Reactively sputtered coatings on architectural glazing for coloured active solar thermal façades

Covering a standard solar thermal collector with a coloured glazing, which is opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar panels into glazed building façades. The colours are based on interference in the thin-film coating on the reverse side of the glass. Coloured thin-film filters with optimised energetic performance and angular stability in their coloured reflection were deposited by reactive magnetron sputtering. For substrates up to 100 mm in diameter the geometric configuration of the deposition chamber and the process parameters were optimised. The optical properties of the coatings were determined by spectroscopic ellipsometry and spectrophotometry. Furthermore, by means of a window test bench, the CIELAB colour coordinates of real-size glasses were determined as a function of the viewing angle. It was also demonstrated that the colour of solar collector glazing can be matched to colours of commercial windows. In comparison to uncoated glass panels, the presented coloured samples for solar thermal panels have an energy loss of only 2.8–4.5% at normal solar incidence. This difference reduces for higher angles of incidence. Thus, taking into account the angular distribution of solar radiation, the energetic losses are even lower.

Reactively Sputtered Nano-Structured Multilayer Coatings on Architectural Glazing for Active Solar Energy Façades

Stefan Mertin

Improving the aesthetic of solar thermal collectors would grant architects a huge potential for a perfect integration of solar panels into building façades: this can be achieved by coloured interference coatings on the cover glass. These coatings also open the possibility to match the colours of the collectors to those of other architectural components and design elements. An important boundary condition for the coloured filter production is however, to provide a sufficiently high solar transmittance. To deal with the latter, sophisticated numerical simulations are needed to improve the coloured filter design. In addition, a large variety of coating materials is important, ideally with huge differences in their refractive indices, while the absorption of all materials needs to be close to zero. This doctoral thesis focuses on the optical film design and the deposition of new coloured thin-film multilayers with an optimised energetic performance and an only little varying coloured reflection at different viewing angles. To access more directly the correlation between solar transmittance, light spectra and visual and energetic performance of the coatings, a thin-film simulation framework has been developed on the basis of Mathematica. New coating designs have reduced the number of parameters necessary to be adjusted and tuned during the coating-development process: this could help to shorten the prototype development phase on industrial coaters significantly as well as the whole coating-development cycle. Based on the new developed coloured filter designs, multilayer stacks were deposited via reactive magnetron sputtering. The deposited coatings exhibit a solar transmittance Tsol > 87%. For greenish colour hues even a Tsol up to 91% was reached, which corresponds to less than 1% loss in Tsol (respectively solar energy performance) in comparison to the uncoated glass substrate. Furthermore, the research deals with the deposition of low-refractive magnesium fluoride (MgF2) and MgF2 containing composites. Hereby, a novel deposition process by reactive magnetron sputtering was developed for MgF2 using a metallic magnesium target and a reactive gas mixture of oxygen (O2) and carbon tetrafluoride (CF4) diluted with argon. The obtained MgF2 films exhibit a very low refractive index of n = 1.382 at 550nm, which is congruent with the polycrystalline bulk, and only a very weak absorption in the whole solar range (300-2500nm). In addition, a novel approach to deposit Mg-F-Si-O composite materials by magnetron co- sputtering from compound MgF2 and silicon dioxide (SiO2) targets was performed. The obtained films show a two-phase system with nanocrystals of MgF2 embedded in a SiO2-rich amorphous matrix. The lowest achieved refractive index amounts to n = 1.424 at 550nm combined with a negligible extinction coefficient (k < 10-9). The investigated sputtered low-index materials open-up manifold possibilities for coloured filters. For instance, by adding a supplementary MgF2 inter-layer, a colour-invariant solar transmittance of Tsol = 85-85.7% could be achieved, as shown by numerical simulations. With this novel optical filter design it will be feasible to offer a whole colour palette for solar thermal collectors exhibiting all the same solar thermal energy performance.

EPFL2015

Coloured coatings for glazing of active solar thermal façades by reactive magnetron sputtering

Martin Joly, Stefan Mertin, Jean-Louis Scartezzini, Andreas Schueler

For building integration of solar-powered energy systems, aesthetic aspects play an important role. Covering a standard solar collector with a coloured glazing, opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar thermal panels into glazed building façades. The thermal energy produced can be used for both solar heating and cooling, as well as for domestic hot water. The principle of the coloured appearance is based on interference in the thin-film coating on the reverse side of the cover glass. Different interference filters based on nano-composite materials deposited by the solgel method were presented at CISBAT 2007 [1]. Currently, we are developing new plasma-deposition processes, which are more suitable for industrial large-scale production. A new state-of-the-art ultra-high vacuum (UHV) system for magnetron sputtering deposition of novel nano-composite solar coatings has recently been designed, constructed, and installed at the Solar Energy and Building Physics Laboratory (LESO-PB). Up to five different magnetron sources can be used simultaneously, in reactive and non-reactive mode. The geometric configuration of the chamber has been optimised for best film homogeneity and allows the deposition on substrates up to 100 mm in diameter. The optical and electronic properties of thin films are closely interrelated and highly relevant for solar coatings. Photoelectron spectroscopy provides information on the coating structure, the deposited material and its chemical state inside the coating, as well as the nature of the interface between different layers. A system for ESCA analysis (Electron Spectroscopy for Chemical Analysis) has recently been installed and put into operation at LESO-PB. By ellipsometry and spectrophotometry, we can determine exactly the different optical properties of the coating, such as layer thickness, refractive index, or absorption coefficient. This provides best conditions for highly efficient research and development on new materials for further optimisation of the coloured interference filters. First results have been obtained with our new experimental infrastructure and will be presented in this contribution.

EPFL2011

Air cooling powered by façade integrated coloured opaque solar thermal panels

Stefan Mertin, Andreas Schueler

For building integration of solar-powered energy systems, aesthetic aspects play an importantrole. Covering a standard solar collector with a coloured glazing, opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar thermal panels into glazed building façades. The thermal energy produced can be used for both solar heating and cooling, as well as for domestic hot water. The principle of the coloured appearance is based on interference in the thin-film coating on the reverse side of the cover glass. Different interference filters based on nano-composite materials deposited by the solgel method were presented at CISBAT 2007 [1]. Currently, we are developing new plasma-deposition processes, which are more suitable for industrial large-scale production. A new state-of-the-art ultra-high vacuum (UHV) system for magnetron sputtering deposition of novel nano-composite solar coatings has recently been designed, constructed, and installed at the Solar Energy and Building Physics Laboratory (LESO-PB). Up to five different magnetron sources can be used simultaneously, in reactive and non-reactive mode. The geometric configuration of the chamber has been optimised for best film homogeneity and allows the deposition on substrates up to 100 mm in diameter. The optical and electronic properties of thin films are closely interrelated and highly relevant for solar coatings. Photoelectron spectroscopy provides information on the coating structure, the deposited material and its chemical state inside the coating, as well as the nature of the interface between different layers. A system for ESCA analysis (Electron Spectroscopy for Chemical Analysis) has recently been installed and put into operation at LESO-PB. By ellipsometry and spectrophotometry, we can determine exactly the different optical properties of the coating, such as layer thickness, refractive index, or absorption coefficient. This provides best conditions for highly efficient research and development on new materials for further optimisation of the coloured interference filters.First results have been obtained with our new experimental infrastructure and will be presented in this contribution.

EPFL2011

Reactively Sputtered Nano-Structured Multilayer Coatings on Architectural Glazing for Active Solar Energy Façades

Stefan Mertin

EPFL2015

Coloured coatings for glazing of active solar thermal façades by reactive magnetron sputtering

Martin Joly, Stefan Mertin, Jean-Louis Scartezzini, Andreas Schueler

EPFL2011

Air cooling powered by façade integrated coloured opaque solar thermal panels

Stefan Mertin, Andreas Schueler

For building integration of solar-powered energy systems, aesthetic aspects play an importantrole. Covering a standard solar collector with a coloured glazing, opaque to the human eye but highly transparent to solar energy, permits a perfect architectural integration of solar thermal panels into glazed building façades. The thermal energy produced can be used for both solar heating and cooling, as well as for domestic hot water. The principle of the coloured appearance is based on interference in the thin-film coating on the reverse side of the cover glass. Different interference filters based on nano-composite materials deposited by the solgel method were presented at CISBAT 2007 [1]. Currently, we are developing new plasma-deposition processes, which are more suitable for industrial large-scale production. A new state-of-the-art ultra-high vacuum (UHV) system for magnetron sputtering deposition of novel nano-composite solar coatings has recently been designed, constructed, and installed at the Solar Energy and Building Physics Laboratory (LESO-PB). Up to five different magnetron sources can be used simultaneously, in reactive and non-reactive mode. The geometric configuration of the chamber has been optimised for best film homogeneity and allows the deposition on substrates up to 100 mm in diameter. The optical and electronic properties of thin films are closely interrelated and highly relevant for solar coatings. Photoelectron spectroscopy provides information on the coating structure, the deposited material and its chemical state inside the coating, as well as the nature of the interface between different layers. A system for ESCA analysis (Electron Spectroscopy for Chemical Analysis) has recently been installed and put into operation at LESO-PB. By ellipsometry and spectrophotometry, we can determine exactly the different optical properties of the coating, such as layer thickness, refractive index, or absorption coefficient. This provides best conditions for highly efficient research and development on new materials for further optimisation of the coloured interference filters.First results have been obtained with our new experimental infrastructure and will be presented in this contribution.

EPFL2011