Curved Glass Assembly Opaque Border Without Frit Firing
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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 analog 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 printing on curved surfaces.
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 fundamental parameters of the printing process by transitioning from conventional analog methods (screen printing, spray printing) to digital printing technology. This enables precise control of ink deposition without requiring high-temperature firing, thereby forming opaque boundary features while avoiding thermal distortion and maintaining glass assembly strength
Solution Approach 2:
The patent replaces the thermal-mechanical system (high-temperature firing to fuse ceramic frit) with a chemical system (digital inkjet deposition and curing of organic ink). This substitution eliminates the need for extreme temperatures that cause uneven heat absorption and subsequent optical distortion, while still achieving durable opaque boundary features
2Ease of manufacture
If conventional analog printing processes are used to deposit enamel, then the process is simple and equipment requirements are low, but the resolution is limited to about 200 dots per inch and mask requirements increase device complexity
Solution Approach 1:
The patent replaces mechanical analog printing methods (requiring masks, screens, and manual deposition) with a digital printing system. This substitution dramatically increases resolution beyond 200 dpi while simplifying the overall process by eliminating mask fabrication and alignment steps, thereby improving manufacturing precision without sacrificing ease of manufacture
Solution Approach 2:
The patent uses digital printing technology to create precise copies of the desired opaque boundary feature pattern directly onto the curved glass substrate. This digital copying approach eliminates the need for physical masks and enables high-resolution reproduction of complex patterns with tight tolerances, significantly improving manufacturing precision
3Ease of manufacture
If conventional analog printing processes are used on flat substrates, then the printing process is straightforward, but accurate and repeatable printing on curved substrates becomes challenging
Solution Approach 1:
The patent employs a dynamic digital printing system that can adapt to curved substrates. The digital printing head can move along the curved surface and adjust deposition parameters in real-time, enabling accurate and repeatable printing on curved glass substrates while maintaining process simplicity through automated control
Solution Approach 2:
The patent changes the substrate geometry parameter from flat to curved and adapts the printing process accordingly. Digital printing technology allows for variable deposition parameters (droplet size, spacing, velocity) that can be dynamically adjusted to match the curved surface geometry, achieving both manufacturing simplicity and high precision on curved substrates
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, enhances the strength of the glass assembly by avoiding ceramic frit-related issues, and enables the creation of more detailed and accurately positioned opaque boundary features with higher resolution than conventional methods.
Implementation Method 1
curing the organic ink to form the opaque boundary feature on at least one of the P2 surface and the P3 surface
Data Source
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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.