Localized Sensor Area on Coated Glass via Patch Segmentation
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Solution Overview
Problem
Existing methods for applying localized coatings on glass substrates, such as those required for optical sensors in vehicles, are costly and complex, often requiring large vacuum chambers, wasteful coating processes, and are not feasible for small-sized glass or bent substrates, with prior solutions like plastic patches being less durable and resistant to environmental conditions.
Innovation Solution
A functionalized glass patch with dedicated coatings is attached to a larger substrate, allowing for localized coating in small areas, using techniques like autoclaving and optical bonding, which reduces costs and complexity by enabling online coating methods and avoiding the need for de-coating and masks, while ensuring strong adhesion and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a coating is applied to the entire glass substrate, then the coating provides uniform protection and functionality across the surface, but it is difficult and costly to remove the coating from specific areas to create localized optically transparent sensor areas
Solution Approach 1:
The glass substrate is divided into two functional zones: a coated area providing protection and functionality, and an uncoated optically transparent sensor area. This segmentation allows each zone to serve its specific purpose without interfering with the other, solving the problem of creating localized transparent areas on coated glass.
Solution Approach 2:
Instead of applying coating only to the sensor area and then removing it (the conventional approach), the invention inverts the process by applying coating to the entire substrate first, then selectively removing it from the sensor area. This inversion simplifies the manufacturing process by using standard full-surface coating equipment and avoiding the complexity of masking and selective deposition.
2Manufacturing precision
If specialized equipment like large vacuum chambers and masks are used to apply localized coatings, then precise localized coating can be achieved, but the manufacturing cost and process complexity increase significantly
Solution Approach 1:
The complex equipment elements (masks, selective deposition systems) are extracted from the process. Instead, a simple removal step using conventional means (chemical etching, mechanical abrasion, or thermal treatment) is employed to create the localized transparent area after standard full-surface coating, dramatically reducing equipment complexity.
Solution Approach 2:
The conventional approach of selectively applying coating is inverted to applying coating universally then selectively removing it. This inversion allows the use of simple, standard coating equipment followed by basic removal processes, avoiding the need for complex specialized equipment.
3Adaptability or versatility
If the glass substrate is bent or small-sized, then it can be adapted to specific vehicle applications, but conventional coating and de-coating methods become infeasible
Solution Approach 1:
The coating is applied to the glass substrate in its final bent or small-sized form before any removal steps. This preliminary coating action allows the use of flexible coating methods that can accommodate non-planar surfaces, and the subsequent removal process can be precisely controlled on the final component shape.
Solution Approach 2:
The coating removal process uses parameter changes (chemical, thermal, or mechanical) that can be applied locally to bent or small-sized substrates. This allows the creation of optically transparent sensor areas on complex geometries that would be incompatible with rigid mask-based conventional methods.
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, increases feasibility, and provides durable, resistant, and aesthetically pleasing localized coatings on glass substrates, enhancing the performance of optical sensors like LiDAR by ensuring high transmission and reduced reflection, especially for infrared light.
Implementation Method 1
using techniques like autoclaving and optical bonding
Implementation Method 2
using techniques like autoclaving and optical bonding
Implementation Method 3
AR coating for IR light is needed and has to be localized only on the integration area ie optically transparent area
Data Source
AI summary
A pane substrate with an optically transparent area comprising at least one optical device on the surface of the pane integrated in the optically transparent area. At least one coated glass patch is provided locally between the pane and the optical device.