CO Laser Cutting of Flexible Thin Glass Without Thermal Buckling
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Solution Overview
Problem
Conventional methods for cutting flexible glass into free-form shapes face challenges such as poor edge quality, low edge strength, and thermal buckling due to the thinness of the glass sheets, especially when using carbon dioxide lasers, which are not effective for glass thicknesses less than 0.3 mm.
Innovation Solution
A carbon monoxide laser cutting technique is employed, which uses a combination of laser heating and a cooling fluid to propagate a crack in the glass sheet, allowing for precise cutting of thin and ultra-thin glass sheets with high edge quality and flexibility to form various shapes, including those with tight radii, by generating a stress differential to drive the crack along an intended path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If carbon dioxide laser cutting is used on thin glass sheets, then cutting capability is achieved, but thermal buckling and overheating occur
Solution Approach 1:
The patent changes the laser wavelength parameter from carbon dioxide (10.6 μm) to carbon monoxide (5.3 μm), which fundamentally alters the interaction with glass material. This parameter change enables effective cutting of thin glass sheets while avoiding thermal buckling and overheating issues that plague CO2 laser processing of materials less than 0.3mm thick.
2Ease of manufacture
If mechanical scoring and breaking is used, then cutting process is simple, but edge quality and strength are insufficient
Solution Approach 1:
The patent replaces the mechanical scoring and breaking system with a laser-based thermal field system. The CO laser creates a controlled thermal gradient that propagates a crack through the glass along the desired path, eliminating the need for mechanical contact and subsequent breaking operations. This substitution delivers superior edge quality and strength while maintaining continuous cutting capability.
3Adaptability or versatility
If glass sheet thickness is reduced for flexibility, then substrate flexibility is improved, but cutting precision and edge strength deteriorate
Solution Approach 1:
The patent utilizes the specific parameter change of laser wavelength to CO (5.3 μm) which creates optimal interaction with glass material across a wide thickness range. This enables precise cutting of ultra-thin flexible glass sheets (including those less than 0.1mm thick) while maintaining high edge quality and strength, resolving the trade-off between flexibility and manufacturability.
4Productivity
If continuous cutting is implemented, then productivity increases, but maintaining consistent quality across the cutting line becomes difficult
Solution Approach 1:
The patent implements continuous laser cutting along the entire cutting line without interruption. The CO laser maintains consistent cutting quality throughout the continuous process, avoiding the quality variations that typically occur when transitioning between different cutting operations or when mechanical breaking is required at intermediate stages.
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 achieves high precision and edge strength in cutting thin glass sheets, reducing manufacturing failures and cycle time, while avoiding overheating issues common with carbon dioxide lasers, and is applicable to a wide range of glass thicknesses, including ultra-thin sheets.
Implementation Method 1
applying a carbon monoxide laser beam to the glass sheet starting at the initiation line and continuously moving the laser beam relative to the glass sheet along a cutting line to elevate a temperature of the glass sheet to provide stress at the cutting line sufficient to cut the glass sheet along the cutting line
Implementation Method 2
applying a cooling fluid simultaneously with the application of the laser beam such that the cooling fluid causes a temperature differential in the glass sheet to induce a stress that propagates a crack in the glass sheet along the cutting line
Implementation Method 3
the cooling fluid causes a temperature differential in the glass sheet to induce a stress that propagates a crack in the glass sheet along the cutting line
Data Source
AI summary
Methods and apparatus provide for: supporting a source glass sheet of 0.3 millimeters (mm) or less in thickness; scoring the glass sheet at an initiation line using a mechanical scoring device; applying a carbon monoxide (CO) laser beam to the glass sheet starting at the initiation line and continuously moving the laser beam relative to the glass sheet along a cutting line to elevate a temperature of the glass sheet to provide stress at the cutting line sufficient to cut the glass; and separating waste glass from the glass sheet to obtain a desired shape.