Classifications

• • 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
  • C03B17/064—Forming glass sheets by the overflow downdraw fusion process; Isopipes therefor
• • 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
• • Y—GENERAL 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
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P40/00—Technologies relating to the processing of minerals
  • Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
  • Y02P40/57—Improving the yield, e-g- reduction of reject rates

Definitions

• the present disclosure relates generally to apparatus with a thermal shield and, more particularly, to apparatus with a thermal shield including a solid monolithic nose.
• a forming vessel within an interior area of a housing.
• the housing helps control atmospheric conditions about the forming vessel when drawing molten material into a ribbon from the forming vessel.
• a closure is typically mounted with respect to the housing to limit a size of an opening into the interior area.
• a thermal shield is known to be movably mounted with respect to the closure. In such a manner, the size of the opening into the interior area can be adjusted to provide appropriate atmospheric conditions within the interior area of the housing.
• an apparatus can include a housing.
• the apparatus can further include a forming vessel at least partially disposed within the housing.
• the apparatus can further include a closure mounted with respect to the housing to limit a size of an opening into the housing.
• the apparatus can further include a thermal shield movably mounted along an adjustment direction with respect to the closure.
• An outer end of the thermal shield can include a solid monolithic nose with a thickness and a width. The thickness can extend perpendicular to the adjustment direction between an upper side of the thermal shield and a lower side of the thermal shield.
• the width can extend in the adjustment direction between an inner end of an inner end portion of the solid monolithic nose and an outer end of the monolithic nose.
• the outer end of the solid monolithic nose can at least partially define the opening into the housing.
• the width of the solid monolithic nose can be within a range of from 2.5 cm to 6.5 cm.
• the thermal shield can further include a lower plate including an outer end portion attached to the inner end portion of the solid monolithic nose.
• the lower plate and the solid monolithic nose can include the same material.
• a fastener can attach the outer end portion of the lower plate to the inner end portion of the solid monolithic nose.
• the fastener and the solid monolithic nose can include the same material.
• a weld bead can attach the outer end of the lower plate to the inner end of the solid monolithic nose.
• a reinforcement plate can include a first edge attached to the lower plate and a second edge attached to the inner end of the solid monolithic nose.
• the reinforcement plate, the solid monolithic nose and the lower plate can include the same material.
• the thermal shield can include an upper plate comprising an outer end portion attached to the inner end portion of the solid monolithic nose.
• the upper plate can include a material with a higher resistance to oxidation than the material of the solid monolithic nose.
• the upper plate can include a plurality of plates arranged in a row along a length of the thermal shield.
• the length of the thermal shield can extend perpendicular to the adjustment direction.
• each plate of the plurality of plates can include a plurality of edges comprising an inner edge, an outer edge, a first side edge and a second side edge that are arranged in the shape of a rhombus.
• the outer end portion of the upper plate can include the outer edges of the plurality of plates.
• each plate of the plurality of plates can further include a first slot only intersecting the outer edge of the plurality of edges and a second slot only intersecting the inner edge of the plurality of edges.
• each plate of the plurality of plates can provide the second slot offset from the first slot in an offset direction extending from the first side edge toward the second side edge of the corresponding plate.
• the apparatus can further comprise a refractory material disposed within a space between the upper plate and the lower plate.
• the apparatus can further include a sheet of material positioned between the refractory material and the upper plate.
• the thermal shield can be positioned below the root of the wedge.
• a method of manufacturing a glass ribbon with the apparatus can include drawing a glass ribbon from the forming vessel. The method can further include drawing the glass ribbon through the opening to exit the housing.
• the method can include moving the thermal shield along the adjustment direction to adjust a width of the opening.
• FIG. 1 illustrates a glass manufacturing apparatus
• FIG. 2 illustrates a perspective cross-sectional view of the glass manufacturing apparatus along line 2-2 of FIG. 1;
• FIG. 3 illustrates an enlarged end view of portions of the cross-section of FIG. 2;
• FIG. 4 illustrates a top view of a thermal shield taken along lines 4-4 of FIG. 3;
• FIG. 5 illustrates a bottom view of the thermal shield of FIG. 4;
• FIG. 6 is a cross-sectional view of the thermal shield along lines 6-6 of
• FIG. 4
• FIG. 7 illustrates a top view of a partially assembled thermal shield
• FIG. 8 is a cross-sectional view of the partially assembled thermal shield along line 8-8 of FIG. 7;
• FIG. 9 illustrates a top view of the partially assembled thermal shield of FIG. 7 further including a refractory material disposed within a space above a lower plate;
• FIG. 10 illustrates a top view of the partially assembled thermal shield of FIG. 9 further including a sheet of material positioned over the refractory material.
• the glass manufacturing apparatus can optionally comprise a glass forming apparatus that forms a glass sheet and/or glass ribbon from a quantity of molten material.
• the glass manufacturing apparatus can optionally include a glass forming apparatus such as a slot draw apparatus, float bath apparatus, down-draw apparatus, up-draw apparatus, press-rolling apparatus or other glass forming apparatus.
• a glass manufacturing apparatus 101 can comprise a glass forming apparatus including a forming vessel designed to produce a glass ribbon 103 from a quantity of molten material 121.
• the glass ribbon 103 produced by embodiment of forming vessels may comprise a high-quality central portion 151 disposed between opposite relatively thick edge beads formed along a first edge 153 and a second edge 155 of the glass ribbon 103.
• a glass sheet 104 may be separated from the glass ribbon 103 by a glass separation apparatus 106.
• the thick edge beads formed along the first edge 153 and the second edge 155 may be removed to liberate the high- quality central portion 151 from the glass ribbon 103.
• the resulting high-quality central portion 151 may be used in a wide variety of desired display applications, including liquid crystal displays (LCDs), electrophoretic displays (EPD), organic light emitting diode displays (OLEDs), plasma display panels (PDPs), or the like.
• LCDs liquid crystal displays
• EPD electrophoretic displays
• OLEDs organic light emitting diode displays
• PDPs plasma display panels
• FIG. 1 schematically illustrates the exemplary glass manufacturing apparatus 101 including a melting vessel 105 oriented to receive batch material 107 from a storage bin 109.
• the batch material 107 can be introduced by a batch delivery device 111 powered by a motor 113.
• An optional controller 115 can be operated to activate the motor 113 to introduce a desired amount of batch material 107 into the melting vessel 105, as indicated by arrow 117.
• a glass melt probe 119 can be used to measure a level of molten material 121 within a standpipe 123 and communicate the measured information to the controller 115 by way of a communication line 125.
• the glass manufacturing apparatus 101 can also include a fining vessel 127 located downstream from the melting vessel 105 and coupled to the melting vessel 105 by way of a first connecting conduit 129.
• molten material 121 may be gravity fed from the melting vessel 105 to the fining vessel 127 by way of the first connecting conduit 129.
• gravity may act to drive the molten material 121 to pass through an interior pathway of the first connecting conduit 129 from the melting vessel 105 to the fining vessel 127.
• bubbles may be removed from the molten material 121 by various techniques.
• the glass manufacturing apparatus 101 can further include a mixing chamber 131 that may be located downstream from the fining vessel 127.
• the mixing chamber 131 can be used to provide a homogenous composition of molten material 121, thereby reducing or eliminating cords of inhomogeneity that may otherwise exist within the molten material 121 exiting the fining vessel 127.
• the fining vessel 127 may be coupled to the mixing chamber 131 by way of a second connecting conduit 135.
• molten material 121 may be gravity fed from the fining vessel 127 to the mixing chamber 131 by way of the second connecting conduit 135.
• the glass manufacturing apparatus 101 can further include a delivery vessel 133 that may be located downstream from the mixing chamber 131.
• the delivery vessel 133 can condition the molten material 121 to be fed into an inlet conduit 141.
• the delivery vessel 133 can function as an accumulator and/or flow controller to adjust and provide a consistent flow of molten material 121 to the inlet conduit 141.
• the mixing chamber 131 may be coupled to the delivery vessel 133 by way of a third connecting conduit 137.
• molten material 121 may be gravity fed from the mixing chamber 131 to the delivery vessel 133 by way of the third connecting conduit 137.
• gravity may drive the molten material 121 to pass through an interior pathway of the third connecting conduit 137 from the mixing chamber 131 to the delivery vessel 133.
• a delivery pipe 139 can be positioned to deliver molten material 121 to the inlet conduit 141 of a forming vessel 140.
• forming vessels can be provided in accordance with features of the disclosure including a forming vessel with a wedge for fusion drawing the glass ribbon, a forming vessel with a slot to slot draw the glass ribbon, or a forming vessel provided with press rolls to press roll glass ribbon from the forming vessel.
• the forming vessel 140 shown and illustrated below is provided to fusion draw molten material into off a root 142 of a forming wedge 209 to produce the glass ribbon 103.
• the molten material 121 is then delivered from the inlet conduit 141 to be received by a trough 201 (see FIG. 2) of the forming vessel 140.
• the forming vessel 140 may draw the molten material 121 into the glass ribbon 103.
• the molten material 121 may be drawn off a root 142 of the forming vessel 140 along downstream direction 211 of the glass manufacturing apparatus 101.
• a width "W" of the glass ribbon 103 can extend between the first vertical edge 153 of the glass ribbon 103 and the second vertical edge 155 of the glass ribbon 103.
• FIG. 2 is a cross-sectional perspective view of the glass manufacturing apparatus 101 along line 2-2 of FIG. 1.
• the forming vessel 140 can include the trough 201 oriented to receive the molten material 121 from the inlet conduit 141.
• the forming vessel 140 can further include a forming wedge 209 including a pair of downwardly inclined converging surface portions 207a, 207b extending between opposed ends of the forming wedge 209.
• the pair of downwardly inclined converging surface portions 207a, 207b of the forming wedge 209 converge along the downstream direction 211 to intersect along a bottom edge to define the root 142 of the forming wedge 209.
• a draw plane 213 of the glass manufacturing apparatus 101 extends through the root 142 wherein the glass ribbon 103 may be drawn in the downstream direction 211 along the draw plane 213. As shown, the draw plane 213 can bisect the root 142 although the draw plane 213 may extend at other orientations relative to the root 142.
• the molten material 121 can flow in a direction 159 into the trough 201 of the forming vessel 140.
• the molten material 121 can then overflow from the trough 201 by simultaneously flowing over corresponding weirs 203a, 203b and downward over the outer surfaces 205a, 205b of the corresponding weirs 203a, 203b.
• Respective streams of molten material 121 then flow along the downwardly inclined converging surface portions 207a, 207b of the forming wedge 209 to be drawn off the root 142 of the forming vessel 140, where the flows converge and fuse into the glass ribbon 103.
• the glass ribbon 103 may then be fusion drawn off the root 142 in the draw plane 213 along downstream direction 211 where, in some embodiments, the glass sheet 104 (see FIG. 1) may then be subsequently separated from the glass ribbon 103.
• the glass ribbon 103 may be drawn from the root 142 with a first major surface 215a of the glass ribbon 103 and a second major surface 215b of the glass ribbon 103 facing opposite directions and defining a thickness "T" of the glass ribbon 103 that can, for example, be less than or equal to about 2 millimeters (mm), less than or equal to about 1 millimeter, less than or equal to about 0.5 millimeters, less than or equal to about 500 micrometers ( ⁇ ), such as less than or equal to about 300 micrometers, such as less than or equal to about 200 micrometers, or such as less than or equal to about 100 micrometers, although other thicknesses may be provided in further embodiments.
• the glass ribbon 103 can include a variety of compositions including but not limited to soda-lime glass, borosilicate glass, alumino-borosilicate glass, an alkali-containing glass, or an alkali- free glass.
• the glass manufacturing apparatus 101 can include a housing 301 comprising an interior area 303.
• the housing 301 can at least partially surround the forming vessel 140 including the forming wedge 209 of the forming vessel 140 wherein the forming wedge 209 and forming vessel can be at least partially positioned within the interior area 303 of the housing 301.
• the housing 301 can include an upper wall 305 extending over the upper portion of the forming vessel 140 with an inner surface facing a free surface 122 of the molten material 121 positioned within the trough 201 and opposed sidewalls 307, 309 attached to the upper wall 305.
• the opposed sidewalls 307, 309 each include an inner surface that can face a corresponding sheet 311a, 311b of molten material 121 flowing over the respective outer surfaces 205a, 205b of the weirs 203a, 203b.
• the housing 301 can further include end walls 161a, 161b that can act to at least partially seal the forming vessel 140 and the forming wedge 209 of the forming vessel 140 within the interior area 303 defined at least partially by the upper wall 305 sidewalls 307, 309 and end walls 161a, 161b.
• the glass manufacturing apparatus 101 can further include a closure 313 mounted with respect to the housing 301 to limit a size of an opening 315 into the interior area 303 of the housing 301.
• the closure 313 may comprise a pair of doors 317a, 317b.
• the pair of doors 317a, 317b may optionally be movable in an extension direction 319a, 319b toward the draw plane 213 or in a retraction direction 321a, 321b away from the draw plane 213 by actuators 323a, 323b to adjust the size of the opening 315 into the interior area 303 of the housing 301.
• the doors 317a, 317b can act as a thermal barrier to help reduce heat loss from the interior area 303. Furthermore, one or any combination of the doors 317a, 317b, thermal shields 337a, 337b, and/ or thermal shields 339a, 339b may be moved in extension directions 319a, 319b to reduce the size of the opening 315 into the interior area 303 of the housing 301 to reduce a flow of air into the interior area 303, thereby reducing loss of thermal energy from the molten material 121 and possibly increasing the temperature of portions of the molten material 121 within the interior area 303.
• one or any combination of the doors 317a, 317b, thermal shields 337a, 337b, and/or thermal shields 339a, 339b may be moved in retraction directions 321a, 321b to increase the size of the opening 315 into the interior area 303 of the housing 301 to increase the flow of air into the interior area 303, thereby increasing loss of thermal energy from the molten material 121 and possibly decreasing the temperature of portions of the molten material 121.
• the size of the opening 315 into the interior area 303 of the housing 301 the temperature of portions of the molten material 121 within the interior area 303 can be adjusted to provide desirable attributes to the glass ribbon 103 being drawn from the forming vessel 140.
• reducing the temperature of the molten material 121 being drawn off the forming wedge 209 may increase the viscosity of the molten material and consequently increase the thickness "T" of the glass ribbon 103 being drawn off the root 142 of the forming wedge 209.
• increasing the temperature of the molten material 121 being drawn off the forming wedge 209 may decrease the viscosity of the molten material and consequently decrease the thickness "T" of the glass ribbon 103 being drawn off the root 142 of the forming wedge 209.
• the pair of doors 317a, 317b can further include additional features further designed to adjust the temperature of portions of the molten material 121 to provide desirable features of the glass ribbon 103 discussed above.
• one or both of the doors 317a, 317b may include the illustrated cooling device 325.
• a cooling device 325 will be discussed with respect to a first door 317a of the pair of doors 317a, 317b with the understanding that, as shown in FIG. 3, an identical or similar cooling device 325 may also be incorporated in the second door 317b of the pair of doors 317a, 317b.
• the door 317a may include a fluid nozzle 327 disposed within an interior area 329 of the door 317a.
• the fluid nozzle 327 can direct a cooling fluid stream 331 (e.g., air stream) to a front wall 333 of the door 317a that faces the draw plane 213.
• the cooling fluid stream 331 can cool the front wall 333 by thermal convection heat transfer while the front wall can absorb heat by radiation heat transfer from the glass ribbon 103 being drawn from the forming vessel 140.
• the temperature of the glass ribbon 103 can be adjusted by way of the cooling device 325 to impact the temperature and viscosity of the glass ribbon 103, thereby providing the glass ribbon 103 with desired characteristics (e.g., thickness "T").
• the glass manufacturing apparatus 101 may further include a thermal shield 335.
• the thermal shield 335 can include an upper pair of thermal shields 337a, 337b disposed vertically above the doors 317a, 317b.
• the upper pair of thermal shields 337a, 337b can be disposed upstream (i.e., opposite the downstream direction 211) from the doors 317a, 317b.
• the thermal shield 335 can include a lower pair of thermal shields 339a, 339b disposed vertically below the doors 317a, 317b.
• the lower pair of thermal shields 339a, 339b can be disposed downstream (i.e., in the downstream direction 211) from the doors 317a, 317b.
• thermal shields e.g., pairs of thermal shields
• FIG. 3 illustrates the upper pair of thermal shields 337a, 337b located entirely vertically above the doors 317a, 317b and the lower pair of thermal shields 339a, 339b located entirely vertically below the doors 317a, 317b
• one or more pairs of thermal shields may be located within the vertical height of the doors 317a, 317b.
• the glass manufacturing apparatus 101 may be provided without the doors 317a, 317b, wherein, for example, the thermal shields (e.g., a single pair of thermal shields 337a, 337b or a plurality of pairs of thermal shields) act without the doors 317a, 317b to define the size of the opening 315 into the interior area 303 of the housing 301.
• the thermal shields e.g., a single pair of thermal shields 337a, 337b or a plurality of pairs of thermal shields
• one or all of the thermal shields 335 may be movably mounted along adjustment directions.
• each thermal shield 337a, 339a corresponding to the first major surface 215a of the glass ribbon 103 may be movably mounted by a corresponding actuator 341 in the extension direction 319a or the retraction direction 321a.
• thermal shield 337b, 339b corresponding to the second major surface 215b of the glass ribbon 103 may be movably mounted by a corresponding actuator 341 in the extension direction 319b or the retraction direction 321b. Consequently, in addition, or alternative to the pair of doors 317a, 317b, the thermal shields 335 may be moved in the extension directions to adjust the size of the opening 315 into the interior area 303 of the housing 301.
• each thermal shield of the pairs of thermal shields 337a-b, 339a-b are disposed vertically below the root 142 of the forming wedge 209 to help control the atmospheric conditions of the wedge that, in the illustrated embodiment, is entirely disposed within the interior area 303. In further embodiments, although not shown, part of the wedge may extend below one or more of the thermal shields.
• FIG. 4 is a top view of an example thermal shield 335 viewed along direction 4-4 in FIG. 3.
• the thermal shields 337a-b, 339a-b can be identical or mirror images of one another.
• the embodiment of the thermal shield 335 shown in FIGS. 4-10 can represent the thermal shields 337a, 339a.
• a mirror image of the thermal shield 335 of FIGS. 4-10 can further represent the thermal shields 337b, 339b.
• the thermal shield 335 may optionally include a central portion 335a disposed between end portions 335b, 335c.
• End portions 335b, 335c may be provided in embodiments with edge directors 163a, 163b shown in FIG. 1.
• the end portions 335b, 335c can provide clearance for portions of the edge directors 163a, 163b that may extend below the root 142 of the forming wedge 209.
• the end portions 335b, 335c may be retracted and/or extended together with a single or a plurality of actuators.
• each end portion 335b, 335c may be retracted and/or extended independently with corresponding actuators 341b, 341c.
• the central portion 335a may be retracted and/or extended together with the end portions 335b, 335c with a single actuator (e.g., actuator 341a) or a plurality of actuators.
• the end portions 335b, 335c may be adjusted together independently from the central portion 335a or each end portion 335b, 335c may be adjusted independently from one another and from the central portion 335a.
• At least the central portion 335a of the thermal shield 335 can include a solid monolithic nose 401a that can, in some embodiments, extend along the entire length "LI" of the central portion 335a.
• the end portions 335b, 335c may also include a solid monolithic nose 401b, 401c similar or identical to the solid monolithic nose 401a of the central portion 335a.
• the solid monolithic nose 401b, 401c of the end portions 335b, 335c may, in some embodiments, extend along the entire length "L2", "L3" of the end portions 335b, 335c.
• the solid monolithic nose 401a can include an outer end portion 601 with an outer end 603 and an inner end portion 605 with an inner end 607.
• the outer end 603 of the solid monolithic nose can at least partially define the opening 315 into the interior area 303 of the housing 301.
• facing outer ends 603 of the pair of thermal shields 337a, 337b can define a width of an opening 343 of the opening 315.
• the outer ends 603 of the solid monolithic noses 401a extend along a straight linear path that are parallel to one another to define a substantially constant width of the opening 343 along the entire length "LI" of the central portion 335a of the thermal shield 335.
• the solid monolithic nose 401a can include a width 609 extending in an adjustment direction 319a, 321a of the thermal shield 335.
• the width 609 can be from about 2.5 centimeters (cm) to about 6.5 cm. In further embodiments, the width 609 can be from about 3 cm to about 6 cm. In still further embodiments, the width 609 can be from about 4 cm to about 5 cm.
• Providing the width 609 of greater than 2.5 cm can help increase the area moment of inertia of the cross-section of the solid monolithic nose 401a to help resist bending, warping, and/or permanent deformation of the nose and other portions of the thermal shield under the high temperature and force loading of the thermal shield 335. At the same time, providing the width 609 of less than 6.5 cm can help reduce the weight and costs of the thermal shield 335.
• the solid monolithic nose can have a thickness 611 extending perpendicular to the adjustment direction 319a, 321a between an upper side of the thermal shield (e.g., uppermost surface 612 of the solid monolithic nose 401a) and a lower side of the thermal shield (e.g., lowermost surface 614 of the solid monolithic nose 401a).
• the thickness 611 can be from about 1 cm to about 3 cm although other thicknesses may be provided in further embodiments. In another embodiment, the thickness 611 can be from about 1.5 cm to about 2.5 cm.
• providing a thickness 611 of greater than about 1 cm can increase the moment of inertia of the cross-section of the solid monolithic nose 401a to help resist bending, warping, and/or permanent deformation fo the nose and other portions of the thermal shield under high temperature and force loading of the thermal shield 335.
• providing a thickness 611 of less than about 3 cm can help reduce the weight and costs of the thermal shield 335.
• the outer end portion 601 of the solid monolithic nose 401a can include the thickness 611 over a width 608 that can be equal to or greater than 50% of the width 609 of the solid monolithic nose 401a.
• the width 608 can be from about 50% to about 90% of the width 609.
• the width 608 can be from about 50% to about 80% of the width 609. In still further embodiments, the width 608 can be from about 50% to about 70% of the width 609. In some embodiments, the outer end portion 601 can be free from any hollow portions or bores along the width 608 of the outer end portion 601. Furthermore, in some embodiments, substantially all or the entire width 608 of the outer end portion 601 can have a thickness 611 that is greater than a thickness of the inner end portion 605.
• the outer end portion 601 having a substantial thickness 611 that is free from bores or hollow portions along the substantial or entire width 608 of the outer end portion 601 can further increase the area moment of inertia of the cross-section provided by the outer end portion 601 of the solid monolithic nose 401a.
• the inner end portion 605 of the solid monolithic nose 401a can include bores 613 designed to receive threaded fasteners 615 to attach an outer end portion 618a of a lower plate 617 and an outer end portion 620a of an upper plate 619 to the inner end portion 605 of the solid monolithic nose 401a.
• an outer end portion 622 of a base support member 624 can include threaded bores 626 also designed to receive the fasteners 615 to attach an inner end portion 618b of the lower plate 617 and an inner end portion 620b of the upper plate 619 to the outer end portion 622 of the base support member 624.
• the solid monolithic nose 401a, upper and lower threaded fasteners 615, upper plate 619, lower plate 617 and base support member 624 can be made from the same or different materials depending on the application. In some embodiments, two or more of the above -referenced components may be fabricated from the same material. In some embodiments, to prevent stress, warping and/or permanent deformation of the thermal shield 335, the lower plate 617 and the solid monolithic nose 401a can include the same material. In addition or alternatively, the lower threaded fasteners 615 used to fasten the outer end portion 618a of the lower plate 617 to the inner end portion 605 of the solid monolithic nose 401a can include the same material.
• the lower threaded fasteners 615, the lower plate 617 and the solid monolithic nose 401a may include the same material. Fabricating the lower threaded fasteners 615, the lower plate 617 and the solid monolithic nose 401a from the same material, such as entirely from the same material, can provide these components with matching coefficient of thermal expansions, thereby avoiding warping, stress and even joint failure under temperature changes that may otherwise result with components including nonmatching coefficient of thermal expansions.
• the lower threaded fasteners 615, the lower plate 617 and the solid monolithic nose 401a may be partially or entirely fabricated from a nickel alloy, such as a nickel- chromium alloy, although other materials (e.g., alloys) may be provided in further embodiments.
• the material can be a nickel-chromium- tungsten-molybdenum alloy that can provide excellent high-temperature strength and outstanding resistance to oxidizing environments at high operating temperatures.
• Such a material can be used for lower portions of the thermal shield 335 that provide a strong support framework for supporting the weight of the thermal shield 335 without stress fractures, bending, warping or permanent deformation of the thermal shield 335.
• the upper plate 619 and the upper threaded fasteners 615 face upwardly towards the forming wedge 209, edge directors 163a, 163b and relatively higher temperature upstream portions of the molten material 121. As such, the upper plate 619 and upper threaded fasteners 615 are exposed to greater radiative heat transfer. In order to avoid oxidation of the upper plate 619 and/or upper threaded fasteners 615 under elevated temperature conditions, these components may be fabricated from a material that has a higher resistance to oxidation at relatively higher temperatures compared to other components of the thermal shield 335.
• the upper plate 619 and the upper threaded fasteners 615 comprises a material with a higher resistance to oxidation at elevated temperatures than the material of the solid monolithic nose 401a and/or other components of the thermal shield 335.
• the upper plate 619 and the upper threaded fasteners 615 may include the same material. Fabricating the upper plate 619 and the upper threaded fasteners 615 from the same material, such as entirely from the same material, can provide these components with matching coefficient of thermal expansions, thereby avoiding stress and even joint failure.
• the upper threaded fasteners 615 and the upper plate 619 may be partially or entirely fabricated from a nickel alloy, such as a nickel-chromium alloy although other materials (e.g., alloys) may be provided in further embodiments.
• the material can be a nickel-chromium-aluminum-iron alloy that can provide excellent high-temperature strength and outstanding resistance to oxidizing at even relatively higher operating temperatures.
• the base support member 624 may not directly face the glass ribbon 103 or forming wedge 209 and can therefore be fabricated from alternative materials such as 310 stainless steel although the base support member 624 may be fabricated from other materials in further embodiments.
• slight clearance may be provided between the upper bores 613 in the solid monolithic nose 401a and the upper threaded fasteners 615.
• slight clearance may be provided between the upper threaded fasteners and the openings in the upper plate 619 receiving the fasteners. Such clearance can allow slight relative movement between the upper plate and the solid monolithic nose 401a, thereby to avoid warping, stress or joint failure from rigidly attaching components together with mismatched coefficient of thermal expansion.
• the upper plate and/or the lower plate can include a single plate or a plurality of plates.
• embodiments of the thermal shield 335 can provide the upper plate 619 as a plurality of upper plates 619a-h.
• each of the end portions 335b, 335c of the thermal shield 335 can comprise a respective single upper plate 619a, 619h although each end portion 335b, 335c may be provided with a plurality of upper plates in further embodiments.
• the central portion 335a of the thermal shield 335 can include the plurality of upper plates 619b-g although the central portion 335a may be provided with a single upper plate in further embodiments.
• the plurality of upper plates 619b-g can be arranged in a row along the length "LI" of the thermal shield 335, wherein the length of the thermal shield extends perpendicular to the adjustment direction 319a, 321a.
• embodiments of the thermal shield 335 can provide the lower plate 617 as a plurality of lower plates 617a-h.
• each of the end portions 335b, 335c of the thermal shield 335 can comprise a respective single lower plate 617a, 617h although each end portion 335b, 335c may be provided with a plurality of lower plates in further embodiments.
• the central portion 335a of the thermal shield 335 can include the plurality of lower plates 617b-g although the central portion 335a may be provided with a single upper plate in further embodiments.
• the plurality of lower plates 617b-g if provided, can be arranged in a row along the length "LI" of the thermal shield 335.
• Providing the upper plate 619 and/or the lower plate 617 as a plurality of plates may be desired to reduce bending, warping and/or permanent deformation along the length of the thermal shield 335 due to temperature fluctuations in use.
• the plates can include a wide range of shapes and sizes.
• the upper plate and/or lower plate can be provided as a plurality of plates in a row of plates (e.g., see plates 617b-g, 619b-g)
• a plurality of the plates may have an identical shape and/or size although different shapes and/or sizes may be provided in further embodiments.
• the plate or plurality of plates can each comprise an outer periphery comprising a quadrilateral shape although other polygonal or non-polygonal shapes may be provided in further embodiments.
• the upper plates 619a, 619h and the lower plates 617a, 617h can each have edges that are arranged in the shape of a rectangle with the edges comprising an inner edge 403, 503, an outer edge 405, 505 parallel to the inner edge 403, 503, a first side edge 407, 507, and a second side edge 409, 509 that may be parallel to the first side edge 407, 507.
• the plurality of plates of the row of plates of the central portion 335a of the thermal shield can optionally comprise edges arranged in the shape of a trapezoid and/or rhombus although rectangular or other shapes may be provided in further embodiments.
• the end plates 617b, 619b, 617g, 619g of the rows of plates can comprise edges that are arranged in the shape of a trapezoid while interior plates 617c-f, 619c-f of the rows of plates can comprise edges that are arranged in shape of a rhombus.
• the upper plates 619b, 619g and lower plates 617b, 617g can each have edges that are arranged in the shape of a trapezoid with the edges comprising an inner edge 411, 511, an outer edge 413, 513 parallel to the inner edge 411, 511, a first side edge 415, 515, and a second side edge 417, 517 that may not be parallel to the first side edge 415, 515.
• the upper plates 619c-f and lower plates 617c-f can each have edges that are arranged in the shape of a rhombus with the edges comprising an inner edge 421, 521, an outer edge 423, 523 parallel to the inner edge 421, 521, a first side edge 425, 525, and a second side edge 427, 527 that may be parallel to the first side edge 425, 525.
• the outer end portion 620a of the upper plate 619 can comprise the outer edges 405, 413, 423 of the plurality of upper plates 619a-h.
• the outer end portion 618a of the lower plate 617 can comprise the outer edges 505, 513, 523 of the plurality of lower plates 617a-h.
• the inner end portion 620b of the upper plate 619 can comprise the inner edges 403, 411, 421 of the plurality of upper plates 619a-h.
• the inner end portion 618b of the lower plate 617 can comprise the inner edges 503, 511, 521 of the plurality of lower plates 617a-h.
• Providing the plurality of plates in the shape of a rhombus and/or trapezoid can provide abutting edges of adjacent plates to occur along a corresponding abutment path 429, 529 that extends at an acute angle 430, 530 relative to the draw plane 213.
• any discontinuity in the heat transfer properties of the plurality of plates due to the discontinuity provided by the abutting edges may be averaged over a width 431, 531 along the draw plane to avoid the glass ribbon 103 from being exposed to a concentrated heat transfer discontinuity resulting from the abutting edges of the adjacent plates that may otherwise occur of the abutment path extended at a 90° angle relative to the draw plane 213.
• At least one of the upper plate 619 and lower plate 617 may be provided with at least one slot designed to help prevent temperature fluctuations from bending, warping and/or permanently deforming the thermal shield 335.
• at least one or all of the plates of the plurality of upper plates 619a-h can include a first slot 433 that can intersect the outer edge 405, 413, 423 of the plurality of upper plates 619a-h and a second slot 435 that can intersect the inner edge 403, 41 1, 421 of the plurality of upper plates 619a-h.
• the first slot 433 can intersect the outer edge 405, 413, 423 of the plurality of upper plates 619a-h without intersecting the inner edge 403, 41 1 , 421 of the plurality of upper plates 619a-h.
• the second slot 435 can intersect the inner edge 403, 41 1, 421 of the plurality of upper plates 619a-h without intersecting the outer edge 405, 413, 423 of the plurality of upper plates 619a-h.
• the first slot 433 and the second slot 435 extend entirely through the plate from the upper major surface of the plate to the lower major surface of the plate to divide the plate at that location; thereby relieving any bending moment that may have developed at that location due to temperature differentials.
• the first slot 433 and the second slot 435 can have a length that may be less than 50% of the width of the plate between the inner edge and the outer edge of the plate.
• the slots can include a length between 10% and 50% of the width of the plate, or 20% to 40% of the width of the plate. Providing a length of the slots 433, 435 less than 50% of the width of the plate can increase the strength of the plate while still providing sufficient division of the plate to relieve bending moments that may otherwise result in warping of the thermal shield 335.
• the length of the slots can be balanced to provide a sufficiently long slot to beneficially maximize any bending moment release while also limiting the length of the slots to maintain the structural integrity of the plates and minimize any thermal discontinuity being exposed to the glass ribbon 103 due to the slots.
• the second slot 435 can be offset from the first slot 433 in an offset direction extending from the first side edge 407, 415, 425 toward the second side edge 409, 417, 427 of the corresponding upper plate 619a-h. Offsetting the slots 433, 435 can help strengthen the plate and minimize thermal discontinuities along the width of the glass ribbon 103 that may otherwise occur with aligned slots.
• the thermal shield 335 can include a reinforcement plate 701.
• the reinforcement plate 701 can include a first edge 801a attached to the lower plate 617, for example, by weld beads 803.
• the reinforcement plate 701 can further include a second edge 801b attached to the inner end 607 of the solid monolithic nose 401a, for example, by weld beads 803.
• the reinforcement plate can further include a third edge 801c attached to the inner end of the base support member 624 with weld beads 803.
• FIG. 803 the reinforcement plate 701 can include a first edge 801a attached to the lower plate 617, for example, by weld beads 803.
• the reinforcement plate 701 can further include a second edge 801b attached to the inner end 607 of the solid monolithic nose 401a, for example, by weld beads 803.
• the reinforcement plate can further include a third edge 801c attached to the inner end of the base support member 624 with weld beads 803.
• weld beads 803 can also further attach the outer end portion 618a of the lower plate 617 to the solid monolithic nose 401a and the inner end portion 618b of the lower plate 617 to the base support member 624.
• reinforcement plate 701 can comprise the same material (e.g., entirely from the same material) as the solid monolithic nose 401a and lower plate 617 to avoid stress and joint failure under temperature differentials.
• the reinforcement plate 701, if provided, can be included in the support framework of the thermal shield 335, including the solid monolithic nose 401a, the lower plate 617 and the optional base support member 624.
• the weld beads 803 can integrate the parts together as an integral support member to further strengthen and increase the rigidity of the thermal shield 335; thereby resisting warping or other deformity (e.g., permanent deformity) of the thermal shield 335 in response to temperature changes.
• deformity e.g., permanent deformity
• a refractory material 627 may be disposed within a space 805 (see FIG. 8) between the upper plate 619 and the lower plate 617.
• the refractory material may comprise refractory ceramic material or other material designed to help minimize heat loss from the interior area 303 of the housing 301.
• a sheet 629 of material positioned between the refractory material 627 and the upper plate 619.
• the sheet 629 of material can help protect the refractory material 627 from being damaged by the upper plate 619. Indeed, as mentioned above, there may be a slight clearance between the fasteners 615 and the fastener openings in the upper plate 619 and/or the fasteners and the bores 613 to accommodate the difference in material types between the solid monolithic nose 401a and the upper plate 619.
• the sheet 629 of material can act to protect the refractory material 627 so that the edges of the upper plate(s) 619 do not directly rub against the refractory material 627. Furthermore, the sheet 629 of material can further help protect from thermal discontinuities in the glass ribbon 103 due to the discontinuity in the upper plates 619b-g caused by abutting edges of adjacent upper plates.
• any discontinuity resulting from the abutting edges of the adjacent upper plates may be at least partially masked by the sheet 629 of material to provide more continuous heat transfer characteristics along the width "W" of the glass ribbon 103. Still further, the sheet 629 can help reduce particles of refractory material 627 or other debris from escaping between abutting edges of the adjacent upper plates. Although not shown, a similar sheet of material may be placed between the refractory material 627 and the lower plate 617 to also reduce particles of refractory material 627 or other debris from escaping between the abutting edges of the adjacent lower plates.
• the sheet 629 of material can comprise a thin foil although a thicker sheet of material may be provided in further embodiments. As shown, in some embodiments, the sheet 629 of material can extend the entire length "LI", “L2", “L3" of the relative portion 335a, 335b, 335c of the thermal shield 335. In some embodiments, the sheet 629 can comprise a material similar or identical to the material used to fabricate the upper plate 619 to provide resistance to oxidation.
• Embodiments of methods of fabricating a thermal shield 335 will be discussed with reference to FIGS. 7-10. Specifically, the method of fabricating will be discussed with respect to the central portion 335a of the thermal shield 335; whereby, unless otherwise noted, the method of fabricating will also similarly or identically apply to fabrication of the end portions 335b, 335c of the thermal shield 335. As shown in FIGS. 7 and 8, the lower plate 617 can be fastened to the base support member 624 and solid monolithic nose 401a.
• threaded fasteners 615 may be threadingly received within threaded bores 626 of the base support member 624 and threaded bores 613 of the solid monolithic nose 401a. In some embodiments, little or no clearance may be provided between the threaded fasteners 615 and the threaded bores 613, 626 and between the threaded fasteners 615 and the fastener openings in the lower plate 617. In such embodiments, a very rigid connection between the lower plate 617 and the base support member 624 and solid monolithic nose 401a can be achieved to help prevent bending of the thermal shield 335 in use.
• the solid monolithic nose 401a, and lower fasteners 615 can be made (e.g., entirely made) from the same relatively strong material with matching coefficients of thermal expansion, large changes temperature changes will not overly stress the joint connections.
• the reinforcement plate 701 may be attached, such as integrally attached, to the base support member 624, lower plate 617 and solid monolithic nose 401a.
• weld beads 803 may integrally attach the first edge 801a of the reinforcement plate 701 to the lower plate 617.
• weld beads 803 may also integrally attach the second edge 801b of the reinforcement plate 701 to the inner end 607 of the solid monolithic nose 401a.
• weld beads 803 may also integrally attach the third edge 801c of the reinforcement plate 701 to the base support member 624.
• weld beads 803 can also be used to attach an outer end of the lower plate 617 to the base support member 624 at the seam between the outer end of the lower plate 617 and the base support member. Furthermore, weld beads 803 can also be used to attach another outer end of the lower plate 617 to the solid monolithic nose 401a at the seam between the outer end of the lower plate 617 and the solid monolithic nose 401a.
• the lower plate 617, the solid monolithic nose 401a, lower fasteners 615 and the reinforcement plate 701 can be made (e.g., entirely made) from the same relatively strong material, large temperature changes will not overly stress the joint connections as the components, being made from the same material, will have the same matching coefficients of thermal expansion. Due to the rigid connections of the components and the relatively strong material that can be used for the components, the lower plate 617, the solid monolithic nose 401a, the lower fasteners, reinforcement plate 701 and associated weld seams can provide a strong rigid support structure that can resist bending, warping and permanent deformation of the thermal shield 335 in use.
• the outer end 603 of the solid monolithic nose 401a can be maintained at a desired shape (e.g. extending on a straight linear path) to allow an opening 343 (see FIG. 3) between facing outer ends 603 of opposed solid monolithic noses 401a to be maintained at a consistent size along the entire length "LI” during a longer production campaign.
• Providing the opening 343 with a consistent size along the entire length "LI” can help provide a consistent cooling convection path along the length "LI” as the convection path travels upwardly, opposite the downstream direction 211, to pass through the opening 343 and into the interior area 303 of the housing 301.
• the refractory material 627 may then be inserted into the space 805 (see FIG. 8) to increase the resistance of the thermal shield 335 to heat transfer through the thermal shield 335, thereby allowing the thermal shield 335 to help minimize undesired thermal loss from the interior area 303 of the housing 301.
• the sheet 629 of material may then be placed over the refractory material 627 and the tops of the reinforcement plates 701.
• the top plate(s) 619 may be attached to the base support member 624 and the solid monolithic nose 401a.
• the upper threaded fasteners 615 may be threadingly received within the threaded bores 613 of the solid monolithic nose and the threaded bores 626 of the base support member 624.
• the top plate(s) 619 may be formed from a material that may be resistant to oxidation at higher temperatures, the top plate(s) 619 may resist oxidation that may otherwise undesirably draw heat from the forming wedge 209. Furthermore, clearance can be provided between the upper fasteners 615 and the threaded bores 613 and/or the threaded bores 626. hi addition or alternatively clearance can be provided between the upper fasteners 615 and some or all of the fastener openings in the upper plate(s) 619.
• the clearance can allow the upper plate(s) 619 to slightly float relative to the base support member 624 and/or the solid monolithic nose 401a during temperature changes to accommodate for a mismatch in coefficient of thermal expansions between the upper plate(s) 619 and the solid monolithic nose 401a and/or other components of the thermal shield 335.
• molten sheets of material may flow along each surface portion of the pair of downwardly inclined converging surface portions 207a, 207b of the forming wedge 209. Molten material can then be drawn off the root 142 of the forming wedge 209 into the glass ribbon 103. As shown in FIG. 3, the glass ribbon may then be drawn through the opening 315, such as through the opening 343 between facing outer ends 603 of the solid monolithic nose 401a. The glass ribbon can then be drawn through the opening 315 to exist the interior area 303 of the housing 301.
• the thermal shield 335 may be moved along the adjustment direction 319a-b, 321a-b to adjust a width of the opening 343. Adjusting the width of the opening can help adjust the convective air flowing through the opening 343 an into the interior area 303 of the housing 301 to adjust the temperature of the interior area 303 and/or the thermal heat transfer from the glass ribbon 103 resulting in a change of convective air flow rate.
• warping and permanent deformation of the solid monolithic nose can be minimized or prevented, thereby maintaining the shape (e.g., extending along a straight linear path) of the outer ends 603 of the solid monolithic nose to provide a consistent spacing of the facing outer ends 603 along the entire length "LI".
• consistent thermal convective heat transfer can be achieved throughout the entire length "LI" over longer production campaigns that may not be possible with prior designs that resulted in warping and/or permanent deformation of the conventional thermal shields.

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• Chemical & Material Sciences (AREA)
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• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Re-Forming, After-Treatment, Cutting And Transporting Of Glass Products (AREA)
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• 2018
  • 2018-10-16 JP JP2020522065A patent/JP7429638B2/ja active Active
  • 2018-10-16 KR KR1020207014489A patent/KR102670459B1/ko active IP Right Grant
  • 2018-10-16 WO PCT/US2018/056111 patent/WO2019079318A1/en active Application Filing
  • 2018-10-16 CN CN201880076744.8A patent/CN111406038B/zh active Active
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