Angled Glass Ceramic Bending via Integrated Ceramization
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Solution Overview
Problem
Current methods for producing angled glass ceramic components with bending radii between 30mm and 200mm are either time-consuming, costly, or require significant investment, and often result in surface waviness that affects the appearance and quality of the final product.
Innovation Solution
Integrating the bending process into the ceramization process by using a forming tool that applies a forming force during the glass plate's heating phase, allowing for deformation within a narrow process window as the glass transitions from the green state to glass ceramic, with support plates and hold-down devices to ensure stable deformation and minimize surface waviness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If gas-powered bending systems are used to produce angled glass ceramic components with small bending radii, then bending radii of about 10 mm can be achieved, but the production process becomes time-consuming and costly with additional separate bending steps required before ceramization
Solution Approach 1:
The patent combines the bending process and ceramization process into a single integrated operation. The glass plate is bent and ceramized simultaneously in one furnace cycle, eliminating the need for separate bending steps before ceramization. This merging of processes directly addresses the productivity issue by reducing total production time while maintaining the capability to achieve small bending radii.
Solution Approach 2:
The patent applies preliminary heating to bring the glass plate to the appropriate temperature range for bending before the actual bending operation occurs within the ceramization furnace. This preliminary preparation ensures the glass is at the correct viscosity state for deformation, enabling efficient bending without requiring separate pre-heating or pre-bending steps.
2Shape
If gravity lowering through own weight during ceramization is used to produce angled glass ceramic panes, then bending radii greater than approx. 200mm can be produced, but the method is relatively time-consuming due to low lowering speed
Solution Approach 1:
The patent applies preliminary heating to bring the glass plate to the appropriate temperature range for bending before the actual bending operation occurs within the ceramization furnace. This preliminary preparation ensures the glass is at the correct viscosity state for deformation, enabling efficient bending without requiring separate pre-heating or pre-bending steps.
Solution Approach 2:
The patent changes the temperature parameter during the ceramization process to optimize glass viscosity for bending. By controlling the temperature profile to achieve optimal viscosity conditions, the glass becomes sufficiently deformable to allow rapid bending with small radii, significantly reducing the time required compared to gravity-based methods.
3Strength
If increasing glass thickness is applied to improve structural strength, then the sinking of the green glass into the mold becomes more difficult, making gravity-based bending increasingly difficult to implement
Solution Approach 1:
The patent changes the temperature parameter during the ceramization process to optimize glass viscosity for bending. By controlling the temperature profile to achieve optimal viscosity conditions, the glass becomes sufficiently deformable to allow rapid bending with small radii, significantly reducing the time required compared to gravity-based methods.
Solution Approach 2:
The patent applies preliminary heating to bring the glass plate to the appropriate temperature range for bending before the actual bending operation occurs within the ceramization furnace. This preliminary preparation ensures the glass is at the correct viscosity state for deformation, enabling efficient bending without requiring separate pre-heating or pre-bending steps.
4Productivity
If a forming tool is used to apply forming force during ceramization, then bending can be achieved within a narrow process window, but precise control of temperature and timing is required
Solution Approach 1:
The patent implements feedback control through temperature sensors and control systems that monitor the ceramization process in real-time. The control system adjusts heating parameters based on measured temperature and process stage, ensuring the glass remains within the optimal viscosity window for bending. This feedback mechanism enables precise control of the narrow process window required for successful forming.
Solution Approach 2:
The patent changes the temperature parameter during the ceramization process to optimize glass viscosity for bending. By controlling the temperature profile to achieve optimal viscosity conditions, the glass becomes sufficiently deformable to allow rapid bending with small radii, significantly reducing the time required compared to gravity-based methods.
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
This method enables a simplified, accelerated, and cost-effective production of angled glass ceramic components with excellent surface quality, achieving bending radii between 30mm and 200mm and ensuring a smooth, optically homogeneous transition between the legs and the bend with minimal surface waviness.
Implementation Method 1
a heating phase is carried out during the ceramization process, during which the glass plate is heated to a ceramization temperature
Implementation Method 2
a forming force is now introduced into the glass material, which creates the bend with a radium of between 30 and 200 mm
Implementation Method 3
the initially dimensionally stable green glass plate comes into a viscous state, as a result of which the part of the green glass plate located above the middle part of the mold sinks
Implementation Method 4
the part of the green glass plate located above the middle part of the mold sinks as a result of gravity
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method for creating a glass ceramic component (10) having at least one angle (14), wherein the angle is formed as a transition between two legs (11a, 11b). Very good surface qualities can be created in a simple manner in the region of the angle (14) wherein the angle (14) is made having a bending radius in the range between 30 mm and 200 mm during the ceramification process during conversion of the glass plate in a green glass state to the glass ceramic plate under the effects of a deformation tool. The invention further relates to a glass ceramic component (10) that is characterized by a particularly good visual quality.