Laser-Scribed Low-E Coating Borders for IGU Corrosion Control
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Solution Overview
Problem
Laminated metal layer thin films in products like mirrors and low-E coatings are prone to corrosion from temperature and humidity gradients, with existing edge deletion techniques being inefficient, costly, and limited in removing coatings from small areas, especially in assembled products.
Innovation Solution
Laser-scribing the edges of metal layers in laminated glass units using a 1064 nm diode fiber laser to create a barrier that electrically isolates the coating, preventing electron transport and slowing or stopping electrochemical corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If edge deletion tables with grinding wheels are used to remove coatings from peripheral edges, then coating corrosion is prevented, but the process becomes complex, costly, and inefficient especially for small areas and assembled products
Solution Approach 1:
The patent replaces the mechanical grinding wheel system with a laser-based system. The laser beam focuses energy to ablate the coating material through vaporization and decomposition, eliminating the need for mechanical contact, complex tables, and debris collection mechanisms while achieving the same corrosion prevention effect through precise edge deletion
Solution Approach 2:
The patent changes the operating parameters by using laser power, pulse duration, and scanning speed instead of mechanical wheel speed, pressure, and width. This allows for precise control of the deletion depth and width, enabling efficient processing of both large and small areas without changing the fundamental system configuration
2Reliability
If wider grinding wheels are used to delete more coating material, then corrosion protection is improved, but the scattering of debris increases and safety is reduced
Solution Approach 1:
The laser-based system replaces mechanical grinding, eliminating the generation of airborne debris particles. The coating material is vaporized and decomposed into gas phase products that can be controlled and contained, removing the safety hazard of debris scattering while maintaining effective coating deletion
3Adaptability or versatility
If edge deletion is performed on already-assembled products, then the process becomes more versatile, but existing techniques cannot effectively treat small areas or post-assembled products
Solution Approach 1:
The laser system provides non-contact processing with a focused beam that can be precisely positioned and scanned. This enables accurate treatment of small areas and complex geometries on assembled products without the constraints of mechanical wheel sizes, table configurations, or debris management issues that limit traditional 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
The laser-scribing technique significantly reduces electrochemical corrosion by increasing the polarization resistance and series resistance, potentially decreasing leakage currents by orders of magnitude, thereby protecting the coating from degradation.
Implementation Method 1
a line is laser-scribed in the coating by exposing the intermediate product to a laser source
Implementation Method 2
laser-scribing at least partially dissolves the coating proximate to the border line
Implementation Method 3
increases the polarization resistance and series resistance, potentially decreasing leakage currents by orders of magnitude
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.