Siloxane Nanoparticle Coating for Controlled Pore Size
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Solution Overview
Problem
Existing methods for creating antireflective coatings on substrates, such as glass, do not effectively produce a porous surface layer with controlled pore size, which limits their ability to enhance light transmissivity and durability.
Innovation Solution
A method involving the use of a coating composition comprising siloxane nanoparticles formed from a mixture of alkoxy silane compounds with organofunctional groups, where the reaction between these compounds creates an organic linking group that, upon drying and heating, forms a porous surface layer with controlled pore size on an inorganic substrate, enhancing light transmissivity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If existing methods are used to create antireflective coatings, then the coating can be applied to the substrate, but the porous surface layer with controlled pore size cannot be effectively produced
Solution Approach 1:
The patent applies porous materials by creating a porous surface layer through the use of siloxane nanoparticles containing organic linking groups. When the coating is applied and heated, the organic linking groups volatilize, leaving behind a porous structure with controlled pore sizes less than 30 nm. This porous structure is essential for achieving both the desired light transmissivity enhancement and durability.
Solution Approach 2:
The patent utilizes parameter changes by controlling the pore size through the selection and ratio of specific siloxane compounds (e.g., TEOS, TMOS, MTES, MPTES). By adjusting the molecular parameters of the precursor materials and the heating conditions, the pore size can be precisely controlled to optimize both light transmissivity and coating durability.
2Illumination intensity
If a porous surface layer is created to enhance light transmissivity, then light transmissivity increases by 1.5-4%, but the coating durability may be compromised without proper pore size control
Solution Approach 1:
The patent employs porous materials with specifically controlled pore sizes (less than 30 nm) to achieve the desired balance between light transmissivity and durability. The porous structure enhances light transmission while the controlled pore size prevents excessive penetration that would compromise coating integrity and durability.
Solution Approach 2:
The patent uses composite materials by combining multiple siloxane compounds with different molecular structures and properties (e.g., TEOS, TMOS, MTES, MPTES) in specific ratios. This composite approach allows the coating to exhibit both high light transmissivity enhancement (1.5-4%) and improved durability through the synergistic effects of the different siloxane components.
3Manufacturing precision
If siloxane nanoparticles with organic linking groups are used, then a porous surface layer can be formed upon heating, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by pre-synthesizing siloxane nanoparticles containing organic linking groups before applying the coating. These pre-formed nanoparticles are designed to automatically volatilize the organic groups upon heating, eliminating the need for complex post-processing steps to create the porous structure. The porous layer forms automatically during the standard heating process.
Solution Approach 2:
The patent uses an intermediary approach by introducing organic linking groups as temporary mediators within the siloxane nanoparticle structure. These organic groups serve as placeholders that facilitate the formation of the porous structure during heating, acting as a mediator that transforms the dense coating into a porous structure without requiring complex manufacturing equipment or processes.
4Illumination intensity
If the average pore size is reduced to less than 30 nm, then light transmissivity is enhanced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent applies parameter changes by systematically adjusting the molecular parameters of the siloxane precursor compounds and their ratios. By changing parameters such as the type of siloxane (TEOS, TMOS, MTES, MPTES), their molecular weights, and their proportions in the coating composition, the pore size can be precisely controlled to be less than 30 nm, achieving both high light transmissivity and manageable manufacturing precision.
Solution Approach 2:
The patent uses composite materials by formulating a mixture of different siloxane compounds with complementary properties. This composite siloxane system allows for precise control of pore size through the synergistic interactions between different siloxane molecules, achieving the target pore size of less than 30 nm while maintaining reasonable manufacturing precision through standard coating and heating processes.
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 results in a porous surface layer with average pore sizes less than 30 nm, significantly increasing light transmissivity by 1.5-4% across various wavelengths and improving the durability of the coating, as demonstrated by increased resistance to salt bath testing and linear Taber abrasion.
Implementation Method 1
heating the coated substrate to volatilize the organic linking groups thereby forming a porous surface layer on the inorganic substrate
Implementation Method 2
coating composition comprises a plurality of siloxane nanoparticles dispersed in an organic solvent
Implementation Method 3
hydrolyzing the mixture to form a coating composition
Data Source
AI summary
A method of making a coated article is described comprising providing an inorganic substrate and coating the substrate with a coating composition. The coating composition comprises a plurality of siloxane nanoparticles dispersed in an organic solvent. A portion of the nanoparticles comprise the reaction product of a first alkoxy silane compound having a first organofunctional group and a second organofunctional group of a second compound and the reaction between the first and second organofunctional groups form an organic linking group. The method further comprises drying the coating composition and heating the coated substrate to volatilize the organic linking groups thereby forming a porous surface layer on the inorganic substrate. In another embodiment an article is described comprising an inorganic substrate, such as glass, and a porous inorganic (e.g. silica) surface layer having an average pore size of less than 30 nm. Also described are coating compositions and methods of making a nanoparticle coating compositions.