Sol-Gel Coated Substrate for Soft Coating Protection
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Solution Overview
Problem
Soft coatings like solar control or insulating low-E coatings on glass substrates have limited mechanical, chemical, and corrosion resistance, making them prone to damage during production, handling, and exposure to environmental factors, which restricts their use in external applications.
Innovation Solution
A coated substrate is developed with a soft coating topped by a sol-gel coating comprising a mixture of titanium oxide, silicon oxide, and optionally bismuth oxide and/or cerium oxide, providing improved mechanical, chemical, and corrosion resistance while maintaining the emissivity and aesthetics of the coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a soft coating is applied to provide solar control or insulating low-E properties, then the emissivity and energy control are improved, but the mechanical, chemical and corrosion resistance deteriorates
Solution Approach 1:
The patent applies a composite structure consisting of a soft coating layer (for IR reflection and low emissivity) combined with a hard protective coating layer (for mechanical and chemical resistance). This multi-layer composite approach allows the soft coating to maintain its opto-energetic properties while the hard coating provides the necessary durability and protection against environmental damage.
Solution Approach 2:
The protective function is segmented into a separate hard coating layer applied over the soft coating. This segmentation allows each layer to specialize: the soft coating handles thermal radiation control while the hard coating handles mechanical protection, thereby resolving the contradiction between functional performance and durability.
2Use of energy by moving object
If a soft coating is used for solar control or insulating properties, then the opto-energetic performance is improved, but the durability against environmental exposure deteriorates
Solution Approach 1:
The composite coating system combines a soft coating optimized for opto-energetic performance with a hard protective coating optimized for environmental durability. The hard coating acts as a barrier against humidity, temperature variations, and chemical exposure, thereby extending the service life of the underlying soft coating without compromising its thermal control functions.
Solution Approach 2:
The hard protective coating serves as an intermediary barrier between the environment and the soft coating. It mediates the interaction by blocking harmful environmental factors (moisture, chemicals, UV radiation) from reaching the soft coating, thus preserving the soft coating's opto-energetic properties over time.
3Loss of energy
If a soft coating is applied to achieve low emissivity, then the heat loss reduction is improved, but the resistance to mechanical damage deteriorates
Solution Approach 1:
The patent employs a composite coating structure where the soft coating layer provides the low emissivity properties for heat loss reduction, while an overlying hard protective layer provides mechanical strength and scratch resistance. This composite approach ensures that the energy-saving soft coating is protected from mechanical damage during handling, installation, and service.
Solution Approach 2:
The hard protective coating is applied in advance as a protective barrier before the soft coating is exposed to mechanical risks. This prior cushioning protects the vulnerable soft coating from scratches, impacts, and other mechanical damages that could compromise its low emissivity properties and thermal performance.
4Use of energy by moving object
If a soft coating is used for exterior glazing applications, then the energy control capability is improved, but the corrosion resistance deteriorates
Solution Approach 1:
For exterior glazing applications, the patent combines a soft coating with excellent opto-energetic performance with a hard protective coating that provides superior corrosion and weathering resistance. The hard coating protects the soft coating from corrosion caused by rain, humidity, and atmospheric pollutants, enabling the use of high-performance soft coatings in previously unsuitable exterior environments.
Solution Approach 2:
The hard protective coating acts as an intermediary shield between the corrosive exterior environment and the soft coating. It prevents moisture, oxygen, and chemical pollutants from reaching and degrading the soft coating, thereby maintaining the energy control capability over the long term in exterior applications.
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 sol-gel coating enhances the durability of soft coatings, allowing them to withstand environmental exposure and heat treatment, broadening their application to external use without significant impact on emissivity, thus extending their use in glazing units for energy-saving purposes.
Implementation Method 1
The sol-gel coating aims at efficiently blocking ultraviolet (UV) radiations and comprises very high amounts of cerium oxide as UV blocker
Implementation Method 2
a sol-gel coating provided on at least a part of said face above the soft coating, wherein the sol-gel coating comprises a mixture of titanium oxide, silicon oxide and optionally bismuth oxide and/or cerium oxide
Data Source
AI summary
The present invention relates to a coated substrate comprising: a substrate; a soft coating provided on at least a part of at least one face of the substrate; a protective sol-gel coating provided on at least a part of said face above the soft coating, to a process for making such coated substrate and to glazing units comprising such coated substrate.