Transparent Ceramic Panel Bending for Complex Geometry
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Solution Overview
Problem
Existing methods for producing transparent ceramic materials with complex geometries are costly and time-consuming, as they require cutting or forming directly into near-net shapes, which often necessitate additional polishing and result in material waste and inefficiencies.
Innovation Solution
A method involving the initial formation of a transparent ceramic panel in a flat or non-planar geometry, which is then polished and bent to conform to a complex shape using a bend jig assembly, allowing the panel to retain its polish and achieve desired geometries without the need for cutting from a boule or green body formation techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If transparent ceramic materials are formed directly into complex shapes or cut from boules, then complex geometries can be achieved, but the process becomes costly and time-consuming with additional polishing requirements
Solution Approach 1:
The patent applies preliminary action by forming the transparent ceramic panel in a flat or non-planar geometry first, polishing it while flat, and only then bending it to the final complex shape. This reverses the conventional approach of forming complex shapes directly, thereby reducing the time and cost associated with multiple processing steps while maintaining geometric complexity.
Solution Approach 2:
The patent inverts the conventional manufacturing sequence by first creating a flat or non-planar panel, polishing it, and then bending it to the desired complex geometry. This inversion eliminates the need for complex forming operations during the initial stage, significantly improving production efficiency while achieving the same complex shapes.
2Shape
If transparent ceramic materials are cut from boules or formed into near-net shapes, then complex geometries can be produced, but material waste increases
Solution Approach 1:
By first forming the panel in a flat or non-planar geometry and then bending it to the final complex shape, the patent eliminates the need for cutting from boules or forming into near-net shapes. This sequential approach allows for more efficient material utilization and reduces waste associated with removing portions of the original material.
3Shape
If transparent ceramic materials are formed directly into complex shapes, then geometry complexity is achieved, but additional polishing is required
Solution Approach 1:
The patent performs the polishing operation while the panel is still in its flat or non-planar geometry, before bending it to the final complex shape. This preliminary polishing step eliminates the need for additional polishing after forming, as the surface is already prepared while the panel is most accessible and stable during the flat state.
Solution Approach 2:
The patent inverts the conventional sequence by polishing the panel before bending it to the complex geometry. This reversal allows the polishing operation to be performed when the panel is in a simple, accessible state, thereby eliminating the need for complex post-processing operations after the shape is formed.
4Shape
If transparent ceramic materials are formed directly into complex shapes, then geometry complexity is achieved, but the process becomes less flexible
Solution Approach 1:
By first forming the panel in a flat or non-planar geometry and then bending it to the final complex shape, the patent increases process flexibility. The flat or non-planar intermediate state provides a flexible working condition that allows for easy polishing and handling, while the final bending operation can be performed using simple bending jigs without requiring complex forming tools.
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
This approach enables the efficient production of transparent ceramic panels with complex geometries that maintain polish and reduce material waste, offering improved optical qualities and structural resilience while minimizing post-processing requirements.
Implementation Method 1
heating the panel to a temperature below a melting point of the panel
Implementation Method 2
bending the panel to conform to a complex geometry
Data Source
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AI summary
A ceramic product includes a transparent ceramic panel having a non-planar geometry including a bend having a slippage plane, an increased haze, a non-uniform thickness, or a combination thereof. A method includes providing a transparent ceramic panel, heating the panel, bending the panel to conform to a non-planar geometry.