Glass Plate Chamfered Edge Micro-Scratch Control

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Solution Overview

Problem

Glass plates used in image display apparatuses and cover glasses often suffer from micro-scratches during manufacturing, which can lead to degradation of flexural strength and make accurate evaluation of strength challenging, as existing methods like chemical strengthening and grinding can introduce tensile stress and micro-scratches that affect their integrity.

Innovation Solution

A glass plate design featuring chamfered edges with predetermined etched portions, where the etched surface has no pits deeper than 1 μm, and a method involving chemical strengthening, cutting, and chamfering to minimize micro-scratches and enhance flexural strength by controlling stress distribution and surface roughness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If chemical strengthening is applied to improve flexural strength, then compression stress layer is formed on the glass plate surface, but tensile stress layer is formed inside the glass plate which may cause breakage when micro-scratches exist

Engineering Contradiction:
Improveflexural strengthVSAvoidbreakage resistance
Core Design Contradiction:
StrengthVSReliability

Solution Approach 1:

The patent applies preliminary action by forming a chamfered surface with controlled valley depth (Rv ≤ 2 μm) and projecting valley depth (Rvk ≤ 0.95 μm) before the glass plate is subjected to use. This preliminary surface treatment prevents micro-scratches from developing into critical defects that would trigger breakage under tensile stress, thereby resolving the contradiction between achieving high flexural strength through chemical strengthening and maintaining breakage resistance.

Inventive Principle:
Principle #10Preliminary action

2Manufacturing precision

If end surface is grinded by rotating grinding wheel to improve surface finish, then surface smoothness is improved, but micro-scratches are formed on the end surface and inside the glass plate

Engineering Contradiction:
Improvesurface finishVSAvoidflexural strength
Core Design Contradiction:
Manufacturing precisionVSStrength

Solution Approach 1:

The patent converts the harmful effect of grinding by introducing a controlled chamfered surface with specific valley depth parameters. Instead of attempting to eliminate all surface irregularities from grinding, the invention controls the valley depth (Rv ≤ 2 μm) and projecting valley depth (Rvk ≤ 0.95 μm) to prevent micro-scratches from becoming critical defects, thereby maintaining flexural strength while achieving acceptable surface finish.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If chamfered surface is formed with deeper valley parts to remove micro-scratches, then surface defects are reduced, but stress concentration increases at the trough part

Engineering Contradiction:
Improvescratch resistanceVSAvoidstress concentration
Core Design Contradiction:
ReliabilityVSStress or pressure

Solution Approach 1:

The patent applies parameter changes by precisely controlling the valley depth (Rv ≤ 2 μm) and projecting valley depth (Rvk ≤ 0.95 μm) of the chamfered surface. These parameter constraints optimize the balance between removing micro-scratches and minimizing stress concentration, ensuring that the valley parts are deep enough to prevent scratch propagation but shallow enough to avoid becoming stress concentration points under load.

Inventive Principle:
Principle #35Parameter changes

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

The proposed solution improves the flexural strength of glass plates by preventing deep micro-scratches and ensuring no pits greater than 1 μm exist in the etched surfaces, thereby enhancing their mechanical integrity and allowing for more accurate strength evaluation.

Implementation Method 1

a chemically strengthened layer (compression stress layer) having a predetermined depth from a front surface of a glass plate is formed on the glass plate by using a process liquid used for ion-exchange

Methodology Applied
Scientific EffectIon exchange: Ion Exchange

Implementation Method 2

In a case where the predetermined portion is etched with a depth of 10 μm, an etched surface of the predetermined portion includes no pit having a depth greater than or equal to 1 μm

Methodology Applied
Scientific EffectChemical etching:

Data Source

PatentUS9700985B2Glass plate and method for manufacturing the glass plate
Publication Date: 2017.07.11 AGC INC
  • US9700985B2 patent drawing
  • US9700985B2 patent drawing
  • US9700985B2 patent drawing

AI summary

A glass plate includes two main flat surfaces, and a side surface adjacent to the two main flat surfaces. At least one edge part of the side surface includes a chamfered part in a thickness direction of the glass plate. The side surface includes a predetermined portion. In a case where the predetermined portion is etched with a depth of 10 μm, an etched surface of the predetermined portion includes no pit having a depth greater than or equal to 1 μm. The predetermined portion is a portion of the side surface in which a distance from one of the two main flat surfaces adjacent to the chamfered part in the thickness direction of the glass plate is less than or equal to ⅕ of the thickness of the glass plate.