Apparatus for forming a nanostructured thin film with porosity gradient on an array of sloped outdoor panel surfaces using meniscus drag
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Solution Overview
Problem
Current methods for retrofitting silicon photovoltaic panels and glass windows with thin-film antireflective coatings are costly and disruptive, as they require dismantling and reprocessing, and existing light reflection sensors are inadequate for measuring large areas effectively, leading to inefficient application and quality control of these coatings.
Innovation Solution
A portable coating apparatus that uses meniscus drag deposition to apply a nanostructured thin film with a porosity gradient on sloped panel surfaces, allowing for uniform coating application without dismantling and incorporating a portable light reflectance sensor for efficient quality control and feedback in the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional thin-film coating methods are used for retrofitting photovoltaic panels and glass windows, then high-quality uniform coatings can be achieved, but the process requires dismantling and reprocessing which is costly and disruptive
Solution Approach 1:
The patent replaces traditional mechanical coating systems (spray booths, dip tanks, roller coaters) with a portable meniscus drag applicator that can be manually moved across large surfaces. This substitution enables high-quality coating application directly on installed panels and windows without requiring dismantling or specialized manufacturing facilities, thus resolving the contradiction between coating quality and retrofitting ease.
Solution Approach 2:
The patent employs meniscus drag deposition with controlled capillary action to achieve uniform film thickness through parameter optimization (viscosity, surface tension, withdrawal speed). This allows precise control of coating parameters in field conditions, maintaining manufacturing precision while enabling easy retrofitting application.
2Measurement precision
If fiber optic probe sensors are used to measure coating quality, then precise spot measurements can be obtained, but the small spot size is insufficient to accurately represent the average performance across the whole solar panel
Solution Approach 1:
The patent combines multiple fiber optic probe measurements across different locations on the panel surface to create a comprehensive assessment of average coating performance. By merging data from multiple precise spot measurements, the system overcomes the limitation of small spot size and accurately represents overall coating quality.
Solution Approach 2:
The patent implements a feedback control system where real-time sensor measurements of coating thickness and uniformity are fed back to adjust coating parameters during application. This ensures that the average performance across the entire panel meets specifications while maintaining precise control at each measurement location.
3Manufacturing precision
If multiple readings are taken with fiber optic probes to develop statistically significant samples, then accurate average coating performance can be estimated, but the process becomes cumbersome and time consuming
Solution Approach 1:
The patent implements continuous coating application with real-time continuous monitoring, eliminating the need for multiple discrete readings. The meniscus drag applicator deposits coating continuously while sensors continuously measure thickness and uniformity, providing statistically significant data without interrupting the coating process, thus maintaining high productivity.
Solution Approach 2:
The portable applicator system integrates multiple functions into a single device: coating application, real-time thickness measurement, uniformity assessment, and quality control feedback. This multi-functional integration eliminates the need for separate measurement devices and multiple readings, speeding up the overall process while maintaining assessment accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective, efficient application of high-quality, uniform thin-film coatings on large surfaces, improving energy transmission and reducing glare, while allowing on-site retrofitting of photovoltaic panels and glass windows, and providing accurate, rapid assessment of coating quality.
Implementation Method 1
uses at least one or more meniscus drag deposition mechanisms to deposit a solution
Implementation Method 2
which then forms a nanostructured thin film with a porosity gradient dependent at least in part on the evaporation of the various solvents
Implementation Method 3
incorporating a portable light reflectance sensor for efficient quality control and feedback in the coating process
Data Source
AI summary
A thin-film coating applicator assembly is disclosed for coating substrates in outdoor applications. The innovative thin-film coating applicator assembly is 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.