Patterned Coated Glass for Bird Collision Reduction
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Solution Overview
Problem
Current coated articles with functional coatings on substrates lack efficient methods to integrate patterned features that enhance optical properties and durability, particularly in insulating glass units, where microabrasions and asymmetric patterns are not effectively addressed for improved solar control and visibility.
Innovation Solution
A coated article comprising a substrate with a functional coating that includes a base layer, multiple metallic layers, and a top layer, where the second side features a patterned microabrasion design, enhancing optical properties and durability through a layered structure that includes microabrasions and asymmetric patterns, applied using methods like chemical vapor deposition or physical vapor deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a functional coating is applied to the second side of the substrate, then solar control and energy efficiency are improved, but bird collision safety and optical visibility deteriorate
Solution Approach 1:
The functional coating is divided into multiple separate metallic layers (first metallic layer, second metallic layer, third metallic layer) with intervening dielectric layers between them. This segmentation allows each layer to contribute differently to optical properties, enabling solar control functionality while maintaining visibility and reducing bird collisions through the combined effect of the layered structure.
Solution Approach 2:
The coating uses composite material structure combining multiple metallic layers (silver, aluminum, or other reflective metals) with dielectric layers (oxides, nitrides, or other insulating materials). This composite approach enables simultaneous achievement of solar reflectance, visible light transmission, and durability, resolving the contradiction between energy efficiency and safety/visibility.
2Loss of energy
If a functional coating is applied to the second side of the substrate, then solar control is improved, but optical visibility deteriorates
Solution Approach 1:
The coating is segmented into multiple metallic layers with different optical characteristics, separated by dielectric layers. The first metallic layer provides solar reflectance, while the second and third metallic layers enhance visible light transmission. The dielectric layers between them control interference effects, enabling simultaneous solar control and optical visibility.
Solution Approach 2:
The invention changes multiple parameters of the coating system: thickness of each metallic and dielectric layer, composition of materials, and arrangement sequence. By optimizing these parameters, the coating achieves specific optical performance targets for both solar control and visible light transmission, resolving the contradiction between energy efficiency and visibility.
3Ease of manufacture
If a simple coating structure is used, then ease of manufacture is improved, but durability and optical properties deteriorate
Solution Approach 1:
The coating is segmented into multiple functional layers, each with specific purposes: first metallic layer for solar reflection, dielectric layers for protection and optical control, second and third metallic layers for enhanced performance. This segmentation improves durability and optical properties while remaining manufacturable through sequential deposition processes.
Solution Approach 2:
The composite structure combining metallic and dielectric materials provides both durability and optimal optical properties. The dielectric layers protect the metallic layers from oxidation and damage, while the metallic layers provide solar control. This composite approach enhances reliability without significantly complicating the manufacturing process.
4Ease of manufacture
If a simple coating structure is used, then ease of manufacture is improved, but solar control and durability deteriorate
Solution Approach 1:
The coating is segmented into multiple metallic layers (first, second, and third) with dielectric layers between them. This segmentation enables superior solar control through cumulative reflection and interference effects, while the manufacturing process remains straightforward by depositing each layer sequentially using standard coating equipment.
Solution Approach 2:
The composite structure of multiple metallic and dielectric layers achieves enhanced solar control performance that cannot be obtained with simple single-layer coatings. The different materials contribute different optical properties, and their combination provides superior solar reflectance and energy efficiency while remaining manufacturable through conventional multi-layer deposition techniques.
Data Source
AI summary
A coated article includes a substrate comprising a first side comprising a first surface and a second side comprising a second surface, wherein the second surface is opposite the first surface and a functional coating positioned over at least a portion of the second side. The functional coating includes a base layer positioned over at least a portion of the second surface, wherein the base layer includes a first film positioned over at least a portion of the second surface and a second film positioned over at least a portion of the first film; a metallic layer positioned over at least a portion of the base layer; and a top layer positioned over at least a portion of the metallic layer. The second side comprises a patterned feature. Methods of making a coated article and an insulating glass unit are also provided.