Dichroic Filter Sputtering With Water Vapor for IR-Reflecting Composites
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Solution Overview
Problem
Existing methods struggle to produce transparent, infrared-reflecting composites with high visible light transmittance while minimizing near-infrared transmittance without compromising physical integrity and color neutrality.
Innovation Solution
A method involving sputter deposition with controlled introduction of water vapor in the range of 1% to 30% relative to inert gas flow to deposit dichroic filters, comprising metal layers sandwiched between dielectric layers, optimizing layer thickness and structure for enhanced visible light transmission and reduced near-infrared reflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional multi-layer construction methods are used to achieve complex composite structures, then structural complexity and functionality are improved, but manufacturing time and production costs increase
Solution Approach 1:
The composite structure is divided into discrete modular units (blocks) that can be independently manufactured and then assembled. Each block contains integrated reinforcement elements and energy-reflecting materials, allowing parallel production of multiple blocks rather than sequential layering, thereby reducing overall manufacturing time while maintaining structural complexity.
Solution Approach 2:
Reinforcement elements (rebars, meshes, fibers) are pre-positioned within formable blocks before the concrete matrix is applied. Energy-reflecting materials are also pre-integrated into specific blocks. This preliminary arrangement eliminates the need for time-consuming on-site layering and positioning operations, significantly accelerating production while preserving the intended multi-layer composite architecture.
2Adaptability or versatility
If conventional multi-layer construction methods are used to achieve complex composite structures, then structural complexity and functionality are improved, but production costs increase
Solution Approach 1:
By segmenting the composite into standardized blocks with integrated reinforcements and energy-reflecting materials, the system enables bulk purchasing and standardized manufacturing of components. This reduces per-unit costs compared to custom on-site construction, while the modular nature preserves structural complexity and adaptability.
Solution Approach 2:
Multiple functions (structural reinforcement, concrete matrix, energy-reflecting capability) are merged into single integrated blocks. This consolidation eliminates the need for separate procurement and installation of reinforcement materials and energy-reflecting layers, reducing labor costs and material handling expenses while maintaining the multi-functional composite performance.
3Ease of manufacture
If conventional construction methods are used, then material placement flexibility is maintained, but construction time and labor requirements increase
Solution Approach 1:
All material placement operations (reinforcement positioning, energy-reflecting material installation, concrete application) are performed in advance during block fabrication. This preliminary action transfers the flexibility requirement to the manufacturing phase rather than the construction phase, allowing rapid on-site assembly without compromising material placement quality.
Solution Approach 2:
The construction process is segmented into independent block fabrication and on-site assembly phases. Material placement flexibility is exercised during block manufacturing under controlled conditions, while the construction phase benefits from reduced time requirements due to the pre-prepared modular units.
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 method achieves a significant reduction in near-infrared transmittance while maintaining high visible light transmittance and color neutrality, providing improved energy shielding and temperature control in various environments.
Implementation Method 1
a concrete matrix in which steel reinforcement bars and wire mesh are embedded
Implementation Method 2
at least one energy-reflecting composite block includes a polymeric material having a dielectric constant between 2.25 and 12.96... such that electromagnetic energy incident upon the energy-reflecting composite is reflected
Data Source
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AI summary
Disclosed is a method for the production of a visual light transmitting and infra-red reflecting composite including, adhered to one side of a transparent support, at least one dichroic filter (DF) which filter comprises at least one metal layer that is sandwiched in between two layers of dielectric metal oxide, dielectric compound or dielectric salt, wherein the layers of the filter are deposited sequentially onto the transparent support using sputter-deposition in at least one sputtering chamber, wherein the process comprises, in the sputtering chamber where at least one of the dielectric layers is sputtered, the introduction of at least one inert gas and water, and wherein the molar flow of the water that is introduced into the sputtering chamber is in the range of 1% to 30% relative to the total molar flow of inert gas that is introduced into the same sputtering chamber.