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

doi:10.3901/JME.2600256

Abstract

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

CLC Number:

TG156

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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URL: http://www.cjmenet.com.cn/EN/10.3901/JME.2600256

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

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