Scoring Tool Alignment for Thin Glass Using Triangulation
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Solution Overview
Problem
The challenge lies in accurately aligning scoring tools for thin and ultra-thin glass substrates to prevent premature breaking and ensure high edge strength during score and break separation, particularly when handling glass thicknesses below 50 μm, where manual alignment is cumbersome and prone to errors, and existing methods struggle with maintaining consistent cutting forces.
Innovation Solution
An apparatus and method that utilize a position detection system based on triangulation to precisely align the cutting edge of the scoring tool relative to the advancement direction, allowing for automatic adjustment of the cutting edge's orientation and inclination, enabling precise alignment with deviations less than ±1°, and applying low, constant cutting forces to minimize transverse forces and prevent premature breaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual alignment of the scoring tool is used, then the alignment can be performed without complex equipment, but the alignment precision is low and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated optical measurement system. A detector determines the actual orientation of the cutting edge, and this information is used to automatically calculate and execute alignment corrections, substituting human-operated mechanical adjustment with an automated measurement-and-control system.
Solution Approach 2:
The scoring tool is equipped with reflective surfaces that enable it to determine its own actual orientation through the detection system. The tool essentially measures itself and provides the necessary alignment data, eliminating the need for external complex alignment equipment.
2Manufacturing precision
If high scoring contact pressure force is applied, then the scoring precision is improved for thicker glass, but the risk of surface damage increases for ultra-thin glass
Solution Approach 1:
The patent changes the pressure parameter dynamically based on glass thickness. For ultra-thin glass (less than 50 μm), the scoring contact pressure force is reduced to below 1 N to prevent surface damage, while for thicker glass, higher forces can be applied to maintain scoring precision. This adaptive parameter adjustment resolves the contradiction between scoring quality and surface integrity.
3Productivity
If automatic alignment system is implemented, then alignment precision and productivity are improved, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment mechanisms with a streamlined system combining a simple detector, reflective surfaces on the scoring tool, and automated calculation. This substitution achieves high productivity through automation while keeping the physical device complexity relatively low.
Solution Approach 2:
The system uses optical reflection to create a virtual copy of the cutting edge orientation, which is then detected and used for alignment calculations. This optical copying approach enables automated alignment without requiring direct physical contact or complex mechanical sensing.
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 approach achieves high edge strength comparable to CO2 laser cutting, reduces the risk of premature breaking, and allows for efficient production of pre-scored glass substrates with edge strengths up to 300 MPa, suitable for industrial-scale processing of thin and ultra-thin glass substrates.
Implementation Method 1
The apparatus utilizes a position detection system based on triangulation to precisely align the cutting edge of the scoring tool
Data Source
AI summary
A method is provided for aligning scoring tools and for scoring glass, in particular thin glass, along predetermined scoring lines in preparation for breaking along the score. Glass substrates, in particular thin glass substrates, produced by such method are also provided. The method includes the determination of the actual orientation of the cutting edge of the scoring tool and aligning of the cutting edge to a target orientation of the cutting edge.