Non-Circular Glass Forming Die Gap Design for Uniform Pressure
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Solution Overview
Problem
In press forming of glass, existing methods face challenges in achieving uniform pressure distribution and preventing air bubbles and incomplete filling due to non-circular forming die surfaces, leading to defective shapes and reduced manufacturing accuracy.
Innovation Solution
A manufacturing method involving a forming die with non-circular, planar-view contour shapes where the gap between the forming surfaces widens from the inner to the outer side, ensuring uniform pressure distribution and effective filling of the glass material, and a machining process to achieve the desired shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional forming dies with uniform gap are used, then the structure is simple, but the glass material cannot be sufficiently filled and air bubbles remain in non-circular regions
Solution Approach 1:
The forming die employs non-uniform gap distribution where the gap width varies from the center to the periphery. Specifically, the gap is smaller at the center and larger at the periphery, creating local variations in the forming die structure that adapt to different filling requirements in different regions, thereby enabling complete filling of glass material without air bubbles.
Solution Approach 2:
The forming die breaks the symmetric uniform gap structure by introducing asymmetric gap variations relative to the forming cavity. The gap distance from the upper and lower forming surfaces to the glass material is deliberately made non-uniform across the forming area, with systematic variation from center to periphery, which resolves the filling problem in non-circular regions.
2Manufacturing precision
If conventional uniform pressure distribution is applied, then the pressure application is simple, but incomplete filling and air bubbles occur in peripheral regions
Solution Approach 1:
The pressing mechanism applies non-uniform pressure distribution where the pressure intensity varies from the center to the periphery of the glass material. The pressure is smaller at the center and larger at the periphery, creating local pressure differences that drive glass material flow into peripheral regions, ensuring complete filling without air bubbles while maintaining systematic pressure control.
3Ease of manufacture
If the forming die gap is uniform, then the manufacturing process is simple, but the glass material flow is insufficient to fill non-circular contour regions
Solution Approach 1:
The forming die incorporates non-uniform gap dimensions where the gap width systematically varies from the center to the periphery. This local variation in gap structure is designed to match the flow characteristics of glass material, ensuring sufficient material flow into non-circular peripheral regions while maintaining manufacturability through systematic dimensional control.
4Productivity
If conventional forming methods are used, then the process is straightforward, but air bubbles remain trapped in the glass material
Solution Approach 1:
The forming die is pre-designed with non-uniform gap distribution that anticipates and prevents air bubble formation during the pressing process. By establishing the appropriate gap variation pattern before pressing begins, the system proactively ensures complete glass material flow that displaces air from the forming cavity, eliminating air bubbles while maintaining efficient manufacturing.
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 method ensures complete filling of the glass material, prevents air bubbles, and enhances the accuracy and yield of glass formed bodies with desired shapes, improving manufacturing productivity.
Implementation Method 1
heating a plate-shaped glass material; pressing the heated plate-shaped glass material by the forming die
Implementation Method 2
cooling and solidifying the glass material transferred shapes of forming surfaces of the forming die by the pressing
Data Source
AI summary
The present invention provides a manufacturing method of glass formed body and a forming die which make it possible to sufficiently fill a glass material in the forming die and manufacture a glass formed body having a desired shape. The manufacturing method of glass formed body includes: heating a plate-shaped glass material; pressing the heated plate-shaped glass material by the forming die; and cooling and solidifying the glass material transferred shapes of forming surfaces of the forming die by the pressing, wherein planar-view contour shapes of the forming surfaces are non-circular, a gap formed by the forming surfaces is formed so as to become wider from an inner side toward an outer side of the forming surfaces, and pressure distribution occurring in the plate-shaped glass material in the pressing is uniform in a contour region of each of the forming surfaces.