Multi-Layer Thin Glass Sheet Drawing Process
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Solution Overview
Problem
Existing methods for forming thin glass sheets are challenging, as traditional forming processes become difficult at thinner thicknesses, and etching or grinding processes are costly and can introduce flaws.
Innovation Solution
A method involving a glass preform with multiple layers, where the preform is heated and drawn to form a thinner glass sheet with specific thickness ratios, allowing for the retention of pristine surfaces and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional forming processes are used to produce thin glass sheets, then the glass sheet can be formed at standard thicknesses, but the processes become difficult and impractical when attempting to achieve thinner thicknesses
Solution Approach 1:
The glass sheet is divided into multiple layers with different compositions, where each layer serves a specific function. This segmentation allows the formation of very thin total thickness (at most about 100 μm) while maintaining structural integrity and manufacturability, as each layer can be optimized independently for its specific role in the forming process and final application.
Solution Approach 2:
The invention uses a composite glass structure with at least a first glass layer and a second glass layer having different compositions. This composite approach enables the achievement of thin overall thickness while maintaining formability and strength, as each glass composition can be tailored to provide specific properties needed for the forming process and final product performance.
2Manufacturing precision
If etching or grinding processes are used to reduce glass sheet thickness, then the desired thin thickness can be achieved, but the processes are costly and can introduce flaws into the glass
Solution Approach 1:
The glass sheet is formed with the desired thin thickness through a specialized forming process that creates the multi-layer structure in advance, rather than starting with a thicker sheet and removing material. This preliminary formation of the thin structure eliminates the need for subsequent etching or grinding operations, thereby avoiding the introduction of flaws and reducing costs associated with these subtractive processes.
Solution Approach 2:
The multi-layer glass composition is designed so that each layer contributes to the overall strength and integrity of the thin sheet. This composite structure allows the thin glass sheet to maintain sufficient mechanical strength without requiring flaw-introducing finishing processes, as the layered architecture inherently provides structural robustness at thin dimensions.
3Shape
If the glass sheet is made thinner to achieve desired thickness ratios, then the flexibility and specific design requirements are met, but the structural strength may be compromised
Solution Approach 1:
The glass sheet comprises at least a first glass layer and a second glass layer with different compositions, where each layer can be optimized for specific properties. This composite structure enables the achievement of thin overall thickness and desired thickness ratios while maintaining structural strength, as each layer contributes different mechanical and physical properties that collectively enhance the overall performance of the thin sheet.
Solution Approach 2:
Different regions or layers of the glass sheet have different compositions tailored to specific local requirements. This local quality optimization allows certain layers to provide enhanced strength or stiffness where needed, while other layers can be optimized for flexibility or other specific properties, enabling the thin sheet to meet both shape requirements and strength demands simultaneously.
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 enables the production of thin glass sheets with maintained thickness ratios, achieving thicknesses not possible with conventional techniques, while preserving the glass's innate strength and flexibility.
Implementation Method 1
A method is provided involving a glass preform with multiple layers. The preform is heated and drawn to form a thinner glass sheet
Implementation Method 2
The drawing unit is configured to draw the glass preform in a distal direction to form a drawn glass sheet extending distally from the glass preform. A thickness of the drawn glass sheet is less than a thickness of the glass preform.
Data Source
AI summary
A method includes heating a glass preform having a plurality of glass layers and drawing the glass preform in a distal direction to form a drawn glass sheet extending distally from the glass preform and having the plurality of glass layers. The drawn glass sheet is thinner than the glass preform. The drawn glass sheet can be rolled onto a collection spool. At least a portion of a glass layer can be removed from the drawn glass sheet. An exemplary glass sheet includes a first glass layer, a second glass layer adjacent to the first glass layer, and a thickness of at most about 0.1 mm. An exemplary ion exchanged glass sheet includes a thickness of at most about 0.1 mm and a surface layer that is under a compressive stress and extends into an interior of the glass sheet to a depth of layer.