Glass Mold Gas Release Mechanism for Deformation Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing glass processing molds cause uneven shrinkage and deformation of glass products due to point contact and strong adhesion, leading to increased production costs and risk of cracking, especially with larger diameters where thermal expansion differences result in strain that can exceed the glass product's capacity.
Innovation Solution
A mold design featuring a lower and upper mold core with gas inlets and outlets that allow inert gas to flow through channels, separating the glass product from the mold before full cooling, ensuring even cooling and preventing contact-induced deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the glass product is allowed to cool down completely for natural shrinkage, then the deformation and cracking risk is reduced, but the production cycle time increases
Solution Approach 1:
A release layer is introduced as an intermediary between the glass product and the mold cavity. This release layer allows controlled separation during cooling, enabling the glass product to shrink naturally without direct contact constraints, thereby reducing deformation and cracking while maintaining efficient production cycles
Solution Approach 2:
The mold cavity is designed with dynamic release mechanisms that adapt during the cooling process. The cavity can dynamically adjust its interaction with the glass product, transitioning from a constrained state during forming to a more open state during cooling, allowing natural shrinkage without extending the overall production cycle
2Shape
If the mold cavity has large angle features, then the lens shape can be formed, but the glass product cannot shrink freely causing strain and cracking
Solution Approach 1:
The release layer serves as a mediator that decouples the geometric constraints of the mold cavity from the glass product during cooling. This allows the glass product to shrink freely in all directions, including horizontally, without being constrained by the cavity's large angle features, thus preventing strain accumulation and cracking
Solution Approach 2:
The mold cavity is segmented into distinct functional zones: a forming zone with large angle features for shaping the lens, and a release zone with controlled clearance that allows free shrinkage. This segmentation enables the cavity to simultaneously provide shape definition during forming and shrinkage freedom during cooling
3Shape
If the glass product contacts the mold surface, then the lens can be formed with preset shape, but uneven cooling occurs causing deformation
Solution Approach 1:
The release layer acts as a thermal intermediary that modifies the heat transfer characteristics between the mold cavity and the glass product. It provides sufficient contact area during forming to achieve the preset shape, while during cooling it distributes the thermal contact more uniformly, preventing localized rapid cooling and deformation
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 design enables uniform cooling of glass products, prevents deformation, and increases production efficiency by allowing the mold to process subsequent substrates sooner, reducing the risk of cracking and shortening the production cycle.
Implementation Method 1
transmitting gas into the first gas channel by the gas supply mechanism through the first gas inlet, when a temperature of the glass product drops in a glass transition temperature, the gas flowing out from the first gas outlet to separate the glass substrate from the lower mold core
Implementation Method 2
cooling the glass product... enables uniform cooling of glass products, prevents deformation
Implementation Method 3
the shrinkage rate of the glass product 301 during the cooling process is greater than that of the mold 302... the glass product 301 shrinks more
Data Source
AI summary
A mold includes a lower mold core and an upper mold core. The lower mold core has a first outside surface and a first molding surface including a first molding portion and a first supporting portion surrounding the molding portion. The upper mold core has a second molding surface opposite to the first molding surface and encloses a molding cavity with the first molding surface. The lower mold core includes a first gas inlet on the first outside surface, a first gas outlet on the first supporting portion, and a first gas channel in the lower mold core, the first gas channel connecting the first gas inlet and the first gas outlet. Gas flow out from the first gas outlet to separate the glass product from the lower mold core before the glass product is completely cooled down, which can avoid many adverse effects during the glass product process.