Burnable Coating Mask for Precise Substrate Segmentation
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Solution Overview
Problem
Existing methods, such as laser deletion, incompletely remove functional coatings from substrates, leading to customer rejection.
Innovation Solution
A substrate with a burnable coating mask is used, where a mask coating layer is applied to certain sections and a functional coating layer is applied over it. Upon heating, the mask coating layer and a portion of the functional coating are removed, leaving areas without the functional coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser deletion is used to remove functional coating, then coating removal is achieved, but complete removal is not guaranteed leading to customer rejection
Solution Approach 1:
A mask coating layer is introduced as an intermediary substance applied to areas where functional coating should be removed. This mask layer serves as a protective barrier during the heating process, allowing selective removal of the functional coating only in specific areas while preserving it elsewhere, thereby achieving complete and reliable coating removal where needed.
Solution Approach 2:
The patent utilizes changes in thermal parameters by heating the substrate to a specific temperature range (500-1000°C) to enable selective removal. The mask coating layer is designed to be removed at these temperatures, while the functional coating remains stable, allowing precise control over which coating is removed based on temperature parameter management.
2Quantity of substance
If functional coating is applied over entire substrate, then complete coverage is achieved, but sensor interference occurs in certain sections
Solution Approach 1:
The substrate surface is segmented into different areas: a first area where the mask coating layer is applied and a second area where it is not. The functional coating is then applied over the entire substrate, but the mask layer creates a protected region in the first area. After heating, the mask layer and overlying functional coating are removed from the first area, leaving the functional coating only in the second area, thus segmenting the functional coating coverage to prevent sensor interference.
Solution Approach 2:
The mask coating layer acts as a temporary intermediary that defines the boundary where functional coating should be removed. By applying the mask layer to specific areas before functional coating application, and then selectively removing the mask layer after heating, the functional coating is precisely positioned to avoid sensor interference areas while maintaining complete coverage where needed.
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 method effectively segments the substrate, ensuring complete removal of the functional coating without damaging the substrate, addressing customer concerns and achieving precise coating patterns.
Implementation Method 1
When the coated substrate is heated, the burnable coating mask, and a portion of the functional coating layer over the burnable coating mask is removed
Data Source
AI summary
A substrate having a burnable coating mask includes: a substrate having a first section and a second section; a mask coating layer over the first section of the substrate; and a functional coating layer over at least a portion of the mask coating layer and over the second section of the substrate. A method of segmenting a substrate having a layer thereover, a method of preparing a segmented substrate having a layer thereover, a segmented substrate, and a transparency are also disclosed.