Spherical Bead Interleaving for Glass Sheet Transit Damage
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Solution Overview
Problem
Planar substrates, such as glass sheets, experience transit damage during shipment, including 'wormtracks' and other defects, due to inadequate protection and handling, leading to quality issues and rejection.
Innovation Solution
A shipping system utilizing substantially spherical beads as interleaving material between substrates, with a specific diameter distribution and spacer configuration to distribute load evenly and prevent pressure points, combined with a wrapping system that creates a vacuum seal to minimize environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional interleaving material is used between substrates, then the substrates are protected during shipping, but pressure points and concentrated loads cause transit damage such as wormtracks and scratches
Solution Approach 1:
The patent applies local quality by using spherical beads with specific size distributions (predominantly 0.5-2.0 mm diameter) that create uniform localized contact points across the substrate surface. This distributes the protective function evenly across all regions rather than using a single uniform material layer, preventing concentrated pressure points while maintaining protection quality.
Solution Approach 2:
The patent changes the physical parameters of the interleaving material by using spherical beads with controlled diameter distributions rather than traditional flat or irregular materials. The specific parameter control (bead diameter primarily between 0.5-2.0 mm, with most between 0.6-1.4 mm) transforms how the material distributes load and prevents transit damage while maintaining protection.
2Quantity of substance
If beads with wide size distribution are used, then more beads can fill the spaces between substrates, but smaller beads create pressure points and fail to distribute load evenly
Solution Approach 1:
The patent applies local quality by ensuring that the majority of beads (at least 75%, preferably at least 90%) fall within a specific diameter range (0.5-2.0 mm, with most 0.6-1.4 mm). This creates uniform local contact characteristics across the entire substrate surface, preventing smaller beads from creating pressure points while maintaining adequate coverage.
Solution Approach 2:
The patent changes the size distribution parameters of the beads by controlling that at least 75% (preferably at least 90%) of beads have diameters within 0.5-2.0 mm, with at least 75% (preferably at least 90%) having diameters between 0.6-1.4 mm. This parameter control ensures even load distribution while maintaining sufficient bead quantity for coverage.
3Stress or pressure
If beads with large diameter are used, then pressure distribution is improved, but fewer beads can be positioned between substrates reducing coverage
Solution Approach 1:
The patent optimizes the bead diameter parameters by setting the majority of beads (at least 75%, preferably at least 90%) within the 0.5-2.0 mm range, with most between 0.6-1.4 mm. This parameter selection achieves the optimal balance: beads are large enough to distribute pressure effectively but small enough to provide sufficient coverage and quantity between substrates.
Solution Approach 2:
The patent applies partial action by using a controlled distribution where the majority of beads (at least 75%, preferably at least 90%) are within the optimal size range for pressure distribution, while allowing a smaller portion to vary. This ensures adequate coverage while maintaining effective pressure distribution across the substrate surface.
4Device complexity
If substrates are shipped without adequate interleaving protection, then shipping cost and complexity are reduced, but transit damage such as wormtracks, scratches, and coating damage occur
Solution Approach 1:
The patent applies this principle by using spherical beads as a simple, inexpensive interleaving material that provides effective protection during shipping. The beads are a basic material that can be easily applied and removed, providing disposable-like protection without complex systems, thereby reducing shipping system complexity while preventing transit damage.
Solution Approach 2:
The patent changes the protective approach by using spherical beads with specific diameter distributions (at least 75%, preferably at least 90% within 0.5-2.0 mm range) instead of traditional interleaving materials. This parameter-controlled approach provides adequate protection against transit damage while maintaining simplicity in the shipping system.
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
The system significantly reduces transit damage by evenly distributing load and preventing pressure points, ensuring the quality of planar substrates during long-distance shipping and storage.
Implementation Method 1
substantially spherical beads positioned between the substrates of the pack and configured to carry a load
Implementation Method 2
a wrapping system that creates a vacuum seal to minimize environmental impact
Data Source
AI summary
A shipping system for shipping planar substrates includes a plurality of planar substrates stacked to form a pack and a plurality of interleaving material including substantially spherical beads positioned between the substrates of the pack and configured to carry a load. Substantially all of the beads have a diameter within 25% of Dmax, where Dmax is a diameter corresponding to a size of an opening of an upper limit sieve used in the shipping system. Also disclosed are a spacer for use in a shipping system for shipping planar substrates, a wrapped system for shipping planar substrates, a method of wrapping a system for shipping planar substrates, and a powder applicator.