Multi-Layer Solar Control Coating Reducing Haze
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Solution Overview
Problem
Solar control coatings used in architectural and automotive applications face challenges with durability and maintaining optical properties over time, particularly in degrading environments, which affects their performance in blocking or filtering solar radiation.
Innovation Solution
A multi-layered functional coating comprising a substrate with a first layer, a seed layer, a metallic layer, a primer layer, and a second layer, applied in specific atmospheric conditions, using materials like titanium, niobium, and stainless steel to enhance durability and optical performance, and reduce haze when heated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If solar control coatings are applied to block or filter solar radiation, then solar energy transmittance is reduced, but coating durability and optical properties degrade over time
Solution Approach 1:
The coating is divided into multiple functional layers including a first layer, seed layer, metallic layer, primer layer, and second layer. Each layer serves a specific function: the first layer provides initial solar control, the seed layer prepares the surface, the metallic layer enhances durability and optical properties, the primer layer ensures adhesion, and the second layer provides additional protection. This segmentation allows each layer to optimize its specific function while collectively maintaining coating durability.
Solution Approach 2:
The coating employs composite material structures with different layers made from various materials suited to their specific functions. The metallic layer incorporates materials that provide both durability and optical performance, while the primer and seed layers use materials optimized for adhesion and surface preparation. This composite approach ensures the coating maintains both solar control functionality and long-term durability.
2Illumination intensity
If visible light transmittance is increased to allow driver visibility, then solar radiation blocking performance is reduced
Solution Approach 1:
The coating applies different optical properties to different regions of the spectrum. The first layer, metallic layer, and second layer are configured to selectively block solar infrared and ultraviolet radiation while allowing visible light to pass through. The seed layer and primer layer ensure proper adhesion and surface preparation. This local quality differentiation enables the coating to provide both visibility and solar radiation blocking simultaneously.
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 maintains its durability and optical properties, effectively blocking or filtering solar radiation while ensuring high visible light transmittance and reducing haze, even after heat treatment, thus enhancing the performance of solar control coatings.
Implementation Method 1
applying a seed layer in the second chamber under the second atmosphere over and in direct contact with at least a portion of the first layer
Implementation Method 2
moving the substrate into a second chamber comprising a second atmosphere, wherein the second atmosphere comprises not greater than 15 vol. % N2 and not greater than 5 vol. % O2
Implementation Method 3
These solar control coatings block or filter selected ranges of electromagnetic radiation, such as, in the range of solar infrared or solar ultraviolet radiation
Implementation Method 4
The coated article has reduced haze after heating to a temperature of greater than or equal to 1,000° F.
Data Source
AI summary
A coated article includes a substrate and a functional coating applied over at least a portion of the substrate, the functional coating including: a first layer over the substrate; a seed layer over the first layer, the seed layer selected from the group consisting of titanium, titanium aluminum, niobium, titanium niobium, stainless steel, mixtures thereof, alloys thereof, and combinations thereof; a metallic layer over the seed layer; a primer layer over the metallic layer, the primer layer selected from the group consisting of titanium, titanium aluminum, niobium, titanium niobium, nickel chromium, stainless steel, mixtures thereof, alloys thereof, and combinations thereof; and a second layer over the primer layer. A method of making the coated article, a method of reducing haze in a coated article, a method of protecting a metallic layer in a coated article, an insulating glass unit, and a windshield are also provided.