Glass Sheet Thermal Beam Cutting for Controlled Curved Breakage
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Solution Overview
Problem
Existing methods for shape cutting glass sheets with curved cuts are inefficient, particularly for thick or coated/laminated sheets, as they often result in uncontrollable breakage, damage to coatings, and require the use of refrigerating fluids or flames, leading to environmental issues and product rejection.
Innovation Solution
A method using a machine with a double gantry scoring device and a thermal cutting assembly featuring an incandescent light bulb to create a controlled thermal gradient for breaking the glass along a curved cutting line, eliminating the need for liquids or gases by focusing a thermal beam to achieve spontaneous breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If naked flames or refrigerating fluids are used for breaking glass sheets, then breakage can be achieved along the scoring line, but the breakage process becomes difficult to control and often occurs spontaneously along different cutting lines
Solution Approach 1:
The patent replaces the mechanical forcing method and thermal shock method with a controlled thermal gradient method. Instead of using naked flames or refrigerating fluids, the invention uses a heating device that applies heat in a controlled manner to create a specific thermal gradient pattern (higher temperature at edges than at the center) that reliably produces breakage along the scoring line without spontaneous breakage.
Solution Approach 2:
The patent changes the thermal parameters by controlling the temperature distribution pattern - specifically creating a thermal gradient where the edges are heated to a higher temperature than the center. This controlled parameter change (temperature distribution) ensures reliable and predictable breakage along the scoring line.
2Manufacturing precision
If refrigerating fluids are used for breaking glass sheets, then breakage occurs along the scoring line, but the sheet becomes fouled and needs cleaning
Solution Approach 1:
The patent substitutes the refrigerating fluid method with a pure thermal gradient method using heating devices. This eliminates the harmful effect of fluid fouling on the glass sheet surface while maintaining the ability to achieve precise breakage along the scoring line through controlled thermal gradients.
3Manufacturing precision
If refrigerating fluids are used for breaking glass sheets, then breakage can be achieved, but the fluids evaporate or disperse in the working environment requiring suction devices
Solution Approach 1:
The patent replaces the refrigerating fluid system with a heating-based thermal gradient system. This substitution eliminates the problems of fluid evaporation, dispersion, and the need for suction devices, while still achieving controlled breakage along the scoring line through the thermal gradient effect.
4Manufacturing precision
If naked flames or refrigerating fluids are used for breaking glass sheets, then breakage can be achieved, but coated glass sheets have their coatings removed or damaged
Solution Approach 1:
The patent changes the thermal parameters by applying heat in a controlled and distributed manner rather than using concentrated naked flames. The thermal gradient method uses moderate temperature increases that achieve breakage through differential expansion without reaching temperatures that would damage sensitive coatings on the glass sheet.
5Manufacturing precision
If refrigerating fluids are used for breaking glass sheets, then breakage can be achieved, but laminated glass sheets cannot be cut because the intermediate layer must be heated and softened
Solution Approach 1:
The patent changes the thermal approach from rapid cooling (which hardens the intermediate layer) to controlled heating with a specific gradient pattern (edges hotter than center). This parameter change allows the intermediate layer to be properly softened for breakage while maintaining control over the breaking process, enabling the method to work with both monolithic and laminated glass sheets.
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 method allows for precise, controlled cutting of glass sheets without the use of liquids or gases, reducing breakage time and improving product quality, and can be applied to various types of glass sheets, including coated and laminated ones, while minimizing environmental impact.
Implementation Method 1
a thermal cutting assembly 8 for heating a zone of the sheet 2 arranged along the cutting line 3 and causing the gradual and spontaneous breakage of the sheet 2 itself
Implementation Method 2
causing the gradual and spontaneous breakage of the sheet 2 itself by effect of a thermal gradient generated in the sheet 2
Implementation Method 3
concentration device 22 for concentrating the thermal beam 19 emitted by the source 18 and generating an output thermal beam 23 either concentrated or converging in a focusing point 24
Implementation Method 4
heating a zone of the sheet 2 arranged along the cutting line 3 and causing the gradual and spontaneous breakage of the sheet 2 itself by effect of a thermal gradient generated in the sheet 2
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A sheet glass (2) is broken along at least one predetermined cutting line (3) by making an scoring line (7) coinciding with the cutting line on at least one of the extended surfaces (2A,2B) of the sheet and directing a thermal beam (19) emitted by a thermal source (18) of an electric light bulb (11) towards the scoring line, thus triggering a breakage front in a point of the scoring line and moving the thermal beam (9) along the breakage line causing a continuous advancement of the breakage front along the scoring line (7).