Glass Ribbon Tapered Edge Etching at Target Thickness
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Solution Overview
Problem
Manufacturing glass ribbons with a target thickness and tapered edges is a slow and costly process, leading to increased surface roughness and reduced optical quality due to traditional cutting and etching methods.
Innovation Solution
A method involving masking specific regions of the glass ribbon and etching these exposed areas to create tapered edges, allowing for the separation of ribbon portions at a target thickness without shielding surfaces, thereby maintaining optical quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cutting and etching methods are used to form tapered edges on glass ribbons, then the glass ribbon can be processed to target thickness, but surface roughness increases and optical quality is reduced
Solution Approach 1:
The patent replaces traditional mechanical cutting methods with a chemical etching process. Glass ribbons are subjected to controlled chemical etching in a molten salt bath, which dissolves the glass material to form tapered edges without mechanical contact. This substitution eliminates the surface roughness and optical quality degradation associated with mechanical cutting while achieving precise tapered edge geometry.
2Manufacturing precision
If glass ribbons are initially formed at larger than target thickness and then cut and etched to target thickness, then the final thickness can be achieved, but the process becomes slow and costly
Solution Approach 1:
The patent performs preliminary formation of the glass ribbon at the exact target thickness using a controlled glass forming process. By establishing the correct thickness upfront, the subsequent etching step only needs to form the tapered edges without removing significant material, dramatically reducing processing time and cost while maintaining precise thickness control.
Solution Approach 2:
The patent controls the etching parameters (temperature, composition, and duration of molten salt bath) to achieve selective removal of glass material at the edges only. By adjusting these parameters, the process forms tapered edges while preserving the central thickness at the target value, enabling both precision and high productivity.
3Manufacturing precision
If surfaces of the glass ribbon are shielded during processing to maintain target thickness, then thickness can be maintained, but the process becomes challenging and costly
Solution Approach 1:
The patent applies local quality by creating different surface conditions at different locations on the glass ribbon. The edges are exposed to the molten salt etchant while the central region is protected or exposed for shorter durations, resulting in tapered edges at the periphery and uniform thickness in the center. This localized differential etching eliminates the need for physical shielding while maintaining thickness consistency.
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 method enables the production of glass ribbons with tapered edges at a target thickness, reducing stress during bending and improving optical quality while minimizing surface roughness and production costs.
Implementation Method 1
etching the first exposed region and the second exposed region to separate a first ribbon portion, comprising the first region and the third region, from a second ribbon portion, comprising the second region and the fourth region, and form a first tapered edge at the first ribbon portion and a second tapered edge at the second ribbon portion
Data Source
AI summary
A glass ribbon includes a first major surface extending along a first plane. The glass ribbon includes a second major surface extending along a second plane substantially parallel to the first plane. A first thickness is defined between the first major surface and the second major surface along a thickness direction perpendicular to the first major surface. The first thickness is within a range from about 25 μm to about 125 μm. An edge surface extends between the first plane and the second plane. The edge surface comprises a height in the thickness direction that is less than the first thickness. Methods of manufacturing a glass ribbon are also provided.