Glass Panel Unit Manufacturing via Substrate Cutting
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Solution Overview
Problem
The existing methods for manufacturing glass panel units with excellent thermal insulation properties require dedicated equipment for each specific size, making it difficult and costly to produce glass panel units and windows of various sizes.
Innovation Solution
A method involving a providing step, pillar arrangement, bonding, sealing, and cutting steps, where a first substrate with a larger contour is provided alongside a second substrate with a smaller contour, pillars are arranged and bonded between them, the internal space is evacuated and sealed, and the first substrate is cut to match the second substrate's contour, allowing for the use of standardized equipment to produce glass panel units of various sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dedicated equipment is used for each specific size of glass panel unit, then manufacturing precision and quality are ensured, but manufacturing cost increases and production flexibility decreases
Solution Approach 1:
The patent applies universality by using a single standardized substrate size (A3 format) for all glass panel unit productions regardless of the final product size. The same equipment and processing steps are used for all orders, with only the cutting stage varying to produce different sizes. This eliminates the need for dedicated equipment for each size while maintaining manufacturing precision through standardized processes.
Solution Approach 2:
The manufacturing process is segmented into standardized upstream steps (substrate preparation, pillar arrangement, bonding, sealing) that remain constant, and a flexible downstream cutting step that adapts to different product requirements. This segmentation allows the majority of the process to be standardized while retaining flexibility in the final customization stage.
2Loss of substance
If glass panes are provided with exact specifications of final product, then material waste is reduced, but equipment complexity and manufacturing cost increase
Solution Approach 1:
Instead of cutting glass panes to exact final dimensions first and then assembling, the patent inverts the process by assembling components on a larger standardized substrate and then cutting the entire assembly to the final size. This reversal allows using a single standardized substrate size for all productions, reducing equipment complexity while managing material waste through efficient substrate utilization.
Solution Approach 2:
The patent performs preliminary assembly of all components (pillars, sealing materials, glass panes) on a standardized A3 substrate before final cutting. This preliminary action on a uniform substrate simplifies the assembly process and equipment requirements, while the final cutting step efficiently removes excess material to achieve the exact final dimensions with minimal waste.
3Adaptability or versatility
If multiple substrates of different sizes are used, then product variety is achieved, but manufacturing cost and process complexity increase
Solution Approach 1:
The patent achieves product variety while maintaining ease of manufacture by using a universal A3-sized substrate for all productions. The same substrate preparation, pillar arrangement, bonding, and sealing processes are applied universally, with only the final cutting step varying to create different product sizes and configurations, thereby eliminating the need for multiple substrate sizes and associated equipment variations.
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 manufacturing costs by enabling the production of glass panel units of various sizes using the same equipment and simplifies the cutting process, while maintaining excellent thermal insulation properties.
Implementation Method 1
the internal space is sealed so as to be kept evacuated
Data Source
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AI summary
An object of the present disclosure is to manufacture glass panel units of various sizes with the manufacturing cost cut down. A glass panel unit manufacturing method includes a providing step, a pillar arrangement step, a bonding step, a sealing step, and a cutting step. The providing step includes providing a first substrate (1) and a second substrate (2) having a smaller contour than the first substrate (1). The pillar arrangement step includes arranging a plurality of pillars (4) on the first substrate (1). The bonding step includes hermetically bonding peripheral edges of the second substrate (2) onto the first substrate (1) while interposing the plurality of pillars (4) between the second substrate (2) and the first substrate (1). The sealing step includes sealing up an internal space (SI) created between the second substrate (2) and the first substrate (1), while keeping the internal space evacuated (SI). The cutting step includes cutting the first substrate (1) to the contour of the second substrate (2).