Solar-Control Coating With NiNx Blocker for Flexible Polymeric Panes
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Solution Overview
Problem
Existing solar-control coatings on rigid glass substrates face issues with cracking and reduced elasticity due to the use of nickel-chromium-oxide (NiCrOx) blocker layers when applied to flexible or polymeric substrates, which are prone to expansion, contraction, and bending, compromising corrosion resistance and optical transmittance.
Innovation Solution
A solar-control structure using a nickel nitride (NiNx) or nickel-oxi-nitride (NiOxNx) blocker layer is applied directly on a polymeric substrate, with a thickness ranging from 1 to 4 nm, ensuring improved elasticity and corrosion resistance by maintaining an amorphous state even under deformation, and allowing higher sputtering power levels for better deposition rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nickel-chromium-oxide (NiCrOx) blocker layer is used on rigid glass substrates, then corrosion resistance is improved, but elasticity and bendability deteriorate causing cracking on flexible substrates
Solution Approach 1:
The patent changes the chemical composition parameters of the blocker layer from nickel-chromium-oxide (NiCrOx) to nickel nitride (NiNx) or nickel-oxi-nitride (NiOxNx). This parameter change transforms the material properties: the nickel nitride-based blocker maintains corrosion resistance while exhibiting superior elasticity and bendability, preventing cracking on flexible substrates. The compositional change allows the blocker to accommodate substrate deformation without failure.
Solution Approach 2:
The patent employs composite material strategies by creating a multi-layer structure where nickel nitride or nickel-oxi-nitride serves as the blocker layer in combination with other functional layers (silver functional layer, dielectric layers). This composite approach leverages the complementary properties of each material: nickel nitride provides elasticity and corrosion resistance, while maintaining optical transparency and adhesion to both rigid and flexible substrates.
2Reliability
If nickel-chromium-oxide (NiCrOx) blocker layer is used, then corrosion resistance is improved, but manufacturing complexity increases due to lower sputtering power requirements
Solution Approach 1:
The patent changes the sputtering process parameters by using nickel nitride or nickel-oxi-nitride as the blocker layer material. This material substitution enables higher sputtering power levels (higher cathode power) to be applied during deposition, directly increasing the deposition rate and manufacturing productivity while maintaining adequate corrosion resistance properties.
3Strength
If conventional blocker layers are used on polymeric substrates, then adhesion is achieved, but cracking occurs due to substrate expansion and contraction
Solution Approach 1:
The patent changes the material composition of the blocker layer to nickel nitride or nickel-oxi-nitride, which fundamentally alters the mechanical properties. This compositional change provides both adequate adhesion to polymeric substrates and superior crack resistance through enhanced elasticity, allowing the coating system to withstand substrate thermal expansion and contraction without cracking.
Solution Approach 2:
The patent employs a thin-film blocker layer made of nickel nitride or nickel-oxi-nitride that acts as a flexible protective shell. This thin film structure accommodates the flexibility requirements of polymeric substrates while providing continuous protection against environmental corrosion, maintaining integrity during substrate deformation cycles.
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 NiNx layer provides enhanced elasticity and corrosion resistance, preventing cracking and maintaining optical performance on flexible substrates, enabling higher production yields and improved adhesion to textured surfaces, while allowing higher cathode power for efficient deposition.
Implementation Method 1
Solar irradiation control by reflecting infrared (IR) light using a coating comprising at least one thin silver (Ag) functional layer
Implementation Method 2
Solar-control coatings are typically deposited on rigid glass substrates using sputter deposition
Data Source
AI summary
The present disclosure provides a solar-control infrared-reflecting thin-film stack on a polymeric substrate. The stack comprises a chromium-free nickel nitride or nickel-oxi-nitride blocker layer which results in an improved bendability of the stack which makes it ideal for using on polymeric panes in architectural and automotive glazing wherein such panes sustain expansion, contraction, and bending caused by environmental conditions, such as fluctuating temperature and humidity.