Electromagnetic Shield Intermediate Layer for Soda Lime Glass
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Solution Overview
Problem
Existing electromagnetic shields face challenges in achieving exceptional shielding and visibility while using soda lime glass, as they tend to cloud due to moisture reaction, and materials like Cu are costly or reflective, limiting their industrial application.
Innovation Solution
A glass substrate with an intermediate layer of Cr, Mo, or W oxides and Al oxides, combined with an Al electroconductive layer, and an ITO layer to reduce reflectance and prevent clouding, formed using sputtering and wet etching techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If soda lime glass is used as the base material, then manufacturing cost is reduced, but the glass becomes cloudy due to Na reaction with moisture
Solution Approach 1:
An intermediate layer comprising Cr, Mo, or W and their oxides is introduced between the soda lime glass substrate and the Al electroconductive layer. This intermediate layer acts as a barrier that prevents Na from the glass from reacting with moisture in the air, thereby preventing clouding while allowing the use of cost-effective soda lime glass.
Solution Approach 2:
The electromagnetic shield employs a composite structure consisting of multiple layers: soda lime glass substrate, intermediate layer (Cr/Mo/W with oxides), and Al electroconductive layer. This composite material approach combines the low cost of soda lime glass with the protective and functional properties of the intermediate and metal layers.
2Reliability
If Al is used in the electroconductive layer, then corrosion resistance is improved, but reflectance increases and visibility is hindered
Solution Approach 1:
The intermediate layer comprising Cr, Mo, or W and their oxides serves as an intermediary between the glass substrate and the Al electroconductive layer. This intermediate layer reduces the reflectance of visible light from the Al layer, thereby improving visibility while maintaining the corrosion resistance benefits of Al.
3Illumination intensity
If a black layer with glass component is formed and baked at 350-500° C., then visibility is improved, but shielding characteristics are reduced due to metal layer oxidation
Solution Approach 1:
The intermediate layer comprising Cr, Mo, or W and their oxides creates a chemically stable environment that prevents oxidation of the Al electroconductive layer. This eliminates the need for high-temperature baking that would cause oxidation, thereby maintaining both visibility and shielding characteristics.
4Reliability
If Ag is used in the metal layer, then oxidation is suppressed, but manufacturing cost increases
Solution Approach 1:
The intermediate layer comprising Cr, Mo, or W and their oxides provides oxidation protection to the Al electroconductive layer, eliminating the need to use expensive Ag. This intermediate barrier layer suppresses oxidation effectively while maintaining low manufacturing costs.
Solution Approach 2:
The patent replaces expensive Ag with a cost-effective combination of Cr/Mo/W and their oxides in the intermediate layer, achieving similar oxidation protection at lower cost. The Al electroconductive layer is protected by this cheaper intermediate barrier rather than using inherently oxidation-resistant but expensive Ag.
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 solution provides high transmittance, low reflectance, and environmental resistance, ensuring exceptional shielding and visibility without clouding, even in high-temperature and high-humidity conditions, while maintaining low material costs.
Implementation Method 1
the Na in the soda lime glass can react with the moisture in the air to form NaOH, some of the glass melts, the Al or the like in the wire and the Ca in the glass react and gradually diffuse through the glass surface
Implementation Method 2
after the intermediate layer and the electroconductive layer are formed by sputtering or vacuum deposition
Implementation Method 3
openings are formed by wet etching
Implementation Method 4
an electromagnetic shield member is installed on the front surface thereof. An electromagnetic shield member prevents electromagnetic waves generated by the display from leaking out
Data Source
AI summary
There is provided an inexpensive electromagnetic shield that can achieve exceptional shielding and display visibility characteristics, and provide high environmental resistance as necessary. In an electromagnetic shield (1), an intermediate layer (3) is formed on a glass substrate (2) comprising soda lime glass, an electroconductive layer (4) of Al is formed thereon, and openings (5) are formed by wet etching on the intermediate layer (3) and the electroconductive layer (4) after these layers have been formed by sputtering or vacuum deposition. Furthermore, an ITO layer (6) is formed on the entire glass surface including the intermediate layer (3) and the electroconductive layer (4) after the openings (5) are formed. In this configuration, the intermediate layer (3) comprises a mixture of at least one metal selected from chromium, molybdenum, and tungsten, and at least one oxide selected from oxides of silicon, oxides of aluminum, and oxides of titanium.