Continuous Glass Sheet Forming via Pneumatic Expansion
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Solution Overview
Problem
Current methods for producing ultra-thin, flexible glass sheets are not suitable for large-volume commercial production, and existing materials like polymeric substrates and metal foils are inadequate for sealing OLED displays due to permeability issues with oxygen and moisture.
Innovation Solution
A method and system involving a susceptor bearing with a porous sidewall that expands and thins a glass tube by blowing it radially with a pressurized fluid, maintaining it above the softening point, and then cooling and sectioning it to form continuous glass sheets, using a heating system and drawing mechanism to regulate temperature and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If glass is used to provide hermetic sealing for OLED displays, then impermeability to oxygen and moisture is improved, but flexibility deteriorates because glass is not generally a flexible material
Solution Approach 1:
The patent changes the thickness parameter of glass to ultra-thin dimensions (less than 150 micrometers, preferably less than 100 micrometers), which fundamentally alters the material's mechanical properties. This parameter change enables the glass to achieve flexibility while maintaining its hermetic sealing capability, resolving the contradiction between impermeability and flexibility.
2Shape
If existing methods for producing ultra-thin glass are used, then thinness is improved, but productivity deteriorates because they are not suitable for large volume commercial production
Solution Approach 1:
The patent replaces traditional mechanical contact-based forming methods with a blowing process where pressurized gas is introduced through a susceptor bearing to expand and thin the glass tube. This substitution enables continuous production of ultra-thin glass sheets with large surface area, achieving both thinness and high productivity suitable for commercial applications.
3Manufacturing precision
If mechanical contact is used to form glass sheets, then manufacturing precision is improved, but surface finish deteriorates due to increased surface roughness
Solution Approach 1:
The patent employs a pneumatic blowing process where pressurized gas flows through the susceptor bearing to expand and thin the glass tube without mechanical contact. This pneumatic approach maintains precise dimensional control through pressure and temperature parameters while producing glass sheets with low surface roughness, eliminating the trade-off between precision and surface quality.
4Shape
If the glass tube is blown radially with pressurized fluid, then thinness and flexibility are improved, but device complexity increases due to the susceptor bearing system
Solution Approach 1:
The patent utilizes a susceptor bearing with a porous sidewall that serves multiple functions: it contains the pressurized gas, distributes it uniformly, and supports the glass tube during the blowing process. The porous structure enables complex fluid distribution through a relatively simple geometric form, achieving thin glass formation without proportionally increasing device complexity.
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
Enables the production of thin, continuous glass sheets with low surface roughness and flexibility, suitable for large-scale commercial use, while providing a hermetic seal for OLED displays by minimizing mechanical contact and ensuring impermeability to oxygen and moisture.
Implementation Method 1
The tube of glass may be maintained at a temperature above a softening point of the glass as the tube of glass is drawn over the susceptor bearing
Implementation Method 2
The tube of glass may be suspended over the susceptor bearing by blowing the tube of glass away from the susceptor bearing in a radial direction with a pressurized fluid supplied to the internal chamber
Implementation Method 3
The drawing mechanism is disposed below the susceptor bearing and includes at least one tractor wheel positioned to contact the tube of glass and draw the tube of glass over the susceptor bearing in a downward direction
Implementation Method 4
Thereafter, the tube of glass may be cooled and sectioned to form a continuous glass sheet
Data Source
AI summary
A method for forming a continuous glass sheet from a tube of glass includes expanding and thinning the tube of glass by drawing the tube of glass over susceptor bearing comprising a porous sidewall defining an internal chamber. The diameter of the susceptor bearing may increase between a top portion and a bottom portion. The tube of glass may be maintained at a temperature above a softening point of the glass as the tube of glass is drawn over the susceptor bearing. The tube of glass is suspended over the susceptor bearing by blowing the tube of glass away from the susceptor bearing in a radial direction with a pressurized fluid supplied to the internal chamber and emitted from the porous sidewall as the tube of glass is drawn over the susceptor bearing. Thereafter, the tube of glass is cooled and sectioned to form a continuous glass sheet.