Cold-Shaping Glass Sheets Using Vacuum Chucks and Automated Pressing
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Solution Overview
Problem
Current methods for forming curved glass substrates and assemblies at ambient temperature face challenges such as high cost, optical distortion, and low throughput due to the use of structural adhesives with long curing times, making them unsuitable for high-volume production of display components in automotive applications.
Innovation Solution
An apparatus and method for cold-shaping glass sheets using vacuum chucks, automated pick and dispensing mechanisms, and a pressing apparatus to apply a curable adhesive between the glass sheet and a frame, allowing for high-throughput production of finished glass sheet assemblies without the need for extended curing times.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If thermal forming is used to form curved glass substrates, then the glass can be shaped, but it causes high cost, optical distortion, and surface marking
Solution Approach 1:
The patent changes the temperature parameter from high-temperature thermal forming to ambient temperature cold forming. This parameter change eliminates thermal effects that cause optical distortion and surface marking while still achieving the desired curved shape through mechanical force applied at room temperature.
Solution Approach 2:
The patent replaces the thermal field (heat-based forming) with a mechanical field (force-based cold forming). By using mechanical pressure and vacuum holding instead of thermal energy, the process achieves shaping without the harmful thermal effects that cause optical distortion and surface defects.
2Strength
If structural adhesives are used to join bent glass sheets to frames, then strong bonds are achieved, but curing times of 15 minutes or longer significantly reduce throughput
Solution Approach 1:
The patent performs preliminary cold-forming of the glass sheet to its final curved shape before adhesive application. This preliminary shaping eliminates the need for post-bonding adjustments and allows immediate progression to the next assembly step, reducing overall cycle time despite using structural adhesives.
Solution Approach 2:
The patent implements a continuous automated assembly process where cold-formed glass sheets are immediately transferred to framing stations without interruption. The automated pick-and-place mechanisms ensure continuous operation, minimizing idle time and maintaining high throughput even with adhesive curing requirements.
3Productivity
If automated pick and dispensing mechanisms are used for cold-shaping, then throughput can be increased, but device complexity increases
Solution Approach 1:
The patent divides the automated assembly system into distinct functional modules: vacuum chuck modules for holding and shaping, automated pick mechanisms for transfer, dispensing mechanisms for adhesive application, and framing modules. This segmentation allows each module to be optimized independently and simplifies maintenance while maintaining high throughput.
Solution Approach 2:
The patent designs the automated mechanisms to perform multiple functions. For example, the vacuum chucks not only hold the glass sheets but also apply shaping forces. The automated pick mechanisms both transfer sheets and position them precisely. This multi-functionality reduces the number of separate devices needed, lowering overall system complexity.
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
Enables the efficient and high-throughput production of curved glass assemblies suitable for automotive applications by minimizing adhesive curing time and maintaining optical clarity, addressing the limitations of existing methods.
Implementation Method 1
a plurality of vacuum chucks configured within a moveable table
Data Source
AI summary
An apparatus for cold-shaping a glass sheet that includes: a plurality of vacuum chucks configured within a moveable table; a first automated pick mechanism proximate the table; an automated dispensing mechanism proximate the table; and a pressing apparatus. The first pick mechanism is configured to shape a glass sheet onto one of the chucks. The dispensing mechanism is configured to dispense a curable adhesive onto the glass sheet or a frame. One of the first pick mechanism and the dispensing mechanism is configured to position the frame onto the glass sheet such that the adhesive is disposed between the glass sheet and the frame. The pressing apparatus is configured to press the frame and the adhesive onto the glass sheet to define a finished glass sheet assembly. The glass sheet is bendable at ambient temperature. Methods for cold-shaping a glass sheet are also included in the disclosure.