Appliance Transparency Coating Uniformity and Heat Reflection
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Solution Overview
Problem
Conventional appliance transparencies, such as oven doors and microwave oven windows, face issues with uneven heat reflective coatings, requiring multiple coatings and components, which can lead to aesthetic and functional drawbacks like color variations and reduced visibility.
Innovation Solution
A coated transparency structure featuring a substrate with a first heat and/or radiation reflecting coating applied by chemical deposition and a second coating applied by physical deposition, comprising a gradient layer of silicon dioxide and tin oxide, and a doped metal oxide layer, along with optional reflective metal layers, to enhance visibility and reduce heat radiation transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If spray pyrolysis of fluorine-doped tin oxide coatings is used to reduce heat reflection, then heat reflection performance is improved, but coating thickness uniformity deteriorates leading to color and reflectance variations
Solution Approach 1:
The patent changes the deposition parameters by switching from spray pyrolysis to chemical vapor deposition (CVD) or atomic layer deposition (ALD). These methods provide better control over coating thickness and uniformity while maintaining the heat reflection performance of fluorine-doped tin oxide coatings.
Solution Approach 2:
The patent replaces the mechanical spray pyrolysis process with chemical vapor deposition or atomic layer deposition processes. This substitution eliminates the coating uniformity issues associated with spray methods while achieving the same thermal reflective function.
2Loss of energy
If four separate coatings are applied to two glass sheets to provide heat reflection, then heat reflection performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent merges the multiple coating steps into a single coating process on a single glass sheet. Instead of applying four separate coatings to two sheets, the invention applies one or two coatings to one glass sheet, simplifying the manufacturing process while maintaining heat reflection performance.
Solution Approach 2:
The patent makes the single glass sheet perform multiple functions that previously required two sheets. The coated glass sheet simultaneously provides structural integrity, heat reflection, and aesthetic appearance, eliminating the need for multiple sheets and coatings.
3Object-affected harmful factors
If wire mesh screen is used to prevent microwave radiation transmission, then radiation protection is improved, but visibility through the transparency deteriorates
Solution Approach 1:
The patent extracts the wire mesh screen from the microwave oven door structure. Instead of using a physical mesh that blocks visibility, the invention uses a coating on the glass that selectively blocks microwave radiation while maintaining optical transparency, thus eliminating the visibility obstruction.
Solution Approach 2:
The patent changes the approach from physical barrier (wire mesh) to functional coating. The coating modifies the electromagnetic properties of the glass to block microwaves while maintaining visible light transmission, fundamentally changing how radiation protection is achieved.
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
The solution provides improved visibility and reduced heat radiation transmission with fewer coatings, eliminating the need for multiple glass sheets and wire mesh screens, resulting in a more aesthetically pleasing and functionally effective appliance transparency.
Implementation Method 1
a first heat and/or radiation reflecting coating formed over at least a portion of the first major surface by a chemical deposition process
Implementation Method 2
a second heat and/or radiation reflecting coating formed over at least a portion of the second major surface by a physical deposition process
Implementation Method 3
These sheets have heat reflective coatings on both their inner and outer surfaces to reduce heat from the interior of the oven escaping into the ambient atmosphere
Data Source
Figure 1~2
Figure 3
AI summary
A transparency includes a substrate having a first major surface and a second major surface. A first coating is provided over at least a portion of the first major surface, the first coating including one or more metal oxide layers. A second coating is provided over at least a portion of the second major surface, the second coating including one or more metallic layers.