Laser Scribing of Low-E Coating Edges for Corrosion Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Laminated products with metal layer inclusive coatings face corrosion issues due to electrochemical corrosion driven by stress and ionized moisture ingress, which existing edge deletion techniques fail to effectively prevent or slow down, especially in pre- and post-assembled insulated glass units.
Innovation Solution
Laser-scribing the edges of metal layer inclusive coatings using a diode fiber laser at 1064 nm to electrically isolate the coating, creating a barrier that prevents electron transport and reduces electrochemical corrosion by dissolving or vaporizing the coating material into non-conductive forms, thereby increasing corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If edge deletion tables are used to remove coating from peripheral edges, then corrosion prevention is improved, but device complexity and processing time increase
Solution Approach 1:
The patent replaces the mechanical edge deletion table system with a laser-based system. The laser beam delivers energy to the coating material at the peripheral edges, vaporizing or dissolving it without requiring complex mechanical machinery. This substitution of mechanical systems with optical/thermal energy delivery achieves the same corrosion prevention function while dramatically simplifying the device requirements.
Solution Approach 2:
The patent changes the approach from mechanical removal to thermal/vaporization removal by controlling laser parameters (power, pulse duration, wavelength). By adjusting these parameters, the coating material is selectively removed or modified at the edges to create corrosion-resistant structures without the need for mechanical contact or complex positioning systems.
2Reliability
If edge deletion tables are used to remove coating, then corrosion resistance is improved, but processing time and costs increase
Solution Approach 1:
The laser system eliminates the need for slow mechanical scanning and material removal processes. The concentrated laser energy rapidly heats and vaporizes the coating material at the edges, achieving corrosion-resistant structures in a fraction of the time required by mechanical edge deletion tables.
Solution Approach 2:
The patent employs pulsed laser delivery to the coating material. By delivering energy in controlled pulses rather than continuous operation, the process achieves efficient material removal or modification while allowing for optimal heat management and precise control of the corrosion-resistant structure formation, reducing overall processing time.
3Manufacturing precision
If edge deletion tables create debris, then coating removal is achieved, but additional debris handling processes are required
Solution Approach 1:
The laser energy causes the coating material to undergo phase transitions from solid to vapor or plasma state, allowing the material to be removed as vapor rather than mechanical debris. This phase change approach eliminates the generation of solid particulate waste that would require additional handling and disposal processes.
Solution Approach 2:
Replacing mechanical abrasion with laser-induced vaporization changes the physical state of removed material from solid debris to vapor, which can dissipate naturally or be more easily managed, eliminating the need for complex debris collection and handling systems.
4Manufacturing precision
If grinding wheels are used for edge deletion, then coating removal is effective, but the system becomes less adaptable to different product configurations
Solution Approach 1:
The laser system replaces fixed mechanical grinding wheels with a flexible optical beam that can be precisely positioned and shaped. The laser can be programmed to follow complex paths and adjust its parameters dynamically, making it highly adaptable to different product configurations, sizes, and coating types without requiring physical tool changes or system reconfiguration.
Solution Approach 2:
The laser system incorporates dynamic control of beam position, focus, and parameters through computer programming. This allows the same laser apparatus to adapt to various product configurations by changing operational parameters rather than physical components, providing versatility across different product types and sizes.
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 laser-scribing technique significantly reduces electrochemical corrosion by creating a high polarization resistance, effectively slowing or stopping the corrosion process and extending the lifespan of laminated products, including insulated glass units.
Implementation Method 1
Laser-scribing the edges of metal layer inclusive coatings using a diode fiber laser at 1064 nm to electrically isolate the coating, creating a barrier that prevents electron transport and reduces electrochemical corrosion by dissolving or vaporizing the coating material into non-conductive forms
Implementation Method 2
The laser-scribing technique significantly reduces electrochemical corrosion by creating a high polarization resistance, effectively slowing or stopping the corrosion process and extending the lifespan of laminated products, including insulated glass units
Data Source
AI summary
Certain example embodiments of this invention relate to techniques for laser ablating/scribing peripheral edges of a coating (e.g., a low-emissivity, mirror, or other coating) on a glass or other substrate in a pre- or post-laminated assembly, pre- or post-assembled insulated glass unit, and/or other product, in order to slow or prevent corrosion of the coating. For example, a 1064 nm or other wavelength laser may be used to scribe lines into the metal and/or metallic layer(s) in a low-emissivity or other coating provided in an already-laminated or already-assembled insulated glass unit or other product, e.g., around its periphery. The scribe lines decrease electron mobility from the center of the coating to the environment and, thus, slow and sometimes even prevent the onset of electrochemical corrosion. Associated products, methods, and kits relating to same also are contemplated herein.