Glass Piece Molding with Single-Crystalline Substrate
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Solution Overview
Problem
Current methods for forming glass pieces with patterned surfaces, such as optical components, are limited in precision and efficiency, particularly in creating cavities and protrusions with controlled slope angles and dimensions using traditional etching and molding techniques.
Innovation Solution
A method involving a single-crystalline mold substrate with precisely formed cavities and protrusions, where a glass source material is pressed and heated to fluidify, filling the mold cavities and wrapping around protrusions, allowing for controlled re-solidification to create glass pieces with patterned surfaces having specific slope angles and dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional etching and molding techniques are used to form glass pieces with patterned surfaces, then manufacturing processes can be implemented, but manufacturing precision and efficiency are limited
Solution Approach 1:
The invention uses a mold substrate with cavities and protrusions that serves as a physical template or copy of the desired pattern. The glass source material is pressed against this mold, transferring the pattern geometry directly to the glass piece. This copying approach eliminates the need for complex etching processes while achieving high precision in reproducing the patterned surface features.
Solution Approach 2:
The invention controls the temperature and pressure parameters during the molding process to achieve optimal results. By heating the glass source material to its softening temperature and applying controlled pressure, the glass becomes moldable and can precisely replicate the mold substrate's cavity and protrusion geometry, thereby achieving high manufacturing precision efficiently.
2Manufacturing precision
If glass source material is pressed and heated to fluidify, then glass pieces with precise dimensions and slope angles can be formed, but process control complexity increases
Solution Approach 1:
The invention exploits the phase transition of glass from solid to softened viscous state and back to solid. By heating the glass source material to its softening temperature, it transitions to a moldable state that can flow into and replicate the mold substrate's cavity geometry with precise slope angles. Upon cooling, it re-solidifies, preserving the precise dimensional features.
Solution Approach 2:
The invention employs dynamic control of temperature and pressure during the molding process. The temperature is controlled to maintain the glass in a softened state only during the critical molding phase, allowing precise replication. The pressure is dynamically adjusted to ensure complete cavity filling while preventing defects, then released upon solidification. This dynamic parameter control enables precise slope angle formation.
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 enables the production of glass pieces with high mechanical, chemical, and temperature stability, featuring 3D patterned surfaces with precise dimensions and slope angles, suitable for applications in semiconductor devices and optical components without shrinkage, providing enhanced insulation and dielectric strength.
Implementation Method 1
a temperature of the source material and a force exerted on the source material are controlled such that fluidified source material flows into the cavity in the mold substrate
Implementation Method 2
The source material and the mold substrate are pressed against each other
Data Source
AI summary
A source material, which is based on a glass, is arranged on a working surface of a mold substrate. The mold substrate is made of a single-crystalline material. A cavity is formed in the working surface. The source material is pressed against the mold substrate. During pressing a temperature of the source material and a force exerted on the source material are controlled to fluidify source material. The fluidified source material flows into the cavity. Re-solidified source material forms a glass piece with a protrusion extending into the cavity. After re-solidifying, the glass piece may be bonded to the mold substrate. On the glass piece, protrusions and cavities can be formed with slope angles less than 80 degrees, with different slope angles, with different depths and widths of 10 micrometers and more.