STRUCTURAL COLORS HAVING UV REFLECTANCE VIA SPRAY LAYER-BY-LAYER PROCESSING

• US 20110014366A1
• Filed: 09/29/2010
• Published: 01/20/2011
• Est. Priority Date: 05/18/2009
• Status: Active Grant

• Current Assignee: Massachusetts Institute of Technology, Toyota Motor Corporation
• Original Assignee: Massachusetts Institute of Technology, Toyota Motor Corporation, Toyota Motor Engineering & Manufacturing North America Incorporated (Toyota Motor Corporation)
• Inventors: Nogueira, Grinia Michelle, Banerjee, Debasish, Cohen, Robert E., Rubner, Michael F.
• Granted Patent: US 8,313,798 B2
• Time in Patent Office: Days
• US Class Current: 427/162
• CPC Class Codes: G02B 5/208 for use with infrared or ultraviolet radiation, e.g. for separating visible light from infrared and/or ultraviolet radiation

Abstract

A process for fabricating a structural color having ultraviolet reflectance is provided. The process includes providing an atomizing nozzle, a first nanoparticle solution and a second nanoparticle solution. The atomizing nozzle is used to spray a plurality of first nanoparticle solution layers, the plurality of first nanoparticle layers forming a low index of refraction stack. In some instances, a polymer solution can be sprayed before and/or after the spraying of each first nanoparticle solution layer. The atomizing nozzle is also used to spray a plurality of second nanoparticle solution layers, the plurality of second nanoparticle layers form a high index of refraction stack. Similar to the first nanoparticle solution layers, a polymer solution can be sprayed before and/or after the spraying of each second nanoparticle solution layer.

Claims

1. A process for fabricating a structural color having ultraviolet reflectance, the process comprising:

providing an atomizing nozzle;

providing a first nanoparticle solution and a second nanoparticle solution;

spraying a plurality of first nanoparticle solution layers;

the plurality of first nanoparticle layers forming a low index of refraction stack;

spraying a plurality of second nanoparticle solution layers;

the plurality of second nanoparticle layers forming a high index of refraction stack;

spraying additional layers to form a plurality of alternating low index of refraction stacks and high index of refraction stacks, the low index of refraction stacks extending across the high index of refraction stacks and vice versa; and

calcinating the low index of refraction stacks and the high index of refraction stacks to form a plurality of alternating low index of refraction layers and high index of refraction layers;

the alternating low index of refraction layers and high index of refraction layers having a dual reflection spectrum that reflects electromagnetic radiation in an ultraviolet region and a narrow band of electromagnetic radiation in a visible region.

2. The process of claim 1, wherein the plurality of low index of refraction stacks and high index of refraction stacks each have a non-quarter wave thickness.

3. The process of claim 1, wherein the plurality of alternating low index of refraction layers and high index of refraction layers reflect more than 70% of the electromagnetic radiation in the ultraviolet region and more than 60% of the narrow band of electromagnetic radiation in the visible region.

4. The process of claim 1, wherein the first nanoparticles are SiO₂ nanoparticles and the second nanoparticles are TiO₂ nanoparticles.

5. The process of claim 1, wherein the plurality of alternating stacks of low index of refraction and high index of refraction are in the form of a flake.

6. The process of claim 5, wherein the flake is a pigment for a paint.

7. The process of claim 1, wherein the spraying and rinsing are computer controlled.

8. The process claim 1, wherein the plurality of alternating layers of low index of refraction layers and high index of refraction layers have a layered structure described by [A 0.5qH pL (qH pL)^N 0.5qH G], where:

A represents air;

q is a multiplier of a quarter wave thickness of the high index of refraction layers;

H is the quarter wave thickness of the high refracting index layers for a given wavelength λ

₀;

p is a multiplier of a quarter wave thickness of the low index of refraction material;

L is the thickness of the low refracting index layer for the given wavelength λ

₀;

N represents the total number of layers between bounding layers of the high index of refraction material; and

G represents a substrate.

9. A process for fabricating a structural color having ultraviolet reflectance, the process comprising:

providing a plurality of atomizing nozzles;

providing a first nanoparticle solution and a first polymer solution;

providing a second nanoparticle solution and a second polymer solution;

spraying a plurality of first nanoparticle bilayers, each first nanoparticle bilayer made by spraying a first nanoparticle solution layer and a first polymer solution layer using a first set of the plurality of atomizing nozzles;

rinsing each first nanoparticle bilayer using a second set of the plurality of atomizing nozzles before an additional first nanoparticle bilayer is sprayed;

the plurality of first nanoparticle bilayers forming a low index of refraction stack;

spraying a plurality of second nanoparticle bilayers, each second nanoparticle bilayer made by spraying a second nanoparticle solution layer and a second polymer solution layer;

rinsing each second nanoparticle bilayer before an additional second nanoparticle bilayer is sprayed;

the plurality of second nanoparticle bilayers forming a high index of refraction stack;

spraying additional layers to form a plurality of alternating low index of refraction stacks and high index of refraction stacks, the low index of refraction stacks extending across the high index of refraction stacks and vice versa;

decomposing the first polymer from the low index of refraction stacks and the second polymer from the high index of refraction stacks and forming a plurality of alternating low index of refraction layers and high index of refraction layers;

the alternating low index of refraction layers and high index of refraction layers having a dual reflection spectrum that reflects electromagnetic radiation in an ultraviolet region and a narrow band of electromagnetic radiation in a visible region.