Laser-Formed Pillar Mounting for Low-Burr Glass Panel Units
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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, leading to decreased 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 reduce burr formation and streamline the delivery process by forming and mounting pillars in situ, eliminating the need for intermediate stocking.
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 manufacturing efficiency decreases due to intermediate stocking
Solution Approach 1:
The patent combines the pillar formation process and the pillar delivery process into a single integrated system. The laser beam forms pillars directly on the holder that will be used for delivery, eliminating the separate punching and stocking steps. This merging of operations resolves the contradiction by achieving both precise pillar formation (no burr) and high productivity (direct delivery to substrate).
Solution Approach 2:
The patent replaces the mechanical punching process with a laser-based formation process. Instead of using physical punches that generate burr, a laser beam is used to form pillars without contact, eliminating burr generation. This substitution also eliminates the need for intermediate stocking, improving manufacturing efficiency.
2Ease of manufacture
If pillars are punched and stocked, then pillars are available for manufacturing, but the number of process steps increases and efficiency decreases
Solution Approach 1:
The patent performs pillar formation in advance, directly on the holder that will be used for delivery. The pillars are formed while the holder is in position, ready for immediate delivery to the substrate. This preliminary action eliminates the need for separate stocking operations and reduces manufacturing time while simplifying the overall process.
Solution Approach 2:
The holder serves multiple functions: it is used for laser pillar formation, for holding/storing the formed pillars, and for delivering the pillars to the substrate. This multi-functionality eliminates the need for separate stocking containers and simplifies the manufacturing process, reducing both process steps and time loss.
3Productivity
If pillars are formed by punching, then pillars can be produced, but additional stocking steps are required
Solution Approach 1:
The patent merges the pillar formation operation with the pillar delivery operation by forming pillars directly on the holder. This eliminates the need for separate stocking steps and reduces device complexity while improving productivity. The same holder that receives the formed pillars is directly used for delivery to the substrate.
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 efficiently delivers pillars with significantly reduced burr formation, enhancing manufacturing efficiency by forming and mounting pillars directly onto the substrate, thereby improving the thermal insulation properties of glass panel units.
Implementation Method 1
irradiating the sheet with a laser beam to punch out the plurality of pillars
Implementation Method 2
having the plurality of pillars, which have been punched out of the sheet, held by the holder
Data Source
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AI summary
A plurality of pillars with significantly reduced burr are delivered efficiently onto a substrate. A pillar delivery method is a method for delivering a plurality of pillars (3) onto a substrate (91), including a glass panel (910), 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 (1), a sheet (2) for use to form pillars and irradiating the sheet (2) with a laser beam to punch out the plurality of pillars (3). The holding step includes having the plurality of pillars (3), which have been punched out of the sheet (2), held by the holder (1). The mounting step includes picking up some or all of the plurality of pillars (3) from the holder (1) and mounting the pillars (3) onto the substrate (91).