Windows Future of DOEs R

1
WindowsFuture of DOEs RD

• P. Marc LaFrance, CEM
• December 10 -12, 2002
• Chicago

2
1
Introduction
2
DOE Windows Program
3
Historical Link to Roadmaps
4
Next Steps and Implementation
3
United States Energy Use, Buildings Sector
Total Building Envelope Energy Impact 13.4 quads
(Windows Impact 3.8 quads, additional 1 quad
for lighting savings) 13.9 of Energy in US
Economy and about 3.5 of the world.
4
U.S. Energy Use - Windows

• US Annual Energy Use 96.2 Quads
• Residential Buildings 19.2 Quads
• Commercial Buildings 15.4 Quads
• Windows 4.8 Quads or 5 of US Energy
• Direct consumption
• Residential Heating 2 Quads
• Residential Cooling 0.7 Quads
• Commercial Heating 0.5 Quads
• Commercial Cooling 0.6 Quads
• Additional 1 Quad Potential for Daylighting
  Savings (of 3.8 Quads Lighting in Commercial
  Buildings)

5
Super Insulating and Dynamic Windows Needed to
Achieve Zero Energy Buildings
Increasing levels of performance
Bars above black line represent window energy load
6
Windows Vision Energy Losers --gt Neutral --gt
Net Energy Suppliers

• Heating 2.5Q use -gt 0 -gt 1Q Net Gain
• Reduce heat losses so that ambient solar energy
  balances and exceeds loss
• Need lower heat loss technologies but control of
  solar gain
• Cooling 1.3Q use -gt .3Q
• Reduce cooling loads
• Static control -gt dynamic control
• Lighting 4Q use -gt 3Q
• Replace electric lighting with daylight
  (commercial buildings)

7
Total Building Envelope and Window RD Budget
8
Research Institutions

• LBNL Lawrence Berkeley National Laboratory
• NREL National Renewable Energy Laboratory
• UMinn University of Minnesota
• ORNL Oak Ridge National Laboratory
• UMass - University of Massachusetts
• FSEC - Florida Solar Energy Center
• LANL - Los Alamos National Laboratory
• NETL - National Energy Technology Laboratory
• Industry Subcontractors

9
1
Introduction
2
DOE Windows Program
3
Historical Link to Roadmaps
4
Next Steps and Implementation
10
1
Introduction
2
DOE Windows Program
Technology Development

• Dynamic Solar Control Glazings
• Highly Insulated Products
• Daylight Control and Redirection Technologies
• Advanced Coating Systems
• Advanced Façade Systems

Design Tools and Technology Support
3
Historical Link to Roadmaps
4
Next Steps and Implementation
11
Technology Development -Dynamic Solar Control

• Electrochromics, Shading Systems

OFF
ON
12
U.S. Smart Window InitiativeIndustry-Governmen
t Cost-shared Partnership

• Field test and demonstration program
• Develop and demonstrate systems solutions
• Reduce installed costs
• Demonstrate acceptable durability

Field Test
Coated Glazings
Window systems
Building Demonstration
13
New Electrochromic Field Tests

• Develop and evaluate EC window-lighting systems
• Quantify energy and demand savings in a realistic
  building
• Evaluate user interface and EC acceptance
• Color
• Glare
• Switching speed

14
NETL AWARD - Electrochromic Window Manufacturing
Technology, SAGE Electrochromics, Inc.

• Project Period Apr 99 Sep 03 (Now in Budget
  Period II)
• Scope/Objective Develop and Implement Pilot
  Line-Scale Real-Time Process Monitoring to
  Improve the Manufacturability of High-Performance
  Static and Electrochromic Glazings
• Budget Period I Significant Improvement to
  Substrate Cleanliness, Inspection and Optical
  Monitoring/Control of Deposition Processes.
• Budget Period II Integrate/Demonstrate Real-Time
  Manufacturing Process Monitoring and Control
  System.
• Deliverables
• Budget Period I Report (Jul 02)
• Final Report

15
NETL AWARD - Focused RD for Electrochromic Smart
Windows, SAGE Electrochromics, Inc.

• Project Period Sep 01 Jan 04
• Scope/Objective Accelerate the widespread
  acceptance of energy saving electrochromic
  windows in buildings.
• Phase 1 - Improve window performance regarding
  neutral color, uniform coating, durability
• Phase 2 - Reduce manufacturing costs through
  process developments that increase yield and
  throughput.
• Deliverables
• Budget Period 1 Report (Dec 02)
• Final Report
• 12 x 12 Demonstration EC device

16
NREL Electrochromic Durability

• Use state-of-the-art durability testing
  facilities to perform accelerated testing on
  chromogenic windows.
• Test prototype windows for industrial partners,
  report results, and engaged in technical
  discussions with them.
• Improve understanding of several critical
  mechanisms controlling ECW performance and
  durability
• Participate in key NFRC, ASTM, IGMA, and IEA
  (sub)committee work. Assist in writing ASTM
  procedures and NFRC ratings
• Established a methodology for service lifetime
  prediction
• Patent novel devices and materials for ECW
  applications.

17
New Concepts for Electrochromic Windows

• Goals Novel approaches that
• Increase performance range, e.g. wider dynamic
  range, faster switching time
• Reduce manufacturing cost
• Reflective Hydride Films
• Electrotint Technology
• Gasochromic Windows

18
Reflective Hydride Films - LBNL

• New approach to EC coatings
• Achieved ltlt 1 Transmittance
• Initial European results used rare earth
  hydrides, expensive
• New coatings using transition metal hydrides

• Patents filed
• Industry collaborations in progress

19
Electrotint Technology - LANL

• Electrochromic windows utilizing rugged green
  technology
• Technology
• Liquid-filled window
• Low UV/thermal susceptibility, low thermal
  expansion, and high conductivity of fill
  components avoids historical durability issues
  for liquid-fill windows
• Liquid-filled windows allow inexpensive
  manufacturing
• Progress
• Produced 1 square foot prototype
• Produced durable prototypes (5 x 4 inch)
• Demonstrated rugged sealing technology
• Licenses under negotiation
• Cost of 6 per sq ft
• Switching rates and shading levels comparable to
  more expensive windows
• Current RD
• Polymer swelling of liquid to reduce hydraulic
  pressure
• Durability testing underway
• Multifunctional windows (shading, insulating,
  security, lighting)

20
Gasochromic Windows

• IG system provides H2 for switch
• Switching below H2 combustion limit
• Simplified device design
• No ion conductor
• No counterelectrode
• No transparent conductors
• Working prototypes in Europe
• Exploring operation with reflective devices

21
1
Introduction
2
DOE Windows Program
Technology Development

• Dynamic Solar Control Glazings
• Highly Insulated Products
• Daylight Control and Redirection Technologies
• Advanced Coating Systems
• Advanced Façade Systems

Design Tools and Technology Support
3
Historical Link to Roadmaps
4
Next Steps and Implementation
22
Technologies to Reduce Heat Loss
Technology Development - Highly Insulating Windows

• Five Proven, Cost-Effective Approaches
• Multiple glazings
• Low-Emissivity Coatings
• Low Conductance Gas Fills
• Warm edge low conductance spacers
• Insulated Frame Systems

23
Thermal Example of Higher Performing Windows
Dual, Clear, Alum. spacer
Dual, Clear, Foam spacer
Dual, Low-e, Foam spacer
Superwindow,4-lites, low-e, Kr
-6.0C
20C
24
NETL AWARD - Affordable Window Insulation with
R-10/inch RatingAspen Aerogels, Inc.

• Project Period 09/29/00 09/29/03
• The objective of the project is to develop the
  chemistry, process, and equipment to produce
  continuous sheets (nominally 16"x8'x0.25) of
  transparent, resilient, hydrophobic aerogel
  suitable for use in affordable insulated glass
  windows that would have an R-6 rating.
• In Phase 1, Aspen developed an aerogel
  formulation that will give high transparency,
  hydrophobicity, and resiliency.
• In Phase 2, Aspen is developing the manufacturing
  process and designing and fabricating a bench
  scale device to make sheets of aerogels.
• In Phase 3 (continuation decision in December
  2002), Aspen will design, fabricate, assemble,
  test, and operate a near production scale
  prototype aerogel sheet manufacturing system.
• Deliverables Topical Reports for Budget Periods
  1 (completed) and 2 (expected December 2002), and
  Final Report

25
1
Introduction
2
DOE Windows Program
Technology Development

• Dynamic Solar Control Glazings
• Highly Insulated Products
• Daylight Control and Redirection Technologies
• Advanced Coating Systems
• Advanced Façade Systems

Design Tools and Technology Support
3
Historical Link to Roadmaps
4
Next Steps and Implementation
26
Light Control

• Conventional control of direction of light
• glass block
• fritted glass
• diffusers
• shading systems
• New Options
• Special blinds
• Prismatic glazings
• Holographic materials
• Laser cut panels
• Light pipes
• Fiber optics

27
Emerging Daylighting Technology
28
Modeling visual performance and comfort
RADIANCE simulation of conventional and
electrochromic windows for different day types
and seasons in Phoenix, Arizona.
29
1
Introduction
2
DOE Windows Program
Technology Development

• Dynamic Solar Control Glazings
• Highly Insulated Products
• Daylight Control and Redirection Technologies
• Advanced Coating Systems
• Advanced Façade Systems

Design Tools and Technology Support
3
Historical Link to Roadmaps
4
Next Steps and Implementation
30
Improved Solar Control Coatings

• Sunbelt, new residential construction served by
  spectrally selective low-E in IG
• Interest in new, more durable options
• Improved handling for small manufacturers
• Retrofit market
• Commercial markets
• Non- sealed IGs and single glazed applications

31
Options for Improved Coatings

• Alter materials or deposition process
• pyrolytic solar control
• dielectric multilayers, holograms, liquid crystal
• selective oxides and nitrides
• plasma-assisted sputtering and evaporation

Plasma Source IR 100 Winner, 1999
Linear source for sputtering systems
32
1
Introduction
2
DOE Windows Program
Technology Development

• Dynamic Solar Control Glazings
• Highly Insulated Products
• Daylight Control and Redirection Technologies
• Advanced Coating Systems
• Advanced Façade Systems

Design Tools and Technology Support
3
Historical Link to Roadmaps
4
Next Steps and Implementation
33
Complex Fins and Overhangs

• Complex overhangs and/or fins provide solar
  control yet admit daylight and allow for views.
• Dynamic solutions improve energy efficiency,
  demand responsiveness, and occupant comfort.

34
Highly Glazed Double Facades

• Glass Double Facades have significant potential
  for solar gain reductions, natural ventilation,
  and reduced thermal conductance
• BUT performance of current systems is not well
  known
• Other benefits
• Connection with outdoors
• Reduce chiller system
• Improve air quality
• Noise mitigation

35
1
Introduction
2
DOE Windows Program
Technology Development
Design Tools and Technology Support

• Tools for Product Design and Performance Ratings
• Commercial Building Fenestration Systems
• Durability and Product Life Cycle
• Retrofit Products and Applications
• Other activities

3
Historical Link to Roadmaps
4
Next Steps and Implementation
36
Performance Metrics require Accurate Assessment
Tools

• Software for Rating and Design
• Built on
• Algorithm Development
• Which is supported by
• Algorithm Validation

37
DOE Software Tools LBNL team

• Predict performance of new product concepts and
  existing product lines
• Thermal, Optical, Energy Performance Analysis
• Simulation (compared to Testing) is
• Cheaper
• Faster
• More consistent
• More accurate

38
WINDOW/THERM/Optics Software Best Known to
Support NFRC Ratings

• Calculate properties on NFRC labels (100,000
  products rated)
• ---- but also used to
• Integrate energy efficiency into new product
  development
• Meet performance specs from architects
  consulting engineers

39
Software Use

• Available at no cost off the web
• Equal resource for all of industry
• 3000 users in US more internationally
• Major User Groups
• Glass Industry
• Window Industry
• Industry Consultants/NFRC Simulators
• Architects and Engineers
• Educators and students
• Maintenance required for existing residential
  products to update algorithms for harmonization,
  maintain data bases, bug fixes, NFRC user support.

40
Understanding Skylights

• Measured skylight performance does not agree well
  with predictions that do not account for the
  effect of the skylight well

(CFD Test Problem Vertical Slot)
41
Algorithm Validation
IR Thermography Lab
Window Field Test Facility
42
1
Introduction
2
DOE Windows Program
Technology Development
Design Tools and Technology Support

• Tools for Product Design and Performance Ratings
• Commercial Building Fenestration Systems
• Durability and Product Life Cycle
• Retrofit Products and Applications
• Other activities

3
Historical Link to Roadmaps
4
Next Steps and Implementation
43
Windows Systems for High Performance Commercial
Buildings
Goal of Tools and Information To assist
designers in making more energy efficient choices
regarding windows and glazing in commercial
buildings (this includes manufactured units and
site-built systems). Meeting this goal requires
a whole systems approach involving the many
functions and energy-related impacts of windows
and glazing.
44
Ceramic Frit and Etched Glass

• Conventional glass with opacifier or frit
  patterns (e.g. Chicago OHare Airport) can reduce
  solar heat gain yet maintain views and access to
  daylight. Tools must be able to accurately model
  impacts of such designs.

45
Developing Enhanced Modeling Techniques for new
Technologies

• Understand physics
• Develop physical models
• Develop software models
• Validate models and software

46
Modeling Curtainwalls
With Bolt
No Bolt
Uframe 2.43 Btu/h-ft2-F Uedge 0.42 Btu
/h-ft2-F
Uframe 1.54 Btu/h-ft2-F Uedge 0.39 Btu
/h-ft2-F
47
Commercial Windows Book

• Annual Energy Use Comparison of Windows

48
1
Introduction
2
DOE Windows Program
Technology Development
Design Tools and Technology Support

• Tools for Product Design and Performance Ratings
• Commercial Building Fenestration Systems
• Durability and Product Life Cycle
• Retrofit Products and Applications
• Other activities

3
Historical Link to Roadmaps
4
Next Steps and Implementation
49
IG DurabilityExpert Panel Priority
Recommendations

• Support new accelerated testing
• Consolidate test protocols into new ASTM standard
• Assess durability of existing IGs
• Develop and implement plan for predicting service
  life
• Educate industry and improve QA
• Improve knowledge base on moisture transmission

50
NETL AWARD - Non-Intrusive Sensor for
IGUsAerodyne Research, Inc.

• Project Period Sep 00 Jun 03
• Scope/Objective Develop a sensor to verify
  proper gas filling (lt 2 oxygen) of Insulated
  Glass Units (IGU) in a non-destructive manner.
  Sensor will provide capability to determine
  window seal failures during both the
  manufacturing process and post-installation.
• Phase 1 Design, construct, and test a lab
  prototype (complete)
• Phase 2 Design, construct, and test a field
  ready prototype (complete)
• Phase 2 modification Construct 3 additional
  field ready sensors and perform 3rd party
  independent verification
• Deliverables
• Budget Period 1 Report (complete)
• Final Report

51
NETL AWARD - Insulated Glass (IG) Knowledge Base,
Aspen Research Corporation

• Project Period Sep 01 Dec 03 (End of Budget
  Period I)
• Scope/Objective Support Window Industry
  Technology Roadmap by Quantifying Durability,
  Understanding Mechanisms of Failure, Developing a
  Predictive Tool to Assist Designers and
  Accelerated Test Protocols which Correlate to
  Field Service Life
• Budget Period I Develop Failure Modes and
  Effects Analysis with Industry Input
• Budget Period II Develop Predictive Design Tool
  and Accelerated Test Protocols
• Deliverables
• Budget Period I Report (Dec 02) Final Report
  (Dec 03)
• Durability Information Knowledge Base

52
Long Term Energy Performance

• Process appears to be stalled
• DOE needs strong industry leadership
• Government can provide critical objective
  support role

53
1
Introduction
2
DOE Windows Program
Technology Development
Design Tools and Technology Support

• Tools for Product Design and Performance Ratings
• Commercial Building Fenestration Systems
• Durability and Product Life Cycle
• Retrofit Products and Applications
• Other activities

3
Historical Link to Roadmaps
4
Next Steps and Implementation
54
Retrofit Products

• Support of NFRC process for efficient retrofit
  products
• Analysis and support of possible ENERGY STAR
  Low-e storm windows

55
Retrofit Shading Systems

• Many retrofit products utilize shading systems
  with complex optical and thermal properties.

56
1
Introduction
2
DOE Windows Program
Technology Development
Design Tools and Technology Support

• Tools for Product Design and Performance Ratings
• Commercial Building Fenestration Systems
• Durability and Product Life Cycle
• Retrofit Products and Applications
• Other activities

3
Historical Link to Roadmaps
4
Next Steps and Implementation
57
NETL AWARD - Integrated Energy-Efficient
Window/Walls, Aspen Research Corp.

• Project Period Sep 99 Dec 02
• Scope/Objective Literature search on combined
  window/wall systems that are more energy
  efficient by integration of material and
  construction processes to include
• wall construction
• HVAC coordination
• framing configurations
• window installation
• utility coordination
• Deliverables
• Final Report (Dec 02)

58
Residential Windows Knowledge Base

• Residential Windows Book A Guide to New
  Technologies and Energy Performance
• Comprehensive set of principles, materials and
  assemblies, performance information and resources
• Efficient Windows Collaborative Web Site
• Contains all information from book plus
  performance information on 50 US cities and a
  wide range of window design options
• Soon to be expanded to 250 cities and more window
  and design options
• www.efficientwindows.org
• Fact Sheets
• Printed from the web site for 50 US cities

Efficient Windows Collaborative
59
1
Introduction
2
DOE Windows Program
3
Historical Link to Roadmaps
4
Next Steps and Implementation
60
Roadmap Priorities

• DOE will support roadmap activities that align
  with its mission Improving the energy
  efficiency, comfort and affordability of
  Buildings for the 21st century.
• DOE has begun to align many of its research
  activities with the Roadmap results.
• Manufacturers, architects, engineers, states, and
  utilities are encouraged to work with the
  Department, or individually, on the high-priority
  needs identified in the roadmap.
• The roadmap becomes a tool for communication and
  collaboration which enables industry and
  government to embark on joint projects

61
DOE Windows Roadmap Process
January 5-6, 1999 Leesburg, VA
Spring 2001
Sept. 23-24, 1998 Chicago, IL
July - October 1999
January - July 1999
1
3
2
4
5
Executive Forum
Roadmap Development Workshop
Roadmap Review Workshop
Implementation
Industry Survey

• History of the fenestration industry
• Context for the window industry vision
• Vision statement elements

• Refined vision statement
• Identified ranked barriers
• Identified possible actions to overcome barriers

• Review and modify Roadmap Document

• DOE program alignment competitive solicitation
• Will there be continued organized collaboration
  beyond this process?

• Described specific research needs
• Relative level of investment certainty of
  success
• Potential contribution to achieving the Vision

62
Major Research Areas In Roadmap
Windows Research Activities
Imaging
Solar Daylight Control
Design
Insulation

• Altitude adaptive IG
• Stronger sealant
• High security windows
• High glass-frame ratio
• Blast resistance
• Fenestration durability
• Fire rated windows
• Sunscreening
• Modular windows
• Ventilation
• Integral wind power

• Projected display
• Interior display
• Electrochromic display
• Advanced holograms
• Exterior display
• Monochromic display
• Multichromic display

• Aerogels
• Insulating components
• Monolithic IG
• Vacuum glass
• Gas retention
• Insulating coatings

• Electrochromics scale-up
• Photochromics scale-up
• Low-E coatings
• Thermochromics scale-up
• Holograms
• Smart photochromics
• Color photochromics

Photovoltaics
Analytical Tools
Manufacturing

• Larger PV panels
• PV vision glass
• PV thin film
• Environmentally benign PV
• PV coatings
• Attractive PV panels

• Billet stock from recycle
• Energy efficient extrusion
• Laser imprinting
• Low cost IG

• Thermal modeling
• Building energy software
• Solar heat gain
• EC failure modes
• Window selection software
• EC service life prediction
• Slope U-factor
• Holographic modeling

Electronics

• Power supply miniturization
• Integral wiring
• Power system balancing
• Integral smart system

63
DOE Alignment of the RD Programs Roadmap
Priorities

• DOE has refocused portions of its portfolio to
  ensure alignment with the roadmap and continues
  to explore ways for direct industry involvement
  including competitive RD solicitations.
• Key questions to address include
• What are the criteria for choosing projects (e.g.
  contribution, risk, energy savings)?
• What counts in aligning existing RD budget
  with roadmap?
• When do you collaborate on RD with logical
  champions?

64
DOE EVALUATION OF ROADMAP PRIORITIES

• Technical Merit
• Energy, Environmental and Economic Benefit
• Commercial Potential
• Contribution to BT Strategy

65
Based on this review, BT has been increasing
activities in the following areas

• Increased efforts on the improved integration of
  fenestration with other building systems, both
  strategies and hardware.
• Increased efforts on solar and daylight control
  technologies
• Increased and continued work on development of
  performance metrics
• Increased and continued work on enabling
  technologies Durable, high performance coatings
  Durable IG Smart Windows

66
1
Introduction
2
DOE Windows Program
3
Historical Link to Roadmaps
4
Next Steps and Implementation
67
Overall Strategy

• The strategy for technology roadmap
  implementation will insure progress, maintain
  consistency, and form an integrated plan for
  stakeholders, DOE program managers, and congress.
• The two major components of the strategy are
• Coordinate Continued Stakeholder Communication
• Implement Roadmap Components

68
Coordinate ContinuedStakeholder
Communication(such as this meeting)

• Continued stakeholder communication is critical
  to ensure that the roadmaps are living documents.
  The implementation phase will
• Provide feedback on implementation plan process
• Allow channel for continuous roadmap updating
• Provide information on solicitation RFP
  announcements
• Facilitate the non-DOE roadmap components

69
Implement Roadmap Components

• The components of each roadmap are being reviewed
  systematically to
• Identify what is already going on
• Prioritize the work do be done
• Decide/enlist logical champions for each effort
  (DOE, other government, Industry, or others)
• Make it happen! (funding, accountability)
• Already, this is underway and some initial
  results have been presented

70
This Meetings Outcome

• Transparency of key DOE activities
• Feedback on overall strategy and program activity
• Key stakeholder input for establishment of high
  priority areas in upcoming solicitation
• DOE to examine areas to enhance public policy