Method for Forming a Nanostructured Thin Film with Porosity Gradient on an Array of Sloped Outdoor Panel Surfaces Using Meniscus Drag
a nanostructured thin film and meniscus technology, applied in the direction of climate sustainability, building components, construction, etc., can solve the problems of inability to meet the requirements of high-quality thin-film coating retrofitting photovoltaic panels and window panes, inability to meet the requirements of light reflection from a relatively large spot size, and inability to achieve high-quality thin-film coatings. , the effect of reducing the cost of retrofitting and reducing the cost of retrofi
Inactive Publication Date: 2020-04-02
DEVOS JOHN ARTHUR
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Benefits of technology
The patent describes a new device that can apply a layer of liquid coating to the surface of different objects such as solar panels and windows. This coating can make the object more durable and resistant to moisture. The device can also change the thickness and hardness of the coating based on the needs of the object. The coating can be applied using different methods such as spray-coating or roller coating. The thickness of the coating can be adjusted by different parameters like viscosity of the coating solution. The device can apply a single layer or multiple layers of coating. Overall, this patent describes a portable and versatile tool for applying coatings to improve the performance of various objects.
Problems solved by technology
However, retrofitting older panels not originally coated with antireflective coatings requires dismantling of the photovoltaic array and sending the individual panels to a factory or facility for coating, an expensive and disruptive endeavor.
Currently, there are no viable, cost effective solutions for retrofitting photovoltaic panels and window panes with high quality thin-film coatings.
Currently available light reflection sensors are not capable of measuring the light reflection from a relatively large spot size on the top surface of solar panels installed in the field and comparing the results before and after application of a performance enhancement coating.
The very small spot size analyzed by a typical sensor using a fiber optic probe is insufficient to accurately measure in one reading an area large enough to determine the average performance across the whole solar panel of solution deposited performance enhancing coatings.
This is due in part because variations in the top surface structure of solar panel cover glass and variations in solution deposited coating may not be adequately represented within the very small spot size read by the fiber optic probe.
The process of taking numerous measurements and transporting and setting up a typical fiber optic sensor with a separate computing device for each solar panel to be measured is relatively cumbersome and time consuming compared with a device with integrated computing and human readable display that can determine the average performance difference in light reflection properties by taking just one measurement before and just one measurement after application of a performance enhancement coating.
In addition, a thin film necessarily presents more than one reflective interface from which incident light can reflect to create destructive interference conditions suppressing the light reflected from each interface.
By focusing on optimizing optical properties, many commercial AR coatings suffer from inferior mechanical properties, such as low abrasion resistance, brittleness, short lifespan and low thermal / chemical stability.
In all cases, the manufacture of multiple layer coatings is inherently more expensive and complicated in comparison to application of a single layer.
Furthermore, the high curing temperatures preclude the possibility of applying optical coatings outside of a manufacturing environment, where specialty ovens or heat treating assembly lines are necessary to applying and baking optical coatings on large substrates such as photovoltaic panels.
Over time for large arrays, these small increases in conversion efficiency translate to significant increases in profit margins for commercial operations.
The endeavor is highly disruptive and costly both in downtime and processing costs.
No examples are currently available describing a single layer optical coating having both optimized optical and mechanical characteristics and that cures at temperatures less than 100° C. Moreover, no example of an optical coating method or process exists to produce a single layer optical coating with tuned optical, mechanical and chemical properties on demand, whereby the important properties can be easily tuned to meet the environmental demands of the substrate.
Method used
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[0105]Referring to FIG. 1, the inventive apparatus for forming a nanostructured thin film with porosity gradient on an array of sloped outdoor panel surfaces using meniscus drag comprises an applicator A100 which mounts onto an array of sloped outdoor panel surfaces A101, and that uses at least one or more meniscus drag deposition mechanisms A102 to deposit a solution A103 comprising various solvents, partially polymerized siloxanes, and amorphous silica with a wet film thickness ranging from 5 um to 100 um which then forms a nanostructured thin film A104 comprising nanostructured silica and ranging in thickness from 50 nm to 250 nm with a porosity gradient dependent at least in part on the evaporation of the various solvents onto the sloped outdoor panel surfaces A105. In at least multiple locations across the nanostructured thin film A104 (ranging across at least 20%-80% or more of the nanostructured thin film A104, the porosity gradient ranges from at most 30% porosity nearest at...
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Abstract
A method of forming a thin film coating on sloped outdoor panel surfaces is disclosed. The method uses a thin-film coating applicator assembly for coating substrates in outdoor applications. The innovative method of forming a thin-film coating may be adapted to apply performance enhancement coatings on installed photovoltaic panels and glass windows in outdoor environments. The coating applicator is adapted to move along a solar panel or glass pane while applicator mechanisms deposit a uniform layer of liquid coating solution to the substrate's surface. The applicator assembly comprises a conveyance means disposed on a frame. Further disclosed are innovative applicator heads that comprise a deformable sponge-like core surrounded by a microporous layer. The structure, when in contact with a substrate surface, deposits a uniform layer of coating solution over a large surface.
Description
CROSS REFERENCES TO RELATED APPLICATIONS[0001]This application claims priority to U.S. Provisional Patent Application Ser. No. 62 / 739,326 filed on Sep. 30, 2018, entitled “A Method for Forming a Nanostructured Thin Film with Porosity Gradient on an Array of Sloped Outdoor Panel Surfaces Using Meniscus Drag”, the disclosure of which is hereby incorporated by reference.[0002]This application refers and includes material from U.S. Pat. No. 10,010,902 filed on Sep. 26, 2016 entitled “Thin-film coating apparatus for applying enhanced performance coatings on outdoor substrates”, and U.S. Patent Application No. 2018 / 014,5628 filed on May 15, 2016 entitled Sensor for “Measuring Reflected Light for Optimizing Deposited Performance Enhancement Coatings on Substrates”, and U.S. patent application Ser. No. 15 / 129,403 filed on Sep. 26 2016 entitled “Low Temperature Curable Energy Transmission Enhancement Coatings Having Tunable Properties Including Optical, Hydrophobics and Abrasion Resistance”,...
Claims
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Login to View More IPC IPC(8): H01L31/0216B05D1/02G02B1/11F24S70/30C09D5/00C09D7/61C09D7/40C09D7/20C09D183/04
CPCC09D7/61C03C17/007C03C2217/73H01L31/02168G02B1/11C03C2218/118C09D7/20C09D183/04F24S70/30B05D1/02C03C17/002C09D7/67C03C2218/113C09D5/006C03C17/009C03C2218/114C03C2218/112C03C2217/478C03C2217/445C03C2217/732B05D1/26B05D5/061B05D2401/10B05D2518/12G02B1/18G02B1/113G01N21/8422G01N2021/8416G01N2021/8427G01N21/55Y02B10/20Y02E10/40Y02E10/50H01L31/048C09D183/02B82Y30/00B82Y40/00C09D7/70C08K3/36C08K2201/011C08K7/26C08L83/00B05C1/16B05C5/0291G01N21/6489H01L31/0481B05B7/0093B05B12/004B05C5/027C03C17/25E06B9/24E06B2009/2417B05C1/06B05D2601/22
InventorDEVOS, JOHN ARTHUR
OwnerDEVOS JOHN ARTHUR