Thin Glass Roll Bending Radius and Chemical Toughening
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Solution Overview
Problem
Thin glass rolls face challenges in maintaining integrity during storage and transport due to tensile stress and potential fractures, especially when rolled or bent, with existing mechanical processing methods causing edge defects that can lead to breakage, and there is a need for compact dimensions while ensuring long service life.
Innovation Solution
Determining the optimal bending radius for the inner side of the glass roll through breaking tests and statistical analysis, using exponential terms to scale service life and compactness, and integrating chemical toughening processes like ion exchange to enhance strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the glass ribbon is wound into a roll with small inner diameter for compact storage, then storage compactness is improved, but the bending stress on the innermost layer increases leading to higher breakage risk
Solution Approach 1:
The patent applies chemical tempering to change the physical-chemical parameters of the glass surface, creating a compressed stress layer that fundamentally alters the mechanical properties of the glass. This allows the glass to withstand the high bending stresses inherent in compact rolling while maintaining integrity during storage and transport.
Solution Approach 2:
The chemical tempering process is performed in advance before the glass is wound into rolls. By pre-strengthening the glass edges and surfaces through ion exchange, the glass is prepared to resist the bending stresses that will occur during subsequent rolling, storage, and handling operations.
2Productivity
If mechanical scoring and breaking methods are used to cut glass edges, then manufacturing efficiency is improved, but edge quality deteriorates with microscopic cracks and chipping
Solution Approach 1:
The patent transitions from mechanical cutting to chemical tempering, changing the physical-chemical parameters of the glass edge through ion exchange. This chemical process eliminates the mechanical stress and micro-cracks associated with traditional cutting methods, producing smooth, defect-free edges that are resistant to fracture.
Solution Approach 2:
The patent replaces the mechanical scoring and breaking system with a chemical tempering process. Instead of using diamond wheels or carbide tools to cut the glass, the invention uses ion exchange chemistry to strengthen and seal the edges, eliminating mechanical contact that causes micro-fractures.
3Adaptability or versatility
If the glass thickness is reduced to achieve thin glass applications, then application versatility is improved, but tensile strength and fracture resistance worsen
Solution Approach 1:
The patent fundamentally changes the physical-chemical parameters of thin glass through chemical tempering and edge sealing. By creating a compressed stress layer on the surface and sealing edges through ion exchange, the glass achieves enhanced tensile strength and fracture resistance despite its reduced thickness, enabling versatile applications in flexible displays and other thin-glass applications.
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 allows for the creation of glass rolls with reduced breakage rates and extended service life, enabling compact storage and handling while minimizing the risk of fractures, even with varying edge qualities and bending directions.
Implementation Method 1
chemically toughening the glass ribbon by ion exchange in surface regions
Data Source
AI summary
A glass ribbon in the form of a glass roll is provided that is optimized with respect to the requirements of a long service life and at the same time compact dimensions. A bending radius on the inner side of the thin glass roll is determined by performing breakage tests on samples of the glass material, statistical parameters are determined on the basis of the breakage tests, and the statistical parameters are converted into a range of bending radii which meet the requirements on service life and the most compact dimensions possible of the thin glass roll.