Substrate Edge Smoothing via Electric Arc
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Solution Overview
Problem
Current methods for smoothing or beveling substrate edges are either too slow, expensive, or introduce additional cracks, particularly in brittle substrates, and fail to effectively prevent crack propagation from edges into the substrate.
Innovation Solution
A method involving an electrode connected to a voltage source, positioned near the substrate edge, applying a voltage to form an electric arc and heat the edge, which can either lift or melt material to smooth or bevel the edge, controlled by parameters such as voltage amplitude, frequency, and movement speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical methods are used to smooth or bevel edges, then edge smoothing is achieved, but the process is too slow and introduces additional cracks
Solution Approach 1:
The patent replaces mechanical smoothing methods with an electrical field-based method. An electrode applies high voltage (100 V to 10^7 V) at high frequency (10 kHz to 10 GHz) to the substrate edge, creating electric arcs that heat and vaporize material. This substitution eliminates mechanical contact that causes cracks while achieving rapid edge smoothing and bevelling.
Solution Approach 2:
The patent changes the physical state and properties of the electrode and substrate interaction by using extremely high voltage amplitudes (100 V to 10^7 V) and high frequencies (10 kHz to 10 GHz). These parameter changes enable electric arc formation that rapidly heats and removes material from the substrate edge, achieving both high speed and high precision without mechanical contact.
2Manufacturing precision
If mechanical methods are used to smooth or bevel edges, then edge smoothing is achieved, but additional cracks are introduced into substrates
Solution Approach 1:
The patent replaces mechanical smoothing methods with an electrical field-based method. An electrode applies high voltage (100 V to 10^7 V) at high frequency (10 kHz to 10 GHz) to the substrate edge, creating electric arcs that heat and vaporize material. This substitution eliminates mechanical contact that causes cracks while achieving rapid edge smoothing and bevelling.
3Manufacturing precision
If current smoothing methods are used, then edge treatment is achieved, but the process is too expensive
Solution Approach 1:
The patent replaces complex mechanical smoothing systems with a simpler electrical field-based system. The method uses an electrode connected to a voltage source to create electric arcs, eliminating the need for complex mechanical tools, tooling changes, and extensive operator skill, thereby reducing equipment and operational costs.
Solution Approach 2:
The electric arc method is self-regulating in that the arc automatically adjusts to the substrate surface topology. The high-frequency oscillation causes the arc to naturally follow the edge contour, eliminating the need for complex control systems or skilled operators to maintain consistent edge treatment, thereby reducing operational complexity and cost.
4Productivity
If high voltage and high frequency are applied to form electric arc, then edge smoothing and bevelling are achieved rapidly, but precise control of the process is required
Solution Approach 1:
The patent employs high-frequency periodic action (10 kHz to 10 GHz) of the voltage applied to the electrode. This rapid oscillation causes the electric arc to pulse and follow the substrate edge contour naturally, creating a self-regulating effect that smooths and bevells the edge without requiring complex real-time control systems to manage the arc stability and positioning.
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 method produces substrates with reduced or eliminated edge cracks, facilitating easier handling and reducing the risk of substrate breakage, while being cost-effective and easy to perform, with controlled parameters ensuring precise edge smoothing or beveling.
Implementation Method 1
applying a voltage to said edge by means of said electrode, said voltage having an amplitude in the range of from 100 V to 107 V and having a frequency in the range of from 10 kHz to 10 GHz, thereby causing electric arc formation between said electrode and said edge and thereby heating said edge
Data Source
AI summary
The present invention relates to a method of smoothing and/or bevelling an edge of a substrate. The present invention also relates to a substrate produced by the method according to the present invention, in particular a substrate having an edge smoothed and/or bevelled by the method according to the present invention.