WO2019026091A1 - Glass bending mold - Google Patents

Glass bending mold Download PDF

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Publication number
WO2019026091A1
WO2019026091A1 PCT/IN2018/050507 IN2018050507W WO2019026091A1 WO 2019026091 A1 WO2019026091 A1 WO 2019026091A1 IN 2018050507 W IN2018050507 W IN 2018050507W WO 2019026091 A1 WO2019026091 A1 WO 2019026091A1
Authority
WO
WIPO (PCT)
Prior art keywords
glass
bending mold
glass bending
mold member
mold
Prior art date
Application number
PCT/IN2018/050507
Other languages
French (fr)
Inventor
Arunvel Thangamani
Samson RICHARDSON D
Robin C JAYARAM
Original Assignee
Saint-Gobain Glass France
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
Application filed by Saint-Gobain Glass France filed Critical Saint-Gobain Glass France
Priority to CN201880050150.XA priority Critical patent/CN110997581A/en
Publication of WO2019026091A1 publication Critical patent/WO2019026091A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B23/00Re-forming shaped glass
    • C03B23/02Re-forming glass sheets
    • C03B23/023Re-forming glass sheets by bending
    • C03B23/03Re-forming glass sheets by bending by press-bending between shaping moulds
    • C03B23/0302Re-forming glass sheets by bending by press-bending between shaping moulds between opposing full-face shaping moulds
    • CCHEMISTRY; METALLURGY
    • C03GLASS; MINERAL OR SLAG WOOL
    • C03BMANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B40/00Preventing adhesion between glass and glass or between glass and the means used to shape it, hold it or support it
    • C03B40/005Fabrics, felts or loose covers
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02PCLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00Technologies relating to the processing of minerals
    • Y02P40/50Glass production, e.g. reusing waste heat during processing or shaping
    • Y02P40/57Improving the yield, e-g- reduction of reject rates

Definitions

  • the present disclosure relates to an improved glass bending mold for imparting a desired shape to a glass sheet, and more particularly to the glass bending mold made from a novel material.
  • the curved or bent sheets of glass are commonly employed in present- day civil structures, buildings as glazing closures, facades or windows, mirrors and automotive vehicles as front or rear windshield or side window.
  • Such glass sheets have to be conventionally bent by glass bending molds. The bending takes place by heating the glass to a higher temperature where the glass is viscoelastic in nature. The soften glass is bent to the desired shape by the mold.
  • the sheet of glass is placed into a mold made of metal.
  • the most commonly used metals are aluminium and cast iron.
  • the main drawbacks with the metal molds are high energy consumption, high oxidation resistance, high wear resistance, high corrosion resistance, high thermal conductivity, high thermal expansion, high density, heavy and high deformation.
  • aluminum there is a tendency for loss of form that is deformation because of the high thermal expansion of aluminium.
  • cast iron loss of form or deformation is less of a problem but the difficulty is then often encountered because the cast iron molds exert an undue chilling effect on the glass due to high thermal conductivity.
  • the metallic molds are heavier and denser; as a result, there is a higher energy consumption during the operation.
  • the molds rework is also difficult and need complete replacement in case of any damage such as due to corrosion or wear.
  • Wooden molds have, in general, been satisfactory when operating at relatively low production rates which give the wooden mold a chance to cool between individual pressing operations. However, when the production rate is increased, the heat load on the wooden mold is much higher and the wooden mold begins to suffer. It is then found that the wooden mold soon tends to suffer the loss of form because of warping, splitting or burning under the heavy heat load which is applied to them and breaks down with extended use.
  • Refractory molds have a low thermal expansion, hence no distortion in shape even when the mold is reheated a number of times.
  • the refractories have good thermal shock stability as compared to metals. This results in the development of no cracks even after a long service period. Further, the refractories can be easily machined. All these properties make a refractory mold suitable for high production operations. However, the refractory molds are much heavier in weight as compared to metallic and hence consume more power. Further, the thermal conductivity of the refractory mold is low, hence it becomes difficult to maintain a constant temperature during the bending process.
  • Carbon or graphite molds are preferred over metallic ones in the industry as graphite has good characteristics such as high workability, high- temperature strength, and thermal conductivity, however, it is liable to be oxidized under high-temperature conditions leading to wearing out. This leads to seriously affects the service life of the mold and the glass molding accuracy.
  • the graphite and carbon are less rigid and hence are more flexible. The graphite at a higher temperature will deform and this leads to defaults in shapes while bending. Further, graphite molds are much more expensive than the metallic mold.
  • US2330279 discloses the molds formed from a plaster composition such as plaster of Paris or gypsum paste.
  • the plaster molds are readily formable to an accurate predetermined shape and may be easily duplicated. Also, such molds will readily withstand the elevated temperatures to which they are subjected and will not become distorted or lose their accuracy even though different portions thereof engage the heated glass sheet different lengths of time during the bending operation. Further, plaster molds will not mar the glass surfaces and have a long life through repeated bending cycles. Plaster molds also do not require preheating nor do they become charred at elevated temperatures.
  • plaster molds do not cause chill cracks in the glass.
  • a still further advantage of plaster molds is the ease with which the bending faces thereof may be redressed for radii and surface corrections.
  • the plaster mold has the less mechanical strength and over the increase in production rate plaster mold gets worn out.
  • One such mold is formed of an epoxy resin having a fibrous glass reinforcement.
  • Such molds are, however, quite expensive. Also, it has been found that the heat to which the blocks are exposed during a press bending operation is capable of causing blistering of an epoxy resin after the mold has been in use for some time.
  • the bending of the glass structure is being done in a very high precision, at the same time having a high production stability, therefore, to be able to obtain a glass shaped as desired through a press bending mold.
  • the mold should have an excellent workability at a high temperature and further have excellent thermal conductivity, oxidation resistance, wear resistance, corrosion resistance, but also inert on the glass, good releasability, bending at high accuracy, lighter in weight, easily machined and low in cost. None of the above- mentioned materials provide a complete solution for the press bending mold. Each of the materials mentioned above has some disadvantages when used in the bending mold. Hence, there is a need to provide an alternate material for the mold which can withstand high temperature and overcomes all the disadvantages of the existing materials for glass bending. Summary of the Disclosure
  • a glass bending mold member for bending a glass sheet comprising of a first material having a large mechanical strength and formed from a group consisting essentially of cellulose paper/fibres, carbon fibres, cotton fabrics, synthetic yarn fabrics, glass fibres/fabrics, nonwoven fabrics, wood flour, metallic fibres and/or mixture thereof; and a second material having a high binding property and chemical resistance and formed from a group consisting essentially of phenol formaldehyde resin, fluoropolymers, polysulfone (PSU), poly(ethersulfone) (PES) and polyetherimide (PEI), poly(phenylene sulfide) (PPS), polyetheretherketone (PEEK), polyether ketones (PEK), aromatic polymers, poly(p-phenylene), gypsum and/or mixtures thereof.
  • the glass bending mold member can survive thermal mechanical cycles, can have repeated machinability and surface roughness same as that of the glass sheet
  • FIG. 1 is a front elevational view of a horizontal glass bending mold according to an embodiment of the present disclosure
  • FIG. 2 is a front elevational view of a vertical glass bending mold according to an embodiment of the present disclosure
  • FIG. 3 is an isometric view of a male or female mold member of the glass bending mold
  • FIG. 1 shows a horizontal press bending mold system 100 according to an embodiment of the present disclosure.
  • the horizontal press bending mold 100 generally comprises a pair of female and male mold members 102, 104 respectively, spaced vertically from each other and movable toward each other.
  • the glass mold members 102, 104 or the female or male members 102, 104 might be used interchangeably.
  • a glass sheet 106 which has been heat-softened by a heating furnace and is horizontally fed by conveyor rollers (not shown) between the female and male mold members 102, 104.
  • the female and male mold members 102, 104 are brought together to bend the glass sheet 106 to a shape imparted by complementary bending surfaces 102a, 104a of the female and male mold members 102, 104, respectively.
  • the female and male mold members 102, 104 are of high heat resistance and mechanical strength.
  • a metal cloth 108 is applied to each of the bending surfaces 102a, 104a.
  • the metal cloth 108 is applied to the bending surface 102a, 104a of each of the female and male mold members 102, 104.
  • the metal cloth 108 is used to reduce the optical defects on the glass sheet 106due to thermal shocks resulting from direct contact with the mold.
  • the metal cloth 108 No cloth marks will be imparted by the metal cloth 108 to the surfaces of the bent glass sheet 106 hence, remains free from optical defects such as light transmitting and reflecting distortions.
  • the female and male mold members 102, 104 itself is highly durable in use and could not be unraveled progressively from a broken region thereof so that the mold member will be replaced less frequently.
  • the thickness of the metal cloth 108 can be selected as desired for an increased service life.
  • the metal cloth is required to protect the mold to resist the high furnace temperature. Further, the metal cloth 108 protects the surface of the glass sheet 106 from distortions or local defects.
  • the metal cloth 108 can be replaced by textile cloth or fabrics made out of stainless steel fibres, knitted fabric.
  • the mold members 102, 104 are made of at least two different materials, comprising a first material having large mechanical strength and formed from the group consisting essentially of cellulose paper/fibres, carbon fibres, cotton fabrics, synthetic yarn fabrics, glass fibres/fabrics, nonwoven fabrics, wood flour, metallic fibres and/or mixture thereof, and a second material having high binding property and chemical resistance and formed from the group consisting essentially of phenol formaldehyde resin, fluoropolymers, polysulfone (PSU), poly(ethersulfone) (PES) and polyetherimide (PEI), poly(phenylene sulfide) (PPS), polyetheretherketone (PEEK), polyether ketones (PEK), aromatic polymers, poly(p-phenylene), gypsum and/or mixtures thereof.
  • the first material is the reinforcement and the second material is the matrix.
  • the matrix is a material into which the reinforcement is embedded, and is completely continuous. This means that there is a path through the matrix to any point in the material, unlike two materials sandwiched together.
  • the reinforcement material is embedded into a matrix.
  • the reinforcement does not always serve a purely structural task (reinforcing the compound), but is also used to change physical properties such as wear resistance, friction coefficient, or thermal conductivity.
  • the reinforcement can be either continuous or discontinuous.
  • the first and second material of the glass bending mold member 102, 104 can survive thermal mechanical cycles.
  • the glass bending mold member 102, 104 can be repeatedly machinable.
  • the surface roughness of the glass bending mold member 102, 104 is same as that of the glass sheet 106. This protects the surface of the glass sheet 106 from distortions or local defects.
  • the two materials are either arranged in layers across the thickness of the mold members 102, 104 or are arranged in the form of reinforced composite structure of first and second material.
  • the fibers have a diameter ranging from 5 nanometres to 100 micrometres.
  • the first material having large mechanical strength is being provided in the range of 5% to 95% of the total mold weight.
  • the second material having high binding property and chemical resistance is being provided in the range of 5% to 95% of the total mold weight.
  • the mold members 102, 104 may be made of a material comprising of a mixture of two or more first and second material, different in nature and combined at any desired ratio for higher heat resistance or durability.
  • the mold members 102, 104 have a thickness ranging from 5 to 500 mm.
  • the mol member 102, 104 has a coefficient of thermal expansion in the range from 3 x 10 "6 m/m/°C to 150 x 10 "6 m/m/°C and a compressive strength in the range from 25 MPa to 500 MPa. Further, the mold member 102, 104 is stable to a temperature in the range from 120°C to 750°C.
  • FIG. 2 shows a glass bending mold system 100 constructed as a vertical press bending mold.
  • the vertical press bending mold 100 generally comprises a pair of female and male mold members 102, 104 spaced horizontally from each other and movable toward each other.
  • a glass sheet 106 which has been heat-softened by a heating furnace is vertically gripped by a pair of tongs 110 between the female and male mold members 102, 104.
  • the female and male mold members 102, 104 are brought together to bend the glass sheet 106 to a shape imparted by complementary shaping surfaces 102a, 104a of the female and male mold members 102, 104, respectively.
  • a metal cloth 108 is applied to each of the bending surfaces 102a, 104a.
  • FIG. 3 shows an isometric view of a female or a male mold member 102, 104.
  • the female and/or male mold members 102, 104 consists of a plurality of suction holes 114 disposed on the bending surface 102a and 104a of the female and/or male mold members 102, 104 for enabling vacuum suction of a bent glass sheet 106 to enable lifting and holding of the glass sheet 106 (not shown).
  • the bending surface 102a, 104a of the glass bending mold 102, 104 can be curved, contoured, angular, wedge-shaped or a combination thereof.
  • the suction holes 114 are through holes.
  • the female and/or male mold members 102, 104 optionally includes a plurality of cooling orifices 112 disposed on the bending surface 102a and 104a as well as channels 118 extending through/ across the female and/or male mold members 102, 104 and in communication with orifices 112.
  • the channels are used for cooling the mold.
  • the plurality of channels 118 is in fluid communication with the plurality of cooling/support fins 120 for holding and cooling the mold.
  • the cooling/support fins 120 are formed from the material of high thermal conductivity and/or high mechanical strength.
  • the cooling/support fins 120 are formed from the material from a group consisting essentially of copper, aluminium, and bronze.
  • the cooling/support fins 120 can be designed around the suction holes 114 and/or cooling channels 118, such that it acts as a heat exchanger or additionally carry the cooling fluid, which in turn improve the cooling of the mold by increase in surface area or due to the excess cooling fluid flowing through them.
  • the design also provides increased mechanical support and enables easy assembly with the glass bending mold.
  • the female and male mold members 102, 104 are optionally mounted by means of at least one supporting frame provided on the periphery or disposed of across the bending surface 104a, 102a of the male and/or female mold members 104, 102.
  • the mold members 102, 104 are covered by a coating of the material of high oxidation resistance and/or high heat resistance and/or an insulating material 116.
  • the coating material 116 is formed from the group consisting essentially of silica, alumina, magnesia, lime, fluoropolymers (PTFE), fire clay and/or mixtures thereof.
  • the coating material 116 on the bend surface 102a, 104a of the mold member 102, 104 is in the range of ⁇ 10 of total mold weight.
  • the coating material or insulating material 116 has a thickness in the range of 0.1mm to 500mm.
  • the insulating material 116 is formed from the group consisting essentially of glass fibres, glass fabrics, glass wool and/or mixtures thereof.
  • the female mold member 102 of the glass bending mold 100 is a peripheral ring which supports the glass sheet 106 during the bending operation and the male mold member 104 is utilized to bend the glass sheet 106 to required geometry.
  • the glass bending mold member 102, 104 is manufactured by following methods but not limited to casting/molding, additive manufacturing. Casting or moulding (centrifugal casting, continuous casting, vacuum molding, transfer molding, compression molding, hot pressing) involves preparing the mixture of the first material with the second material to form a moldable/semi- solid material. The shape of the final glass bending mold member 102, 104 is attained by pouring the mixture into the final shaped casting structure.
  • the suction holes 114 or cooling channels 118 or cooling/support fins 120 can also be placed before the curing process into the casting structure.
  • the layers of the first material and the second material can be placed one over the other which can be cured individually or as a complete glass bending mold member 102, 104.
  • the layer thickness varies from 50 - ⁇ each.
  • the machining process is employed in case the glass bending mold member 102, 104 is made in the form of a block and the final bending surface 102a, 104a of the mold is achieved by surface milling, grinding or polishing.
  • the suction holes 114 are drilled onto the surface of the glass bending mold member 102, 104.
  • the cooling channels 118 can also be milled or drilled into the mold based on the design of the glass bending mold member 102, 104. Machining process can be used to modify/rework the bending surface 102a, 104a curvature.
  • the bending surface 102a, 104a of the mold members 102, 104 is a precisely curved surface finely finished by shaving or grinding.
  • the first and second material were arranged in layers to form following sample mold and evaluated for a number of properties as indicated below.
  • Sample 1 First Material: cotton fabric and Second Material: phenol formaldehyde resin with glass wool insulation (8%) and metal cloth.
  • Sample 2 First Material: glass fibers (30%) and Second Material: gypsum (60%) with glass wool insulation (8%) and metal cloth.
  • the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion.
  • a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus.
  • “or” refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Re-Forming, After-Treatment, Cutting And Transporting Of Glass Products (AREA)

Abstract

A glass bending mold member (102, 104) comprising of a first material having a large mechanical strength and formed from a group consisting essentially of cellulose paper/fibres, carbon fibres, cotton fabrics, synthetic yarn fabrics, glass fibres/fabrics, nonwoven fabrics, wood flour, metallic fibres and/or mixture thereof, and; a second material having a high binding property and chemical resistance and formed from a group consisting essentially of phenol formaldehyde resin, fluoropolymers, polysulfone (PSU), poly(ethersulfone) (PES) and polyetherimide (PEI), poly(phenylene sulfide) (PPS), polyetheretherketone (PEEK), polyether ketones (PEK), aromatic polymers, poly(p-phenylene), gypsum and/or mixtures thereof. The glass bending mold member can survive thermal mechanical cycles, can have repeated machinability and surface roughness same as that of the glass sheet (106).

Description

GLASS BENDING MOLD
Technical Field
[0001] The present disclosure relates to an improved glass bending mold for imparting a desired shape to a glass sheet, and more particularly to the glass bending mold made from a novel material.
Background
[0002] Background description includes information that may be useful in understanding the present disclosure. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed disclosure, or that any publication specifically or implicitly referenced is prior art.
[0003] The curved or bent sheets of glass are commonly employed in present- day civil structures, buildings as glazing closures, facades or windows, mirrors and automotive vehicles as front or rear windshield or side window. Such glass sheets have to be conventionally bent by glass bending molds. The bending takes place by heating the glass to a higher temperature where the glass is viscoelastic in nature. The soften glass is bent to the desired shape by the mold.
[0004] Currently, the sheet of glass is placed into a mold made of metal. The most commonly used metals are aluminium and cast iron. The main drawbacks with the metal molds are high energy consumption, high oxidation resistance, high wear resistance, high corrosion resistance, high thermal conductivity, high thermal expansion, high density, heavy and high deformation. For instance, if aluminum is used, there is a tendency for loss of form that is deformation because of the high thermal expansion of aluminium. If cast iron is used, loss of form or deformation is less of a problem but the difficulty is then often encountered because the cast iron molds exert an undue chilling effect on the glass due to high thermal conductivity. Further, the metallic molds are heavier and denser; as a result, there is a higher energy consumption during the operation. The molds rework is also difficult and need complete replacement in case of any damage such as due to corrosion or wear.
[0005] One attempt at solving the above-mentioned problem has been to replace the metal molds with molds made of other materials such as wooden, refractory, carbon or graphite. Wooden molds have, in general, been satisfactory when operating at relatively low production rates which give the wooden mold a chance to cool between individual pressing operations. However, when the production rate is increased, the heat load on the wooden mold is much higher and the wooden mold begins to suffer. It is then found that the wooden mold soon tends to suffer the loss of form because of warping, splitting or burning under the heavy heat load which is applied to them and breaks down with extended use.
[0006] Refractory molds have a low thermal expansion, hence no distortion in shape even when the mold is reheated a number of times. The refractories have good thermal shock stability as compared to metals. This results in the development of no cracks even after a long service period. Further, the refractories can be easily machined. All these properties make a refractory mold suitable for high production operations. However, the refractory molds are much heavier in weight as compared to metallic and hence consume more power. Further, the thermal conductivity of the refractory mold is low, hence it becomes difficult to maintain a constant temperature during the bending process.
[0007] Carbon or graphite molds are preferred over metallic ones in the industry as graphite has good characteristics such as high workability, high- temperature strength, and thermal conductivity, however, it is liable to be oxidized under high-temperature conditions leading to wearing out. This leads to seriously affects the service life of the mold and the glass molding accuracy. In addition, the graphite and carbon are less rigid and hence are more flexible. The graphite at a higher temperature will deform and this leads to defaults in shapes while bending. Further, graphite molds are much more expensive than the metallic mold.
[0008] Another approach has been to replace the wooden or refractory mold with gypsum material.US2330279 discloses the molds formed from a plaster composition such as plaster of Paris or gypsum paste. The plaster molds are readily formable to an accurate predetermined shape and may be easily duplicated. Also, such molds will readily withstand the elevated temperatures to which they are subjected and will not become distorted or lose their accuracy even though different portions thereof engage the heated glass sheet different lengths of time during the bending operation. Further, plaster molds will not mar the glass surfaces and have a long life through repeated bending cycles. Plaster molds also do not require preheating nor do they become charred at elevated temperatures. In addition, due to their insulating qualities, plaster molds do not cause chill cracks in the glass. A still further advantage of plaster molds is the ease with which the bending faces thereof may be redressed for radii and surface corrections. However, the plaster mold has the less mechanical strength and over the increase in production rate plaster mold gets worn out.
[0009] It's been discovered that simple materials cannot fulfil all the requirements for the press bending mold. The reinforced materials are more successful in forming glass bending molds.
[0010] One such mold is formed of an epoxy resin having a fibrous glass reinforcement. Such molds are, however, quite expensive. Also, it has been found that the heat to which the blocks are exposed during a press bending operation is capable of causing blistering of an epoxy resin after the mold has been in use for some time.
[0011] The bending of the glass structure is being done in a very high precision, at the same time having a high production stability, therefore, to be able to obtain a glass shaped as desired through a press bending mold. The mold should have an excellent workability at a high temperature and further have excellent thermal conductivity, oxidation resistance, wear resistance, corrosion resistance, but also inert on the glass, good releasability, bending at high accuracy, lighter in weight, easily machined and low in cost. None of the above- mentioned materials provide a complete solution for the press bending mold. Each of the materials mentioned above has some disadvantages when used in the bending mold. Hence, there is a need to provide an alternate material for the mold which can withstand high temperature and overcomes all the disadvantages of the existing materials for glass bending. Summary of the Disclosure
[0012] In one aspect of the present disclosure a glass bending mold member for bending a glass sheet comprising of a first material having a large mechanical strength and formed from a group consisting essentially of cellulose paper/fibres, carbon fibres, cotton fabrics, synthetic yarn fabrics, glass fibres/fabrics, nonwoven fabrics, wood flour, metallic fibres and/or mixture thereof; and a second material having a high binding property and chemical resistance and formed from a group consisting essentially of phenol formaldehyde resin, fluoropolymers, polysulfone (PSU), poly(ethersulfone) (PES) and polyetherimide (PEI), poly(phenylene sulfide) (PPS), polyetheretherketone (PEEK), polyether ketones (PEK), aromatic polymers, poly(p-phenylene), gypsum and/or mixtures thereof. The glass bending mold member can survive thermal mechanical cycles, can have repeated machinability and surface roughness same as that of the glass sheet
[0013] Other features and aspects of this disclosure will be apparent from the following description and the accompanying drawings.
Brief Description of the Drawings
[0014] Embodiments are illustrated by way of example and are not limited in the accompanying figures.
[0015] FIG. 1 is a front elevational view of a horizontal glass bending mold according to an embodiment of the present disclosure;
[0016] FIG. 2 is a front elevational view of a vertical glass bending mold according to an embodiment of the present disclosure;
[0017] FIG. 3 is an isometric view of a male or female mold member of the glass bending mold;
[0018] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the disclosure.
Detailed Description
[0019] The present disclosure is now discussed in more detail referring to the drawings that accompany the present application. In the accompanying drawings, like and/or corresponding elements are referred to by like reference numbers.
[0020] Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or the like parts. The present disclosure is to provide a novel material for glass bending mold.
[0021] FIG. 1 shows a horizontal press bending mold system 100 according to an embodiment of the present disclosure. The horizontal press bending mold 100 generally comprises a pair of female and male mold members 102, 104 respectively, spaced vertically from each other and movable toward each other. The glass mold members 102, 104 or the female or male members 102, 104 might be used interchangeably. A glass sheet 106 which has been heat-softened by a heating furnace and is horizontally fed by conveyor rollers (not shown) between the female and male mold members 102, 104. Then, the female and male mold members 102, 104 are brought together to bend the glass sheet 106 to a shape imparted by complementary bending surfaces 102a, 104a of the female and male mold members 102, 104, respectively. With the arrangement of the present disclosure, the female and male mold members 102, 104 are of high heat resistance and mechanical strength. A metal cloth 108 is applied to each of the bending surfaces 102a, 104a. The metal cloth 108 is applied to the bending surface 102a, 104a of each of the female and male mold members 102, 104. The metal cloth 108 is used to reduce the optical defects on the glass sheet 106due to thermal shocks resulting from direct contact with the mold. No cloth marks will be imparted by the metal cloth 108 to the surfaces of the bent glass sheet 106 hence, remains free from optical defects such as light transmitting and reflecting distortions. The female and male mold members 102, 104 itself is highly durable in use and could not be unraveled progressively from a broken region thereof so that the mold member will be replaced less frequently. The thickness of the metal cloth 108 can be selected as desired for an increased service life. The metal cloth is required to protect the mold to resist the high furnace temperature. Further, the metal cloth 108 protects the surface of the glass sheet 106 from distortions or local defects. The metal cloth 108 can be replaced by textile cloth or fabrics made out of stainless steel fibres, knitted fabric.
[0022] The mold members 102, 104 are made of at least two different materials, comprising a first material having large mechanical strength and formed from the group consisting essentially of cellulose paper/fibres, carbon fibres, cotton fabrics, synthetic yarn fabrics, glass fibres/fabrics, nonwoven fabrics, wood flour, metallic fibres and/or mixture thereof, and a second material having high binding property and chemical resistance and formed from the group consisting essentially of phenol formaldehyde resin, fluoropolymers, polysulfone (PSU), poly(ethersulfone) (PES) and polyetherimide (PEI), poly(phenylene sulfide) (PPS), polyetheretherketone (PEEK), polyether ketones (PEK), aromatic polymers, poly(p-phenylene), gypsum and/or mixtures thereof. The first material is the reinforcement and the second material is the matrix. The matrix is a material into which the reinforcement is embedded, and is completely continuous. This means that there is a path through the matrix to any point in the material, unlike two materials sandwiched together. The reinforcement material is embedded into a matrix. The reinforcement does not always serve a purely structural task (reinforcing the compound), but is also used to change physical properties such as wear resistance, friction coefficient, or thermal conductivity. The reinforcement can be either continuous or discontinuous. The first and second material of the glass bending mold member 102, 104 can survive thermal mechanical cycles. The glass bending mold member 102, 104 can be repeatedly machinable. The surface roughness of the glass bending mold member 102, 104 is same as that of the glass sheet 106. This protects the surface of the glass sheet 106 from distortions or local defects.
[0023] In an embodiment, the two materials are either arranged in layers across the thickness of the mold members 102, 104 or are arranged in the form of reinforced composite structure of first and second material. The fibers have a diameter ranging from 5 nanometres to 100 micrometres. The first material having large mechanical strength is being provided in the range of 5% to 95% of the total mold weight. The second material having high binding property and chemical resistance is being provided in the range of 5% to 95% of the total mold weight. The mold members 102, 104 may be made of a material comprising of a mixture of two or more first and second material, different in nature and combined at any desired ratio for higher heat resistance or durability. The mold members 102, 104 have a thickness ranging from 5 to 500 mm. The mol member 102, 104 has a coefficient of thermal expansion in the range from 3 x 10"6 m/m/°C to 150 x 10"6 m/m/°C and a compressive strength in the range from 25 MPa to 500 MPa. Further, the mold member 102, 104 is stable to a temperature in the range from 120°C to 750°C.
[0024] FIG. 2 shows a glass bending mold system 100 constructed as a vertical press bending mold. The vertical press bending mold 100 generally comprises a pair of female and male mold members 102, 104 spaced horizontally from each other and movable toward each other. A glass sheet 106 which has been heat-softened by a heating furnace is vertically gripped by a pair of tongs 110 between the female and male mold members 102, 104. Then, the female and male mold members 102, 104 are brought together to bend the glass sheet 106 to a shape imparted by complementary shaping surfaces 102a, 104a of the female and male mold members 102, 104, respectively. A metal cloth 108 is applied to each of the bending surfaces 102a, 104a.
[0025] FIG. 3 shows an isometric view of a female or a male mold member 102, 104. The female and/or male mold members 102, 104 consists of a plurality of suction holes 114 disposed on the bending surface 102a and 104a of the female and/or male mold members 102, 104 for enabling vacuum suction of a bent glass sheet 106 to enable lifting and holding of the glass sheet 106 (not shown). The bending surface 102a, 104a of the glass bending mold 102, 104 can be curved, contoured, angular, wedge-shaped or a combination thereof. The suction holes 114 are through holes. The female and/or male mold members 102, 104 optionally includes a plurality of cooling orifices 112 disposed on the bending surface 102a and 104a as well as channels 118 extending through/ across the female and/or male mold members 102, 104 and in communication with orifices 112. The channels are used for cooling the mold. Further, the plurality of channels 118 is in fluid communication with the plurality of cooling/support fins 120 for holding and cooling the mold. The cooling/support fins 120 are formed from the material of high thermal conductivity and/or high mechanical strength. The cooling/support fins 120 are formed from the material from a group consisting essentially of copper, aluminium, and bronze. The cooling/support fins 120 can be designed around the suction holes 114 and/or cooling channels 118, such that it acts as a heat exchanger or additionally carry the cooling fluid, which in turn improve the cooling of the mold by increase in surface area or due to the excess cooling fluid flowing through them. The design also provides increased mechanical support and enables easy assembly with the glass bending mold. Further, the female and male mold members 102, 104 are optionally mounted by means of at least one supporting frame provided on the periphery or disposed of across the bending surface 104a, 102a of the male and/or female mold members 104, 102.
[0026] In an embodiment, the mold members 102, 104 are covered by a coating of the material of high oxidation resistance and/or high heat resistance and/or an insulating material 116. The coating material 116 is formed from the group consisting essentially of silica, alumina, magnesia, lime, fluoropolymers (PTFE), fire clay and/or mixtures thereof. The coating material 116 on the bend surface 102a, 104a of the mold member 102, 104 is in the range of <10 of total mold weight. The coating material or insulating material 116 has a thickness in the range of 0.1mm to 500mm. The insulating material 116 is formed from the group consisting essentially of glass fibres, glass fabrics, glass wool and/or mixtures thereof.
[0027] In an alternative embodiment, the female mold member 102 of the glass bending mold 100 is a peripheral ring which supports the glass sheet 106 during the bending operation and the male mold member 104 is utilized to bend the glass sheet 106 to required geometry. [0028] In an embodiment, the glass bending mold member 102, 104 is manufactured by following methods but not limited to casting/molding, additive manufacturing. Casting or moulding (centrifugal casting, continuous casting, vacuum molding, transfer molding, compression molding, hot pressing) involves preparing the mixture of the first material with the second material to form a moldable/semi- solid material. The shape of the final glass bending mold member 102, 104 is attained by pouring the mixture into the final shaped casting structure. This is then hardened through the curing process by varying the temperature, pressure, UV curing or chemical reaction or a combination of the same. The suction holes 114 or cooling channels 118 or cooling/support fins 120 can also be placed before the curing process into the casting structure. Alternatively, the layers of the first material and the second material can be placed one over the other which can be cured individually or as a complete glass bending mold member 102, 104. The layer thickness varies from 50 - ΙΟΟμπι each. In the additive manufacturing, it is possible to use a combination of first and second material and is manufactured as a combination of layered printing of the first and second material.
[0029] In an embodiment, the machining process is employed in case the glass bending mold member 102, 104 is made in the form of a block and the final bending surface 102a, 104a of the mold is achieved by surface milling, grinding or polishing. The suction holes 114 are drilled onto the surface of the glass bending mold member 102, 104. The cooling channels 118 can also be milled or drilled into the mold based on the design of the glass bending mold member 102, 104. Machining process can be used to modify/rework the bending surface 102a, 104a curvature. The bending surface 102a, 104a of the mold members 102, 104 is a precisely curved surface finely finished by shaving or grinding.
Example 1
[0030] The first and second material were arranged in layers to form following sample mold and evaluated for a number of properties as indicated below. Sample 1: First Material: cotton fabric and Second Material: phenol formaldehyde resin with glass wool insulation (8%) and metal cloth.
Sample 2: First Material: glass fibers (30%) and Second Material: gypsum (60%) with glass wool insulation (8%) and metal cloth.
Table 1: The above samples were tested and had the following properties:
Figure imgf000012_0001
[0031] All of these performed testing and results shown in Table 1 evidences that Sample 1 and Sample 2 meet the sufficient requirements in performance of various standards for the glass bending mold. Sample 1 and sample 2 are thermally stable and dimensional variations are minimum when tested within the operating conditions of a glass bending mold. The thermo- structural properties of the sample 1 are better than sample 2, but, both samples satisfy the minimum requirements for the glass bending mold. Sample 1, during the machining process generated considerable amount of powder. However, the powder was removable from the machine. Whereas sample 2, the powder removal from the machine was tedious. Machining accuracy for sample 1 is better than sample 2, thereby, casting is preferred manufacturing method for sample 2 for improving the machining accuracy
[0032] Note that not all of the activities described above in the general description or the examples are required, that a portion of a specific activity may not be required, and that one or more further activities may be performed in addition to those described. Still further, the order in which activities are listed is not necessarily the order in which they are performed.
[0033] Benefits, other advantages, and solutions to problems have been described above with regard to specific embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential feature of any or all the claims.
[0034] The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and illustrations are not intended to serve as an exhaustive and comprehensive description of all of the elements and features of apparatus and systems that use the structures or methods described herein. Certain features, that are for clarity, described herein in the context of separate embodiments, may also be provided in combination in a single embodiment. Conversely, various features that are, for brevity, described in the context of a single embodiment, may also be provided separately or in a sub combination. Further, reference to values stated in ranges includes each and every value within that range. Many other embodiments may be apparent to skilled artisans only after reading this specification. Other embodiments may be used and derived from the disclosure, such that a structural substitution, logical substitution, or another change may be made without departing from the scope of the disclosure. Accordingly, the disclosure is to be regarded as illustrative rather than restrictive.
[0035] The description in combination with the figures is provided to assist in understanding the teachings disclosed herein, is provided to assist in describing the teachings, and should not be interpreted as a limitation on the scope or applicability of the teachings. However, other teachings can certainly be used in this application.
[0036] As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having" or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited only to those features but may include other features not expressly listed or inherent to such method, article, or apparatus. Further, unless expressly stated to the contrary, "or" refers to an inclusive-or and not to an exclusive-or. For example, a condition A or B is satisfied by any one of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).
[0037] Also, the use of "a" or "an" is employed to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the disclosure. This description should be read to include one or at least one and the singular also includes the plural, or vice versa, unless it is clear that it is meant otherwise. For example, when a single item is described herein, more than one item may be used in place of a single item. Similarly, where more than one item is described herein, a single item may be substituted for that more than one item.
[0038] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. The materials, methods, and examples are illustrative only and not intended to be limiting. To the extent that certain details regarding specific materials and processing acts are not described, such details may include conventional approaches, which may be found in reference books and other sources within the manufacturing arts.
[0039] While aspects of the present disclosure have been particularly shown and described with reference to the embodiments above, it will be understood by those skilled in the art that various additional embodiments may be contemplated by the modification of the disclosed machines, systems and methods without departing from the spirit and scope of what is disclosed. Such embodiments should be understood to fall within the scope of the present disclosure as determined based upon the claims and any equivalents thereof.
List of Elements
TITLE: GLASS BENDING MOLD
100 Glass bending mold system
102 Female mold
102a Bending surface of female mold
104 Male mold
104a Bending surface of male mold
106 Glass sheet
108 Metal Cloth
110 Pair of tongs
112 Cooling Orifices
114 Suction holes
116 Coating/Insulating Material
118 Channels
120 Cooling/support fins

Claims

Claims We claim:
1. A glass bending mold member (102, 104) for bending a glass sheet (106) comprising:
a first material having a large mechanical strength and formed from a group consisting essentially of cellulose paper/fibres, carbon fibres, cotton fabrics, synthetic yarn fabrics, glass fibres/fabrics, nonwoven fabrics, wood flour, metallic fibres and/or mixture thereof; and,
a second material having a high binding property and chemical resistance and formed from a group consisting essentially of phenol formaldehyde resin, fluoropolymers, polysulfone (PSU), poly(ethersulfone) (PES) and polyetherimide (PEI), poly(phenylene sulfide) (PPS), polye there therketone (PEEK), poly ether ketones (PEK), aromatic polymers, poly(p-phenylene), gypsum and/or mixtures thereof; wherein the glass bending mold member (102, 104) can survive thermal mechanical cycles, can have repeated machinability and surface roughness same as that of the glass sheet (106).
2. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said first and second materials are arranged as layers across the thickness of said mold.
3. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said first and second materials are arranged in the form of composite structure.
4. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said mold takes the form of layer formed of at least one of the first and second material.
5. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said mold take the form of reinforced composite formed of at least one of the first and second material.
6. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said mold has a coefficient of thermal expansion in the range from 3 x 10"6 m/m/°C to 150 10"6 m/m/°C.
7. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said mold has a compressive strength in the range from 25 MPa to 500 MPa.
8. The glass bending mold member (102, 104) as claimed in claim 1 , wherein said mold is stable to a temperature in the range from 120°C to 750°C.
9. A glass bending mold system (100) comprising:
a glass bending mold member (102, 104) as claimed in claim 1 ; and
a metal cloth (108) disposed on the bending surface (104a, 102a) of said mold member (104, 102).
10. The glass bending mold system (100) as claimed in claim 9, wherein said glass bending mold member (102, 104) comprises of a male mold member (104) having a bending surface (104a) and a female mold member (102) having a bending surface (102a) complementary to said bending surface (104a) of the male mold member (104).
11. The glass bending mold system (100) as claimed in claim 9, wherein said bending surface can be curved, contoured, angular, wedge shaped or a combination thereof.
12. The glass bending mold system (100) as claimed in claim 9, wherein said glass bending mold member (104, 102) are covered by a coating of material of high oxidation resistance and/or high heat resistance and/or an insulating material (116).
13. The glass bending mold system (100) as claimed in claim 9, wherein said coating material (116) is formed from the group consisting essentially of silica, alumina, magnesia, lime, fluoropolymers (PTFE), fire clay and/or mixtures thereof.
14. The glass bending mold system (100) as claimed in claim 9, wherein said coating material (116) is in the range of <10 of total mold weight.
15. The glass bending mold system (100) as claimed in claim 9, wherein said insulating material (116) is formed from the group consisting essentially of glass fibres, glass fabrics, glass wool and/or mixtures thereof.
16. The glass bending mold system (100) as claimed in claim 9, wherein said coating of material of high heat resistance and/or an insulating material (116) have a thickness in the range of 0.1mm to 500mm.
17. The glass bending mold system (100) as claimed in claim 9, wherein said glass bending mold members (104, 102) optionally consists of a plurality of cooling orifices (112) disposed on the bending surface (104a, 102a) of the glass bending mold member (104, 102).
18. The glass bending mold system (100) as claimed in claim 9, wherein said glass bending mold member (104, 102) optionally consists of a plurality of channels (118) extending through/across the glass bending mold member (104, 102).
19. The glass bending mold system (100) as claimed in claim 9, wherein said plurality of channels (118) are in fluid communication with the plurality of cooling orifices (112) for cooling the glass bending mold member (104, 102).
20. The glass bending mold system (100) as claimed in claim 9, wherein said plurality of channels (118) are in fluid communication with the plurality of cooling/support fins (120) for holding and cooling the glass bending mold member (104, 102).
21. The glass bending mold system (100) as claimed in claim 9, wherein said cooling/support fins (120) are formed from the material of high thermal conductivity and/or high mechanical strength.
22. The glass bending mold system (100) as claimed in claim 9, wherein said cooling/support fins (120) are formed from the material from a group consisting essentially of metals like copper, aluminium and bronze or polymer composite materials with graphene/graphite reinforcements, carbon fibres and combination thereof.
23. The glass bending mold system (100) as claimed in claim 9, wherein said mold member (104, 102) are optionally mounted by means of at least one supporting frame provided on periphery or disposed across the bending surface (104a, 102a) of the mold members (104, 102).
24. The glass bending mold system (100) as claimed in claim 9, wherein said glass bending mold member (104, 102) optionally consists of a plurality of suction holes (114) disposed on the bending surface (104a, 102a) of the glass bending mold members (104, 102) for enabling vacuum suction of a bent glass sheet (106).
25. The glass bending mold system (100) as claimed in claim 9, wherein said supporting frame optionally consists of a plurality of suction holes (114) for enabling vacuum suction of a bent glass sheet (106).
26. The glass bending mold system (100) as claimed in claim 9, wherein said plurality of suction holes (114) is through holes.
27. The glass bending mold system (100) as claimed in claim 9, is a horizontal or vertical press bending mold.
28. The glass bending mold system (100) as claimed in claim 9, wherein the glass bending mold member (104, 102) being movable manually/automatically toward each other to shape a heat-softened glass sheet (106).
PCT/IN2018/050507 2017-08-04 2018-08-03 Glass bending mold WO2019026091A1 (en)

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