Electrochromic Coated Glass Laser Processing for Uniform Edge Coating
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Solution Overview
Problem
The manufacturing of electrochromic coated glass articles faces challenges such as damage to the electrochromic film due to moisture and particles generated during cutting and grinding processes, leading to uncoated or non-uniformly coated regions, and limited manufacturing flexibility and increased costs.
Innovation Solution
The use of ultrashort pulsed laser beams to create controlled defects and discontinuities in the electrochromic layer on glass substrates, allowing for precise coating and subsequent cutting to desired shapes and sizes without significant damage, enabling uniform coating and increased manufacturing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the glass substrate is cut and ground before coating with electrochromic film (cut-and-coat process), then the electrochromic film is protected from damage during manufacturing, but the glass substrate develops uncoated or non-uniformly coated regions due to fixturing interference
Solution Approach 1:
The patent applies preliminary action by coating the glass substrate with electrochromic film before cutting and grinding operations. This reverses the traditional sequence, allowing the film to be deposited on the complete substrate surface first, then protected during subsequent manufacturing steps through controlled laser processing that prevents film damage while achieving precise cuts.
2Manufacturing precision
If the glass substrate is coated with electrochromic film before cutting (coat-and-cut process), then uniform coating coverage is achieved, but the electrochromic film is damaged by moisture and particles generated during cutting and grinding
Solution Approach 1:
The patent replaces traditional mechanical cutting and grinding methods with laser-based processing. This substitution eliminates the harmful effects of aqueous coolants, particles, and mechanical stress that damage the electrochromic film, while still achieving precise cutting and shaping of the coated glass substrate.
Solution Approach 2:
The laser processing creates a localized processing environment that avoids exposure to harmful moisture and particles. By using laser energy directly on the coated substrate, the process maintains an inert environment around the electrochromic film during cutting operations, preventing blistering and breakdown.
3Ease of manufacture
If traditional cutting and grinding methods are used on electrochromic coated glass, then manufacturing is straightforward, but the process generates moisture and particles that damage the electrochromic film
Solution Approach 1:
The patent replaces mechanical cutting and grinding systems with laser processing systems. This substitution eliminates the generation of harmful moisture and particles while maintaining manufacturing efficiency, as laser processing can be performed in a controlled environment without requiring extensive cooling or particle removal infrastructure.
4Measurement precision
If fixturing components are used to hold the glass substrate during coating, then the substrate is positioned accurately, but the fixturing interferes with edge-to-edge coating coverage
Solution Approach 1:
By coating the substrate before cutting, the need for extensive fixturing during the coating process is eliminated. The substrate can be handled more simply since the critical coating operation occurs before precision cutting, allowing edge-to-edge coverage without fixturing interference.
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 results in glass articles with uniform electrochromic coatings and reduced manufacturing costs, allowing for precise control over tinted and untinted regions and improved flexibility in producing glass articles with minimal laser damage to the electrochromic layer and substrate.
Implementation Method 1
The use of ultrashort pulsed laser beams to create controlled defects and discontinuities in the electrochromic layer on glass substrates
Implementation Method 2
electrochromic coating disposed on at least a portion of the second surface, wherein upon application of voltage to the glass article a first region of a coated portion of the glass substrate has a first visible light transmission that is less than a second visible light transmission of a second region
Data Source
AI summary
Disclosed herein are glass articles coated on at least one surface with an electrochromic layer and comprising minimal regions of laser damage, and methods for laser processing such glass articles. Insulated glass units comprising such coated glass articles are also disclosed herein.