JP7060604B2 - Insulated glass laminate with non-uniform coating layer and sealed cavities of gas molecules - Google Patents

Description

Background of disclosure 1. Fields of Disclosure This disclosure relates to insulated glass laminates.

2. 2. Description of Related Techniques Glass laminates are used in high temperature applications as windows and site glasses for the purpose of viewing heated cavities. To minimize heat loss from the cavity, the laminate has multiple glass panels with gaps between the panels to prevent direct heat transfer from the cavity to the outer panels, but between the panels. The temperature of the outer panel still rises due to the convection heat transfer through which the air passes through the gap, and the heat escapes to the surrounding environment. Insulation coatings are used to prevent heat loss, but many coatings are inadequate.

A light diffuser is an element that allows visible light to pass through, but minimizes the transmission of medium and long wavelength infrared light. Most light diffusers are not always suitable for insulating functional parts such as LEDs, cameras, lighting assemblies, wiring, sensors and semiconductor parts from high temperatures in residential and commercial ovens and other heated cavities. .. This is especially problematic for functional components such as LEDs that are not designed to withstand high temperatures. One technique for insulating the lighting assembly from the high temperatures in the oven is to provide an air gap that cools the lighting assembly by convection. Another technique is the use of heat sinks. Yet another approach is to block the lighting assembly with a lens coated with a low emissivity coating. However, such techniques do not always adequately insulate functional elements from high temperatures.

Summary of Disclosure This disclosure describes an insulating glass laminate that reduces or prevents heat loss from heated cavities. In some embodiments, the insulating glass laminate comprises a non-uniform low conductive or non-conductive coating layer that forms a chemical bond with at least one inner surface of the substrate, where the coating layer is about 0. It can have a thickness of .010 inches or less. In some embodiments, the non-uniform low conductive or non-conductive coating layer has multiple sealed three-dimensional cavities between the substrates, each with a very small volume, each with a small amount of gas molecules inside. Helps to form. The presence of small amounts of gas molecules in each cavity minimizes convective heat transfer between substrates, thereby minimizing heat loss to the ambient environment through the laminate.

Some recent literature suggests that insulated glass laminates are the best insulators when the gas cavity has a thickness of about 15 mm, where thinner cavities have even higher conductivity. The thicker cavities have a loss and the thicker cavities have a higher convection loss. This knowledge suggests that reducing the thickness of the cavity increases conduction loss, but conduction loss is not increased in the present disclosure.

The insulating glass laminates of the present disclosure have, in a non-limiting example, heated cavities for high temperature applications such as windows and viewing windows in residential and commercial ovens and where low heat loss and low exit window temperatures are desired. Can be used for applications. In some embodiments, high temperature applications exceed about 175 ° C.

In one embodiment, the present disclosure discloses non-uniform low conductivity or non-uniformity forming a chemical bond with at least one inner surface of a first glass substrate having an inner surface and a second glass substrate having an inner surface. Provided is an adiabatic laminate including a conductive coating layer. The coating layer has a thickness of about 0.010 inches or less and forms a pattern that contacts at least about 30% or less of one inner surface. There are a plurality of sealed gas molecule cavities between the substrates.

The present disclosure also relates to light diffusers that insulate functional components such as LEDs, cameras, lighting assemblies, wiring, sensors and semiconductor components in or near heated cavities. In some embodiments, the light diffuser comprises an insulating glass laminate described herein. The light diffuser can have an insulating glass laminate placed between the oven cavity and the functional element, so that the laminate partially or completely insulates the functional element from the temperature inside the cavity. do. In some embodiments, a heat reflective coating is provided on one or more components of the laminate to provide additional insulation.

Shown shows a portion of a laminate having a plurality of circular cavities formed with a non-uniform coating layer that contacts at least about 30% or less of the inner surface of at least one substrate. The schematic diagram of the laminated body of this disclosure is shown. A schematic diagram of an oven that shields functional components using the laminate of the present disclosure is shown.

Detailed Description of Disclosure The present disclosure provides an insulating glass laminate that reduces or prevents heat loss from heated cavities. In some embodiments, the insulating glass laminate has a non-uniform low conductivity that forms a chemical bond with at least one inner surface of the first glass substrate having an inner surface and the second glass substrate having an inner surface. A non-uniform low conductive or non-conducting coating layer comprising a sexual or non-conductive coating layer having a thickness of about 0.010 inch or less and no more than about 30% of at least one inner surface. There are multiple sealed cavities of gas molecules between the substrates that form a pattern of contact with the substrate.

In some embodiments, the plurality of sealed cavities of the gas molecule include, but are limited to, about 5 to about 400, about 100 to about 400, or about 5 to about 50 cavities per square centimeter of the coating layer. Not done. The width of the coating measured between each cavity can be, but is not limited to, about 0.5, about 0.01 to about 0.5, or about 0.02 to about 0.1 millimeters. The coating layer should prevent the substrate from coming into contact. One of the purposes of the coating layer is to provide spacing between the substrates to trap gas molecules in multiple sealed cavities between the substrates.

In some embodiments, the conductivity of the coating layer is about 5 W / (m · K) or less, or about 3.5 W / (m · K) or less. In some embodiments, the conductivity of the coating layer is lower than the conductivity of the substrate in contact with the coating composition. For the purposes of the present disclosure, the "low conductivity" coating layer has a conductivity of about 5 W / (m · K) or less, and the "non-conductive" coating layer is 0 or about 0 W / (m · K). It has a conductivity of K).

The coating layer creates an insulating layer between the substrates to minimize convective currents and reduce heat transfer between the substrates. In some embodiments, the coating layer, in a non-limiting example, each cures a ceramic compound, a glass compound or a combination thereof, and optionally other compounds (some of which cure the coating composition). A low conductive or non-conductive coating layer formed from a coating composition such as an enamel, a frit, or a combination thereof, which may evaporate when formed). In certain embodiments, the ceramic and glass compounds in the coating layer have similar composition and thermal expansion properties as compared to the substrate in contact with the coating layer.

1 and 2 show schematic views of the laminate 10 of the present disclosure. The laminate 10 has a first glass base material 20, a second glass base material 30, and a coating 40. As described above, the coating 40 has holes 45 forming a cavity between the base materials 20 and 30 in the laminate 10.

The coating composition is a frit, a mixture of inorganic chemicals produced by ultra-quenching a complex combination of molten materials and enclosing the resulting chemicals as non-migrating components of vitreous solid flakes or granules. May include. A frit includes, in a non-limiting example, all of the chemicals identified below when they are deliberately made in the manufacture of the frit. The main elements include, but are not limited to, oxides of some or all of the elements listed below, and here may also include fluorides of these elements: aluminum, antimony, arsenic, barium, Bismus, boron, cadmium, calcium, cerium, chromium, cobalt, copper, gold, iron, lantern, lead, lithium, magnesium, manganese, molybdenum, neodymium, nickel, niobium, phosphorus, potassium, silicon, silver, sodium, strontium, Tin, titanium, tungsten, vanadium, zinc, zirconium, and combinations thereof. The most common frit are bismuth and zinc based frit. The frit may include pigments added in small proportions for coloring purposes.

Non-limiting examples of suitable coating compositions are:
Crystalline silica: 11-15%
Borate: 19-22%
Zinc oxide: 25-29%
Titanium dioxide: 32-36%
Manganese compound: 0-2%
Iron oxide: 0-2%
Chromium compound: 0-2%
Cobalt compound: 0-3%
Alumina: 3-6%

Another non-limiting example of a suitable coating composition is:
Crystalline silica: 34-38%
Borate: 8-12%
Zinc oxide: 16-20%
Titanium dioxide: 5-9%
Manganese compound: 0-3%
Iron oxide: 0-3%
Chromium compound: 11-15%
Copper compound: 8-12%

The non-uniform coating layer may be applied to the substrate by silk screen printing or any other suitable technique. As shown in FIG. 1, the non-uniform coating layer has voids and does not contact the entire surface of the substrate. The non-uniform coating layer can form a regular or irregular pattern. For example, in the case of silk screen printing, the coating composition is injected through the screen to form a pattern. The patterned non-uniform coating composition helps to form multiple sealed cavities of gas molecules between the substrates. The coating layer may be transparent or colored. If desired, an intermediate layer, an additional substrate and an additional coating layer may be present.

The laminate can be formed by chemically bonding the coating layer to at least one substrate by any method known to those of skill in the art. As a non-limiting example, the laminate may apply the coating composition to a first substrate, heat the coating composition to adhere the coating composition to the first substrate, a second substrate. The material can be formed by a process comprising applying the material to a heated coating composition and firing the heated coating composition to form a chemical bond between the coating layer and at least one substrate. can. In another embodiment, the laminate applies the coating composition to the first substrate, the second substrate to the coating composition, and then the coating composition is fired to at least with the coating layer. It is formed by a step involving forming a chemical bond with one substrate. In all embodiments, the at least one coating layer, the first substrate and the second substrate can form a chemical bond with at least one of the other.

Because the coating layer of the present disclosure, at least the coating layer in contact with the substrate, shares an oxygen atom and becomes part of the Si—OX chain so that the coating layer is chemically bonded to the substrate. It is pyrolytic. Pyrolytic coatings are "hard" coatings, unlike "soft" coatings such as paints that are mechanically bonded to a substrate. Compared to adhesive coatings, pyrolytic coatings have excellent wear resistance, do not easily come off, and typically do not require a protective topcoat. The pyrolytic coatings of the present disclosure can be applied by any method known to those of skill in the art, for example by high temperature plasma processes or deposition using silk screens.

As used herein, the term "glass" includes soda lime, borosilicates, lithium aluminosilicates, and combinations thereof, including but not limited to glass and glass ceramics. The term "base material" means a platform to which the coatings and other elements described herein can be applied. The shape of the base material is not limited. The substrate may be flat, curved, concave or convex and may have rectangular, square or other dimensions. In some embodiments, the substrate comprises a glass material and has a thickness of about 1 to about 10 mm or about 2 to about 5 mm.

The coating layer is non-uniform because it does not cover the entire surface area of the substrate. Instead, the non-uniform coating layer is distributed in a pattern that helps form multiple sealed cavities between the substrates for gas molecules. This pattern can include many segments of the coating that are coupled in a grid to surround multiple cavities. Cavities are voids in nature and can be occupied by gas molecules with virtually no movement. The shape of the cavity is not important. The cavity can be in the form of a honeycomb, circle, or any other shape that creates multiple three-dimensional gas-filled voids between the two substrates and coating segments between the voids. FIG. 1 shows a portion of a laminate having a plurality of circular cavities and a non-uniformly patterned coating layer in contact with at least about 30% or less of the inner surface of at least one substrate.

In some embodiments, the coating layer has a thickness of about 0.010 inches or less, about 0.005 inches or less, or about 0.001 inches or less. It is desirable to use a low conductive or non-conductive coating composition to form a coating layer with such a thin thickness and to minimize conductive heat transfer. In some embodiments, the non-uniform coating layer is distributed over most of the substrate and is about 30% or less of at least one inner surface of the substrate, about 20% or less of at least one inner surface of the substrate, or Form a pattern of contact with at least 10% or less of at least one inner surface of the substrate (ie, cavities / voids are at least about 70%, about 80% or more, or about 90% or more of at least one inner surface of the substrate. Contact with). These non-uniform coating layers, each of which is small in thickness, help create multiple sealed three-dimensional cavities between the substrates, each with a very small volume with a small amount of gas molecules inside. Due to the small amount of gas molecules present in each cavity, convective heat transfer between substrates is minimized, thereby minimizing heat loss to the ambient environment through the laminate. The cavity essentially acts as insulation. The gas can be air or an inert gas. In some embodiments, there is a partial or complete vacuum within the cavity. In other embodiments, there is no vacuum.

The present disclosure also relates to light diffusers that insulate functional components such as LEDs, cameras, lighting assemblies, wiring, sensors and semiconductor components in or near heated cavities. In some embodiments, the light diffuser comprises an insulating glass laminate described herein. The light diffuser can have an insulating glass laminate placed between the oven cavity and the functional element, so that the laminate can partially or completely remove the functional element from the temperature inside the cavity. Insulate. In some embodiments, a heat reflective coating is provided on one or more components of the laminate to provide additional insulation.

Unlike lenses with or without a low emissivity coating, the adiabatic laminates disclosed herein do not significantly distort the image of the elements behind the laminate. It is as visually transparent as a window or peephole. As a result, the laminate can be used, for example, as a light diffuser to insulate functional elements in or near the oven, while at the same time a camera or other functional element sees the contents of the cavity through the laminate. It also provides sufficient transmission of visible light to enable this.

The light diffuser and functional element can be placed anywhere within the heated cavity, such as the back, sides or top surface. In some embodiments, the light diffuser is parallel to one of the six sides of the oven cavity, eg, within the perimeter of such side, as well as the oven window of the front door of the oven, resulting in , Located between the center of the oven cavity and the functional element.

FIG. 3 shows a schematic view of the oven interior 100 including the laminate 10 that shields the functional component 50. In the illustrated embodiment, the laminate 10 is adjacent parallel to one of the sides of the interior 100 and shields the component 50 from heat. As mentioned above, other positions of the laminate 10 and the component 50 are contemplated by the present disclosure.

Although the present disclosure has been described with reference to one or more specific embodiments, one of ordinary skill in the art can make various modifications to replace the equivalent with its elements without departing from its scope. Will understand. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the scope of the present disclosure. Accordingly, this disclosure is intended not limited to the particular embodiment disclosed as the best embodiment intended to implement this disclosure. The scope disclosed herein includes all partial ranges between them.

10 laminated body, 20 base material, 30 base material, 40 coating, 45 holes, 50 functional parts, 100 inside

Claims (13)

A first glass substrate with an inner surface and
A second glass substrate with an inner surface,
Adiabatic laminates that are present between the first glass substrate and the second glass substrate and include a non-uniform low conductive or non-conductive coating layer that is present between the first glass substrate and forms a chemical bond with at least one of the inner surfaces. It ’s a body,
The non-uniform low conductive or non-conductive coating layer has a thickness of about 0.010 inch or less , contains a plurality of interconnected segments having a plurality of voids , and
A plurality of the inner surface of the first glass substrate, the inner surface of the second glass substrate, the coating layer, and the voids are provided between the first glass substrate and the second glass substrate. Insulated laminate that defines the sealed cavity of . The laminate according to claim 1, comprising about 5 to about 400 cavities per square centimeter of the coating layer. The laminate according to claim 1, wherein the width of the coating as measured between each of the cavities is from about 0.01 to about 0.5 millimeters. The laminate according to claim 1, wherein the coating has a thickness of about 0.005 inch or less. The laminate according to claim 1, wherein the coating has a thickness of about 0.001 inch or less. A step of applying the coating composition to the first substrate, a step of heating the coating composition to bond the coating composition to the first substrate, and a step of heating the second substrate to the heating. The method for forming a laminate according to claim 1, which comprises a step of applying to the coated coating composition and a step of calcining the heated coating composition to form a chemical bond. It includes a step of applying the coating composition to the first substrate, a step of applying the second substrate to the coating composition, and a step of calcining the coating composition to form a chemical bond. , The method for forming the laminate according to claim 1. The laminate according to claim 1, wherein the coating layer comprises an enamel, a frit or a combination thereof, and the enamel, the frit or a combination thereof comprises a ceramic compound, a glass compound, or a combination thereof . The laminate according to claim 1, wherein the coating layer is transparent. The laminate according to claim 1, wherein the coating layer has a conductivity lower than that of the first and second substrates. The laminate according to claim 1, wherein there is no vacuum in the cavity. The oven comprising the laminate according to claim 1, which operates at a temperature above about 175 ° C. 12. The oven according to claim 12, wherein the window or viewing window of the oven includes the laminate.

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