Transparent Conductive Thin Film Coating Without a Buffer Layer
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Solution Overview
Problem
Conventional thin film coatings on transparent substrates face challenges in achieving low emissivity and anti-solar properties while maintaining durability and stability, often degrading due to exposure to air, requiring complex manufacturing processes, and having limited shelf life.
Innovation Solution
The transparent articles feature a multi-layer structure without a buffer layer between the metal and antireflection layers, including an optical matching, adhesion promoting, stress releasing layer, first and second antireflection layers, and optionally an outermost protective transparent layer, which enhances durability and stability, allowing storage for years without immediate lamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a buffer layer is deposited between the metal layer and the second antireflection layer to prevent oxidation, then the metal layer's anti-solar and low emissivity properties are preserved, but the coating system requires increased time, materials, and manufacturing complexity
Solution Approach 1:
The patent removes the buffer layer from the coating structure, extracting the element that caused complexity while maintaining oxidation protection through direct deposition of the second antireflection layer on the metal layer, thus simplifying the overall structure without sacrificing reliability
Solution Approach 2:
The patent changes the deposition parameters and sequence, depositing the second antireflection layer directly on the metal layer with controlled thickness and composition to achieve both oxidation protection and functional performance without requiring a separate buffer layer
2Productivity
If the coating is exposed to air for extended periods before lamination, then manufacturing flexibility is improved, but the coating degrades due to oxygen and moisture migration, losing anti-solar and low emissivity properties
Solution Approach 1:
The patent performs preliminary protective action by depositing the second antireflection layer directly on the metal layer during the coating process itself, creating an immediate protective barrier against oxygen and moisture that allows extended exposure to air without degradation, thus enabling manufacturing flexibility without sacrificing stability
Solution Approach 2:
The second antireflection layer serves as an intermediary protective barrier between the metal layer and the atmospheric environment, mediating the interaction by preventing direct contact with oxygen and moisture while allowing the coating to be stored and handled with manufacturing flexibility
3Device complexity
If the second antireflection layer is deposited directly on the metal layer without a buffer layer, then manufacturing time and complexity are reduced, but oxidation of the metal layer may occur during deposition
Solution Approach 1:
The patent changes the deposition parameters including using controlled vacuum conditions, adjusting deposition rate, and selecting appropriate antireflection layer materials and thicknesses to prevent oxidation during direct deposition on the metal layer, achieving both simplicity and oxidation protection
Solution Approach 2:
The patent converts the potentially harmful oxidation process into a beneficial outcome by controlling the deposition conditions so that minimal controlled oxidation occurs during deposition, which actually enhances the adhesion and performance of the second antireflection layer while maintaining the simplified structure
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 transparent articles with anti-solar, low emissivity, and electrically conductive properties, maintaining optical and electrical performance for up to nine years at ambient humidity and room temperature, with high environmental stability and durability.
Implementation Method 1
a metal layer adapted for infra-red reflection and electrical conductivity
Implementation Method 2
first and second antireflection layers
Data Source
AI summary
Disclosed are transparent articles having a substrate adapted for carrying a transparent and electrically conductive thin film thereon. The thin film includes an optical matching-stress releasing layer directly deposited on the substrate; a first antireflection layer directly deposited on the optical matching layer; a metal layer adapted for infra-red reflection and electrical conductivity directly deposited on the first antireflection layer; a second antireflection layer deposited directly on the metal layer adapted for high visibility and infra-red transmission, and an optionally visible and infra-red region transparent outermost protective layer deposited on the second antireflection layer. In certain aspects, no buffer layer is positioned between the metal layer adapted for infra-red reflection and electrical conductivity and the second antireflection layer. The transparent articles have various uses including electrodes used in electrochromic devices and as glass treatments due to unique transparent, transmissive, and reflective properties.