APPARATUS AND METHOD FOR ALIGNING SCORING NEEDLES AND FOR SCORING GLASS SUBSTRATES

Abstract

A method is provided for aligning scoring tools and for scoring glass, in particular thin glass, along predetermined scoring lines in preparation for breaking along the score. Glass substrates, in particular thin glass substrates, produced by such method are also provided. The method includes the determination of the actual orientation of the cutting edge of the scoring tool and aligning of the cutting edge to a target orientation of the cutting edge.

Claims

1. A method for aligning a scoring a thin or ultra-thin glass substrate along a scoring line, comprising the steps of: providing the glass substrate with a planar surface; moving a mechanical scoring tool to the glass substrate so that the scoring tool does not yet touch the planar surface; pre-aligning a cutting edge of the scoring tool in an advancement direction; determining an actual orientation of the cutting edge; and aligning the scoring tool by changing the actual orientation of the cutting edge by rotating the cutting edge in a plane perpendicular to the planar surface and/or tilting the cutting edge to change an inclination so as to arrange the cutting edge in a desired orientation relative to the advancement direction.

2. The method of claim 1, further comprising: moving the cutting edge onto the planar surface in an area of the scoring line once the cutting edge of the scoring tool has been aligned in the desired orientation; and subjecting the cutting edge to a predetermined cutting force.

3. The method of claim 2, further comprising moving the cutting edge along the scoring line relative to the planar surface to produce a score.

4. The method of claim 3, wherein the cutting force deviates at most 0.05 N when moving the cutting edge along the scoring line.

5. The method of claim 2, wherein the cutting force is not more than 1 N.

6. The method of claim 2, wherein the cutting force is not more than 0.5 N.

7. The method of claim 1, wherein the step of determining the actual orientation comprises using a beam source for emitting electromagnetic radiation.

8. The method of claim 7, wherein the step of determining the actual orientation comprises using a photodetector configured to receive electromagnetic radiation reflected at the scoring tool.

9. The method of claim 8, wherein the photodetector is arranged and adapted for detecting at least a portion of the electromagnetic radiation reflected at the cutting edge.

10. The method of claim 7, wherein the beam source comprises a point light source.

11. The method of claim 7, wherein the beam source is arranged in the advancement direction and is adapted for irradiating the cutting edge to detect the actual orientation of the cutting edge relative to the scoring line and to the planar surface.

12. The method of claim 1, wherein the scoring tool comprises a scoring needle.

13. The method of claim 12, wherein the scoring needle comprises a scoring diamond.

14. The method of claim 12, wherein the scoring needle has a shape selected from the group consisting of acute truncated shape, a truncated pyramid shape, a truncated tetrahedron shape, and a truncated octahedron shape.

15. The method of claim 1, wherein the glass substrate comprises thin glass or ultra-thin glass (UTG).

16. The method of claim 15, wherein the glass substrate has a thickness selected from the group consisting of of not more than 400 μm, not more than 150 μm, not more than 100 μm, not more than 50 μm, not more than 30 μm, not more than 20 μm, and not more than 10 μm.

17. The method of claim 1, further comprising providing a fine adjustment device for aligning the scoring tool.

18. An apparatus for aligning a scoring tool for scoring thin or ultra-thin glass substrates along a predetermined scoring line for score and break separation, comprising: a machine tool; a drivable feed unit; a cutting head; a scoring tool having at least one cutting edge; a driving mechanism for drawing the scoring tool along the predetermined scoring line; a position detection device for detecting an actual orientation of the at least one cutting edge relative to the scoring line and to a surface of the glass substrate to be scored; and an adjustment device configured to adjust the scoring tool on the basis of control values in order to bring the scoring tool from the actual orientation to a predetermined orientation by tilting and/or rotating.

19. The apparatus of claim 18, further comprising a processing unit for determining the control values for aligning the scoring tool.

20. A pre-scored thin or ultra-thin glass substrate, comprising: a thickness is in a range between 400 μm and 10 μm; and a score having depth between 1/20 and ⅕ of the thickness of the material and having an edge strength of at least 300 MPa.

Description

DESCRIPTION OF THE DRAWINGS

[0048] FIG. 1 schematically illustrates thin glass while being scored;

[0049] FIG. 2 is a schematic plan view of a portion of a pre-scored glass substrate; and

[0050] FIG. 3 is a schematic plan view of a partially scored glass substrate.

DETAILED DESCRIPTION

[0051] For the sake of clarity, the same reference numerals in the following detailed description of preferred embodiments designate substantially similar parts in or at these embodiments. For better illustrating the invention, however, the preferred embodiments shown in the figures are not always drawn to scale.

[0052] FIG. 1 schematically illustrates the generation of scores 3 in a glass substrate 1. The scoring head comprises a mechanical scoring tool 20. Scoring tool 20 includes a ground diamond having a front cutting edge 21, which is also referred to as a bow cutting edge. The direction of movement of the scoring tool 20 relative to the glass substrate 1 corresponds to the advancement direction and is indicated by “A”. Glass substrate 1 is a thin glass plate as used for components in the fields of biology, medical technology, electrical engineering, and electronics.

[0053] For determining the actual orientation of the cutting edge 21, a position detection method is suggested which uses a light source and a photodetector. The position detection method is based on the principle of triangulation in which light emitted by the light source is irradiated onto the sensed area and the light reflected from the sensed area is received by the photodetector.

[0054] The sensed area in the sense of the invention is the area of the scoring tool facing the advancement direction, which comprises at least one cutting edge 21.

[0055] FIG. 1 schematically shows a point light source 10 and a photodetector 11. The beam source is arranged in the advancement direction. Electromagnetic radiation 12 of the point light source 10 is radiated towards the cutting edge 21 of scoring tool 20. A portion of this radiation 12 is incident on the scoring tool and is partially reflected at cutting edge 21. A portion of this reflected electromagnetic radiation 13 is then radiated back onto and detected by photodetector 11.

[0056] The electromagnetic radiation 13 reflected at cutting edge 21 can thus be detected by photodetector 11. Based thereon, the actual position of cutting edge 21 with respect to the intended advancement direction and to the surface of the glass substrate can then be determined with computer support. In the illustrated constellation, the scoring tool 20 is already aligned in the target orientation so that a score 3 can be produced.

[0057] The scoring tool 20 is accordingly aligned by rotating the cutting edge 21 in a plane perpendicular to the surface of the glass substrate 1 and/or by tilting the cutting edge 21 to alter its inclination from the current orientation into the required target orientation for generating an optimal score. The tilting of the cutting edge 21 is effected according to the rotation axis designated “X” in FIG. 1. The tilting causes a change in the angle resulting between a straight line along the cutting edge and the advancement direction A. In this manner, a predetermined angle can be set which defines the inclination of the cutting edge relative to the advancement direction.

[0058] While the schematic view illustrates a single scoring head, multiple arrays are often provided in practice in order to simultaneously produce a plurality of scores.

[0059] In addition, a channel 25 is provided in the scoring tool 20, leading to the rear side of the scoring tool and conveying a blasting liquid to the score 3 produced by the scoring tool. Thereby, score 3 is wetted with the blasting liquid. As a result, a moisture film is formed on glass substrate 1. To promote subsequent singularization for producing thin glass plates, this moisture film is heated until it at least partially evaporates with the consequence of cleaving the scores to form smaller sized plates. Singularization may be achieved immediately after the generation of the score, or else at a later time, for example during a subsequent further processing. For this purpose, a burner head with a small flame is provided for the severing process, with a tip that is guided along the scores 3 from below in order to locally heat the glass substrate and to cause the blasting liquid to vaporize. The explosive force developed in the scores 3 in this manner will cause the glass substrate to be cleaved and separated into the individual thin glass plates.

[0060] FIG. 2 schematically shows a plan view of a portion of a pre-scored glass substrate 1. The illustrated glass substrate 1 is an ultra-thin glass having a thickness of at most 150 μm. The upper surface of glass substrate 1 is provided with a pattern of scored lines 2 which extend along the scores 3 already produced and delimit the thin glass plates to be separated from each other.

[0061] The direction of longitudinal extension of the glass substrate 1, indicated by “y” in FIG. 2, corresponds to the axis around which the scoring tool 20 can be rotated in order to be brought from the current orientation to the target orientation. The direction of transverse extension of the glass substrate 1 indicated by “x” corresponds to the axis around which the scoring tool 20 can be tilted in order to change the inclination in the advancement direction. Accordingly, the scoring tool 20 can be rotated about axes which are in parallel to the two horizontal directions of the glass substrate 1.

[0062] Finally, FIG. 3 is a schematic plan view of a partially scored glass substrate 1. The scoring tool 20 preferably comprises at least one diamond 4 with cutting edges 21. Furthermore, the diamond 4 can rotate about the axis indicated by “z” in FIG. 3. This rotation allows the cutting edge 21 to be aligned in the advancement direction “A” of the scoring tool 20 and thus serves to adjust the cutting force.

[0063] The cutting force that need to be applied for scoring is very small and is not more than 1 N for thin glass having a thickness of less than 400 μm. In the case of ultra-thin glass substrates 1 with a thickness in a range from 50 to 150 μm, the cutting force to be applied is at most 0.7 N, preferably at most 0.5 N, depending on the cutting angle and geometry of the diamond. In the case of even thinner glass substrates the required cutting force is even less than that, namely approximately 0.3 N.

[0064] During scoring, a cutting force as constant as possible is applied, which varies by not more than 0.05 N, preferably by less than 0.025 N, in order to produce the most consistent score 3 possible.

[0065] For performing the method according to the invention, an apparatus for aligning a scoring tool for scoring glass substrates along a predetermined scoring line for the purpose of score and break separation is provided, which comprises a machine tool (not shown).

[0066] Furthermore, the apparatus comprises a drivable feed unit, the scoring tool 20, and a drive mechanism for drawing the scoring tool along the predetermined scoring line. For this purpose, a drivable feed carriage may be provided. The scoring tool 20 is movable along horizontal directions x and y. For adjustment in z direction, a feed carriage is provided which preferably comprises a precision drive. By means of a cutting head with a precision drive as disclosed in document DE 10 2014 117 641.3, for example, it is possible to produce the scoring contact pressure force of the scoring tool 20 on the glass substrate 1.

[0067] According to the invention, the apparatus is equipped with a position detection device for detecting the actual orientation of the geometry of the at least one cutting edge of the scoring tool relative to the scoring line and to the surface of the glass substrate to be scored, which position detection device comprises a beam source 10 and a photodetector 11.

[0068] Finally, a processing unit is provided for determining control values for aligning the scoring tool from the current orientation into the target orientation.

[0069] For the purpose of aligning the scoring tool 20, mechanical means for fine adjustment of the scoring tool 20 are provided, which allow to tilt the scoring tool 20 to change its inclination relative to the glass substrate 1 to be scored and to rotate the scoring tool 20 in a plane perpendicular to the surface of the glass substrate 1 to be scored.

[0070] The alignment of the scoring tool may even be effected in automated manner. For this purpose, process control with a closed-loop control circuit is provided, comprising the position detection device, an actual value/target value controller, and the precision drive as well as the fine adjustment means. The actual value/target value controller contains a target value memory for input and storage of target values relating to the orientation of the cutting edge. The target values may depend on the material and the geometry of the cutting edge, the thickness of the glass substrate 1, the type of glass, the ambient conditions, and the cutting support.

[0071] Based on the detected actual orientation of the cutting edge 21 of the scoring tool 20 and a comparison with the stored values for the target orientation of the cutting edge 21, the fine adjustment means are equipped with drives and are driven so that the deviations in the orientation of the cutting edge 21 are minimized.

[0072] As soon as the target orientation of the cutting edge 21 is achieved, a signal is sent to the precision drive and the scoring tool 20 is lowered onto the surface of the glass substrate. After application of the predetermined cutting force, the drive mechanism drives the feed carriage according to the intended scoring line so that a score can be generated along the intended scoring line.

[0073] The method and apparatus according to the invention permit to produce thin glass plates and ultra-thin glass plates of a thickness between 400 μm and 10 μm, preferably of not more than 150 μm. However, it is also possible to produce pre-scored glass substrates with the following features: the glass substrate has a thickness in a range between 400 μm and 10 μm, preferably not more than 150 μm; score depth is between 1/20 and ⅕ of the thickness of the glass substrate; and the at least one score has an edge strength of at least 300 MPa.