Structured Glass Channels With Rounded Walls for Thin-Glass Strength

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Solution Overview

Problem

Existing methods for structuring glass, such as sandblasting and ultrasonic vibratory lapping, are limited in precision and suitability for thin glasses, often resulting in stress, residues, and reduced strength, especially when creating fine structures that extend between the side faces of glass elements.

Innovation Solution

A laser-based process using an ultrashort pulse laser to create filament-shaped flaws in glass, which are then widened by an etching medium to form channels with rounded walls and hemispherical depressions, allowing for precise structuring without significant strength reduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser ablation process is used to produce small structures, then manufacturing precision is improved, but productivity deteriorates due to multiple passes required

Engineering Contradiction:

Improvestructure size precisionVSAvoidprocessing speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the laser pulse duration parameter to ultrashort pulses (femtosecond or picosecond range), which enables precise ablation with minimal thermal damage and allows for through-structures to be created in fewer passes, thereby improving both precision and productivity simultaneously

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If conventional laser ablation is used, then holes can be created, but thermal stressing and microcracks are produced in the peripheral region

Engineering Contradiction:

Improvehole creation capabilityVSAvoidthermal stress and microcracks

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

The patent uses ultrashort pulse durations (femtosecond or picosecond range) which confine the energy deposition time scale to be shorter than the thermal diffusion time scale, preventing heat accumulation and thermal stress in the surrounding material while still achieving effective ablation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs pulsed laser operation with specific pulse duration and repetition rate parameters, delivering energy in discrete ultrashort bursts that allow the material to cool between pulses, preventing cumulative thermal damage and microcrack formation

Inventive Principle:

Principle #19Periodic action

3Ease of manufacture

If mechanical removal methods are used, then holes can be produced, but stresses and residues are left in the glass

Engineering Contradiction:

Improvehole production capabilityVSAvoidstresses and residues

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces mechanical removal methods (sandblasting, ultrasonic vibratory lapping) with a non-contact laser ablation process that removes material through controlled vaporization and ejection, eliminating mechanical stresses and surface residues while maintaining manufacturing capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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 process enables the creation of glass elements with fine structures that extend between side faces without significantly reducing strength, and can even increase strength by dissipating tensile stresses through the rounded depressions, making it suitable for industrial manufacturing.

Implementation Method 1

a laser-based process using an ultrashort pulse laser to create filament-shaped flaws in glass

Methodology Applied

Scientific EffectLaser ablation: Laser Ablation

Implementation Method 2

The laser beam of an ultrashort pulse laser is directed onto one of the side faces of the glass element and concentrated by focusing optics to form an elongated focus in the glass element

Methodology Applied

Scientific EffectLaser: Laser

Implementation Method 3

the glass element is exposed to an etching medium which removes glass of the glass element at a removal rate of less than 15 μm, for example less than 10 μm, for example less than 8 μm per hour

Methodology Applied

Scientific EffectEtching:

Data Source

PatentUS12297137B2Structured plate-like glass element and process for the production thereof

Publication Date: 2025.05.13 SCHOTT AG

AI summary

A method includes: providing a plate-like glass element having side faces and an ultrashort pulse laser having a laser beam; directing the laser beam onto one of the side faces; concentrating the laser beam by focusing optics to form an elongated focus in the glass element; producing a filament-shaped flaw in a volume of the glass element by a radiated-in energy of the laser beam, a longitudinal direction of which runs transverse to one of the side faces, and the ultrashort pulse laser radiates in a pulse or a pulse packet having at least two successive laser pulses to produce the filament-shaped flaw; widening the filament-shaped flaw to form a channel by exposing the glass element to an etching including an etching medium which removes glass at a rate of less than 8 μm per hour; and introducing rounded, hemispherical depressions in a wall of the channel by the etching.