Laser-Scribed Low-E Coating Edges for Assembled IGU Corrosion
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Solution Overview
Problem
Laminated products with metal layer inclusive coatings face corrosion issues due to electrochemical reactions, particularly at the edges, which existing edge deletion techniques fail to effectively prevent or slow down, especially in assembled products and when dealing with small areas, as they require additional machinery, increase processing time, and create debris.
Innovation Solution
Laser-scribing the edges of metal layer inclusive coatings using a diode fiber laser at 1064 nm to create a barrier that electrically isolates the coating, preventing electron transport and thereby retarding electrochemical corrosion, with the scribed material either being incorporated into the substrate or laminating material or vaporized to reform in a non-conductive manner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If edge deletion tables with grinding wheels are used to remove coating from glass edges, then corrosion is prevented by removing metal layers, but device complexity increases and processing time is extended
Solution Approach 1:
The patent replaces the mechanical grinding wheel system with a laser-based system. The laser beam delivers energy to the coating material, causing ablation and removal of metal layers through thermal vaporization rather than mechanical grinding. This substitution eliminates the need for complex mechanical edge deletion tables while achieving the same corrosion prevention effect by creating non-conductive zones at the glass edges.
Solution Approach 2:
The patent changes the operating parameters by using laser energy delivery instead of mechanical contact. By controlling laser power, pulse duration, and scanning speed, the system achieves precise removal of metal-containing coatings without the mechanical complexity of grinding wheels. The laser parameters can be adjusted to control the depth and width of the non-conductive zone created at the edges.
2Reliability
If traditional edge deletion methods are used, then coating corrosion is addressed, but processing time increases due to additional process steps
Solution Approach 1:
The patent combines the edge deletion function with existing glass processing lines by integrating a laser system that can operate in-line with other manufacturing processes. The laser can be positioned to treat edges as the glass passes through, eliminating the need for separate edge deletion stations and reducing overall processing time while maintaining corrosion resistance.
3Reliability
If mechanical grinding wheels are used for edge deletion, then coating is removed to prevent corrosion, but debris is created requiring additional handling
Solution Approach 1:
The patent replaces mechanical grinding with laser ablation, which vaporizes the coating material directly into the gas phase rather than producing solid debris particles. The laser energy converts the metal-containing coating material into vapor that can be removed by conventional exhaust systems, eliminating the debris handling requirements associated with mechanical grinding operations.
4Object-affected harmful factors
If edge sealants are used to protect against corrosion, then corrosion advance is reduced, but reliability decreases as sealants develop cracks over time
Solution Approach 1:
The patent applies preliminary action by creating non-conductive zones at the glass edges through laser treatment before the glass is installed or sealed. This pre-treatment eliminates the electrochemical corrosion pathway at the edges, removing the need for edge sealants and their associated long-term reliability issues with cracking and degradation.
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
The laser-scribing technique effectively slows or stops electrochemical corrosion by increasing the polarization resistance, reducing leakage currents, and eliminating interface current carrying elements, thereby extending the lifespan of laminated products and insulated glass units by several orders of magnitude.
Implementation Method 1
Laser-scribing the edges of metal layer inclusive coatings using a diode fiber laser at 1064 nm to create a barrier that electrically isolates the coating
Implementation Method 2
the scribed material either being incorporated into the substrate or laminating material or vaporized to reform in a non-conductive manner
Implementation Method 3
create a barrier that electrically isolates the coating, preventing electron transport and thereby retarding electrochemical corrosion
Implementation Method 4
coupling energy into the coating and controlling the laser source so as to selectively cause at least a part of the coating, in a desired pattern, to (a) dissolve into the first substrate, the laminating material, and/or an underlayer of the coating, and/or (b) vaporize and re-form in a manner that does not conduct
Data Source
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AI summary
Certain example embodiments of this invention relate to techniques for laser ablating/scribing peripheral edges of a coating (e.g., a low-emissivity, mirror, or other coating) on a glass or other substrate in a pre- or post- laminated assembly, pre- or post-assembled insulated glass unit, and/or other product, in order to slow or prevent corrosion of the coating. For example, a 1064 nm or other wavelength laser may be used to scribe lines into the metal and/or metallic layer(s) in a low-emissivity or other coating provided in an already-laminated or already-assembled insulated glass unit or other product, e.g., around its periphery. The scribe lines decrease electron mobility from the center of the coating to the environment and, thus, slow and sometimes even prevent the onset of electrochemical corrosion. Associated products, methods, and kits relating to same also are contemplated herein.