Aggressive Ceramic Frit for PVD Coating Dissolution on Glass
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Solution Overview
Problem
Existing methods for applying frit patterns on glass substrates with thin film coatings require mechanical edge deletion, which is inefficient and can damage the substrate, and involve complex handling and transportation processes, compromising adhesion and aesthetics.
Innovation Solution
An aggressive ceramic frit is applied directly over the thin film coating on glass substrates, which dissolves the coating upon heat treatment, fusing with the glass to form a strong bond and eliminating the need for mechanical edge deletion, while maintaining aesthetic appeal and adhering to conventional production flows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical edge deletion is used to remove thin film coating before frit application, then the coating is removed, but the substrate is damaged and adhesion is compromised
Solution Approach 1:
The patent replaces the mechanical edge deletion process with a chemical dissolution process. The frit material chemically reacts with and dissolves the thin film coating through heat treatment, eliminating the need for mechanical abrasion that damages the substrate. This chemical substitution resolves the contradiction by achieving complete coating removal without substrate damage.
Solution Approach 2:
The patent changes the physical and chemical parameters of the frit material to enable it to dissolve the thin film coating. By adjusting the composition and reactivity parameters of the frit, it becomes capable of chemically reacting with the coating at heat treatment temperatures, transforming the removal mechanism from mechanical to chemical while protecting the substrate.
2Manufacturing precision
If mechanical edge deletion is used to remove coating, then coating is removed, but handling complexity increases and aesthetics deteriorate
Solution Approach 1:
The patent merges the coating removal function with the frit application process. Instead of performing edge deletion as a separate preliminary step, the frit is applied directly over the coating and the dissolution occurs during the frit's heat treatment cycle. This consolidation eliminates additional handling steps and reduces process complexity while maintaining complete coating removal.
Solution Approach 2:
The frit material is prepared with predetermined chemical properties that enable it to dissolve the thin film coating during subsequent heat treatment. This preliminary configuration of the frit's chemical characteristics allows the coating removal to occur automatically as part of the frit curing process, eliminating the need for separate mechanical removal operations.
3Strength
If frit is applied directly over thin film coating without mechanical deletion, then adhesion improves, but coating dissolution must be achieved
Solution Approach 1:
The patent modifies the chemical composition parameters of the frit material to enhance its reactivity with the thin film coating. By adjusting parameters such as oxide content, particle size, and chemical affinity, the frit is engineered to efficiently dissolve the coating at standard heat treatment temperatures, making the dissolution process easy to achieve while maintaining strong adhesion.
Solution Approach 2:
The patent utilizes composite frit materials containing multiple components that work synergistically. The composite formulation includes substances that facilitate coating dissolution, enhance adhesion to the substrate, and provide color stability. This composite approach simultaneously achieves coating removal and strong bonding without requiring complex manufacturing processes.
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 ensures reliable adhesion and durability of the frit pattern, reduces handling complexities, and achieves complete edge deletion without surface imperfections, enhancing both functional and aesthetic outcomes in glass applications.
Implementation Method 1
the ceramic frit is aggressive in chemically removing the coating on which it is disposed, e.g., when exposed to high temperatures
Implementation Method 2
the frit advantageously fuses well with the glass
Data Source
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AI summary
Certain example embodiments relate to the use of a ceramic frit that dissolves an already-applied thin film coating (disposed via a physical vapor deposition (PVD) process such as sputtering, or other suitable process). In certain example embodiments, the ceramic frit is aggressive in chemically removing the coating on which it is disposed, e.g., when exposed to high temperatures. The frit advantageously fuses well with the glass, provides aesthetically desired colorations, and/or enables components (e.g., insulated glass (IG) unit spacers) to be reliably mounted thereon, in certain example embodiments. Associated coated articles, IG units, methods, etc., are also contemplated herein.