Low Haze Emission Control Coatings via Sputtered TCO and Barrier Layers
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Solution Overview
Problem
Pyrolytic transparent conductive oxide (TCO) coatings on glass substrates have high haze and roughness, and often involve undesirable fluorine processes, while existing alternatives do not meet the requirements for low haze, low roughness, and high visible transmission.
Innovation Solution
A multiple-pane insulating glazing unit with an emission control coating comprising a transparent conductive film of indium tin oxide over an oxygen barrier film of silicon nitride, which achieves haze less than 0.3 and roughness less than 3 nm, along with a monolithic visible transmission of greater than 75%, using sputtered films and a heat treatment process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If pyrolytic transparent conductive oxide coatings are applied on hot glass substrates, then the coatings are durable and hard, but the haze and roughness increase significantly
Solution Approach 1:
The patent changes the deposition temperature parameter from high (pyrolytic process on hot glass) to low (sputtering on room temperature or warm glass), which fundamentally alters the coating formation mechanism to achieve low roughness while maintaining durability through subsequent heat treatment
Solution Approach 2:
The patent uses composite material structure combining sputtered transparent conductive oxide with silicon oxide or silicon nitride barrier layers, creating a multi-layer system that achieves both durability and smooth surface properties that neither material could achieve alone
2Ease of manufacture
If pyrolytic processes with fluorine are used, then transparent conductive oxide coatings can be formed, but environmental and health concerns arise
Solution Approach 1:
The patent eliminates the harmful fluorine-based pyrolytic process entirely by adopting sputtering technology, converting the harmful manufacturing approach into a beneficial environmental-friendly process while maintaining or improving coating performance
Solution Approach 2:
The patent replaces the chemical pyrolytic deposition mechanism with a physical sputtering process, substituting a chemically harmful process with a physically-based alternative that avoids fluorine emissions
3Object-affected harmful factors
If existing alternative coatings are used to avoid fluorine processes, then environmental concerns are addressed, but the requirements for low haze, low roughness, and high visible transmission are not met
Solution Approach 1:
The patent optimizes multiple parameters including deposition temperature, sputtering power, gas flow rates, and layer thicknesses to achieve the precise optical quality required, demonstrating that parameter optimization can simultaneously satisfy environmental and performance requirements
Solution Approach 2:
The patent employs multi-layer composite structures with carefully controlled thicknesses of transparent conductive oxide and barrier layers, where the composite design enables achievement of low haze and high transmission while maintaining fluorine-free composition
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 provides a durable, low-emissivity coating with improved optical properties, maintaining high visible transmission and low sheet resistance, while avoiding fluorine-based processes and reducing surface roughness, thus enhancing the thermal and optical performance of glass substrates.
Implementation Method 1
using sputtered films
Implementation Method 2
using sputtered films and a heat treatment process
Data Source
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AI summary
The invention relates to a method for forming a liquid radiation curable resin capable of curing into a solid upon irradiation comprising at least one thermally sensitive visual effect initiator. The liquid radiation curable resin is capable of curing into three-dimensional articles having selective visual effects. The resulting three-dimensional articles possess excellent color and/or transparency stability and excellent mechanical properties.