Glass Panel Unit Bonding and Cutting Method
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Solution Overview
Problem
Conventional manufacturing methods for glass panel units require pre-shaping glass substrates to specific dimensions and shapes, leading to inefficiencies in production due to the need for dedicated furnaces and processes for each type of panel, resulting in decreased efficiency and increased redundant space usage.
Innovation Solution
A method involving a placing step where two glass substrates are positioned with a seal member in between, followed by bonding and then cutting along an imaginary plane passing through the seal member to form a temporary-assembled unit, which can be cut into multiple glass panel units with desired dimensions and shapes, reducing the need for multiple furnaces and improving handling and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If glass substrates are pre-shaped to specific dimensions and shapes before bonding, then the glass panel unit can be manufactured with desired shape and dimensions, but the manufacturing efficiency decreases and redundant space increases
Solution Approach 1:
The glass substrates are prepared in a standardized format (e.g., sheets or plates) before bonding, and the specific shape and dimensions are determined after bonding by cutting the sealed unit. This preliminary preparation of substrates in a common format improves manufacturing efficiency while maintaining the ability to produce various shapes and dimensions through post-bonding cutting.
Solution Approach 2:
The manufacturing process is segmented into two stages: first, bonding glass substrates in a standardized configuration to form a sealed unit; second, cutting the sealed unit into desired shapes and dimensions. This segmentation allows the bonding process to be optimized for efficiency while the cutting process provides the necessary shape customization.
2Manufacturing precision
If glass substrates are pre-shaped to specific dimensions, then the glass panel unit can be manufactured with desired shape and dimensions, but the device complexity increases due to dedicated furnaces and processes for each type
Solution Approach 1:
A single bonding process and furnace configuration can be used for different types of glass panel units by bonding substrates in standardized formats and then cutting them into various shapes and dimensions. This universal bonding process eliminates the need for dedicated furnaces and processes for each product type, reducing device complexity.
Solution Approach 2:
Glass substrates are prepared in advance in standardized formats that can be processed by a single bonding process, and the final shape and dimension variations are achieved through post-bonding cutting. This preliminary standardization allows one bonding process to serve multiple product types.
3Manufacturing precision
If glass substrates are cut to determined shape and dimensions in advance, then the glass panel unit can be manufactured with desired shape and dimensions, but the loss of time increases due to multiple separate processes
Solution Approach 1:
The bonding and cutting operations are merged into a more integrated process where glass substrates are bonded first and then cut as a unified sealed unit. This merging eliminates the need for separate cutting operations for each substrate before bonding, reducing the total number of process steps and time loss.
Solution Approach 2:
The bonding process is performed as a preliminary action on standardized substrate formats, and the final shape customization is achieved through cutting after bonding. This sequence consolidates operations and reduces the time that would otherwise be spent on multiple separate cutting and bonding steps.
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 allows for efficient production of glass panel units with desired dimensions and shapes, improves handling and strength by cutting through the seal member as if a single glass plate, and enhances thermal insulation by evacuating or filling the internal space with gases, thus reducing manufacturing costs and increasing productivity.
Implementation Method 1
in a sealing furnace, the pair of glass substrate between which the seal member is sandwiched are heated, and thereby bonded to each other with the seal member
Data Source
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AI summary
An object would be to propose a manufacturing method for glass panel unit enabling efficient manufacture of a glass panel unit with desired shape and dimensions. A first glass substrate (1) and a second glass substrate (2) which are placed to face each other with a seal member (3) in-between are bonded to each other with the seal member (3). Subsequently, the first glass substrate (1), the seal member (3), and the second glass substrate (2) are cut collectively along a cut plane (900) passing through the seal member (3) from one of the first glass substrate (1) and the second glass substrate (2) bonded to each other. Thereby, a glass panel unit is manufactured. It is preferable that an inside space (4) with thermally insulating properties is formed between the first glass substrate (1) and the second glass substrate (2).