Laser Repair of Electroactive Laminate Defects

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Solution Overview

Problem

During the fabrication of non-light-emitting variable transmission laminate devices, defects can form, leading to reduced yield, electrical shorts, non-uniform tinting, and shortened operational lifetime.

Innovation Solution

A method for repairing defects in electroactive laminate devices involves locating the defect and using a pattern of laser pulses to ablate surrounding layers, ensuring a space between pulses and potentially overlapping pulses in subsequent passes to create a circumferential trench around the defect.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional fabrication methods are used, then manufacturing process is simple, but defects form reducing yield and device reliability

Engineering Contradiction:

ImproveyieldVSAvoiddevice performance

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent implements preliminary inspection and classification of defects during fabrication, separating defective units from good units before final assembly. This allows for targeted repair or rejection of specific defective components, improving overall yield without compromising the performance of good units.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts and removes defective elements from the laminate structure through selective ablation or removal processes. By taking out only the defective portions rather than discarding entire units, the method improves yield while maintaining the integrity and performance of the remaining device structure.

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If defects are present in the laminate, then manufacturing cost decreases, but electrical shorts and operational failures increase

Engineering Contradiction:

Improveelectrical insulationVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent incorporates inspection and feedback mechanisms during the fabrication process that detect electrical shorts and insulation defects. This feedback allows for real-time identification and correction of issues, ensuring electrical insulation integrity while maintaining manufacturing efficiency through automated detection systems.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces manual inspection and defect detection with automated optical, electrical, or computational methods. This substitution increases the reliability of electrical insulation detection without proportionally increasing manufacturing complexity, as automated systems can operate consistently and rapidly.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If laser ablation is used to repair defects, then defect isolation is effective, but energy consumption and processing time increase

Engineering Contradiction:

Improvedefect isolationVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent segments the laser ablation process into targeted zones around specific defects rather than treating the entire laminate uniformly. By localizing energy application only to areas containing defects, the method achieves effective defect isolation while significantly reducing overall energy consumption and processing time.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent applies different treatment intensities and parameters to different regions of the laminate based on defect detection. Areas with defects receive targeted laser ablation for isolation, while defect-free areas undergo minimal or no treatment, optimizing energy usage while maintaining reliable defect isolation where needed.

Inventive Principle:

Principle #3Local quality

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 effectively isolates defects from the rest of the device, preventing electrical shorts and improving the appearance and performance of the laminate, thereby increasing yield and operational lifetime.

Implementation Method 1

using a pattern of laser pulses to ablate surrounding layers, ensuring a space between pulses and potentially overlapping pulses in subsequent passes to create a circumferential trench around the defect

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Data Source

PatentUS20250102841A1Fabricating non-light-emitting variable transmission laminates

Publication Date: 2025.03.27 SAGE ELECTROCHROMICS INC

AI summary

A method of repairing an electroactive laminate is disclosed. The method can include locating a defect in the electroactive laminate and laser ablating around the defect using laser pulses in a pattern, where a first laser pulse is followed by a second laser pulse in succession, and wherein the pattern comprises a space between any two laser pulses being fired in succession, and wherein the pattern comprises overlapping pulses between a pulse fired in a first circumferential pass and a pulse fired in a second circumferential pass.