Glass Roll Flanged Core Cushioning
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Solution Overview
Problem
Glass films used in flat panel displays and solar cells are prone to breaking due to stress concentration when rolled and placed on surfaces, particularly at the end portions, which are exposed and vulnerable to contact with flanges during handling and transportation.
Innovation Solution
A glass roll configuration is developed with a flanged roll core and a cushion sheet interposed between the glass film and the flange, where the glass film's end portions are cut to prevent direct contact and misalignment, using a cushioning means to absorb impacts and vibrations, and the cushion sheet is extended to cover the edges, preventing breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If the glass film is thinned to achieve further thinning for flat panel displays and solar cells, then the flexibility and processability are improved, but the glass film becomes more prone to breaking due to stress concentration
Solution Approach 1:
An intermediate layer is provided between the glass film and the placed surface (pallet) in advance, before the glass film is subjected to stress during handling and transportation. This intermediate layer acts as a cushioning element that distributes the load and prevents direct contact between the glass film and the hard surface, thereby preventing stress concentration and breakage while allowing the glass film to be sufficiently thin.
2Ease of operation
If the glass roll is placed on a pallet with the roll core in a laid posture to facilitate handling, then the ease of operation is improved, but stress concentration occurs on the contact portion of the glass film through the intermediate layer, leading to breakage
Solution Approach 1:
The intermediate layer serves as a mediator between the glass film and the placed surface. When the glass roll is placed on the pallet in a laid posture, the intermediate layer absorbs and distributes the contact stress, preventing direct transmission of concentrated loads to the glass film. This allows the glass roll to be handled conveniently in a laid posture while maintaining the integrity of the thin glass film.
3Ease of operation
If the end portions of the glass film are exposed in the width direction for standard packaging, then the ease of operation is improved, but the end portions are likely to serve as origins of breakage due to direct contact with flanges during handling and transportation
Solution Approach 1:
The intermediate layer extends beyond the end portions of the glass film in the width direction, providing beforehand cushioning protection to the exposed end portions. When the glass roll is handled or transported, the intermediate layer absorbs impacts and prevents direct contact between the vulnerable end portions of the glass film and external objects such as flanges, thereby preventing breakage while maintaining standard packaging configuration.
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 configuration effectively prevents breakage of the glass film at the end portions by separating them from the flange and providing cushioning, ensuring reliable protection and smooth handling during winding and transportation.
Implementation Method 1
cushioning means is arranged between the flange and the end portion in the width direction of the glass film
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a glass roll utilizing a flanged roll core, and reliably inhibiting a glass film from breaking from an end portion in a width direction thereof as an origin of breakage. A glass roll (1) is formed by winding a glass film (4) and a cushion sheet (5), under a state of being superposed, around a roll core (3) including a flange (2) at each end portion thereof, in which an end portion in a width direction of the glass film (4) is separated from the flange (2) on each side in the width direction of the glass film (4), and the cushion sheet (5) is extended beyond the end portion in the width direction of the glass film (4) to the flange (2) side, to thereby form an extension portion (5a).