OSC Low-E

Professional Low-E Solution

OSC Low-E is professional solution and best for thin film design, inversion fitting, material refractive index fitting and management, uniformity adjustment and control, database management(design, process data, production data) and so on.

OSC Low-E is developed based on Filmstar,with fast calculation and optimization of Filmstar and our working experience on low-E industry, OSC Low-E can solve the actual problems of our clients prominently.

Low-E production line is pretty expensive. The excellent performance of OSC Low-E such as fast calculation, accurate inversion can significantly improve the efficiency. The rapid uniformity adjustment and control is solid upgrade and guarantee for product quality.

Introduction


Low emission (known as low-E) glass is a thin film product with multiple layers of metal or other compounds coated on the glass.

Comparing with ordinary glass and traditional architectural coated glass, the low-E coating has a high transmittance of visible light and high reflectance of the far-infrared and then has excellent thermal insulation and good light transmission.

However, the issues of low-e coating production line such as low efficiency, huge waste, non-sustainable development and others have plagued the majority of Low-E coating companies, and even Low-E coating upstream and downstream enterprises.

The current Prominent issues are:

  • Adjustment depends on experience, manual calculation or excel:passable for heat-reflective glass, single silver design but not suitable for the double silver, three silver and more complex design.
  • Spectrum and color can not meet the requirements. Even Sometime achieve objective,the coating equipment parameters have to be re-adjusted after exception handling. There is no plan at all for reciprocating and wasting a lot of time.
  • Uniformity, consistency can not be controlled, especially the problem of high angle interference color can not be solved.
  • Acknowledge of Coating line equipment, materials and process control is limited to equipment manufacturers or reference books. There is no specific details and verifiable traceability relationship.
  • Adjustment is a wheel war and lead to staff fatigue, complain and high turnover rate.
  • A lot of waste (glass, coating target, electricity).
  • Orders can not be delivered in time, new orders can not undertake.
  • Customer Complaints.

OSC Low-E is developed based on Filmstar, a famous optical thin film software from USA and it is popular for arround 30 years.

OSC Low-E continues Filmstar's advantages such as high computing power and high optimization speed and combines our practical application and practical operation of Low-E industry.

It was developed by our domestic and foreign Low-E coating experts and software engineers combining first line users' needs, practical experience of product development engineers and process adjustment engineers, a number of cutting-edge technology and so on.

It highlights to solve the actual problems of users rapidly and effectively.

We obtained the actual verification of good results after several years of top coating production line tests and many times functional amendment based on the actual process running parameters.


Main Features

Main Function-Development

Development is a procedure to get correct thin film design based on spectrum or color target through solving equations with many strategies.

Development can be done without occupying the time for production. Imitation or customized color need enough time to design the thin film stack and get the required spectrum, color and also taking into account the physical properties such as resistivity, resistance Acid and alkali, abrasion resistance and so on.


Development procedure


Development Introduction

Main Function-Inversion fitting

Inversion fitting is the key step of adjustment. The speed and accuracy of the inversion fitting directly determine the efficiency and product quality.

Thickness of each layer is inverted according to the thin film stack and known spectrum by Solving equations with many strategies.

We can get the adjusted thickness through comparing simulated thickness with the standard thickness.

Through the step-by-step inversion fitting, you can adjust the actual thin film thickness to the standard thickness resulting in the desired spectrum, color And physical characteristics.


Inversion fitting Procedure


Inversion fitting Introduction

Main Function-Index Fitting

The refractive index of the material(substrate, coating material) is the most important data for the thin film calculation(Development, inversion fitting).

  • Fitting the refractive index of the material by the photometric method need one or more of the transmittance, the reflectance and the film thickness. When the accuracy of the test data is the same, the fitting result is more reliable with more data type.
  • We can fit the refractive index of a substrate or a kind of coating material. In general, we need know the refractive index of the substrate(can be fitted in advance) before we can fit the refractive index of coating material.
  • Multi-angle photometric data may be helpful for the convergence of the refractive index fitting procedure.

Material Refractive Index Fitting

Main Function-Uniformity Adjustment and Control

Uniformity refers to the difference between the different positions of the glass.

The problems that may arise from uniformity include overall optical properties (color, emissivity), physical properties (abrasion resistance, temperature shock), chemical properties (acid and alkali resistance), etc.

The reason is one or more Layers of thin film design are different(thickness or composition) from one position to others.

There are many factors that affect the uniformity, including the structure of the equipment itself, magnets, gas distribution pipes, shielding, target substrate distance, etc., but also the auxiliary gas settings.

The uniformity is adjusted by modeling factors both in terms of positions and in real time.

The uniformity is controlled by monitoring the spectrum/resistance of each piece of glass real time during the production process and adjusting it in case deviation from normal level.


Main Function-Process Data Management

We manage the process data of the coating lines through local, LAN and cloud databases (Optional).

The users can store, inquire and call the process data including the film design, the material refractive index, process, the coating parameters Settings, uniformity data and so on.


Main Function-Production Data Management

We manage the production data of the coating production lines through the local, LAN and cloud databases (optional).

Users can store, query and invoke the production data including spectra, colors and production adjustment records.


Other Function

Other features are currently being developed and debugged. Include optimization objectives(spectral objectives, color objectives) management, equipment spare parts management, order management, human resources management, customer management and more.

Typical Users

Our solution has been implenmentated on difference Low-E coating production line in China. The main products of these production lines are 3-Ag and 2 Ag.

We have more users in the following industries and application fields:

  • Low-E coating production line.
  • University Laboratory

The coating equipment of users who use OSC Low-E sucessfully:

  • VON ARDENNE sputtering line.
  • xxx sputtering line.
  • User self-made sputtering line.

Product and Service

Product Composition

Software, Instrument(optional:spectrometer and Surface resistance measurement module), server on demand,desktop,laptop and so on.

Pre-sales consulting and demo

User needs research, product features, price estimates, delivery estimates.

Make solution

Make solution accoring to user's request: hardware,software,customized function, training, delivery, price, time and so on.

Implement Solution

Hardware and software procurement, custom features development and testing, the overall training, on-line commissioning, acceptance and others.

Training

  1. We provide at east one time training for all clients to make sure they can use our products well. The training plan will be prepared according to the basic knowledge of participants,request,product features,technical difficulty and so on. The minimum training time is 5 working days.
  2. On-demand training needs: hardware upgrade, product replacement, new employee onboard. We will coordinate according to the actual situation.

Technical Support

Instruction for usage, trouble shooting, questions via telphone,email, remote control, instant conversation and so on.

Technical Consultation

Upgrade coating production line,Renovation project,repair,product development,material search ect.

After-sales Service

Warranty of Hardware, debug for software, upgrade function of software etc.

Application scenarios and Examples

RD of three-silver thin film design

Uniformity Adjustment

Refractive index fitting of material

Frequently Asked Questions

  • Is there any requirement on the format of online spectrometer?

    We support most of the commercial spectral file formats.


    We also provide extended methods to support more spectral file formats, please contact us to confirm.

  • Do you provide a computer? What are the requirements on the computer?

    For new users, we provide options to purchase computer with our solution. The computer is well-known brand, high level configuration, after our testing, to meet the performance requirements of our software.


    The user-provided computer, we will implement our solution on users' computer and we will explain to the user to replace the computer in case there is an unsolvable problem from computer itself.


    We recommend a branded machine with high configuration (CPU and memory) to ensure longer use and better performance.

  • Is it harder to use? Do you provide training?

    The difficulty varies from person to person.


    Generally, it will better when you have some basic knowledge of optical thin film (included in the training content) and software operating skills (similar to Office)


    We will provide training to our new users and reponse to training request of existing users.


    We will try to ensure all of our users can have good practice on our solution.

  • Is the calculation speed really so fast?

    After multi-user, multiple production line products (double silver, single silver), multi-computing platform (from XP to Win10) test, users feel the calculation time is only 1% or less of other similar products.


    Of course, the thin film stack adjustment speed and performance of quality control are constrained by too many factors. We will try our best to help users to improve that.

  • Do you offer a free trial?

    Because most of our solution need configure based on the actual situation of the user's line and develop their own material parameters. It need a period of time to get familiar with our products and achieve the best results. We do not provide an online trial in order to avoid wasting time.


    However, we provide presentations, demo show and instructions that familiarize users with our products and provide technical specifications to ensure that users buy the products and services they want.


    Please contact us for further information.