Sequential Glass Pressing for Thin Complex Article Forming
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Solution Overview
Problem
Existing press forming techniques are limited in producing glass-based articles with complex shapes and thickness variations due to high force requirements, especially for thicknesses less than 1.4 mm, as the flow resistance increases significantly with decreasing thickness.
Innovation Solution
A method involving sequential formation of reduced-area pressing zones by moving portions of molding members relative to each other, reducing the flow path length and viscosity of molten glass, allowing for lower force requirements to achieve desired thicknesses and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional press forming techniques are used to produce thin glass-based articles, then the required pressing force increases significantly, but existing pressing apparatuses are incapable of producing certain geometries given these force constraints
Solution Approach 1:
The pressing process is divided into multiple sequential stages, with each stage forming a reduced-area pressing zone that progresses through the mold. This segmentation allows the total pressing force to be distributed over time and space, reducing the peak force requirement while achieving the desired thin thickness control.
Solution Approach 2:
The method performs preliminary forming actions in sequential reduced-area zones before final thickness reduction. By progressively pre-forming the glass in staged zones, the material flow is controlled to reduce viscosity and resistance before the final pressing stage, enabling thin thickness achievement with lower overall force.
2Manufacturing precision
If the desired thickness of the glass-based article decreases, then the channel size for molten glass flow reduces, but flow resistance increases significantly
Solution Approach 1:
The forming process segments the glass flow path into multiple reduced-area pressing zones. Each zone creates a controlled, progressive flow path that maintains adequate channel size throughout the process, preventing excessive flow resistance even as the final thickness becomes very small.
Solution Approach 2:
Preliminary forming actions in upstream reduced-area zones prepare the glass by reducing its viscosity and establishing controlled flow patterns before the material enters narrower channels. This preliminary preparation significantly reduces flow resistance in subsequent zones where thin thickness is achieved.
3Manufacturing precision
If sequential pressing with multiple reduced-area pressing zones is implemented, then thinner glass-based articles can be produced, but the pressing apparatus becomes more complex
Solution Approach 1:
The pressing apparatus incorporates movable portions that can dynamically reposition to create sequential reduced-area pressing zones. This dynamic capability allows a single apparatus to perform multiple pressing stages without requiring separate fixed molds for each zone, reducing overall system complexity while achieving thin thickness control.
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 production of glass-based articles with thicknesses less than or equal to 1.2 mm and large cross-sectional areas, using simpler and less expensive pressing equipment, overcoming the limitations of current techniques.
Implementation Method 1
As molten glass is pressed, the glass must flow from the mold center outwards to form the periphery of the glass-based article
Implementation Method 2
pressing the molten glass between the first pressing surface and the second pressing surface by moving the first molding member and the second molding member towards one another
Data Source
AI summary
A method of forming a glass-based article comprises depositing molten glass onto a first molding member and pressing the molten glass between the first and second molding members by moving the first molding member and the second molding member towards one another. The pressing of the molten glass comprises moving a portion of one of the first and second molding members relative to a remaining portion thereof to form a first reduced-area pressing zone and, after formation of the first reduced-area pressing zone, moving the portion relative to the remaining portion to form a second reduced-area pressing zone where the molten glass is compressed between the first and second molding members.