WO2019100027A2

WO2019100027A2 - Glass manufacturing apparatus and methods of fabricating

Info

Publication number: WO2019100027A2
Application number: PCT/US2018/061875
Authority: WO
Inventors: Jang-hu AN; Yong-kyu KWON; Hosoon Lee; Seong-Kuk Lee; Seonguk MOON
Original assignee: Corning Incorporated
Priority date: 2017-11-20
Filing date: 2018-11-19
Publication date: 2019-05-23
Also published as: WO2019100027A3; TW201922632A; KR20190057793A

Abstract

Glass manufacturing apparatus can comprise an unused melt device with an outlet extending through a sidewall of the unused melt device. In further embodiments, methods of fabricating a glass manufacturing apparatus can include fabricating a melt device with an outlet extending through a sidewall of the melt device. In the above embodiments, the outlet can comprise a first segment opening at an inner surface of the sidewall and a second segment opening at an outer surface of the sidewall. The first segment can comprise an inner cross-sectional profile with a lower portion comprising an arc of a circle and an upper portion defined by an upper periphery of a preformed cavity in the sidewall that may be located above a projection of a circular cross-sectional profile of the second segment.

Description

GLASS MANUFACTURING APPARATUS AND METHODS OF

FABRICATING

CROSS REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of Korean Patent Application Serial No. 10-2017-155145 filed on November 20, 2017 the contents of which are relied upon and incorporated herein by reference in their entirety as if fully set forth below.

FIELD

[0002] The present disclosure relates generally to glass manufacturing apparatus and, more particularly, to glass manufacturing apparatus and methods of fabricating a glass manufacturing apparatus.

BACKGROUND

[0003] It is known to provide a glass manufacturing apparatus designed to produce a glass article from a quantity of molten material. Conventional glass manufacturing apparatus include a furnace designed to heat batch material into a quantity of molten material. The quantity of molten material is thereafter passed through an outlet in a sidewall of the furnace to at least one downstream station for processing the molten material to produce the glass article.

SUMMARY

[0004] The following presents a simplified summary of the disclosure to provide a basic understanding of some embodiments described in the detailed description.

[0005] In accordance with some embodiments, a glass manufacturing apparatus can comprise an unused melt device for subsequent use to produce molten material from a quantity of batch material. The unused melt device can comprise a bottom wall comprising an inner surface and a sidewall extending upward from the bottom wall. The inner surface of the bottom wall and an inner surface of the sidewall can at least partially define a containment area. The sidewall can comprise an outlet extending through the sidewall along a travel path. The outlet can comprise a first segment opening at the inner surface of the sidewall and a second segment opening at an outer surface of the sidewall. The second segment can comprise a circular cross-sectional profile taken perpendicular to the travel path and the first segment can comprise an inner cross-sectional profile taken perpendicular to the travel path at the inner surface of the sidewall. The inner cross-sectional profile can comprise a lower portion comprising an arc of a circle and an upper portion defined by an upper periphery of a preformed cavity in the sidewall that can be located at least partially above a projection of the circular cross-sectional profile of the second segment in a direction of the travel path.

[0006] In some embodiments, a maximum lateral width of the preformed cavity can be within a range from 100% to 150% of a maximum lateral width of the circular cross-sectional profile of the second segment.

[0007] In some embodiments, the range of the maximum lateral width of the preformed cavity can be from 18 cm to 27 cm.

[0008] In some embodiments, the preformed cavity comprises a maximum depth from the inner surface of the sidewall that can be within a range from 25% to 75% of the thickness of the sidewall, the thickness defined between the inner surface of the sidewall and the outer surface of the sidewall at the upper periphery of the preformed cavity in a direction of the travel path.

[0009] In some embodiments, the range of the maximum depth of the preformed cavity can be from 5 cm to 15 cm.

[0010] In some embodiments, a first uppermost elevation of the upper periphery of the preformed cavity may be positioned at a higher elevation than a second uppermost elevation of the circular cross-sectional profile of the second segment.

[0011] In some embodiments, a difference in elevation between the first upper most elevation and the second uppermost elevation can be within a range of from 10% to 100% of a maximum dimension of the circular cross-sectional profile of the second segment.

[0012] In some embodiments, the range of the difference in elevation can be from 2 cm to 18 cm.

[0013] In some embodiments, the preformed cavity can comprise a crescent shaped footprint projecting in the direction of the travel path.

[0014] In some embodiments, the crescent-shaped footprint can comprise three lobes. [0015] In some embodiments, the crescent-shaped footprint may be defined between the upper periphery of the preformed cavity and the projection of the circular cross-sectional profile of the second segment.

[0016] In some embodiments, a tube can extend at least partially within the outlet.

[0017] In some embodiments, the tube can comprise a first end portion that laterally protrudes into the containment area from the inner surface of the sidewall in the direction of the travel path.

[0018] In some embodiments, a cooling jacket can be positioned about an outer periphery of a second end portion of the tube.

[0019] In some embodiments, a method of using the unused melt device can comprise introducing batch material into the containment area. The method can further comprise heating the batch material within the containment area to produce molten material that may be positioned within the containment area. The method can further comprise passing a quantity of the molten material through the outlet, wherein the preformed cavity may inhibit a corrosion of the sidewall by the quantity of the molten material at least at a location above the projection of the footprint of the circular cross-sectional profile of the second segment.

[0020] In accordance with other embodiments, a method of fabricating a glass manufacturing apparatus can comprise fabricating a melt device by producing a sidewall attached to a bottom wall, wherein an inner surface of the bottom wall and an inner surface of the sidewall at least partially define a containment area. The sidewall can comprise an outlet extending through the sidewall along a travel path. The outlet can comprise a first segment opening at the inner surface of the sidewall and a second segment opening at an outer surface of the sidewall. The second segment can comprise a circular cross-sectional profile taken perpendicular to the travel path and the first segment can comprise an inner cross-sectional profile taken perpendicular to the travel path at the inner surface of the sidewall. The inner cross-sectional profile can comprise a lower portion comprising an arc of a circle and an upper portion defined by an upper periphery of a preformed cavity in the sidewall that can be located at least partially above a footprint of the circular cross-sectional profile of the second segment projected in a direction of the travel path. The method can further include connecting the outlet of the melt device to a downstream molten glass station of the glass manufacturing apparatus.

[0021] In some embodiments, the downstream molten glass station can comprise a fining vessel.

[0022] In some embodiments, the preformed cavity can comprise an area produced during a machining procedure.

[0023] In some embodiments, a method of using the glass manufacturing apparatus fabricated with the method of fabricating the glass manufacturing apparatus can include introducing batch material into the containment area. The method can further include heating the batch material within the containment area to produce molten material that may be positioned within the containment area. The method can further include passing a quantity of the molten material through the outlet. The preformed cavity can inhibit a corrosion of the sidewall by the quantity of the molten material at a location at least partially above the projection of the footprint of the circular cross-sectional profile of the second segment. The method can further include passing the quantity of molten material from the outlet to the downstream molten glass station. The method can further include processing the quantity of molten material within the downstream molten glass station.

[0024] In some embodiments, processing the quantity of molten material can comprise removing gas bubbles from the molten material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] These and other features, embodiments and advantages are better understood when the following detailed description is read with reference to the accompanying drawings, in which:

[0026] FIG. 1 illustrates an example embodiment of a glass manufacturing apparatus;

[0027] FIG. 2 illustrates a cross-sectional view of the glass manufacturing apparatus along line 2-2 of FIG. 1;

[0028] FIG. 3 illustrates an enlarged view of the glass manufacturing device taken at view 3 but illustrating an unused melt device prior to using the unused melt device to produce molten material from a batch of material; and

[0029] FIG. 4 illustrates a view of an interior surface of a sidewall of the unused melt device along line 4-4 of FIG. 3. DETAILED DESCRIPTION

[0030] Embodiments will now be described more fully hereinafter with reference to the accompanying drawings in which example embodiments are shown. Whenever possible, the same reference numerals are used throughout the drawings to refer to the same or like parts. However, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein.

[0031] Glass sheets are commonly fabricated by flowing molten glass to a forming body whereby a glass ribbon may be formed by a variety of ribbon forming processes, for example, slot draw, down-draw (e.g., fusion down-draw). The glass ribbon from any of these processes may then be subsequently divided to provide sheet glass suitable for further processing into a desired display application. The glass sheets can be used in a wide range of display applications, for example liquid crystal displays (LCDs), electrophoretic displays (EPD), organic light emitting diode displays (OLEDs), plasma display panels (PDPs), or the like.

[0032] In some embodiments, a nominal thickness of a central portion of the glass sheets can be less than or equal to about 1 millimeter (mm), for example, from about 50 micrometers (pm) to about 750 pm, from about 100 pm to about 700 pm, from about 200 pm to about 600 pm, from about 300 pm to about 500 pm, from about 50 pm to about 500 pm, from about 50 pm to about 700 pm, from about 50 pm to about 600 pm, from about 50 pm to about 500 pm, from about 50 pm to about 400 pm, from about 50 pm to about 300 pm, from about 50 pm to about 200 pm, from about 50 pm to about 100 pm, and all subranges of thicknesses therebetween.

[0033] FIG. 1 schematically illustrates a glass manufacturing apparatus 100 for processing molten material comprising a fusion down-draw apparatus 101 for fusion drawing a glass ribbon 103 for subsequent processing into glass sheets 104. The fusion down-draw apparatus 101 can include a melt device 105 that receives 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 used to activate the motor 113 to introduce a desired amount of batch material 107 into the melt device 105, as indicated by arrow 117. A molten material probe 119 can be used to measure a molten material 121 level within a standpipe 123 and communicate the measured information to the controller 115 by way of a communication line 125.

[0034] The fusion down-draw apparatus 101 can also include a first conditioning station such as a fining vessel 127 located downstream from the melt device 105 and coupled to the melt device 105 by way of a first connecting conduit 129. In some embodiments, glass melt may be gravity fed from the melt device 105 to the fining vessel 127 by way of the first connecting conduit 129. For instance, gravity may drive the glass melt through an interior pathway of the first connecting conduit 129 from the melt device 105 to the fining vessel 127. Within the fining vessel 127, bubbles may be removed from the glass melt by various techniques.

[0035] The fusion draw apparatus can further include a second conditioning station such as a glass melt mixing vessel 131 that may be located downstream from the fining vessel 127. The glass melt mixing vessel 131 can be used to provide a homogenous glass melt composition, thereby reducing or eliminating inhomogeneity that may otherwise exist within the fined glass melt exiting the fining vessel. As shown, the fining vessel 127 may be coupled to the glass melt mixing vessel 131 by way of a second connecting conduit 135. In some embodiments, glass melt may be gravity fed from the fining vessel 127 to the glass melt mixing vessel 131 by way of the second connecting conduit 135. For instance, gravity may drive the glass melt through an interior pathway of the second connecting conduit 135 from the fining vessel 127 to the glass melt mixing vessel 131.

[0036] The fusion draw apparatus can further include another conditioning station such as a delivery vessel 133 that may be located downstream from the glass melt mixing vessel 131. The delivery vessel 133 may condition the glass to be fed into a forming device. For instance, the delivery vessel 133 can act as an accumulator and/or flow controller to adjust and provide a consistent flow of glass melt to the forming vessel. As shown, the glass melt mixing vessel 131 may be coupled to the delivery vessel 133 by way of a third connecting conduit 137. In some embodiments, glass melt may be gravity fed from the glass melt mixing vessel 131 to the delivery vessel 133 by way of the third connecting conduit 137. For instance, gravity may drive the glass melt through an interior pathway of the third connecting conduit 137 from the glass melt mixing vessel 131 to the delivery vessel 133. [0037] As further illustrated, a downcomer 139 can be positioned to deliver molten material 121 from the delivery vessel 133 to an inlet 141 of a forming vessel 143. The glass ribbon 103 may then be fusion drawn off the root 145 of a forming wedge 209 and subsequently separated into the glass sheets 104 by a glass separation apparatus 149. As illustrated, the glass separation apparatus 149 may divide the glass sheet 104 from the glass ribbon 103 along a separation path 151 that extends along a width“W” of the glass ribbon 103 between a first outer edge 153 and a second outer edge 155 of the glass ribbon 103. As illustrated in FIG. 1, in some embodiments, the separation path 151 may extend substantially perpendicular to a draw direction 157 of the glass ribbon 103. In the illustrated embodiment, the draw direction 157 can be the fusion draw direction of the glass ribbon 103 being fusion drawn from the forming vessel 143.

[0038] FIG. 2 is a cross-sectional perspective view of fusion down-draw apparatus 101 along line 2-2 of FIG. 1. As shown, the forming vessel 143 can include a trough 201 oriented to receive the molten material 121 from the inlet 141. The forming vessel 143 can further include a forming wedge 209 including a pair of downwardly inclined converging surface portions 207a, 207b extending between opposed ends 210a, 210b (see FIG. 1) of the forming wedge 209. The pair of downwardly inclined converging surface portions 207a, 207b converge along the draw direction 157 to form the root 145. A draw plane 213 extends through the root 145 wherein the glass ribbon 103 may be drawn in the draw direction 157 along the draw plane 213. As shown, the draw plane 213 can bisect the root 145 although the draw plane 213 may extend at other orientations relative to the root 145.

[0039] In some embodiments, the molten material 121 can flow from the inlet 141 into the trough 201 of the forming vessel 143. 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 145 of the forming vessel 143, where the flows converge and fuse into the glass ribbon 103. The glass ribbon 103 may then be drawn off the root 145 in the draw plane 213 along draw direction 157. [0040] FIG. 1 illustrates a used melt device 105 after the melt device 105 has been used by the glass manufacturing apparatus 100 to produce the molten material 121 from the batch material 107. For purposes of this application, an unused melt device is considered a melt device after fabrication of the melt device and prior to using the melt device for the first time to produce the molten material 121 from the batch material 107. FIG. 3 shows features of an unused melt device 301 similar to the used melt device 105 of FIG. 1 but prior to being used to produce molten material from batch material. Throughout this application, the term“unused melt device” is considered a melt device that has been fabricated but not yet used to produce molten material from batch material. Once fabricated, the unused melt device 301 may subsequently be used to produce the molten material 121 from the quantity of batch material 107 by incorporating the unused melt device 301 for use as the used melt device 105 shown in FIG. 1.

[0041] FIG. 3 illustrates portions of an embodiment of an unused melt device 301. As shown, the unused melt device 301 can include a bottom wall 303 and a sidewall 307 extending upward from the bottom wall 303. In some embodiments, the bottom wall 303 and the sidewall 307 can be fabricated from refractory material (e.g., zirconia) to minimize corrosion of the unused melt device 301 in use and to minimize, such as prevent, contamination of the molten material 121 from particles (e.g., zirconia particles) originating from the sidewalls and/or bottom wall of the melt device in use.

[0042] In some embodiments, the bottom wall 303 may be initially built, for example, with refractory bricks. Once built, the sidewall 307 may be built up from the bottom wall 303, for example, with a plurality of refractory bricks stacked as a wall of bricks on an outer periphery of the bottom wall 303.

[0043] An inner surface 305 of the bottom wall 303 and an inner surface 309 of the sidewall 307 can at least partially define a containment area 311. The sidewall 307 can include an outlet 313 extending through the sidewall 307 along a travel path 315. The outlet 313 can include a first segment 313a opening at the inner surface 309 of the sidewall 307. The outlet 313 can further include a second segment 313b opening at an outer surface 317 of the sidewall 307. As shown, the second segment 313b can include a circular cross-sectional profile 319 taken perpendicular to the travel path 315. In some embodiments, the second segment 313b can include a depth “Dl” extending from the outer surface 317 of the sidewall 307 in an inner direction 325 of the travel path 315. In further embodiments, as shown, the circular cross- sectional profile 319 can extend along the entire depth“Dl” and may have the same diameter through the entire depth“Dl”.

[0044] As shown in FIGS. 3 and 4, the first segment 313a can include an inner cross-sectional profile 321 taken perpendicular to the travel path 315 at the inner surface 309 of the sidewall 307. As shown in FIG. 4, the inner cross-sectional profile 321 can include a lower portion comprising an arc 321a of a circle and an upper portion defined by an upper periphery 321b of a preformed cavity 322 in the sidewall 307. As shown in FIG. 3, the preformed cavity 322 can be located at least partially above a projection 323 of the circular cross-sectional profile 319 of the second segment 313b in the inner direction 325 of the travel path 315.

[0045] Throughout this application, the term“preformed cavity” is intended to mean a cavity that is produced prior to using the unused melt device 301 to produce molten material from a quantity of batch material. As such, a preformed cavity is not formed by corrosion of the sidewall during use of the melt device to produce molten material or conveying the molten material through the outlet. In fact, providing the preformed cavity can avoid aggressive corrosion of the sidewall at the location of the preformed cavity in applications where the sidewall does not include the preformed cavity. Indeed, as the preformed cavity is produced prior to using the melt device, the portions of the sidewall most susceptible to corrosion in use may be removed. As such, the preformed cavity 322 can avoid aggressive corrosion of the sidewall that may otherwise occur without the preformed cavity; thereby reducing, such as avoiding, contamination of the molten material with corroded sidewall particulate (e.g., zirconia particles) that may adversely impact the optical clarity or uniformity of the glass articles produced with the molten material.

[0046] The preformed cavity 322 may include a wide variety of maximum lateral widths“Wl” depending on the particular application. In some embodiments, to minimize aggressive corrosion of the sidewall 307 at areas of the sidewall most susceptible to corrosion, experiments have determined that the preformed cavity 322, in some embodiments, can have a maximum lateral width“Wl” within a range of 100% to 150% of a maximum lateral width“W2” of the circular cross-sectional profile 319 of the second segment 313b. In some embodiments, the range of the maximum lateral width “Wl” of the preformed cavity can be from about 18 centimeters (cm) to about 27 cm although other dimensions may be provided in further embodiments.

[0047] The preformed cavity 322 may include a wide variety of maximum depths“D2” depending on the particular application. In some embodiments, to minimize aggressive corrosion of the sidewall 307 at areas of the sidewall most susceptible to corrosion, experiments have determined that the preformed cavity 322, in some embodiments, can have a maximum depth“D2” from the inner surface 309 of the sidewall 307 in an outer direction 326 of the travel path 315 that may be within a range from about 25% to about 75% of the thickness“T” of the sidewall 307. As shown in FIG. 3, the thickness“T” may be defined between the inner surface 309 of the sidewall 307 and the outer surface 317 of the sidewall 307 at the upper periphery 321b of the preformed cavity 322 in a direction 325, 326 of the travel path 315. In some embodiments, the range of the maximum depth“D2” of the preformed cavity 322 can be from about 5 centimeters (cm) to 15 cm although other dimensions may be provided in further embodiments.

[0048] As shown in FIG. 3, a first uppermost elevation 327 of the upper periphery 321b of the preformed cavity 322 may be positioned at a higher elevation than a second uppermost elevation 329 of the circular cross-sectional profile 319 of the second segment 313b. A wide variety of differences in elevation (i.e., elevational differences“E”) between the first uppermost elevation 327 and the second uppermost elevation 329 can be provided depending on the particular application. In some embodiments, to minimize aggressive corrosion of the sidewall 307 at areas of the sidewall most susceptible to corrosion, experiments have determined that the preformed cavity 322, in some embodiments, can have an elevational different“E” within a range of from about 10% to about 100% of a maximum dimension (e.g., maximum width“W2”) of the circular cross-sectional profile 319 of the second segment 313b. In some embodiments, the range of the difference in elevation“E” can be from about 2 cm to about 18 cm although other dimensions may be provided in further embodiments.

[0049] In some embodiments, the difference in elevation E(f) between an upper elevation of the preformed cavity 322 and the second uppermost elevation 329 of the circular cross-sectional profile 319 of the second segment 313b can be a function of the distance f from the inner surface 309 of the sidewall along the depth “D2”. In some embodiments, as shown, the difference in elevation E(f) along a vertical symmetrical plane 405 of symmetry of the outlet 313 bisecting the circular cross-sectional profile 319 of the second segment 313b can be the maximum at a depth of zero from the inner surface 309. Furthermore, in further embodiments, as shown, the difference in elevation E(f) along the vertical symmetrical plane 405 can be zero at the maximum depth “D2” of the preformed cavity 322. In some embodiments, as shown, the difference in elevation E(f) can be indirectly proportional to the distance f from the inner surface 309. In further embodiments, as shown, the indirect proportional relationship can provide the linear cross-sectional upper contour 341 at the intersection of the vertical symmetrical plane 405 and the preformed cavity 322. Providing the difference in elevation E(f) as a function of the distance f of the preformed cavity 322 can remove greater portions of the sidewall 307 closer to the inner surface 309 that can be most susceptible to corrosion of the sidewall in use.

[0050] As shown by the dashed line 343 in FIG. 3, the maximum depth of portions of the preformed cavity 322 disposed on opposite sides of the vertical symmetrical plane 405 can be less than the maximum depth“D2” that may occur at the vertical symmetrical plane 405. Providing a greater depth above the projection 323 along the vertical symmetrical plane 405 can target removal of portions of the sidewall 307 that would otherwise be more susceptible to corrosion in use. In some embodiments, as shown, the depth may be greatest along the vertical symmetrical plane 405 closest to the projection 323 where the sidewall 307 may be most susceptible to corrosion in use wherein reduced depths are provided at other locations of the preformed cavity 322 depending on expected corrosion rates that can be estimated based on flow characteristics, flow rate, temperature, material type of the molten material 121 and other factors.

[0051] In some embodiments, as shown in FIG. 4, the preformed cavity 322 may comprise a crescent-shaped footprint 401 projecting in the inner direction 325 of the travel path 315. The crescent-shaped footprint 401 can be defined between the upper periphery 321b of the preformed cavity 322 and the projection 323 of the circular cross-sectional profile 319 of the second segment 313b. The crescent-shaped footprint can be most pronounced at the inner surface 309, wherein the crescent shaped footprint can provide removal of portions of the sidewall 307 at above and optionally to the sides of the outlet 313. In some embodiments, the crescent-shaped footprint can comprise three lobes 401a-c that may facilitate production of the preformed cavity 322. Indeed, as shown, each lobe 401a-c can be formed by a linear bore angled at a non-perpendicular direction relative to the inner surface 309 and a non-zero angle relative to the travel path 315 to provide the desired profile that approximates desired removal of the sidewall 307 at locations experimentally determined to be most susceptible to corrosion of the sidewall in use. In some embodiments, boring of the material can be conducted after fabricating the sidewall 307. In further embodiments, ceramic brick(s) or other building block(s) may be bored and then assembled to produce the sidewall 307 with the preformed cavity 322 in the sidewall.

[0052] As further illustrated in FIGS. 3 and 4, a tube 331 can extend at least partially within the outlet 313. For example, as shown the tube 331 can extend entirely through the outlet 313 although the tube may extend less than the length of the outlet 313 in further embodiments. The tube can comprise platinum or other material designed to have a higher resistance to corrosion than the refractory (e.g., zirconia or other refractory material) used to fabricate the sidewall 307. As such, the tube 331, if provided, can help prevent corrosion of the sidewall 307 that may otherwise lead to a breach of the containment area.

[0053] In some embodiments, the tube 331 can include a first end portion 333 that laterally protrudes a lateral distance 335 into the containment area 311 from the inner surface 309 of the sidewall 307 in the inner direction 325 of the travel path 315. Protruding the tube 331 the lateral distance 335 into the containment area 311 can allow portions of the molten material 121 located inward from the inner surface 309 of the sidewall 307 to enter the outlet 313. As such, any corrosion of the sidewall 307 in use may have the opportunity to settle to locations away from the inlet of the tube. As such, the inlet of the tube 331 can be located to capture high quality molten material 121 that has little, if any, corroded particulate from the sidewall 307 entrained within the molten material traveling through the outlet 313.

[0054] As shown in FIG. 3, the tube 331 may optionally comprise a corrugated tube designed to increase the strength of the tube with less material. As shown, the corrugations may be formed by offset circular corrugations although one or more helical corrugations may be provided in further embodiments. Although not shown, in further embodiments, the tube may comprise a smooth tube (i.e., without corrugations) to help reduce stagnant flow areas of molten material that may otherwise occur within the inner valleys of the corrugations. As shown in FIG. 4, the first end portion 333 may include an optional arcuate reinforcement rib 403 at the end of the tube 331 to further reinforce the tube 331 at the outer end of the tube that may be most susceptible to undesired deformation under high temperature and loading conditions.

[0055] As shown in FIG. 3, an optional cooling jacket 337 may be positioned about an outer periphery of a second end portion 334 of the tube 331. The cooling jacket 337 can help freeze any molten material at an exit of the outlet 313 an interface 336 between the outlet 313 and the second end portion 334 of the tube 331. As such, leaking of molten material between the tube 331 and the outlet 313 can be avoided. To achieve cooling, cooling liquid (e.g., refrigerant or water) may be circulated through a fluid circuit that can surround at least a portion or the entire outer periphery of the second end portion 334 of the tube. For instance, a cooling tube can encircle the second end portion 334 with an inlet port 339a to provide cooled liquid and an outlet port 339b to remove the heated liquid after heat has been transferred from the second end portion 334 during circulation of the fluid through the fluid circuit.

[0056] A method of using the unused melt device 301 can include the step of attaching the first connecting conduit 129 to the tube 331 so that a downstream molten glass station (e.g., fining vessel 127) is connected to subsequently receive molten material from the unused melt device 301. The method can then include the step of beginning to use the unused melt device 301 in a manner similar to that shown by the used melt device 105 in FIG. 1. Indeed, the method can include introducing the batch material 107 into the containment area 311. The method can include heating the batch material 107 within the containment area 311 to produce the molten material 121 that may be positioned within the containment area 311. The method can then further include passing a quantity of the molten material 121 through the outlet 313, e.g., via tube 331. The preformed cavity 322 inhibits, such as prevents, a corrosion of the sidewall 307 that might otherwise occur without the preformed cavity 322. In some embodiments, the preformed cavity 322 inhibits, such as prevents, a corrosion of the sidewall by the quantity of the molten material 121 at least at a location above the projection 323 of the footprint of the circular cross-sectional profile 319 of the second segment 313b of the outlet 313.

[0057] Methods of fabricating the glass manufacturing apparatus 100 can include fabricating an unused melt device 301 by producing the sidewall 307 attached to the bottom wall 303. In some embodiments, the sidewall 307 may be built onto the bottom wall 303. For instance, a plurality of refractory bricks may be stacked upon a periphery of the bottom wall 303 and upon one another to create a refractory brick wall built on the bottom wall. Once produced, the inner surface 305 of the bottom wall 303 and the inner surface 309 of the sidewall 307 at least partially define the containment area 311.

[0058] The sidewall 307 comprises the outlet 313 extending through the sidewall 307 along the travel path 315. In some embodiments, the outlet can be produced after the sidewall 307 is produced. Alternatively, refractory bricks or other building blocks may be machined or otherwise provided with features that, once stacked together, provide the outlet 313.

[0059] The outlet 313 can be produced with the first segment 313a opening at the inner surface 309 of the sidewall 307 and a second segment 313b opening at the outer surface 317 of the sidewall 307. The second segment 313b can comprise the circular cross-sectional profile 319 taken perpendicular to the travel path 315. Furthermore, the first segment 313a can comprise the inner cross-sectional profile 321 taken perpendicular to the travel path 315 at the inner surface 309 of the sidewall 307. The inner cross-sectional profile 321 can include the lower portion comprising the arc 321a of a circle and an upper portion defined by the upper periphery 321b of the preformed cavity 322 in the sidewall 307 that can be located at least partially above the footprint of the circular cross-sectional profile 319 of the second segment 313b projected as projection 323 in the inner direction 325 of the travel path 315. In some embodiments, the preformed cavity 322 may be produced by a machining procedure. For example, as discussed above, a boring process may be used to produce the preformed cavity 322 in the sidewall after the sidewall is formed or within building blocks subsequently used to produce the sidewall. In some embodiments, multiple boring procedures may be carried out, for example three boring procedures, wherein each boring procedure produces a corresponding one of the lobes 401a-c of the crescent-shaped footprint 401 of the preformed cavity 322. [0060] The method of fabricating the glass manufacturing apparatus 100 can further include connecting the outlet 313 of the unused melt device 301 to a downstream molten glass station of the glass manufacturing apparatus 100. In some embodiments, the downstream molten glass station can be the illustrated fining vessel 127 although other molten glass stations may be provided in further embodiments such as a glass melt mixing vessel, or a second melt device.

[0061] Methods of using the glass manufacturing apparatus 100 can include introducing the batch material 107 into the containment area 311 and heating the batch material 107 within the containment area 311 to produce the molten material 121 positioned within the containment area 311. The method of using the glass manufacturing apparatus 100 can further include passing the quantity of molten material 121 through the outlet 313, e.g., via tube 331, wherein the preformed cavity 322 inhibits, such as prevents, corrosion of the sidewall 307 that would otherwise occur without the preformed cavity 322. In some embodiments, the preformed cavity 322 inhibits, such as prevents, corrosion of the sidewall 307 by the quantity of the molten material 121 at the location at least partially above the projection 323 of the footprint of the circular cross-sectional profile 319 of the second segment 313b. Molten material may then be passed from the outlet 313, e.g., via tube 331, to the downstream molten station wherein the quantity of molten material 121 may be processed within the downstream molten glass station. In some embodiments, processing the quantity of molten material can comprise removing gas bubbles from the molten material (e.g., with a fining vessel 127), stirring the molten material, further heating the molten material or other processing techniques.

[0062] It should be understood that while various embodiments have been described in detail with respect to certain illustrative and specific embodiments thereof, the present disclosure should not be considered limited to such, as numerous modifications and combinations of the disclosed features are possible without departing from the scope of the following claims.

Claims

What is claimed is:

1. A glass manufacturing apparatus comprising an unused melt device for subsequent use to produce molten material from a quantity of batch material, the unused melt device comprising:

a bottom wall comprising an inner surface; and

a sidewall extending upward from the bottom wall, the inner surface of the bottom wall and an inner surface of the sidewall at least partially defining a containment area, the sidewall comprising an outlet extending through the sidewall along a travel path, the outlet comprising a first segment opening at the inner surface of the sidewall and a second segment opening at an outer surface of the sidewall, the second segment comprising a circular cross-sectional profile taken perpendicular to the travel path, the first segment comprising an inner cross-sectional profile taken perpendicular to the travel path at the inner surface of the sidewall, the inner cross- sectional profile comprising a lower portion comprising an arc of a circle and an upper portion defined by an upper periphery of a preformed cavity in the sidewall that is located at least partially above a projection of the circular cross-sectional profile of the second segment in a direction of the travel path.

2. The apparatus of claim 1, wherein a maximum lateral width of the preformed cavity is within a range from 100% to 150% of a maximum lateral width of the circular cross-sectional profile of the second segment.

3. The apparatus of claim 2, wherein the range of the maximum lateral width of the preformed cavity is from 18 cm to 27 cm.

4. The apparatus of any one of claims 1-3, wherein the preformed cavity comprises a maximum depth from the inner surface of the sidewall that is within a range from 25% to 75% of the thickness of the sidewall, wherein the thickness is defined between the inner surface of the sidewall and the outer surface of the sidewall at the upper periphery of the preformed cavity in a direction of the travel path.

5. The apparatus of claim 4, wherein the range of the maximum depth of the preformed cavity is from 5 cm to 15 cm.

6. The apparatus of any one of claims 1-5, wherein a first uppermost elevation of the upper periphery of the preformed cavity is positioned at a higher elevation than a second uppermost elevation of the circular cross-sectional profile of the second segment.

7. The apparatus of claim 6, wherein a difference in elevation between the first upper most elevation and the second uppermost elevation is within a range of from 10% to 100% of a maximum dimension of the circular cross-sectional profile of the second segment.

8. The apparatus of claim 7, wherein the range of the difference in elevation is from 2 cm to 18 cm.

9. The apparatus of any one of claims 6-8, wherein the preformed cavity comprises a crescent-shaped footprint projecting in the direction of the travel path.

10. The apparatus of claim 9, wherein the crescent-shaped footprint comprises three lobes.

11. The apparatus of claim 9, wherein the crescent-shaped footprint is defined between the upper periphery of the preformed cavity and the projection of the circular cross-sectional profile of the second segment.

12. The apparatus of any one of claims 1-11, wherein a tube extends at least partially within the outlet.

13. The apparatus of claim 12, wherein the tube comprises a first end portion that laterally protrudes into the containment area from the inner surface of the sidewall in the direction of the travel path.

14. The apparatus of any one of claims 12 and 13, further comprising a cooling jacket positioned about an outer periphery of a second end portion of the tube.

15. A method of using the unused melt device according to any one of claims 1- 14, comprising:

introducing batch material into the containment area;

heating the batch material within the containment area to produce molten material that is positioned within the containment area; and

passing a quantity of the molten material through the outlet, wherein the preformed cavity inhibits a corrosion of the sidewall by the quantity of the molten material at least at a location above the projection of the footprint of the circular cross-sectional profile of the second segment.

16. A method of fabricating a glass manufacturing apparatus comprising:

fabricating a melt device by: producing a sidewall attached to a bottom wall, wherein an inner surface of the bottom wall and an inner surface of the sidewall at least partially define a containment area, the sidewall comprising an outlet extending through the sidewall along a travel path, the outlet comprising a first segment opening at the inner surface of the sidewall and a second segment opening at an outer surface of the sidewall, the second segment comprising a circular cross-sectional profile taken perpendicular to the travel path and the first segment comprising an inner cross- sectional profile taken perpendicular to the travel path at the inner surface of the sidewall, the inner cross-sectional profile comprising a lower portion comprising an arc of a circle and an upper portion defined by an upper periphery of a preformed cavity in the sidewall that is located at least partially above a footprint of the circular cross-sectional profile of the second segment projected in a direction of the travel path; and

connecting the outlet of the melt device to a downstream molten glass station of the glass manufacturing apparatus.

17. The method of claim 16, wherein the downstream molten glass station comprises a fining vessel.

18. The method of any one of claims 16 and 17, wherein the preformed cavity comprises an area produced during a machining procedure.

19. A method of using the glass manufacturing apparatus fabricated according to claim 16, comprising:

introducing batch material into the containment area;

heating the batch material within the containment area to produce molten material that is positioned within the containment area;

passing a quantity of the molten material through the outlet, wherein the preformed cavity inhibits a corrosion of the sidewall by the quantity of the molten material at a location at least partially above the projection of the footprint of the circular cross-sectional profile of the second segment;

passing the quantity of molten material from the outlet to the downstream molten glass station; and

processing the quantity of molten material within the downstream molten glass station.

20. The method of claim 19, wherein processing the quantity of molten material comprises removing gas bubbles from the molten material.