Laser Moil Separation for High-Temperature Glass Containers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for cutting glass containers, whether hot or cold, face challenges such as low productivity, energy and water consumption, and the generation of defects like flaking, which affect the quality and stability of the cut edge, and require cumbersome machinery and diamond tools.
Innovation Solution
A method involving a high-temperature glass item with a mobile equipment that rotates and translates, using a laser beam with adjustable power and frequency to cut the glass with precision, avoiding water and diamond tools, and incorporating fire polishing for a clean and crisp separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cold cutting using diamond disc and grinding wheel is used, then cut edge quality is improved, but productivity is reduced and energy/water consumption increases
Solution Approach 1:
The patent replaces mechanical cutting systems (diamond discs, grinding wheels) with a thermal field-based laser cutting system. The laser beam melts and vaporizes glass material through concentrated optical energy, eliminating the need for mechanical contact and subsequent machining operations, thereby improving both productivity and cut quality
Solution Approach 2:
The patent changes the physical state parameter of the glass by heating it to high temperature (above 100°C, preferably above 250°C or 500°C) before cutting. This thermal parameter change makes the glass more susceptible to clean separation through laser irradiation, achieving high-quality cuts without mechanical intervention
2Productivity
If cold cutting using CO2 laser beam is used, then productivity is improved, but surface defects like flaking occur requiring additional machining steps
Solution Approach 1:
The patent changes the temperature parameter by heating the glass to high temperature (above 100°C, preferably above 250°C or 500°C) before laser cutting. This thermal preparation prevents surface defects like flaking by ensuring the glass is in an optimal state for clean laser separation, eliminating the need for subsequent flatting and beveling operations
Solution Approach 2:
The patent performs preliminary heating of the glass item before the actual laser cutting operation. This pre-heating step prepares the glass material in advance to receive the laser beam, preventing surface defects and ensuring clean cuts without requiring additional post-processing steps
3Productivity
If hot cutting is used, then productivity is improved and energy consumption is reduced, but cut edge quality is insufficient due to cutting bead formation
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: glass temperature (above 100°C, preferably above 250°C or 500°C), laser power (0.1-1 mJ per firing), pulse duration (10^-15 to 10^-12 s), and firing frequency (>50 kHz, preferably 200 kHz). This multi-parameter optimization enables high-quality cuts without bead formation while maintaining high productivity
Solution Approach 2:
The patent uses periodic laser pulsing at high frequency (>50 kHz, preferably 200 kHz) to deliver controlled energy doses to the glass. This periodic action allows precise thermal processing that melts and separates the moil cleanly without creating excessive bead, achieving both high quality and high speed
4Manufacturing precision
If multiple machining steps are used for cold cutting, then cut edge quality is improved, but device complexity and adjustment problems increase
Solution Approach 1:
The patent merges multiple separate machining operations (cutting-off, flatting, beveling, fire polishing) into a single integrated laser processing step. The laser beam performs all these functions simultaneously through optimized parameter control, eliminating the need for multiple machines and adjustment mechanisms
Solution Approach 2:
The patent replaces complex mechanical machining systems with a single laser processing system. The laser beam, controlled by optimized parameters, performs cutting, flattening, and beveling in one operation, dramatically reducing device complexity and eliminating adjustment problems associated with multiple mechanical 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 method achieves high-quality hot cutting of glass with reduced energy consumption and waste, improving productivity and surface quality while maintaining a stable production process.
Implementation Method 1
firing a laser beam from optics supported by the mobile equipment towards said edge of said glass item to generate holes and separating the moil from the glass item
Implementation Method 2
firing a laser beam from optics supported by the mobile equipment towards said edge of said glass item to generate holes and separating the moil from the glass item
Implementation Method 3
The glass item is then reheated to relax the residual stresses in the glass
Implementation Method 4
identifying a relative position of the mobile equipment with respect to an edge of said glass item, regulating the distance between the mobile equipment and an edge of said glass item as said glass item is rotating and the mobile equipment and said glass item are jointly moving
Data Source
AI summary
Method for manufacturing a hollow item made of glass, involving receiving a glass item associated with a moil (cap) at a temperature in excess of 100° C., setting the glass item in motion in a direction of conveying and in rotation on itself about an axis of the glass item, moving mobile equipment at a substantially constant distance from the glass item, identifying a relative position of the mobile equipment with respect to an edge of the glass item, regulating the distance between the mobile equipment and an edge of the glass item as the glass item is rotating and as the mobile equipment and the glass item are jointly moving along, firing a laser beam from optics supported by the mobile equipment toward said edge of the glass item in order to make holes and to part the glass item from the moil.