Anti-reflective and anti-soiling coatings with self-cleaning properties

Abstract

Disclosed herein is a method of forming a glass coating including making a sol by hydrolyzing an organosilane in the presence of a least one solvent and at least one catalyst, further adding at least one alkoxysilane, and aging the sol for at least 24 hours.

1 . A method of forming a glass coating, comprising:
 making a sol by hydrolyzing an organosilane in the presence of a least one solvent and at least one catalyst;   further adding at least one alkoxysilane; and   aging the sol for at least 24 hours.   
     
     
         2 . The method of  claim 1 , wherein the organosilane comprises methyltrimethoxysilane. 
     
     
         3 . The method of  claim 1 , wherein the alkyoxysilane comprises at least one of tetramethoxysilane and tetraethoxysilane. 
     
     
         4 . The method of  claim 1 , wherein the at least one solvent comprises at least one member selected from the group consisting of water, methanol, ethanol, 1-propanol, 2-propanol, n-butanol, isobutanol, tert-butanol, pentanol, hexanol, cyclohexanol, ethylene glycol, propylene glycol, ethylene glycol monomethyl ether, ethylene glycol dimethyl ether, propylene glycol monomethyl ether, ethylene glycol dimethyl ether, propylene glycol monomethyl ether, diglyme, acetone, methyl ethyl ketone (butanone), pantanones, methyl t-butyl ether (MTBE), ethyl t-butyl ether (ETBE), acetaldehyde, propionaldehyde, ethyl acetate, methyl acetate, and ethyl lactate. 
     
     
         5 . The method of  claim 1 , wherein at least one catalyst comprises at least one member selected from the group consisting of hydrochloric acid, nitric acid, acetic acid, trifluoromethanesulphonic acid, oxalic acid, sodium hydroxide, aqueous ammonia, pyridine, tetraethylammoniuum hydroxide, and benzyltriethylammonium hydroxide. 
     
     
         6 . The method of  claim 1 , wherein the sol is aged for between 24 and 48 hours. 
     
     
         7 . The method of  claim 1  further comprising:
 a. preparing a coated glass substrate, wherein the preparing comprises applying the aged sol to a glass substrate; 
 b. drying the sol; and 
 c. curing the sol at a temperature of between 20° C. and 200° C., 
 wherein the coated glass substrate has at least one of an anti-reflective property, a high abrasion resistance property, a hydrophobic property, and an anti-soiling property. 
 
     
     
         8 . The method of  claim 7 , wherein the coated glass substrate is further assembled into a solar module. 
     
     
         9 . The method of  claim 7 , wherein the coated glass substrate comprises float-glass, the method further comprising applying the sol on a tin-side of the glass substrate. 
     
     
         10 . The method of  claim 7 , wherein the glass substrate comprises tempered glass. 
     
     
         11 . The method of  claim 7 , wherein applying the aged sol further comprises applying by a technique selected from the group consisting of roll coating, dip coating, spraying, drop rolling and flow coating. 
     
     
         12 . The method of  claim 7 , wherein the curing comprises an operation to cure the sol under ambient conditions. 
     
     
         13 . The method of  claim 7 , wherein the curing comprises an operation to heat the sol to 120° C. 
     
     
         14 . A method, comprising:
 preparing a sol by hydrolyzing an organosilane in the presence of a least one solvent and at least one catalyst, the catalyst comprising at least one of an acid catalyst and a base catalyst;   further adding at least one alkoxysilane; and   aging the sol for at least 30 minutes.   
     
     
         15 . The method of  claim 14 , further comprising aging the sol for a period between 24 and 48 hours. 
     
     
         16 . The method of  claim 15 , wherein the at least one catalyst comprises at least one acid catalyst, wherein the at least one acid catalyst comprises at least one member selected from the group consisting of hydrochloric acid, nitric acid, acetic acid, trifluoromethanesulphonic acid, and oxalic acid. 
     
     
         17 . The method of  claim 15 , wherein the at least one catalyst comprises at least one base catalyst, wherein the at least one base catalyst comprises at least one member selected from the group consisting of sodium hydroxide, aqueous ammonia, pyridine, tetraethylammoniuum hydroxide, and benzyltriethylammonium hydroxide. 
     
     
         18 . The method of  claim 16 , further comprising:
 preparing a coated glass substrate, wherein the preparing comprises applying the aged sol to a glass substrate;   drying the sol; and   curing the sol at a temperature of between 20° C. and 200° C.,   wherein the coated glass substrate has at least one of an anti-reflective property, a high abrasion resistance property, a hydrophobic property, and an anti-soiling property.   
     
     
         19 . The method of  claim 18 , wherein the glass substrate comprises float-glass, the method further comprising applying the sol on a tin-side of the glass substrate. 
     
     
         20 . The method of  claim 19 , wherein the curing comprises an operation to heat the sol to 120° C.