Glass Plate Edge Shaping for Precise Magnetic Disk Chamfers
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Solution Overview
Problem
Existing methods for shaping the edge surfaces of glass plates, particularly for magnetic disk applications, face challenges in achieving precise target shapes due to inaccuracies in edge cutting using ultrashort pulse lasers and the complexity of processing with both ultrashort and CO2 lasers. Additionally, glass materials with high rigidity, necessary for reducing vibration in thin glass substrates, are difficult to process with laser beams.
Innovation Solution
A method for manufacturing glass plates involves shaping the edge surfaces using a laser beam with a single-mode cross-sectional intensity distribution, where the power density and thickness of the glass plate are adjusted such that the width of the luminous flux is greater than the glass plate thickness. This method allows for precise control of the chamfered surface formation and side wall surface creation, ensuring the edge surface is shaped into a target form without variation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ultrashort pulse laser is used to cut the edge of glass plate, then the edge can be cut into desired chamfered shape, but the manufacturing precision of edge surface shape is insufficient and variations occur
Solution Approach 1:
The patent combines ultrashort pulse laser cutting with CO2 laser irradiation in a single integrated process. The ultrashort pulse laser creates the initial chamfered shape, and the CO2 laser subsequently irradiates the edge surface to eliminate variations and achieve precise target shapes, resolving the precision issue while maintaining manufacturing ease
Solution Approach 2:
The patent implements continuous edge surface processing by sequentially applying ultrashort pulse laser cutting followed by CO2 laser irradiation without interrupting the workflow. This continuous action ensures consistent shape precision across the entire edge surface while maintaining efficient manufacturing
2Strength
If glass material with high rigidity is used to reduce vibration in thin glass substrates, then the rigidity increases, but the difficulty of laser beam processing increases due to high softening point
Solution Approach 1:
The patent adjusts laser processing parameters specifically for high rigidity glass materials. By optimizing power density, scanning speed, and irradiation patterns, the CO2 laser can effectively process high softening point glass without compromising the material's rigidity properties, thus resolving the contradiction between strength and manufacturability
3Manufacturing precision
If both ultrashort laser and CO2 laser are used for edge surface shape processing, then the target shape can be achieved, but the device complexity increases
Solution Approach 1:
The patent designs a multi-functional laser processing system where a single apparatus can switch between ultrashort pulse laser cutting and CO2 laser irradiation modes. This universal device performs both cutting and precision shaping functions, reducing overall system complexity while maintaining high manufacturing precision
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 enables the glass plate edge surfaces to be shaped into precise target forms efficiently, reducing surface roughness and ensuring consistent chamfered and side wall surfaces. This results in improved integration of magnetic disks into HDD devices and enhanced performance by preventing particle adhesion on main surfaces.
Implementation Method 1
an edge portion of the edge surface of the glass plate is chamfered into a round shape by softening and/or melting the edge portion by irradiating the edge surface of the glass plate with a laser beam
Implementation Method 2
a member, which is to be removed, is separated through irradiation with a CO2 laser beam
Data Source
AI summary
A method for manufacturing a disk-shaped glass plate in which shape processing is performed on an edge surface of the glass plate includes processing the edge surface into a target shape by irradiating the edge surface with a laser beam while moving the laser beam relative to the edge surface in a circumferential direction of the glass plate. A cross-sectional intensity distribution of the laser beam with which the edge surface is irradiated is a single mode, and W1>Th holds true and Pd×Th is in a range of 0.8 to 3.5 [W/mm] when a width of luminous flux of the laser beam in a thickness direction of the glass plate at an irradiation position of the edge surface is W1 [mm], a thickness of the glass plate is Th [mm], and a power density of the laser beam is Pd.