Single-Layer Anti-Reflective Coating via Coordination Polymer
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Solution Overview
Problem
Current anti-reflection coatings for large areas and quantities, such as solar cells, require multi-layer coatings which are time-consuming and expensive, and lack precise control over porosity, leading to suboptimal refractive index and performance.
Innovation Solution
A single-layer anti-reflection coating composition comprising hydrolyzable silane and metal compounds, along with organic compounds capable of forming coordination polymers, which are thermally treated to create a defined porous structure, allowing for better control over the refractive index and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multi-layer coatings are used to achieve high-quality anti-reflection, then the quality of the coating is improved, but the production time and cost increase
Solution Approach 1:
The patent combines multiple functional layers into a single-layer coating that integrates the anti-reflection functionality of traditional multi-layer coatings. The sol-gel composition forms a unified layer with graded refractive index properties, eliminating the need for separate layers while maintaining high-quality anti-reflection performance and reducing production steps
Solution Approach 2:
The patent uses composite materials in the sol-gel composition, combining metal alkoxides, organic compounds, and solvents to create a single-layer coating with complex internal structure. This composite approach enables the single layer to achieve the optical performance previously requiring multiple layers, reducing production time while maintaining quality
2Productivity
If single-layer coatings are used to reduce production time and cost, then productivity is improved, but control over porosity and refractive index deteriorates
Solution Approach 1:
The patent employs parameter changes in the sol-gel composition, specifically adjusting the ratios of metal alkoxides, organic compounds, and solvents to precisely control the porosity and refractive index of the single-layer coating. By modifying chemical composition parameters during the sol-gel process, the patent achieves manufacturing precision comparable to multi-layer coatings while maintaining high productivity
Solution Approach 2:
The patent creates local quality variations within the single-layer coating through controlled porosity distribution. The sol-gel process enables different regions of the coating to have optimized local properties, with specific porosity levels in different zones to achieve both high productivity and precise manufacturing control
3Reliability
If porous structures are created in the coating, then the refractive index is reduced for better anti-reflection, but the structural control becomes more difficult
Solution Approach 1:
The patent employs self-service through the sol-gel process, where the coating material self-assembles into the desired porous structure during controlled hydrolysis and condensation. The chemical reactions automatically create the optimal pore distribution for refractive index reduction, eliminating the need for complex external structuring equipment while achieving reliable anti-reflection performance
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 solution enables the production of high-quality, single-layer anti-reflection coatings with improved porosity control, achieving broadband solar spectrum transmission and reduced production costs, while maintaining effective anti-reflection properties.
Implementation Method 1
comprises at least one hydrolyzable silane compound, at least one hydrolyzable metal compound, whereby the compound can also be partially hydrolyzed and/or condensed
Implementation Method 2
A well-known class of compounds that build porous structures are coordination polymers, in particular the so-called metal-organic frameworks (MOFs). These are compounds that consist of organometallic centers bridged via ligands.
Implementation Method 3
To produce the anti-reflection coating, the applied composition is thermally treated. The solvent is removed and the organic components, i.e. also the organic compounds, are usually burned out.
Implementation Method 4
The porosity of the coatings, in particular due to the enclosed air, reduces the refractive index of the coating from theoretically 1.5 (pure SiO2) to 1.1 - 1.45 depending on the porosity and the manufacturing process of the SiO2 martix
Data Source
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AI summary
The application describes an anti-reflective coating obtained from a composition of at least one silane compound, at least one metal compound and at least one organic compound having at least two functional groups which can form a coordination polymer. The invention further describes a method for the production of an anti-reflective coating.