Coated Glazing Solar Control via Multi-Layer CVD
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Solution Overview
Problem
Current self-cleaning glazings with solar control properties face manufacturing inefficiencies, increased costs, and quality issues due to the use of body-tinted glass and secondary coatings on the reverse side, which lead to wastage and handling problems.
Innovation Solution
A coated glazing with a specific layer structure comprising a transparent glass substrate coated with a sequence of layers: a first layer with a refractive index over 1.6, a second layer with a lower refractive index, a third layer based on tin dioxide doped with antimony, niobium, and/or neodymium, and a fourth photocatalytic titanium dioxide layer, deposited using chemical vapour deposition (CVD) to provide self-cleaning and solar control properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If body-tinted glass is used to provide solar control properties, then light transmittance is reduced, but manufacturing efficiency decreases and wastage increases
Solution Approach 1:
The invention extracts the solar control function from the glass substrate itself and relocates it to a separate coating layer. Instead of incorporating metal oxide tints into the glass batch (body-tinting), the patent applies a multi-layer coating where the first layer has solar control properties. This separation allows the glass to be produced in standard clear or tinted forms without manufacturing disruptions, while the coating provides the required solar control, thus resolving the contradiction between light transmittance control and manufacturing efficiency.
Solution Approach 2:
The invention segments the solar control function from the glass substrate by creating a distinct coating layer. The coating is divided into multiple layers with specific functions: the first layer provides solar control, the second layer (optional) provides optical properties, and the third layer provides self-cleaning properties. This functional segmentation allows each layer to be optimized independently and eliminates the need to modify glass production processes, thereby maintaining manufacturing efficiency while achieving desired light transmittance levels.
2Illumination intensity
If a second coating is deposited on the reverse side using PVD, then solar control properties are achieved, but manufacturing costs increase and handling issues arise
Solution Approach 1:
The invention merges multiple functions into a single coating applied to one side of the glass. Instead of using PVD to deposit a second coating on the reverse side, the patent applies a multi-layer coating system to one side where the first layer provides solar control, the second layer (optional) provides optical properties, and the third layer provides self-cleaning properties. This consolidation eliminates the need for separate PVD processing on the reverse side, reducing manufacturing complexity and handling requirements while achieving all desired properties in one coating process.
Solution Approach 2:
The coating system is designed with multi-functionality where a single coating structure performs multiple roles. The first layer provides solar control, the optional second layer provides optical properties, and the third layer provides self-cleaning properties. This universal coating design eliminates the need for separate specialized coatings on the reverse side, simplifying the manufacturing process and reducing handling complexity while achieving comprehensive solar control and additional functional properties.
3Illumination intensity
If sputter coating is used on the reverse side, then optical properties are provided, but coating robustness decreases and handling becomes difficult
Solution Approach 1:
The invention replaces the PVD/sputter coating process with a chemical vapour deposition (CVD) process. CVD coatings are known to be more robust and better adhered to the substrate compared to PVD coatings. By using CVD to deposit the multi-layer coating system on one side of the glass, the patent achieves the required optical properties while simultaneously improving coating robustness and reducing handling difficulties, thus resolving the contradiction between providing optical properties and maintaining coating strength.
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 effectively attenuates visible light and solar energy, offering attractive blue coloration and improved manufacturing efficiency by eliminating the need for body-tinted glass and reducing handling issues, while maintaining self-cleaning activity and solar control properties.
Implementation Method 1
a first layer having a refractive index of more than 1.6
Implementation Method 2
an optional second layer having a refractive index that is less than the refractive index of the first layer
Implementation Method 3
a fourth layer based on titanium dioxide, wherein the fourth layer is photocatalytic
Implementation Method 4
Photocatalytic activity arises by the photogeneration, in a semiconductor, of a hole-electron pair when the semiconductor is illuminated by light of a particular frequency
Implementation Method 5
Self-cleaning glazings have a hydrophilic surface. Rain or other water which contacts the hydrophilic surface will spread over the surface and wash dirt away from it
Implementation Method 6
water which contacts the hydrophilic surface will spread over the surface
Implementation Method 7
a third layer based on tin dioxide doped with antimony, niobium and/or neodymium
Implementation Method 8
attenuation of the visible light and solar energy transmitted through the coated glazing
Data Source
AI summary
A coated glazing includes a transparent glass substrate, and a coating located on the glass substrate. The coating is provided with at least the following layers in sequence starting from the glass substrate: a first layer having a refractive index of more than 1.6, an optional second layer having a refractive index that is less than the refractive index of the first layer, a third layer based on tin dioxide doped with antimony, niobium and/or neodymium, and a fourth layer based on titanium dioxide, wherein the fourth layer is photocatalytic.