Biography

Jérome Müller is a physicist from Nancy, East of France. He earned his PhD in Physics from Henry Poincaré – Nancy, University in France before joining the University of Namur as a researcher focused on solar cell modelling and optimization. Later, by joining the company ICS (Innovative Coating Solutions), he expanded his expertise to thin-film deposition processes applied to optical coatings.

Presentation

Functional glass technologies play a central role in applications from photovoltaics to energy-efficient architectural glazing. Among these, low-emissivity (Low-E) glass has gained significant attention due to its ability to reduce energy consumption by reflecting infrared radiation while maintaining high visible light transmittance and neutral color. However, conventional Low-E coatings rely heavily on silver layers, a critical raw material (CRM), making the reduction of silver usage a key technological and economic challenge.
In this work, we investigate dielectric–metal multilayer thin films deposited by magnetron sputtering using physical vapor deposition (PVD). These coatings typically consist of alternating silver and oxide/nitride layers (e.g., TiO₂, ZnO, AZO). The composition, density, and thickness of each layer are strongly influenced by process parameters, which in turn affect film uniformity and optical performance.

The objective of this study is to minimize silver consumption while preserving or enhancing optical properties. To achieve this, a multi-objective genetic algorithm ConstelCoat™ is coupled with a film growth simulation software Virtual Coater™, enabling simultaneous optimization of layer architecture and deposition conditions. The modeling framework spans multiple scales, from three-dimensional industrial coater configurations down to atomic-scale film growth using a kinetic Monte Carlo approach, allowing prediction of key material properties such as composition, density, and effective refractive indices.

Particular attention is given to the impact of coater design and critical deposition parameters (e.g., power, pressure) on both silver layer efficiency and overall coating performance. This integrated approach provides a pathway to design Low-E coatings with reduced reliance on silver, contributing to more sustainable and resource-efficient glazing technologies.