METHODS AND APPARATUS FOR GLASS LAMINATE EDGE FINISHING AND GLASS LAMINATES FORMED THEREBY
An apparatus for finishing a cut edge of a glass laminate includes a support including a surface and an edge, a rail disposed adjacent the support and extending substantially parallel to the edge, a carrier coupled to the rail, and a finishing tool coupled to the carrier and including an abrasive surface positioned adjacent the edge. The carrier is translatable along the rail to translate the abrasive surface relative to the edge. A method includes securing a glass laminate to a support and contacting a cut edge of the glass laminate with an abrasive surface of a finishing tool coupled to a carrier. The carrier is translated along a rail to move the abrasive surface along the cut edge of the glass laminate and transform the cut edge into a finished edge. The glass laminate can have an edge strength of at least about 100 MPa.
This application is a continuation of U.S. patent application Ser. No. 16/341,778 filed on Apr. 12, 2019, which claims the benefit of priority under 35 U.S.C. § 371 of International Patent Application Serial No. PCT/KR2017/011271, filed on Oct. 12, 2017, which in turn claims the benefit of priority to Korean Patent Application No.: 10-2016-0132404 filed Oct. 12, 2016, the content of each of which is incorporated herein by reference in their entirety.
BACKGROUND 1. FieldThis disclosure relates to glass laminates and, more particularly, methods and apparatus for glass laminate edge finishing.
2. Technical BackgroundGlass laminates may be used as components in the fabrication of various appliances, automobile components, architectural structures, and electronic devices. For example, glass laminates may be incorporated as covering materials for various products such as walls, cabinets, backsplashes, appliances, or televisions. However, it may be difficult to cut and/or finish glass laminates without causing fractures in the glass layer and while maintaining sufficient edge strength to enable use of the glass laminates without causing fractures in the glass layer.
SUMMARYDisclosed herein are methods and apparatus for glass laminate edge finishing and glass laminates formed thereby.
Disclosed herein is an apparatus for finishing a cut edge of a glass laminate. The apparatus comprises a support, a rail, a carrier, and a finishing tool. The support comprises a surface and an edge. The rail is disposed adjacent to the support and extends substantially parallel to the edge of the support. The carrier is coupled to the rail. The finishing tool is coupled to the carrier and comprises an abrasive surface positioned adjacent to the edge of the support. The carrier is translatable along the rail to translate the abrasive surface of the finishing tool relative to the edge of the support.
Also disclosed herein is a method comprising securing a glass laminate to a surface of a support. The glass laminate comprises a glass sheet laminated to a non-glass substrate. A cut edge of the glass laminate is contacted with an abrasive surface of a finishing tool coupled to a carrier. The abrasive surface is oriented to apply a force to the glass sheet in a direction toward the non-glass substrate during the contacting. The carrier is translated along a rail extending substantially parallel to an edge of the support to move the abrasive surface along the cut edge of the glass laminate and transform the cut edge into a finished edge.
Also disclosed herein is a glass laminate comprising a flexible glass sheet laminated to a non-glass substrate and an edge strength of at least about 100 MPa.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary, and are intended to provide an overview or framework to understanding the nature and character of the claimed subject matter. The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the description, serve to explain principles and operation of the various embodiments.
Reference will now be made in detail to exemplary embodiments which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts. The components in the drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the exemplary embodiments.
Numerical values, including endpoints of ranges, can be expressed herein as approximations preceded by the term “about,” “approximately,” or the like. In such cases, other embodiments include the particular numerical values. Regardless of whether a numerical value is expressed as an approximation, two embodiments are included in this disclosure: one expressed as an approximation, and another not expressed as an approximation. It will be further understood that an endpoint of each range is significant both in relation to another endpoint, and independently of another endpoint.
In various embodiments, an apparatus for finishing a cut edge of a glass laminate comprises a support, a rail, a carrier, and a finishing tool. The support comprises a surface and an edge. The rail is disposed adjacent to the support and extends substantially parallel to the edge of the support. The carrier is coupled to the rail. The finishing tool is coupled to the carrier and comprises an abrasive surface positioned adjacent to the edge of the support. The carrier is translatable along the rail to translate the abrasive surface of the finishing tool relative to the edge of the support. Surprisingly, finishing the edge of a glass laminate using the apparatus described herein can enable a finished glass laminate with improved edge strength, even compared to an alternative finishing process using the same finishing tool.
In various embodiments, a method comprises securing a glass laminate comprising a glass sheet laminated to a non-glass substrate to a surface of a support. A cut edge of the glass laminate is contacted with an abrasive surface of a finishing tool coupled to a carrier. The abrasive surface is oriented to apply a force to the glass sheet in a direction toward the non-glass substrate during the contacting. The carrier is translated along a rail extending substantially parallel to an edge of the support to move the abrasive surface along the cut edge of the glass laminate and transform the cut edge into a finished edge.
Surprisingly, finishing the edge of a glass laminate using the apparatus and methods described herein can enable a finished glass laminate with improved edge strength, even compared to an alternative finishing process using the same finishing tool. For example, in various embodiments, a glass laminate comprises a flexible glass sheet laminated to a non-glass substrate and an edge strength of at least about 100 MPa. Additionally, or alternatively, the glass laminate demonstrates an increase in edge strength of at least about 100% compared to an unfinished glass laminate having the same configuration.
In various embodiments, glass sheet 102 is formed from or comprises a glass material, a ceramic material, a glass-ceramic material, or a combination thereof. For example, glass sheet 102 is a flexible glass sheet commercially available under the trade name Corning® Willow® Glass (Corning Incorporated, Corning, NY, USA) or a chemically strengthened glass sheet commercially available under the trade name Corning® Gorilla® Glass (Corning Incorporated, Corning, NY, USA). Glass sheet 102 can be formed using a suitable forming process such as, for example, a downdraw process (e.g., a fusion draw process or a slot draw process), a float process, an updraw process, or a rolling process. Glass sheets produced using a fusion draw process generally have surfaces with superior flatness and smoothness when compared to glass sheets produced by other methods. The fusion draw process is described in U.S. Pat. Nos. 3,338,696 and 3,682,609, each of which is incorporated by reference herein in its entirety.
In some embodiments, glass sheet 102 comprises anti-microbial properties. For example, glass sheet 102 comprises a sufficient silver ion concentration at the surface of the glass sheet to exhibit anti-microbial properties (e.g., in the range from greater than 0 to 0.047 μg/cm 2) as described in U.S. Patent Application Publication No. 2012/0034435, which is incorporated by reference herein in its entirety. Additionally, or alternatively, glass sheet 102 is coated with a glaze comprising silver, or otherwise doped with silver ions, to exhibit anti-microbial properties as described in U.S. Patent Application Publication No. 2011/0081542, which is incorporated by reference herein in its entirety. In some embodiments, glass sheet 102 comprises about 50 mol % SiO2, about 25 mol % CaO, and about 25 mol % Na2O to exhibit anti-microbial properties.
In some embodiments, a thickness of glass sheet 102 (e.g., a distance between first surface 103A and second surface 103B) is at least about 0.01 mm, at least about 0.02 mm, at least about 0.03 mm, at least about 0.04 mm, at least about 0.05 mm, at least about 0.06 mm, at least about 0.07 mm, at least about 0.08 mm, at least about 0.09 mm, at least about 0.1 mm, at least about 0.2 mm, at least about 0.3 mm, at least about 0.4 mm, or at least about 0.5 mm. Additionally, or alternatively, a thickness of glass sheet 102 is at most about 3 mm, at most about 2 mm, at most about 1 mm, at most about 0.7 mm, at most about 0.5 mm, at most about 0.3 mm, at most about 0.2 mm, or at most about 0.1 mm. In some embodiments, glass sheet 102 is a flexible glass sheet. For example, the thickness of glass sheet 102 is at most about 0.3 mm. Additionally, or alternatively, glass sheet 102 is a strengthened glass sheet (e.g., a thermally tempered or chemically strengthened glass sheet). For example, the thickness of glass sheet 102 is about 0.4 mm to about 3 mm.
In various embodiments, non-glass substrate 104 is formed from or comprises primarily non-glass materials. For example, non-glass substrate 104 comprises wood-based materials (e.g., wood, chipboard, particleboard, fiberboard, hardboard, cardboard, and/or paper), polymeric materials, and/or metal materials. In some embodiments, non-glass substrate 104 comprises glass, glass-ceramic, and/or ceramic materials as secondary constituents (e.g., fillers). However, in such embodiments, non-glass substrate 104 is free of glass, glass-ceramic, or ceramic sheets (e.g., solid or substantially solid sheets as opposed to fibrous mats or weaves).
In some embodiments, non-glass substrate 104 is formed from or comprises one or more layers of polymer-impregnated paper. For example,
Surface papers 112 impregnated with melamine resin can provide a damage-resistant surface that can help to protect the underlying decorative papers 110. Thus, in embodiments in which the decorative paper is impregnated with a melamine resin, the respective surface layer can be omitted. Additionally, or alternatively, the surface layer that would otherwise be disposed between the glass sheet and the core of the non-glass substrate can be omitted because the glass sheet can serve as the protective layer for the underlying decorative paper. Thus, in some embodiments, the glass laminate comprises a surface layer disposed at the non-glass surface of the non-glass substrate remote from the glass sheet and is free of a surface layer disposed at the glass surface of the non-glass substrate closest to the glass sheet.
In some embodiments, the non-glass substrate comprises a functional layer in addition to the polymer impregnated papers. For example, the functional layer comprises one or more moisture barrier layers embedded within the polymer impregnated papers to prevent moisture from penetrating into the non-glass substrate. The moisture barrier layers can be formed from or comprise a metal, a polymer, or combinations thereof.
In some embodiments, a thickness of non-glass substrate 104 (e.g., a distance between first surface 105A and second surface 105B) is at least about 1 mm, at least about 2 mm, at least about 3 mm, at least about 4 mm, at least about 5 mm, at least about 6 mm, at least about 7 mm, at least about 8 mm, at least about 9 mm, or at least about 10 mm. Additionally, or alternatively, the thickness of non-glass substrate 104 is at most about 100 mm, at most about 90 mm, at most about 80 mm, at most about 70 mm, at most about 60 mm, at most about 50 mm, at most about 40 mm, at most about 30 mm, at most about 29 mm, at most about 28 mm, at most about 27 mm, at most about 26 mm, at most about 25 mm, at most about 24 mm, at most about 23 mm, at most about 22 mm, at most about 21 mm, or at most about 20 mm.
Although non-glass substrate 104 described with reference to
For example, in other embodiments, the non-glass substrate is formed from or comprises a wood-based material comprising wood fragments dispersed in a binder. In some of such embodiments, the wood fragments comprise wood particles, wood chips, and/or wood fibers. Additionally, or alternatively, the binder comprises a resin that binds the wood fragments. For example, in some embodiments, the resin comprises a urea-formaldehyde (UF) resin, a phenol formaldehyde (PF) resin, a melamine-formaldehyde (MF) resin, a methylene diphenyl diisocyanate (MDI) resin, a polyurethane (PU) resin, a compatible mixture thereof, or a compatible combination thereof. In some embodiments, the non-glass substrate is a chipboard material, a fiberboard material (e.g., particleboard, medium density fiberboard (MDF), or hardboard), or a plywood material. For example, the non-glass substrate is a wood-based panel such as a chipboard panel, a fiberboard panel (e.g., a particleboard panel, a MDF panel, or a hardboard panel), or a plywood panel. The wood fragments and binder can be pressed at elevated temperature and pressure to cure the binder and form the non-glass substrate.
Also for example, in other embodiments, the non-glass substrate is formed from or comprises a polymeric material. In some of such embodiments, the polymeric material comprises polyethylene terephthalate (PET), polyethylene naphthalate (PEN), ethylene tetrafluoroethylene (ETFE), thermopolymer polyolefin (TPO™—polymer/filler blends of polyethylene, polypropylene, block copolymer polypropylene (BCPP), or rubber), polyester, polycarbonate, polyvinylbuterate, polyvinyl chloride (PVC), polyethylene or substituted polythyelene, polyhydroxybutyrate, polyhydroxyvinylbutyrate, polyvinylacetylene, transparent thermoplastic, transparent polybutadiene, polycyanoacrylate, cellulose-based polymer, polyacrylate, polymethacrylate, polyvinylalcohol (PVA), polysulphide, polyvinyl butyral (PVB), poly(methyl methacrylate) (PMMA), polysiloxane, or combinations thereof.
In some embodiments, the non-glass substrate comprises a decoration that is visible through the glass sheet or at a non-glass surface of the glass laminate opposite the glass sheet. For example the decoration comprises a decorative layer (e.g., a decorative paper or polymer), ink or paint, or a veneer disposed at an outer surface of the non-glass substrate. Additionally, or alternatively, the non-glass substrate comprises a combination of materials described herein (e.g., polymer impregnated papers, wood-based material, and/or polymeric material).
In various embodiments, adhesive 106 is formed from or comprises a polymeric material. In some embodiments, the polymeric material is selected from the group consisting of a silicone, an acrylate (e.g., polymethyl methacrylate (PMMA)), a polyurethane polyvinylbutyrate, an ethylenevinylacetate, an ionomer, a polyvinyl butyral, compatible mixtures thereof, and compatible combinations thereof. For example, adhesive 106 comprises DuPont SentryGlas®, DuPont PV 5411, Japan World Corporation material FAS, or polyvinyl butyral resin. In some embodiments, adhesive 106 comprises a thermoplastic polymer material. Additionally, or alternatively, adhesive 106 is a sheet or film of adhesive. In some of such embodiments, adhesive 106 comprises a decorative pattern or design visible through glass sheet 102. In some embodiments, adhesive 106 comprises a functional component that exhibits, for example, color, decoration, heat or UV resistance, IR filtration, or combinations thereof. Additionally, or alternatively, adhesive 106 is optically clear on cure, translucent, or opaque.
In some embodiments, a thickness of adhesive 106 (e.g., a distance between second surface 1036 of glass sheet 102 and first surface 105A of non-glass substrate 104) is at most about 5000 μm, at most about 1000 μm, at most about 500 μm, at most about 250 μm, at most about 50 μm, at most about 40 μm, at most about 30 μm, or at most about 25 μm. Additionally, or alternatively, the thickness of adhesive 106 is at least about 5 μm, at least about 10 μm, at least about 15 μm, at least about 20 μm, at least about 50 μm, or at least about 100 μm.
In some embodiments, glass laminate 100 comprises a single glass sheet 102. For example, glass laminate 100 is free of a glass sheet laminated to second surface 105B of non-glass substrate. In some of such embodiments, second surface 105B of non-glass substrate 104 is an exterior surface of glass laminate 100.
Although glass laminate 100 shown in
The glass laminate may not have a desired size and/or shape as formed. Thus, in various embodiments, the glass laminate may be cut to a determined size or shape. In such embodiments, the glass laminate may be referred to as a preform glass laminate, which may be cut to form one or more glass laminates of different sizes and/or shapes. In some embodiments, the preform glass laminate is cut using a mechanical cutting process. For example, the preform glass laminate may be cut using a mechanical cutting tool such as a router, a saw, or another cutting tool. In other embodiments, the preform glass laminate is cut using a fluid jet, a laser, or another cutting device. In some embodiments, the cutting tool is mounted on a computer numerical control (CNC) machine that controls movement of the tool relative to the preform glass laminate. In other embodiments, the cutting tool is a handheld tool.
After cutting the preform glass laminate, the resulting glass laminate comprises one or more cut edges. For example, the one or more cut edges are edges that are formed during the cutting process (e.g., interior regions of the glass laminate preform that become exterior edges of the glass laminate after cutting). The glass laminate comprising the one or more cut edges can be referred to as an unfinished glass laminate. The glass sheet can have small cracks, chips, or other defects along such cut edges. For example, small cracks or chips can be formed in the glass sheet during a mechanical cutting process. Such cracks or other defects can reduce the strength of the glass sheet. If the strength of the glass sheet is not maintained at a suitable level, the glass sheet may break during subsequent transportation, installation, and/or use of the unfinished glass laminate. The unfinished glass laminate can be finished as described herein to form a finished glass laminate. For example, the finishing can remove the cracks or other defects to increase the strength of the glass laminate.
As used herein, the term “edge strength” refers to the strength of a glass sheet of a glass laminate determined using a modified procedure based on the procedure described in ASTM C-158 “Standard Test Methods for Strength of Glass by Flexure (Determination of Modulus of Rupture),” which is incorporated herein by reference in its entirety. The modified procedure is generally the same as the procedure described in ASTM C-158, except for an additional calculation performed to determine the glass strength. The modified procedure comprises determining a load vs. glass stress calibration curve for the glass laminate using one of the following methods: 1) directly measuring the strain in the glass sheet (e.g., by a strain gauge) at multiple loads and then calculating stress in the glass sheet at the multiple loads using its elastic modulus, 2) directly measuring the stress in the glass sheet (e.g., by a stress optical method) at multiple loads, or 3) beam theory analysis of the glass laminate, which may be difficult due to uncertainties in the adhesive properties. The glass laminate is tested using the procedure described in ASTM C-158 to determine the load at which the glass sheet (as opposed to the complete glass laminate) fails, and the calibration curve is used to translate the determined failure load into a glass stress value, which is reported as the edge strength. In some embodiments, it may be desirable to maintain a predetermined edge strength in the glass sheet after cutting the glass laminate and an even higher predetermined edge strength after edge finishing the cut edge of the glass laminate (e.g., using the finishing process and/or apparatus described herein). For example, maintaining an edge strength of the glass sheet of at least about 100 MPa can enable the glass sheet of the glass laminate to survive end use conditions, such as handling and installation, without forming cracks and fractures in the glass sheet.
In some embodiments, apparatus 200 comprises a vacuum system 220, which can be used to secure the glass laminate to surface 212 of support 210 as described herein. In some embodiments, vacuum system 220 comprises a vacuum unit 222. For example, vacuum unit 222 comprises a vacuum pump, a blower, or another device capable of drawing fluid (e.g., air) from one location to another to create a partial vacuum. Vacuum unit 222 is operatively coupled to surface 212 of support 210 to draw a vacuum at the surface. For example, surface 212 comprises a plurality of openings 213 therein, and vacuum unit 222 is operatively coupled to support 210 (e.g., in fluid communication with the openings) to draw fluid (e.g., air) through the openings in the surface to draw a vacuum at the surface. Thus, support 210 serves as a vacuum chuck that is capable of securing the glass laminate to surface 212 thereof as described herein.
Although apparatus 200 is described as comprising vacuum system 220 to secure glass laminate 100 to support 210, other embodiments are included in this disclosure. For example, in other embodiments, the glass laminate is secured to the support using one or more clamps or other mechanical securing devices.
In some embodiments, apparatus 200 comprises a rail 230 disposed adjacent to support 210. Rail 230 can enable movement of a finishing tool relative to support 210 during a finishing process as described herein. For example, rail 230 comprises an elongate track extending longitudinally along a rail axis to enable movement of the finishing tool along a path substantially parallel to the rail axis. In some embodiments, rail 230 comprises a plurality of rails disposed adjacent to different edges of support 210. For example, in the embodiments shown in
In some embodiments, apparatus 200 comprises a carrier 250 coupled to rail 230 and translatable along the rail. A finishing tool can be coupled to carrier 250 to enable movement of the finishing tool relative to support 210 during a finishing process as described herein. Additionally, or alternatively, carrier 250 can enable adjustment of the orientation of the finishing tool relative to support 210 during the finishing process also as described herein. In some embodiments, carrier 250 comprises a plurality of carriers coupled to rail 230. For example, in the embodiments shown in
In some embodiments, carrier 250 is engaged within channel 232 of rail 230. For example, in the embodiments shown in
In some embodiments, carrier 250 is engaged with the one or more rods of rail 230. For example, in the embodiments shown in
In various embodiments, carrier 250 can translate along rail 230 by sliding, rolling, or another translation mechanism. Additionally, or alternatively, translation of carrier 250 along rail 230 can be manual or automatic. For example, in some embodiments, carrier 250 can be manually pushed or pulled along rail 230 by an operator. In other embodiments, carrier 250 can be pushed or pulled by a hydraulic, pneumatic, electric, or other mechanical driving system.
In some embodiments, apparatus 200 comprises a finishing tool 280 coupled to carrier 250.
In some embodiments, finishing tool 280 is coupled to carrier 250 to achieve a determined orientation of abrasive surface 282 relative to support 210.
In some embodiments, finishing tool 280 is oriented relative to support 210 such that abrasive surface 282 is spaced from edge 214 by a distance dH (e.g., a horizontal distance) and from surface 212 by a distance dV (e.g., a vertical distance) as shown in
In some embodiments, finishing tool 280 is oriented relative to support 210 such that an angle β is formed between abrasive surface 282 of the finishing tool and edge 214 of the support. For example, angle β is an angle between abrasive surface 282 and edge 214 of support 210 (or a plane including the edge of the support), measured along a plane parallel to surface 212 of the support as shown in
In some embodiments, carrier 250 is adjustable to adjust the orientation of finishing tool 280 relative to support 210. For example, in the embodiments shown in
In some embodiments, rail 230 is adjustable to adjust the orientation of finishing tool 280 relative to support 210. For example, in some embodiments, rail 230 is rotatable about the rail axis to adjust angle α.
In some embodiments, body 254 of carrier 250 comprises a base 254A and an extension 254B. Base 254A is coupled to rail 230 as described herein to enable carrier 250 to translate relative to the rail. Extension 254B is coupled to base 254A. Base 254A and extension 254B can be separate components or portions of a unitary component. In some embodiments, extension 254B is movable relative to base 254A. For example, in the embodiments shown in
In some embodiments, body 254 of carrier 250 comprises a support arm. Finishing tool 280 can be coupled to the support arm such that the orientation of the finishing tool relative to support 210 is adjustable. For example, in the embodiments shown in
In some embodiments, the support arm is adjustable relative to the extension to move the finishing tool in directions toward and/or away from the rail (e.g., vertical directions). For example, in the embodiments shown in
Although carrier 250 is described in reference to
In some embodiments, the edge of glass laminate 100 is substantially aligned with edge 214 of support 210 as shown in
In some embodiments, the method comprises contacting an edge of glass laminate 100 with abrasive surface 282 of finishing tool 280. The edge can be a cut edge of glass laminate 100, which can have cracks or other defects resulting from a cutting process as described herein.
In some embodiments, the contacting comprises orienting finishing tool 280 relative to glass laminate 100 such that an angle θ is formed between abrasive surface 282 of the finishing tool and an outer surface (e.g., surface 103A or surface 105B) of the glass laminate. For example, angle θ is an angle between abrasive surface 282 and surface 103A of glass sheet 102 of glass laminate 100, measured along a plane perpendicular to the surface of the glass laminate and including the rotational axis of finishing tool 280 (e.g., first axis 284) as shown in
In some embodiments, the contacting comprises orienting finishing tool 280 relative to glass laminate 100 such that an angle φ is formed between abrasive surface 282 of the finishing tool and edge 214 of the glass laminate. For example, angle φ is an angle between abrasive surface 282 and the edge of glass laminate 100 (or a plane including the edge of the glass laminate), measured along a plane parallel to surface 103A of the glass laminate as shown in
In some embodiments, abrasive surface 282 of finishing tool 280 is oriented to apply a force to glass sheet 102 of glass laminate 100 in a direction toward non-glass substrate 104 during the contacting. For example, in the embodiments shown in
In some embodiments, the contacting comprises applying a fluid to abrasive surface 282 and/or the cut edge of glass laminate 100. For example, the contacting comprises spraying water onto abrasive surface 282 and the cut edge of glass laminate 100 during the contacting the cut edge of the glass laminate with the abrasive surface. The fluid can help to lubricate the contact between the abrasive surface and the glass laminate and/or to remove glass or other particles removed from the glass laminate during edge finishing, which can improve the quality of the finished edge.
In some embodiments, the method comprises translating carrier 250 along rail 230 substantially parallel to edge 214 of support 210 to move abrasive surface 282 along the edge of glass laminate. In some of such embodiments, the method comprises maintaining contact between abrasive surface 182 and glass laminate 100 during the translating. Additionally, or alternatively, the method comprises operating finishing tool to rotate or otherwise move abrasive surface 282 during the translating.
In some embodiments, the finished edge comprises a contacted portion 120 and an uncontacted portion 122. For example, contacted portion 120 of the finished edge is a portion of the finished edge formed by removing material from glass laminate 100 during the contacting and translating. Additionally, or alternatively, uncontacted portion 122 of the finished edge is a remaining portion of the finished edge from which substantially no material was removed during the contacting and translating. In other embodiments, the entire cut edge comprises the contacted portion such that the uncontacted portion is omitted. In some embodiments, contacted portion 120 of the finished edge extends through substantially an entire thickness of glass sheet 102 as shown in
In some embodiments, the contacting and translating removes material of glass laminate to a finishing depth dF. For example, finishing depth dF is a distance between an innermost portion of the finished edge and an outermost portion of the finished edge as shown in
The contacting and translating can be repeated on additional edges of glass laminate 100. For example, each edge of glass laminate 100 can be finished as described herein. In some embodiments, after finishing as described herein, glass laminate 100 can have an improved edge strength compared to glass laminates finished using conventional finishing processes. For example, an edge strength of glass laminate 100 comprising the finished edge is at least about 100 MPa. Without wishing to be bound by any theory, it is believed that such improved edge strength is a result of the finished edge being free or substantially free of the cracks or other defects present in the cut edge.
Surprisingly, the edge finishing apparatus and processes described herein can enable improved edge strength compared to conventional edge finishing processes, even when the same finishing tool is used. For example, using the finishing tool in combination with the edge finishing apparatus and processes described herein can enable improved edge strength compared to edge finishing processes using the same finishing tool (e.g., hand finishing with the finishing tool). For example, a glass laminate with edges finished using the apparatus and processes described herein can have an edge strength (e.g., a B10 edge strength) of at least about 100 MPa, determined using the modified procedure based on the procedure described in ASTM C-158 as described herein. Additionally, or alternatively, a glass laminate with edges finished using the apparatus and processes described herein can demonstrate an increase in edge strength (e.g., a B10 edge strength) of at least about 100%, at least about 120%, at least about 140%, at least about 160%, at least about 180%, at least about 200%, at least about 210%, at least about 215%, or at least about 218% compared to an unfinished glass laminate having the same configuration, determined using the modified procedure based on the procedure described in ASTM C-158 as described herein. Without wishing to be bound by any theory, it is believed that the precise control of the orientation of the abrasive surface of the finishing tool, the precise alignment of the rail with the edge of the glass laminate, and the secure engagement of the glass laminate with the surface of the support during the finishing enable the observed improved edge strength.
EXAMPLESVarious embodiments will be further clarified by the following examples.
Comparative Example 1A preform glass laminate having the general configuration shown in
A rectangular segment was cut from a central region of the preform glass laminate using a router bit mounted on a computer numerical control (CNC) machine to form an unfinished glass laminate having four cut edges.
Comparative Example 2An unfinished glass laminate was formed as described in Comparative Example 1. Each of the four cut edges of the unfinished glass laminate was finished by sanding the edge using a handheld rotary sander commercially available as ETS EC 150/5 EQ from Festool USA (Lebanon, Indiana, USA) with 320 grit sandpaper to form a finished glass laminate.
Example 1An unfinished glass laminate was formed as described in Comparative Example 1. Each of the four cut edges of the unfinished glass laminate was finished using the apparatus shown in
It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the spirit or scope of the claimed subject matter. Accordingly, the claimed subject matter is not to be restricted except in light of the attached claims and their equivalents.
Claims
1. An apparatus for finishing a cut edge of a glass laminate, the apparatus comprising:
- a support for the glass laminate comprising a surface and an edge, wherein the glass laminate comprises a glass sheet and a non-glass substrate;
- a rail disposed adjacent to the support and extending substantially parallel to the edge of the support;
- a carrier coupled to the rail; and
- a finishing tool coupled to the carrier and comprising an abrasive surface positioned adjacent to the edge of the support, wherein the finishing tool comprises a first axis perpendicular to the abrasive surface, a second axis perpendicular to the first axis, and a third axis perpendicular to each of the first axis and the second axis;
- wherein the carrier is translatable along the rail to translate the abrasive surface of the finishing tool relative to the edge of the support, and wherein the carrier is adjustable to orient the abrasive surface of the finishing tool relative to the support such that an angle is formed between the abrasive surface and the edge of the support, measured along a plane parallel to the surface of the support;
- wherein the rail is rotatable about a longitudinal axis of the rail to adjust an angle between the abrasive surface of the finishing tool and the surface of the support, wherein the angle is measured along a plane perpendicular to the surface of the support and including the first axis.
2. The apparatus of claim 1, wherein the first axis of the finishing tool is a rotational axis of the abrasive surface of the finishing tool.
3. The apparatus of claim 1, wherein the abrasive surface of the finishing tool is non planar.
4. The apparatus of claim 1, wherein the carrier is adjustable to rotate the finishing tool about the second axis to adjust an angle between the abrasive surface of the finishing tool and the surface of the support, wherein the angle is measured along a plane perpendicular to the surface of the support and including the first axis.
5. The apparatus of claim 1, wherein the carrier is adjustable to rotate the finishing tool about the third axis to adjust an angle between the abrasive surface of the finishing tool and the edge of the support, wherein the angle is measured along a plane parallel to the surface of the support.
6. The apparatus of claim 1, wherein:
- the carrier comprises a body, a first arm coupled to the body, and a second arm coupled to the first arm; and
- the finishing tool is coupled to the second arm of the carrier.
7. The apparatus of claim 6, wherein the second arm of the carrier is rotatable about an axis of the second arm to adjust an angle between the abrasive surface of the finishing tool and the surface of the support.
8. The apparatus of claim 6, wherein the first arm of the carrier swings in an arc about the body to adjust the angle between the abrasive surface of the finishing tool and the edge of the support.
9. The apparatus of claim 1, comprising a vacuum system to draw a vacuum at the surface of the support to secure the glass laminate to the surface of the support.
10. The apparatus of claim 1, wherein the finishing tool comprises a rotary tool comprising a rotational axis, and the abrasive surface comprises an apex and is tapered in a direction outward from the apex toward a periphery of the abrasive surface.
Type: Application
Filed: Aug 28, 2023
Publication Date: Dec 14, 2023
Inventors: Sun-Hwan Kong (Hwaseong-si), Cheol Hee Park (Asan-si), Dong Keun Shin (Hwasung-si)
Application Number: 18/238,807