Electro-Optic Window Indicia Using Laser-Ablated Dust Covers
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Solution Overview
Problem
Existing window systems lack a durable and aesthetically appealing method to incorporate indicia on polymeric dust covers that can effectively change transparency states while maintaining visibility and functionality.
Innovation Solution
A window system with an electro-optic element and a polymeric dust cover featuring laser-induced damage channels with a high aspect ratio, allowing for variable transmissivity and visible indicia, formed using a pulsed laser to create a grid pattern or other designs within the dust cover.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional printing or coating methods are used to add indicia to polymeric dust covers, then the manufacturing process is simple and cost-effective, but the indicia lack durability and aesthetic appeal
Solution Approach 1:
The patent replaces traditional mechanical printing or coating methods with laser-induced damage channel formation. The laser beam directly modifies the polymeric substrate by creating microscopic channels through ablation, eliminating the need for ink, paint, or adhesive applications. This substitution provides durable, permanent indicia that are integral to the dust cover structure while maintaining manufacturing efficiency through automated laser processing.
Solution Approach 2:
The patent utilizes controlled changes in laser parameters (energy density, pulse duration, scanning speed) to create damage channels with specific aspect ratios greater than 10:1. By adjusting these parameters, the process achieves optimal balance between indicia visibility, durability, and manufacturing speed. The high aspect ratio channels provide enhanced durability while the controlled parameter changes ensure consistent quality across production.
2Reliability
If the dust cover is made fully opaque to protect internal components, then protection is maximized, but visibility and aesthetic appeal are reduced
Solution Approach 1:
The patent applies local quality by creating indicia only in specific regions of the dust cover where information display is needed, while leaving the surrounding areas transparent or translucent. This allows the dust cover to provide protection where needed while maintaining visibility and aesthetic appeal in other areas. The laser-induced damage channels are precisely localized to form text, symbols, or patterns only where required.
Solution Approach 2:
The patent transitions from surface-level indicia (2D) to three-dimensional damage channels extending into the bulk of the polymeric substrate. This dimensional change enhances both durability and visibility, as the channels create light-scattering effects that are visible from multiple angles while the depth of the channels provides resistance to surface wear and environmental degradation.
3Illumination intensity
If laser parameters are increased to form deeper damage channels for better visibility, then indicia visibility improves, but the structural integrity of the dust cover may be compromised
Solution Approach 1:
The patent applies partial action by creating damage channels that extend only to the necessary depth to achieve visible indicia, rather than penetrating through the entire dust cover thickness. The aspect ratio is controlled to be greater than 10:1, providing sufficient visibility and durability without excessive material removal. This partial modification achieves the desired effect while preserving the overall structural integrity of the dust cover.
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 solution provides a durable and visually appealing way to indicate functionality while enabling the window system to switch between transparent and darkened states, with the indicia being visible under edge lighting, offering improved aesthetic appeal and functionality.
Implementation Method 1
pulsing the laser beam to form a plurality of damage channels within the substrate
Implementation Method 2
An electro-optic medium is disposed in the cavity that is variably transmissive such that the electro-optic element is operable between substantially clear and darkened states
Data Source
Figure 1A
Figure 1B
Figure 2A~3
AI summary
A window system is provided that includes an electro-optic element having a first substantially transparent substrate defining first and second surfaces. The second surface has a first electrically conductive layer and a second substantially transparent substrate defines third and fourth surfaces. The third surface has a second electrically conductive layer and a primary seal disposed between the first and second substrates. The seal and the first and second substrates define a cavity therebetween. An electro-optic medium is disposed in the cavity that is variably transmissive such that the electro-optic element is operable between substantially clear and darkened states. A polymeric dust cover is positioned away from the electro-optic element defining at least two major surfaces and at least one indicia disposed in the dust cover. The indicia includes a plurality of damage channels having an aspect ratio greater than about 10:1.