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WO2007018592A1 - Procédé de séparation d’un matériau non métallique utilisant un rayonnement micro-onde - Google Patents

Procédé de séparation d’un matériau non métallique utilisant un rayonnement micro-onde Download PDF

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Publication number
WO2007018592A1
WO2007018592A1 PCT/US2006/003394 US2006003394W WO2007018592A1 WO 2007018592 A1 WO2007018592 A1 WO 2007018592A1 US 2006003394 W US2006003394 W US 2006003394W WO 2007018592 A1 WO2007018592 A1 WO 2007018592A1
Authority
WO
WIPO (PCT)
Prior art keywords
accordance
microwave
microwave radiation
separating
propagation path
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2006/003394
Other languages
English (en)
Inventor
Vladislav Sklyarevich
Mykhaylo Shevelev
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Gyrotron Technology Inc
Original Assignee
Gyrotron Technology Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/US2005/026739 external-priority patent/WO2006025994A2/fr
Priority claimed from PCT/US2006/000742 external-priority patent/WO2007018586A1/fr
Application filed by Gyrotron Technology Inc filed Critical Gyrotron Technology Inc
Priority to US10/594,935 priority Critical patent/US20080236199A1/en
Publication of WO2007018592A1 publication Critical patent/WO2007018592A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B33/00—Severing cooled glass
    • C03B33/09—Severing cooled glass by thermal shock
    • C03B33/091—Severing cooled glass by thermal shock using at least one focussed radiation beam, e.g. laser beam
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B33/00—Severing cooled glass
    • C03B33/07—Cutting armoured, multi-layered, coated or laminated, glass products
    • C03B33/076—Laminated glass comprising interlayers
    • C03B33/078—Polymeric interlayers

Definitions

  • This invention generally relates to the physical separation of non-metallic materials into a plurality of smaller pieces.
  • the invention relates to a method for splitting of a glass body, including laminated glasses.
  • the first is cutting glass and other brittle substrates that includes abrasion or scribing by the use of mechanical cutting tools.
  • glass sheets have been cut by scribing the glass with a diamond-tipped scribe or a carbide wheel to weaken the molecular structure. After the scribe has been made, physical pressure is applied to create a force at the scribe line to hopefully break the glass along the scribe line.
  • Another way of splitting bodies of glass and like material into parts is to use the thermal shock process produced by intense local heating of the body. The use of different heat sources for said local heating is known from the art. The most common among them are laser (see, for example US Patent Nos. 6,420,678; 3,629,545; 4,468,534; 5,609,284), hot gas (5,394,505) or fuel (5,394,505) jets. .
  • One significant disadvantage is the inability to obtain smooth edges. This may be unacceptable for many products, for example displays or solar panels, because of the required quality of the edge faces. Accordingly, secondary steps such as grinding, edge seaming, and polishing may be performed. However, such secondary steps slow down the manufacturing process, can be expensive and still, very often do not meet the requirements of the edge quality.
  • edge defects on some of these rough edges may result in crack propagation during further processing or in the ultimate product.
  • the edge strength of the substrate is also reduced. Glass can contaminate the substrate being separated, and require that additional clean-up steps be performed to minimize their impact on the manufacturing process.
  • Cutting laminated glass is especially difficult and has many problems because of the interlayer that resists separation of the body.
  • the most common way to cut laminated glass is to score both sides of the laminate, and bend it first to one side and then to the other side, the two parts of the laminated glass being pulled apart while performing the second bending step.
  • the interlayer then is melted off simultaneously over the entire length of the parting line by a jet of heated air, flame, plasma etc. directed into the gap formed by the bending operation (see, for example, US Patents 5,944,244; 5,931 ,071 ; 5,704,959; 4,739,555; 4,558,622; 4,471 ,895 and 4,434,974). All known methods have the same problems as is described above for non laminated glass plus laminated glass requires more time and effort. It is impossible to cut laminated glass that contains more than two glass sheets by this approach.
  • This invention generally relates to the physical separation of bodies of a brittle non-metallic material, preferably glass sheets and pipes, by a thermal shock process in which a microwave radiation is used for rapid and selective heating of a local area of the body.
  • Materials which may be separated by the inventive method include ceramics, semi-conductor wafer materials, glass, fiberglass, quartz, and the like. Material treated by this method can be used in the production of automotive and aircraft glazings, of construction and architectural window glass and the like, of pharmaceutical glass products and the like, of semiconductor wafers and the like, and glass components of various household items and furniture, and the like, structural optical components, and the like, mobile device displays, solar panels, and also in other fields of production and technologies where precision cutting of non-metallic materials is conducted or desirable.
  • a method is provided for the separation of bodies of a brittle non-metallic material, preferably glass sheets, by a thermal shock.
  • the inventive method utilizes concentrated microwave radiation to rapidly and selectively heat the local area of the body to be thermally separated (e.g., a glass sheet, a glass pipe).
  • a concentrated microwave radiation with appropriate frequency and power density is chosen so as to accomplish heating of at least one selected area of the body at the required separating propagation path to the required temperature in a selected short time while insuring that this temperature is large enough to create a thermal stress through the thickness of the selected area which thereby results in the separating of the body material.
  • the inventive method avoids the use of existing mechanical and thermal tools that are slow and dusty and do not provide a high quality of cut.
  • the present invention includes making the process easily adaptable for many applications, achieving fast cutting speeds and total separation of the substrate, obtaining smooth edges, and eliminating the need for secondary operations. Any kind of brittle material including those having low thermal expansion can be separated by the inventive method.
  • the main advantages of this high-speed method are the ability to cut a wide range of thicknesses (from super thick, more than 20mm to ultra thin, less than 1mm), high quality (dustless, chip and stress-free) and accuracy, reducing manufacturing costs and increasing production rate. Many other specific advantages also exist including but not limited to cutting complex shapes, the elimination of the cost and issues of grinding, transporting and transferring cut parts for grinding, cleaning cuts.
  • Accuracy and cutting speed can be increased if an additional heat source with a power distribution that is significantly sharper than in the applied concentrated microwave radiation follows or is applied simultaneously or before the body's exposure to microwave.
  • this additional heat source creates a sharp maximum of thermal stress just on the propagation path that reduces the deviation of separating line along the propagation path. This allows also an increase in the cutting speed.
  • the said additional source is selected from the group consisting of laser, gas torch, microwave, and other sources of concentrated energy.
  • FIG. 1 schematically illustrates the temperature profile and compressive stresses that are produced inside a glass sheet when it is irradiated by concentrated microwave radiation.
  • FIG. 2 schematically illustrates a method for cutting, with simultaneous cooling in accordance with one embodiment of the invention .
  • FIG. 3 illustrates the compressive stresses that are produced inside a glass sheet when it is irradiated by an elongated microwave beam.
  • FIG. 4 illustrates a method in accordance with the teachings of the method of the present invention for cutting laminated glass with an elongated microwave beam that has different power density at its front and back.
  • the present invention relates to a method of thermally separating a brittle non- metallic material, preferably a glass sheet, by a thermal shock.
  • a microwave radiation with appropriate frequency and power density is used.
  • the frequency (wavelength) of the concentrated microwave and power density of the applied microwave radiation are important parameters of the inventive method which must be determined for each type of body material and thickness of bodies processed.
  • the process parameters are chosen so as to accomplish heating of selected area of a body at the required separating propagation path to required temperature in a selected time such that the difference in this temperature and the temperature of the rest of the body material is large enough to create a thermal stress that results in the separating of the body material in the heated area.
  • said stress is created not only on the surface but through the thickness as well.
  • Flat, non-flat, and pipe types of bodies can be separated using the inventive method.
  • These treatments include but are not limited to the glass sheet employed in the production of windshields, side windows, and rear windows for vehicles such as automobiles and the like, the production of architectural window glass and related materials, the production of pharmaceutical glass products such as vials, ampoules, pipettes, and the like, display glass for mobile devices, solar panels, and the like, glass components of various household items and furniture, and the like, fiberglass and the like, as well as, semiconductor materials employed in the production of semiconductor wafers and the like.
  • the cutting of glass under the action of thermal stresses, consists of the following.
  • concentrated microwave radiation microwave beam 1 (see Figure 1)
  • the concentrated microwave radiation 1 passes through the glass sheet and heats the area throughout the depth.
  • Curve 5 illustrates the temperature profile inside the glass sheet 4 that is created by this heating.
  • Compressive stresses 6 are produced in the material being heated because the surrounding areas remain under lower temperature, as well as, surface temperature reduction just after heating under cooling by cold ambient air. The splitting of the plate glass occurs when these thermally-induced stresses exceed glass tensile strength.
  • the compressive stresses can be increased because they mainly depend on the volume of the glass that is heated up, and the temperature gradients in and around the heated area.
  • the rate of thermal splitting (cutting speed) in turn is dependent on how rapidly appropriate compressive stresses are created. All this means that the selected area should be heated throughout the thickness and it should be heated rapidly and to a high enough temperature.
  • the particular frequency chosen should ensure the heating of the selected glass sheet area throughout the thickness of the glass sheet with maximum coupling of the incident microwave energy in the area.
  • the chosen frequency should be cost effective and microwave generators for the selected frequency should be readily available at the required power.
  • the frequency range of microwave energy that meets these requirements for most actual thicknesses and material properties where the inventive method can be applied is in the gigahertz range.
  • the necessary power density drastically rises if the microwave frequency is lower than 10 GHz, and creates many technical and economic problems. Therefore a higher microwave frequency is more preferable.
  • the current state-of-the-art level of microwave technique makes it very difficult and expensive to install a power system with a frequency higher than 1000 GHz.
  • the effective microwave frequency range for the present invention is between about 10 GHz and about 1000 GHz.
  • the preferable frequency is such that the skin layer for this frequency in the body material approximately equals its thickness. In this case, heating across the thickness is guarantied.
  • a microwave absorbent having a greater microwave absorption than the body material at a selected microwave irradiation frequency, is applied along the required separating propagation path. This allows increasing the cutting speed and accuracy because higher absorption increases the heating rate.
  • Heating rate increases more if microwave irradiation frequency is selected such that the skin layer for this frequency in the absorbent approximately equals its thickness.
  • the absorbent is selected from the group consisting of semi-metals, carbides, nitrides, oxides, sulfides, suicides, boron, carbon, graphite and metals.
  • Cutting speed increases also if selected heated area and its surrounds of the body of material are cooled during exposure to microwave, as well as, before and after exposure, because this increases compressive stresses.
  • a stream of cold gas 7 (see Figure 2), for example, liquid nitrogen steam that blows on the body, can be used for said cooling because gases are transparent to microwave.
  • the body can be cooled by placing it on a cooled metal support and/or by placing a cold correspondently shaped plate on the surface that is exposed to microwave.
  • the material of said plate is transparent to microwave and is selected from the group consisting of oxide ceramics, nitride ceramics, quartz and diamond. Accuracy and cutting speed can be increased if the exposure to concentrated microwave radiation is conducted through a metal mask with an opening along the required propagation path.
  • an applied concentrated microwave radiation (microwave beam) 1 (see Figure 3) is elongated in the direction of the required separating propagation path 3. This allows increasing the cutting speed and accuracy because it creates higher compressive stresses, 6.
  • the compressive stress increases also by moving the microwave beam during cutting along the separating propagation path from the beginning to the end and back at least two times. The beam power density and moving speed are selected sufficient to separate of the body material in the selected number of moves.
  • a microwave beam during the cutting of laminated glass moves at least two times along the separating propagation path from the beginning to the end and back.
  • the beam power density during at least the first time is selected sufficient to selectively eat polymer adhesive film to its delaminating temperature (around 80C-110C) along the separating propagation path before being followed by the step of separating of the glass body.
  • cutting laminated glass is provided by an elongated microwave beam, in the direction of the required separating propagation path 3 (see Figure 4), with different power density in the beam at the front 8a and the back 8b.
  • the beam length, power density at its front, and speed are selected to be sufficient to heat polymer adhesive film 9 to its delaminating temperature (around 80C-110C) before being followed by the step of separating of the glass body.
  • Concentrated microwave radiation with the necessary frequency and power density can be achieved using generators such as the gyrotron, klystron, traveling wave tube, and backward wave oscillator, and the like.
  • Accuracy and cutting speed can be increased if an additional heat source with a power distribution that is significantly sharper than in the applied concentrated microwave radiation follows or is applied simultaneously or before the body's exposure to microwave.
  • this additional heat source creates a sharp maximum of thermal stress just on the propagation path that reduces the deviation of separating line along the propagation path. This allows also an increase in the cutting speed.
  • the said additional source is selected from the group consisting of laser, gas torch, microwave, and other sources of concentrated energy.
  • the main distinctions of the inventive method are high cutting speed, quality of cut, and range of thicknesses that can be cut, as well as, eliminating the need for secondary operations. Any kind of brittle material including those having low thermal expansion can be separated by the inventive method.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Health & Medical Sciences (AREA)
  • Optics & Photonics (AREA)
  • Toxicology (AREA)
  • Thermal Sciences (AREA)
  • Re-Forming, After-Treatment, Cutting And Transporting Of Glass Products (AREA)
  • Processing Of Stones Or Stones Resemblance Materials (AREA)

Abstract

La présente invention concerne un procédé de découpe à grande vitesse de matériaux non métalliques (14), de préférence de verre et de verre feuilleté. Dans le procédé de l’invention un rayonnement micro-onde concentré (1) avec une fréquence et une puissance appropriées est choisi afin de réaliser le chauffage au moins une zone sélectionnée (2) du corps sur le chemin propagation de la séparation requis (3) à la température requise en un laps de temps réduit sélectionné tout en garantissant que cette température est suffisamment élevée pour créer une contrainte thermique (6) dans l’épaisseur de la zone sélectionnée qui résulte en la séparation du matériau du corps. Dans un mode de réalisation de l’invention, un procédé de coupe du verre feuilleté à grande vitesse est décrit dans lequel un rayonnement micro-onde concentré est utilisé pour séparer le film adhésif avant l’étape de séparation du corps en verre.
PCT/US2006/003394 2005-07-28 2006-01-30 Procédé de séparation d’un matériau non métallique utilisant un rayonnement micro-onde Ceased WO2007018592A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US10/594,935 US20080236199A1 (en) 2005-07-28 2006-01-30 Method of Separating Non-Metallic Material Using Microwave Radiation

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
PCT/US2005/026739 WO2006025994A2 (fr) 2004-08-31 2005-07-28 Procede pour separer de la matiere non metallique en utilisant une emission de micro-ondes
USPCT/US2005/026739 2005-07-28
USPCT/US2006/000742 2006-01-05
PCT/US2006/000742 WO2007018586A1 (fr) 2005-07-28 2006-01-05 Procédé de séparation d'un matériau non métallique utilisant une radiation par micro-ondes

Publications (1)

Publication Number Publication Date
WO2007018592A1 true WO2007018592A1 (fr) 2007-02-15

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/003394 Ceased WO2007018592A1 (fr) 2005-07-28 2006-01-30 Procédé de séparation d’un matériau non métallique utilisant un rayonnement micro-onde

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3453097A (en) * 1964-10-19 1969-07-01 Gerhard Mensel Glasbearbeitung Method of working glass with absorbent by a laser beam
US3875766A (en) * 1973-12-20 1975-04-08 Fifth Res Method for the direct manufacture of discrete tempered glass sheets
US5609284A (en) * 1992-04-02 1997-03-11 Fonon Technology Limited Method of splitting non-metallic materials
US20040025539A1 (en) * 2000-09-27 2004-02-12 Erich Fischer Method and device for cutting glass tubes

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3453097A (en) * 1964-10-19 1969-07-01 Gerhard Mensel Glasbearbeitung Method of working glass with absorbent by a laser beam
US3875766A (en) * 1973-12-20 1975-04-08 Fifth Res Method for the direct manufacture of discrete tempered glass sheets
US5609284A (en) * 1992-04-02 1997-03-11 Fonon Technology Limited Method of splitting non-metallic materials
US20040025539A1 (en) * 2000-09-27 2004-02-12 Erich Fischer Method and device for cutting glass tubes

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