Apparatus for removing particles on the glass edge of a display

Abstract

Provided herein is a cleaning wheel for removing particulates from a substrate and a method for manufacturing the same. The cleaning wheel includes a composition comprising a first volume of a plurality of abrasive particles and a second volume of a polymeric matrix, the plurality of abrasive particles being suspended in the polymeric matrix. The composition is formed to have pores. The first volume is at least 20% but less than 35% of the total volume of the cleaning wheel. The second volume is at least 20% of the total volume of the cleaning wheel. The pores are at least 35% of the total volume of the cleaning wheel.

Description

Description of Related Applications

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 63 / 416,995, filed October 18, 2022, the contents of which are relied upon and incorporated herein by reference in its entirety. [Technical Field]

[0002] FIELD OF THE INVENTION Embodiments of the present invention relate generally to cleaning devices for glass substrates, and more particularly to cleaning wheel compositions configured to effectively remove particulates from glass substrates. [Background technology]

[0003] Glass sheets for displays are often finished by polishing and grinding the glass sheets to achieve the required shape and bending strength. However, grinding and polishing the edges of a substrate (e.g., a glass sheet) can result in glass particles that migrate from the edge of the glass substrate to a major surface (e.g., a display surface). The glass particles can cause defects in display quality, such as missing pixels. Summary of the Invention

[0004] Embodiments of the present disclosure relate to edge cleaning wheel compositions that remove and / or retain glass particulates from edges formed on glass substrates to prevent adverse effects on the glass substrate due to particle migration (e.g., pixel loss from fusion between particles and a major surface of the substrate).

[0005] The compositions of the present invention can remove a higher percentage of glass particles while reducing the heat generated by friction between the edge cleaning wheel and the glass substrate. This reduces the temperature of the glass particles and prevents bonding between the glass particles and the main surface of the substrate. The compositions of the present invention also provide an increased service life (e.g., increased number of uses) of the cleaning wheel. In this regard, some embodiments of the present invention utilize a composition formed of a plurality of abrasive particles, each within a determined particle size range, suspended in a polymer matrix having pores introduced therein. The composition is molded into a cleaning wheel that is used to rub against a substrate to remove glass particles. Furthermore, in some embodiments, the polymer matrix provides compliance within the edge cleaning wheel. In this regard, the polymer matrix can retain a portion of the glass particles on the edge cleaning wheel (thereby preventing the glass particles from migrating to the main (e.g., display) surface). In particular, the pores within the edge cleaning wheel provide structural compliance for the edge cleaning wheel to remove and retain glass particles from the glass substrate.

[0006] In an exemplary embodiment, a cleaning wheel is provided. The cleaning wheel is formed from a composition including a first volume of a plurality of abrasive particles and a second volume of a polymeric matrix. The plurality of abrasive particles are suspended in the polymeric matrix. The composition further comprises pores. The first volume of abrasive particles is at least 20% but less than 35% of the total volume of the cleaning wheel. The second volume is at least 20% of the total volume of the cleaning wheel, and the pores are at least 35% of the total volume of the cleaning wheel.

[0007] In some embodiments, the plurality of abrasive particles may be silicon carbide. In some embodiments, each of the plurality of abrasive particles has a particle size between 20 and 50 micrometers. In some embodiments, the particle size of each of the plurality of abrasive particles may be between 30 and 40 micrometers. In some embodiments, the first volume of abrasive particles may be between 20% and 30% of the total volume of the cleaning wheel. In some embodiments, the first volume of abrasive particles may be between 20% and 25% of the total volume of the cleaning wheel.

[0008] In some embodiments, the second volume of the polymer matrix can be between 20% and 35% of the total volume of the cleaning wheel. In some embodiments, the second volume of the polymer matrix can be between 25% and 30% of the total volume of the cleaning wheel. In some embodiments, the polymer matrix can be polyurethane.

[0009] In some embodiments, the pores may be between 35% and 55% of the total volume of the cleaning wheel. In some embodiments, the pores may be between 45% and 55% of the total volume of the cleaning wheel. In some embodiments, the cleaning wheel may have a Shore D hardness of between 40 and 55. In some embodiments, the cleaning wheel may be configured to remove at least 75% of substrate particles from a glass substrate.

[0010] In some embodiments, the plurality of abrasive particles may be coated with a coupling agent, hi some embodiments, the coupling agent may be a metallic coating.

[0011] In another exemplary embodiment, a method for removing particles from a substrate is provided. The method includes providing a cleaning wheel defining a cleaning wheel composition. The cleaning wheel composition includes a first volume of a plurality of abrasive particles and a second volume of a polymeric matrix. The plurality of abrasive particles are suspended in the polymeric matrix. The composition further includes pores. The first volume of the abrasive particles is at least 20% but less than 35% of the total volume of the cleaning wheel. The second volume is at least 20% of the total volume of the cleaning wheel, and the pores are at least 35% of the total volume of the cleaning wheel. The method further includes applying a cooling fluid to the interface between the cleaning wheel and the substrate. The method further includes rotating the cleaning wheel to remove substrate particles from the interface between the cleaning wheel and the substrate. The removed substrate particles are at least partially removed by the cooling fluid.

[0012] In some embodiments, the plurality of abrasive particles may be silicon carbide. In some embodiments, the polymer matrix may be polyurethane. In some embodiments, the composition may further comprise a coupling agent applied to the plurality of abrasive particles. In some embodiments, the substrate may be glass.

[0013] In yet another embodiment, a process for forming a cleaning wheel is provided. The process includes combining a first volume of a plurality of abrasive particles in a second volume of a polymer matrix and a third volume of a pore inducer into a mixture. The process further includes placing the mixture in a mold and heating the mixture in the mold to form the cleaning wheel. The mold is heated to a temperature such that the pore inducer sublimes, creating pores in the cleaning wheel.

[0014] In some embodiments, the first volume of the plurality of abrasive particles is at least 20% but less than 35% of the total volume of the cleaning wheel. In some embodiments, the second volume is at least 20% of the total volume of the cleaning wheel. In some embodiments, the pores are at least 35% of the total volume of the cleaning wheel. In some embodiments, the process further comprises coating the plurality of abrasive particles with a coupling agent. [Brief explanation of the drawings]

[0015] Having now described the invention in general terms, reference will now be made to the accompanying drawings, which are not drawn to scale. [Figure 1A] 1 is a cross-sectional view of an exemplary cleaning wheel according to some embodiments described herein. [Figure 1B] 1 is a cross-sectional view of an exemplary cleaning wheel and glass substrate according to some embodiments described herein. [Figure 1C] 1 is a cross-sectional view of an exemplary glass substrate being shaped and polished with an exemplary cleaning wheel according to some embodiments described herein; [Figure 2A] 1 is a cross-sectional view of an exemplary glass substrate having a defect, according to some embodiments described herein. [Figure 2B] FIG. 2B is a top view of the example glass substrate shown in FIG. 2A, according to certain embodiments described herein. [Figure 3] 1 illustrates an exemplary composition of a cleaning wheel according to some embodiments described herein. [Figure 4A] FIG. 1 illustrates an example edge cleaning wheel according to certain embodiments described herein. [Figure 4B] 1 illustrates groove degradation due to thermal degradation, according to certain embodiments described herein. [Figure 4C] FIG. 1 illustrates an example groove of a cleaning wheel without thermal degradation, according to some embodiments described herein. [Figure 4D]1 illustrates an example groove of a cleaning wheel exhibiting thermal degradation, according to some embodiments described herein. [Figure 5A] 1 illustrates the degradation of grooves in an exemplary cleaning wheel over the life of the exemplary cleaning wheel, according to certain embodiments described herein. [Figure 5B] 1 illustrates the degradation of grooves in an exemplary cleaning wheel over the life of the exemplary cleaning wheel, according to certain embodiments described herein. [Figure 5C] 1 illustrates the degradation of grooves in an exemplary cleaning wheel over the life of the exemplary cleaning wheel, according to certain embodiments described herein. [Figure 6A] 1 illustrates the degradation of grooves in an exemplary cleaning wheel over the life of the exemplary cleaning wheel, according to certain embodiments described herein. [Figure 6B] 1 illustrates the degradation of grooves in an exemplary cleaning wheel over the life of the exemplary cleaning wheel, according to certain embodiments described herein. [Figure 7A] 1 is a cross-sectional view of a cleaning wheel groove showing structural densification of the groove according to some embodiments described herein; [Figure 7B] FIG. 7B is a top view of the grooves of the example cleaning wheel shown in FIG. 7A, according to certain embodiments described herein. [Figure 8] 1 is a flow diagram of an exemplary method for using a cleaning wheel according to some embodiments described herein. [Figure 9] 1 is a flow diagram of an exemplary method for forming a cleaning wheel according to some embodiments described herein. [Figure 10] 1 is a graph showing the thermal diffusivity of two exemplary compositions according to some embodiments described herein. DETAILED DESCRIPTION OF THE INVENTION

[0016] Some exemplary embodiments are described more fully herein with reference to the accompanying drawings, in which some, but not all, exemplary embodiments are shown. Indeed, the examples described and illustrated herein should not be construed as limiting the scope, applicability, or configuration of the present disclosure. Rather, these exemplary embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like reference numerals refer to like elements throughout.

[0017] Glass substrates that may be used to form laminates typically have edge surfaces that are substantially perpendicular to the major surfaces. Because glass substrates are cut from larger sheets, the edge surfaces may contain micrometer-scale flaws, such as subsurface microcracks. When the glass substrate is subjected to stress, the cracks may further propagate and cause the glass substrate to break. In addition, the edges form sharp corners that can easily chip, forming glass splinters that contaminate the surface. To reduce breakage and / or chipping, the edge surfaces are usually finished using an edge finishing process to achieve a desired contour and smoothness. In addition, the edge finishing process can remove flaws from the edge surfaces and contour the corners.

[0018] The edge finishing process may utilize multiple wheels, including grinding wheels and edge cleaning wheels configured to shape and polish the glass substrate.

[0019] 1A-C generally illustrate a process for edge finishing a glass substrate using an edge cleaning wheel according to various exemplary embodiments of the present disclosure. As used herein, edge cleaning can include one or both of grinding and polishing.

[0020] 1A shows a cross-sectional view of an exemplary edge cleaning wheel 120 made of the matrix structure described herein. The edge cleaning wheel 120 may have preformed grooves that rotate around a spindle 110.

[0021] In some embodiments, the pre-finished glass substrate 130 may define a first major surface 133 a and a second major surface 133 b opposite the first major surface 133 a. A first pre-finished edge 132 and a second pre-finished edge 134 may connect the first major surface 133 a to the second major surface 133 b.

[0022] In some embodiments, the pre-finished glass substrate 130 may undergo multiple edge finishing operations, including shaping, scratch reduction, and edge cleaning operations. The shaping operations may contour the corners formed at each of the intersections of the first pre-finished edge 132 and the second pre-finished edge 134 with the first major surface 133 a and the second major surface 133 b, respectively. In this regard, grinding forces may remove glass substrate at each of the corners, thereby rounding the corners.

[0023] The scratch reduction operation can reduce the number of scratches created by the forming wheel. The scratch reduction operation can further provide a basic polish to the first prefinished edge 132 and the second prefinished edge 134, thereby reducing surface roughness. After each of these processes, there will still be substrate particles on the first prefinished edge 132 and the second prefinished edge 134.

[0024] During edge cleaning, one of the first pre-finished edge 132 and the second pre-finished edge 134 is positioned within the groove 121 of the edge cleaning wheel 120 and contacts the edge cleaning wheel 120 as the edge cleaning wheel 120 rotates about the spindle 110.

[0025] During edge finishing, the first pre-finished edge 132 and the second pre-finished edge 134 are contoured by the edge cleaning wheel 120. In this regard, the grooves 121 of the edge cleaning wheel 120 move along the length of the pre-finished edge 132. During edge cleaning, a force may be applied by the edge cleaning wheel 120 to the pre-finished glass substrate 130. In this regard, the force may remove any substrate particles on the first pre-finished edge 132 and the second pre-finished edge 134, thereby polishing the first pre-finished edge 132 and the second pre-finished edge 134 into a first finished edge 132a and a second finished edge 134a, respectively (as shown in FIG. 1C ). In this manner, the finished glass substrate 130a can define a first finished edge 132a and a second finished edge 134a that are contoured relative to the first major surface 133a and the second major surface 133b, as shown in Figure 1C. Although shown with one edge cleaning wheel 120, in some embodiments, two edge cleaning wheels can be used to simultaneously finish each of the first pre-finished edge 132 and the second pre-finished edge 134.

[0026] During edge cleaning, friction between the edge cleaning wheel 120 and the pre-finished glass substrate 130 removes a portion of the stray glass material from the first pre-finished edge 132 and / or the second pre-finished edge 134. In one or more embodiments, the edge cleaning wheel 120 and the portion of the glass substrate that is subjected to edge cleaning may be cooled by a fluid during edge finishing. In some embodiments, the cooling fluid may be a liquid, such as water. In some embodiments, particles removed from the pre-finished glass substrate 130 may be carried out of the system 100 by the cooling fluid.

[0027] However, in some embodiments, some glass particles generated during the edge cleaning process may be released by the edge cleaning wheel and not removed by the coolant. In this regard, as shown in Figures 2A-B, glass particles 135 may migrate to and adhere to the first major surface 133a or the second major surface 133b of the finished glass substrate 130a. These troublesome glass particles may adversely affect display quality by removing or blocking one or more pixels on the finished glass substrate 130a.

[0028] To explain, the troublesome glass particles may migrate through microcracks, scratches, or the like extending from the first prefinished edge 132 and adhere to the first major surface after being dislodged from the first prefinished edge 132. Additionally, in some embodiments, friction between the edge cleaning wheel 120 and the first prefinished edge 132 or the second prefinished edge 134 generates heat. This heat may cause the glass particles removed from the first prefinished edge 132 or the second prefinished edge 134 to heat up and / or remain hot. In this regard, if one of the glass particles migrates to either the first major surface 133 a or the second major surface 133 b as the glass particle cools, the glass particle may adhere to the respective major surface, thereby causing one or more pixels to cease functioning.

[0029] As described with respect to various embodiments of the present invention, the composition of the edge cleaning wheel 120 can be modified to reduce the amount of glass particles that are removed from the pre-finished glass substrate 130 and remain on the edge cleaning wheel 120 or are not flushed out of the edge cleaning wheel system 100 by the coolant.

[0030] An exemplary embodiment of the present invention provides an edge cleaning wheel for use in edge finishing of glass substrates, comprising a bonded matrix structure with abrasive particles within the matrix structure. References to abrasive particles "within" the matrix structure refer to abrasive particles that are chemically bonded to and / or at least partially mechanically encapsulated within the matrix structure of the edge cleaning wheel. Figure 3 shows the composition of an exemplary edge cleaning wheel 120. The composition of the edge cleaning wheel 120 includes a plurality of abrasive particles 123 suspended within a matrix 125, defining pores 127.

[0031] The composition of the edge cleaning wheel 120 may include a first volume of a plurality of abrasive particles 123, a second volume of matrix 125, and pores 127. In some embodiments, the composition of the edge cleaning wheel 120 defines the entire volume of the cleaning wheel, with at least 20% but less than 35% of the entire volume of the cleaning wheel consisting of a plurality of abrasive particles, at least 20% of the entire volume of the cleaning wheel consisting of matrix, and at least 35% of the entire volume of the cleaning wheel being pores.

[0032] In some embodiments, the plurality of abrasive particles 123 can have a hardness equal to or greater than the hardness of the glass substrate. In some embodiments, the plurality of abrasive particles 123 can be configured to remove glass particles from the glass substrate without redepositing the glass particles to the glass substrate. In some embodiments, the plurality of abrasive particles 123 can be silicon carbide (SiC), alumina (Al2O3), cubic boron nitride (CBN), and / or combinations thereof. In a preferred embodiment, the plurality of abrasive particles 123 can be SiC.

[0033] In some embodiments, the plurality of abrasive particles 123 may be specified in terms of particle size (and distribution). In some embodiments, the plurality of abrasive particles 123 may specify a particle size between 10 and 60 micrometers, between 20 and 50 micrometers, or between 30 and 40 micrometers. In some embodiments, the plurality of abrasive particles 123 may be less than 200 mesh, less than 300 mesh, less than 400 mesh, less than 500 mesh, or even less than 600 mesh. In some embodiments, the plurality of abrasive particles 123 may be between 400 and 600 mesh.

[0034] In some embodiments, the plurality of abrasive particles 123 may contribute to and / or control the lifespan of the edge cleaning wheel 120. In this regard, increasing the amount of abrasive particles may increase the lifespan of the edge cleaning wheel 120 by reducing the workload per individual particle. However, increasing the first volume (e.g., the volume of the plurality of abrasive particles 123) may increase the heat generated by the edge cleaning wheel 120 during cleaning. Therefore, the first volume may need to be balanced between sufficient lifespan of the edge cleaning wheel 120 and the heat generated during edge cleaning.

[0035] In some embodiments, the first volume may be at least 20% of the total volume of the edge cleaning wheel, at least 25% of the total volume of the edge cleaning wheel, or even at least 30% of the total volume of the edge cleaning wheel. In some embodiments, the first volume may be between 20% and 30% of the total volume of the edge cleaning wheel, more preferably between 20% and 25% of the total volume of the edge cleaning wheel. In some embodiments, the first volume may be increased by decreasing the mesh size of the plurality of abrasive particles 123.

[0036] In some embodiments, the matrix 125 can be configured to bond the plurality of abrasive particles 123 together. In some embodiments, the matrix 125 can provide inherent material compliance to the edge cleaning wheel 120. In some embodiments, the matrix 125 can be configured to retain glass particles that are removed from the glass substrate during edge cleaning.

[0037] In some embodiments, matrix 125 can be a polymer matrix, hi some embodiments, matrix 125 can include polyurethane or other polymers that can provide compliance properties similar to polyurethane.

[0038] In some embodiments, matrix 125 may be selected for thermal stability characteristics. In this regard, matrix 125 may maintain its structure when exposed to high heat (e.g., due to friction between an edge cleaning wheel and a glass substrate). In some embodiments, matrix 125 may exhibit high thermal diffusivity. Thermal diffusivity is a heat transfer property related to the efficiency of a substrate (e.g., matrix 125) to transfer heat to the surroundings (e.g., air). Therefore, matrix 125 may be selected to have an acceptable thermal diffusivity over a wide temperature range, or particularly for operating temperatures.

[0039] In some embodiments, the second volume (e.g., the volume of matrix 125) may be at least 20% of the total volume of the edge cleaning wheel, at least 25% of the total volume of the edge cleaning wheel, or even at least 30% of the total volume of the edge cleaning wheel. In some embodiments, the second volume may be between 20% and 35% of the total volume of the edge cleaning wheel, and more preferably between 25% and 30% of the total volume of the edge cleaning wheel.

[0040] In some embodiments, the compliance of the matrix 125 may be modified to have a range of durometers. In this regard, the composition of the matrix 125 may provide bonding properties between the glass particles and the edge cleaning wheel 120.

[0041] In some embodiments, the pores 127 may contribute to the structural compliance of the edge cleaning wheel 120. In some embodiments, the pores 127 of the edge cleaning wheel 120 may contribute to heat dissipation during edge cleaning. In this regard, heat generated by friction between the edge cleaning wheel 120 and the first prefinished edge (e.g., 132 in FIG. 1B ) may be dissipated through the pores of the edge cleaning wheel 120, thereby reducing the temperature of the glass particles removed from the first prefinished edge. Explaining, in an edge cleaning process in which a coolant is applied to the interface between the first prefinished edge 132 and the edge cleaning wheel 120, a portion of the coolant may flow through the pores 127 of the edge cleaning wheel 120 and, therefore, dissipate heat from within the edge cleaning wheel 120, as described with reference to FIGS. 4A-D .

[0042] In embodiments, the combination of structural compliance provided by the pores 127 and material compliance provided by the matrix 125 creates localized product compliance within the edge cleaning wheel 120 at the interface between the edge cleaning wheel and the glass substrate (see, e.g., FIG. 1C). Additionally, the combination of structural and material compliance may define the hardness of the edge cleaning wheel 120. In some embodiments, the edge cleaning wheel 120 may define a hardness defined on the Shore D scale between 40 and 50.

[0043] In some embodiments, the pores 127 of the edge cleaning wheel 120 may be at least 35% of the total volume of the edge cleaning wheel, at least 40% of the total volume of the edge cleaning wheel, at least 45% of the total volume of the edge cleaning wheel, or even at least 50% of the total volume of the edge cleaning wheel. In some embodiments, the pores 127 may be 35%-55% of the total volume of the edge cleaning wheel, or more preferably 45%-55% of the total volume of the edge cleaning wheel.

[0044] In some embodiments, the composition of the edge cleaning wheel 120 may further include a coupling agent. In some embodiments, the coupling agent may be applied to the plurality of abrasive particles 123 before mixing with the matrix 125. In this regard, the coupling agent may be configured to improve bonding between the matrix 125 and the plurality of abrasive particles 123. In some embodiments, the coupling agent may be a silane or similar compound. In this regard, when the surface of the edge cleaning wheel 120 deteriorates, the plurality of abrasive particles 123 remain attached to the matrix 125, and therefore, the plurality of abrasive particles do not bond with the glass substrate. In some embodiments, the coupling agent may contribute to a favorable removal mechanism for reducing adhered glass particles by minimizing the generation of new glass debris from the glass substrate. In some embodiments, the coupling agent may be a metal coating. In this regard, the metal coating may create a rough surface on the plurality of abrasive particles 123, thereby allowing the matrix 125 to form a mechanical bond therewith.

[0045] In some embodiments, the pores 127 in the edge cleaning wheel composition are created by a pore initiating agent that can be configured to expand or sublime during heating and / or compression, thereby creating pores in the molded edge cleaning wheel 120. [Example]

[0046] 4B-7B show images of edge cleaning wheels with different compositions as the length of the glass substrate exposed to the edge cleaning wheel increases at different times during the wheel's life. Table 1 shows four example edge cleaning wheel compositions described herein. Specifically, the compositions are defined as ranges of volume percentages of the total volume of the cleaning wheel. Each composition tested for the description below falls within a volume range for each of the abrasive particles (1% by volume), matrix (2% by volume), and pores (pores).

[0047] [Table 1]

[0048] The compositions in Table 1 were tested for particle removal along a glass substrate to compare the edge-cleaning wheel's lifespan and the amount of glass particles removed by the edge-cleaning wheel. In this regard, the edge-cleaning wheel's lifespan was determined based on the depth of the groove (e.g., 121 in Figure 1B) created by contacting the edge-cleaning wheel with the glass substrate. Specifically, a relative rating (e.g., excellent, good, fair, poor, and ineffective) was given based on performance during testing, and the corresponding relative numerical value was determined accordingly. Additionally, an indication of the resulting bond type, as being compatible or incompatible with retaining the removed particles, is provided for each composition.

[0049] Each of compositions A through D utilized SiC as the abrasive particles. Composition A utilized a polyurethane matrix, while composition B utilized a different matrix. Compositions A and B utilized a coupling agent, while compositions C and D did not include a coupling agent. As shown in Figure 10, composition A exhibited a stable emissivity over a wide range of operating temperatures, while the emissivity of composition B increased with increasing operating temperature.

[0050] Compositions A and B were found to have relatively excellent overall performance. Composition A exhibited good wheel life while removing the greatest amount of glass particles from the glass substrate. Composition B removed a sufficient amount of glass particles and exhibited good wheel life. Composition C did not remove an adequate amount of glass particles from the glass substrate. Therefore, composition C exhibited the greatest life, but inadequate performance. Composition D, when tested, generated excessive amounts of heat and therefore did not produce reliable results (e.g., excessive heat would actually increase the number of removed particles deposited on the display).

[0051] Compositions A and B each included a coupling agent to increase the compliance of the edge cleaning wheel. Without being bound by theory in this regard, it is believed that the use of a coupling agent in the edge cleaning wheel composition increases the amount of glass particles removed from the glass substrate during the cleaning process. The performance of Compositions A and B is shown in Figures 4A-7B, as described below.

[0052] 4A-D illustrate thermal degradation of an edge cleaning wheel 720. FIG. 4A illustrates an edge cleaning wheel 720 with a groove 721 for receiving a pre-finished edge of a glass substrate (e.g., the first pre-finished edge 132 of FIG. 1B). FIG. 4B illustrates thermal degradation of the edge cleaning wheel 720 within the groove 721. As shown, the composition of the edge cleaning wheel 720 within the groove 721 has deteriorated compared to the portion of the edge cleaning wheel 720 outside the groove 721. To further illustrate, FIG. 4C illustrates the edge cleaning wheel 720 and groove 721 without thermal degradation, while FIG. 4D illustrates the edge cleaning wheel 720 and groove 721 with thermal degradation. In this regard, with proper thermal control, a plurality of abrasive particles 723 are uniformly distributed throughout the matrix 725 within and outside the groove 721, as shown in FIG. 4C. In contrast, the edge cleaning wheel 720 without thermal control, shown in Figure 4D, is degraded within the grooves 721, as indicated by the change in the distribution of the abrasive particles 723 within the grooves 721 and throughout the matrix 725 outside the grooves 721. Therefore, without thermal control, the edge cleaning wheel 720 would be exposed to high heat during the finishing process, which would result in the loss of the abrasive particles 723 and a shortened lifespan of the edge cleaning wheel 720.

[0053] 5A-5C show scanning electron microscope (SEM) images of an exemplary edge cleaning wheel 220 having composition B, which includes SiC 233 (abrasive particles) and a matrix 225, but no coupling agent. The length of the edge of the glass substrate engaged with the grooves 221 of the edge cleaning wheel 220 increased from 50 meters (FIG. 5A) to 200 meters (FIG. 5C). FIG. 5A shows the edge cleaning wheel 220 defining grooves 221 that are 50 micrometers deep. As the edge length of the glass substrate being processed increased, the groove depth increased and the number of abrasive particles 223 within the grooves 221 decreased. For example, the groove 221 shown in FIG. 5B is 115 micrometers deep, and the groove 221 shown in FIG. 5C is 478 micrometers deep. Therefore, as the length of the glass substrate being processed increased, the grooves of the edge cleaning wheel 220 became deeper and retained fewer abrasive particles 223.

[0054] 6A-B show SEM images of an example edge cleaning wheel 320 having composition A including SiC 323 and a polyurethane matrix 325, along with a coupling agent, as the length of the glass substrate engaged with the grooves 321 of the edge cleaning wheel 320 increases from 52 meters to 200 meters. FIG. 6A shows the surface of the edge cleaning wheel 320 after 50 meters of contact with the glass substrate, while FIG. 6B shows the surface of the edge cleaning wheel 320 after 200 meters of contact with the glass substrate.

[0055] Comparing composition A (FIG. 6B) with composition B (without coupling agent) (FIG. 5C) after 200 meters of cleaning, it can be seen that the edge cleaning wheel 320 with composition A retains more SiC within the cleaning wheel than the edge cleaning wheel 320 with composition B. In this regard, it can be determined that the use of a coupling agent contributes to the retention of multiple abrasive particles within the grooves of the edge cleaning wheel.

[0056] 7A-B show XRT images of the combined effects of matrix compliance, pores, and contact pressure between the edge cleaning wheel 420 and the glass substrate. As shown, the edge cleaning wheel 420 includes two distinct grooves, a first groove 413 and a second groove 415, separated by a non-grooved surface 417 between them. Each of the first groove 413 and the second groove 415 exhibits structural densification at the bottom of the groove. In this regard, as the edge cleaning wheel 420 continues to operate, the particle density of abrasive particles (e.g., SiC particles) within the grooves of the edge cleaning wheel 420 will increase. The structural densification within the first groove 413 and the second groove 415 can be seen in FIG. 7B. As shown, the edge cleaning wheel 420 includes a plurality of abrasive particles 423 and a matrix 425. In each of the first grooves 413 and the second grooves 415, the density of the plurality of abrasive particles 423 is higher and the density of the matrix 425 is lower when compared to the non-grooved surface 417. Therefore, the concentration of the plurality of abrasive particles decreases as the edge cleaning wheel is exposed to a longer length of the glass substrate.

[0057] Example Flowchart FIG. 8 is a flow diagram illustrating an example method 500 for removing particles from a glass substrate according to some embodiments described herein. In operation 510, a substrate, such as a glass substrate, is provided. In operation 520, an edge cleaning wheel is provided. In some embodiments, the edge cleaning wheel can be formed using one of the compositions described above. In operation 530, a coolant can be applied to the interface between the substrate and the cleaning wheel during operation. In some embodiments, the coolant can be water or another liquid, such as one configured to dissipate heat from either the cleaning wheel or the substrate and / or remove any dislodged particles. In operation 540, particles can be removed from the substrate by the cleaning wheel. In some embodiments, particles can be removed in the coolant flow or retained within the pores of the cleaning wheel.

[0058] FIG. 9 is a flow chart illustrating an example method 600 for forming an edge cleaning wheel according to some embodiments described herein. Optionally, in operation 610, a coupling agent may be applied to a first volume of abrasive particles. In operation 620, a mixture may be formed including the first volume of abrasive particles, a second volume of a matrix, and a third volume of a pore inducer. In operation 630, the mixture may be placed in a mold. In operation 640, the molded mixture may be heated. In some embodiments, the pore inducer may sublimate during heating. In some embodiments, the molded mixture may be heated and compressed non-axially during molding, if desired. After molding, the molded cleaning wheel may be removed from the mold.

[0059] In particular, although the above operations in FIGS. 8-9 are described in a particular order, they may be performed in a different order and / or some of the operations may be performed simultaneously.

[0060] conclusion Thus, it will be readily apparent to those skilled in the art that the present invention is susceptible to broad utility and application. Many embodiments and adaptations of the present invention other than those described herein, as well as numerous variations, modifications, and equivalent arrangements, will be apparent or reasonably suggested from the present invention and the foregoing description thereof, without departing from the spirit or scope of the present invention. Thus, while the present invention has been described in detail herein in connection with preferred embodiments thereof, it should be understood that this disclosure is illustrative and exemplary of the invention and is made solely for the purpose of providing a complete and enabling disclosure of the invention. The foregoing disclosure is not intended, and should not be construed, to limit the invention or to exclude other embodiments, adaptations, variations, modifications, and equivalent arrangements.

[0061] Preferred embodiments of the present invention will be described below in detail.

[0062] Embodiment 1 In the cleaning wheel, a first volume of a plurality of abrasive particles; a second volume of a polymeric matrix having the plurality of abrasive particles suspended therein; and formed from a composition comprising the composition defines pores; A cleaning wheel, wherein the first volume is at least 20% and less than 35% of the total volume of the cleaning wheel, the second volume is at least 20% of the total volume of the cleaning wheel, and the pores are at least 35% of the total volume of the cleaning wheel.

[0063] Embodiment 2 2. The cleaning wheel of embodiment 1, wherein the plurality of abrasive particles are silicon carbide.

[0064] Embodiment 3 3. The cleaning wheel of claim 1 or 2, wherein each abrasive particle of the plurality of abrasive particles has a particle size between 20 and 50 micrometers.

[0065] Embodiment 4 4. The cleaning wheel of embodiment 3, wherein each particle of the plurality of abrasive particles has a particle size of 30 to 40 micrometers.

[0066] Embodiment 5 5. The cleaning wheel of any one of embodiments 1 to 4, wherein the first volume of the plurality of abrasive particles is between 20% and 30% of the total volume of the cleaning wheel.

[0067] Embodiment 6 6. The cleaning wheel of embodiment 5, wherein the first volume of the plurality of abrasive particles is between 20% and 25% of the total volume of the cleaning wheel.

[0068] Embodiment 7 7. A cleaning wheel according to any one of the preceding embodiments, wherein the second volume of the polymer matrix is ​​between 20% and 35% of the total volume of the cleaning wheel.

[0069] Embodiment 8 8. A cleaning wheel according to any one of the preceding embodiments, wherein the second volume of the polymer matrix is ​​between 25% and 30% of the total volume of the cleaning wheel.

[0070] Embodiment 9 9. The cleaning wheel of any one of the preceding claims, wherein the polymer matrix comprises polyurethane.

[0071] Embodiment 10 10. A cleaning wheel according to any one of the preceding embodiments, wherein the pores occupy between 35% and 55% of the total volume of the cleaning wheel.

[0072] Embodiment 11 11. A cleaning wheel according to any one of the preceding embodiments, wherein the pores occupy between 45% and 55% of the total volume of the cleaning wheel.

[0073] Embodiment 12 12. A cleaning wheel according to any one of the preceding claims, wherein the cleaning wheel has a Shore D hardness of between 40 and 55.

[0074] Embodiment 13 13. The cleaning wheel of any one of the preceding embodiments, wherein the cleaning wheel is configured to remove at least 75% of particles from a glass substrate.

[0075] Embodiment 14 14. The cleaning wheel of any one of the preceding claims, further comprising a coupling agent applied to the plurality of abrasive particles.

[0076] Embodiment 15 15. The cleaning wheel of embodiment 14, wherein the coupling agent comprises a metallic coating.

[0077] Embodiment 16 1. A method for removing particles from a substrate, comprising: applying a cooling fluid to an interface between a cleaning wheel and the substrate; The composition of the cleaning wheel is a first volume of a plurality of abrasive particles; a second volume of matrix having the plurality of abrasive particles suspended therein; Including, the cleaning wheel composition comprises pores; applying a coolant, wherein the first volume is at least 20% but less than 35% of the total volume of the cleaning wheel, the second volume is at least 20% of the total volume of the cleaning wheel, and the pores are at least 35% of the total volume of the cleaning wheel; and rotating the cleaning wheel to remove substrate particles from the substrate at an interface between the cleaning wheel and the substrate, the removed substrate particles being at least partially removed by the cooling liquid; A method comprising:

[0078] Embodiment 17 17. The method of claim 16, wherein the plurality of abrasive particles are silicon carbide.

[0079] Embodiment 18 18. The method of embodiment 16 or 17, wherein the polymeric matrix comprises polyurethane.

[0080] Embodiment 19 19. The method of any one of claims 16 to 18, wherein the cleaning wheel further comprises a coupling agent applied to the plurality of abrasive particles.

[0081] Embodiment 20 20. The method of any one of claims 16 to 19, wherein the substrate is made of glass.

[0082] Embodiment 21 In the process of forming the cleaning wheel, combining a first volume of a plurality of abrasive particles, a second volume of a polymer matrix, and a third volume of a pore-initiating agent into a mixture; placing the mixture in a mold; and heating the mixture in the mold to form a cleaning wheel, the mixture being heated to a temperature such that the pore-initiating agent sublimes, thereby creating pores in the cleaning wheel; A method comprising:

[0083] Embodiment 22 22. The process of embodiment 21, wherein the first volume is at least 20% and less than 35% of the total volume of the cleaning wheel.

[0084] Embodiment 23 23. The process of embodiment 21 or 22, wherein the second volume is at least 20% of the total volume of the cleaning wheel.

[0085] Embodiment 24 24. The process of any one of embodiments 21 to 23, wherein the pores are at least 35% of the total volume of the cleaning wheel.

[0086] Embodiment 25 25. The process of any one of claims 21 to 24, further comprising coating the plurality of abrasive particles with a coupling agent. [Explanation of symbols]

[0087] 110 Spindle 120, 220, 320, 720 Edge cleaning wheels 121, 221, 321, 721 groove 123, 223, 323, 423, 723 Abrasive particles 125, 225, 325, 425, 725 matrix 127 pores 130 Glass substrate 130a Finished glass substrate 132 First Prefinished Edge 132a First Finished Edge 133a first principal surface 133b Second principal surface 134 Second Prefinished Edge 134a Second Finished Edge 135 Glass particles 413 First Groove 415 Second Groove 420 Edge

Claims

1. In the cleaning wheel, a first volume of a plurality of abrasive particles; a second volume of a polymeric matrix having the plurality of abrasive particles suspended therein; and formed from a composition comprising the composition defines pores; A cleaning wheel, wherein the first volume is at least 20% and less than 35% of the total volume of the cleaning wheel, the second volume is at least 20% of the total volume of the cleaning wheel, and the pores are at least 35% of the total volume of the cleaning wheel.

2. The cleaning wheel of claim 1 , wherein the plurality of abrasive particles are silicon carbide.

3. The cleaning wheel of claim 1 , wherein each abrasive particle of the plurality of abrasive particles has a particle size between 20 and 50 micrometers.

4. 4. The cleaning wheel of claim 3, wherein each particle of the plurality of abrasive particles has a particle size of 30 to 40 micrometers.

5. The cleaning wheel of claim 1 , wherein the first volume of the plurality of abrasive particles is between 20% and 30% of the total volume of the cleaning wheel.

6. The cleaning wheel of claim 5 , wherein the first volume of the plurality of abrasive particles is between 20% and 25% of the total volume of the cleaning wheel.

7. The cleaning wheel of claim 1 , wherein the second volume of the polymeric matrix is ​​between 20% and 35% of the total volume of the cleaning wheel.

8. The cleaning wheel of claim 1 , wherein the second volume of the polymeric matrix is ​​between 25% and 30% of the total volume of the cleaning wheel.

9. The cleaning wheel of claim 1 , wherein the polymeric matrix comprises polyurethane.

10. The cleaning wheel of claim 1 , wherein the pores are between 35% and 55% of the total volume of the cleaning wheel.

11. The cleaning wheel of claim 1 , wherein the pores are between 45% and 55% of the total volume of the cleaning wheel.

12. The cleaning wheel of claim 1 , wherein the cleaning wheel has a Shore D hardness of between 40 and 55.

13. The cleaning wheel of claim 1 , wherein the cleaning wheel is configured to remove at least 75% of particles from a glass substrate.

14. The cleaning wheel of claim 1 further comprising a coupling agent applied to the plurality of abrasive particles.

15. The cleaning wheel of claim 14 , wherein the coupling agent comprises a metallic coating.

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