Flexible Mold Base with Dual Resin Sheets Prevents Glass Breakage

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Solution Overview

Problem

The existing flexible mold bases with a resin layer on one side of a glass sheet are prone to breakage when wound in an endless manner, leading to potential contamination from glass fragments during manufacturing processes, especially when the end surfaces of the glass sheet come into contact, causing breakage and scattering of glass pieces.

Innovation Solution

A flexible mold base configuration featuring an intermediate sheet with resin sheets bonded to both main surfaces, including spacer sheets made of resin at the ends to protect the glass sheet, preventing direct contact and breakage, and using low-viscosity adhesive layers to facilitate easy removal and reduce contamination.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a glass sheet base with resin layer on one side is used, then dimensional stability is improved, but breakage resistance deteriorates when wound in endless manner

Engineering Contradiction:

Improvedimensional stabilityVSAvoidbreakage resistance

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The base is constructed as a composite structure with a glass sheet core providing dimensional stability and two resin sheets providing protection and flexibility. This composite design combines the advantages of both materials: the glass sheet maintains dimensional stability while the resin sheets prevent breakage and enable endless winding by protecting the glass sheet surfaces and allowing the structure to flex without fracturing.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If glass sheet is used as base, then dimensional stability is improved, but contamination risk increases due to glass breakage

Engineering Contradiction:

Improvedimensional stabilityVSAvoidglass fragment contamination

Core Design Contradiction:

Stability of the object's compositionVSObject-generated harmful factors

Solution Approach 1:

Resin sheets are bonded to both main surfaces of the glass sheet beforehand to create a protective cushioning layer. This pre-applied protection prevents direct contact and potential breakage of the glass sheet during handling, winding, and manufacturing processes, thereby preventing glass fragment contamination before it can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

The resin sheets act as intermediary protective layers between the glass sheet and the external environment. These intermediary layers absorb mechanical stresses and prevent direct contact that could cause glass breakage, thereby eliminating the source of contamination while maintaining the dimensional stability provided by the glass core.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If resin layer is formed only on one side of glass sheet, then ease of manufacture is improved, but reliability deteriorates due to breakage when wound endlessly

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidreliability during endless winding

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Resin sheets are applied to both main surfaces of the glass sheet, providing localized protection where it is most needed. This ensures that the surfaces in contact with other members or environment are protected, preventing breakage during endless winding while maintaining manufacturing feasibility through standardized bonding processes.

Inventive Principle:

Principle #3Local quality

4Device complexity

If end surfaces of glass sheet come into contact when wound, then device complexity is reduced, but breakage risk increases

Engineering Contradiction:

Improvestructural simplicityVSAvoidbreakage resistance

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

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 configuration significantly reduces glass sheet breakage and contamination by preventing direct contact between end surfaces and containing broken glass pieces, ensuring high accuracy in pattern transfer and ease of operation during manufacturing.

Implementation Method 1

resin sheets bonded to both main surfaces of the intermediate sheet through intermediation of bonding layers

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11931924B2Method for producing flexible mold, flexible mold substrate and method for producing optical component

Publication Date: 2024.03.19 NIPPON ELECTRIC GLASS CO LTD

AI summary

Provided is a base (1) for a flexible mold that is to be wound in an endless manner, and the base includes: an intermediate sheet (2); and first and second resin sheets (3, 5) bonded to both main surfaces of the intermediate sheet (2) through intermediation of first and second bonding layers (4, 6), respectively. The intermediate sheet (2) includes: first and second spacer sheets (7, 8), which are each made of a resin, and are arranged at one end portion and another end portion in a winding direction, respectively; and a glass sheet (9) arranged between those spacer sheets (7, 8).