Laser Glass Web Separation Under Controlled Thermal Stress
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Solution Overview
Problem
Conventional methods for separating glass webs are inefficient, particularly in creating a clean separation without damaging the glass and ensuring precise control over the separation process, especially when the glass web is moving.
Innovation Solution
A method involving the use of laser beams to create thermal stress along a designated separation path on the glass web, where a defect is introduced under controlled thermal conditions to facilitate clean separation without damaging the glass, utilizing reflective surfaces and focused laser beams to redirect and concentrate heat precisely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separation techniques are used on stationary glass ribbon, then separation can be achieved, but productivity is reduced due to interruption in traversing the glass ribbon
Solution Approach 1:
The patent applies the dynamics principle by transitioning from stationary glass ribbon separation to moving glass ribbon separation. The laser beam system is designed to track and follow the moving glass ribbon, maintaining continuous separation capability without interruption. This dynamic approach allows the separation process to occur while the glass ribbon is in motion, eliminating downtime and increasing productivity.
Solution Approach 2:
The patent employs preliminary action by first creating thermal stress along the entire separation path before introducing the defect that initiates crack propagation. This pre-conditioning of the glass along the desired separation line ensures that when the crack is initiated, it propagates cleanly and completely along the predetermined path, enabling continuous separation of moving glass ribbon without interruption.
2Manufacturing precision
If laser beams are used to create thermal stress along the separation path, then manufacturing precision is improved, but device complexity increases due to additional optical components
Solution Approach 1:
The patent applies segmentation by using multiple laser beams divided into different functional groups: one or more beams for creating thermal stress along the separation path, and another beam (or portion of a beam) for creating the defect that initiates crack propagation. This segmentation of laser functions allows precise control over the separation process while managing system complexity through modular optical component design.
Solution Approach 2:
The patent implements multi-functionality by designing the optical system to perform multiple functions using integrated components. The same optical system that directs laser beams for thermal stress creation is also configured to redirect portions of the beam for defect creation. This universal approach reduces the need for separate dedicated systems for each function, thereby managing device complexity while maintaining high manufacturing precision.
3Productivity
If the glass web is separated while moving, then productivity is improved, but measurement precision becomes more difficult due to motion effects
Solution Approach 1:
The patent employs feedback mechanisms to maintain precise separation path control during glass ribbon motion. The system continuously monitors the position and movement of the glass ribbon and adjusts the laser beam trajectory accordingly. This real-time feedback ensures that the thermal stress is applied precisely along the intended separation path even as the glass moves, maintaining measurement precision while enabling continuous high-speed separation.
Solution Approach 2:
The patent replaces traditional mechanical separation systems with an optical-based laser system. Instead of using mechanical tools that physically contact and score the glass during motion, the patent uses laser beams to create thermal stress and initiate cracks optically. This substitution eliminates mechanical wear and positioning issues associated with moving mechanical separators, thereby maintaining precision during high-speed continuous separation.
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 allows for precise and efficient separation of glass webs by creating a controlled thermal stress that initiates a full-body crack along the designated path, reducing the time and energy required for separation and minimizing residual stress, suitable for both stationary and moving glass webs.
Implementation Method 1
exposing a separation path on the glass web to at least one laser beam to produce thermal stress along the separation path
Implementation Method 2
redirecting a portion of the at least one laser beam to create a defect on the separation path while the separation path is under thermal stress
Data Source
AI summary
Methods of separating a glass web include exposing a separation path on the glass web to a laser beam that produces thermal stress along the separation path without damaging the glass web. The methods further include redirecting a portion of the laser beam to create a defect on the separation path while the separation path is under thermal stress produced during the exposing the separation path on the glass web to the laser beam, whereupon the glass web separates along the separation path in response to creating the defect. Apparatus are further provided for separating a glass web with at least one laser beam generator that produces a laser beam to heat a separation path and a mirror configured to reflect an end portion of the laser beam to create a defect at a location of the separation path on the glass web.