DRAFT-CONFIDENTIAL

1. Light Regulating1Insulated GlassforImproved Work Environments and Energy Savings in Buildings DRAFT-CONFIDENTIAL 1Refers to Regulation of Natural Light by an Electrical Device - from a 2-Way Switch to Full-Automation.

2. 1. OVERVIEW 2. PROBLEM & SOLUTION 3. MANAGEMENT Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

3. Glass Industry in NC • There are 5 major producers of insulated glass (IG) in the state. • The IG producers are located in rural counties. Many are tobacco-depressed counties. • Glass production in the state is depressed, too. • Annual gross sales of IG in the state are 200M$/yr • Light regulating IG can double IG production in the state; 5% to 10% nationally, gross profits by 20% to 40%. • The growth of insulated glass production in the state brings good economic development to tobacco-depressed counties. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

4. Goal & Obstacles • Goal: The increased use of natural light in interior spaces, because of its important benefits to worker health, worker satisfaction, worker productivity, and energy efficiency of buildings, is an important nationally-recognized goal. • Past and Current Obstacles: Architectural design for a wide range of lighting conditions and human needs is complicated. Design costs on a one-off basis are usually prohibitive. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

5. Solution & Strategy • Problem Solution: Make light regulating insulated glass available to architects and designers. • Strategy: Bring together experience and expertise in glass production in the state, architectural lighting, design, and business. Draw on the success of a new technology for light regulating insulated glass. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

6. Background & Status • Background: The proposal draws on a new integrated method for producing electrically-operated slats in a standard insulated glass system. • Current status: The light regulating insulated glass and the production line for it have been prototyped and units have been field tested. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

7. 1. OVERVIEW 2. PROBLEM & SOLUTION 3. MANAGEMENT Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

8. Current Implementation Problems withDay Lighting • Little in-house experience with natural day lighting at architectural offices • The lack of architectural guidelines in absence of accepted practices in day lighting • Without multi-purpose building products for day lighting, design is performed on a one-off basis. • Today’s cost to design a natural day lit space is high. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

9. Light Regulating Insulated Glass • Light regulating apertures solve the current implementation problems. • A light regulating aperture is an aperture in which the light passing through is regulated by an electrical device. • from a 2-way switch… • to a fully-automated system with light sensors • Disregarding the complications of the device, the ability to regulate light provides the architect with a means to perform day lighting design more efficiently. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

10. Comparison Between Light Regulation Technologies (1-4) • Light Regulating Insulated Glass (LR-IG) • Switch-operated blinds sealed in insulated glass • Developed at North Carolina State University • Electro-Chromatic Glass • Looses or gains transparency through an applied voltage • Under development at the Department of Energy’s Lawrence Berkeley Laboratory • Conventional Motorized Shading • Conventional blinds that are motorized • Currently available Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

11. Comparison Between Light Regulation Technologies (2-4) • Light Regulating Insulated Glass • Integrated system of electrically controlled blinds and insulated glass. • 3 years from market availability • Electro-Chromatic Glass • Glass matrix that changes illuminence from clear to opaque. • 25 years from market availability • Conventional Motorized Shading • Motorized systems in windows and doors. • Currently available Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

12. Comparison Between Light Regulation Technologies (3-4) High-Level Comparison Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

13. Comparison Between Light Regulation Technologies (4-4) • The parameters in the table measure likely impact of the 3 major light regulating technologies. • Drawbacks of each • Light Regulating Insulated Glass is not far from market readiness if a reliable and cost effective production process can be developed. But the blinds can’t be drawn out of view – excluding the technology from many residential markets. • Electro-chromatic Glass, while the “holy grail” of solutions, has not been able to overcome product life problems and power consumption is too high. • Conventional motorized systems are already available but their high cost and low reliability prevent wide acceptance. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

14. Architectural Opportunities • Accessibility Lobbies, Cathedral/Vaulted Rooms • High Humidity Health Spas, Indoor Pools, Bathrooms • Low Maintenance Hotels, Office Buildings, Hospitals, Nursing Homes, Schools • Controlling Light Stadiums, Theatres, Auditoriums, School Day-Lighting, Entertainment Rooms • Partitioning Space Office Clusters • Safety/Security Hospitals, Mental Institutions, Nursing Homes, Day Care Centers, Young Children’s Rooms • Hygiene and Allergies Food Preparation Areas, Clean Rooms, Hospitals, Schools, Bedrooms • Energy Efficiency (HVAC/ Day-Lighting), Office Buildings, Schools, Public Buildings • Disabilities All Applications Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

15. 1. OVERVIEW 2. PROBLEM & SOLUTION 3. MANAGEMENT (a) Open LR-IG window-wall in a board room (b) Closed LR-IG window-wall Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

16. Organizational Chart Luis Martin-Vega Dean, College of Engineering, NCSU Marvin Malecha Dean, College of Design, NCSU Leon Silverstein CEO, Arch Aluminum & Glass Larry Silverberg Prof of MAE NCSU Wayne Place Prof of Architecture NCSU Board of Directors Assistant Engineer Assistant Designer Engineering Graduate Students (7) Design Graduate Students (4) Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

17. Grant Outcomes (Years 1 to 3) • Redesign • Production Line • Consortium (Sustainability) Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

18. Consortium • Business Investment • Low capital investment: 50K per production line • High/quick return on investment: 970K$ gross per year per production line • 100 ft2/hr x 8hrs/shift x 250 shifts/yr x hrs x 5$/ft2 – 30K$ space/yr • assumes fully occupied 8-hr shifts • neglects wastage • Profitable business model • Mission – To oversee LR-IG technology • Set up lines & supply parts & equipment • Provide customer support (to glass producers) Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

19. Grant Impact (After Year 3) • Boost to the Glass Industry in the State • Boost to Tobacco-Depressed Counties • Jobs at Glass Companies • Business Owners • Architectural Opportunities • Citizens of NC who Enjoy Improved Work Environments and Lower Energy Costs Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

20. Responsibilities of the Assistant Designerand the Assistant Engineer • General Responsibilities • Works to achieve project goals • Works with students in support of project goals • Is responsible for overall cleanliness and safety of lab space • Provides supplies needed for development • Additional Responsibilities of the Assistant Engineer • Oversees improvements to production line • Is responsible for maintaining fully-functioning engineering lab • Low-volume capability to produce insulated glass • Houses production line • Additional Responsibilities of the Assistant Designer • Is responsible for maintaining fully-functioning design lab • Capability to simulate & test day lighting properties Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

21. Milestones Yr 1 2 3 • Day Lighting • Redesign • Production Line • Quality Assurance • Consortium Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

22. Graduate Student Thesis and Dissertation Topics Production Line & Quality Assurance MS Eng (2-3) Ladder & Tab PhD Eng ( 1-3) Automated Assembly MS Eng (2-3) Quality Assurance Criteria & Testing MS Eng (2-3) Installation & Training Consortium PhD Design (2-4) Architectural Spaces PhD Design (2-4) Day Lighting Guidelines Day Lighting PhD Design (1-3) Slat Geometry Optimization MS Design (1-2) Lighting Criteria & Testing Redesign MS Eng (1-2) Roll-Forming of Slats MS Eng (2-3) Laminated Wire Grid Design Engineering PhD 3 1 MS 1 6 Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

23. Number of Graduate Students by Year (PhD-MS) Year 1 2 3 4*_ Design 1-1 3-1 3-0 2-0 Engineering 1-2 1-5 1-3 0-0 Totals 4-3 4-6 4-3 2-0 *Year after funding ceases Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

24. Tasks* • Production • Wire Grid Lamination • Automated Tab Insertion • Quality Assurance Testing • Identify & Measure Failure Modes • Installation at a Demonstration Site • Training & Procedures • Day Lighting Guidelines • Architectural Spaces • Guidelines Planning • Documentation • Consortium • Day Lighting • Set up Day Lighting Lab • Lighting Criteria • Measurement System • Simulation • Geometry Optimization • Redesign • Set up Production Line • Roll Forming • Ladder & Tab Redesign • Transformer *Tasks go through preliminary & final design reviews with external reviewers, & certain documentation procedures. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

25. End of Slide Presentation Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

26. Light Regulation by Electrostatic Means (1-2) Method Venetian blind hangs in insulated glass. An electrostatic switch, when turned on, places static electricity on aluminum slats inside the air space. This induces an opposite charge on the glass creating an attraction force between the slats and the glass that causes the slats to rotate toward the glass (open). The electrostatic switch, when turned off, removes the static electricity from the slats, which allows the slats to naturally fall (close) by gravity. Electric operation ranges from a simple on-off switch to full automation. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

27. Light Regulation by Electrostatic Means (2-2) PROPERTIES • One electrostatic transformer operates a unit of any size. • The number of part types in the air space is 4: slats, ladders, tabs, and hooks. The slats are the only moving parts. • Electrostatic actuation is electrically capacitive so power 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 of operation – comparable to fire detectors & garage door openers. • The system is standardized for insulated glass. • Other methods are confined to small-scale use because of user costs. Light Regulating Insulated Glass for Improved Work Environments and Energy Savings in Buildings

28. Production and Field Testing of a New Technology for Light Regulation Production Procedure 1. Set up rotating table. Introduction The 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. Electrostatic Induction Figures below show side view of slats and glass in open & closed positions. Slats open by electrostatic Induction. Objective The main objective was to evaluate every aspect of the design through manufacture and field testing. 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 Method Field 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. Slats close By gravity. Results Demonstrated the feasibility of light regulating technology in field tests. Verified affordability and quality production. 2005