Ternary Metal Oxide Dielectric Layer for Low-E Panels
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Solution Overview
Problem
Conventional low-e panels often crack along grain boundaries when bent or shaped and exhibit significant changes in color during heat treatment due to the use of dielectric layers like silicon nitride and tin oxide, which lack structural and optical stability.
Innovation Solution
The use of a ternary metal oxide dielectric layer, such as zinc-tin-titanium oxide or zinc-antimony oxynitride, which forms an amorphous phase, reducing grain boundaries and enhancing structural and optical stability, and incorporating nitrogen to create a stable barrier against sodium diffusion and environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional dielectric layers (silicon nitride, tin oxide) are used in low-e panels, then the panels can be manufactured with standard materials and processes, but the panels crack along grain boundaries when bent or shaped
Solution Approach 1:
The patent changes the material parameters of the dielectric layer by using a ternary metal oxide system (e.g., zinc-tin-antimony oxide) instead of conventional binary compounds. This compositional parameter change eliminates grain boundary formation while maintaining manufacturability through standard sputtering processes
Solution Approach 2:
The patent employs a composite dielectric layer combining multiple metal oxides (zinc oxide, tin oxide, antimony oxide) in specific ratios. This composite approach creates a homogeneous amorphous structure that provides both manufacturing compatibility and superior crack resistance when bent or shaped
2Ease of manufacture
If conventional dielectric layers (silicon nitride, tin oxide) are used in low-e panels, then the panels can be produced with existing technology, but the panels exhibit significant color changes during heat treatment
Solution Approach 1:
The patent modifies the chemical composition parameters of the dielectric layer by incorporating a ternary metal oxide system with controlled stoichiometry. This parameter change stabilizes the material against color changes during heat treatment while maintaining compatibility with existing manufacturing processes
Solution Approach 2:
The patent uses a dielectric layer composition that is resistant to degradation during heat treatment, eliminating the need for post-tempering color correction or replacement. The layer maintains its optical properties throughout the product lifecycle
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 ternary metal oxide dielectric layer improves the panels' resistance to cracking and maintains optical properties, reducing color changes during heat treatment and providing a stable barrier against environmental factors like moisture and air.
Implementation Method 1
The ternary oxide is, for example, based on tin oxide or zinc oxide, and includes an additional two elements... The resulting dielectric layer forms an amorphous phase and demonstrates improved structural and optical stability
Implementation Method 2
The various layers typically include dielectric layers, such as silicon nitride, tin oxide, and zinc oxide, to provide a barrier between the stack and both the glass and the environment
Data Source
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AI summary
Embodiments provided herein describe a low-e panel and a method for forming a low-e panel. A transparent substrate is provided. A metal oxide layer is formed over the transparent substrate. The metal oxide layer includes a first element, a second element, and a third element. A reflective layer is formed over the transparent substrate. The first element may include tin or zinc. The second element and the third element may each include tin, zinc, antimony, silicon, strontium, titanium, niobium, zirconium, magnesium, aluminum, yttrium, lanthanum, hafnium, or bismuth. The metal oxide layer may also include nitrogen.