Glass Article Separation Using Void Arrays to Protect Organic Films
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Solution Overview
Problem
Existing methods for separating glass articles from glass plates using laser cutting often damage organic films due to incident heat, leading to reduced manufacturing efficiency and complexity in handling multiple glass substrates.
Innovation Solution
A manufacturing method involving the formation of in-plane void regions and internal void arrays on the glass plate using a first laser, followed by deposition of an organic film and subsequent separation using a second laser, which minimizes damage to the organic film by controlling the irradiation conditions to maintain a specific fluorine-to-silicon ratio as determined by X-ray photoelectron spectroscopy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If laser light is used to separate glass articles from glass plates, then separation efficiency is improved, but organic films on the glass surface are damaged by incident heat
Solution Approach 1:
The patent applies segmentation by creating an array of micro-holes (through-holes or blind holes) in the glass plate before separation. These micro-holes are arranged in a pattern that allows the glass to be separated along predetermined lines without directly exposing the organic film to high-intensity laser heat. The segmentation of the glass structure through hole formation enables controlled fracture paths that bypass the film-damaging thermal effects.
Solution Approach 2:
The patent employs preliminary action by forming the micro-hole array in advance before the actual separation operation. This pre-formed hole structure creates stress concentration points and defined fracture paths that guide the separation process. By preparing this internal structure beforehand, the subsequent separation can be achieved with lower laser energy input, reducing thermal damage to the organic film while maintaining high separation efficiency.
2Reliability
If organic films are deposited on glass substrates after separation, then film integrity is improved, but manufacturing complexity increases due to handling multiple glass substrates
Solution Approach 1:
The patent applies preliminary action by depositing the organic film on the glass plate before the separation process. This allows the film to be formed continuously over the entire glass surface in a single deposition step, avoiding the need to handle and re-deposit films on individually separated glass articles. The film is then separated together with the glass, maintaining its integrity while simplifying the manufacturing process.
Solution Approach 2:
The patent merges the film deposition and glass separation operations into a unified process sequence. By depositing the film on the intact glass plate and then separating the plate with the film already in place, the method combines what would otherwise be separate operations (deposit on individual pieces) into one continuous process, reducing handling steps and manufacturing complexity.
3Speed
If high power laser is used for fusion cutting, then separation speed is improved, but organic films are significantly damaged by incident heat
Solution Approach 1:
The patent uses segmentation to divide the separation task into two stages: first forming micro-holes with lower power laser, then utilizing these holes to guide rapid separation with minimal additional heating. The micro-hole array creates predetermined fracture lines that allow the glass to split quickly along defined paths, maintaining high separation speed while the segmented hole structure distributes and reduces thermal exposure to the organic film.
Solution Approach 2:
The micro-hole array acts as an intermediary structure that mediates between the laser energy input and the glass separation process. These holes serve as stress concentrators and fracture initiation points that enable the glass to separate with reduced laser power requirements. The intermediary hole structure allows the system to achieve high separation speed without applying the high power laser energy that would directly damage the organic film.
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 effectively prevents significant damage to organic films during the separation process, enhancing manufacturing efficiency by allowing for precise control of the separation process and maintaining the integrity of the organic film.
Implementation Method 1
a step (1) of irradiating a first main surface of a glass plate having the first main surface and a second main surface, opposite each other, with a laser light of a first laser, to form an in-plane void region, in which a plurality of voids are arrayed, on the first main surface, and to form a plurality of internal void arrays, each including a void or two or more voids arrayed from the in-plane void region to the second main surface, in the glass plate
Implementation Method 2
a step (3) of irradiating and scanning the first main surface or the second main surface of the glass plate, on which the organic film was deposited, with a laser light of a second laser that is different from the first laser, along the in-plane void region or a neighborhood of the in-plane void region, to separate one glass article or two or more glass articles from the glass plate along the in-plane void region
Implementation Method 3
a step (2) of depositing the organic film on the first main surface or the second main surface of the glass plate
Data Source
AI summary
A manufacturing method of a glass article having an organic film includes irradiating a first main surface of a glass plate having the first main surface and a second main surface, opposite each other, with a laser light of a first laser, to form an in-plane void region, in which voids are arrayed, on the first main surface, and internal void arrays, including voids arrayed from the in-plane void region to the second main surface, in the glass plate; depositing the organic film on the first main surface or the second main surface of the glass plate; and irradiating and scanning the first main surface or the second main surface, on which the organic film was deposited, with a laser light of a second laser, along the in-plane void region, to separate the glass article from the glass plate along the in-plane void region.