基于电场辅助垂直喷射临界接触大尺寸非平整透明电加热玻璃增减材复合制造研究

doi:10.3901/JME.2600256

摘要/Abstract

摘要： 具有除冰、除雾、除霜功能的大尺寸透明玻璃加热器(TGHs)广泛应用于挡风玻璃、玻璃幕墙、展示冷柜等领域。然而，现有技术在大尺寸、非平整玻璃基底上制造高性能TGHs存在均匀一致性差、效率低、成本高等问题，制约了其广泛工业化应用。针对这些挑战性难题，提出一种结合电场辅助垂直喷射临界接触打印、湿法刻蚀和电镀的增减材复合制造新工艺。通过调控泰勒锥的锥形，结合提出的垂直熔融喷射临界接触打印模式，增大打印高度(最大打印高度0.7 mm)，在平整度误差超过0.28 mm的基材上实现了均匀一致聚己内酯(PCL)掩模的打印，所使用的低成本热熔融PCL打印材料，解决了长时间打印喷头易堵塞的难题。随后，利用湿法刻蚀(减材体成形)和电镀(增材体成形)，实现金属网栅高效低成本制造。结合优化的工艺参数制造的大尺寸TGHs(300 mm×300 mm)线宽变化小于1.5 μm，线阻变化小于0.3 Ω，在95.73%的透光率下线阻仅为0.39 Ω/mm，并具有均匀的电加热性能。经刮擦、附着力和超声测试后电阻变化率小于0.7%，经酸碱腐蚀测试后电阻变化率小于5%，72 h高温高湿测试后电阻变化率小于16.8%。提出的方法为低成本、高效、批量化生产具有高透光、高导电性的大尺寸TGHs提供了一种具有良好工业化应用前景的解决方案。

关键词: 电场辅助垂直喷射, 临界接触打印, 大尺寸透明电加热玻璃, 复合制造, 增减材制造

Abstract: Large-size transparent glass heaters (TGHs) with de-icing, de-fogging, and de-frosting functions are widely used in windshields, glass curtain walls, and display coolers. However, existing technologies for fabricating high-performance TGHs on large-size, non-flat glass substrates suffer from poor uniform consistency, low efficiency, and high cost, which constrain their widespread industrialized applications. To address these challenges, a novel additive and subtractive composite fabrication process combining electric field-assisted vertical jet critical contact printing, wet etching and electroplating is proposed. By regulating the taper of the Taylor cone and combining the proposed vertical melt-jet critical contact printing mode, the printing height is increased (maximum printing height of 0.7 mm), and uniform and consistent polycaprolactone (PCL) mask printing is this method has been demonstrated to be effective even when the substrate exhibits a flatness error of more than 0.28 mm, and the utilisation of a low-cost hot-melt PCL printing material serves to address the issue of nozzle clogging that can occur over extended periods. Subsequent to this, the combination of wet etching (a subtractive process) and plating (an additive process) has been shown to facilitate the efficient and cost-effective fabrication of metal grids. Large-size TGHs (300 mm×300 mm) fabricated in combination with optimised process parameters exhibit a line width variation of less than 1.5 μm, a line resistance variation of less than 0.3 Ω, and a line resistance of only 0.39 Ω/mm at 95.73% transmittance, and demonstrate uniform electrical heating performance. The resistance change was found to be less than 0.7% after scratch, adhesion and ultrasonic tests, less than 5% after acid and alkali corrosion tests, and less than 16.8% after 72 h high temperature and high humidity tests. The proposed method provides a solution with good prospects for industrialised applications for the low-cost, high-efficiency, and batch production of large-size TGHs with high transmittance and high conductivity.

Key words: electric field assisted vertical injection, critical contact printing, large size transparent electrically heated glass, composite manufacturing, additive and reduced material manufacturing

中图分类号:

TG156

张兵, 张厚超, 孙铭泽, 李红珂, 朱晓阳, 许权, 赵佳伟, 兰红波. 基于电场辅助垂直喷射临界接触大尺寸非平整透明电加热玻璃增减材复合制造研究[J]. 机械工程学报, 2026, 62(5): 419-433.

ZHANG Bing, ZHANG Houchao, SUN Mingze, LI Hongke, ZHU Xiaoyang, XU Quan, ZHAO Jiawei, LAN Hongbo. Study of Additive and Subtractive Composite Manufacturing of Large-size Non-flat Transparent Electrically Heated Glass Based on Electric Field-assisted Vertical Jet with Critical Contacting[J]. Journal of Mechanical Engineering, 2026, 62(5): 419-433.

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链接本文: http://www.cjmenet.com.cn/CN/10.3901/JME.2600256

http://www.cjmenet.com.cn/CN/Y2026/V62/I5/419

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