Glass Substrate Composition Reducing Inclusions and Warpage
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Solution Overview
Problem
Current methods for manufacturing glass substrates for display devices fail to adequately reduce solid inclusions, gas inclusions, thickness range, and warpage, which are critical for improving the quality and performance of these devices.
Innovation Solution
A composition comprising SiO2, Al2O3, B2O3, CaO, MgO, and SrO, with specific weight ratios and an M value calculation, is used to produce glass substrates, combined with sonication and the insertion of rods during the glass melt process to enhance homogenization and reduce inclusions and warpage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional glass manufacturing methods are used, then production process is simple, but solid inclusions and gas inclusions content is high
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the glass batch, specifically setting Al2O3 at 18-25 wt%, B2O3 at 12-20 wt%, CaO at 8-15 wt%, MgO at 3-8 wt%, and SrO at 2-5 wt%. This systematic parameter optimization resolves the contradiction by achieving low inclusion content through controlled composition rather than complex processing equipment.
Solution Approach 2:
The patent employs composite materials by creating a multi-component glass system that combines traditional glass formers (SiO2, B2O3) with specific amounts of alumina and multiple metal oxides (CaO, MgO, SrO). This composite approach eliminates inclusions by designing a chemically balanced system where components work synergistically to prevent inclusion formation, rather than using simpler single-component systems.
2Manufacturing precision
If conventional glass manufacturing methods are used, then manufacturing process is straightforward, but thickness range and warpage are high
Solution Approach 1:
The patent achieves improved thickness control and reduced warpage by optimizing chemical composition parameters, particularly the balance between network formers and modifiers. The specific ratio of CaO to MgO to SrO creates a glass matrix with controlled viscosity and thermal properties, enabling precise thickness control during floating or rolling processes without requiring complex manufacturing equipment.
Solution Approach 2:
The patent applies local quality by ensuring uniform distribution of specific components (particularly SrO and B2O3) throughout the glass batch to create homogeneous local regions with consistent thermal and mechanical properties. This uniformity at the local level prevents warpage and thickness variations during cooling and processing.
3Reliability
If glass substrate quality is improved by reducing inclusions and warpage, then display device performance improves, but production cost increases
Solution Approach 1:
The patent optimizes the balance between quality and cost by carefully selecting parameter ranges for each oxide component. For example, SrO is limited to 2-5 wt% rather than higher amounts that would improve quality further but increase cost significantly. This parameter optimization achieves acceptable display device quality (low inclusions and warpage) while controlling raw material costs through efficient use of expensive components.
Solution Approach 2:
The patent uses relatively inexpensive oxide components (CaO, MgO, B2O3) as substitutes for more expensive materials that could achieve similar quality improvements. The composition design copies the functional benefits of high-performance glass systems using cost-effective raw materials, maintaining display device reliability while controlling production costs.
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 approach significantly lowers the content of solid and gas inclusions, thickness range, and warpage, resulting in improved coating defects, displaying effects, and fracture toughness, thereby enhancing the quality and yield of display devices.
Implementation Method 1
either or both of step 1) and step 2) comprise sonication
Implementation Method 2
by means of controlling the types and contents of components in the composition for preparing a glass and/or in the glass to satisfy a specific matching relationship
Data Source
AI summary
The invention discloses a composition for preparing glass, a glass article and a use thereof, and a glass article made from the composition. The glass article is preferably a glass substrate made from a composition with an M value of from about 1 to about 10 as calculated by the empirical equation: M=0.13×wt (B2O3)×wt (B2O3)+0.42×wt (CaO)+0.55×wt (MgO)+0.75×wt (SrO)−0.05×wt (Al2O3)×wt (Al2O3). A use of the glass article (especially the glass substrate) for manufacturing a display device is disclosed herein, wherein the glass article has better properties, such as lowered content of solid inclusions and gas inclusions, lowered thickness range and lowered warpage.