Method of manufacturing reflectors for a solar concentrator apparatus

Abstract

Glass reflectors for concentrating sunlight in a solar energy system are disclosed. A concave mold is used to shape the glass reflectors in which the surface of the mold that contacts the float glass has a grooved surface profile comprising a plurality of cusps. The surface of the mold also has a plurality of concave valleys. Glass reflectors are preferably manufactured by heating a sheet of float glass positioned over the mold until the sheet of glass sags to contact the mold. If necessary, the glass may also stretch to conform to the shape of the mold. In the case of large monolithic glass reflectors, the edges of the dish-shaped glass are rolled around the periphery of the mold. The glass reflector is then silvered to create a dish-shaped mirror that reflects solar radiation to a focus.

1 . (canceled) 
     
     
         2 . A method of manufacturing a curved glass reflector for use in a solar energy system, comprising the steps of:
 heating a sheet of glass positioned over a mold having a plurality of adjacent concave grooves that intersect in cusps providing a cusp surface profile;   forming the sheet of glass into a curved dish shape conforming to the cusp surface profile of the mold by sagging and stretching the sheet of glass using gravitational force until the sheet of glass touches the cusps of the mold, the cusp surface profile of the mold limiting thermal conduction between the mold and the glass; and   cooling the sheet of glass to prevent continued drooping of the sheet of glass between the cusps of the mold.   
     
     
         3 . The method of  claim 2 , further comprising the step of:
 creating a reflective surface on the sheet of glass that has been formed into a curved dish shape so that said glass is adapted for use to reflect solar energy to a focal point for conversion in a solar energy system.   
     
     
         4 . The method of  claim 2 , wherein the mold has been coated with chromium. 
     
     
         5 . The method of  claim 2 , wherein the mold has been coated with nickel. 
     
     
         6 . The method of  claim 2 , wherein the mold has been coated with a nickel-chromium alloy.