3M Corporation - Polymeric Multilayer Infrared Reflecting Film Development

Transcription

1 3M Corporation - Polymeric Multilayer Infrared Reflecting Film Development The objective of this project is to develop a polymeric multilayer infrared reflecting film that is essentially clear and colorless in the visible portion of the electromagnetic spectra (visible light transmission of about 89%) while reflecting 90-95% of the infrared energy in the 850 nm to 1830 nm specified spectra. The film will have a nominal thickness of 3 mils, be polymeric in nature (contains no metals, metal oxides, or other material types) and be essentially clear in appearance. Large scale production prototypes of the film will be accomplished through a succession of extrusion trials progressing from simple systems to the designed system. Physical and optical measurements of samples will be taken and processing refined with each step leading to final production of film prototypes. The samples will be assessed with modeling software for overall energy savings. The scope of the work to be performed consists of modeling, extrusion, and physical and optical assessment of the extrusion outputs. A new extrusion feedblock will be developed to enable final product construction. Applied Materials, Inc. -Development of High Rate Coating Technology for Low Cost Electrochromic Dynamic Windows The objective of this project is to develop and demonstrate the feasibility of high-rate deposition of critical electrochromic layers using new novel vacuum coating sources, to develop a full electrochromic process flow by combining conventional processes with new deposition sources, to characterize, test, evaluate, and optimize the resulting coatings and devices, and to demonstrate an electrochromic device using the new process flow and sources. The long term objective is to integrate these innovations to enable production of low cost electrochromic windows produced on highly reliable and high yielding manufacturing systems. Device and process modeling will be performed to obtain the necessary parameters to build a working device and develop high rate processes for critical device layers. Concurrently, the high rate process sources will be designed and built. The integrated deposition system will be modified for necessary high rate source installations. Remaining sections of the deposition equipment will be fitted with traditional sources to complete the sequential arrangement of the sources. As the standard chambers become available, the process for cathode, anode and indium-tin oxide will be optimized for future incorporation into device fabrication steps. Integrated deposition equipment will be made operational for full process and device development. Initially, high rate deposition development will be done for individual critical layers. Once acceptable processes are obtained, remaining processes will be activated to fabricate the devices. The process development and optimization will be conducted on suitable glass substrates for known device stack materials. The resulting device performance will be compared with devices fabricated with the standard baseline processes. Known performance criteria will be used to characterize the device properties. In addition, studies will be conducted to determine coating properties as well as crosscontamination effects, if any. The processes will be improved, as necessary, to develop active working electrochromic devices. Dow Chemical - Advanced Insulation for High Performance Cost-Effective Wall, Roof and Foundation Systems The objective of this project is to explore and develop high performing insulation with increased R/inch and low impact on climate change that will facilitate the design of highly insulating building envelope systems with greater durability and lower overall system cost than envelopes with equivalent performance made with materials available today. The targeted performances for the materials are: R-value >7.5 per inch, with little or no loss of R-value over time; good fire performance (class A or incombustible); minimal impact on environment; and, cost-effective (cost per unit of R-value lower than high performance insulation available today). Increased insulation performance will be obtained with the new materials without costly redesign of buildings envelopes, and without major changes to building practices.

2 This will enable early adoption of future increased insulation standards within both IECC and ASHRAE code standards, facilitate the design of zero-energy buildings that will retain their performance over time, and make high insulation performance affordable to lower income families most affected by the increasing burden of energy prices. This project will develop nanoporous polymeric materials that will have reduced thermal conductivity without relying on any fluorocarbons with significant climate change potential. The demonstration of the technology will be achieved in three main tasks: 1) Proof-of-concept R&D resources will be focused on materials science and fundamentals, on the production of samples in small batches, and on developing measurement techniques to characterize such small samples. Marketing resources will focus on gathering information on customer requirements and on mapping out opportunities by sector and applications; 2) Concept Validation R&D resources will optimize formulation of the product and the processing conditions to approach customer requirements at the small batch scale. A small scale, semi-continuous process will be designed to reproduce the performance of batch samples. An updated risk assessment will be delivered; and 3) Feasibility of continuous production R&D and Process Engineering and Manufacturing will build a continuous pilot process and produce prototypes to demonstrate product performance in relation to code requirements: insulation, mechanical, fire, moisture. A detailed scale up and commercialization strategy will be proposed, involving R&D and Process Engineering and Manufacturing, Marketing and IP/Legal. Dow Corning Corporation - Contributing To Net Zero Building: High Energy Efficient EIFS Wall Systems The objective of this project is to enhance exterior insulation and finishing system (EIFS) envelope systems to reach R-40 efficiency levels and meet the need for high efficiency insulated walls. Additionally, the project is designed to remove barriers to EIFS use on retrofit commercial buildings which desire high insulation walls but are limited due to the excessive thickness of insulation required to achieve comparable R-40 values. The project will confirm that the Vacuum Insulated Panel (VIP) is a viable insulation material to incorporate into EIFS wall systems that will not be compromised by structural deficiencies due to lack of tensile strength or mechanical properties and to develop 4-5 EIFS/VIP prototype designs for further testing. Laboratory and field trials will be conducted to determine the viability of the selected design in regards to ease of application and a full productivity analysis. The selected system will be validated for full code compliance. Project results will be used to outline future plans for commercialization. The project will focus on six distinct tasks which cover: materials testing; design conceptualization and industrial design to minimize VIP limitations; application standards development; lab testing of multiple prototypes; field testing of a selected design; and, testing for building code compliance and acceptance. Characterization of the VIP material will determine potential structural or material weaknesses, development of a selection of new EIFS configurations (prototypes) that utilize VIP and development of procedures and techniques to minimize damage to the VIP insulation during installation. Prototypes will be refined, lab trials of multiple prototypes performed and a field trial implemented to understand the thermal performance characteristics of the system. The selected system will be tested to insure that it meets all necessary EIFS building and fire codes in partnership with third party laboratories to deliver independent test data for review and approval. EverSealed Windows, Inc. - High Reliability R10 Windows Using Vacuum Insulating Glass Units The objective of this project is to develop and demonstrate a residential whole-window with an overall minimum insulating performance of R-10. Phase 1 will develop and demonstrate a lead-free and heavymetals free solder glass for bonding a specific metal alloy (the metal for the hermetic, flexible seal, or bellows ) to the two glass panes of a prototype Vacuum Insulated Glass Unit (VIGU). Glass-to-metal

3 bonds will be tested for both strength and level of hermeticity. The bonds must exhibit a low enough leak rate to hold a pressure in the VIGU that never exceeds 10-3 torr over a 25-year lifetime in the intended end-use environment. Phase 2 will complete the design of the bellows for the prototype VIGU. The components will be fabricated and assembled for at least three prototype VIGUs to undergo thermal and durability testing. The VIGU will be tested in compliance with industry and National Fenestration Rating Council (NFRC) for Insulating Glass Units (IGUs). Additional, more strenuous tests will be conducted to demonstrate that the prototype VIGU exceeds current industry/nfrc durability requirements. VIGU components will be fabricated and prototype VIGUs assembled after successful testing for use in residential windows. The whole windows will be designed and their parts fabricated by a window industry collaborator. The collaborator will assemble windows which incorporate the VIGU as the glass components and test the thermal performance of the whole window with the goal of achieving a minimum thermal performance of R-10. Industrial Science & Technology Network, Inc. - Advanced Building Insulation by CO 2 Foaming Process The objective of this project is to develop a cost-effective, rapid foaming process using supercritical CO 2 to minimize surface tension, create and preserve nanopores and overcome manufacturing inefficiencies. Design innovations will be incorporated to boost insulating power matching that accomplishable by previous nanopore super insulation approaches more economically, without the use of hydrofluorocarbons, including: creating and orienting oblate pore structures, aligning interfaces to block radiation loss, and incorporating secondary nanostructure. These design innovations will complement previous nanopore approaches, reduce production cost and improve the commercialization potential of nanopore insulating foams. Oriented anisotropic pore structures will be created to substantially increase the insulation value in the heat flow direction by maximizing the utilization and balance of the composite properties. A design enhancement strategy, using CO 2 as the main blowing agent, will be undertaken to progressively reduce the thermal conductivity to: R-5.5/inch by growing oblate pore morphology (short polar axis and long equator axes) and orienting pores in a preferred direction; further reduce thermal conductivity to R-6.85/inch with elimination of radiation loss through the use of aligned reflecting surfaces; and, to achieve a super insulation value of R-9.6/inch by successfully creating secondary nanopore structures between the asymmetrical pores. Pleotint, Inc. - Demonstration with Energy and Daylighting Assessment of Sunlight Responsive Thermochromic (SRT TM ) Window Systems The objective of this project is to demonstrate thermochromic windows under various conditions to quantify total energy usage and projected energy savings versus conventional commercial grade double pane, fixed tint windows incorporating a low E coating in a vertical glazing. This project will document energy saved in a scientific manner to facilitate energy reduction retrofits into both existing and new building construction. This collaborative project will install thermochromic windows and test for energy savings, including daylighting, and demonstrate comfort issues like light level, reaction time, heat, glare and sound reduction. The collaboration includes: pre-lamination of the Pleotint PVB (polyvinylbutyral) films; glass fabrication, lamination, and preparation of the insulated glass units; side-by-side testing with the fixed tint windows and calculation of energy use; installation and testing of skylights; modeling of building performance using EnergyPlus and comparison of model output versus actual energy usage. Quanta Technologies, Inc. - Low-E Retrofit Demonstration and Educational Program The objective of this project is to demonstrate the widespread capability of low-emissivity (low-e) storm windows and low-e retrofit glazing systems to rapidly and significantly improve the energy efficiency of both existing residential and commercial building stock. Supporting objectives include (a) determination of real world energy

4 savings, peak load reductions, and other benefits associated with this technology, (b) identification of any market or technical barriers that may hinder widespread application, and (c) development of an educational model program to facilitate rapid expansion and replication on a state-by-state or regional basis. Energy performance of low-e storm window installations on homes in a state weatherization assistance program will be tracked. The developed database will allow quantification of the energy savings and benefits of low-e storm windows on a larger scale and with more diverse housing types than previous studies, as well as identification of any technical or market barriers to widespread use. The data will be packaged as part of a model educational program that will establish a basis for replication in other states. A second residential case study will be conducted on the use of low-e storm windows in a warm/mixed southern climate. The year-round heating and cooling energy savings, air infiltration, and peak load benefits of low-e storm windows, along with cost effectiveness, technical barriers, and applicability of low-e storm windows will be determined. Low-e storm windows with both high and low solar heat gains will be compared to clear glass storm windows and single glazing. A third case study of low-e retrofit systems on commercial buildings will be conducted in cold and mixed climates to determine year-round heating and cooling energy savings and peak load benefits, as well as other ancillary benefits. The commercial study shall also include additional testing in the areas of air infiltration, water leakage, structural performance, and thermal stress performance to identify any potential barriers that could limit broad application. Soladigm, Inc. - Low Cost, High-Energy Savings, Solid State Dynamic Windows The objective of this project is to transition Soladigm s dynamic window technology from a 2-inch wide lab-scale, batch-type process for fabricating electrochromic glass to a large-area, 60-inch wide inline physical vapor deposition (PVD) manufacturing process optimized for high volume, low cost production to make full-size insulated glass units (IGUs) with the performance of current lab-scale prototypes. A pilot-line will be implemented to develop preliminary production characteristics for the electrochromic glass, including mapping the impact of process changes. Key production parameters, including deposition rate, throughput, and material costs will be optimized. A 30 wide prototype IGU with similar performance characteristics to the baseline 2" lab-scale prototype will be fabricated on the pilot tool. Full ASTM E-2141 reliability tests will be run on the IGUs. The pilot-line will be modified and re-optimize to accommodate large format substrates. The final output will be a 60 wide IGU product prototype with complete field testing. Southwall Technologies, Inc. - R10 Heat Mirror Technology with Optimized SHGC The objective of this project is to develop a Heat Mirror (HM)-based R-10 window solution with improved solar heat gain coefficient (SHGC) performance for the residential window market. Heat Mirror, with multi-cavity window performance at an efficient form and weight factor, will support improved acceptance of high-performance glazing through lower cost of structural window frame components, reduced transportation cost, and easier installation. This project will develop a new highperformance R-10 HM/high SHGC window design, review market positioning and evaluate manufacturing solutions required for broad market adoption. Project objectives will be accomplished by: identifying viable technical solutions based on modeling of modern and potential coating stacks and IGU designs; development of new coating material sets for HM thin film stacks, as well as improved HM IGU designs to accept multiple layers of HM films; matching promising new coating designs with new HM IGU designs to demonstrate performance gains; and, in cooperation with a window manufacturer, assess the potential for high-volume manufacturing and cost efficiency of a HM-based R-10 window with improved solar heat gain characteristics. A broad view of available materials and design options will be applied to achieve the desired improvements. Gated engineering methodologies will be employed to guide the development process from concept generation to a window demonstration.

5 TRACO Delaware, Inc. - Production Engineering for R5 and Higher Windows The objective of this project is to design and production engineer commercial grade R5 windows, in a cost effective manner, from existing framing and glazing technologies. The project specifically aims to address this challenge through product design refinement and production equipment design and process improvement to reduce the production cost of R5 and higher windows. Two key paths will be undertaken to achieve these objectives; product design will create a product which will meet R5 commercial window specifications while optimizing material requirements (e.g. frame material, wall thicknesses, thermal break width, type of coating, and hardware) for the windows. Product design will be based on existing framing systems, coatings, and glazing technologies. A series of R5 commercial grade windows (e.g., fixed, projected, casement, tilt-turn, single-hung, double-hung, single-slider, and double-slider) will be designed; and production engineering for R5 commercial windows will improve several area of manufacturing for R5 commercial windows. Capability will be added to produce energy efficient frames, coating, and glazing. Manufacturing time, re-work and scrap rates will be reduced. Throughput will be increased by design and process optimization. A high-volume triple glazed IGU manufacturing line with warm edge spacer capacity will be installed that will produce R9 or better IGU with significantly lower labor and time costs compared to current triple glazed unit manufacturing. Improvements will also be made in the thermal break manufacturing line and paint line to achieve a significant increase in throughput with reduced waste and labor. CPFilms, Inc. - Low-Emissivity Energy-Control Retrofit Window Film The objective of this project is to develop, validate, and commercialize a range of cost effective, lowemissivity, energy-control retrofit window films with significantly improved performance over current technology. These films will offer the energy saving properties of the modern low-e windows without the associated high cost for replacement and installation, provide lower energy use for heating and cooling, and provide financial payback than can be achieved more quickly than with replacement windows or currently commercially available window films. Research will be conducted to enable technologies similar to those used in low-e glass coatings to be used on retrofit window films. Areas of research will include: improving the flexibility of the low-e coatings; improving the corrosion resistance of the metals used in the coatings; and, creating an highly abrasion resistant IR transmissive coating. Pilot and production scale-up trials will be conducted to produce a commercial product. SAGE Electrochromics, Inc. - Electrochromic Glazings: Improved Performance, Lower Cost The objective of this project is to improve the energy performance and lower the cost of electrochromic (EC) smart windows for residential and commercial building applications. This project will address two critical of EC windos: lowering the cost and improving the energy performance of EC glazing. These objective will be addressed by: improving the Solar Heat gain Coefficient (SHGC) range between the tinted and clear states; reducing the cost of EC windows by utilizing lower cost materials and coater process improvements; lowering the U-Value; and, ensuring the implemented changes have no detrimental effect on window durability. A combination of materials development and economies of scale facilitated by increased production volume will be used to achieve cost reductions. Syntroleum, Corporation - Development of Low Cost Bio-Based Phase Change Material Studies have shown that incorporating Phase Change Material (PCM) in building envelopes (attic insulation, wall boards, etc.) can reduce energy consumption for home heating and cooling by 30percent or more. However, high manufacturing costs have limited PCM use to novelty products. The objective of this project is to lower the cost of PCM manufacture by demonstrating a more selective (and

6 sustainable) process for n-paraffin production and continuous high throughput equipment for its encapsulation. This combination is expected to produce a step-reduction in PCM costs, thus opening the new construction and retrofit market to this promising building envelope material. The project scope of work will include: lab compounding and differential scanning calorimeter (DSC) studies to show viability of low cost encapsulation of C 16 -C 18 paraffins in polyethylene polymer pellets; demonstration of a chemical process to convert bio-oils to C 16 -C 18 paraffins at high yield and selectivity at the pilot plant scale; scale-up of low cost encapsulation of C 16 -C 18 paraffins in polyethylene via under-water pelletizing technology; testing the PCM pellets in building envelopes using dynamic hot box experiments; and, market research to assess the impact of lower cost PCMs on increased use in building materials.