Multi-layer panel and method of manufacturing such a panel

Abstract

A method of manufacturing a multi-layer panel having a curved reflective and/or transmitting facing layer that includes the steps of increasing and/or decreasing pressure on a side of a thin membrane to form a pressure differential across the thin membrane that causes the thin membrane to deform to a required shape; applying a first layer of material to an outer surface of the thin membrane while the thin membrane is maintained in the required shape by the increase and/or decrease in pressure, and allowing the first layer of material to cure for a pre-determined time.

1 - 18 . (canceled) 
     
     
         19 . A mirror comprising:
 a concave thin foil membrane stiffened by a first layer placed on an outer surface of the thin foil membrane to provide structural rigidity to the mirror.   
     
     
         20 . The mirror of  claim 19 , wherein the concave thin foil membrane has a parabolic shape. 
     
     
         21 . The mirror of  claim 19 , wherein the first layer of material comprises any one of the group of materials comprising polyesters, epoxies, silicones and polyurethanes. 
     
     
         22 . The mirror of  claim 19 , wherein the first layer of material is a slow curing material. 
     
     
         23 . The mirror of  claim 19  wherein the first layer of material comprises filler to increase the viscosity of the first layer material during curing. 
     
     
         24 . The mirror of  claim 23  wherein the filler is aluminium. 
     
     
         25 . The mirror of  claim 19 , wherein the first layer of material further comprises a black dye added to the first layer of material to enhance the reflectivity of the first layer of material. 
     
     
         26 . The mirror of  claim 19 , further comprising a second layer of material, the second layer of material used to reinforce the first layer of material. 
     
     
         27 . The mirror of  claim 19 , wherein the second layer of material comprises a fibre glass mat which is impregnated with a polyester resin. 
     
     
         28 . (canceled) 
     
     
         29 . The mirror of  claim 19 , wherein the mirror has a diameter of at least 5 meters. 
     
     
         30 . The mirror of  claim 19 , wherein the foil membrane has a width of at least 6 meters. 
     
     
         31 . The mirror of  claim 19 , wherein the foil membrane is at least semi-transparent. 
     
     
         32 . The mirror of  claim 19 , wherein the foil membrane is fire retardant. 
     
     
         33 . The mirror of  claim 19 , wherein the foil membrane is an antistatic foil. 
     
     
         34 . The mirror of  claim 19 , wherein the mirror is operative to reflect virtual images 2 meters high×2 meters wide.