Electro-optic Element Laser Ablation Indicia
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Solution Overview
Problem
Current electro-optic elements and assemblies in vehicular and building applications face challenges related to high costs, aesthetics, and functionality, particularly in reducing material and processing costs while enhancing aesthetics and functionality.
Innovation Solution
The development of electro-optic elements with a conductive seal and spectral filter portions, where the spectral filter portions and indicia are fabricated using laser ablation to define isolation areas and create a visually appealing design, allowing for the use of materials that may not be compatible with the electro-optic medium, and enabling durable electrical communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing methods are used for electro-optic elements, then functional requirements are met, but manufacturing costs and processing complexity are high
Solution Approach 1:
The patent replaces traditional mechanical masking and etching processes with laser ablation to define isolation areas and indicia. The laser directly ablates the conductive layer and spectral filter material without requiring physical masks or complex alignment mechanisms, thereby reducing manufacturing cost while achieving precise isolation area definition.
Solution Approach 2:
The patent utilizes laser parameters (power, pulse duration, wavelength) to selectively ablate different materials (conductive layer, spectral filter) in a controlled manner. By adjusting laser parameters, precise isolation areas are created without affecting surrounding functional regions, achieving high manufacturing precision through parameter control rather than mechanical means.
2Illumination intensity
If all conductive materials are used for electrical functionality, then electrical performance is optimized, but aesthetic appearance deteriorates due to visible conductive material
Solution Approach 1:
The patent segments the conductive layer into distinct regions: isolated conductive portions that provide electrical functionality and isolation areas that are free of conductive material. This segmentation allows visible areas to be free of conductive material for aesthetic purposes while maintaining electrical pathways where needed, thus achieving both aesthetic appearance and electrical reliability.
Solution Approach 2:
The patent extracts conductive material from specific regions to create isolation areas and indicia. By removing conductive material from areas that would be visible, the aesthetic appearance is improved while electrical pathways are preserved in functional regions, maintaining electrical communication durability through selective extraction.
3Reliability
If spectral filter material is applied over conductive material, then electrical conductivity is maintained, but visibility of conductive material and seal remains an issue
Solution Approach 1:
The patent performs preliminary laser ablation to define isolation areas and remove conductive material before final assembly and sealing. This preliminary action ensures that when the spectral filter is applied, the conductive material is already positioned only in areas where it needs to be, preventing visibility issues while maintaining electrical conductivity where required.
Solution Approach 2:
The spectral filter acts as an intermediary layer that, when combined with the laser-defined isolation areas, masks the visibility of conductive material and seal portions. The isolation areas created by laser ablation serve as intermediaries that strategically position conductive material to maintain electrical conductivity while the spectral filter provides additional optical masking for aesthetic purposes.
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 reduces manufacturing costs and enhances the aesthetic appeal by obscuring the primary seal and conductive material from view, while ensuring durable electrical communication and compatibility with the electro-optic medium, thus addressing the limitations of existing technologies.
Implementation Method 1
ablating by a laser portions of the spectral filter to define a viewable portion of the electro-optic element and at least one indicia in the viewable portion
Implementation Method 2
ablating by a laser portions of the spectral filter and the first electrically conductive portion to form an isolation area
Data Source
Figure 1
Figure 2A~2B
AI summary
An electro-optic element is provided that includes a first substrate having a first surface, and a second surface having a first electrically conductive portion disposed thereon. The element also includes a second substrate having a third surface, a fourth surface, and a second electrically conductive portion disposed on at least the third surface. A primary seal is between the second and third surfaces, wherein the seal and the second and third surfaces define a cavity. An electro-optic medium disposed in the cavity. In addition, the second surface further includes at least one indicia disposed thereon between the electro-optic medium and the second surface.