DRAFT-CONFIDENTIAL

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11Refers to Regulation of Natural Light by an Electrical Device - from a Refers to Regulation of Natural Light by an Electrical Device - from a 2-Way Switch to Full-Automation.2-Way Switch to Full-Automation.

Light RegulatingLight Regulating11

Insulated GlassInsulated Glass

forfor

Improved Work Environments Improved Work Environments and Energy Savings in and Energy Savings in BuildingsBuildings

1. OVERVIEW1. OVERVIEW2. PROBLEM & SOLUTION2. PROBLEM & SOLUTION3. MANAGEMENT3. MANAGEMENT

Light Regulating Insulated Glass for Improved Work Environments and Energy Savings Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildingsin Buildings

Glass Industry in NCGlass Industry in NC There are 5 major producers of insulated glass (IG) in the There are 5 major producers of insulated glass (IG) in the

state.state. The IG producers are located in rural counties. Many are The IG producers are located in rural counties. Many are

tobacco-depressed counties. tobacco-depressed counties. Glass production in the state is depressed, too.Glass production in the state is depressed, too. Annual gross sales of IG in the state are 200M$/yrAnnual gross sales of IG in the state are 200M$/yr Light regulating IG can double IG production in the state; Light regulating IG can double IG production in the state;

5% to 10% nationally, gross profits by 20% to 40%.5% to 10% nationally, gross profits by 20% to 40%. The growth of insulated glass production in the state brings The growth of insulated glass production in the state brings

good economic development to tobacco-depressed good economic development to tobacco-depressed counties. counties.


Goal:Goal: The increased use of natural light in The increased use of natural light in interior spaces, because of its important interior spaces, because of its important benefits to worker health, worker satisfaction, benefits to worker health, worker satisfaction, worker productivity, and energy efficiency of worker productivity, and energy efficiency of buildings, is an important nationally-buildings, is an important nationally-recognized goal. recognized goal.

Past and Current Obstacles:Past and Current Obstacles: Architectural Architectural design for a wide range of lighting conditions design for a wide range of lighting conditions and human needs is complicated. Design costs and human needs is complicated. Design costs on a one-off basis are usually prohibitive.on a one-off basis are usually prohibitive.


Goal & ObstaclesGoal & Obstacles

Problem Solution:Problem Solution: Make light Make light regulating insulated glass available to regulating insulated glass available to architects and designers.architects and designers.

Strategy:Strategy: Bring together experience Bring together experience and expertise in glass production in the and expertise in glass production in the state, architectural lighting, design, and state, architectural lighting, design, and business. Draw on the success of a new business. Draw on the success of a new technology for light regulating insulated technology for light regulating insulated glass. glass.


Solution & StrategySolution & Strategy

BackgroundBackground: The proposal draws : The proposal draws on a new integrated method for on a new integrated method for producing electrically-operated slats producing electrically-operated slats in a standard insulated glass system.in a standard insulated glass system.

Current statusCurrent status: The light regulating : The light regulating insulated glass and the production insulated glass and the production line for it have been prototyped and line for it have been prototyped and units have been field tested. units have been field tested.


Background & StatusBackground & Status


1. OVERVIEW1. OVERVIEW2. PROBLEM & 2. PROBLEM & SOLUTIONSOLUTION

3. MANAGEMENT3. MANAGEMENT

Current Implementation Problems withCurrent Implementation Problems withDay LightingDay Lighting

Little in-house experience with natural day lighting Little in-house experience with natural day lighting at architectural officesat architectural offices

The lack of architectural guidelines in absence of The lack of architectural guidelines in absence of accepted practices in day lightingaccepted practices in day lighting

Without multi-purpose building products for day Without multi-purpose building products for day lighting, design is performed on a one-off basis. lighting, design is performed on a one-off basis.

Today’s cost to design a natural day lit space is Today’s cost to design a natural day lit space is high.high.


Light Regulating Insulated GlassLight Regulating Insulated Glass Light regulating apertures solve the current Light regulating apertures solve the current

implementation problems. implementation problems. A light regulating aperture is an aperture in which the A light regulating aperture is an aperture in which the

light passing through is regulated by an electrical light passing through is regulated by an electrical device.device.– from a 2-way switch…from a 2-way switch…– to a fully-automated system with light sensors to a fully-automated system with light sensors

Disregarding the complications of the device, the Disregarding the complications of the device, the ability to regulate light provides the architect with a ability to regulate light provides the architect with a means to perform day lighting design more means to perform day lighting design more efficiently. efficiently.


Comparison Between Light Regulation Comparison Between Light Regulation Technologies (1-4)Technologies (1-4)

– Light Regulating Insulated Glass (LR-IG)Light Regulating Insulated Glass (LR-IG) Switch-operated blinds sealed in insulated glassSwitch-operated blinds sealed in insulated glass Developed at North Carolina State UniversityDeveloped at North Carolina State University

– Electro-Chromatic GlassElectro-Chromatic Glass Looses or gains transparency through an applied voltageLooses or gains transparency through an applied voltage Under development at the Department of Energy’s Under development at the Department of Energy’s

Lawrence Berkeley LaboratoryLawrence Berkeley Laboratory

– Conventional Motorized ShadingConventional Motorized Shading Conventional blinds that are motorizedConventional blinds that are motorized Currently availableCurrently available


Light Regulating Insulated GlassLight Regulating Insulated Glass– Integrated system of electrically controlled blinds and Integrated system of electrically controlled blinds and

insulated glass. insulated glass. – 3 years from market availability3 years from market availability

Electro-Chromatic GlassElectro-Chromatic Glass – Glass matrix that changes illuminence from clear to Glass matrix that changes illuminence from clear to

opaque. opaque. – 25 years from market availability25 years from market availability

Conventional Motorized ShadingConventional Motorized Shading– Motorized systems in windows and doors. Motorized systems in windows and doors. – Currently availableCurrently available



High-Level ComparisonHigh-Level Comparison

Figure 1: High-level Technology Comparison

010203040506070

Market Ready Low Volume High Volume

Yrs

or

$/sq

ft

Electrostatic Electrocromatic Conventional



The parameters in the table measure likely impact of the 3 The parameters in the table measure likely impact of the 3 major light regulating technologies. major light regulating technologies.

Drawbacks of eachDrawbacks of each

– Light Regulating Insulated Glass is not far from market Light Regulating Insulated Glass is not far from market readiness if a reliable and cost effective production readiness if a reliable and cost effective production process can be developed. But the blinds can’t be drawn process can be developed. But the blinds can’t be drawn out of view – excluding the technology from many out of view – excluding the technology from many residential markets.residential markets.

– Electro-chromatic Glass, while the “holy grail” of Electro-chromatic Glass, while the “holy grail” of solutions, has not been able to overcome product life solutions, has not been able to overcome product life problems and power consumption is too high.problems and power consumption is too high.

– Conventional motorized systems are already available Conventional motorized systems are already available but their high cost and low reliability prevent wide but their high cost and low reliability prevent wide acceptance.acceptance.Light Regulating Insulated Glass for Improved Work Environments and Energy Savings Light Regulating Insulated Glass for Improved Work Environments and Energy Savings

in Buildingsin Buildings


Architectural OpportunitiesArchitectural Opportunities AccessibilityAccessibility Lobbies, Cathedral/Vaulted RoomsLobbies, Cathedral/Vaulted Rooms High HumidityHigh Humidity Health Spas, Indoor Pools, BathroomsHealth Spas, Indoor Pools, Bathrooms Low MaintenanceLow Maintenance Hotels, Office Buildings, Hospitals, Hotels, Office Buildings, Hospitals,

Nursing Homes, SchoolsNursing Homes, Schools Controlling LightControlling Light Stadiums, Theatres, Auditoriums, Stadiums, Theatres, Auditoriums,

School Day-Lighting, Entertainment School Day-Lighting, Entertainment RoomsRooms Partitioning SpacePartitioning Space Office ClustersOffice Clusters Safety/SecuritySafety/Security Hospitals, Mental Institutions, Nursing Hospitals, Mental Institutions, Nursing

Homes, Day Care Centers, Young Homes, Day Care Centers, Young Children’s RoomsChildren’s Rooms Hygiene and AllergiesHygiene and Allergies Food Preparation Areas, Clean Food Preparation Areas, Clean

Rooms, Rooms, Hospitals, Schools, BedroomsHospitals, Schools, Bedrooms Energy EfficiencyEnergy Efficiency (HVAC/ Day-Lighting), Office Buildings, (HVAC/ Day-Lighting), Office Buildings,

Schools, Public BuildingsSchools, Public Buildings DisabilitiesDisabilities All ApplicationsAll Applications



1. OVERVIEW1. OVERVIEW2. PROBLEM & 2. PROBLEM & SOLUTIONSOLUTION

3. MANAGEMENT3. MANAGEMENT

(a) Open LR-IG window-wall in a board room (b) Closed LR-IG window-wall

Organizational ChartOrganizational Chart

Board of

Directors

Luis Martin-VegaDean, College of

Engineering, NCSU

Leon SilversteinCEO, Arch

Aluminum & Glass

Marvin MalechaDean, College of

Design, NCSU

Wayne PlaceProf of

Architecture NCSU

Assistant Engineer

Engineering Graduate Students

(7)

Larry SilverbergProf of MAE

NCSU

Assistant Designer

Design Graduate Students

(4)Light Regulating Insulated Glass for Improved Work Environments and Energy Savings Light Regulating Insulated Glass for Improved Work Environments and Energy Savings

in Buildingsin Buildings

Grant Outcomes (Years 1 to 3)Grant Outcomes (Years 1 to 3)

Redesign Redesign Production LineProduction Line Consortium (Sustainability)Consortium (Sustainability)


ConsortiumConsortium Business InvestmentBusiness Investment

– Low capital investment: 50K per production lineLow capital investment: 50K per production line– High/quick return on investment: 970K$ gross High/quick return on investment: 970K$ gross

per year per production lineper year per production line

– 100 ft100 ft22/hr x 8hrs/shift x 250 shifts/yr x hrs x 5$/ft/hr x 8hrs/shift x 250 shifts/yr x hrs x 5$/ft22 – 30K$ – 30K$ space/yrspace/yr

– assumes fully occupied 8-hr shiftsassumes fully occupied 8-hr shifts– neglects wastageneglects wastage

Profitable business modelProfitable business model

Mission – To oversee LR-IG technologyMission – To oversee LR-IG technology– Set up lines & supply parts & equipmentSet up lines & supply parts & equipment– Provide customer support (to glass producers)Provide customer support (to glass producers)


Grant Impact (After Year 3) Grant Impact (After Year 3)

Boost to the Glass Industry in the StateBoost to the Glass Industry in the State Boost to Tobacco-Depressed Counties Boost to Tobacco-Depressed Counties Jobs at Glass CompaniesJobs at Glass Companies Business OwnersBusiness Owners Architectural OpportunitiesArchitectural Opportunities Citizens of NC who Enjoy Improved Work Citizens of NC who Enjoy Improved Work

Environments and Lower Energy CostsEnvironments and Lower Energy Costs


Responsibilities of the Assistant DesignerResponsibilities of the Assistant Designerand the Assistant Engineerand the Assistant Engineer

General ResponsibilitiesGeneral Responsibilities– Works to achieve project goalsWorks to achieve project goals– Works with students in support of project goals Works with students in support of project goals – Is responsible for overall cleanliness and safety of lab spaceIs responsible for overall cleanliness and safety of lab space– Provides supplies needed for developmentProvides supplies needed for development

Additional Responsibilities of the Assistant EngineerAdditional Responsibilities of the Assistant Engineer– Oversees improvements to production lineOversees improvements to production line– Is responsible for maintaining fully-functioning engineering lab Is responsible for maintaining fully-functioning engineering lab

Low-volume capability to produce insulated glassLow-volume capability to produce insulated glass Houses production lineHouses production line

Additional Responsibilities of the Assistant DesignerAdditional Responsibilities of the Assistant Designer– Is responsible for maintaining fully-functioning design lab Is responsible for maintaining fully-functioning design lab

Capability to simulate & test day lighting propertiesCapability to simulate & test day lighting properties


MilestonesMilestonesYrYr 11 22 33

Day LightingDay Lighting RedesignRedesign Production LineProduction Line Quality AssuranceQuality Assurance ConsortiumConsortium


Graduate Student Thesis and Dissertation TopicsGraduate Student Thesis and Dissertation Topics

Day LightingDay Lighting

PhD Design (1-3) Slat Geometry PhD Design (1-3) Slat Geometry Optimization Optimization

MS Design (1-2) Lighting Criteria MS Design (1-2) Lighting Criteria & Testing & Testing

RedesignRedesign

MSMS Eng (1-2) Roll-Forming of SlatsEng (1-2) Roll-Forming of SlatsMSMS Eng (2-3) Laminated Wire Grid Eng (2-3) Laminated Wire Grid

Production Line & Quality Production Line & Quality AssuranceAssurance

MS Eng (2-3) Ladder & TabPhD Eng (PhD Eng ( 1-3) Automated 1-3) Automated

AssemblyAssemblyMSMS Eng (2-3) Quality Assurance Eng (2-3) Quality Assurance

Criteria Criteria & Testing & TestingMS Eng (2-3) Installation & TrainingMS Eng (2-3) Installation & Training ConsortiumConsortium

PhD Design (2-4) Architectural SpacesPhD Design (2-4) Architectural SpacesPhD Design (2-4) Day Lighting PhD Design (2-4) Day Lighting

GuidelinesGuidelinesDesignDesign

EngineeringEngineeringPhD 3PhD 3 1 1MSMS 1 6 1 6


Number of Graduate Students by YearNumber of Graduate Students by Year(PhD-MS)(PhD-MS)

YearYear 1 1 2 2 3 3 4*_ 4*_

DesignDesign 1-11-1 3-1 3-1 3-03-0 2-02-0EngineeringEngineering 1-21-2 1-51-5 1-31-3 0-00-0

TotalsTotals 4-34-3 4-64-6 4-34-3 2-02-0

*Year after funding ceases*Year after funding ceases


TasksTasks** Day LightingDay Lighting Set up Day Lighting LabSet up Day Lighting Lab Lighting Criteria Lighting Criteria Measurement SystemMeasurement System SimulationSimulation Geometry OptimizationGeometry Optimization

RedesignRedesign Set up Production Line Set up Production Line Roll Forming Roll Forming Ladder & Tab RedesignLadder & Tab Redesign TransformerTransformer

**Tasks go through preliminary & final design reviews with external reviewers, & certain Tasks go through preliminary & final design reviews with external reviewers, & certain documentation procedures. documentation procedures.


ProductionProduction Wire Grid LaminationWire Grid Lamination Automated Tab InsertionAutomated Tab Insertion

Quality Assurance TestingQuality Assurance Testing Identify & Measure Failure ModesIdentify & Measure Failure Modes Installation at a Demonstration SiteInstallation at a Demonstration Site Training & ProceduresTraining & Procedures

Day Lighting GuidelinesDay Lighting Guidelines Architectural Spaces Architectural Spaces Guidelines Planning Guidelines Planning DocumentationDocumentation

ConsortiumConsortium

End of Slide PresentationEnd of Slide Presentation


MethodMethod1.1.Venetian blind hangs in insulated glass. Venetian blind hangs in insulated glass. 2.2.An electrostatic switch, when turned on, An electrostatic switch, when turned on, places static electricity on aluminum slats places static electricity on aluminum slats inside the air space.inside the air space.3.3.This induces an opposite charge on the glass This induces an opposite charge on the glass creating an attraction force between the slats creating an attraction force between the slats and the glass that causes the slats to rotate and the glass that causes the slats to rotate toward the glass (open).toward the glass (open).4.4.The electrostatic switch, when turned off, The electrostatic switch, when turned off, removes the static electricity from the slats, removes the static electricity from the slats, which allows the slats to naturally fall (close) which allows the slats to naturally fall (close) by gravity. Electric operation ranges from a by gravity. Electric operation ranges from a simple on-off switch to full automation.simple on-off switch to full automation.

Light Regulation by Electrostatic Means (1-Light Regulation by Electrostatic Means (1-2)2)


PROPERTIESPROPERTIES One electrostatic transformer operates a unit of any size.One electrostatic transformer operates a unit of any size. The number of part types in the air space is 4: slats, ladders, tabs, The number of part types in the air space is 4: slats, ladders, tabs,

and hooks. The slats are the only moving parts.and hooks. The slats are the only moving parts. Electrostatic actuation is electrically capacitive so power Electrostatic actuation is electrically capacitive so power

consumption is on the order of 0.0025$ per square foot per year. consumption is on the order of 0.0025$ per square foot per year. A commercial building with 10,000 square foot of LR-IG windows costs 25$ per year A commercial building with 10,000 square foot of LR-IG windows costs 25$ per year of operation – comparable to fire detectors & garage door openers. of operation – comparable to fire detectors & garage door openers.

The system is standardized for insulated glass.The system is standardized for insulated glass. Other methods are confined to small-scale use because of user Other methods are confined to small-scale use because of user

costs.costs.


Light Regulation by Electrostatic Means (2-Light Regulation by Electrostatic Means (2-2)2)

Production and Field Testing of a New Technology for Light Regulation

IntroductionThe light regulating system consists of a Venetian blind sealed between the panes of insulated glass.

The blinds open and close electro-statically. The electrostatically actuated blinds replace the manually operated system of pulleys, gears, and gear box.

ObjectiveThe main objective was to evaluate every aspect of the design through manufacture and field testing.

Production Procedure

1. Set up rotating table.

ResultsDemonstrated the feasibility of light regulating technology in field tests.

Verified affordability and quality production.

2005

Electrostatic Induction

MethodField testing was performed in the Talley Student Center of North Carolina State University. A set of eight units, each measuring about three feet by five feet, were produced and installed in the Talley Student Center Boardroom.

2. Assemble slats, ladders and tabs

3. Remove the slat racks

4. Assemble the air spacer and install

5. Install glass

6. Perform functional test

7. Seal unit

8. Store unit

Slats open by electrostatic Induction.

Slats closeBy gravity.

Figures below show side view of slats and glass in open & closed positions.

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