Bent Glass Substrate Manufacturing via Gravity Sagging
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Solution Overview
Problem
Existing methods for manufacturing bent glass substrates face challenges such as large thickness variations, difficulty in forming complex shapes, and the generation of wrinkles, especially when trying to create substrates with small curvature radii and deep bending depths.
Innovation Solution
A method involving a support member with a mold surface that matches the desired curved shape, where the substrate is heated and allowed to sag by its own weight before being deformed by an external force, allowing for precise transfer of the curved shape without significant thickness changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If press forming using upper and lower dies or vacuum forming is used to deform glass, then the glass can be shaped into a bent form, but the thickness of the glass plate varies significantly
Solution Approach 1:
The glass plate is pre-heated to a specific temperature range (400-600°C) before the actual bending operation. This preliminary heating softens the glass just enough to enable bending while maintaining thickness uniformity, avoiding the need for aggressive press forming that causes thickness variation.
Solution Approach 2:
The invention changes the temperature parameter of the glass plate to a specific range (400-600°C) that optimizes the balance between deformability and thickness maintenance. By controlling the temperature parameter, the glass becomes sufficiently soft for bending while preserving its structural integrity and uniform thickness.
2Shape
If the glass plate is heated to a high temperature and deformed by external force, then the bending can be achieved, but wrinkles are easily generated on the glass surface
Solution Approach 1:
The invention optimizes the temperature parameter to a specific range (400-600°C) that provides sufficient softness for bending while avoiding excessive heat that causes wrinkling. This precise temperature control prevents the glass from becoming too soft and forming wrinkles during the bending process.
Solution Approach 2:
The invention applies just enough external force to achieve the desired bend without over-deforming the glass. By using moderate force rather than excessive force, the glass is shaped into the bent form while avoiding the generation of wrinkles on the surface.
3Ease of manufacture
If the glass plate is heated and deformed by its own weight, then the process is simple, but complex bent shapes cannot be accurately manufactured
Solution Approach 1:
The invention optimizes the temperature parameter to a specific range (400-600°C) that provides sufficient softness for the glass to conform accurately to the mold surface while still allowing relatively simple processing. This temperature control enables both ease of manufacture and high shape accuracy.
Solution Approach 2:
The invention introduces a mold surface as an intermediary that defines the desired bent shape. The heated glass plate is placed on this mold surface, which guides the deformation process and ensures accurate reproduction of complex shapes without requiring complex external forcing mechanisms.
4Use of energy by moving object
If the glass plate is heated to a low temperature, then energy consumption is reduced, but the glass becomes difficult to deform
Solution Approach 1:
The invention optimizes the temperature parameter to a specific range (400-600°C) that provides the optimal balance between energy consumption and deformability. This temperature is high enough to soften the glass for easy bending but not so high as to cause excessive energy consumption or unwanted side effects like wrinkling.
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 the accurate formation of bent substrates with complex shapes and small curvature radii, reducing the risk of wrinkles and maintaining consistent thickness, thus improving the precision and quality of the bending process.
Implementation Method 1
heating the second region of the substrate to soften the second region of the substrate by the heating
Implementation Method 2
placing the second region along the mold surface of the support member by an own weight of the second region
Data Source
AI summary
A method for manufacturing a bent substrate, which forms a bent part in at least a part of a substrate, in which the substrate includes a second region and a first region, the method for manufacturing including: supporting the first region of the substrate on a substrate support surface of a support member including a mold surface having a same curved surface shape as that of the bent part and the substrate support surface that supports the first region, in a state of facing the second region of the substrate to the mold surface; heating the second region of the substrate to soften the second region of the substrate by the heating; placing the second region along the mold surface of the support member by an own weight of the second region; and transferring the curved surface shape of the mold surface to the second region by an external force.