Low-Reflection Coated Glass Plate for Photoelectric Devices
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Solution Overview
Problem
Existing low-reflection coatings on glass substrates for photoelectric conversion devices are prone to damage, contamination, and deterioration during production and outdoor use, leading to reduced light transmission and efficiency.
Innovation Solution
A low-reflection coating comprising a porous film with 35-70% solid spherical silica particles and a binder containing silica and a hydrophobic group, applied to the glass substrate after assembly, providing a transmittance gain of 1.5% or more and excellent contamination removal properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a low-reflection coating is formed on the glass substrate using conventional methods (vacuum deposition, sputtering, CVD, or fine particle-containing film), then the light transmittance is increased, but the coating is prone to damage, contamination, and deterioration during production and outdoor use
Solution Approach 1:
The patent employs a porous low-reflection coating layer containing fine pores with an average diameter of 0.1 to 10 μm and a porosity of 10 to 80%. This porous structure reduces the refractive index of the coating, enhancing light transmittance while the interconnected pore network provides pathways for contamination removal and reduces stress concentration, thereby improving durability during production and outdoor use
Solution Approach 2:
The patent creates a composite coating structure combining inorganic fine particles (silica, alumina, zirconia, or titania with average diameter 0.01 to 1 μm) dispersed in a binder resin matrix. This composite structure provides both the optical properties needed for high transmittance and the mechanical properties for durability, while the fine particles reinforce the coating against damage and contamination
2Illumination intensity
If the low-reflection coating is applied before assembly, then the light transmission efficiency is improved, but the coating becomes vulnerable to damage during subsequent production processes
Solution Approach 1:
The patent applies the low-reflection coating after the glass substrate and other components are assembled into the final device structure. This preliminary action of coating at the final stage protects the coating from mechanical damage, chemical exposure, and contamination that would occur during subsequent production processes, while still achieving the desired light transmission efficiency enhancement
Solution Approach 2:
The patent uses a thin film coating with a thickness of 1 to 20 μm that is flexible enough to conform to the glass substrate surface and resistant enough to withstand handling and assembly processes. The thin film structure provides sufficient optical performance while minimizing the risk of damage during production
3Illumination intensity
If a fine particle-containing film is used as low-reflection coating, then the transmittance gain is achieved, but the coating surface is prone to contamination adhesion
Solution Approach 1:
The patent employs a porous coating structure with interconnected pores that allows contamination particles to be trapped within the pore network rather than adhering to the outer surface. The porous structure with 10 to 80% porosity creates a tortuous path for contaminants, reducing their ability to adhere firmly and facilitating easier cleaning and maintenance
Solution Approach 2:
The patent introduces a binder resin as an intermediary material that disperses fine inorganic particles and creates a surface morphology resistant to contamination adhesion. The binder resin matrix with specific surface properties acts as a mediator between the inorganic particles and the environment, reducing the tendency for organic and inorganic contaminants to adhere to the coating surface
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 coating achieves high transmittance gain and chemical durability, effectively resisting contamination and wear, maintaining light transmission efficiency even under outdoor conditions.
Implementation Method 1
a porous film having a thickness of 80 to 800 nm and comprising: fine silica particles being solid and spherical and having an average particle diameter of 80 to 600 nm; and a binder containing silica as a main component and containing a hydrophobic group
Implementation Method 2
low-reflection coating which is a porous film... the low-reflection coating produces a transmittance gain of 1.5% or more when provided on the substrate
Implementation Method 3
a binder containing silica as a main component and containing a hydrophobic group... excellent contamination removal properties
Data Source
Figure 1
AI summary
The low-reflection coating of the present invention is adapted to be provided on at least one principal surface of a substrate. The low-reflection coating is a porous film having a thickness of 80 to 800 nm, the porous film including: fine silica particles being solid and spherical and having an average particle diameter of 80 to 600 nm; and a binder containing silica as a main component and containing a hydrophobic group, the fine silica particles being bound by the binder. The low-reflection coating contains 35 to 70 mass% of the fine silica particles, 25 to 64 mass% of the silica of the binder, and 0.2 to 10 mass% of the hydrophobic group of the binder. The low-reflection coating produces a transmittance gain of 1.5% or more when provided on the substrate.