Dynamic Glass Mold Rods for Multi-Stage Forming
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Solution Overview
Problem
The existing glass forming processes require re-alignment and cooling of glass substrates between forming stages, leading to increased thermal cycles and stress-induced defects in the final glass panels.
Innovation Solution
A glass forming system with adjustable rods and actuators that allow for multi-stage forming within a glass bending furnace, eliminating the need for substrate removal and re-alignment, and using a reconfigurable pad to dynamically shape the glass substrate during the forming process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If glass substrate is removed and re-aligned between forming stages, then alignment precision can be maintained, but thermal cycles increase and stress-induced defects occur
Solution Approach 1:
The system employs dynamically adjustable rods with actuators that can change position and configuration during the forming process. This allows the mold geometry to be modified without removing the glass substrate, maintaining thermal stability while achieving precise shaping through dynamic rod positioning rather than static re-alignment operations.
Solution Approach 2:
The forming process maintains continuous heating and forming action by keeping the glass substrate in the furnace throughout the entire process. The actuators continuously adjust rod positions to achieve the desired shape, eliminating interruptions and cooling cycles that would otherwise be required for re-alignment operations.
2Adaptability or versatility
If glass substrate is removed between forming stages, then multi-stage forming can be performed, but processing time increases due to cooling and re-alignment
Solution Approach 1:
The system achieves multi-stage forming through dynamic reconfiguration of the rod positions using actuators, rather than physical removal and re-alignment of the substrate. Each stage can be executed by programmatically adjusting rod positions while the substrate remains in the furnace, dramatically reducing processing time while maintaining full multi-stage capability.
Solution Approach 2:
The forming operation continues uninterrupted with the substrate remaining in the heated furnace throughout all forming stages. The actuators perform continuous or sequential position adjustments to execute multiple forming stages without cooling cycles, eliminating time losses associated with substrate removal, cooling, and re-alignment operations.
3Ease of manufacture
If fixed mold geometry is used, then manufacturing simplicity is maintained, but adaptability to different glass shapes is limited
Solution Approach 1:
The system replaces fixed mold geometry with dynamically adjustable rods that can be positioned independently by actuators. This maintains manufacturing simplicity through standardized rod components while achieving unlimited adaptability to different glass shapes through programmable position control, allowing the same physical hardware to produce various geometries.
Solution Approach 2:
The mold is segmented into multiple independent rods rather than a single fixed structure. Each rod can be independently positioned by its own actuator, enabling complex shape variations while keeping individual rod components simple and standardized. This segmentation provides both manufacturing ease and geometric adaptability simultaneously.
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 reduces thermal stress and defects by maintaining the glass substrate in the furnace throughout the process, improving the quality and efficiency of formed glass panels.
Implementation Method 1
A glass forming system with adjustable rods and actuators that allow for multi-stage forming within a glass bending furnace
Data Source
AI summary
A glass forming system includes a support that is configured to be installed in a glass bending furnace. The glass forming system further includes rods that are located adjacent to one another and spaced from each other to define a perimeter that encloses an open space. Each of the rods is coupled to the support. The glass forming system further includes actuators that are attached to the support. Each of the actuators is configured to move a corresponding one of the rods independently from the other rods. The glass forming system further includes a pad that is carried by the rods and that defines an engagement surface upon which a glass substrate is placed. A geometry of the engagement surface is reconfigurable based on movement of one or more of the rods.