Conductive Coating for Electrodeposition on Non-Conductive Glass
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Solution Overview
Problem
Existing electrocoating processes are limited in applying conductive coatings to non-conductive substrates like glass, as they require the substrate to be electrically charged, which is not possible with non-conductive materials, and metal particle-containing primers can degrade at elevated temperatures, affecting optical and solar control properties.
Innovation Solution
A method involving the formation of a conductive coating, typically an inorganic coating with metal layers, over a substrate using techniques like chemical vapor deposition or magnetron sputter vapor deposition, which can then act as an electrode for electrodeposition of a polymeric coating, allowing for the application of electrocoats on non-conductive substrates without charging the substrate itself.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a non-conductive substrate like glass is used, then optical and solar control properties are maintained, but the substrate cannot be electrically charged to act as an electrode in the electrocoating process
Solution Approach 1:
A conductive coating is applied as an intermediary layer between the non-conductive glass substrate and the electrocoating process. This conductive coating serves as the electrode that can be electrically charged, while the glass substrate itself remains electrically inactive but retains its optical properties. The conductive coating mediates the electrical requirements of electrodeposition without compromising the optical performance of the glass.
2Ease of operation
If a metal particle-containing resinous primer is applied to provide conductivity, then the substrate can be electrocoated, but the primer can decompose or disintegrate at elevated temperatures used to coat glass sheets
Solution Approach 1:
The invention changes the material parameters of the conductive coating from organic resin-based to inorganic oxide-based materials. This parameter change enables the conductive coating to withstand the high temperatures (typically above 400°C) required for glass coating processes without decomposing or disintegrating, while still maintaining electrical conductivity for the electrodeposition process.
Solution Approach 2:
The conductive coating is formed as a composite inorganic material comprising metal oxide particles dispersed in a glass matrix. This composite structure provides both the electrical conductivity needed for electrodeposition and the thermal stability required to withstand glass coating temperatures. The metal oxide particles maintain their conductive properties while the glass matrix provides thermal resistance.
3Ease of operation
If a conductive coating is formed over the substrate, then a conductive surface is provided for electrodeposition, but the coating thickness and composition must be precisely controlled to maintain optical properties
Solution Approach 1:
The conductive coating is designed with locally optimized properties where metal oxide particles are strategically distributed within the glass matrix. The concentration and size of metal oxide particles are controlled to provide sufficient conductivity only in the regions where electrodeposition is needed, while maintaining optical transparency in other regions. This local quality approach allows precise control over both conductive and optical properties.
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 the application of electrocoats on non-conductive substrates like glass without compromising their optical and solar control properties, providing a conductive surface for electrodeposition while maintaining the substrate's integrity.
Implementation Method 1
forming at least one conductive coating over at least a portion of the substrate by a process selected from chemical vapor deposition or magnetron sputter vapor deposition
Implementation Method 2
forming at least one conductive coating over at least a portion of the substrate by a process selected from chemical vapor deposition or magnetron sputter vapor deposition
Implementation Method 3
At least one polymeric coating material can be electrodeposited over at least a portion of the conductive coating
Data Source
AI summary
A coated article includes a non-conductive substrate, such as glass. At least one conductive coating is formed over at least a portion of the substrate, such as by chemical vapor deposition or physical vapor deposition. The conductive coating can be a functional coating and can have a thickness in the range of greater than 0 Å to less than 25,000 Å, such as less than 10,000 Å. At least one polymeric coating is electrodeposited over at least a portion of the conductive coating.