Laser Patterning Functional Coating on Curved Glass

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Solution Overview

Problem

Existing methods for producing patterned functional coatings on curved vehicle window panes face issues such as edge defects and structural integrity loss due to reactions and heating effects during the bending process, leading to optical defects and laborious protective layer removal.

Innovation Solution

A device and method utilizing a laser to pattern the functional coating after bending the glass, eliminating the need for a protective layer and allowing for precise patterning with reduced process steps and improved optical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If the electrically conductive layer is applied before bending the glass pane, then the patterning can be performed earlier in the process, but the coating reacts with the surrounding atmosphere during heating and bending, causing edge defects and compromising structural integrity

Engineering Contradiction:

Improveprocess timeVSAvoidstructural integrity of functional coating

Core Design Contradiction:

Loss of timeVSReliability

Solution Approach 1:

The patent inverts the conventional sequence by applying the functional coating after bending and heating the glass pane, rather than before. This reversal eliminates the reaction between the coating and atmosphere during high-temperature processing, preventing edge defects and structural compromise while maintaining process efficiency

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The glass pane is pre-bent and pre-heated to the final shaping temperature before the functional coating is applied. This preliminary preparation ensures the glass is in its final configuration, allowing subsequent coating application without exposure to high temperatures that would cause harmful reactions

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the electrically conductive layer is patterned on a flat glass pane before bending, then the patterning process is simpler, but overlapping and misalignment occur at edges when larger areas are processed, creating stepped patterns

Engineering Contradiction:

Improvepatterning process simplicityVSAvoidpattern edge alignment

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent inverts the conventional sequence by performing patterning after bending rather than before. This allows the entire large-area surface to be patterned in a single continuous operation on the already-curved glass, eliminating overlapping and misalignment issues that occur when processing large flat areas in multiple steps

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If the glass pane is heated to high temperature for bending, then the glass can be curved to meet aerodynamic and stylistic requirements, but the electrically conductive layer is heated excessively causing flow processes and loss of structural integrity

Engineering Contradiction:

Improvecurved glass pane shapeVSAvoidstructural integrity of functional coating

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The patent inverts the sequence by completing the high-temperature bending process before applying the functional coating. This ensures the glass achieves its required curved shape through heating, while the coating is applied to the already-cooled or lower-temperature glass, avoiding excessive heating and flow processes that would compromise structural integrity

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The glass pane undergoes preliminary heating and bending to achieve its final curved shape before the functional coating is applied. This preliminary shaping action separates the high-temperature formative process from the coating application, protecting the coating from thermal damage

Inventive Principle:

Principle #10Preliminary action

4Reliability

If a protective layer is applied before bending to prevent reactions, then the functional coating is protected during heating, but complete removal of the protective layer after bending is laborious and time-consuming

Engineering Contradiction:

Improveprotection during bendingVSAvoidprotective layer removal time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent inverts the conventional approach by eliminating the protective layer step entirely. Instead of applying protection before bending and removing it afterward, the functional coating is applied after bending, making the protective layer and its laborious removal completely unnecessary

Inventive Principle:

Principle #13The other way round (Inversion)

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

Enables the production of curved glass panes with high precision and economic efficiency by avoiding edge reactions and heating-induced defects, while simplifying the production process by shifting the patterning step to after bending.

Implementation Method 1

at least one laser (11), and a guidance unit (12). The guidance unit (12) is provided for guiding the beam of the laser (11) over the functional coating (5) such that parts of the functional coating (5) are removed in order to pattern the functional coating (5)

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS11362473B2Device and method for producing a patterned functional coating for a glass layer

Publication Date: 2022.06.14 SAINT GOBAIN SEKURIT FRANCE

AI summary

A device and a method for producing a patterned functional coating on a first curved glass layer, the device including a support for holding the first curved glass layer, at least one laser, and a guidance unit, provided for guiding the beam of the laser over the functional coating, such that parts of the functional coating are removed in order to pattern the functional coating.