METHOD FOR CONTROLLING THE THICKNESS OF A SUBSTRATE

Abstract

A method for controlling the thickness of a glass ribbon and an article produced thereby are provided. The method includes: providing a glass ribbon by drawing from a melt or redrawing from a preform; predefining a nominal thickness of the glass ribbon; determining the thickness of the glass ribbon over its entire net width; determining at least one deviation of the thickness of the glass ribbon from the predefined nominal thickness; identifying the area of the thickness deviation in the glass ribbon; and heating the area of the at least one thickness deviation in the glass ribbon using a laser, so that the glass ribbon attains the predefined thickness.

Claims

1. A method for controlling thickness of a glass ribbon, comprising: providing a glass ribbon by drawing from a melt or redrawing from a preform with a drawing rate (v.sub.GB) and an average thickness (D) in a net portion; predefining a nominal thickness of the glass ribbon; determining a thickness of the glass ribbon over an entire net width (B); determining at least one deviation of the thickness from the nominal thickness; identifying an area on the glass ribbon of the at least one deviation; and heating the area using a laser beam to cause the area to attain the nominal thickness, wherein the heating further comprises controlling at least a power of the laser beam, a duration of irradiation of the laser beam, or a wavelength of the laser beam as a function of the thickness, wherein the laser is equipped with a scanning head configured to scan the entire net width of the glass ribbon; and wherein the following relationship applies between the entire net width (B), the drawing rate (v.sub.GB), a beam diameter (D) of the laser beam, a scanning rate of a laser (v.sub.Las), and a correction factor k:
2.Math.k.Math.v.sub.GB.Math.B<D.Math.v.sub.Las.sub..

2. The method as claimed in claim 1, wherein the correction factor k is at least equal to or greater than 1.

3. The method as claimed in claim 1, wherein the correction factor k is at least equal to or greater than 10.

4. The method as claimed in claim 1, wherein, prior to the heating, the area has a viscosity in a range between 10.sup.4 and 10.sup.9 dPa.Math.s, and wherein areas of excessive thickness are subjected to a greater laser power than areas of appropriate or undersized thickness.

5. The method as claimed in claim 1, wherein the scanner has an optical lever or a length of the optical path between the glass ribbon and a scanner mirror of between at least 1.8 m and at most 5.0 m.

6. The method as claimed in claim 1, wherein the laser power is at most 3000 W.

7. The method as claimed in claim 1, wherein the laser beam acts on a deformation zone of the glass ribbon.

8. The method as claimed in claim 1, wherein the step of providing the glass ribbon by drawing or redrawing comprises drawing or redrawing by virtue of a weight of the glass ribbon.

9. The method as claimed in claim 1, wherein the laser is a CO.sub.2 laser.

10. The method as claimed in claim 1, wherein the step of determining of the thickness comprises measuring selected from the group consisting of an interference measurement, a chromatic confocal measurement, a white light topography measurement, a white light interferometry measurement, and combinations thereof.

11. The method as claimed in claim 1, further comprising directing the laser beam by a galvanometer scanner and/or a polygon mirror wheel.

12. A method for controlling thickness between a first and a second face of at least one selected area of a glass or plastic substrate which does not exhibit waviness of greater than 5 mm in wavelength, comprising: providing a molten glass or plastic shaping the molten glass or plastic into a ribbon; monitoring a thickness of the ribbon; detecting at least one thickness deviation in an area of the ribbon; selecting at least one area of the molten glass or plastic, the at least one area corresponding to the area of the thickness deviation; and heating the at least one area using a laser beam which is directed so as to act on the selected area, wherein the heating causes the at least one selected area of the ribbon to attain a predetermined thickness, and wherein the heating further comprises at least controlling a power, a holding time, or a wavelength of the laser beam acting on the selected area as a function of the thickness.

13. The method according to claim 12, wherein the shaping does not involve applying a tension at the edges of the ribbon.

14. The method according to claim 12, wherein the shaping involves applying a tension at the edges of the ribbon.

15. The method according to claim 14, wherein the molten glass or plastic has a viscosity of less than 10.sup.9 dPa.Math.s

16. The method according to claim 12, wherein the laser beam is provided by a laser equipped with a scanning head such that an entire net width of the ribbon is scanned, and wherein the following relationship applies between a drawing rate of the ribbon (v.sub.B), a net width of the ribbon (B), a beam diameter (D) of the laser beam, a scanning rate of the laser (v.sub.Las), and a correction factor k:
2.Math.k.Math.v.sub.B.Math.B<D.Math.v.sub.Las.sub..

17. The method as claimed in claim 16, wherein the correction factor k is equal to or greater than 1.

18. The method as claimed in claim 16, wherein the correction factor k is equal to or greater than 10.

19. The method as claimed in claim 16, wherein the scanning head has an optical distance or a length of an optical path between the ribbon and a scanner mirror of between at least 1.8 m and at most 5.0 m.

20. The method as claimed in claim 16, wherein the scanning head includes a galvanometer drive and/or a polygonal mirror wheel.

21. The method as claimed in claim 12, wherein the step of monitoring the thickness comprises measuring selected from the group consisting of an interference measurement, a chromatic confocal measurement, a white light topography measurement, a white light interferometry measurement, and combinations thereof.

22. The method as claimed in claim 12, wherein the heating comprises directing the laser beam from a device for generating the laser beam onto a reflective surface and reflecting the laser beam there towards the at least one selected area.

23. The method as claimed in claim 12, wherein the laser beam is successively directed onto a plurality of selected areas of the ribbon.

24. The method as claimed in claim 23, wherein the plurality of selected areas extend over the entire net width of the ribbon.

25. The method as claimed in claim 24, wherein, for each of the selected areas, at least the power, the holding time, and/or the wavelength of the laser beam is selectively controlled and adjusted.

26. The method as claimed in claim 12, wherein at least 20% of the output power of the laser beam is absorbed within the ribbon.

27. The method as claimed in claim 12, wherein the molten glass or plastic are provided in a melting process with subsequent shaping or in a redrawing process by heating a preform made of glass or plastics.

28. The method as claimed in claim 27, wherein the shaping is accomplished by a process selected from the group consisting of a float process, a drawing process, a down-draw process, and an overflow fusion process.

29. A sheet glass comprising a thickness of 300 μm or less, a thickness variation of not more than 25 μm based on substrate sizes in a range of more than 100 mm in diameter, and without waviness of more than 5 mm in wavelength, wherein the glass is selected from then group consisting of an alkali silicate glass, an alkali alkaline earth silicate glass, a soda-lime glass, a mixed-alkali lime silicate glass, a boron silicate glass, a phosphate silicate glass, a boron phosphate silicate glass, an aluminum silicate glass, an alkali aluminum silicate glass, an alkali alkaline earth aluminum silicate glass, a boron aluminum silicate glass, and a boron phosphate aluminum silicate glass.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0099] The invention will now be explained by way of example with reference to the figures wherein the same reference numerals denote the same elements and wherein:

[0100] FIG. 1 shows the basic arrangement of glass ribbon, scanner, and laser in one embodiment of the method according to the invention;

[0101] FIG. 2 shows the basic arrangement of glass ribbon, scanner, and laser according to a further embodiment of the invention, with additional optics between the scanner and the glass ribbon for enlarging the optical lever;

[0102] FIGS. 3A, 3B, and 3C schematically illustrate thickness profiles for a glass ribbon produced by the method according to the invention and for a glass ribbon not produced by the method according to the invention.

DETAILED DESCRIPTION

[0103] FIG. 1 schematically illustrates the arrangement of the laser and the glass ribbon in the method of the invention. Shown are the device 1 for generating a laser beam 11, and scanner 2 which is equipped with a polygon mirror wheel here, by way of example. Laser power and scanner angle are controlled by controller 3. Furthermore, preform 5 of the glass ribbon is illustrated. By way of example, preform 5 is a monolithic glass preform here. Hence, the method for producing a glass ribbon is a so-called redrawing process in the illustrated example. Here, the shaping of the glass ribbon 6 is achieved by selective heating of the preform 5 in the schematically illustrated deformation zone 51 while the glass ribbon is moved in the direction indicated by arrow 7. The deformation zone is defined as the zone in which the glass is capable of being shaped, that is to say where the glass has a viscosity between 10.sup.4 and 10.sup.9 dPa.Math.s, preferably between 10.sup.4 and 10.sup.8 dPa.Math.s. The resulting glass ribbon comprises a so-called quality portion 8 in which the properties of the resulting glass ribbon 6 are within the predefined specifications for the product properties. This quality portion 8 has a width B and is delimited by edges 9 of the quality portion 8. Outside quality portion 8, edge rolls might contact the surface of the glass ribbon, for example, so that in this case the glass will not have a sufficient surface quality there. Furthermore, the edge portions of the glass ribbon usually exhibit further uneven surface areas, for example in the form of thickened edges, also referred to as borders. Also indicated is the optical distance 4 between the laser and the glass ribbon. In the context of the present invention, optical distance refers to the length of the optical path between the glass ribbon and the scanner mirror. Therefore, the terms “optical distance” and “optical path length” are used synonymously within the context of the present invention. The optical path may as well be shorter if optical components, e.g. in the form of mirrors and/or lenses, are utilized between the scanner mirror and the glass ribbon, which enlarge the angular deflection of the scanner mirror. In such a case, the specified distance then refers to the “optical lever”, that is the distance which would be required to achieve the same deflection of the laser beam without the one or more optical component(s).

[0104] Laser beam 11 is directed across the glass ribbon 6 by scanner 2 along path 10, so that the laser scans over the net width B of the quality portion 8 of the glass ribbon 6. Along path 10, the glass ribbon 6 has a viscosity between 10.sup.4 and 10.sup.9 dPa.Math.s, preferably between 10.sup.4 and 10.sup.8 dPa.Math.s.

[0105] More generally, without being limited to the example illustrated herein, a glass ribbon 6 may as well be produced by being directly drawn from a melt, for example in a so-called down-draw process or overflow fusion process.

[0106] FIG. 2 is a further schematic view of an arrangement of the laser and the glass ribbon according to another embodiment of the inventive method. In contrast to the method illustrated in FIG. 1, optics 12 are additionally introduced into the beam path between scanner 2 and glass ribbon 6 in order to enlarge the optical lever for a given distance 41 between the glass ribbon and the scanner mirror.

[0107] FIG. 3A schematically shows a diagram of two thickness profiles 203, 213 for a glass sheet 21 obtained according to the invention and for a glass sheet 20 not produced according to the invention. The x-axis represents the position of the sensed location on the glass sheet. The y-axis represents the deviation from the nominal thickness in arbitrary units, with nominal thickness at 0. It can be clearly seen that the thickness profile 203 for a glass sheet 20 which was produced without thickness correction according to the method of the invention exhibits significantly stronger deviations from the nominal thickness than thickness profile 213 for a glass sheet 21 which was produced by the method of the invention.

[0108] FIG. 3B schematically shows a glass sheet 20 not produced according to the invention, which has faces 201, 202. Furthermore, the thickness profile 203 of glass sheet 20 is also shown here. FIG. 3C schematically illustrates glass sheet 21 with faces 211 and 212, and glass sheet 21 was obtained using the method of the invention for thickness correction. Moreover, thickness profile 213 is shown. The two thickness profiles 203 and 213 are drawn with the same scale. Again, it can be clearly seen that the glass sheet 21 obtained according to the invention exhibits clearly smaller deviations from the nominal thickness than glass sheet 20 which was produced without thickness correction.

LIST OF REFERENCE NUMERALS

[0109] 1 Device for generating a laser beam [0110] 10 Scanning distance of the laser [0111] 11 Laser beam [0112] 12 Optics for increasing the optical lever [0113] 2 Scanner [0114] 3 Controller [0115] 4 Optical distance/optical path length [0116] 41 Actual distance scanner mirror to glass ribbon [0117] 5 Preform [0118] 51 Deformation zone [0119] 6 Drawn glass ribbon [0120] 7 Drawing direction [0121] 8 Quality portion [0122] 9 Limits of quality portion [0123] 20 Glass sheet without thickness correction [0124] 201,202 Faces of glass sheet 20 [0125] 203 Thickness profile of glass sheet 20 [0126] 21 Glass sheet with thickness correction [0127] 211,212 Faces of glass sheet 21 [0128] 213 Thickness profile of glass sheet 21