Glazing Surface Layer with TiO2-ZrO2 Composite for Scratch Resistance
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Solution Overview
Problem
Current glazing systems with anti-solar and low-emissive properties face challenges in achieving sufficient chemical and mechanical resistance without compromising optical properties, with previous protective layers like titanium oxide being difficult to produce and not providing comprehensive protection.
Innovation Solution
A surface layer composed of titanium oxide combined with high-hardness metal oxides such as ZrO2 and Cr2O3, with specific weight proportions and thickness, is used to enhance mechanical and chemical resistance while maintaining optical neutrality and transparency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional protective layers like SiO2 or SnO2 are used, then mechanical resistance is improved, but manufacturing difficulty increases or chemical resistance is insufficient
Solution Approach 1:
The patent uses composite material TiO2-ZrO2-SiO2-Cr2O3-HfO2-Y2O3 with specific weight ratios (TiO2: 40-70%, ZrO2: 10-30%, SiO2: 5-20%, Cr2O3: 2-10%, HfO2: 1-5%, Y2O3: 1-5%) to achieve both high mechanical resistance and ease of manufacture. The composite structure combines the hardness of ZrO2 and Cr2O3 with the chemical stability of SiO2 and TiO2, creating a surface layer that is both durable and manufacturable using standard sputtering processes.
Solution Approach 2:
The patent optimizes the thickness parameter of the protective surface layer to 3-35 nm, which provides sufficient mechanical protection while maintaining optical transparency. This parameter optimization allows the layer to function as both a protective coating and an optical filter, eliminating the need for separate thick protective layers that would compromise visibility.
2Reliability
If titanium oxide is used as protective coating, then chemical resistance is improved, but manufacturing complexity increases due to low spray speeds
Solution Approach 1:
The patent merges multiple oxide materials (TiO2, ZrO2, SiO2, Cr2O3, HfO2, Y2O3) into a single composite surface layer that can be deposited in one continuous sputtering process. This eliminates the need for multiple sequential deposition steps required by traditional titanium oxide coatings, thereby maintaining chemical resistance while significantly improving manufacturing productivity.
3Strength
If thicker protective layers are used to improve mechanical resistance, then scratch resistance is improved, but visible transmission decreases
Solution Approach 1:
The patent optimizes the thickness of the protective surface layer to a precise range of 3-35 nm. At this optimized thickness, the layer provides sufficient scratch resistance through its composite high-hardness material structure while remaining thin enough to maintain high visible light transmission. The specific composition ratios further enhance this by providing mechanical strength without excessive light absorption.
4Strength
If nitrogen atmosphere deposition is used for nitride layers, then mechanical resistance is improved, but application versatility decreases
Solution Approach 1:
The patent uses an inert or oxidizing atmosphere during sputtering deposition instead of requiring a nitrogen atmosphere. This allows the formation of oxide layers (TiO2, ZrO2, SiO2, Cr2O3) that provide mechanical resistance without the need for nitrogen-containing environments. The process is compatible with standard vacuum sputtering equipment and can be applied to various substrates including glass, plastics, and metals, thereby significantly improving application versatility.
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 proposed surface layer significantly improves mechanical resistance to scratches and chemical agents, maintains high visible transmission, and withstands humidity and salt spray tests, offering superior durability and optical performance compared to previous systems.
Implementation Method 1
functional layers that reflect infrared radiation
Implementation Method 2
dielectric layers that protect the former and minimize the reflection of visible wavelengths
Implementation Method 3
magnetron-assisted vacuum deposition techniques, known as 'magnetron sputtering'
Implementation Method 4
magnetron-assisted vacuum deposition techniques
Implementation Method 5
provide these systems with the chemical and mechanical resistance properties mentioned above
Implementation Method 6
exhibit sufficient resistance to the various forms of aggression to which it is likely to be exposed
Data Source
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Figure 3~4
AI summary
The invention relates to an essentially transparent glazing comprising an assembly of thin layers deposited in a vacuum with a magnetron, and having sun-proof and/or low-emission properties, wherein the surface protection layer comprises a layer containing titanium oxide and at least one other high-hardness metal oxide selected from the group including ZrO2, SiO2, Cr2O3.