Low emittance coatings and the thermal performance of vacuum glazing

The thermal performances of vacuum glazings employing coatings with emittance between 0.02 and 0.16 were simulated using a three-dimensional finite volume model. Physical samples of vacuum glazings with hard and soft coatings with emittance of 0.04, 0.12 and 0.16 were fabricated and their thermal performance characterised experimentally using a guarded hot box calorimeter. Good agreement was found between experimental and theoretical thermal performances for both a vacuum glazing with a soft coating (emittance 0.04) and those with hard coatings (emittance 0.12 and 0.16). Simulations showed that for a low value of emittance (e.g. 0.02), the use of two low-emittance coatings gives limited improvement in thermal performance of the glazing system. The use of a single high performance low-emittance coating in a vacuum glazing has been shown to provide excellent performance.     

Comparison of vacuum glazing thermal performance predicted using two- and three-dimensional models and their experimental validation

Thermal performance of vacuum glazing predicted by using two-dimensional (2-D) finite element and three-dimensional (3-D) finite volume models are presented. In the 2-D model, the vacuum space, including the pillar arrays, was represented by a material whose effective thermal conductivity was determined from the specified vacuum space width, the heat conduction through the pillar array and the calculated radiation heat transfer between the two interior glass surfaces within the vacuum gap. In the 3-D model, the support pillar array was incorporated and modelled within the glazing unit directly. The predicted difference in overall heat transfer coefficients between the two models for the vacuum window simulated was less than 3%. A guarded hot box calorimeter was used to determine the experimental thermal performance of vacuum glazing. The experimentally determined overall heat transfer coefficient and temperature profiles along the central line of the vacuum glazing are in very good agreement with the predictions made using the 2-D and 3-D models.     

Predicted thermal performance of triple vacuum glazing

The simulated triple vacuum glazing (TVG) consists of three 4 mm thick glass panes with two vacuum gaps, with each internal glass surface coated with a low-emittance coating with an emittance of 0.03. The two vacuum gaps are sealed by an indium based sealant and separated by a stainless steel pillar array with a height of 0.12 mm and a pillar diameter of 0.3 mm spaced at 25 mm. The thermal transmission at the centre-of-glazing area of the TVG was predicted to be 0.26 W m⁻² K⁻¹. The simulation results show that although the thermal conductivity of solder glass (1 W m⁻¹ K⁻¹) and indium (83.7 W m⁻¹ K⁻¹) are very different, the difference in thermal transmission of TVGs resulting from the use of an indium and a solder glass edge seal was 0.01 W m⁻² K⁻¹. This is because the edge seal is so thin (0.12 mm), consequently there is a negligible temperature drop across it irrespective of the material that the seal is made from relative to the total temperature difference across the glazing. The results also show that there is a relatively large increase in the overall thermal conductance of glazings without a frame when the width of the indium edge seal is increased. Increasing the rebate depth in a solid wood frame decreased the heat transmission of the TVG. The overall heat transmission of the simulated 0.5 m by 0.5 m TVG was 32.6% greater than that of the 1 m by 1 m TVG, since heat conduction through the edge seal of the small glazing has a larger contribution to the total glazing heat transfer than that of the larger glazing system.     

A modified pump-out technique used for fabrication of low temperature metal sealed vacuum glazing

A modified pump-out technique, incorporating a novel pump-out hole sealing process, has been developed that enables a high level of vacuum to be achieved between the panes of a vacuum glazing. The modified pump-out method provides several potential opportunities for the fabrication of a vacuum glazing with improved thermal performance. In particular, improved flexibility for production of a wide range of glazing sizes may allow a lower cost of manufacture to be achieved by avoiding the expense of a high vacuum oven which would otherwise be required for commercial production of high performance, large-scale vacuum glazings.The thermal performance of the vacuum glazing fabricated using the pump-out technique was characterized using a guarded hotbox calorimeter and theoretically analyzed using a finite volume model. The excellent experimentally determined thermal performance of the fabricated vacuum glazing was in good agreement with that predicted theoretically.     

Thermal conductance measurement on vacuum glazing

A method is described for measuring the thermal conductance of vacuum glazing that is well-suited for integration into the manufacturing process of such devices. The sample of vacuum glazing to be measured, initially at elevated temperature, is placed in contact with a second sample of vacuum glazing with a known thermal conductance. The external surfaces of the glazings are then cooled by forced flow of air at room temperature, and a measurement is made of the rate of decrease of the temperature of the contacting glass sheets of the two samples. The method is simple to implement, and can be automated. The results obtained with the method are quite reproducible. The measurement can be made as the production samples of vacuum glazing cool at the completion of the manufacturing process, resulting in significant savings in time and labour compared with other methods.     

Temperature-induced stresses in vacuum glazing: Modelling and experimental validation

A temperature difference across a sample of vacuum glazing causes differential expansion of one glass sheet relative to the other. In vacuum glazing with a fused edge seal, this results in tensile and compressive stresses in the glass sheets, and bending of the structure. The physical origins of these stresses and deflections are discussed, and a finite element model is used to determine their magnitude. The model has been validated by comparison with experimental data for a well-characterised sample of vacuum glazing under accurately defined external conditions. Modelling data are presented for two glazing designs which have properties that are characteristic of the extremes of performance of this type of glazing. It is shown that mechanical edge constraints can profoundly alter the spatial distribution of stresses in the glazing.     

Experimental validation of a numerical model for heat transfer in vacuum glazing

Flat vacuum glazings consisting of a narrow evacuated space between two glass panes separated by an array of small support pillars have been fabricated. A guarded hot box calorimeter was designed and constructed to measure their heat transfer coefficients. Experimental measurements of temperatures and rates of heat transfer were found to be in very good agreement with those predicted using a developed finite element model. A method for determining the heat transfer coefficient of the evacuated gap has been established and comparisons are made between the measured and predicted glass surface temperature profiles of the exposed glass area and the heat transfer coefficients of the total glazing system in order to validated the model.     

Stresses in vacuum glazing fabricated at low temperature

This paper reports an experimental and theoretical study of the stresses in and durability of vacuum glazing fabricated at low temperature using an indium based edge seal. For the first time a finite-element model with support pillars incorporated directly, enabled the stresses in the whole structure to be explicitly calculated. Experimental validations of the finite element model predictions were undertaken. Modelling results are presented for a case with American Society of Testing and Materials standard winter boundary conditions. It was found that, for the particular system studied, the predicted stress level in the structure is essentially the same for indium sealed and solder glass sealed vacuum glazing, and the magnitude of stress values in the indium seal is comparable with that dictated by the indium strength characteristics.     

Thermal performance analysis of an electrochromic vacuum glazing with low emittance coatings

Thermal performance of an electrochromic (EC) vacuum glazing (VG) was modelled under ASTM standard winter conditions. The EC VG comprised three 0.5 m by 0.5 m glass panes with a 0.12 mm wide evacuated space between two 4 mm thick panes sealed contiguously by a 6 mm wide indium based edge seal with either one or two low-emittance (low-e) coatings supported by a 0.32 mm diameter square pillar grid spaced at 25 mm. The third glass pane on which the 0.1 mm thick EC layer was deposited was sealed to the evacuated glass unit. The whole unit was rebated by 10 mm within a solid wood frame. The low-e coating absorbed 10% of solar energy incident on it. With the EC VG installed with the EC component facing the outdoor environment, for an incident solar radiation of 300 W m⁻², simulations demonstrated that when the EC layer is opaque for winter conditions, the temperature of the inside glass pane is higher than the indoor air temperature, due to solar radiation absorbed by the low-e coatings and the EC layer, the EC VG is a heat source with heat transferred from the glazing to the interior environment. When the emittance was lower to 0.02, the outdoor and indoor glass pane temperatures of the glazing with single and two low-e coatings are very close to each other. For an insolation of 1000 W m⁻², the outdoor glass pane temperature exceeds the indoor glass pane temperature, consequentially the outdoor glass pane transfers heat to the indoor glass pane.     

Thermal performance of an electrochromic vacuum glazing

Using a three-dimensional finite volume model, the thermal performance of an electrochromic vacuum glazing was simulated for insolation intensities between 0 and 1200 W m⁻². The electrochromic evacuated glazing simulated consisted of three glass panes 0.5 m by 0.5 m with a 0.12 mm wide evacuated space between two 4 mm thick panes supported by 0.32 mm diameter pillars spaced on a 25 mm square grid contiguously sealed by a 6 mm wide metal edge seal. The third glass pane on which the electrochromic layer was deposited was assumed to be sealed to the evacuated glass unit. The simulations indicate that when facing the indoor environment, the temperature of the glass pane with the electrochromic layer can reach 129.5 °C for an incident insolation of 600 W m⁻². At such temperatures unacceptable occupant comfort would ensue and the durability of the electrochromic glazing would be compromised. The glass pane with the electrochromic layer must therefore face the outdoor environment.     

Effect of glass thickness on the thermal performance of evacuated glazing

Flat evacuated glazing consists of two plane glass panes separated by a narrow internal evacuated space. Separation in the space is maintained by an array of support pillars typically 0.32 mm in diameter and 0.12 mm high arranged on a regular square grid with an inter-pillar separation of up to 40 mm. A detailed three-dimensional finite volume model has been employed to determine the variation of thermal performance of an evacuated glazing as a function of glass pane thickness. It was predicted that for evacuated glazing of dimensions of 0.3 m by 0.3 m and 0.5 m by 0.5 m, reducing glass pane thickness gave improved thermal performance. For evacuated glazings with dimensions of 1 m by 1 m, the opposite was predicted.     

The effect of glazing shape upon the thermal performance of buildings

The great incidence that glazing has in a building energy conservation makes it one of the most important parameters to be taken into account especially in commercial buildings, where the surface occupied by glass areas is very important. So, different shapes of glass areas and their influence in the energy consumption of a commercial building are studied in this paper. Horizontal glazing (with different heights) and vertical glazing (with the same area as the horizontal ones), separated by opaque areas are considered in a base case building. A traditional wall and a curtain-wall are considered, and the different annual consumptions per conditions unit surface, both in winter and summer, are obtained.     

Modeling of thermal stresses and lifetime prediction of planar solid oxide fuel cell under thermal cycling conditions

A typical operating temperature of a solid oxide fuel cell (SOFC) is above 600 °C, which leads to severe thermal stresses caused by the difference in material mechanical properties during thermal cycling. Interfacial shear stress and peeling stress are the two types of thermal stresses that can cause the mechanical failure of the SOFC. Two commonly used SOFC configurations (electrolyte-supported and anode-supported) were considered for this study. The paper developed a mathematical model to estimate the thermal stresses and to predict the lifetime of the cell (Ni/8YSZ-YSZ-LSM). Due to the mismatch of the material mechanical properties of the cell layers, a crack nucleation induced by thermal stresses can be predicted by the crack damage growth rate and the initial damage distribution in the interfacial layer for each thermal cycle. It was found that the interfacial shear stress and peeling stress were more concentrated near the electrode free edge areas. The number of cycles needed for failure decreased with the increase in the porosity of electrode. The number of cycle for failure decreased with increase in electrolyte thickness for both anode- and electrolyte-supported SOFC. The model provides insight into the distribution of interfacial shear stress and peeling stress and can also predict damage evolution in a localized damage area in different SOFC configurations.     

Understanding thermal and redox cycling behaviors of flat-tube solid oxide fuel cells

The performance stability of solid oxide fuel cells (SOFCs) under thermal and redox cycles is vital for large-scale applications. In this work, we investigated the effects of thermal and redox cycles on cell performances of flat-tube Ni/yttria-stabilized zirconia (Ni/YSZ) anode-supported SOFCs. Cell performance was considerably affected by the duration of oxidation during redox cycles and the heating rate during the thermal cycles. The cell tolerated 20 short-term redox cycles (5 min oxidation) without significant performance degradation. Besides, the cell exhibited superior stability during 8 thermal cycles with a slow heating rate (4 °C min⁻¹) to that with a fast heating rate (8 °C min⁻¹). These results reflected that the thick anode support (2.7 mm) offered strong resistance to the shocks caused by redox and thermal cycling. Moreover, the morphological changes of the Ni phase during the redox and thermal cycling were investigated using Ni-film anode cells. Agglomeration of Ni particles and dissociation between the Ni film and the YSZ substrate were confirmed after 5 redox cycles, whereas no significant changes in Ni film emerged after 8 thermal cycles.     

Some fatty acids used for latent heat storage: thermal stability and corrosion of metals with respect to thermal cycling

The present study includes thermal stability of some fatty acids as phase change materials (PCMs). The selected fatty acids were stearic, palmitic, myristic and lauric acid with melting temperatures between 40–63°C and industrial-grade with 90–95 % purity. Latent heat storage capacity and phase transition temperature of the PCMs were determined by Differential Scanning Calorimetry (DSC) technique as a function of after repeated thermal cycles such as 40, 410, 700 and 910. The present work also comprises the investigation of corrosion resistance of some construction materials to the fatty acids over a long period. The containment materials tested were stainless steel (SS 304 L), carbon steel (steel C20), aluminium (Al) and copper (Cu). Gravimetric analysis as mass loss (mg/cm²), corrosion rate (mg/day) and a microscopic or matellographic investigation were performed for corrosion tests after 910 thermal cycles. DSC measurements showed that all fatty acids investigated as PCMs have a good thermal stability as a function of latent heat and phase transition temperature range for an actual middle-term thermal energy storage utility. However, in long-term solar thermal applications, the palmitic acid and myristic acid may be considered more suitable PCMs than the others. From the gravimetric and metallographic results, it can be concluded that stainless steel (SS 304L) with chromium oxide (Cr₂O₃) surface layer and Al with aluminium oxide (Al₂O₃) surface layer are essentially compatible with the investigated fatty acids. Carbon steel (Steel C20) and Cupper (Cu) are only preferantially compatible with PCMs.     

Investigations on thermal and optical performances of a glazing roof with PCM layer

The thermal and optical performances of a roof in a building containing phase change material (PCM) were investigated in this paper. The glazing roof model consists of two layers of glass and one layer of PCM. The purpose of filling the roof structure with PCM is to utilize the solar energy efficiently. The effectiveness of thermal and optical performances of the roof PCM system was determined by analyzing the heat flux and temperature at the indoor surface with different absorption coefficients and refractive index of PCM in solid and liquid states. The results show that the absorption coefficients and refractive index of solid and liquid PCMs have both effects on thermal performance in the roof PCM system. Of all the thermal performances, the effect on internal temperature, temperature lag, and total transmitted energy is smaller and the effect on solar transmittance and transmitted solar energy is bigger. The absorption coefficients have the opposite effect with the refractive index on interior temperature lag. Considering the indoor daylight, increasing the refractive index and absorption coefficient of liquid PCM is a better method to better the thermal performance of a roof PCM system. Copyright © 2017 John Wiley & Sons, Ltd.     

Spectrally selective laminated glazing consisting of solar control and heat mirror coated glass: preparation, characterization and modelling of heat transfer

In this study, solar control coatings were prepared by sequential depositions of thin films of ZnS (40 nm)–CuS (150 nm) and ZnS (40 nm)–Bi₂S₃ (75 nm)–CuS (150 nm) from chemical baths on 3 mm thick commercial sheet glass. These were laminated to 3 mm thick clear glass or commercially available SnO₂ based heat mirror coating of sheet resistance 15 Ω on float glass of 3 mm thickness using a poly(ethylene vinyl acetate), EVA, sheet of 0.36 mm thickness in a vacuum process at 120 °C for 30 min. In total, the thickness of the glazing was 6.35 mm. The glazings possess visible transmittance, weighted for D65 solar spectra and sensitivity of the human eye for daylight vision, of 36% or 14% with solar absorptance of 71% or 78% depending on the coating type, i.e ZnS–CuS or ZnS–Bi₂S₃–CuS-heat mirror respectively. The solar heat gain coefficient (SHGC) was evaluated for these glazings at exterior temperatures of 15 and 32 °C for an exterior convective heat transfer coefficient (h_ex) of 6–100 Wm⁻² K⁻¹ using a mathematical model. The model predicts the extent of reduction in SHGC through the presence of the heat mirror coating as a function of h_ex and hence helps to decide on the relative benefit, which may be derived through their use in different locations. Though the deposition technique mentioned here involves longer duration compared with vacuum techniques, it may be developed into a low throughput, low-capital alternate technology for small-scale production.     

The oil bath thermal cycling absorption process design and separation process research

Thermal cycling absorption process (TCAP) has been developed for years to support the separation of hydrogen isotopes, which has the characteristics of high separation efficiency and high recovery rate. The design of separation column structure, heating and cooling (H&C) system and technological parameters are the basis of TCAP technical process study and are the key points of TCAP engineering research. In this work, an improved separation system has been designed and built based on an oil bath H&C system for the first time. The separation column in this facility is 45 m long and the packing weight in the column is up to 8 kg. The separation experiments were carried out based on this facility, and the process parameters were adjusted according to the size of the separation column, which proved the superior performance of this facility. The separation experiments show that for 50% D₂ - 50% H₂ feed gas, the deuterium abundance can reach to 99% and the steady state extraction can be realized in production mode with the processing capacity over 400 standard L per day. Another experiment has been carried out with 1% D₂ - 99% H₂ feed gas, and the deuterium abundance exceeded 10%, verifying the separation ability at low abundance deuterium feed gas. Furthermore, the extraction rate can reach to 25% column capacity when the deuterium abundance in production gas is 5%.     

Internal thermal coupling in direct-flow coaxial vacuum tube collectors

This investigation covers the impact of low flow rates on the efficiency of coaxial vacuum tube collectors. Measurements show an efficiency reduction of 10% if reducing the flow rate from 78 kg/m² h to 31 kg/m² h for a collector group with 60 parallel vacuum tubes with a coaxial flow conduit at one-sided connection. For a more profound understanding a model of the coaxial tube was developed which defines the main energy fluxes including the internal thermal coupling. The tube simulations show a non-linear temperature profile along the tube with the maximum temperature in the outer pipe. Due to heat transfer to the entering flow this maximum is not located at the fluid outlet. The non-linearity increases with decreasing flow rates. The experimentally determined flow distribution allows simulating the measured collector array. The simulation results confirm the efficiency decrease at low flow rates. The flow distribution has a further impact on efficiency reduction, but even at an ideal uniform flow, a considerable efficiency reduction at low flow rates is to be expected. As a consequence, low flow rates should be prevented for coaxial tube collectors, thus restricting the possible operation conditions. The effect of constructional modifications like diameter or material variations is presented. Finally the additional impact of a coaxial manifold design is discussed.     

Fast thermal cycling of acetanilide and magnesium chloride hexahydrate for indoor solar cooking

Solar cookers are broadly divided into a direct or focusing type, indirect or box-type and advanced solar cookers. The focusing and box-type solar cookers are for outdoor applications. The advanced solar cookers have the advantage of being usable indoors and thus solve one of the problems, which impede the social acceptance of solar cookers. The advanced type solar cookers are employing additional solar units that increase the cost. Therefore, the solar cooker must contain a heat storage medium to store thermal energy for use during off-sunshine hours. The main aim of this study is to investigate the influence of the melting/solidification fast cycling of the commercial grade acetanilide C₈H₉NO (T_m = 116 °C) and magnesium chloride hexahydrate MgCl₂·6H₂O (T_m = 116.7 °C) on their thermo-physical properties; such as melting point and latent heat of fusion, to be used as storage media inside solar cookers. Five hundred cycles have been performed. The thermo-physical properties are measured using the differential scanning calorimetric technique. The compatibility of the selected phase change materials (PCMs) with the containing material is also studied via the surface investigation, using the SIM technique, of aluminum and stainless steel samples embedded in the PCM during cycling. It is inferred that acetanilide is a promising PCM for cooking indoors and during law intensity solar radiation periods with good compatibility with aluminum as a containing material. However, MgCl₂·6H₂O is not stable during its thermal cycling (even with the extra water principle) due to the phase segregation problem; therefore, it is not recommended as a storage material inside solar cookers for cooking indoors. It is also indicated that MgCl₂·6H₂O is not compatible with either aluminum or stainless steel.