Laser-Cut Pillar Transfer for Burr-Reduced Glass Panel Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing glass panel units result in pillars with burrs and require additional manufacturing steps due to the need for stocking punched pillars, reducing efficiency.
Innovation Solution
A pillar delivery method and apparatus that uses a laser cutter to form pillars directly near the substrate, with a holder and mounter to efficiently deliver pillars with reduced burr, eliminating the need for stocking and additional processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If pillars are made by punching process, then pillars can be manufactured, but burr is generated and additional stocking steps are required
Solution Approach 1:
The patent replaces the mechanical punching process with a laser beam irradiation process to form pillars. The laser beam melts and evaporates the material to create precise pillar shapes without mechanical contact, eliminating burr generation and the need for subsequent deburring or stocking operations.
Solution Approach 2:
The patent utilizes phase transitions of material (solid to liquid to vapor) through laser heating. The laser beam irradiates the sheet material, causing localized melting and evaporation to form pillars directly, avoiding mechanical deformation that creates burr in traditional punching methods.
2Productivity
If pillars are stocked after punching, then pillars are available for manufacturing, but the number of process steps increases and efficiency decreases
Solution Approach 1:
The patent performs preliminary pillar formation directly at the manufacturing location using laser irradiation, eliminating the need for separate stocking and retrieval operations. The pillars are formed on-demand and immediately positioned on the substrate, streamlining the manufacturing process.
Solution Approach 2:
The patent combines the pillar formation process with the mounting process into a single integrated operation. The laser forms pillars and the mounting apparatus positions them on the substrate in one continuous workflow, eliminating separate stocking and retrieval 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
The method and apparatus enable efficient delivery of pillars with significantly reduced burr directly onto the substrate, enhancing manufacturing efficiency and reducing the number of processing steps.
Implementation Method 1
irradiating the sheet with a laser beam to punch out the plurality of pillars
Data Source
AI summary
A pillar delivery method is a method for delivering a plurality of pillars onto a substrate, including a glass panel, to manufacture a glass panel unit. The pillar delivery method includes an irradiation step, a holding step, and a mounting step. The irradiation step includes setting, over a holder, a sheet for use to form pillars and irradiating the sheet with a laser beam to punch out the plurality of pillars. The holding step includes having the plurality of pillars, which have been punched out of the sheet, held by the holder. The mounting step includes picking up some or all of the plurality of pillars from the holder and mounting the pillars onto the substrate.