Quadrangular Prism Cutting Resin Support Method
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Solution Overview
Problem
The formation of quadrangular prisms on brittle substrates, such as in ultrasonic probes and scintillators, often results in a high aspect ratio, leading to prism instability and potential falling during the cutting process due to cutting water blast, rendering them unusable.
Innovation Solution
A processing method involving an excess-sized plate-shaped substrate with an excess area surrounding the product area, where first and second cut grooves are formed and then filled with resin, followed by removing the excess area to prevent prism falling, by carefully positioning the cutting blade to leave uncut portions in the excess area and cutting along boundaries to separate the excess area from the product area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep cut grooves are formed to create quadrangular prisms with large aspect ratio, then the product functionality is improved, but the quadrangular prisms fall due to cutting water blast
Solution Approach 1:
The patent applies preliminary action by forming support portions along the cutting path before the final cutting operation. These support portions are created by making preliminary cuts that leave unremoved material acting as temporary supports during the cutting process, preventing the quadrangular prisms from falling due to cutting water blast while maintaining the required deep groove geometry
Solution Approach 2:
The support portions act as intermediary elements between the cutting blade and the quadrangular prisms. These intermediate structures provide temporary mechanical support to the deep grooves during the cutting process, absorbing the impact of cutting water blast and preventing prism collapse, while being removed in a subsequent finishing step
2Manufacturing precision
If the cutting blade passes near the end of cutting to form deep grooves, then the quadrangular prisms are formed with required dimensions, but the prisms fall due to cutting water blast
Solution Approach 1:
The support portions are formed in advance along the cutting path to provide structural reinforcement before the harmful cutting water blast occurs. These preliminary structures are positioned to intercept and dissipate the cutting water energy before it can impact the deep grooves and cause prism failure
Solution Approach 2:
The support portions serve as cushioning structures that absorb and dissipate the cutting water blast energy before it reaches the quadrangular prisms. By placing these support elements ahead of the harmful effect, the patent protects the final product from damage while maintaining cutting 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
This method effectively suppresses the falling of quadrangular prisms, ensuring their functionality and usability by maintaining their structural integrity during the cutting and resin filling process.
Implementation Method 1
The cutting blade and the plate-shaped substrate are relatively moved to thereby slice the plate-shaped substrate
Implementation Method 2
the rigidity of the plate-shaped substrate is increased by filling the first cut grooves with the resin
Implementation Method 3
there is a case that some of the quadrangular prisms may fall due to the blast of a cutting water in cutting the plate-shaped substrate on one side of the plate-shaped substrate where the cutting blade passes near the end of cutting
Data Source
AI summary
Disclosed herein is a processing method for forming a plurality of quadrangular prisms on a plate-shaped substrate having a product area. The processing method includes the steps of preparing an excess-sized plate-shaped substrate having an excess area surrounding the product area, cutting the excess-sized plate-shaped substrate in a first direction by using a cutting blade to thereby form a first cut groove extending in the first direction, cutting the excess-sized plate-shaped substrate in a second direction perpendicular to the first direction by using the cutting blade to thereby form a second cut groove extending in the second direction, filling the first cut groove and the second cut groove with a resin, and cutting the excess-sized plate-shaped substrate along the boundary between the product area and the excess area by using the cutting blade to thereby remove the excess area from the excess-sized plate-shaped substrate.