Patent Application
20170238424
The invention relates to the application of electrically conductive bus bars onto a low-emissivity coating of glass used, in particular, in the manufacture of electrically heated glass structures for transport, aviation, shipbuilding, armored vehicles (triplexes, bulletproof glass), glass packages, architectural glazing, etc.
At present, the application of conductive bus bars onto a low-emissivity coating of glass is effected in the commercial production by a number of ways:
1. Process of applying a bus bar by ultrasonic soldering.
The process is carried out by applying a solder (indium tin) using an ultrasonic soldering iron, which is reciprocated over a template at a speed of 2-5 mm/s. Then, to reduce the electrical resistance, a molybdenum tape mesh is applied over the solder by soldering.
Disadvantages of this process are that it is manual, labor-intensive, low efficient and multi-staged; in addition, the method is expensive due to the high cost of the ultrasonic soldering iron, this imposing constraint on the provision of several soldering stations.
2. Process of applying conductive bus bars by screen printing method on an inkjet printer using a silicate-silver paste as the ink.
Disadvantages of this process are also that it is a multi-staged (drying is added after application of the paste); the process uses expensive consumables and a high cost printer; there are difficulties with soldering current-carrying wires; furthermore, the bus bars applied by the method cannot operate under high heating power.
3. Process of applying bus bars by setting a metal strip with a glue line applied thereon, positioning the strip in the desired place and pressing to a low-emissivity coating in the triplexing process to provide electrical contact.
Disadvantages of this process include unreliable electrical contact and reduced service life due to rapid aging of the structure in service.
4. Process of applying conductive bus bars onto a low-emissivity surface of glass by gas dynamic cold spray method.
The process of applying coatings by gas dynamic cold spray method was first disclosed in WO 9119016 A1 or U.S. Pat. No. 5,302,414.
This method involves heating a compressed gas (air); supplying the gas into a supersonic nozzle to form there a supersonic flow; supplying a powder material into this flow; increasing the speed of the material by the supersonic flow and directing it through an outlet variable cross section nozzle onto a surface being processed.
This process is also known to be used for applying conductive bus bars on a low-emissivity glass surface. In particular, the method is currently used by Obninsk Center for Powder Spraying (http://dymet.info), as well as by CenterLine company (http://www.supersonicspray.com/).
In the procedure of applying bus bars onto a low-emissivity glass surface, this process is generally performed in a two stages, where the first stage comprises applying an underlayer of a powdered mixture of aluminum and zinc (to provide more adhesion), and then a layer of powdered mixture of copper and zinc is applied (to provide better electrical performance and facilitate soldering current-carrying wires to the bus bar). Each stage is carried out at specified flow temperature t° C. and powder mass flow rate Q (g/s), at constant speed V (mm/s) of moving the nozzle and compressed air pressure P (atm). The process is carried out using templates or masks overlaid on the glass to form the geometric shape of the bus bar, especially its beginning and end. The process is carried out in an aspiration chamber whose design allows the application of only straight lines on one side of the product.
The conventional method has the following disadvantages:
use of templates and masks for forming the beginning, end and discontinuities of the bus bars assumes securing them on the low-emissivity surface (with a sufficiently high pressing force), which can lead to its disruption and ultimately to defect product;
application of bus bars in an aspiration chamber containing a high concentration of suspended powder; the possibility of powder deposition on the surface of the product requires obligatory inclusion of washing and drying steps in the process, this leading to increased costs and to problems that arise in soldering current-carrying wires to the bus bar due to saturation of micropores of the bus bar with moisture;
inability to integrate the process in a single production line since a separate room is required;
need to have a unique template for each workpiece;
inability of extremely tight pressing of all generators of the template against the glass surface, this resulting in blurred boundaries of the bus bar (powder blown upon the tray) and moiré on its boundary, which is to be removed by acidic liquids;
inability of implementing the method to 3D models due to the complexity of installation and manufacture of templates and the aforementioned problems.
There are also several methods that can be used for applying bus bars to a limited extent, for example, reduction of copper on the surface of glass products from an autocatalytic solution by a laser-induced method, and sputtering metallic powders in a coaxial jet of powder and laser beam.
These methods cannot be generally practiced, by their nature, in commercial production for this process.
Therefore, the most technically relevant method is a method of applying bus bars onto a low-emissivity glass surface by gas dynamic cold spray method with the aid of a spraying nozzle of a gas dynamic spraying apparatus, disclosed in U.S. Pat. No. 8,758,849 B2.
The patent generally discloses the use of gas dynamic cold spray method in the process of applying conductive bus bars onto a low-emissivity glass surface.
It should be noted that the prior art document is silent about a process of forming the beginning and end of the bus bar and about process steps that could enable practicing the method. It only specifies that a mask can be used or not. However, the non-use of a mask in this method for forming the beginning and end of a bus bar is possible only if spraying is started and ended outside of the glass.
At the same time, as shown in
Analysis has shown that the above method has a number of other significant drawbacks that limit the abilities of its use in the process of applying bus bars onto a low-emissivity glass surface.
In particular, the method does not disclose the possibility of a delay in the powder supply into the nozzle as it is moving to a specified point on the surface. In this method the process is carried out traditionally, with feeding the powder into the nozzle before its positioning above the surface, and the supply is disabled upon going the nozzle beyond the surface, since there is no specific information on other embodiments of the process.
Furthermore, disadvantages of the prior art solution also include the following: the effect of delayed action of the spraying process when applying a broken line is not taken into account; the mechanism of feedback and its time range is not disclosed, taken into account that the process proceeds in motion and there is a delayed response in the action of actuators and the gas dynamic spraying apparatus, in particular, in the change of powder flow density; the presence of mechanical finishing of the resulting surface in the technological process.
The mechanism of aspiration of non-adherent powder and high concentration of non-removed suspended powder in the treatment area is undisclosed either.
The ability of powder deposition onto the surface of a product necessitates the inclusion of washing and drying steps in the process, which leads to increased costs and problems that arise in soldering current-carrying wires to the bus bar due to the saturation of micropores of the bus bar with moisture. Since the process involves the use of an aspiration chamber, the size of workpieces is restricted by the aspiration chamber dimensions, and the process cannot be integrated in a single production line since a separate room is required.
The object of the present invention is to provide a method which could overcome the aforementioned disadvantages of the prior art.
In particular, the basic object of the invention is to enable the formation of an electrically conductive bus bar having distinct boundaries and geometric dimensions at the beginning, end and discontinuities of its path in any given area on the glass surface without the use of special templates and masks.
The object is attained in a method of applying electrically conductive bus bars onto a low-emissivity surface of glass by gas dynamic cold spray method with the aid of a spraying nozzle of a gas dynamic spraying apparatus, the method comprising:
providing in the gas dynamic spraying apparatus an estimated bulk weight of a powder, sufficient for spraying the powder over the entire length of the bus bar;
moving the spraying nozzle to a beginning point of the bus bar without supplying the sprayed powder thereto, and
upon positioning the moved nozzle at the beginning point of the bus bar, supplying the sprayed powder into the spraying nozzle and moving the spraying nozzle with a constant speed from the beginning point to an end point of the bus bar;
wherein upon reaching the end point of the bus bar, the nozzle movement is reversed towards the beginning point of the bus bar with a speed greater than the speed of the nozzle from the beginning point to the end point of the bus bar.
The reversed movement of the nozzle is preferably effected over a distance of about 2-3 cm.
The provision of an estimated bulk weight of the powder, sufficient for spraying the powder over the entire length of the bus bar, upon reaching a predetermined point of the path is preferably effected for an estimated part of a feed pipe by cutting off this part from a feeder by means of air valves further mounted in the gas dynamic spraying apparatus.
In a preferred embodiment, the bulk weight of the powder formed in the cut off part of the feed pipe is determined with account of the length of the applied area of the bus bar, its section and geometry, and is calculated based on process parameters accepted in the process, such as temperature, powder flow rate, compressed air pressure, and speed of the nozzle.
Preferably the sprayed powder is a fine powder, such as a homogeneous powder or a mixture of powders, the size of the applied fine powder being 5-5.0 μm.
Preferably, according to the present method a single-layer bus bar can be applied using a two-component powder, for example, Al+Zn, at a temperature of about 240° C., to provide a sufficient adhesion in combination with a higher (up to 3 times) utilization rate of the powder, and then a second layer of powdered copper (Cu) can be applied onto the edge of the bus bar (in the place of soldering a current-carrying wire) to provide a contact pad for soldering, which provides the best contact between the bus bar and the current-carrying wire when soldering. This is preferable for the electrically heated glass structures, where the adhesion of the powder to a low-emissivity glass surface, achieved in this case, satisfies the service conditions (for example, in architectural glazing).
To enhance adhesion of the powder to the glass surface, before applying the powder onto the glass surface, a part of the surface along the path, over which the bus bar is to be applied, is preferably treated with an abrasive powder, e.g. Al2O3 corundum, to partially remove the low-emissivity layer and thereby increase the relief of the surface of penetration of the powder into the glass. In this case, the material of the bus bar is then disposed with an offset of 2-3 mm from the axis of the application path to ensure electrical contact of the bus bar with the low-emissivity glass surface around said part with removed low-emissivity layer, i.e. to maintain its electrical contact with the low-emissivity glass surface.
Furthermore, the beginning and/or end points of the bus bar can be disposed both on the low-emissivity surface and on the part of the surface with removed low-emissivity layer.
The applying of the bus bar is preferably effected in two stages, where the first stage comprises applying the powder for forming an underlayer of the bus bar, and the second stage comprises applying the fine powder to form the final bus bar. At the two-stage application of the bus bar (application of two layers of powders having different composition) the underlayer is preferably a mixture of powdered zinc with polishing powders (for example, Fe2O3; CeO2, etc.).
The process of applying the powder is preferably controlled by software, into which delay functions are introduced to take into account the delayed action of the gas dynamic spraying apparatus.
The method further comprises withdrawing dust and gas mass from the powder application area with the aid of a gas dynamic dust and gas ejection valve mounted on the spraying apparatus coaxially with the nozzle; wherein the ejecting jet in the dust and gas ejection valve is the jet of sprayed powder as such, which provides aspiration of the mass of powder non adherent to the surface.
In this application, the term “low-emissivity glass surface” refers to an energy saving glass typically used in glass packages and having a metallic coating that transmits light almost like an ordinary glass, but is able to reflect back into the room most of the thermal radiation or the long wave component of the radiation.
“Gas dynamic cold spray method” refers to the technology described above, which in other countries may have different names (including such terms as: gas dynamic cold spray process; cold spray; kinetic energy spray, or other combinations of these terms).
The method according to the invention offers the following technical advantages:
The method enables forming a bus bar having distinct boundaries and geometric dimensions in the beginning, end and discontinuities in its path in any given area of the surface without the use of special templates and masks, which are usually secured to the low-emissivity surface of glass and lead to disruption of this surface.
The method enables a delay in the powder supply into the nozzle as the nozzle is moving to a desired point on the surface, in particular, owing to including a delay function in the software and adapting it to the process.
Owing to the properly chosen exposure time and flow rate of the powder, a bus bar can be formed with an equal cross-section throughout its length, including the bus bar beginning and its end.
Design and process solutions that implement the method in practice enable the application of bus bars both in 2D models and 3D models, onto external and internal surfaces.
With the aid of ejection of dust and gas mass in the gas dynamic ejection valve, the sprayed powder jet provides aspiration of the mass of powder non adherent to the surface of up to 99.5% of the total weight, where 0.5% of non-aspirated powder is not in the suspended form, but is deposited on the surface of the glass and can be removed from the bus bars by wiping with a wad.
Process equipment used in this method can be integrated into the existing process of manufacturing electrically heated glasses; this automates the process, reduces the number of process steps, and improves the performance of electrically heated products owing to optimized configuration of the bus bars and reduced cost of their production. Efficiency of the step of applying bus bars onto glass is increased by 5-6 times.
Hereinafter the invention will be explained in more detail by describing a particular embodiment in conjunction with the accompanying drawings, where:
The spray gun 1 comprises an air heater 14, a Laval nozzle 6 and an outlet variable cross-section nozzle 7. Each of the feeders 2 is connected alternately using a tee 12 via the pipes 5 to the outlet nozzle 7.
Furthermore, in one embodiment, a dust and gas ejection valve 8 can be mounted on the outlet nozzle 7, in which the ejecting jet is the jet of sprayed powder per se.
As also shown in
The apparatus further comprises a control stand with power supplies and industrial PC (not shown in
A method according to the present invention is performed as follows.
As explained above, the gas dynamic cold spray technique used in the method involves heating a compressed gas (air), supplying it into a supersonic nozzle and forming a supersonic flow therein, and supplying a powder material into the flow, increasing the speed of the material by the supersonic flow and directing it through an outlet variable cross section nozzle onto the workpiece surface.
The process of applying bus bars is carried out using LDesigner software product (ATEKO Company), to which a delay function is added to take into account the delayed response of the equipment and to adapt it to the process.
LDesigner 5.0 software product consists of two parts:
(a) Graphic editor (LDesigner 5.0 Graphic Editor), which provides wide opportunities for creating, editing and processing images. Its main features include a modern, easy to use graphical interface (including detailed menus, toolbars, hotkeys, image editing using the mouse) and the ability to work with vector and raster graphics created using popular graphics editors (such as CorelDraw or AutoCAD); and
(b) Marker (LDesigner 5.0 Marking Program), which controls the three-axis table and process equipment.
The marker implements the algorithm of applying bus bars onto the glass, created in the LDesigner.
The process is carried out in the following sequence:
Operator starts the “Marker” program at the control stand, thereby providing implementation of the specified project and carrying out the process of applying bus bars.
With that, a spraying nozzle of the spray gun 1 is moved to beginning point B of the bus bar 11 without supplying the sprayed powder therein, and upon positioning the moved nozzle at the beginning point B of the bus bars 11 the sprayed powder is admitted into the nozzle, and the spraying nozzle is moved with a constant speed from the beginning point B towards end point D of the bus bar (see
The process of applying bus bars can be either single-stage or multi-stage, where an underlayer is pre-applied of a powder exhibiting better “wettability” to the glass to increase the adhesion of the bus bar to the low-emissivity surface of the glass.
The gas dynamic cold spray process is carried out using powders with a fraction of 5 to 50 μm; it is generally a mixture of powders of several components, one of which exhibits a better “wettability” to the surface, and the other exhibits adhesion and cohesion. This combination of powders is typical for the underlayer, while the second and subsequent layers generally consist of components that enhance the electrical and process properties. For example, a mixture of copper and zinc (or pure copper) reduces the electrical resistance and simplifies the process of soldering current-carrying wires. Using the above combination of compositions of powders and alternating the layers a bus bar can be produced that is capable of conducting high currents without temperature gradient between the bus bar and the electrically heated surface.
Bulk weight of the powder, formed in the cut-off part of the feed pipes, is calculated using known formulas and adjusted at experimental weighing and experimental sputtering of these bulk volumes on a sample of the bulk weight at the process parameters accepted in the process:
with determining the length of the applied area of the bus bar, its cross section and geometry.
Owing to the properly chosen exposure time (τ=d/v(sec), where d is the diameter of the spraying nozzle, v is the speed of its movement relative to the low-emissivity surface) and the powder flow rate, a bus bar is formed that has an equal cross-section throughout its length, including the beginning of the bus bar and its end.
The use of an air dynamic dust and gas ejection valve 8, in which, as mentioned, the ejecting jet is the working spraying jet, and which is mounted coaxially on the spraying nozzle 7, enables the process to be implemented without a special aspiration chambers, therefore the method and the equipment developed on its basis can be integrated in the existing process of manufacturing electrically heated glass to replace low efficient and costly processes and construct fully automated lines.
To carry out the present method, the described above apparatus was used with “DIMET” gas dynamic spraying system (Model 423) supplied from the aforementioned Obninsk Center for Powder Spraying, which was supplemented with required additions relating to installation of additional air valves and the air dynamic dust and gas ejection valve.
An example will be described for a two-stage method of applying bus bars, wherein:
Process engineer creates in the LDesigner graphic editor a graphic file of the project with applied electrically conductive bus bars and specifies process parameters for each object:
Next, the process engineer generates the algorithm for applying bus bars, determines the processing sequence and imports the generated project in LDesigner “Marker” program.
The apparatus operator performs the following actions:
Further, the process of applying bus bars runs automatically on the specified algorithm and the predetermined parameters.
A solenoid valve (not shown) of the gas dynamic spraying apparatus opens, and compressed air enters the spray gun 1 and is heated there through the Laval nozzle 6 and increases its speed, and flows to the variable cross section nozzle 7 and further to the air dynamic dust and gas ejection valve 8 (
At the same time the air valve 3 opens and connects the first feeder 2 with the feed pipe 5 (
Next, the compressed air supply is shut off by closing a solenoid valve included in the system. With this, powder supply into the nozzle does not occur, and the nozzle moves from zero aspiration point A (
Then, the second stage, application of Cu+Zn powder composition, is carried out. Here, the spraying nozzle 7 is moved at idling speed to the zero aspiration point A (buil-in solenoid valve is closed). At the zero aspiration point A the solenoid valve opens, the air valve 3 closes and the air valve 4 opens. Thereby the second feeder 2 is operated, and the feed pipe and the spray gun are blown off from the Al+Zn powder and filled with Cu+Zn powder.
The process proceeds for 1.5-2 seconds. The spraying nozzle 7 is then moved from the point A to the point B according to the same algorithm as during the application of the bus bar underlayer, and the main layer of Cu+Zn powder is applied. The process parameters are the same, except that the temperature of the spraying jet is set in the range of from 240 to 400° C.
At that the process of forming a conductive bus bar on the low-emissivity glass surface is completed.
As will be apparent to persons skilled in the art based on the described invention, many changes and modifications may be made in the above-described and other embodiments of the present invention, not going beyond its scope defined in the appended claims.
For example, the provision of the estimated bulk weight of the powder, sufficient for applying the powder over the entire length of the bus bar, is not obligatory carried out by cutting off a part of the pipe upon reaching a specified point of the bus bar, but can also be calculated before moving the nozzle along the entire bus bar length.
Furthermore, although reference was made to some types of powders and their mixtures, it should be clear to those skilled in the art that other types of powders can be also used. Therefore, the above detailed description of a preferred embodiment should be taken as illustrative and not restrictive.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2014138799 | Sep 2014 | RU | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/RU2015/000530 | 8/21/2015 | WO | 00 |
