face of a mirror according to the invention may bear an
optical coating, e.g. an anti-reflecting coating, preventing or
restricting reflection of light from the front face of the
mirror.
The use of chemically tempered float glass is advantageous since
such a glass sheet has a precisely flat surface for receiving the
light reflecting coating which is desirable for mirrors of high
optical quality.
It is understood that this invention is susceptible to modification
in order to adapt it to different usages and conditions, and,
accordingly, it is desired to comprehend such modifications within
the invention as may fall within the scope of the appended
claims.
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