Solar Mirror E-Coating Without Mechanical Contact Marks

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Solution Overview

Problem

Conventional electrodepositable coating processes for solar mirrors require mechanical contact to establish an electrical circuit, leading to uncoated contact areas that are susceptible to chemical attack and affect the uniformity and durability of the protective coating.

Innovation Solution

A method involving multiple electrically conductive liquid streams is used to deposit an electrodepositable protective coating on solar mirrors, maintaining the streams spaced to form a current path without mechanical contact, ensuring uniform coverage and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical contact is used to establish electrical circuit for electrodepositable coating, then the coating process can be completed, but uncoated contact areas are created that are susceptible to chemical attack and reduce uniformity

Engineering Contradiction:

Improvecoating uniformityVSAvoidchemical attack susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the mechanical contact element (clip or connector) from the electrodepositable coating system. Instead of using a physical contact to establish the electrical circuit, the invention uses a conductive liquid stream that flows over the entire surface including edges, eliminating the uncoated contact areas that were previously necessary for circuit completion.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The conductive liquid stream serves as an intermediary that simultaneously establishes the electrical circuit and provides coating material. The liquid conductor bridges the gap between the power supply and the substrate surface, allowing current flow without mechanical contact, while also delivering the electrodepositable coating composition to all surfaces including edges.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If mechanical contact is used to complete electrical circuit, then the coating process is simpler, but the contact area cannot be coated and visual appearance is affected

Engineering Contradiction:

Improvecoating process simplicityVSAvoidcoating coverage uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical contact system (clips, connectors, physical touchpoints) with a fluid-based electrical conduction system. The conductive liquid stream carries electrical current without requiring solid-to-solid contact, thereby eliminating the mechanical elements that created uncoated areas while maintaining circuit completion.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention employs a liquid (hydraulic) system to deliver both electrical conductivity and coating material. The conductive liquid stream is pumped and controlled through fluid delivery mechanisms, using hydraulic principles to maintain flow, pressure, and distribution across the substrate surface including hard-to-reach edges.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If mechanical contact is used for electrodepositable coating, then the process is conventional and established, but the contact area creates coating voids that reduce durability

Engineering Contradiction:

Improvecoating durabilityVSAvoidcoating system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The conductive liquid stream performs multiple functions simultaneously: it establishes the electrical circuit for electrodeposition, delivers the coating composition to the substrate, and ensures complete surface coverage including edges. This multi-functionality eliminates the need for separate mechanical contact elements while improving coating durability through uniform coverage.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

This approach eliminates uncoated areas, enhancing the durability and uniformity of the protective coating against chemical and mechanical damage, while maintaining the visual appearance of the solar mirrors.

Implementation Method 1

an electrodepositable coating, which is also referred to as an 'e-coat' or electrodeposition coating composition, is deposited onto a conductive surface of a substrate using an electrical process

Methodology Applied

Scientific EffectElectrodeposition: Electrodeposition

Implementation Method 2

maintaining the first and the second electrically conductive liquid materials spaced from one another to provide a third area of the first surface between the first and the second areas to establish a current path through the first liquid material, the third area of the conductive surface and through the second liquid material

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS8557099B2Electrocurtain coating process for coating solar mirrors

Publication Date: 2013.10.15 VITRO FLAT GLASS LLC

AI summary

An electrically conductive protective coating or film is provided over the surface of a reflective coating of a solar mirror by flowing or directing a cation containing liquid and an anion containing liquid onto the conductive surface. The cation and the anion containing liquids are spaced from, and preferably out of contact with one another on the surface of the reflective coating as an electric current is moved through the anion containing liquid, the conductive surface between the liquids and the cation containing liquid to coat the conductive surface with the electrically conductive coating.