Substrate Cutting System with Flowable Water Environment
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Solution Overview
Problem
Conventional cutting technologies, such as mechanical cutter wheels, generate debris with irregular surfaces that can scratch substrates like glass, plastic, or quartz, leading to failures in module assembly processes, and water-jet cutting is not suitable due to poor accuracy, abrasive requirements, and potential damage from high hydraulic pressure.
Innovation Solution
A substrate cutting system that uses a cutting tank with a flowable water environment created by an injection and drain pump, where the cutter assembly operates within the tank to remove debris through water flow, incorporating a centrifugal separation system for recyclable de-ionized water and a filter to maintain cleanliness and prevent surface scratches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mechanical cutter wheel is used to cut the substrate, then the cutting process can be performed, but substrate material debris is generated that can scratch the substrate surface and cause module assembly failures
Solution Approach 1:
A flowable water environment is introduced as an intermediary medium between the cutter wheel and the substrate. The water carries debris away from the cutting line and prevents direct contact between debris and the substrate surface, thereby eliminating surface scratches while maintaining cutting capability
Solution Approach 2:
Hydraulic principles are applied by using flowing water to transport debris from the cutting zone. The water flow acts as a fluid transport mechanism that continuously removes debris particles, preventing them from settling on and scratching the substrate surface
2Object-generated harmful factors
If air ejection is used to remove debris during cutting, then some debris can be sputtered away, but debris still remains on the substrate surface
Solution Approach 1:
The system transitions from pneumatic debris removal (air ejection) to hydraulic removal (flowing water). The water environment provides continuous, complete debris evacuation from the cutting zone, ensuring no debris remains on the substrate surface and achieving a reliably clean surface
3Object-affected harmful factors
If water is used to create a flowable environment in the cutting tank, then debris can be effectively removed, but water consumption increases
Solution Approach 1:
The system recovers and reuses water that has become contaminated with debris. A pump circulates water from the cutting tank back into the tank, creating a closed-loop system that minimizes water consumption while maintaining effective debris removal capabilities
Solution Approach 2:
The water circulation system provides feedback by continuously monitoring and adjusting water flow to maintain optimal debris removal. The pump-based circulation ensures water is continuously refreshed in the cutting zone without requiring constant fresh water input, achieving efficient debris removal with minimal water loss
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
Effectively removes debris during cutting, reducing particle contamination and improving cutting accuracy, preventing surface scratches, and enhancing the cleanliness of the module assembly process while conserving water resources through a circulation loop.
Implementation Method 1
The injection pump is configured to inject water into the cutting tank; and the drain pump is configured to draw water from the cutting tank. A flowable water environment is formed in the cutting tank by an action of the injection pump and the drain pump.
Implementation Method 2
The third pipeline is provided with a centrifugal separation tank, and the bottom of the centrifugal separation tank is provided with a discharge valve.
Implementation Method 3
The object stage fixes the substrate by a suction component. The suction component includes a cutting tray and a plurality of air pipelines. The cutting tray is disposed on the object stage and is provided with suction holes connected to the plurality of air pipelines.
Data Source
AI summary
A substrate cutting system is provided. The substrate cutting system includes a cutting tank, an object stage, a cutter assembly, an injection pump and a drain pump; the injection pump is configured to inject water into the cutting tank, and the drain pump is configured to draw water out from the cutting tank. A flowable water environment is formed in the cutting tank by an action of the injection pump and the drain pump. The object stage is a movable base configured to transport a substrate to be cut to the water environment in the cutting tank. The cutter assembly is configured to cut the substrate.