# US 2016/0258596 A1 · Reflector and methods of fabrication thereof

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- Number: US 2016/0258596 A1
- Document ID: US20160258596A1
- Status: Published application
- Kind: A1
- Application number: 14/634,911
- Filed: 2015-03-02
- Published: 2016-09-08
- Earliest claimed: 2015-03-02
- Assignees: GE Lighting Solutions, LLC
- Applicants: GE Lighting Solutions, LLC
- Inventors: Dengke Cai; Tianji Zhao; Mark J. Mayer; Koushik Saha; Benjamin James Ward
- Web page: https://patentgrep.com/patent/US20160258596A1

## CPC

- F21V 7/28: characterised by coatings
- G02B 1/14: Protective coatings, e.g. hard coatings
- F21V 7/10: Construction
- F21Y 2115/10: Light-emitting diodes [LED]
- G02B 5/0808: {having a single reflecting layer (G02B5/0883, G02B5/0891 take precedence)}
- F21V: FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- G02B: OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- F21Y: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED

## Abstract

A reflector that includes a substrate and a film disposed onto the substrate is provided. The film may include gas barrier layers configured to protect a reflective layer included in the film by blocking gas molecules from the top of the reflective layer and gas molecules originating from the bottom of the reflective layer.

## Claims

### Claim 1

A reflector, comprising:
a substrate;
a multilayer film disposed onto the substrate;
wherein the multilayer film includes (i) gas barrier layers configured to protect a reflective layer included in the film by blocking gas molecules originating from the top of the reflective layer and gas molecules originating from the bottom of the reflective layer; and (ii) a top layer configured to protect the reflective layer against mechanical tearing.

### Claim 2 (depends on 1)

The reflector of claim 1, wherein the multilayer film comprises a porcelain enamel layer in contact with the substrate.

### Claim 3 (depends on 1)

The reflector of claim 1, wherein at least one of the gas barrier layers is a silicon sub-oxide.

### Claim 4 (depends on 1)

The reflector of claim 1, wherein the reflective layer substantially comprises silver.

### Claim 5 (depends on 1)

The reflector of claim 1, wherein the top layer is an anti-scratching layer.

### Claim 6

A reflector, comprising:
a substrate having an interior surface;
a reflective surface supported by the substrate;
a levelling layer intermediate the interior surface and the reflective surface, the levelling layer comprising a porcelain enamel;
a gas barrier layer disposed on top of the reflective surface; and
a protective layer disposed on top of the gas barrier layer.

### Claim 7 (depends on 6)

The reflector of claim 6, further comprising another gas barrier layer disposed on top of the levelling layer.

### Claim 8 (depends on 6)

The reflector of claim 6, wherein the porcelain enamel comprises a fused mixture of one or more oxides.

### Claim 9 (depends on 6)

The reflector of claim 6, wherein the substrate is a metallic substrate.

### Claim 10 (depends on 6)

The reflector of claim 6, wherein all the layers comprised therein are made of inorganic compounds.

### Claim 11 (depends on 6)

The reflector of claim 6, wherein all the layers comprised therein include inorganic compounds.

### Claim 12 (depends on 6)

The reflector of claim 6, wherein at least one layer includes an organic material.

### Claim 13 (depends on 12)

The reflector of claim 12, wherein the at least one layer is a polymeric material.

### Claim 14 (depends on 13)

The reflector of claim 13, wherein the polymeric material has inorganic particulates embedded therein.

### Claim 15

A method of fabricating a reflector, comprising:
forming a substrate; and
disposing a film onto the substrate, the film comprising a levelling layer in contact with the substrate, and the film comprising a reflective layer;
wherein the film further comprises gas barrier layers configured to protect the reflective film from diffusive and reactive species and an anti-scratching layer configured to protect the reflective layer from mechanical tearing.

### Claim 16 (depends on 15)

The method of claim 15, wherein the substrate is a metallic substrate.

### Claim 17 (depends on 15)

The method of claim 15, wherein the levelling layer is a porcelain enamel.

### Claim 18 (depends on 15)

The method of claim 15, wherein the reflective layer is substantially made of silver.

### Claim 19 (depends on 15)

The method of claim 15, wherein one of the gas barrier layers is a based on a silicon oxide.

### Claim 20 (depends on 15)

The method of claim 15, wherein the film further comprises an anti-scratching layer.