Glass Thinning via Horizontal Chemical Etching
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Solution Overview
Problem
Conventional methods for thinning glass sheets struggle to achieve ultra-thin thicknesses with tight tolerance control, reduced thickness variability, and enhanced optical clarity, making it difficult to produce glass suitable for flexible and curved display applications.
Innovation Solution
A method involving multiple passes through an etching zone with alternating etchant application and frequent washing, where the glass sheet is flipped and reoriented to ensure uniform etching, allowing for precise control of thickness reduction without mechanical polishing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If conventional glass thinning techniques (vertical etching in bath followed by mechanical polishing) are used, then glass sheet thickness is reduced, but thickness uniformity and optical clarity deteriorate
Solution Approach 1:
The patent replaces mechanical polishing with a chemical etching process to achieve thickness reduction. The glass sheet is subjected to controlled chemical etching in a horizontal configuration, eliminating the need for subsequent mechanical polishing while maintaining thickness uniformity and optical quality.
Solution Approach 2:
The patent changes the etching configuration from vertical (traditional bath etching) to horizontal, with the glass sheet positioned horizontally during etching. This dimensional change allows for better control of etchant flow and more uniform thickness reduction across the glass surface.
2Length of stationary object
If conventional glass thinning techniques are used, then glass sheet thickness is reduced, but optical clarity deteriorates
Solution Approach 1:
The patent replaces mechanical polishing with chemical etching, which produces superior optical clarity. The chemical process creates a more uniform surface without the micro-scratches and stress-induced optical degradation associated with mechanical polishing.
Solution Approach 2:
The patent controls etching parameters including etchant concentration, temperature, and exposure time to optimize both thickness reduction and optical clarity. By carefully adjusting these parameters, the process achieves the desired thickness while maintaining high optical quality.
3Manufacturing precision
If tight tolerance control and reduced thickness variability are required, then processing complexity increases
Solution Approach 1:
The patent divides the etching process into multiple sequential steps with intermediate measurements and adjustments. The glass sheet undergoes progressive etching in stages, allowing for better control of thickness reduction and easier maintenance of tight tolerances compared to a single aggressive etching step.
Solution Approach 2:
The patent incorporates feedback control where the glass sheet is measured during the etching process, and subsequent etching parameters are adjusted based on measured thickness and uniformity. This closed-loop control achieves tight tolerance control without requiring overly complex processing equipment.
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 approach achieves a final thickness with a DOI greater than or equal to 98.5 and thickness variability within 3-9 microns, meeting the requirements for ultra-thin glass with improved optical clarity and reduced stress, suitable for flexible display applications.
Implementation Method 1
passing the glass sheet through an etching zone along a conveyance path a plurality of times until an initial thickness of the glass sheet is reduced to a final predetermined thickness of the glass sheet
Data Source
AI summary
Methods for thinning glass are provided, including methods for reducing a thickness of a glass sheet by subjecting the glass sheet to an etching process. The methods can include passing the glass sheet through an etching zone along a conveyance path a plurality of times until an initial thickness of the glass sheet is reduced to a final predetermined thickness of the glass sheet, and washing the glass sheet after each pass through the etching zone.