US20110314870A1 - Glass manufacturing system and method for forming a high quality thin glass sheet - Google Patents

Glass manufacturing system and method for forming a high quality thin glass sheet Download PDF

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Publication number
US20110314870A1
US20110314870A1 US13/202,110 US201013202110A US2011314870A1 US 20110314870 A1 US20110314870 A1 US 20110314870A1 US 201013202110 A US201013202110 A US 201013202110A US 2011314870 A1 US2011314870 A1 US 2011314870A1
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Prior art keywords
glass sheet
glass
rolls
edge
rolling
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Abandoned
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US13/202,110
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Allan M. Fredholm
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Corning Inc
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Fredholm Allan M
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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/06—Forming glass sheets
    • C03B17/061—Forming glass sheets by lateral drawing or extrusion
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/06—Forming glass sheets
    • C03B17/061—Forming glass sheets by lateral drawing or extrusion
    • C03B17/062—Forming glass sheets by lateral drawing or extrusion combined with flowing onto a solid or gaseous support from which the sheet is drawn
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/06—Forming glass sheets
    • C03B17/067—Forming glass sheets combined with thermal conditioning of the sheets
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/06—Forming glass sheets
    • C03B17/068—Means for providing the drawing force, e.g. traction or draw rollers

Definitions

  • the present invention relates in general to the glass manufacturing field and, in particular, to a glass manufacturing system and method for forming a high quality thin glass sheet which has a thickness less than about 2 mm and more preferably less than about 100 ⁇ m.
  • Some existing glass manufacturing systems and processes which use a fusion draw or a slot draw can produce glass sheets with such low thicknesses but they either have high production costs or do not yield sufficient surface quality.
  • existing glass manufacturing systems which incorporate a slot draw produce inferior quality glass sheets with small thicknesses and also have high production costs.
  • the existing glass manufacturing systems which incorporate a fusion draw can produce very good quality glass sheets with small thicknesses but they have high production costs.
  • the existing glass manufacturing systems which incorporate the fusion draw and slot draw are limited to the production of glasses that do not devitrify easily.
  • the fusion draw and the slot draw processes require the delivery of a molten glass which has a fairly high viscosity that is for instance greater than about 50,000 poises at the last point where the molten glass touches a non-moving body, like at a root of an isopipe in the fusion draw process or at an exit of a slot in the slot draw process.
  • a molten glass which has a fairly high viscosity that is for instance greater than about 50,000 poises at the last point where the molten glass touches a non-moving body, like at a root of an isopipe in the fusion draw process or at an exit of a slot in the slot draw process.
  • a molten glass which has a fairly high viscosity that is for instance greater than about 50,000 poises at the last point where the molten glass touches a non-moving body, like at a root of an
  • the present invention provides a glass manufacturing system that includes: (a) a delivery system where molten glass transitions from a guided flow to a free fall flow; (b) a rolling roll pair having two rolling rolls which receive the molten glass free falling from the delivery system and draw the molten glass to form a glass sheet; and (c) a temperature controlled environment with a cross temperature gradient where two outer edges of the glass sheet are exposed to a hotter temperature than a central portion of the glass sheet.
  • the temperature controlled environment provides the cross temperature gradient to stretch the glass sheet such that the glass sheet has a substantially constant thickness.
  • the glass manufacturing system may also utilize at least one of a compensated rolling roll pair and edge roll pair(s) to help manufacture the glass sheet.
  • the present invention provides a method for manufacturing a glass sheet, where the method includes the steps of: (a) providing a molten glass; (b) drawing the molten glass between two rolling rolls to form a glass sheet; and (c) heating the glass sheet in a temperature controlled environment which has a cross temperature gradient such that two outer edges of the glass sheet are exposed to a hotter temperature than a central portion of the glass sheet.
  • the temperature controlled environment provides the cross temperature gradient to stretch the glass sheet such that the glass sheet has a substantially constant thickness.
  • the method may also utilize at least one of a compensated rolling roll pair and edge roll pair(s) to help manufacture the glass sheet.
  • FIGS. 1A and 1B are respectively a front view and side view of an exemplary glass manufacturing system having a vertical rolling configuration in accordance with an embodiment of the present invention
  • FIG. 2 is a diagram illustrating an exemplary compensated rolling roll pair that can be used in the glass manufacturing system shown in FIG. 1 in accordance with an embodiment of the present invention
  • FIG. 3 is a graph that illustrates the shape of a glass sheet after being drawn by the compensated rolling roll pair shown in FIG. 2 in accordance with an embodiment of the present invention
  • FIG. 4 is a graph that illustrates how a temperature controlled environment within the glass manufacturing system shown in FIG. 1 can be used to produce a glass sheet with a desired viscosity in accordance with an embodiment of the present invention
  • FIG. 5 is a graph that illustrates the final thickness profiles of glass sheets made by four different experimental glass manufacturing systems in accordance with different embodiments of the present invention.
  • FIG. 6 is a side view of an exemplary glass manufacturing system having an inclined rolling configuration in accordance with an embodiment of the present invention.
  • FIG. 7 is a side view of an exemplary glass manufacturing system having a horizontal rolling configuration in accordance with an embodiment of the present invention.
  • the exemplary glass manufacturing system 100 includes a delivery system 102 within which there is a guided flow of molten glass 104 (not shown) that transitions to a free fall flow of molten glass 104 which is provided to a rolling roll pair 106 .
  • the rolling roll pair 106 has two rolling rolls 108 a and 108 b which receive the free falling molten glass 104 and draw the molten glass 104 to form a glass sheet 110 .
  • the rolling roll pair 106 is provided molten glass 104 that has a viscosity approximately between about 150-10,000 poises.
  • molten glass 104 with a viscosity between about 150-10,000 poises include the commercial D0035 glass from Corning Inc., the precursor glass of the commercial Kerablack glass ceramic from Eurokera and the precursor glass of spinel glass ceramics described in U.S. Pat. No. 5,968,857 (the contents of which are incorporated by reference herein).
  • the two rolling rolls 108 a and 108 b can roll the molten glass 104 to form the glass sheet 110 which has a thickness typically between about 2-5 mm and a surface roughness as low as 4 nm Ra and even 1 nm Ra can be achieved.
  • the glass manufacturing system 100 can have one or more additional rolling roll pairs 112 (one shown) each with rolling rolls 114 a and 114 b located below the rolling roll pair 106 which further draw and more accurately form the glass sheet 110 .
  • one or both of the rolling rolls 108 a and 108 b (and if desired one or both of the rolling rolls 114 a and 114 b ) may be a compensated rolling roll such that when the molten glass 104 is drawn between the rolling rolls 108 a and 108 b (and if used rolling rolls 114 a and 114 b ) then the glass sheet 110 formed has a central portion 116 that is thicker relative to the two outer edges 118 a and 118 b .
  • the rolling rolls 108 a and 108 b may be driven by one or more drive controllers-motors (not shown).
  • the drive controllers-motors can be used to control the speed at which the molten glass 104 is drawn, the torque at which the molten glass 104 is drawn, or a combination of both speed and torque that the molten glass 104 is drawn to obtain the glass sheet 110 .
  • the glass manufacturing system 100 also includes a temperature controlled environment 120 in which there is a cross temperature gradient where the two outer edges 118 a and 118 b of the glass sheet 110 are exposed to a hotter temperature than the central portion 116 of the glass sheet 110 .
  • the temperature controlled environment 120 provides the cross temperature gradient to stretch the glass sheet 110 such that most if not all of the glass sheet 110 has a substantially constant thickness which is preferably less than about 2 mm and more preferably less than about 100 ⁇ m.
  • the substantially constant thickness discussed herein is the thickness across the width of the glass sheet 110 as opposed to the thickness from the top-to-bottom of the drawn glass sheet 110 .
  • the temperature controlled environment 120 can be made by enclosing at least a section of the process and using (for example): (1) thermal insulation to limit cooling from outside the manufacturing process; (2) active cooling such as forced air, or radiative heat sinks such as water cooled devices etc. to maintain a lower temperature at the central portion 116 of the glass sheet 110 ; and/or (3) active heating such as electric heating that is applied through windings of heated tubes etc. to reheat the glass sheet 110 and in particular reheat the outer edges 118 a and 118 b of the glass sheet 110 .
  • a main purpose of the temperature controlled environment 120 is to slightly re-soften the glass sheet 110 after the rolling operation to stretch the glass sheet 110 using a reasonably low force.
  • This re-heated zone should be rather compact, i.e. not too long down below the rolling roll pairs 106 and 112 since a reheat zone that is too long would lead to an increased loss of width in the glass sheet 110 .
  • the temperature controlled environment 120 can have several different zones in sequence and within one or more of these zones the two outer edges 118 a and 118 b of the glass sheet 110 may be exposed to a colder temperature than the central portion 116 of the glass sheet 110 .
  • the glass manufacturing system 100 can include a first edge roll pair 122 and a second edge roll pair 124 , where a first edge portion 126 a of the glass sheet 110 is drawn between two edge rolls 128 a and 128 b which are associated with the first edge roll pair 122 , and an opposing second edge portion 126 b of the glass sheet is drawn between two edge rolls 130 a and 130 b associated with the second edge roll pair 124 .
  • the first and second edge roll pair 122 and 124 are located within the temperature controlled environment 120 which maintains a temperature that enables an adequate glass viscosity such that the glass sheet 110 can be stretched while substantially maintaining a width of the glass sheet 110 .
  • edge roll pairs 132 a , 132 b , 134 a , 134 b , 136 a , 136 b , 138 a and 138 b located below the first and second edge roll pairs 122 and 124 to further draw and stretch the glass sheet 110 while substantially maintaining the width of the glass sheet 110 .
  • the edge roll pairs 122 , 124 , 132 a , 132 b , 134 a , 134 b , 136 a , 136 b , 138 a and 138 b touch the glass sheet 110 while it is still in a formable condition for instance below 10 7 poises and avoid contacting the glass sheet 110 in the central portion 116 which is otherwise known as the usable part or the quality area.
  • the edge roll pairs 122 , 124 , 132 a , 132 b , 134 a , 134 b , 136 a , 136 b , 138 a and 138 b cause the glass sheet 110 to locally follow the linear speed of the corresponding edge rolls and will usually cause some sort of deformation of the glass sheet 110 such as for example local thinning or imprinting some pattern that is machined on the surfaces of the edge rolls but will substantially maintain the width of the glass sheet 110 .
  • one or more of the edge rolls pairs 122 , 124 , 132 a , 132 b , 134 a , 134 b , 136 a , 136 b , 138 a and 138 b may be driven by one or more drive controllers-motors (not shown).
  • the drive controllers-motors can be used to control the speed at which the glass sheet 110 is drawn, the torque at which the glass sheet 110 is drawn, or a combination of both speed and torque that the glass sheet 110 is drawn.
  • the glass manufacturing system 100 can also include if desired one or more pulling roll pairs 140 (one shown) where each pulling roll pair has two pulling rolls 142 a and 142 b which receive and further draw the glass sheet 110 to help obtain the desired thickness in at least its central portion 116 (usable part).
  • the pulling roll pair 140 receives the glass sheet 110 from the temperature controlled environment 120 and if used the lowest edge roll pairs 138 a and 138 b (for example).
  • the pulling roll pair 140 operates at a lower temperature when compared to the temperature controlled environment 120 and its main function is to impose a speed on the glass sheet 110 . At this point, the glass sheet 110 depending on the temperature could have a viscosity of 10 13 poises.
  • the two pulling rolls 142 a and 142 b extend across the width of the glass sheet 110 but have an undercut 144 a and 144 b formed therein so that the glass sheet 110 is contacted only near the two outer edges 126 a and 126 b .
  • the pulling roll pair 140 could have four rolls where two rolls grab one outer edge 126 a and the other two rolls grab the other outer edge 126 b .
  • one or more of the pulling rolls 142 a and 142 b associated with the pulling roll pair 140 may be driven by one or more drive controllers-motors (not shown).
  • the drive controllers-motors can be used to control the speed at which the glass sheet 110 is drawn, the torque at which the glass sheet 110 is drawn, or a combination of both speed and torque that the glass sheet 110 is drawn.
  • another embodiment of the invention includes a glass manufacturing system ( 100 , 100 ′, 100 ′′) comprising:
  • molten glass ( 104 ) transitions from a guided flow to a free fall flow
  • a rolling roll pair ( 106 ) having two rolling rolls ( 108 a , 108 b ) which receive the free fall flow of the molten glass and draw the molten glass to form a glass sheet ( 110 ), wherein the molten glass has a viscosity in a range of 150-10,000 poises when received by the two rolling rolls, wherein the glass sheet has a thickness between about 2-5 mm and a roughness between about 1-4 nm Ra after being drawn by the two rolling rolls;
  • a second edge roll pair ( 124 ), wherein a first edge portion ( 126 a ) of the glass sheet is drawn between two edge rolls ( 128 a , 128 b ) associated with the first edge roll pair, and an opposing second edge portion ( 126 b ) of the glass sheet is drawn between two edge rolls ( 130 a , 130 b ) associated with the second edge roll pair, wherein the first edge roll pair and the second edge roll pair stretch the glass sheet while substantially maintaining a width of the glass sheet, and wherein the first edge roll pair and the second edge roll pair are located within the temperature controlled environment, wherein the glass sheet has a thickness less than about 2 mm and a roughness less than about 4 nm Ra after travelling through the temperature controlled environment.
  • At least one of the rolling rolls can be a compensated roll such that when the molten glass is drawn between the rolling rolls then the glass sheet formed has a center portion that is thicker relative to the two outer edges.
  • Such an embodiment may also further comprise at least one pair of pulling rolls ( 140 ) where each pair of pulling rolls has two pulling rolls ( 142 a , 142 b ) which receive and draw the glass sheet after the glass sheet has travelled through the temperature controlled environment.
  • a glass manufacturing system 100 which utilizes the rolling roll pair(s) 106 and 112 (possibly the optional compensated rolling roll pair(s) 106 and 112 ), the temperature controlled environment 120 , and possibly the optional edge roll pair(s) 122 , 124 , 132 a , 132 b , 134 a , 134 b , 136 a , 136 b , 138 a and 138 b , and the optional pulling roll pair(s) 140 can manufacture a glass sheet 110 that has a thickness less than about 2 mm and a roughness less than about 4 nm Ra and more preferably a thickness less than about 100 ⁇ m and a roughness of about 0.25 nm Ra.
  • the glass manufacturing system 100 can have very good thickness control where there is a substantially constant thickness within the central portion 116 of the glass sheet 110 . It should be noted that stretching the glass sheet 110 after rolling does not necessarily result in the glass sheet 110 having a substantially constant thickness in the central portion 116 of the glass sheet 110 . In the experiments described next it will be explained which types of process variants and parameters can be used to help the glass manufacturing system 100 produce the glass sheet 110 which has at least a central portion 116 thereof with a desired thickness distribution.
  • the glass manufacturing system 100 had four different setups as shown in TABLE #1.
  • the experimental glass manufacturing systems 100 associated with cases A and B used one motor-driven constant rolling roll pair 106 in which both rolling rolls 108 a and 108 b had 17.5 cm diameters.
  • the experimental glass manufacturing systems 100 associated with cases C and D used one motor-driven compensated rolling roll pair 106 in which one rolling roll 108 a was a compensated roll and the other rolling roll 108 b was a flat roll such that when the molten glass 104 was drawn between the compensated roll 108 a and the flat roll 108 b then the glass sheet 110 formed had a central portion 116 that was thicker relative to the two outer edges 118 a and 118 b .
  • FIG. 2 illustrates an exemplary compensated rolling roll pair 106 that has one flat roll 108 b and one compensated roll 108 a , where the compensated roll 108 a has a central portion 202 with a diameter that is relatively small and then gradually increases in size as one moves toward the end portions 204 a and 204 b .
  • FIG. 3 is a graph that illustrates the shape of the glass sheet 110 after being rolled by the compensated rolling roll pair 106 but before being drawn where the x-axis indicates the distance from a centerline (m) of the glass sheet 110 and the y-axis indicates the rolled thickness (m) of the glass sheet 110 .
  • the compensated rolling roll pair 106 may have two compensated rolling rolls 108 a and 108 b where both rolls have a central portion 202 with a diameter that is relatively small and then gradually increases in size as one moves toward the end portions 204 a and 204 b.
  • the experimental glass manufacturing system 100 associated with case A did not utilize a temperature controlled environment 120 .
  • the experimental glass manufacturing systems 100 associated with cases B-D did utilize a temperature controlled environment 120 in which there was a cross temperature gradient where the two outer edges 118 a and 118 b of the glass sheet 110 are exposed to a hotter temperature than the central portion 116 of the glass sheet 110 .
  • the temperature controlled environment 120 was created to produce a temperature on the center portion 116 of the glass sheet 110 which corresponds to the viscosity curves 402 and 404 shown in the graph of FIG. 4 .
  • the x-axis indicates the distance (m) from the rolling roll pair 106
  • the y 1 -axis (left side) associated with curve 402 indicates glass viscosity (poises)
  • the y 2 -axis (right side) associated with curve 404 indicates log (viscosity).
  • the temperature controlled environment 120 was made by enclosing a section of the manufacturing process below the rolling roll pair 106 and using electrical heaters to heat the outer edges 118 a and 118 b of the glass sheet 110 and using controlled heat loss to maintain the lower temperature at the central portion 116 of the glass sheet 110 .
  • the experimental glass manufacturing systems 100 associated with cases A-C did not utilize edge rolls.
  • the experimental glass manufacturing system 100 associated with case D utilized one set of edge roll pairs 122 and 124 on each side of the glass sheet 110 where the first edge portion 126 a of the glass sheet 110 was drawn between two edge rolls 128 a and 128 b associated with the first edge roll pair 122 , and the opposing second edge portion 126 b of the glass sheet 110 was drawn between two edge rolls 130 a and 130 b associated with the second edge roll pair 124 .
  • Each edge roll 128 a , 128 b , 130 a and 130 b had a 2 inch diameter and each touched a 3 cm width on either the first or second edge portion 126 a and 126 b of the glass sheet 110 .
  • the edge rolls 128 a , 128 b , 130 a and 130 b where placed 0.5 m below the rolling roll pair 106 and within the temperature controlled environment 120 .
  • the experimental glass manufacturing systems 100 associated with cases A-D utilized one pulling roll pair 140 which was located 1.5-2 m below the rolling roll pair 106 .
  • the pulling roll pair 140 had two pulling rolls 142 a and 142 b which had a 100 mm outer diameter and extended across the width of the glass sheet 110 but they had an undercut 144 a and 144 b so that the glass sheet 110 was contacted only near the two outer edges 126 a and 126 b.
  • the experimental glass manufacturing systems 100 used a glass ceramic precursor having the following composition: SiO 2 68.25 wt %, Al 2 O 3 19.2 wt %, Li 2 O 3.5 wt %, MgO 1.2 wt %, ZnO 1.6 wt %, BaO 0.8 wt %, TiO 2 2.6 wt %, ZrO 2 1.7 wt %, As 3 O 4 0.6 wt %, Na 2 O+K 2 O 0.35 wt %, and V 2 O 5 0.2 wt %.
  • the glass manufacturing system 100 can use different materials in a glass state (e.g., glass or glass ceramic precursors) to manufacture many different types of glass sheets 110 including for example: a glass-ceramic sheet, a borosilicate glass sheet (e.g., Pyrex® glass), a white crown glass sheet, or an alkali-free glass sheet.
  • the experimental glass manufacturing systems 100 had a throughput of about 60 tons/day and flow density of about 90 pounds/hour per inch to manufacture 1.5 m wide glass sheets 110 .
  • the experimental glass manufacturing systems 100 had a rolling speed of about 3.75 m/min in which there was rolled a 3 mm thick glass sheet 110 .
  • the experimental glass manufacturing systems 100 also had redraw ratio of three in which an exit speed of the final glass sheet 110 was three times faster than the rolling speed of the upstream glass sheet 110 . The results of these experiments are discussed next with respect to FIG. 5 .
  • FIG. 5 there is a graph that illustrates the final thickness profiles of the glass sheets 110 manufactured by the experimental glass manufacturing systems 100 based on cases A-D in accordance with different embodiments of the present invention.
  • the x-axis indicates the distance (m) from the centerline of the glass sheet 110
  • the y-axis indicates a local thickness (m)
  • cases A-D respectively correspond to lines 502 a , 502 b , 502 c and 502 d .
  • each type of modification namely the compensated rolling roll, thermal environment gradient or edge rolls has an influence on the thickness profile of the glass sheet 110 .
  • the present invention it is possible to manufacture a glass sheet 110 with a substantially constant thickness in the largest part of the width of the glass sheet 110 with a wide range of draw ratios.
  • the present invention can provide a process to provide high quality thin sheets of glass with one or more of the following attributes:
  • the exemplary glass manufacturing systems 100 described above with respect to FIGS. 1-5 used a vertical rolling configuration to manufacture the glass sheet 110 in accordance with an embodiment of the present invention.
  • the present invention can have an embodiment in which a glass manufacturing system 100 ′ had an inclined rolling configuration when manufacturing the glass sheet 110 as shown in FIG. 6 .
  • the present invention can have an embodiment in which a glass manufacturing system 100 ′′ had a horizontal rolling configuration when manufacturing the glass sheet 110 as shown in FIG. 7 .
  • the exemplary glass manufacturing systems 100 and 100 ′ are shown with only one rolling roll pair 106 but they could have any number of rolling roll pairs.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Glass Compositions (AREA)
  • Re-Forming, After-Treatment, Cutting And Transporting Of Glass Products (AREA)
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US20190169059A1 (en) * 2017-12-04 2019-06-06 Corning Incorporated Methods for forming thin glass sheets
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KR101941820B1 (ko) * 2018-06-15 2019-04-15 한민섭 포장용 밴드의 폭 연신 장치
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CN102414133A (zh) 2012-04-11
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CN102414133B (zh) 2015-02-18
US10273179B2 (en) 2019-04-30

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