Recycled Cover Substrate Composition Control
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Solution Overview
Problem
Post-consumer cover substrates for electronic devices, which have undergone ion-exchange processes, are not suitable for recycling due to compositional changes, making them unsuitable for reincorporation into new cover glass as they deviate from the required target composition, affecting optical performance and mechanical resistance.
Innovation Solution
Determining the composition of recycled post-consumer cover substrates and calculating the maximum amount that can be added to a batch of oxides to maintain the desired composition, forming a new cover substrate with a significant weight percentage of recycled material that can be ion-exchanged, ensuring the resulting substrate meets specifications for optical and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If post-consumer cover substrates are recycled and reincorporated into new cover glass, then material waste is reduced and sustainability is improved, but the compositional deviation from target specifications worsens, affecting optical performance and mechanical resistance
Solution Approach 1:
The patent applies parameter changes by adjusting the batch composition parameters to accommodate recycled substrate. Specifically, it determines the actual composition of recycled post-consumer cover substrate and calculates modified batch formulations that compensate for the compositional deviation caused by recycling, thereby maintaining the final product within specification limits while incorporating recycled materials
Solution Approach 2:
The patent applies local quality by treating the recycled substrate portion differently from virgin materials. It calculates specific compensation amounts for each oxide component based on the recycled substrate's actual composition, applying localized compositional adjustments only to the extent necessary to maintain overall specification compliance while maximizing recycled content incorporation
2Reliability
If the composition of cover substrate is kept within tight specifications, then optical performance and mechanical resistance are maintained, but the ability to incorporate recycled materials worsens due to compositional deviation
Solution Approach 1:
The patent changes the batch composition parameters dynamically based on the recycled substrate's actual composition. By measuring the recycled material's oxide content and calculating appropriate compensation amounts, the process maintains reliable optical and mechanical performance while adapting to accommodate recycled materials that would otherwise be incompatible with tight specifications
Solution Approach 2:
The patent implements feedback by determining the actual composition of recycled post-consumer cover substrate before incorporating it into new batches. This compositional analysis provides feedback that drives the calculation of compensation amounts, creating a closed-loop system that ensures specification compliance while maximizing recycling compatibility
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
Enables the recycling and reuse of post-consumer cover substrates in new electronic devices while maintaining the necessary optical and mechanical performance, reducing raw material and energy consumption, and addressing the limitations of existing recycling methods.
Implementation Method 1
The cover substrate is sometimes chemically toughened via an ion-exchange process. The ion-exchange process changes the composition of the cover substrate at a region contiguous with a primary surface of the substrate.
Data Source
AI summary
A cover substrate for an electronic device including greater than or equal to 1% by weight post-consumer recycled cover substrate. A method of forming the cover substrate including the steps of (i) determining the composition of the post-consumer recycled cover substrate, (ii) determining the maximum amount of the post-consumer recycled cover substrate that can be added to a predetermined batch without causing the resulting cover substrate to fall out of specification, and (iii) forming the cover substrate from the combined recycled post-consumer cover substrate and the predetermined batch. Additionally, a method that includes steps of (i) determining the composition of the post-consumer recycled cover substrate, (ii) determining a target weight percentage of the post-consumer recycled cover substrate in a cover substrate, and (iii) determining weight percentages of other oxides to be added to the target weight percentage for the resulting combination to produce the cover substrate with a desired composition.