Laser Ablated Surface Indicia on Electrochromic Substrates
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Solution Overview
Problem
Existing laser ablation processes for dimmable mirrors and windows lack the ability to selectively create visible patterns that are invisible in a transparent state and visible in a darkened state, limiting their functionality and aesthetic appeal.
Innovation Solution
A two-stage laser ablation process is applied to an electrochromic device, where the first stage removes a coating layer, and the second stage modifies the conductive layer within the ablated area to create a selectively visible indicia by altering its thickness, resistance, or color, ensuring the pattern is invisible in a transparent state and visible in a darkened state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-stage laser ablation process is used to remove the coating layer, then the coating layer is effectively removed, but the ability to create selectively visible patterns is lost
Solution Approach 1:
The laser ablation process is divided into two distinct stages: a first stage that removes the coating layer to create a first ablated area, and a second stage that modifies the conductive layer within a portion of the first ablated area to create a second ablated area. This segmentation allows independent optimization of each stage for its specific function, enabling both effective coating removal and selective pattern creation.
Solution Approach 2:
The second laser ablation process is applied only to a specific portion of the first ablated area where the indicia should appear. This localized treatment modifies the conductive layer properties (thickness, resistance, or color) only in the desired pattern locations, creating areas that are visible in the darkened state but invisible in the transparent state, thus achieving spatially varying functionality.
2Illumination intensity
If the conductive layer is modified to create visible patterns, then aesthetic appeal is enhanced, but the transparency in the clear state is compromised
Solution Approach 1:
The second laser ablation process applies partial action by treating only a portion of the first ablated area rather than the entire surface. This selective modification creates the desired visible patterns while leaving other areas unchanged, maintaining the overall transparency and conductive layer integrity where patterns are not desired.
Solution Approach 2:
The laser processing parameters (power, speed, pulse duration) are carefully controlled to modify the conductive layer properties subtly enough to create visible patterns in the darkened state while preserving sufficient conductive layer material to maintain transparency in the clear state. The modification changes thickness, resistance, or color parameters without complete removal.
3Adaptability or versatility
If a two-stage laser ablation process is implemented, then selectively visible indicia are created, but the manufacturing complexity increases
Solution Approach 1:
The same laser system is used for both ablation stages, performing multiple functions with a single device. The laser can operate in different modes (continuous wave vs. pulsed) and at different power levels to achieve both coating removal and conductive layer modification, reducing the need for multiple specialized equipment while maintaining selective pattern creation capability.
Solution Approach 2:
The first laser ablation process performs preliminary action by removing the coating layer and creating the first ablated area, which prepares the substrate for the second stage. This preliminary preparation enables the second process to focus solely on modifying the conductive layer without the interference of the coating layer, simplifying the overall process control.
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 process effectively creates a selectively visible pattern that is invisible during normal operation and becomes visible when the electrochromic medium is in a darkened state, enhancing the functionality and aesthetic appeal of dimmable mirrors and windows.
Implementation Method 1
subjecting the substrate to a first laser ablation pass such that the coating layer is removed from at least a portion of the conductive layer
Implementation Method 2
subjecting the portion of the substrate to one or more additional laser ablation passes to modify a property of at least a sub-portion of the portion of the conductive layer
Implementation Method 3
The second ablated area is at least partially invisible while the electrochromic medium is in a transparent state. The second ablated area is visible while the electrochromic medium is in a darkened state
Data Source
AI summary
A product includes a substrate that is at least partially transparent to visible light. The substrate includes a first surface, an opposing second surface, and a conductive layer disposed on the opposing second surface. The conductive layer has a first ablated area and a second ablated area entirely disposed within and overlapping a portion of the first ablated area. The second ablated area includes a selectively visible indicia.