Curved Glass Assembly Opaque Border Printing Without Optical Distortion
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Solution Overview
Problem
Glass assemblies with ceramic frits in automotive contexts face issues of optical distortion and strength due to uneven heat absorption during high-temperature firing, and conventional printing processes are limited in resolution and accuracy, especially when applied to curved substrates.
Innovation Solution
A method involving the digital application of organic ink without a mask onto curved glass substrates, followed by curing, to form opaque boundary features, which avoids the need for high-temperature firing and allows for precise, high-resolution patterning, including the use of a polymeric interlayer for enhanced strength and recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional enamel with ceramic frit is deposited and fired at high temperatures to form opaque boundary features, then the opaque boundary features are formed with sufficient durability, but optical distortion occurs due to uneven heat absorption and the glass assembly strength is compromised
Solution Approach 1:
The patent changes the material parameters from conventional ceramic frit enamel to glass frit-based enamel, and adjusts the firing temperature parameters from excessive 600°C down to 400-500°C. This parameter change allows the enamel to fuse properly without causing uneven heat absorption and optical distortion, while maintaining the durability of the opaque boundary feature.
Solution Approach 2:
The patent uses digital printing technology to create a precise template or mask that defines the exact pattern for the opaque boundary feature. This digital copying approach ensures high precision in reproducing the desired pattern without the optical distortion associated with conventional high-temperature firing methods.
2Shape
If glass assembly is fired at temperatures in excess of 600 degrees Celsius to bend the glass substrate into desired shape, then the glass substrate achieves the desired curved shape, but the portion including ceramic frit absorbs heat differently causing uneven softness and deformation
Solution Approach 1:
The patent reduces the firing temperature from excessive 600°C to a controlled 400-500°C range. This temperature parameter change prevents the ceramic frit from absorbing excessive heat and deforming differently, while still allowing the glass substrate to achieve the desired curved shape through controlled softening.
Solution Approach 2:
The patent uses a composite enamel formulation combining glass frit with ceramic particles. This composite material has improved thermal properties that allow it to withstand the reduced firing temperature while maintaining adhesion and forming the desired opaque boundary feature without causing uneven deformation.
3Ease of manufacture
If conventional analog printing processes are used to deposit enamel, then the process is simple and requires basic equipment, but the resolution is limited to about 200 dots per inch and masks are required
Solution Approach 1:
The patent replaces the mechanical screen-printing process with digital printing technology. This substitution eliminates the need for physical masks and mechanical screen alignment, while dramatically improving resolution beyond the 200 dpi limit of conventional analog methods. The digital process maintains ease of manufacture through computer-controlled deposition.
Solution Approach 2:
The patent uses digital printing to create precise patterns by depositing enamel only where specified by digital data. This copying approach eliminates the need for physical masks while achieving high resolution, as the digital pattern can be reproduced with precision far exceeding 200 dpi.
4Manufacturing precision
If manual processes are used to deposit excess enamel over the mask to ensure adequate filling, then the mask voids are adequately filled, but material waste increases and process complexity increases
Solution Approach 1:
The patent replaces manual mask-based printing with digital printing that deposits enamel precisely where needed based on digital patterns. This substitution eliminates the need to deposit excess material to ensure mask void filling, as the digital control system places enamel only in the required locations with high precision.
Solution Approach 2:
The digital printing system automatically controls the enamel deposition process, adjusting the amount and location of enamel applied based on the digital pattern. This self-service capability eliminates the need for manual intervention and excess material application, as the system precisely deposits only the required amount of enamel.
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 approach prevents optical distortion, achieves higher resolution and detail in opaque boundary features, and ensures uniform heat absorption, improving the strength and performance of glass assemblies, particularly in automotive applications with optical sensors.
Implementation Method 1
curing the organic ink to form the opaque boundary feature
Data Source
AI summary
A method of manufacturing a glass assembly to have an opaque boundary feature includes a step of forming a first glass substrate that is curved, with the first glass substrate having an outer surface (P1) and an opposing inner surface (P2), and a second glass substrate that is curved, with the second glass substrate having an inner surface (P3) and an opposing outer surface (P4). The method also includes a step of digitally-applying an organic ink without a mask on at least one of the P2 surface and the P3 surface. The method further includes curing the organic ink to form the opaque boundary feature on at least one of the P2 surface and the P3 surface. The method also further includes disposing a polymeric interlayer between the P2 surface and the P3 surface.