Annular Laser Defect Isolation in Conductive Glazing
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Solution Overview
Problem
Existing methods for producing electrically conductive coatings in switchable glazings often result in defects such as short-circuits due to metallic particles, which are difficult to isolate without causing aesthetic issues or requiring complex and time-consuming laser scanning mechanisms.
Innovation Solution
A method using a laser with an annular beam profile to focus radiation around defects, creating a de-coated region that isolates the defect from the surrounding coating, preventing current flow without the need for complex scanning mechanisms and minimizing visible damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam with conventional Gaussian profile is moved around the defect to generate a de-coated region, then defects can be effectively isolated, but the de-coated regions become extensive and perceptible with the naked eye, adversely affecting aesthetics
Solution Approach 1:
The patent applies a doughnut-shaped laser beam profile that concentrates radiation in a ring pattern around the defect rather than uniformly across a large area. This localized energy distribution creates a de-coated region that is precisely confined to where needed, minimizing the overall de-coated area while maintaining effective defect isolation. The ring-shaped intensity distribution ensures that only the immediate surrounding of the defect is affected, preserving aesthetic quality.
2Reliability
If a laser beam is moved around the defect using a laser scanning mechanism, then defects can be isolated, but the mechanism requires numerous moving parts which renders the method time-consuming and failure prone
Solution Approach 1:
The patent replaces the mechanical laser scanning system with a stationary laser source that emits a doughnut-shaped beam profile. Instead of moving the laser beam physically around the defect using mirrors and scanning mechanisms, the invention uses the inherent ring-shaped intensity distribution of the laser beam to naturally surround the defect. This eliminates numerous moving parts, reduces mechanical complexity, and decreases the time required for defect isolation while maintaining effective isolation.
3Reliability
If direct laser radiation is used to remove deposited metal particles, then particles can be removed, but fragments of the particle can redeposit on the coating such that new defects occur
Solution Approach 1:
The patent extracts or removes the problematic metal particles from the coating using the concentrated laser radiation in the doughnut-shaped beam. The ring pattern of the laser beam efficiently targets and vaporizes the particles surrounding the defect area. By using this focused energy distribution, particles are completely vaporized rather than merely displaced, preventing fragment redeposition and the formation of new defects.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively isolates defects, reducing the likelihood of short-circuits and hotspots while maintaining the aesthetic quality of the glazing by creating a smaller, less conspicuous de-coated region, and significantly reducing processing time and equipment complexity.
Implementation Method 1
focusing the radiation of a laser with an annular beam profile on the coating, wherein the annular beam profile surrounds the defect, and producing an annular de-coated region, by simultaneously removing the coating in the region of the beam profile
Data Source
AI summary
A method for producing a pane having an electrically conductive coating is described. The method includes applying an electrically conductive coating onto a substrate, identifying defects of the coating, focusing the radiation of a laser having an annular beam profile on the coating, wherein the annular beam profile surrounds the defect, and producing an annular de-coated region by simultaneously removing the coating in the region of the beam profile.