High Performance Organic, Inorganic Or Hybrid Seals

Abstract

The present invention describes a new method for creating hybrid edge seals using metal, alloy, powder coated metal and other conductive surfaces in between two substrates. The methods utilize various materials, seal designs, and geometries of hybrid seals based on polymeric powder coatings and glass powder coatings.

Description

BACKGROUND OF THE INVENTION[0001]1. Field of Invention[0002]The invention describes a new method for creating hybrid edge seals using metal, alloy, powder coated metal and other conductive surfaces in between two substrates. These inventions describe different materials, seal designs, and geometries of hybrid seals based on polymeric powder coatings and glass powder coatings on conductive surfaces.[0003]2. Description of Related Art[0004]Many conventional heating methods suffer the problem of overheating substrates in the effort to heat and flow a seal material. Further much energy is wasted due to unwanted heating of the entire mass of substrates. Therefore, selective sealing methods wherein the seal material alone is heated are attractive from energy saving point of view.[0005]Laser sealing is a widely investigated selective sealing process, among various selective heating processes such as laser sealing, induction heating, microwave heating, broadband IR (Infrared) lamp heating, ...

AI Technical Summary

Benefits of technology

This patent is about the need for moisture barrier films and edge seals for various electronic devices and windows. The technical effects of this patent include the use of a hybrid edge seal with powder coatings and metal / alloy spacers to protect against moisture and oxygen ingress, which can damage silicon solar cells and shorten the lifespan of electronic devices and windows. This will reduce the cost of energy and improve the reliability of these devices.

Problems solved by technology

Many conventional heating methods suffer the problem of overheating substrates in the effort to heat and flow a seal material.

Further much energy is wasted due to unwanted heating of the entire mass of substrates.

Even in all these selective heating methods unwanted heating of substrates does occur.

The process can be time consuming because such a large mass of material must be heated, which can be problematic.

The resulting seal may also have large voids and bubbles that could reduce the strength of the seal.

Since most of the heat is generated at the substrate / seal material interface, it is more likely that the seal material and the substrate plate may crack.

Similar problems arise in other selective sealing processes where IR, visible or UV lights are used for sealing.

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