Glass Roll Laser Cutting and Protective Sheet Winding
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Solution Overview
Problem
Conventional package forms for glass films are prone to breakage due to flexibility and stress concentration, especially when wound into rolls, as they lack effective protection for the end surfaces and are susceptible to micro cracks and flaws.
Innovation Solution
A glass roll is formed by winding a glass film with a thickness of 1 µm to 200 µm, cut using laser cutting to minimize defects, and a protective sheet is wound around the roll core to prevent breakage from external impacts and stress concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If glass plate is thinned into a glass film to improve flexibility, then flexibility is improved, but breakage resistance deteriorates
Solution Approach 1:
The patent applies the nesting principle by winding the glass film into a roll form, where multiple layers of glass film are nested around a core. This nested structure provides mutual support and protection, reducing breakage risk while preserving the inherent flexibility of thin glass film. The roll configuration allows the fragile thin film to be handled and transported without direct exposure to external stresses.
Solution Approach 2:
The patent implements beforehand cushioning by introducing protective sheets between layers of glass film during the winding process. These protective sheets are placed in advance to cushion against impacts and stresses that may occur during handling and transportation. This preventive measure addresses the breakage vulnerability of thin glass film before actual use.
2Device complexity
If conventional package forms are used for glass film, then packaging simplicity is maintained, but breakage risk increases due to stress concentration
Solution Approach 1:
The patent applies the intermediary principle by introducing protective sheets as mediator elements between layers of glass film. These protective sheets act as intermediaries that distribute stresses and prevent direct contact between glass film surfaces, thereby reducing stress concentration and breakage risk. The protective sheets are simple to implement but effectively resolve the packaging-breakage contradiction.
Solution Approach 2:
The patent employs composite materials by combining glass film with protective sheets in a layered structure. This composite packaging structure leverages the strength and protective properties of the protective sheets while maintaining the flexibility and functionality of the glass film. The composite approach enhances overall breakage resistance without significantly complicating the packaging process.
3Volume of moving object
If glass film is wound into a roll to improve space saving, then space efficiency is improved, but end surface defects increase leading to breakage
Solution Approach 1:
The patent applies beforehand cushioning by placing protective sheets at the end surfaces of the glass film before winding into a roll. This preventive cushioning protects the vulnerable end surfaces from defects and damage during the winding process and subsequent handling. The protective sheets are positioned in advance to prevent micro cracks and flaws that would otherwise occur at the exposed end surfaces.
Solution Approach 2:
The patent uses flexible protective sheets that can conform to the curved surface of the rolled glass film. These thin film protectors wrap around the end surfaces, providing protection without rigid constraints. The flexible nature of the protective sheets allows them to adapt to the roll geometry while effectively shielding the glass film end surfaces from harmful factors.
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 solution provides a robust and flexible glass roll with reduced risk of breakage from end surface defects, maintaining the glass film's integrity during handling and storage by minimizing micro cracks and stress concentrations.
Implementation Method 1
each end cut surface in a width direction to be cut by laser cutting
Data Source
Figure 1~2
Figure 3a~4
Figure 5~6
AI summary
To provide a glass roll capable of reliably preventing a glass film from breaking from an end surface of the glass film as an origin of breakage, a glass roll (1) is formed by winding a glass film (2) into a roll while superposing the glass film (2) on a protective sheet (3), the glass film (2) being formed by an overflow downdraw method to have a thickness of 1 µm or more and 200 µm or less, and to have each end surface in a width direction to form a cut surface cut by laser splitting.