Patent Application
20250067114
The invention relates to a spacer for panes, in particular for glass panes of double-glazed or multi-glazed windows or doors, according to the preamble of claim 1, and to an arrangement comprising at least one such spacer and two panes lying against it.
US 2018/0 066 469 A1 discloses spacers for panes, having rounded or beveled corners and steps in the form of grooves. This document also discloses that the spacers may be ceramic and may have a functional coating.
Against this background, US 2015/0 079 313 A1 discloses a functional coating which is capable of yielding and is applied to a main body of the spacer to smooth its surface.
Finally, U.S. Pat. No. 10,550,627 B1 discloses a spacer having a stepped surface and the effect, by a functional coating, of smoothing the surface and also avoiding glass damage.
Against this background, it is known from the prior art to produce double-glazed or triple-glazed windows or doors. The intermediate space between the glass panes can be filled with a gas, preferably an inert gas, in order to meet certain specifications regarding the thermal conductivity or the sound insulation. However, it is particularly advantageous in terms of the thermal conductivity and the sound insulation if there is a vacuum between the glass panes.
A vacuum between the glass panes in turn leads to a negative pressure in relation to the atmospheric pressure, which leads to a considerable load on the glass panes. The larger the area of a glass pane, the higher the force is that the atmospheric pressure exerts on a glass pane. When certain loads are exceeded, glass panes bend in the direction of the vacuum to such an extent that they break.
In order to counter this problem, it is known from the prior art to arrange spacers between the glass panes, the spacers supporting the glass panes against each other predominantly at a certain point or points.
In this case, a spacer lies with its one end by means of a contact surface against a glass pane and with its other end by means of a contact surface against the opposite glass pane.
In practice, it may be necessary to arrange a very large number of spacers between two large-area glass panes, with each spacer being pressed very strongly against the glass panes at contact areas by the atmospheric pressure. At the contact areas, in particular in the area of borders, tips or edges of a spacer, stress peaks may occur both in the glass and in the spacer and may lead to damage, in particular of the glass panes.
The invention is therefore based on the object of specifying an arrangement with a spacer between two panes, in particular two glass panes, in which the stress curve in the vicinity of a contact surface, at least in the glass, is overall as uniform and low as possible, i.e. stress peaks, which may damage a pane, are reduced or avoided as far as possible.
The present invention achieves the above-mentioned object by the features of the independent claims.
According to the invention, it has been recognized that a contact surface has to have or assume a most ideal dome shape in order as little as possible to load a pane which lies against it under pressure.
Owing to this dome shape, which preferably only arises as a relief geometry when a pane presses against the spacer, stress peaks due to borders or sharp material jumps are reduced or even avoided particularly at an edge of a main body.
This is the case because the pane lies almost only or only against the dome-like contact surface of the main body, which contact surface is compressible owing to the deformation zone associated with it.
Furthermore, it has been recognized that the contact surface can be deformed under pressure by a suitable formation or structuring of it per se, or of the deformation zone delimited axially outward by it, such that the curvature of the pane resulting in the region of the spacer under pressure stresses is ideally placed against the dome of the spacer and a particularly advantageous pressing between the pane and the spacer can arise. With said pressing, the maximum pressure or the maximum stress is minimized according to the invention.
According to the invention, it has finally been recognized that the spacer has to have a cap-like structure which is substantially rotationally symmetrical or formed by regularities or a relief of this type, which cap-like structure or relief, unless it imparts an ideal dome shape to the contact surface even without the application of a pane, transfers said contact surface at least into such a dome shape when a pane applies pressure to it.
The means could guide the deformation zone at least as far as the peripheral edge of the main body and extend the dome shape of the contact surface as far as the peripheral edge in such a way that the contact surface, and therefore the main body, is axially deformable at its peripheral edge. This makes it possible for the contact surface to overlap the hard edge of a relatively hard and almost incompressible material lying beneath it, such that a pane does not come into contact with said hard material.
Alternatively, the contact surface could be spaced apart from a peripheral edge in such a way that a pane does not come into contact with the hard edge. For the spacing, a step, preferably a circumferential step, could be provided at the edge region.
The means could be arranged symmetrically and/or regularly with respect to an axis, in particular longitudinal axis or axis of symmetry of the main body, through the center of the contact surface such that they form points which are diametrically opposite with respect to the axis and which lie on the imaginary or real surface of a spherical cap or on a circular arc with a radius of curvature, which is on average in the range of 0.5 mm to 100 mm, preferably 0.7 mm to 70 mm, further preferably 0.8 mm to 50 mm, further preferably 1 mm to 45 mm, further preferably 1.5 mm to 20 mm, further preferably 2 mm to 30 mm or 0.3 mm to 50 mm, further preferably 0.5 mm to 45 mm, further preferably 0.8 mm to 30 mm or 2 mm to 200 mm, further preferably 3 mm to 100 mm and particularly preferably 5 mm to 80 mm.
A rotational symmetry or lateral regularity of the means permits the setting of an ideal end geometry. The end geometry can be achieved starting from an initial geometry, which can be defined or described by a radius of curvature which clearly defines a spherical cap or a circular arc in cross section, said spherical cap or circular arc axially limiting, encasing, or passing through a structuring of the spacer, or passing through the functional focal points thereof. It is quite essential that the radius of curvature is an initial radius of curvature which can be transferred into a smaller, preferably a larger or constant, end radius of curvature of the contact surface because the contact surface preferably undergoes a convex flattening when a pane presses against it.
The end radius of curvature which arises under pressure loading in the installed state is on average ≥1 mm, preferably ≥2 mm, further preferably ≥3 mm, further particularly preferably ≥5 mm. In all the aforementioned cases, the end radius of curvature is either ≤50 mm or ≤40 mm. The shape of the radius is preferably rotationally symmetrical, but may also deviate from the rotational symmetry.
The means could comprise step edges and/or step surfaces and/or dome portions and/or a dome, which are or is introduced in a core material of the main body of lower deformability and/or in a coating of the core material of higher deformability. Steps can be used to create pyramid-like or frustoconical, preferably spherical-segment-shaped, elevations that are deformed into a dome when a pane presses against them.
The structures introduced into the main body and/or the coating have heights/depths which are on average ≥0.1 μm, preferably ≥0.2 μm. In all the aforementioned cases, the heights/depths are ≤20 μm, preferably ≤15 μm, further particularly preferably ≤10 μm. The structures introduced may also have average heights/depths of 0.3 μm±0.1 μm, 0.4 μm±0.1 μm or 0.5 μm±0.1 μm.
The structures introduced into the main body and/or the coating have widths/diameters which are on average ≥1 μm, preferably ≥5 μm. In all the aforementioned cases, the widths/diameters are ≤300 μm, preferably ≤200 μm, further particularly preferably ≤100 μm. The structures introduced can also have average widths/diameters of 20 μm±5 μm, 30 μm±5 μm.
The number of steps in the coating and/or in the core material is ≥1, ≥2, further ≥3, further ≥4. In all the aforementioned cases, the number is ≤50. The falling or rising of the contact surface may merge at the limit into a curve following a radius of curvature.
The structuring of the main body and/or of the coating may also be carried out in such a way that a contact surface following a radius of curvature is formed with an average height difference between the center and edge region of the spacer of ≥0.1 μm, preferably ≥0.2 μm, further preferably ≥1 μm, further particularly preferably ≥2 μm. In all the aforementioned cases, the height difference is ≤20 μm, preferably ≤15 μm, further particularly preferably ≤10 μm. The introduced removal may also have an average height difference between the center and edge region of 1 μm±0.5 μm, 2 μm±0.5 μm or 3 μm±0.5 μm.
The deformation zone could comprise a coating which has a higher deformability than a core material, wherein the means comprise coating portions which follow one another in a step-like manner and gradually taper in their width toward a coating dome or coating peak, wherein the coating dome or coating peak forms an axially outermost coating portion, which can be turned toward a pane. In such a case, an elevation could preferably be formed from a coating which rests on a flat surface of a core material. Thus, a surface of a core material can be well covered completely, and therefore its hard edges or edge points are no longer contactable by the pane.
The deformation zone could comprise a coating which has a higher deformability than the core material, wherein the means comprise core material portions which follow one another in a step-like manner and taper in their width toward a core material dome or core material peak, wherein the core material dome or core material peak forms an outermost core material portion, which can be turned toward a pane, and wherein the coating covers and/or surrounds the core material dome or core material peak. Owing to this configuration, the hard core material already approximately predetermines the dome shape.
The coating could cover and/or enclose at least one or more core material portions. Thus, a relatively thin coating can only just form an envelope or encasement of the hard core material, which envelope or encasement, in contrast to the core material, can be further flattened such that the final dome shape arises under pressure of a pane.
Preferably in all previously described embodiments, the end radii of curvature of the domes were only able to be formed under pressure of the pane. In an embodiment in which a uniform layer thickness of a coating is present on a preformed dome of the core material, the end radius of curvature could already be completely or almost completely formed. In this special embodiment, only the steps of an envelope of the core material would be compensated for, so to speak, and therefore a substantially round dome is formed.
The means could comprise recesses which extend from a surface of the core material into the interior thereof, wherein the recesses are at least partially filled with a coating on the core material or can be filled by pressurization of the contact surface, wherein the coating has a higher deformability than the core material. By means of recesses or accumulations or clusters of such recesses appropriately arranged regularly or symmetrically, it is possible to produce mean functional layer thicknesses of the coating, which, in combination with the core material of the contact surface, impart a dome shape when a pane presses against the contact surface.
Such recesses can be in the form of bores, blind holes, hollows, or cavities with a linear, circular, angular, serrated, meandering, helical, spiral or honeycomb-like form, or in the form of portions of said forms. It is also conceivable that the recesses are formed by mixed forms of the aforementioned depressions or by portions of the depressions.
The depth and/or lateral width of the recesses and/or the lateral extensions thereof that may be present in some sections could increase or decrease from a center of the contact surface radially and laterally outward. Advantageously, the depth and/or width of recesses and/or lateral extensions increase(s) in the direction of the edge of the main body, and therefore the material of a coating can deviate to a greater extent axially downward or laterally outward when a pane presses against the coating axially from above. It is thus possible to assist the formation of a dome shape of the contact surface in an edge region.
The thermal conductivity of the main body is ≤15 W/mK, preferably ≤5 W/mK, further preferably ≤3 W/mK, further particularly preferably ≤1 W/mK, in the axial direction. For all the abovementioned regions, the thermal conductivity is at least 0.01 W/mK.
A core material lying inside the main body could comprise an inorganic material, e.g. a metal or a glass or a ceramic or a glass ceramic. A glass, a ceramic or glass ceramic can form the hard, relatively incompressible core of a main body, in particular a pillar, which is at least partially covered at its opposite longitudinal ends with a coating.
A glass, a ceramic or a glass ceramic has much lower thermal conductivity than a metal.
The porosity of a ceramic main body should be on average ≥1%, preferably ≥2%, further preferably ≥5%, further particularly preferably ≥10%. In all the aforementioned cases, the porosity is ≤50%, preferably ≤40%, further particularly preferably ≤30%. The porosity may also be 10%±5%, 20%±5% or 30%±5% on average.
Recesses can be produced chemically, for example by plasma etching, mechanically or by using electromagnetic or particulate radiation.
Laser processing is preferred, as it allows the most delicate structures to be introduced reliably and in a clearly defined manner.
A coating could comprise a microporous material, in particular a microporous ceramic and furthermore, in particular, a nanoporous, glassy or glass-ceramic material.
These materials are preferably applied to the core material as a coating suspension:
The particulate systems comprise particles with mean particle sizes <10 μm, preferably <5 μm, further preferably <2 μm and particularly preferably <1 μm, but preferably substantially ≥100 nm, and a dispersing medium.
The sol-gel systems include molecules of organometallic compounds or salts of metals or nanoparticles as precursors of a ceramic, or ceramic nanoparticles with a particle size of less than 100 nm, or mixtures thereof.
The sol-gel systems are liquid systems which comprise molecules of precursors of oxide ceramics or glasses, i.e. organometallic compounds or nanoparticles of precursors of oxide ceramic or glass-forming components, or nanoparticles of oxide ceramic or glass-forming components, or
The sol-gel systems may be water-based or solvent-based.
The molecular precursors may comprise organometallic compounds (e.g. aluminum isopropoxide or tetraethyl orthosilicate) or already partially pre-condensed commercially available sol-gel systems (e.g. inosil, Inomat GmbH, Neunkirchen, Germany) or salts (e.g. zirconium acetate) or hydroxides and/or oxyhydroxides of metals (e.g. aluminum). During a temperature treatment, the precursors oxidize into ceramics starting at temperatures below 300° C. and temperatures below 400° C. in air.
The systems mixed with particulates or pure sol-gel systems are applied to the core material by dip coating, spray coating, application by squeegee, screen printing, spinning, doctor blade, slot die, electrophoresis or other procedures. Preferred application variants are spraying, screen printing, electrophoresis, application by squeegee, slot die and doctor blade.
The coating systems are solidified by drying. Preferably, the coatings are further solidified during a temperature treatment.
Further preferably, the temperature treatment of the coating is baked at >50° C., preferably >80° C., further preferably >100° C., further preferably >150° C., further preferably >200° C., further preferably >250° C., further preferably >300° C., further preferably >350° C., but at less than 1300° C., preferably at less than 1000° C., preferably at less than 800° C.
During the temperature treatment, the coating solidifies so that it is stable for transport and/or is preferably additionally converted into a purely inorganic material. The coating is more strongly compressible than the core material.
Vapor deposition, CVD and PVD are less preferred methods.
The coating may comprise other organic or inorganic particulate components that modify the deformability, hardness, porosity, or stability of the coating. These components can be metal particles, graphite, hexagonal boron nitride, soot, polymethyl methacrylate (PMMA), polytetrafluoroethylene (PTFE), tungsten or tungsten oxide, for example in the form of microspheres, irregularly shaped particles, fibers, platelets or agglomerates, or mixtures thereof.
The material of the coating could therefore be inorganic or substantially inorganic. However, it could also be organic, metallic or of glass or be a mixed form. Furthermore, it may be both porous and dense, or formed with a gradient in the porosity.
The embodiment which is described below and in which the material of the coating is arranged on both sides of the spacer, and structures, in particular steps, are attached, preferably mirror-symmetrically, in the spacer, is preferred. Strict symmetry is not necessary as long as only the dome shape is attainable.
The material of the coating may have further properties, with it not being necessary for both sides of the spacer to have the same properties. Thus, the material of the coating can be colored, electrically conductive or insulating, magnetizable, hydrophilic, hydrophobic, of the same or different density on both sides, or adhesive per se or by means of embedded particles. The porosities of the coatings on both sides of the spacer may also differ.
Functionalization of the coating can have a positive influence in particular on the positioning of the spacers on the pane. Additional temporary coatings can also be applied shortly before application to increase adhesion (e.g. water, ethanol, cyclododecane).
The volume reduction of the deformation zone and/or of a coating on the core material could be on average in the range of 0.01 to 0.7, preferably 0.02 to 0.6, further preferably 0.03 to 0.5, further preferably 0.05 to 0.45, further preferably 0.05 to 0.4 or 0.01 to 0.4, more preferably 0.02 to 0.3, further preferably 0.035 to 0.25 or 0.01 to 0.3, further preferably 0.02 to 0.25, and particularly preferably 0.035 to 0.2. These volume reductions are advantageous when a glass pane is placed onto a spacer of the type described here. The value 0.01 corresponds to a compression of 1% from an initial volume to a final volume.
The diameter of the main body at its widest circumference could be on average in the range of 0.05 mm to 1 mm, preferably 0.2 mm to 0.6 mm, further preferably 0.3 mm to 0.5 mm or 0.2 mm to 0.5 mm, further preferably 0.2 mm to 0.45 mm, or 0.3 mm to 0.6 mm, particularly preferably 0.35 mm to 0.6 mm. Such a spacer is sufficiently small that it does not interfere visually when it is placed between two panes. In addition, it is ensured that the spacer does not form a much too large heat or cold bridge.
The main body could be substantially cylindrical, in the manner of a column and/or pillar, wherein a contact surface is provided, and wherein an average layer thickness of a deformable coating on a core material is higher in a central region than in an edge region. A coating thus protects a pane from contact with a sharp edge.
Alternatively, a contact surface with a peak in a central region could be provided, wherein a coating having a substantially homogeneous layer thickness is arranged on a core material. Thus, a coating can be applied to a core material pre-formed in a dome-like, preferably spherical-segment-like manner.
Further alternatively, a contact surface with a peak in the central region could be provided, wherein a coating with a layer thickness increased in an edge region is arranged on the core material. This combines the advantages of the first two alternatives. Preferably, the contact surface is flat.
The thickness of the coating is on average ≤30 μm, preferably ≤20 μm, further preferably ≤15 μm, further preferably ≤10 μm, further particularly preferably ≤5 μm, but always ≥0.1 μm and can vary over the surface. The coating may also have an average thickness of 5 μm±2.5 μm, 10 μm±2.5 μm or 15 μm±2.5 μm.
An arrangement comprising at least two panes, in particular glass panes, between which a spacer having a main body with two opposite contact surfaces is arranged, wherein each contact surface lies against a pane under pressure, is characterized in that each deformation zone is compressed and/or deformed in such a way that its respective contact surface is convexly curved or flattened such that it follows the curvature of the pane lying against it.
Said arrangement comprising at least two panes, in particular glass panes, between which a spacer having a main body with two opposite contact surfaces is arranged, wherein each contact surface lies against a pane under pressure, is in particular characterized in that each deformation zone is compressed and/or deformed in such a way that its respective contact surface is convexly curved or in particular flattened at the edges in relation to the center such that, following the curvature of the pane, it forms a spherical segment with a defined radius of curvature and follows a concave depression of the pane lying against it. Therefore, when a vacuum is applied in a vacuum insulating glass, the convex spherical segment formed from the contact surface of the spacer has a radius of curvature which is comparable to an equivalent radius of curvature of the concave depression which is formed in the curved pane, which is deformed under compressive stress, in the region of the contact surface of the spacer.
The dome shape assumed by the contact surface enables optimum contact conditions to be achieved. Owing to the lower maximum stress of the Hertzian pressure arising at the pane, the number of spacers can be significantly reduced compared to the prior art without reducing a safety factor. This has the technical advantage that, with fewer spacers, the heat transfer via the spacers can also be reduced as a whole.
In this respect, an arrangement with a spacer between two panes, in particular two glass panes, is specified, at which stress peaks, which may damage a pane, are reduced or avoided as far as possible. The spacer of the arrangement may be configured in a manner as disclosed in this description.
The arrangement could have a number of spacers between the two panes of 1000 to 4000, preferably 1500 to 3000, further preferably 1500 to 2500 or 300 to 3000, further preferably 750 to 2500, further preferably 1000 to 2000 or 1500 to 5000, further preferably 1500 to 3500 and particularly preferably 2000 to 3000 per m2 of pane area. This ensures optimum support of the panes under optimized thermal conditions. In such an arrangement, it is possible to use relatively few spacers per unit of area to provide gentle support of the panes, and therefore fewer heat bridges are created between the panes.
The height of the spacer described here is advantageously on average in the range of 50 μm to 600 μm, preferably in the range of 100 μm to 500 μm, further preferably in the range of 100 μm to 300 μm, further preferably in the range of 100 μm to 250 μm, further preferably in the range of 50 μm to 500 μm, further preferably in the range of 50 μm to 300 μm, and particularly preferably in the range of 50 μm to 250 μm.
The quotient h2/H of the heights h2 from the highest point of the spacer (G or KG) to the highest point of an edge region of the spacer and the overall height H of the spacer advantageously lies in the range of 0 to 0.1, preferably in the range of 0 to 0.075, further preferably in the range of 0 to 0.05, further preferably in the range of 0 to 0.035, further particularly preferably in the range of 0 to 0.025, further preferably in the range of 0 to 0.02.
In principle, all possible deformation mechanisms are conceivable for deforming the deformation zone and/or the coating and/or the core material, namely elastic or plastic, the compacting or compressing of porous structures, and the simultaneous interaction of such mechanisms. A mechanism for compacting or compressing porous structures is preferred.
The sectional views shown in the figures are sections through the longitudinal axes of the respective spacers, which are rotationally symmetrical. Where only one side of a spacer is shown, the axially opposite side of the spacer is optionally formed identically to the side shown. Axially opposite sides are illustrated separated from one another in some figures by dashed lines.
The points P3, P4 are located in the highest edge region starting from the center plane of the spacer 1. The coating peak G of the spacer 1 protrudes axially outward over the edge region with a height h2.
The dome-forming means, which impart the dome shape to the contact surface 4, are arranged symmetrically and regularly with respect to an axis A through the center of the contact surface 4 in such a manner that they form diametrically opposite points P1, P2 with respect to the axis A, which lie on the surface of the spherical cap with the radius of curvature r.
The radius of curvature r describes, as the initial radius of curvature, a fictitious spherical cap which runs through means or functional points thereof that make it possible for the contact surface 4 to be compressible and deformable into an end form. The dome-shaped end form of the contact surface can be described by a spherical cap with an end radius of curvature R, which is shown schematically in some figures.
Each deformation zone 5 can be compressed and deformed in such a way that its respective contact surface 4 is convexly curved or flattened such that it follows the curvature of the pane 2 lying against it. Each contact surface 4 is to this extent part of a deformation zone 5.
The means guide the deformation zone 5 at least as far as the peripheral edge 6 of the main body 3 and extend the dome shape of the contact surface 4 as far as the circumferential peripheral edge 6 in such a way that the contact surface 4 is axially deformable at the peripheral edge 6, even if the edge 6 were to be virtually incompressible and sharp because of a lower-lying, hard core material 7. The pane 2 is thus not exposed to any stress peaks at the peripheral edge 6.
In
The points P3, P4, and the coating peak G lie at one height. Thus, the height h2 assumes a value of 0.
The points P3, P4, and the core material peak KG lie at one height. Thus, the height h2 assumes a value of 0.
A deformation zone 5 described here may be formed by the coating 8 alone or in interaction with the core material 7.
The core material 7 described here comprises a ceramic, in particular a ceramic comprising zirconium oxide. The coating 8 comprises a microporous material, namely a microporous ceramic sol-gel material.
A spacer 1 of the type described here can be produced by way of example according to the following method.
The method comprises the following steps:
The method is described in more detail below, specifically with reference to
A plurality of concentrically arranged grooves 12 are introduced into said plate 11 on both sides by laser radiation. Then, according to
As a final step, according to
Specific exemplary embodiments for the production of spacers are given below:
A ceramic film made of 3Y TZP ZrO2 with a thickness of 200 μm and an external dimension of 100 mm×100 mm is presented.
The film surfaces are structured in accordance with example O (selection from O1 to O7).
A sol-gel coating according to example B (selection from B1 to B6) is then applied on both sides such that the surfaces of the ceramic film, including the structuring, are coated. The production of the underlying sol is described in example S (selection from S1 to S7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter (Monaco 1035, from Coherent, 270 fs, 15 W, 250 kHz, 2100 mm/s, 400 passes, double line).
A ceramic film made of ZTA Al2O3 with a thickness of 250 μm and an external dimension of 100 mm×100 mm is presented.
The film surfaces are structured in accordance with example O (selection from O1 to O7).
A sol-gel coating according to example B (selection from B1 to B6) is then applied on both sides such that the surfaces of the ceramic film, including the structuring, are coated. The production of the underlying sol is described in example S (selection from S1 to S7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter.
A glass film made of borosilicate (AF 32® eco, from Schott) with a thickness of 200 μm and an external dimension of 100 mm×100 mm is presented.
The film surfaces are structured in accordance with example O (selection from O1 to O7).
A sol-gel coating according to example B (selection from B1 to B6) is then applied on both sides such that the surfaces of the glass film, including the structuring, are coated. The production of the underlying sol is described in example S (selection from S1 to S7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter.
A porous ceramic film made of Al2O3 (residual porosity 20%, average pore size 2 μm) with a thickness of 250 μm and an external dimension of 100 mm×100 mm is presented.
The film surfaces are structured in accordance with example O (selection from O1 to O7).
A sol-gel coating according to example B (selection from B1 to B6) is then applied on both sides such that the surfaces of the ceramic film, including the structuring, are coated. The production of the underlying sol is described in example S (selection from S1 to S7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter.
A stainless steel film of 1.4301 with a thickness of 200 μm and an external dimension of 100 mm×100 mm is presented.
The film surfaces are structured in accordance with example O (selection from O1 to O7).
A sol-gel coating according to example B (selection from B1 to B6) is then applied on both sides such that the surfaces of the stainless steel film, including the structuring, are coated. The production of the underlying sol is described in example S (selection from S1 to S7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter.
A film according to example A (selection from A1 to A5) is structured on both sides according to example O (selection from O1 to O7).
A sol-gel coating according to example B (selection from B1 to B6) is then applied on both sides such that the surfaces of the ceramic film, including the structuring, are coated. The production of the underlying sol is described in example S (selection from S1 to S7).
The coated film surfaces are structured in accordance with example O (selection from O1 to O7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter.
A sol-gel coating according to example B (selection from B1 to B6) is applied on both sides of a film according to example A (selection from A1 to A5). The production of the underlying sol is described in example S (selection from S1 to S7).
The coated film surfaces are structured in accordance with example O (selection from O1 to O7).
The circular spacers with an outer diameter of 500 μm are cut out along the outer diameter.
Annular grooves with a depth of 2 μm, a width of 25 μm and an outer radius of 250 μm are introduced in the center of the film with a laser at ten adjacent locations (Monaco 1035, from Coherent; the following parameters were used for ZrO2: 270 fs, 4 W, 108 kHz, 500 mm/s, 1 pass, single line). Additional annular grooves with an outer radius of 150 μm, a depth of 2 μm and a width of 25 μm are introduced centered within the first annular grooves.
The process is repeated on the rear side of the film in exactly the same positions such that the annular grooves on the upper side and lower side of the film are exactly opposite one another.
Annular grooves with a depth of 3 μm, a width of 25 μm and an outer radius of 200 μm are introduced in the center of the film with a laser at ten adjacent locations. Additional annular grooves with an outer radius of 100 μm, a depth of 2 μm and a width of 25 μm are introduced centered within the first annular grooves. Blind holes with a depth of 1 μm and a diameter of 25 μm are introduced centered within the first two annular grooves.
The process is repeated on the rear side of the film in exactly the same positions such that the grooves on the upper side and lower side of the film are exactly opposite one another.
Annular grooves with a depth of 1 μm, a width of 30 μm and an outer radius of 265 μm are introduced in the center of the film with a laser at ten adjacent locations. A gradual removal is generated by laser beam shaping centered within the annular grooves. Higher thicknesses remain in the center of the annular grooves than in the outer region.
The process is repeated on the rear side of the film in exactly the same positions such that the annular grooves on the upper side and lower side of the film are exactly opposite one another.
Annular grooves with a depth of 1 μm, a width of 30 μm and an outer radius of 265 μm are introduced in the center of the film with a laser at ten adjacent locations. A gradual removal is generated by laser beam shaping centered within the annular grooves. Higher thicknesses remain in the center of the annular grooves than in the outer region.
A structuring is created on the rear side of the film starting from the centers of the previously introduced annular grooves. Annular grooves with a depth of 2 μm, a width of 25 μm and an outer radius of 250 μm are introduced on the rear side of each annular groove with a laser. Additional annular grooves with an outer radius of 150 μm, a depth of 2 μm and a width of 25 μm are introduced centered within said annular grooves.
Annular grooves with a depth of 1 μm, a width of 30 μm and an outer radius of 265 μm are introduced in the center of the film with a laser at ten adjacent locations. Centered within the annular grooves, 35 blind holes with a radius of 13 μm and a depth of 2 μm are introduced lying at an equal distance from one another on an outer radius of 200 μm. Centered within the annular grooves, a further 26 blind holes with a radius of 13 μm and a depth of 2 μm are introduced lying at an equal distance from one another on an outer radius of 150 μm.
The process is repeated on the rear side of the film in exactly the same positions such that the annular grooves on the upper side and lower side of the film are exactly opposite one another.
Annular grooves with a depth of 1 μm, a width of 30 μm and an outer radius of 265 μm are introduced in the center of the film with a laser at ten adjacent locations. Centered within the annular grooves, 35 blind holes with a radius of 13 μm and a depth of 3 μm are introduced lying at an equal distance from one another on an outer radius of 200 μm. Centered within the annular grooves, a further 17 blind holes with a radius of 13 μm and a depth of 2 μm are introduced lying at an equal distance from one another on an outer radius of 100 μm. Centered within the annular grooves, additional blind holes with a radius of 13 μm and a depth of 1 μm are introduced.
The process is repeated on the rear side of the film in exactly the same positions such that the annular grooves on the upper side and lower side of the film are exactly opposite one another.
Annular grooves with a depth of 1 μm, a width of 30 μm and an outer radius of 265 μm are introduced in the center of the film with a laser at ten adjacent locations. Centered within the annular grooves, 20 blind holes with a radius of 25 μm and a depth of 2 μm are introduced lying at an equal distance from one another on an outer radius of 200 μm. Centered within the annular grooves, a further 12 blind holes with a radius of 20 μm and a depth of 2 μm are introduced lying at an equal distance from one another on an outer radius of 100 μm. Centered within the annular grooves, additional blind holes with a radius of 13 μm and a depth of 2 μm are introduced.
The process is repeated on the rear side of the film in exactly the same positions such that the annular grooves on the upper side and lower side of the film are exactly opposite one another.
60 g of boehmite (PB 950, from PIDC, particle size 5 μm to 15 μm, crystallite size 3 nm to 5 nm) are mixed with 400 g of demineralized water and stirred with an electric agitator for 10 min. The suspension is then heated to 85° C. to 90° C. and continuously stirred further. After the suspension has reached the desired temperature, a total of 19 g of a 65% strength HNO3 acid is slowly added with a pipette and stirred in. By addition of HNO3, the suspension firstly clears up slightly before the viscosity increases and the mixture becomes strongly gelled.
The resulting gel is cooled in air to room temperature.
When the suspension is heated, some of the water evaporates. The evaporated quantity is determined by weighing before and after heating. The evaporated water is added and stirred into the gel.
Aluminum oxide (CT 3000 SG, from Almatis, mean particle size 0.5 μm) in a ratio of 8:1 in relation to the boehmite mass and an organic binder (Optapix C95, from Zschimmer und Schwarz) with a quantity of 5% based on the total solid mass of boehmite and Al2O3 are added to the gel and ground in an attritor mill.
A required dilution before application is carried out with demineralized water.
60 g of boehmite (PB 950, from PIDC, particle size 5 μm to 15 μm, crystallite size 3 nm to 5 nm) are mixed with 400 g of demineralized water and stirred with an electric agitator for 10 min. The suspension is then heated to 85° C. to 90° C. and continuously stirred further. After the suspension has reached the desired temperature, a total of 19 g of a 65% strength HNO3 acid is slowly added with a pipette and stirred in. By addition of HNO3, the suspension firstly clears up slightly before the viscosity increases and the mixture becomes strongly gelled. The resulting gel is cooled in air to room temperature.
When the suspension is heated, some of the water evaporates. The evaporated quantity is determined by weighing before and after heating. The evaporated water is added and stirred into the gel.
Aluminum oxide (CT 3000 SG, from Almatis, mean particle size 0.5 μm) in a ratio of 1:1 in relation to the boehmite mass and an organic binder (Optapix C95, from Zschimmer und Schwarz) with a quantity of 5% based on the total solid mass of boehmite and Al2O3 are added to the gel and ground in an attritor mill.
A required dilution before application is carried out with demineralized water.
Aluminum oxide (CT 3000 SG, from Almatis) is added to water glass (sodium silicate, from Carl Roth) in a ratio of 1:1 in relation to the mass and ground in an attritor mill.
A required dilution before application is carried out with demineralized water.
A ready-to-use sol-gel binder (ino®decor basis+, from inomat) is used.
A required dilution before application is carried out with ethanol.
Pyrogenic silica (HDK N20, from Wacker-Chemie) is added to the binder from example S4 in a ratio of 1:20 in relation to the suspension mass, incorporated by means of an agitator unit and then dispersed by means of Ultra Turrax (from IKA).
A required dilution before application is carried out with ethanol.
100 g of tetraethoxysilane (TEOS, from ABCR) are mixed with 20 g of perfluoropolyether (PFPE, Fluorolink® S10, Solvay Solexis), 40 g of demineralized water, 30 g of isopropanol and 0.2 g of hydrogen chloride and stirred with an electric agitator for 30 min. The resulting suspension is then diluted with 275 g of isopropanol and 75 g of butyl alcohol and stirred again for 30 min.
Silica sol (DP5820, from Nyacol) with an amount of 3% based on the total solid mass of TEOS and PFPE is added to the suspension and mixed.
A required dilution before application is carried out with ethanol.
10% of polytetrafluoroethylene (PTFE, 50TF 5070GZ, from 3M) based on the suspension mass are added to the binder from example S2, incorporated by means of an agitator unit and then dispersed at low speeds by means of Ultra Turrax.
A required dilution before application is carried out with ethanol.
By diluting suspension S (selection from S1 to S5), a solid mass content of 10% is set. This is filled into an airbrush system and applied on both sides with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h.
The coating has a thickness of approx. 2 μm.
After baking, a firmly adhering layer is obtained, which can undergo a volume reduction of >20% by external action of pressure.
A circumferential edge with a width of 1 cm is discarded for further processing.
By diluting suspension S (selection from S1 to S5), a solid mass content of 10% is set. This is filled into an airbrush system and applied on both sides with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h.
The coating has a thickness of approx. 2 μm.
A solid mass content of 10% is set by diluting suspension S6. This is filled into an airbrush system and applied on one side with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 200° C. for 2 h.
The additional coating has a thickness of approx. 2 μm.
A circumferential edge with a width of 1 cm is discarded for further processing.
By diluting suspension S (selection from S1 to S5), a solid mass content of 10% is set. This is filled into an airbrush system and applied on both sides with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h.
The coating has a thickness of approx. 2 μm.
A solid mass content of 10% is set by diluting suspension S7. This is filled into an airbrush system and applied on one side with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle. The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 500 K/h at 300° C. for 10 min.
The additional coating has a thickness of approx. 2 μm.
A circumferential edge with a width of 1 cm is discarded for further processing.
By diluting suspension S (selection from S1 to S5), a solid mass content of 10% is set. This is filled into an airbrush system and applied on both sides with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h.
The coating has a thickness of approx. 2 μm.
The baked layers are infiltrated with polytetrafluoroethylene (PTFE, 50TF 5070GZ, from 3M, diluted with demineralized water to a solid mass content of 2%) by immersion in the existing solution.
The infiltrated coating is then dried in the drying oven at 60° C. for one to two days.
A circumferential edge with a width of 1 cm is discarded for further processing.
By diluting suspension S (selection from S1 to S5), a solid mass content of 10% is set. This is filled into an airbrush system and applied on both sides with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h.
The coating has a thickness of approx. 2 μm.
The baked layers are infiltrated with a soot solution (Derussol® 345, from Orion Engineered Carbons, diluted with demineralized water to a solid mass content of 2%) by immersion. This facilitates the optical detectability of the spacers.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h in a nitrogen atmosphere.
A circumferential edge with a width of 1 cm is discarded for further processing.
By diluting suspension S (selection from S1 to S5), a solid mass content of 10% is set. This is filled into an airbrush system and applied on both sides with a spray pressure of 1.7 bar and at a distance of 10 cm from the film to be coated by a 0.5 mm spray nozzle.
The coating is then dried in the drying oven at 60° C. for one to two days. The dried layer is baked at a heating rate of 100 K/h at 450° C. for 1 h.
The coating has a thickness of approx. 2 μm.
A layer of cyclododecane (ATTBIME® AB24) is applied on one side to temporarily increase the adhesion. This makes it easier to position the spacers on the glass pane. Said layer sublimates completely and without residue under vacuum.
A circumferential edge with a width of 1 cm is discarded for further processing.
| Number | Date | Country | Kind |
|---|---|---|---|
| 10 2021 124 102.2 | Sep 2021 | DE | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/072910 | 8/17/2022 | WO |
