Sacrificial Coating for Electrochromic Glass Surface Protection
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Solution Overview
Problem
The manufacturing process of glass substrates for electrochromic devices is prone to scratches, smudging, fingerprints, particles, and contamination, leading to defects and reduced yield due to the lack of reliable protection during handling and processing operations.
Innovation Solution
A sacrificial coating is deposited on the glass substrate prior to handling and processing operations to protect the transparent conductor layer, which can be easily removed during subsequent washing or tempering steps, thereby reducing contamination and defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If handling and processing operations are performed on glass substrates during manufacturing, then the substrate can be prepared for electrochromic device fabrication, but scratches, smudging, fingerprints, particles, and contamination occur on the substrate surface
Solution Approach 1:
A sacrificial coating is applied to the glass substrate surface before handling and processing operations. This preliminary protective layer prevents direct contact between the substrate and potential contaminants or mechanical damage sources during subsequent manufacturing steps, thereby maintaining surface quality while enabling necessary handling operations.
Solution Approach 2:
The sacrificial coating acts as an intermediary layer between the glass substrate and external environmental factors (fingers, tools, particles). This intermediate protective barrier absorbs potential damage and contamination, protecting the underlying substrate surface during handling and processing operations.
2Manufacturing precision
If the glass substrate is protected during handling and processing, then contamination and defects are reduced, but additional processing steps and materials are required
Solution Approach 1:
The sacrificial coating is designed as a temporary, easily removable protective layer. This disposable coating provides necessary protection during handling and processing, then can be quickly removed without requiring complex removal equipment or procedures, thereby minimizing added process complexity.
Solution Approach 2:
The sacrificial coating is formulated with specific chemical and physical properties that allow it to be easily removed through simple washing or tempering processes. By controlling the coating's composition and removal characteristics, the protection function is achieved without significantly increasing fabrication process complexity.
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 sacrificial coating effectively prevents scratches, smudging, and contamination, enhancing the quality of the electrochromic device by reducing defects and increasing the efficiency of the fabrication process.
Implementation Method 1
A sacrificial coating is deposited on the glass substrate prior to handling and processing operations to protect the transparent conductor layer
Implementation Method 2
which can be easily removed during subsequent washing or tempering steps
Implementation Method 3
which can be easily removed during subsequent washing or tempering steps
Data Source
AI summary
Methods for protecting an electrochromic stack, individual layers of the electrochromic stack, a first transparent conductor layer, a second transparent conductor layer, one or more bus bars, or a low E layer on a glass substrate. Methods for protecting the outside surfaces of an insulate glass unit including the substrate and one or more mating lites are also described herein. Methods include laminating a sacrificial coating over the substrate and/or the one or more mating lites, and peeling off the sacrificial coating from the substrate and/or the one or more mating lites.