Gravity Bending Glass Mold with Counterweight Articulated Wings
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Solution Overview
Problem
Conventional gravity bending moulds face challenges in achieving high curvature of glass sheets for vehicle windows with consistent optical quality and surface control, often resulting in imperfections and difficulty in controlling the bending operation due to the complexity of existing designs and the need for additional forces that can mark the glass surface.
Innovation Solution
A gravity bending mould with a final and intermediate peripheral rim system, where the intermediate mould is initially raised and then lowered to allow two phases of bending, enabling precise control over the curvature by aligning movable shaping rails to form a continuous peripheral rim, allowing the glass to sag and bend under gravity, thus avoiding the use of additional press bending dies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a press bending die is used to apply additional downward force on the glass sheets, then the desired high curvature can be achieved, but the upper surface of the glass sheet is contacted during bending which may lead to marking and reduction in surface quality
Solution Approach 1:
The patent employs counterweights connected to the articulated wings to provide the necessary downward force during bending without requiring a press bending die. The counterweights create a mechanical advantage that allows gravity to do the work of bending while the wings remain elevated, preventing surface marking.
Solution Approach 2:
The patent replaces the mechanical press bending die system with a gravity-based system using counterweights and articulated wings. This substitution eliminates the need for direct contact between a pressing mechanism and the glass surface, thereby preventing surface marking while achieving the desired curvature.
2Force
If a press bending die is used to achieve high curvature, then the bending force can be increased, but the equipment costs are increased
Solution Approach 1:
The counterweight system provides the necessary bending force through gravitational force acting on the counterweights, eliminating the need for expensive press bending equipment. This mechanical advantage system achieves high bending force without requiring complex and costly machinery.
Solution Approach 2:
The system uses the weight of the counterweights themselves to generate the bending force, rather than requiring an external power source or complex mechanical system. The counterweights automatically provide the necessary force as the wings move from the open to closed position.
3Shape
If a press bending die is used to achieve high curvature, then the bending operation can be completed, but the production rate is reduced compared to using solely gravity bending
Solution Approach 1:
The patent replaces the multi-step process involving press bending with a single gravity-based bending operation using articulated wings and counterweights. This streamlined process eliminates the need for additional pressing steps, thereby increasing production rate while achieving the same curvature results.
4Shape
If an auxiliary rim is mounted on the articulated wing to introduce cross curvature, then high curvature can be achieved, but the auxiliary rim must be released during bending which requires continued dynamic motion and makes control difficult
Solution Approach 1:
The patent divides the bending operation into two distinct phases: longitudinal bending by the main articulated wings and cross curvature introduction by the auxiliary rim. This segmentation allows each component to perform its function independently and simultaneously, eliminating the need for sequential operation and improving control.
Solution Approach 2:
The patent merges the functions of longitudinal and cross bending into a single simultaneous operation. The auxiliary rim is fixed to the articulated wing structure, allowing both longitudinal curvature (from wing rotation) and cross curvature (from auxiliary rim geometry) to be introduced at the same time without requiring separate release and actuation steps.
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 enhances the control over the bending process, reduces surface imperfections, and maintains high optical quality by separating the introduction of longitudinal and cross curvatures, allowing for the production of glass sheets with high curvature and improved compatibility with windscreen wiper systems at a higher production rate.
Implementation Method 1
the glass sheets are supported on a bending mould while being conveyed through a heating lehr of a glass bending furnace
Implementation Method 2
as the glass heats it softens and progressively sags downwardly under gravity
Data Source
AI summary
A gravity bending mold for bending glass sheets is disclosed. The mold comprises a final mold having a final peripheral shaping rim and an intermediate mold having an intermediate peripheral shaping rim. The final mold has a final articulated end portion having a final movable shaping rail and is mounted at an end of the mold. The intermediate mold has an intermediate articulated end portion having an intermediate movable shaping rail and is mounted at the end of the mold adjacent to the final articulated end portion. The final articulated end portion and the intermediate articulated end portion are arranged so that at least a portion of the final movable shaping rail is alignable with at least a portion of the intermediate movable shaping rail to form part of the intermediate peripheral shaping rim. There is also provided a method of bending glass sheets using such a mold.