WO2017223034A1

WO2017223034A1 - Apparatus and method for glass delivery orientation

Info

Publication number: WO2017223034A1
Application number: PCT/US2017/038244
Authority: WO
Inventors: Rashid Abdul-Rahman; Paul E. KNUTSON; Gautam Narendra Kudva; Shawn Rachelle Markham
Original assignee: Corning Incorporated
Priority date: 2016-06-23
Filing date: 2017-06-20
Publication date: 2017-12-28
Also published as: KR20190012264A; TW201808833A; CN109415235A; JP2019518703A

Abstract

A glass manufacturing apparatus and method includes a forming apparatus and a melting and delivery component. The melting and delivery component is configured to flow molten glass along a delivery pathway that extends along at least a portion of the melting and delivery component in a first direction. The forming apparatus extends in a longitudinal direction that is at an angle relative to the first direction.

Description

APPARATUS AND METHOD FOR GLASS DELIVERY ORIENTATION

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S.

Provisional Application Serial No. 62/353881, filed on June 23, 2016, the content of which is relied upon and incorporated herein by reference in its entirety.

Field

[0002] The present disclosure relates generally to an apparatus and method for making glass articles and more particularly to an apparatus and method for making glass articles with multiple delivery orientations.

Background

[0003] In the production of glass articles, such as glass sheets for display applications, including televisions and hand held devices, such as telephones and tablets, there is a continual need to increase the efficiency and flexibility of processes and apparatuses used for the production of the glass articles.

SUMMARY

[0004] Embodiments disclosed herein include a glass article manufacturing apparatus. The apparatus includes a forming apparatus and a melting and delivery component that is configured to flow molten glass along a delivery pathway that extends along at least a portion of the melting and delivery component along a first direction. The forming apparatus extends in a longitudinal direction that is at an angle relative to the first direction.

[0005] Embodiments disclosed herein also include a method for making a glass article. The method includes processing a glass melt along a melting and delivery component that is configured to flow molten glass along a delivery pathway that extends along at least a portion of the melting and delivery component along a first direction. The method also includes processing the glass melt in a forming apparatus. The forming apparatus extends in a longitudinal direction that is at an angle relative to the first direction.

[0006] Additional features and advantages of the embodiments disclosed herein will be set forth in the detailed description which follows, and in part will be readily apparent to those skilled in the art from that description or recognized by practicing the disclosed embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.

l [0007] It is to be understood that both the foregoing general description and the following detailed description present embodiments intended to provide an overview or framework for understanding the nature and character of the claimed embodiments. The accompanying drawings are included to provide further understanding, and are incorporated into and constitute a part of this specification. The drawings illustrate various embodiments of the disclosure, and together with the description serve to explain the principles and operations thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] FIG. 1 is a schematic view of an example fusion down draw glass making apparatus and process;

[0009] FIG. 2 is a top view of an embodiment of the exemplary apparatus and process of FIG. 1, wherein the forming apparatus is oriented such that the sheet conveyance component extends in a second direction that is approximately perpendicular to a first direction as described herein;

[0010] FIG. 3 is an exploded top view showing an angle between a longitudinal direction of a forming apparatus and a first direction as described herein, as well as a relationship between an orientation of an inlet conduit of the forming apparatus relative to an exit conduit of a delivery vessel;

[0011] FIG. 4 is a top view of an alternative embodiment of the exemplary apparatus and process of FIG. 1, wherein the forming apparatus is oriented such that the sheet conveyance component extends in a second direction that approximately the same as a first direction as described herein;

[0012] FIG. 5 is a top view of an alternative embodiment of the exemplary apparatus and process of FIG. 1, wherein the forming apparatus is oriented such that the sheet conveyance component extends in a second direction that is approximately the opposite of a first direction as described herein; and

[0013] FIG. 6 is a top cutaway view of a forming apparatus according to embodiments disclosed herein, wherein the height of the forming apparatus can be independently adjustable in at least one of the longitudinal and transverse directions. DETAILED DESCRIPTION

[0014] Reference will now be made in detail to the present preferred embodiments of the present disclosure, examples of 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. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0015] Ranges can be expressed herein as from "about" one particular value, and/or to "about" another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, for example by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0016] Directional terms as used herein - for example up, down, right, left, front, back, top, bottom - are made only with reference to the figures as drawn and are not intended to imply absolute orientation.

[0017] Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order, nor that with any apparatus specific orientations be required. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or that any apparatus claim does not actually recite an order or orientation to individual components, or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, or that a specific order or orientation to components of an apparatus is not recited, it is in no way intended that an order or orientation be inferred, in any respect. This holds for any possible non-express basis for interpretation, including: matters of logic with respect to arrangement of steps, operational flow, order of components, or orientation of components; plain meaning derived from grammatical organization or punctuation, and; the number or type of embodiments described in the specification.

[0018] As used herein, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a" component includes aspects having two or more such components, unless the context clearly indicates otherwise. [0019] Shown in FIG. 1 is an exemplary glass manufacturing apparatus 10. In some examples, the glass manufacturing apparatus 10 can comprise a glass melting furnace 12 that can include a melting vessel 14. In addition to melting vessel 14, glass melting furnace 12 can optionally include one or more additional components such as heating elements (e.g. , combustion burners or electrodes) that heat raw materials and convert the raw materials into molten glass. In further examples, glass melting furnace 12 may include thermal management devices (e.g., insulation components) that reduce heat lost from a vicinity of the melting vessel. In still further examples, glass melting furnace 12 may include electronic devices and/or electromechanical devices that facilitate melting of the raw materials into a glass melt. Still further, glass melting furnace 12 may include support structures (e.g., support chassis, support member, etc.) or other components.

[0020] Glass melting vessel 14 is typically comprised of refractory material, such as a refractory ceramic material, for example a refractory ceramic material comprising alumina or zirconia. In some examples glass melting vessel 14 may be constructed from refractory ceramic bricks. Specific embodiments of glass melting vessel 14 will be described in more detail below.

[0021] In some examples, the glass melting furnace may be incorporated as a component of a glass manufacturing apparatus to fabricate a glass substrate, for example a glass ribbon of a continuous length. In some examples, the glass melting furnace of the disclosure may be incorporated as a component of a glass manufacturing apparatus comprising a slot draw apparatus, a float bath apparatus, a down-draw apparatus such as a fusion process, an up- draw apparatus, a press-rolling apparatus, a tube drawing apparatus or any other glass manufacturing apparatus that would benefit from the aspects disclosed herein. By way of example, FIG. 1 schematically illustrates glass melting furnace 12 as a component of a fusion down-draw glass manufacturing apparatus 10 for fusion drawing a glass ribbon for subsequent processing into individual glass sheets.

[0022] The glass manufacturing apparatus 10 (e.g., fusion down-draw apparatus 10) can optionally include an upstream glass manufacturing apparatus 16 that is positioned upstream relative to glass melting vessel 14. In some examples, a portion of, or the entire upstream glass manufacturing apparatus 16, may be incorporated as part of the glass melting furnace 12.

[0023] As shown in the illustrated example, the upstream glass manufacturing apparatus 16 can include a storage bin 18, a raw material delivery device 20 and a motor 22 connected to the raw material delivery device. Storage bin 18 may be configured to store a quantity of raw materials 24 that can be fed into melting vessel 14 of glass melting furnace 12, as indicated by arrow 26. Raw materials 24 typically comprise one or more glass forming metal oxides and one or more modifying agents. In some examples, raw material delivery device 20 can be powered by motor 22 such that raw material delivery device 20 delivers a predetermined amount of raw materials 24 from the storage bin 18 to melting vessel 14. In further examples, motor 22 can power raw material delivery device 20 to introduce raw materials 24 at a controlled rate based on a level of molten glass sensed downstream from melting vessel 14. Raw materials 24 within melting vessel 14 can thereafter be heated to form molten glass 28.

[0024] Glass manufacturing apparatus 10 can also optionally include a downstream glass manufacturing apparatus 30 positioned downstream relative to glass melting furnace 12. In some examples, a portion of downstream glass manufacturing apparatus 30 may be incorporated as part of glass melting furnace 12. In some instances, first connecting conduit 32 discussed below, or other portions of the downstream glass manufacturing apparatus 30, may be incorporated as part of glass melting furnace 12. Elements of the downstream glass manufacturing apparatus, including first connecting conduit 32, may be formed from a precious metal. Suitable precious metals include platinum group metals selected from the group of metals consisting of platinum, iridium, rhodium, osmium, ruthenium and palladium, or alloys thereof. For example, downstream components of the glass manufacturing apparatus may be formed from a platinum-rhodium alloy including from about 70 to about 90% by weight platinum and about 10% to about 30% by weight rhodium. However, other suitable metals can include molybdenum, palladium, rhenium, tantalum, titanium, tungsten and alloys thereof.

[0025] Downstream glass manufacturing apparatus 30 can include a first conditioning (i.e., processing) vessel, such as fining vessel 34, located downstream from melting vessel 14 and coupled to melting vessel 14 by way of the above-referenced first connecting conduit 32. In some examples, molten glass 28 may be gravity fed from melting vessel 14 to fining vessel 34 by way of first connecting conduit 32. For instance, gravity may cause molten glass 28 to pass through an interior pathway of first connecting conduit 32 from melting vessel 14 to fining vessel 34. It should be understood, however, that other conditioning vessels may be positioned downstream of melting vessel 14, for example between melting vessel 14 and fining vessel 34. In some embodiments, a conditioning vessel may be employed between the melting vessel and the fining vessel wherein molten glass from a primary melting vessel is further heated to continue the melting process, or cooled to a temperature lower than the temperature of the molten glass in the melting vessel before entering the fining vessel.

[0026] Bubbles may be removed from molten glass 28 within fining vessel 34 by various techniques. For example, raw materials 24 may include multivalent compounds (i.e. fining agents) such as tin oxide that, when heated, undergo a chemical reduction reaction and release oxygen. Other suitable fining agents include without limitation arsenic, antimony, iron and cerium. Fining vessel 34 is heated to a temperature greater than the melting vessel temperature, thereby heating the molten glass and the fining agent. Oxygen bubbles produced by the temperature-induced chemical reduction of the fining agent(s) rise through the molten glass within the fining vessel, wherein gases in the molten glass produced in the melting furnace can diffuse or coalesce into the oxygen bubbles produced by the fining agent. The enlarged gas bubbles can then rise to a free surface of the molten glass in the fining vessel and thereafter be vented out of the fining vessel. The oxygen bubbles can further induce mechanical mixing of the molten glass in the fining vessel.

[0027] Downstream glass manufacturing apparatus 30 can further include another conditioning vessel such as a mixing vessel 36 for mixing the molten glass. Mixing vessel 36 may be located downstream from the fining vessel 34. Mixing vessel 36 can be used to provide a homogenous glass melt composition, thereby reducing cords of chemical or thermal inhomogeneity that may otherwise exist within the fined molten glass exiting the fining vessel. As shown, fining vessel 34 may be coupled to mixing vessel 36 by way of a second connecting conduit 38. In some examples, molten glass 28 may be gravity fed from the fining vessel 34 to mixing vessel 36 by way of second connecting conduit 38. For instance, gravity may cause molten glass 28 to pass through an interior pathway of second connecting conduit 38 from fining vessel 34 to mixing vessel 36. It should be noted that while mixing vessel 36 is shown downstream of fining vessel 34, mixing vessel 36 may be positioned upstream from fining vessel 34. In some embodiments, downstream glass manufacturing apparatus 30 may include multiple mixing vessels, for example a mixing vessel upstream from fining vessel 34 and a mixing vessel downstream from fining vessel 34. These multiple mixing vessels may be of the same design, or they may be of different designs.

[0028] Downstream glass manufacturing apparatus 30 can further include another conditioning vessel such as delivery vessel 40 that may be located downstream from mixing vessel 36. Delivery vessel 40 may condition molten glass 28 to be fed into a downstream forming device. For instance, delivery vessel 40 can act as an accumulator and/or flow controller to adjust and/or provide a consistent flow of molten glass 28 to forming body 42 by way of exit conduit 44. As shown, mixing vessel 36 may be coupled to delivery vessel 40 by way of third connecting conduit 46. In some examples, molten glass 28 may be gravity fed from mixing vessel 36 to delivery vessel 40 by way of third connecting conduit 46. For instance, gravity may drive molten glass 28 through an interior pathway of third connecting conduit 46 from mixing vessel 36 to delivery vessel 40.

[0029] Downstream glass manufacturing apparatus 30 can further include forming apparatus 48 comprising the above-referenced forming body 42 and inlet conduit 50. Exit conduit 44 can be positioned to deliver molten glass 28 from delivery vessel 40 to inlet conduit 50 of forming apparatus 48. For example in examples, exit conduit 44 may be nested within and spaced apart from an inner surface of inlet conduit 50, thereby providing a free surface of molten glass positioned between the outer surface of exit conduit 44 and the inner surface of inlet conduit 50. Forming body 42 in a fusion down draw glass making apparatus can comprise a trough 52 positioned in an upper surface of the forming body and converging forming surfaces 54 that converge in a draw direction along a bottom edge 56 of the forming body. Molten glass delivered to the forming body trough via delivery vessel 40, exit conduit 44 and inlet conduit 50 overflows side walls of the trough and descends along the converging forming surfaces 54 as separate flows of molten glass. The separate flows of molten glass join below and along bottom edge 56 to produce a single ribbon of glass 58 that is drawn in a draw direction 60 from bottom edge 56 by applying tension to the glass ribbon, such as by gravity, edge rolls 72 and pulling rolls 82, to control the dimensions of the glass ribbon as the glass cools and a viscosity of the glass increases. Accordingly, glass ribbon 58 goes through a visco-elastic transition and acquires mechanical properties that give the glass ribbon 58 stable dimensional characteristics. Glass ribbon 58 may, in some embodiments, be separated into individual glass sheets 62 by a glass separation apparatus 100 in an elastic region of the glass ribbon. A robot 64 may then transfer the individual glass sheets 62 to a conveyor system using gripping tool 65, whereupon the individual glass sheets may be further processed.

[0030] FIG. 2 is a top view of an embodiment of the apparatus of FIG. 1 , wherein the glass manufacturing apparatus includes a sheet conveyance component 150 that can be used to process at least one of a glass ribbon and sheet exiting forming apparatus 48. In the embodiment illustrated in FIG. 2, the constituents upstream of and including exit conduit 44 comprise melting and delivery component 140. As shown in FIG. 2, the glass manufacturing apparatus is configured to flow molten glass along a delivery pathway, which can extend along at least a portion of the melting and delivery component 140, such as along the entirety of the melting and delivery component 140, along a first direction D l . For example, the delivery pathway extending along Dl can at least extend from mixing vessel 36 to delivery vessel 40. The delivery pathway extending along Dl may also extend for a longer distance along melting and delivery component 140, such as from fining vessel 34 to delivery vessel 40, including from melting vessel 14 to delivery vessel 40, and further including from storage bin 18 to delivery vessel 40.

[0031] The forming apparatus 48 in the embodiment illustrated in FIG. 2 is oriented in a longitudinal direction L. In this embodiment, sheet conveyance component 150 extends in a second direction D2 that is approximately perpendicular to the first direction Dl .

[0032] Embodiments disclosed herein include those in which the forming apparatus 48 extends in a longitudinal direction L that is at an angle relative to first direction Dl . FIG. 3 shows an exploded top view showing an angle Θ between a longitudinal direction L of forming apparatus 48 and a first direction Dl . Angle Θ can be any non-zero value, such as from about 1 degree to about 360 degrees, such as from about 1 degree to about 180 degrees, and further such as from about 1 degree to about 90 degrees, including about 90 degrees.

[0033] Forming apparatus 48 can extend in a longitudinal direction L that is at an angle Θ relative to first direction Dl , for example, by changing the orientation of inlet conduit 50 of forming apparatus 48 relative to the first direction Dl , as shown, for example, in FIG. 3, which shows the changeable orientation of inlet conduit 50 relative to exit conduit 44 of delivery vessel 40. Specifically, delivery vessel 40 is in fluid communication with exit conduit 44 and forming body 42 of forming apparatus 48 is in fluid communication with inlet conduit 50, wherein inlet conduit 50 is orientable relative to the exit conduit 44. As can be seen in FIG. 3, because both exit conduit 44 and inlet conduit 50 each have approximately circular cross-sections (in the embodiment of FIG. 3, inlet conduit 50 circumferentially surrounds exit conduit 44), inlet conduit 50 can be orientable, as indicated by arrows 170, relative to exit conduit 44. Specifically, inlet conduit 50 can be oriented at any angle relative to exit conduit 44 and first direction Dl , such as any angle from about 0 to about 360 degrees, including any angle from about 0 to about 180 degrees.

[0034] As the inlet conduit 50 of forming apparatus 48 may be orientable at any angle relative to first direction Dl , longitudinal direction L of forming apparatus 48 (as shown in FIGS. 2, 4, and 5) is configured to be orientable at an angle Θ relative to first direction Dl . This enables molten glass to flow into delivery vessel 40 along first direction Dl and to flow into forming body 42 along longitudinal direction L of forming apparatus 48, thereby enabling a variety of flow orientations depending on longitudinal direction L relative to first direction Dl . For example, as shown in FIG. 2, longitudinal direction L of forming apparatus 48 may be approximately the same as first direction Dl . Alternatively, as shown, for example, in FIGS. 4 and 5, longitudinal direction L of forming apparatus 48 may be approximately perpendicular to the first direction Dl . Longitudinal direction L of forming apparatus 48 may also extend in other angles relative to the first direction Dl (not shown).

[0035] While FIGS. 4 and 5 both show embodiments in which the longitudinal direction L of forming apparatus 48 is approximately perpendicular to first direction Dl , they each respectively show sheet conveyance components 150 that extend in approximately opposite second directions D2. Specifically, FIG. 4 shows a top view of an embodiment of the apparatus of FIG. 1, wherein the sheet conveyance component 150 extends in a second direction D2 that is approximately the same as the first direction Dl . Conversely, FIG. 5 shows a top view of an embodiment of the apparatus of FIG. 1 , wherein the sheet conveyance component 150 extends in a second direction D2 that is approximately the opposite as the first direction Dl .

[0036] While FIGS. 2, 4, and 5 show embodiments wherein the second direction D2 is approximately perpendicular to, the same as, and opposite as, the first direction D l , respectively, it is to be understood that embodiments disclosed herein include those in which the second direction D2 is configured to extend at any angle relative to the first direction Dl , such as where the second direction D2 ranges from about 0 degrees to about 360 degrees, such as from about 0 degrees to about 180 degrees relative to the first direction Dl .

[0037] Regardless of the orientation of the forming apparatus 48 relative to the first direction Dl , the height of the forming apparatus 48, and likewise, forming body 42, can be adjusted such that flow of glass over forming body 42 results in production of a glass ribbon having desired characteristics. For example, as shown in FIG. 6, the height of the forming apparatus 48 can be independently adjustable in at least one of the longitudinal L and transverse T directions for any of the orientations disclosed herein. Such adjustments can be made, for example, by use of independently adjustable suspension jack mechanisms that are situated above corner positions of forming apparatus 48, as illustrated by points A-D in FIG. 6.

[0038] Sheet conveyance component 150 may convey a glass ribbon or individual sheets separated from a glass ribbon in the second direction D2. For example, sheet conveyance component 150, may, in some exemplary embodiments, include a catenary zone, which can bend a glass ribbon, such a thin, flexible glass ribbon from approximately vertical to the second direction via a specified sweep angle. Sheet conveyance component 150 may further comprise other ribbon or sheet finishing, inspection, and/or packaging components, such as washing components, coating components, edge finishing components, etching components, and, in the case of a thin, flexible glass ribbon, rolling components (not shown).

[0039] Embodiments disclosed herein, including a forming apparatus that extends in a longitudinal direction that is at an angle relative to a first direction, can enable several advantages over previously known glass article manufacturing apparatuses and methods, including more efficient use of facility space, particularly where the second direction is configured to be the same as or the opposite to the flow direction. Embodiments disclosed herein may also reduce potentially undesirable effects of gradients, such as viscosity or compositional gradients, that may be present and directionally dependent in an exit conduit of a delivery vessel by enabling the flow direction of a forming apparatus to be adjusted to an orientation that minimizes the effects of such gradients. This can, in turn, result in the formation of a glass article or sheet with improved attributes, such as improved thickness or compositional uniformity.

[0040] While the above embodiments have been described with reference to a fusion down draw process, it is to be understood that such embodiments are also applicable to other glass forming processes, such as float processes, slot draw processes, up-draw processes, and press-rolling processes.

[0041] It will be apparent to those skilled in the art that various modifications and variations can be made to embodiment of the present disclosure without departing from the spirit and scope of the disclosure. Thus it is intended that the present disclosure cover such modifications and variations provided they come within the scope of the appended claims and their equivalents.

Claims

What is claimed is:

1. A glass article manufacturing apparatus comprising:

a forming apparatus; and

a melting and delivery component that is configured to flow molten glass along a delivery pathway that extends along at least a portion of the melting and delivery component along a first direction;

wherein the forming apparatus extends in a longitudinal direction that is at an angle relative to the first direction.

2. The glass article manufacturing apparatus of claim 1 , further comprising a sheet conveyance component that extends in a second direction.

3. The glass article manufacturing apparatus of claim 1 , wherein the melting and delivery component comprises a delivery vessel in fluid communication with an exit conduit and the forming apparatus comprises a forming body that is in fluid communication with an inlet conduit, wherein the glass article manufacturing apparatus is configured to flow molten glass into the delivery vessel along the first direction and is configured to flow molten glass into the forming body along the longitudinal direction.

4. The glass article manufacturing apparatus of claim 1 , wherein the angle between the first direction and the longitudinal direction ranges from about 1 degree to about 90 degrees.

5. The glass article manufacturing apparatus of claim 2, wherein the second direction is approximately the same as the first direction.

6. The glass article manufacturing apparatus of claim 2, wherein the second direction is approximately the opposite as the first direction.

7. The glass article manufacturing apparatus of claim 1 , wherein the first direction extends along the entirety of the melting and delivery component.

8. The glass article manufacturing apparatus of claim 1, wherein the height of the forming apparatus is independently adjustable in at least one of the longitudinal and transverse directions.

9. The glass article manufacturing apparatus of claim 2, wherein the sheet conveyance component comprises a catenary zone.

10. A method for making a glass article comprising:

processing a glass melt along a melting and delivery component that is configured to flow molten glass along a delivery pathway that extends along at least a portion of the melting and delivery component along a first direction; and processing the glass melt in a forming apparatus;

11. The method of claim 10, further comprising processing at least one of a glass ribbon and sheet along a sheet conveyance component that extends in a second direction.

12. The method of claim 10, wherein the melting and delivery component comprises a delivery vessel in fluid communication with an exit conduit and the forming apparatus comprises a forming body that is in fluid communication with an inlet conduit, wherein the glass article manufacturing apparatus is configured to flow molten glass into the delivery vessel along the first direction and is configured to flow molten glass into the forming body along the longitudinal direction.

13. The method of claim 10, wherein the angle between the first direction and the longitudinal direction ranges from about 1 degree to about 90 degrees.

14. The method of claim 11 , wherein the second direction is approximately the same as the first direction.

15. The method of claim 11 , wherein the second direction is approximately the opposite as the first direction.

16. The method of claim 10, wherein the first direction extends along the entirety of the melting and delivery component.

17. The method of claim 10, wherein the height of the forming apparatus is independently adjustable in at least one of the longitudinal and transverse directions.

18. The method of claim 11 , wherein the sheet conveyance component comprises a catenary zone.