Temperable Silver Low-E Glass Coating
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Solution Overview
Problem
Existing temperable glass coatings face issues with expensive materials, complex process control, intricate layer structuring, inadequate optical properties, and significant changes in essential properties during the tempering process.
Innovation Solution
A temperable substrate coating system comprising layers of Si3N4, TiO2, Ag, NiCrOx, and Si3N4, using standard target materials like boron-doped silicon and titanium-doped silicon aluminum, with specific sputtering process parameters to maintain minimal changes in properties after tempering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If expensive or exotic materials are used for sputter targets to achieve good optical properties, then the optical performance is improved, but the manufacturing cost increases
Solution Approach 1:
The patent replaces expensive exotic materials with cheaper, readily available materials such as standard silicon targets (doped with boron) and titanium-doped silicon aluminum targets. These conventional materials achieve the required optical properties without the high cost of exotic alternatives, effectively substituting expensive materials with economical ones.
Solution Approach 2:
The patent optimizes process parameters including sputtering power, gas flow rates, and layer thicknesses to maximize the performance of standard materials. By carefully controlling these parameters, the coating achieves optimal optical properties using conventional, cost-effective target materials rather than requiring expensive exotic materials.
2Illumination intensity
If complex layer structuring is implemented to achieve desired optical properties, then the optical performance is improved, but the device complexity increases
Solution Approach 1:
The patent combines multiple functions into a simplified five-layer structure where Si3N4 layers provide both mechanical stability and optical properties, TiO2 provides adhesion and optical control, Ag provides thermal reflection, and NiCrOx provides additional thermal control. This merged structure achieves the required performance with fewer distinct material types and simpler processing compared to more complex multilayer systems.
Solution Approach 2:
The Si3N4 layers serve multiple functions including providing mechanical stability, controlling optical properties, and serving as buffer layers. The TiO2 layer provides both adhesion promotion and optical control. This multi-functionality reduces the need for additional specialized layers, simplifying the overall structure while maintaining performance.
3Ease of manufacture
If standard target materials are used to reduce manufacturing cost, then the manufacturing cost is reduced, but the optical properties may be inadequate
Solution Approach 1:
The patent carefully controls sputtering parameters including power density, gas composition, and layer thickness to optimize the optical properties of standard materials. For example, specific Si3N4 layer thicknesses and densities are controlled to achieve the desired optical performance, demonstrating that parameter optimization can compensate for using conventional rather than exotic materials.
Solution Approach 2:
The patent uses composite target materials such as silicon doped with boron and titanium-doped silicon aluminum. These composite materials provide enhanced properties compared to pure elements, achieving good optical performance while remaining cost-effective and readily available.
4Strength
If the coating is tempered to improve mechanical stability, then the mechanical properties are improved, but the essential properties of the coated glass change significantly
Solution Approach 1:
The patent designs the coating structure with inherent stability features that cushion against tempering-induced changes. The specific composition and structure of the Si3N4, TiO2, Ag, and NiCrOx layers are optimized to minimize thermal expansion mismatches and stress development during tempering, thereby maintaining optical properties while achieving mechanical strengthening.
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 cost-effective, simple, and robust silver low-E coating with minimal property changes post-tempering, achieving high transmission, optimal optical properties, and robust mechanical stability with minimal differences before and after tempering.
Implementation Method 1
The different layers are, as a rule, produced with the aid of sputter processes, in which by means of positive ions particles are knocked out of so-called targets, which particles are subsequently deposited on the substrate
Data Source
AI summary
The invention relates to a silver low-E coating for glass which is temperable and can be applied by means of sputter processes onto the glass. The individual layers of the coating are cost-effective standard materials. One embodiment of the invention for example is comprised of a glass substrate, an Si3N4 layer disposed thereon of a thickness of approximately 15 nm, a TiO2 layer of 15 nm thickness on the Si3N4 layer, a 12.5 nm thick Ag layer on the TiO2 layer, a NiCrOx layer of approximately 5 nm thickness on the Ag layer and a terminating 45 nm thick Si3N4 layer.