WO2021030097A1 - Glass manufacturing apparatus and methods - Google Patents

Glass manufacturing apparatus and methods Download PDF

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Publication number
WO2021030097A1
WO2021030097A1 PCT/US2020/044828 US2020044828W WO2021030097A1 WO 2021030097 A1 WO2021030097 A1 WO 2021030097A1 US 2020044828 W US2020044828 W US 2020044828W WO 2021030097 A1 WO2021030097 A1 WO 2021030097A1
Authority
WO
WIPO (PCT)
Prior art keywords
wall
thermal control
manufacturing apparatus
laser
glass manufacturing
Prior art date
Application number
PCT/US2020/044828
Other languages
English (en)
French (fr)
Inventor
Alexey Sergeyevich Amosov
Robert Delia
Bulent Kocatulum
Alexander Lamar Robinson
William Anthony Whedon
Original Assignee
Corning Incorporated
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Corning Incorporated filed Critical Corning Incorporated
Priority to KR1020227008302A priority Critical patent/KR20220047604A/ko
Priority to CN202080062948.3A priority patent/CN114616213A/zh
Priority to JP2022509022A priority patent/JP2022544409A/ja
Publication of WO2021030097A1 publication Critical patent/WO2021030097A1/en

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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
    • C03B17/061—Forming glass sheets by lateral drawing or extrusion
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/06—Forming glass sheets
    • C03B17/067—Forming glass sheets combined with thermal conditioning of the sheets

Definitions

  • the present disclosure relates generally glass manufacturing apparatus and methods and, more particularly, to glass manufacturing apparatus including a thermal control device and methods of manufacturing glass including adjusting a temperature of molten material flowing through a footprint of a slot.
  • a glass manufacturing apparatus can comprise a forming device.
  • the forming device can comprise a pipe having a pipe wall defining a flow passage.
  • the forming device can comprise a slot in fluid communication with the flow passage and extending through the pipe wall.
  • the slot can comprise a footprint circumscribed by an outer periphery of the slot.
  • the glass manufacturing apparatus can also comprise a thermal control device defining a thermal control path, a projection of the thermal control path intersecting the footprint.
  • the forming device can further comprise a first wall comprising a first outer surface.
  • the first wall can be attached at a first peripheral location of an outer surface of the pipe wall.
  • the forming device can also comprise a second wall comprising a second outer surface.
  • the second wall can be attached at a second peripheral location of the outer surface of the pipe wall.
  • the first outer surface and the second outer surface can converge at a root of the forming device.
  • the integral junction can comprise a root of the forming device.
  • the projection can be circumscribed by the footprint.
  • the thermal control device can comprise a plurality of thermal control devices arranged along a flow direction of the flow passage.
  • the pipe wall can comprise a thickness in a range from about 0.5 millimeters to about 10 millimeters.
  • the pipe wall can comprise platinum or a platinum alloy.
  • the thermal control device can comprise an electric heater.
  • the electric heater can comprise a plurality of electric heaters.
  • a thermal insulator can be positioned between a first electric heater of the plurality of electric heaters and a second electric heater of the plurality of electric heaters.
  • the electric heater can comprise one or more of molybdenum disilicide, silicon carbide, or lanthanum chromite.
  • the thermal control device can comprise a gas nozzle.
  • the thermal control device can comprise a laser.
  • the laser can be configured to emit a laser beam comprising a wavelength in a range from about 760 nanometers to about 5,000 nanometers.
  • a mirror can be configured to reflect the laser beam emitted from the laser so that the laser beam scans the footprint.
  • the mirror can be rotatable.
  • the mirror can comprise a polygonal mirror.
  • the laser can comprise a plurality of laser diodes.
  • the glass manufacturing apparatus can further comprise a housing comprising a wall defining an interior region and a wall passage extending through the wall. The forming device can be positioned in the interior region.
  • the thermal control path can be aligned with the passage.
  • the glass manufacturing apparatus can additionally comprise a tube positioned within the wall passage.
  • the thermal control device can comprise a gas nozzle.
  • the housing can comprise an interior surface facing the forming device and an exterior surface opposite the interior surface.
  • a thermal insulator can extend from the exterior surface.
  • the thermal control device can comprise an electric heater.
  • the electric heater can comprise a plurality of electric heaters.
  • the thermal insulator can be positioned between a first electric heater of the plurality of electric heaters and a second electric heater of the plurality of electric heaters.
  • the electric heater can be rotatable about an axis.
  • the wall passage can comprise a slot comprising a length and a width less than the length.
  • the thermal control device can comprise a laser.
  • the laser can be configured to emit a laser beam comprising a wavelength in a range from about 760 nanometers to about 5,000 nanometers.
  • the laser can be configured to scan a length of the pipe by emitting the laser beam through the wall passage.
  • the laser can comprise a laser diode.
  • the laser diode can be optically coupled to a first end of an optical fiber.
  • a second end of the optical fiber can face the slot.
  • the optical fiber can partially extend through the wall passage.
  • a method of manufacturing glass can comprise flowing molten material along a flow direction of a flow passage defined by a pipe wall of a pipe.
  • a slot can extend through the pipe wall and can comprise a footprint circumscribed by an outer periphery of the slot.
  • the method can comprise flowing the molten material through the footprint of the slot.
  • the method can also comprise operating a thermal control device defining a thermal control path, the thermal control path, a projection of the thermal control path intersecting the footprint.
  • the method can further comprise adjusting a temperature of the molten material at a location where the thermal control path intersects the molten material.
  • the method can comprise flowing a first stream of the molten material from the location in a first direction along a first outer surface of a forming device.
  • the method can also comprise flowing a second stream of the molten material from the location in a second direction along a second outer surface of the forming device.
  • the first stream and the second stream can converge to form a glass ribbon.
  • the location can be located entirely within a projection of the footprint extending outwardly from the slot in an outward direction perpendicular to the flow direction.
  • adjusting the temperature of the molten material at the location can comprise decreasing the temperature of the molten material.
  • operating the thermal control device can comprise ejecting gas from a gas nozzle.
  • adjusting the temperature of the molten material at the location can comprise increasing the temperature of the molten material.
  • operating the thermal control device can comprise circulating electricity through a heating element.
  • the method can comprise rotating the heating element about an axis.
  • operating the thermal control device can comprise emitting a laser beam from a laser.
  • an absorption depth of the laser beam in the molten material can be in a range from about 50 micrometers to about 10 millimeters.
  • the laser beam can comprise a wavelength in a range from about 760 nanometers to about 5,000 nanometers.
  • the method can comprise scanning the laser beam across a length of the slot.
  • the method can comprise reflecting the laser beam emitted from the laser off a mirror.
  • the method can comprise rotating the mirror.
  • the mirror can comprise a polygonal mirror.
  • FIG. 1 schematically illustrates an exemplary embodiment of a glass manufacturing apparatus in accordance with embodiments of the disclosure
  • FIG. 2 shows a cross-sectional view of the forming device along line
  • FIG. 3 is an enlarged view 3 of FIG. 2; [0055] FIG. 4 shows a cross-sectional view of the forming device along line
  • FIG. 5 is an enlarged view 5 of FIG. 2 according to some embodiments of the disclosure.
  • FIG. 6 is an enlarged view 5 of FIG. 2 according to some embodiments of the disclosure.
  • FIG. 7 is an enlarged view 5 of FIG. 2 according to some embodiments of the disclosure.
  • FIG. 8 is an enlarged view 5 of FIG. 2 according to some embodiments of the disclosure.
  • FIG. 9 shows a view of the thermal control device along line 9-9 of
  • FIG. 6 is a diagrammatic representation of FIG. 6
  • FIG. 10 shows a side view of the thermal control device according to some embodiments of the disclosure.
  • FIG. 11 shows a cross-sectional view of the thermal control device along line 11-11 of FIG. 7.
  • glass articles e.g., separated glass ribbons
  • LCDs liquid crystal displays
  • EPDs electrophoretic displays
  • OLEDs organic light emitting diode displays
  • PDPs plasma display panels
  • touch sensors photovoltaics, or the like.
  • Embodiments of the disclosure herein can provide the technical benefits of adjusting the mass flow rate, viscosity, and/or temperature of molten material leaving a slot of a pipe of a forming device using a thermal control device.
  • Embodiments of the disclosure can provide localized control and/or adjustment of the mass flow rate, viscosity, and/or temperature of the molten material.
  • the location where the mass flow rate, viscosity, and/or temperature of molten material can be controlled may be entirely within a projection of a footprint defined by an outer periphery of the slot. Additionally, acting on the molten material leaving the slot can reduce the need for additional thermal control later in the glass manufacturing process.
  • a design of the slot can be used to reduce the region where the thermal control device acts on the molten material.
  • Embodiments comprising thin pipe walls e.g., from about 0.5 millimeters to about 10 millimeters
  • adjusting the mass flow rate, viscosity, and/or temperature of the molten material can also permit simultaneous control of both a first stream of molten material and a second stream of molten material.
  • providing the forming device within an interior region of a housing can reduce (e.g., minimize, prevent) uncontrolled heat loss and/or thermal currents from impacting the quality of the glass ribbons produced while increasing the localization of the effect of the thermal control device.
  • Providing a passage through the wall of the housing can allow a thermal control device positioned at least partially positioned outside of the interior region to act on the molten material.
  • Providing the passage with a tube can further reduce uncontrolled heat loss and/or thermal current as well as permit adjustment (e.g., repositioning, removal, insertion, replacement) of the thermal control device.
  • Providing thermal insulators extending from an exterior surface of the wall of the housing can further localize the effect of the thermal control device.
  • a glass manufacturing apparatus 100 can comprise a glass melting and delivery apparatus 102 and a forming apparatus 101 comprising a forming device 140 designed to produce a glass ribbon 103 from a quantity of molten material 121.
  • the term “glass ribbon” refers to material after it is drawn from the forming device 140 even when the material is not in a glassy state (e.g., above its glass transition temperature).
  • the glass ribbon 103 can comprise a central portion 152 positioned between opposite, edge beads formed along a first outer edge 153 and a second outer edge 155 of the glass ribbon 103.
  • a separated glass ribbon 104 can be separated from the glass ribbon 103 along a separation path 151 by a glass separator 149 (e.g., scribe, score wheel, diamond tip, laser). In some embodiments, before or after separation of a separated glass ribbon
  • the edge beads formed along the first outer edge 153 and the second outer edge 155 can be removed to provide the central portion 152 as a separated glass ribbon 104 having a more uniform thickness.
  • the glass melting and delivery apparatus 102 can comprise 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.
  • a controller 115 can optionally be operated to activate the motor 113 to introduce an amount of batch material 107 into the melting vessel 105, as indicated by arrow 117.
  • the melting vessel 105 can heat the batch material 107 to provide molten material 121.
  • a glass melt probe 119 can be employed 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 melting and delivery apparatus 102 can comprise a first conditioning station comprising a fining vessel 127 located downstream from the melting vessel 105 and coupled to the melting vessel
  • molten material 121 can be gravity fed from the melting vessel 105 to the fining vessel 127 by way of the first connecting conduit 129.
  • gravity can drive the molten material 121 through an interior pathway of the first connecting conduit 129 from the melting vessel 105 to the fining vessel 127.
  • bubbles can be removed from the molten material 121 within the fining vessel 127 by various techniques.
  • the glass melting and delivery apparatus 102 can further comprise a second conditioning station comprising a mixing chamber 131 that can be located downstream from the fining vessel 127.
  • the mixing chamber 131 can be employed to provide a homogenous composition of molten material 121, thereby reducing or eliminating inhomogeneity that may otherwise exist within the molten material 121 exiting the fining vessel 127.
  • the fining vessel 127 can be coupled to the mixing chamber 131 by way of a second connecting conduit 135.
  • molten material 121 can be gravity fed from the fining vessel 127 to the mixing chamber 131 by way of the second connecting conduit 135.
  • gravity can drive the molten material 121 through an interior pathway of the second connecting conduit 135 from the fining vessel 127 to the mixing chamber 131.
  • the glass melting and delivery apparatus 102 can comprise a third conditioning station comprising a delivery vessel 133 that can 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 can be coupled to the delivery vessel 133 by way of a third connecting conduit 137.
  • molten material 121 can be gravity fed from the mixing chamber 131 to the delivery vessel 133 by way of the third connecting conduit 137.
  • gravity can drive the molten material 121 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 forming apparatus 101, for example, the inlet conduit 141 of the forming device 140.
  • Forming apparatus 101 can comprise a forming device 140 with a forming wedge (e.g., forming wedge 209 in FIG. 2) for drawing (e.g., fusion drawing) the glass ribbon 103.
  • a forming wedge e.g., forming wedge 209 in FIG. 2
  • the forming device 140 shown and disclosed below can be provided to draw (e.g., fusion draw) the molten material 121 off a bottom edge, defined as a root 235, of a forming wedge 209 to produce a ribbon of molten material 121 that can be drawn into the glass ribbon 103.
  • the molten material 121 can be delivered from the inlet conduit 141 to the forming device 140.
  • the molten material 121 can then be formed into the glass ribbon 103 based in part on the structure of the forming device 140. For example, as shown, the molten material 121 can be drawn off the bottom edge (e.g., root 235) of the forming device 140 along a draw path extending in a draw direction 154 of the glass manufacturing apparatus 100.
  • edge directors 237, 238 can direct the molten material 121 off the forming device 140 and define, at least in part, a width “W” of the glass ribbon 103. In some embodiments, the width “W” of the glass ribbon 103 can extend between the first outer edge 153 of the glass ribbon 103 and the second outer edge 155 of the glass ribbon 103.
  • the width “W” of the glass ribbon 103 can be about 20 millimeters (mm) or more, about 50 mm or more, about 100 mm or more, about 500 mm or more, about 1,000 mm or more, about 2,000 mm or more, about 3,000 mm or more, about 4,000 mm or more, although other widths can be provided in further embodiments.
  • the width “W” of the glass ribbon 103 can be in a range from about 20 mm to about 4,000 mm, from about 50 mm to about 4,000 mm, from about 100 mm to about 4,000 mm, from about 500 mm to about 4,000 mm, from about 1,000 mm to about 4,000 mm, from about 2,000 mm to about 4,000 mm, from about 3,000 mm to about 4,000 mm, from about 2,0 mm to about 3,000 mm, from about 50 mm to about 3,000 mm, from about 100 mm to about 3,000 mm, from about 500 mm to about 3,000 mm, from about 1,000 mm to about 3,000 mm, from about 2,000 mm to about 3,000 mm, from about 2,000 mm to about 2,500 mm, or any range and subrange therebetween.
  • FIG. 2 shows a cross-sectional view of the forming apparatus 101 (e.g., forming device 140) along line 2-2 of FIG. 1.
  • the forming device 140 can include a pipe 201 oriented to receive the molten material 121 from the inlet conduit 141.
  • the forming device 140 can further include the forming wedge 209 comprising a first wall 213 and a second wall 214 comprising a pair of downwardly inclined converging surface portions.
  • the first wall 213 and the second wall 214 can comprise the pair of downwardly inclined converging surface portions of the forming wedge 209 converging along the draw direction 154 to intersect along the root 235 of the forming device 140.
  • the pipe 201 can comprise a pipe wall 205 comprising an inner surface 206 defining a flow passage 207.
  • the pipe wall 205 partially circumscribes the flow passage 207 to define the flow passage 207.
  • the pipe 201 can comprise a slot 203 in fluid communication with the flow passage 207 and extending through the pipe wall 205.
  • the slot 203 can extend through an opening in an outer surface 204 of the pipe wall 205, an opening in the inner surface 206 of the pipe wall 205, and a thickness of the pipe wall 205 defined between the outer surface 204 and the inner surface 206.
  • the slot 203 may comprise a single continuous slot although a plurality of slots may be provided that are aligned along a flow direction 208 (see FIG. 4) of the flow passage 207.
  • the slot 203 may include enlarged ends.
  • the slot 203 can vary along in the flow direction 208 by decreasing, for example, intermittently or continuously decreasing from an intermediate portion to a first outer end portion and a second outer end portion.
  • the slot 203 or can include multiple rows of slots that may extend in the flow direction 208 and parallel to one another.
  • the slot 203 can comprise a footprint 301 circumscribed by an outer periphery 303 of the slot 203.
  • the footprint 301 of the slot 203 is considered the minimum slot area defined by the innermost portions of the outer periphery 303 circumscribing the slot 203.
  • the inner most portions of the outer periphery 303 of the slot 203 can comprise the outermost edge or surface at or between the outer surface 204 and/or inner surface 206 of the pipe wall 205.
  • the footprint 301 is defined by the innermost edge 305 of the slot 203 at the inner surface 206 of the pipe wall 205.
  • the innermost edge 305 defines the slot width 307 in a direction perpendicular to the flow direction 208.
  • the slot 203 can comprise a through-slot that extends through the pipe wall 205.
  • the slot 203 can be open to the outer surface 204 and the inner surface 206 of the pipe wall 205 to provide fluid communication between the flow passage 207 and the outer surface 204 of the pipe wall 205.
  • the slot 203 (optionally comprising a plurality of slots) can be provided in the outer surface 204 of the pipe wall 205 at the uppermost apex of the pipe 201 in any of the embodiments of the disclosure.
  • the slot (optionally comprising a plurality of slots) may extend along a slot plane that bisects the slot and can further bisect the pipe 201 and/or root 235.
  • bisecting the pipe 201 and/or root 235 with the slot plane (e.g., bisecting the slot) along the uppermost apex of the pipe 201 can help evenly divide the molten material exiting the slot(s) into oppositely flowing streams (e.g., first stream 211 of molten material 121, second stream 212 of molten material 121).
  • the pipe wall 205 of the pipe 201 may comprise an electrically conductive material.
  • a material is electrically conductive if it comprises a resistivity at 20°C of about 0.0001 ohm-meters (Qm) or less (e.g., a conductivity of about 10,000 Siemens-per-meter (S/m) or more).
  • electrically conductive materials include manganese, nickel-chrome alloys (e.g., nichrome), steel, titanium, iron, nickel, zinc, tungsten, gold, copper, silver, platinum, rhodium, iridium, osmium, palladium, ruthenium and combinations thereof.
  • the pipe wall 205 of the pipe 201 may comprise platinum or a platinum alloy, although other materials may be provided that are compatible with the molten material and provide structural integrity at elevated temperatures.
  • the platinum alloy may comprise platinum-rhodium, platinum-iridium, platinum-palladium, platinum-gold, platinum-osmium, platinum-ruthenium, and combinations thereof.
  • the platinum or platinum alloy may also comprise refractory metals, for example, molybdenum, rhenium, tantalum, titanium, tungsten, ruthenium, osmium, zirconium, zirconium dioxide (zirconia), and/or alloys thereof.
  • the platinum or platinum alloy can comprise an oxide dispersion-strengthened material.
  • the entire pipe wall 205 may comprise or consist essentially of platinum or a platinum alloy.
  • the conduit can comprise a platinum pipe 201 comprising the pipe wall 205 defining the flow passage 207.
  • the pipe wall may comprise one or more of the above materials without platinum.
  • a thickness of the pipe wall 205 can be defined between an outer surface 204 of the pipe wall 205 and the inner surface 206 of the pipe wall 205.
  • a thickness of the pipe wall 205 of the conduit can be in a range from about 0.5 millimeter (mm) to about 10 mm, from about 0.5 mm to about 7 mm, from about 0.5 mm to about 3 mm, from about 1 mm to about 10 mm, from about 1 mm to about 7 mm, from about 3 mm to about 10 mm, from about 3 mm to about 7 mm, or any range or subrange therebetween.
  • Providing the pipe 201 with the thickness of the pipe wall 205 within any of the above ranges can provide a thickness that is large enough to provide a desired level of structural integrity for the pipe 201 while also providing a thickness that can be minimized to reduce the costs of the materials to produce the pipe 201 (e.g., platinum pipe).
  • Providing a pipe wall 205 with a thin thickness can reduce the thermal mass of the forming device 140 around a location 315 (see FIG. 3) where a thermal control device 251 acts on the molten material 121, which can increase the effect of the thermal control device 251.
  • the pipe wall 205 of the pipe 201 can comprise a wide range of sizes, shapes, and configurations to reduce manufacturing and/or assembly costs and/or increase the functionality of the pipe 201.
  • the outer surface 204 and/or the inner surface 206 of the pipe wall 205 may comprise a circular shape, although other curvilinear shapes (e.g., oval) or polygonal shapes may be provided in further embodiments.
  • Providing a curvilinear shape (e.g., a circular shape) of both the outer surface 204 and the inner surface 206 can provide a pipe wall 205 with a constant thickness and can provide a pipe wall 205 with high structural strength and help promote consistent flow of molten material 121 through the flow passage 207 of the pipe 201.
  • the outer surface 204 and/or the inner surface 206 of the pipe 201 can include geometrically similar circular shapes (or other shapes) along its length in a direction perpendicular to the view shown in FIGS. 2 and 4.
  • the flow rate through the slot 203 can be controlled (e.g., maintained substantially the same) by modifying the width of the slot 203.
  • the pipe 201 of any of the embodiments of the disclosure can comprise a continuous pipe although a segmented pipe may be provided in further embodiments.
  • the pipe 201 of the can comprise a continuous pipe that is not segmented along its length. Such a continuous pipe may be beneficial to provide a seamless pipe with increased structural strength.
  • a segmented pipe may be provided.
  • the pipe 201 of the forming device 140 can optionally comprise pipe segments that can be connected together in series at joints between abutting ends of pairs of adjacent pipe segments.
  • the joints may comprise welded joints to integrally join the pipe segments as an integral pipe.
  • the joints may comprise a diffusion-bonded joint, a male/female joint, or a threaded joint. Providing the pipe 201 as a series of pipe segments may simplify fabrication of the pipe 201 in some applications.
  • the forming wedge 209 can include the first wall 213 defining a first outer surface 223 and the second wall 214 defining a second outer surface 224.
  • the first wall 213 e.g., platinum wall
  • the second wall 214 e.g., platinum wall
  • the pipe wall 205 of the pipe 201 e.g., platinum pipe
  • the second wall 214 can be attached to the pipe wall 205 of the pipe 201 (e.g., platinum pipe) via a second interface at a second peripheral location 208b of the outer surface 204 of the pipe 201.
  • the first peripheral location 208a and the second peripheral location 208b can be each located downstream from the slot 203 of the pipe 201. Consequently, the slot 203 can be circumferentially located between the first peripheral location 208a and the second peripheral location 208b.
  • the upstream end of the first wall 213 and the upstream end of the second wall 214 can be integrally joined to the pipe wall 205 of the pipe 201 and machined to have a smooth corresponding interface between the outer surface 204 of the pipe 201 and the outer surface of the walls (e.g., first outer surface 223 of the first wall 213, second outer surface 224 of the second wall 214).
  • integrally joining the upstream end of the first wall 213 and the upstream end of the second wall 214 to the pipe wall 205 can comprise forming a joint, for example, a welded joint, a diffusion bonded joint, a male/female joint, or a threaded joint.
  • the upstream portion of the first wall 213 and the upstream portion of the second wall 214 can initially flare away from one another along the draw direction 154 from the corresponding interface with the pipe 201.
  • flaring the first wall and second wall away from one another can facilitate the flow of molten material along the draw direction while also allowing increased space for the support beam in some embodiments.
  • the upstream portions of the first wall and second wall can be parallel with one another.
  • the first outer surface 223 and the second outer surface 224 can converge in the draw direction 154 to form the root 235 of the forming wedge 209.
  • the root 235 may comprise an integral junction at a convergence of the first outer surface 223 and the second outer surface 224.
  • the integral junction may comprise a unitary (e.g., monolithic) material or may comprise a joint.
  • joints may comprise a diffusion-bonded joint, a male/female joint, or a threaded joint.
  • the first wall 213 and/or the second wall 214 of the forming device 140 can comprise an electrically conductive material, as defined above.
  • the first wall 213 and/or the second wall 214 may comprise platinum and/or a platinum alloy similar or identical to the composition of the pipe 201 discussed above, although different compositions may be employed in further embodiments.
  • the first wall 213 and the second wall 214 can each comprise platinum.
  • the first wall 213 and/or the second wall 214 may comprise one or more of the materials discussed above for the pipe 201 without containing platinum.
  • a thickness 225 of the first wall 213 can be defined between the first outer surface 223 and a first inner surface 233.
  • a thickness 226 of the second wall 214 can be defined between the second outer surface 224 and a second inner surface 234.
  • the thickness 225 of the first wall 213 and/or the thickness 226 of the second wall 214 can, for example, be within a range 0.5 mm to about 10 mm, from about 0.5 mm to about 7 mm, from about 0.5 mm to about 3 mm, from about 1 mm to about 10 mm, from about 1 mm to about 7 mm, from about 3 mm to about 10 mm, from about 3 mm to about 7 mm, or any range or subrange therebetween.
  • a reduced thickness can result in overall reduced material costs.
  • the first wall 213 may comprise the first inner surface 233 opposite the first outer surface 223 of the first wall 213.
  • the second wall 214 may comprise the second inner surface 234 opposite the second outer surface 224 of the second wall 214.
  • the first inner surface 233 and the second inner surface 234 may partially define a cavity 220 within the forming device 140, as shown in FIG. 2.
  • the cavity 220 may be further defined by the pipe wall 205 of the pipe 201.
  • a support beam 157 may be positioned in the cavity 220 partially defined by the first inner surface 233 and the second inner surface 234.
  • the support beam 157 positioned in the cavity 220 can support a weight of the pipe 201 and the molten material 121 within the flow passage 207.
  • the support beam 157 may be configured to help maintain the shape and/or dimensions of the pipe 201, for example, the shape and dimensions of the slot 203.
  • the support beam 157 can extend laterally outside of the width of the root 235 to be supported (e.g., simply supported) at opposite locations 158a, 158b as shown in FIG. 1.
  • the support beam 157 can be longer than the width “W” of the formed glass ribbon 103 and can extend through the cavity 220 laterally extending through the forming device 140 to fully support the forming device 140. Additionally, as shown in FIG. 2, the support beam 157 can be positioned between the first wall 213 and the second wall 214 within the cavity 220 of the forming device 140, which can provide the walls with sufficient structural integrity to resist deformation in use despite the low thickness of the first wall 213 and/or second wall 214. As such, the structure of the first wall 213 and the second wall 214 can be maintained by the support beam 157 positioned therebetween.
  • first wall 213 and the second wall 214 converge in the draw direction 154 to form the root 235 wherein a strong triangular construction can be formed by the first wall 213 and the second wall 214.
  • a structurally rigid configuration can be achieved with thin walls within the ranges specified above.
  • Support beams of the disclosure can, for example, be provided as a single monolithic support beam.
  • the support beam can optionally include a first support beam and a second support beam that supports the first support beam.
  • the first support beam and second support beam can comprise a stack of support beams where the first support beam is stacked on top of the second support beam. Providing a stack of support beams can simplify and/or reduce the cost of fabrication.
  • the second support beam can be longer than the first support beam such that opposite end portions of the second support beam can extend laterally outside of the width of the root 235 to be supported (e.g., simply supported) at opposite locations (e.g., locations 158a, 158b).
  • the second support beam can be longer than the width “W” of the formed glass ribbon 103 and can extend through the cavity 220 laterally extending through the forming device 140 to fully support the forming device 140.
  • the second support beam may comprise a shape, for example, the illustrated rectangular shape although a hollow shape, a shape of an I- beam or another shape may be provided to reduce material costs while still providing a high bending moment of inertia for the support beam.
  • the first support beam can be fabricated with a shape to support the conduit to help maintain the shape and dimensions of the conduit as discussed above.
  • the support beam 157 can comprise a support material comprising one or more ceramics.
  • a ceramic material for the support beam can comprise silicon carbide (SiC).
  • other ceramics e.g., oxides, carbides, nitrides, oxynitrides
  • the support material can be designed to maintain its mechanical properties and dimensional stability at a temperature of about 1200°C or more, about 1300°C or more, about 1400°C or more, about 1500°C or more, about 1600°C or more, or about 1700°C or less.
  • the support beam 157 can be fabricated from a support material with a creep rate from 1 x 10 12 s 1 to 1 x 10 14 s 1 under a pressure in a range from about 1 MegaPascal (MPa) to 5 MPa at a temperature of about 1400°C or more.
  • Such a support material can provide sufficient support for the pipe and molten material carried by the conduit at high temperatures (e.g., 1400°C) with minimal creep to provide a forming device 140 that minimizes use of platinum or other expensive refractory materials ideal for physically contacting the molten material without contaminating the molten material while providing a support beam 157 fabricated from an inexpensive material that can withstand large stresses under the weight of the forming device 140 and molten material 121 carried by the forming device 140.
  • the support beam 157 fabricated from the material discussed above can withstand creep under high stress and temperature to allow maintenance of the position and shape of the conduit and walls (e.g., platinum walls) associated with the conduit.
  • the support beam 157 may comprise the first support beam and the second support beam, and the first support beam and the second support beam may be fabricated from substantially the same or identical material although alternative materials may be provided in further embodiments.
  • the material of the first wall 213 and/or second wall 214 may be incompatible for physical contact with the material of the support beam 157.
  • the first wall 213 and/or second wall 214 can comprise platinum (e.g., platinum or a platinum alloy) and the support beam 157 can comprise a support material (e.g., silicon carbide) that may corrode or otherwise chemically react with the platinum of the first wall 213 and/or second wall 214 if the platinum were permitted to contact the support beam 157.
  • any portion of the wall (e.g., first wall 213, second wall 214) and any portion of the pipe 201 may be prevented from physically contacting any portion of the support beam 157.
  • the first wall 213 and the second wall 214 are each spaced from physically contacting any portion of the support beam 157.
  • the pipe 201 can be spaced from physically contacting any portion of the support beam 157.
  • Various techniques can be used to space the wall from the support beam 157. For example, pillars or ribs may be provided to provide spacing.
  • a layer of intermediate material 210 may be provided between a wall (e.g., the first wall 213, the second wall 214) and the support beam 157 to space the corresponding wall (e.g., the first wall 213, the second wall 214) from contacting the support beam 157.
  • the layer of intermediate material 210 may be continuously provided between all portions of the first wall 213 and/or second wall 214 and adjacent spaced portions of the support beam 157.
  • a layer of intermediate material 210 may be provided between the pipe 201 and the support beam 157 to space the pipe 201 from contacting the support beam 157.
  • the layer of intermediate material 210 may be continuously provided between all portions of the pipe 201 and adjacent spaced portion of the support beam 157. Without wishing to be bound by theory, providing a continuous layer of intermediate material 210 can facilitate even support across all portions of the first wall 213, the second wall 214, and the pipe 201 by the support beam 157 spaced from the aforementioned structures.
  • Various materials can be used as the intermediate material 210 depending on the materials of the walls (e.g., first wall 213, second wall 214) and the support beam 157.
  • the intermediate material 210 can comprise a material that is compatible for contacting the pipe 201, the first wall 213, and/or the second wall 214 (e.g., platinum) and the support member (e.g., silicon carbide) under high temperature and pressure conditions associated with containing and guiding the molten material 121 with the forming device 140.
  • the intermediate material 210 can comprise a refractory material.
  • suitable refractory materials comprise zirconia and alumina.
  • other refractory materials e.g., oxides, quartz, mullite may be used.
  • platinum or platinum alloy walls e.g., first wall 213, second wall 214 and platinum pipe (e.g., pipe 201) can be spaced from physically contacting any portion of a support beam 157 (e.g., comprising silicon carbide) by way of a layer of intermediate material 210 (e.g., alumina).
  • a support beam 157 e.g., comprising silicon carbide
  • intermediate material 210 e.g., alumina
  • the glass manufacturing apparatus 100 can comprise a housing 240 with a housing wall 241 defined between an interior surface 243 and an exterior surface 245 opposite the interior surface 243 of the housing wall 241.
  • an interior region 247 of the housing 240 can be defined by the interior surface 243 of the housing wall 241.
  • the interior surface 243 of the housing wall 241 can face the forming device 140.
  • the housing wall 241 at least partially surrounds the forming device 140 so that the forming device 140 and a portion of the glass ribbon 103 are positioned within the interior region 247 of the housing 240.
  • a bulk material of the housing 240 located between the interior surface 243 and the exterior surface 245, can comprise a first material, which may be a ceramic or other material with a low thermal conductivity.
  • a first material which may be a ceramic or other material with a low thermal conductivity.
  • the first material comprises a thermal conductivity of about 150 W m 1 K 1 or less, 50 W m 1 K 1 or less, of about 30 W m 1 K 1 or less, in a range from about 0.01 W m 1 K 1 to about 150 W m 1 K 1 , in a range from about 0.01 W m 1 K 1 to about 50 W m 1 K 1 , or in a range from about 0.25 W m 1 K _1 to about 30 W m 1 K 1 , or any range and subrange therebetween, although other thermal conductivities may be permissible in other embodiments.
  • the housing 240 can provide the technical benefit of reducing (e.g., minimizing, preventing) uncontrolled heat loss and/or thermal currents from impacting the quality of the glass ribbon 103 produced.
  • the first material can maintain structural integrity and provide dimensional stability at an operating temperature of the interior region 247 of the housing 240 when there is molten material 121 in the forming device 140.
  • the operating temperature may be about 500°C or more, about 800°C or more, about 1000°C or more, about 1200° or more, about 1500°C or more, about 1700°C or less, or about 1600°C or less.
  • the operating temperature may be in a range from about 500°C to about 1700°C, from about 800°C to about 1700°C, from about 1000°C to about 1700°C, from about 1200° to about 1700°C, from about 500°C to about 1600°C, from about 800°C to about 1600°C, from about 1000°C to about 1600°C, or from about 1200° to about 1600°C, or any range and subrange therebetween.
  • the first material comprises a melting temperature above 1600°C. If the first material comprises an amorphous material, the operating temperature may be below the glass transition temperature of that material.
  • the first material comprises boron nitride (BN), silicon carbide (SiC), zirconium dioxide (ZrO 2), a SiAlON (i.e., a combination of alumina and silicon nitride and can have a chemical formula such as Sio-m- nAlm+nOn i6-n, Si6-nAl n O n N8-n, or Sh-nAlnOi+nNi-n, where m, n, and the resulting subscripts are all non-negative integers), aluminum nitride (AIN), graphite, alumina (AI2O3), silicon nitride (S13N4), fused quartz, mullite (i.e., a mineral comprising a combination of aluminum oxide and silicon dioxide), or a combination of two or more of the aforementioned materials.
  • boron nitride BN
  • SiC silicon carbide
  • ZrO 2 zirconium dioxide
  • the housing 240 if present, and the thermal control device 251 (e.g., thermal control devices 251a, 251b, 251c, and 251d) can be positioned within an interior region of an outer housing.
  • the outer housing may comprise one or more of the materials, thermal conductivities, and/or structural properties discussed above with regards to the housing 240.
  • the outer housing may reduce heat loss from the interior region.
  • a wall passage 249 extends through the housing 240 from an opening in the exterior surface 245 of the housing wall 241 to an opening in the interior surface 243 of the housing wall 241.
  • Providing a wall passage 249 through the housing wall 241 can permit positioning of the thermal control device 251 at least partially outside of the interior region 247 that can still act on the molten material 121 within the interior region 247.
  • the wall passage 249 can provide the technical benefit of localizing the effect of the thermal control device 251 to permit local adjustment of the molten material 121.
  • a tube 503 comprising a second material may be positioned within (as shown) and can be aligned with the wall passage 249 although the wall passage 249 may be provided without a tube 503 in other embodiments (e.g., see FIGS. 6-10).
  • the tube 503 comprises the second material that may be the same as the first material of the housing wall 241.
  • the second material of the tube 503 may comprise a thermal conductivity that is about the same or greater than a thermal conductivity of the first material of the wall passage 249.
  • the second material may still comprise a melting temperature of about 1600°C or more.
  • the first material may comprise a thermal conductivity less than about 25 W m 1 K 1 (e.g., fused quartz, fused silica, zirconium dioxide, mullite, a SiAlON, graphite) and the second material may comprise a thermal conductivity of about 30 W m 1 K 1 or more (e.g., silicon nitride, boron nitride, alumina, silicon carbide, aluminum nitride).
  • the second material may serve to homogenize temperatures within the wall passage 249 relative to a passage without the second material (e.g., without a tube 503).
  • the tube 503, if provided, can comprise a plurality of tubes that can be positioned with a corresponding one of a plurality of wall passages (e.g., surrounded by the first material of the housing 240).
  • one or more of the tubes may be fixedly mounted within the corresponding wall passage. Fixed mounting may be achieved, for example, by press fitting the tube within the wall passage.
  • the tube 503 may comprise a lining of the wall passage 249 that can coat the wall passage 249. The tube 503 can provide the technical benefit of further reducing uncontrolled heat loss and/or thermal currents. Additionally, the tube 503 can permit adjustment (e.g., repositioning, removal, insertion, replacement) of the thermal control device 251.
  • the tube 503 can comprise a thickness 505 measured between an outer surface portion of the tube 503 and opposite an inner surface portion of the tube 503.
  • the thickness 505 of the tube 503 can be about 100 nm or more, about 1 pm or more, about 10 pm or more, about 50 pm or more, about 2,000 pm or less, about 990 pm or less, about 490 pm or less, about 400 pm or less, about 300 pm or less, about 200 pm or less, or about 100 pm or less.
  • the thickness 505 of the tube 503 can be in a range from about 100 nm to about 2,000 pm, from about 1 pm to about 2,000 pm, from about 10 pm to about 2,000 pm, from about 50 pm to about 2,000 pm, from about 100 nm to about 990 pm, from about 1 pm to about 990 pm, from about 10 pm to about 990 pm, from about 50 pm to about 990 pm, from about 100 nm to about 490 pm, from about 1 pm to about 490 pm, from about 10 pm to about 490 pm, from about 50 pm to about 490 pm, from about 100 nm to about 400 pm, from about 1 pm to about 400 pm, from about 10 pm to about 400 pm, from about 50 pm to about 400 pm, from about 100 nm to about 300 pm, from about 1 pm to about 300 pm, from about 10 pm to about 300 pm, from about 50 pm to about 300 pm, from about 100 nm to about 200 pm, from about 1 pm to about 200 pm, from about 10 pm to about 200 pm, from about 50 pm to about 50 pm
  • the second material may comprise a portion of the housing 240 surrounding the wall passage 249 without a tube 503.
  • the wall passage 249 may be in the portion of the housing wall 241 comprising the second material.
  • the wall passage 249 may not be provided with a tube 503.
  • the above-referenced tube 503 comprising a second material can optionally be positioned within the wall passage 249 also comprising a second material so that tube 503 can be adjusted or interchanged independent from the housing 240 itself.
  • the wall passage 249 may comprise a cross-section (e.g., perpendicular to an elongated axis of the wall passage 249) with a cross-sectional passage area.
  • the cross-sectional passage area can be about 0.01 mm 2 or more, about 0.04 mm 2 or more, about 0.1 mm 2 or more, about 500 mm 2 or less, about 100 mm 2 or less, about 50 mm 2 or less, about 10 mm 2 or less, about 5 mm 2 or less, about 1 mm 2 or less, about 0.8 mm 2 or less, about 0.4 mm 2 or less, about 0.2 mm 2 or less, or about 0.1 mm 2 or less.
  • the cross-sectional passage area can be in a range from about 0.01 mm 2 to about 500 mm 2 , from about 0.04 mm 2 to about 500 mm 2 , from 0.1 mm 2 to about 500 mm 2 , from about 0.01 mm 2 to about 100 mm 2 , from about 0.04 mm 2 to about 100 mm 2 , from 0.1 mm 2 to about 100 mm 2 , from about 0.01 mm 2 to about 50 mm 2 , from about 0.04 mm 2 to about 50 mm 2 , from 0.1 mm 2 to about 50 mm 2 , from about 0.01 mm 2 to about 10 mm 2 , from about 0.04 mm 2 to about 10 mm 2 , from 0.1 mm 2 to about 10 mm 2 , from about 0.01 mm 2 to about 5 mm 2 , from about 0.04 mm 2 to about 5 mm 2 , from 0.1 mm 2 to about 5 mm 2 , from about 0.01 mm 2 to about 1 mm 2 , from about
  • the cross-sectional passage area can be minimized to reduce the amount of heat transferred through the wall passage 249 while still accommodating an optical fiber 703 (discussed below) that may extend into the wall passage 249, a tube 503 if present, and a thermal control device 251 (discussed below).
  • a thermal insulator 903a, 903b, and/or 903c can extend from the exterior surface 245 of the housing wall 241.
  • the thermal insulator 903a, 903b, and/or 903c can be attached to the exterior surface 245 of the housing wall 241 and extend from the exterior surface 245 in a direction extending away from the interior region 247.
  • a plurality of wall passages e.g., wall passages 249a, 249b, 249c, and 249d
  • a thermal insulator (e.g., thermal insulator 903a) can be laterally positioned between an adjacent pair of wall passages (e.g., wall passage 249a, wall passage 249b).
  • a plurality of thermal insulators (e.g., thermal insulator 903a, 903b, and 903c) can be attached to the exterior surface 245 and extend from the exterior surface 245 of the housing wall 241.
  • a wall passage e.g., wall passage 249b
  • the thermal insulator 903a, 903b, and/or 903c can comprise one or more of the materials listed above for the first material and/or second material. Thermal insulators 903a-c can provide the technical benefit of localizing the effect of the thermal control device(s) 253.
  • the glass manufacturing apparatus 100 comprises one or more thermal control devices 251.
  • the glass manufacturing apparatus 100 can comprise a plurality of thermal control devices (e.g., thermal control devices 251a, 251b, 251c, and 251d).
  • the plurality of thermal control devices can be arranged (e.g., in a row) along the flow direction 208 of the flow passage 207.
  • a thermal control path 253 can extend from the thermal control device 251 towards the slot 203.
  • the thermal control path 253 may comprise a linear path.
  • the thermal control path 253 may comprise multiple linear path segments.
  • there may be a plurality of thermal control paths e.g., thermal control paths 253a, 253b, 253c, and 253d.
  • a number of thermal control paths 253 may be equal to a number of thermal control devices 251.
  • one thermal control path 253 may be associated with one thermal control device 251.
  • one thermal control device 251 may be associated with one thermal control path 253.
  • one thermal control device may be associated with a plurality of thermal control paths.
  • the thermal control device 251 can be positioned outside of the interior region 247 of the housing 240.
  • the thermal control path 253 may extend through the wall passage 249.
  • the thermal control path may be aligned with the wall passage 249.
  • a thermal control path 253 is aligned with a wall passage if a direction of a portion of the thermal control path 253 passing through the wall passage 249 extends in the direction of a central line of the wall passage 249.
  • the thermal control path 253 can be both aligned with the wall passage and can include a central axis of the wall passage 249.
  • a projection 309 of the thermal control path 253 may intersect the footprint 301.
  • a projection 309 of the thermal control path 253 extends along the thermal control path 253 and continues beyond an end 311 of the thermal control path 253 opposite the thermal control device 251 in a direction 313 of the thermal control path 253.
  • the projection 309 of the thermal control path 253 can be circumscribed by the footprint 301. Positioning the thermal control path 253 such that the projection 309 of the thermal control path 253 is circumscribed by the footprint 301 can reduce the need for additional thermal control later in the glass manufacturing process.
  • Positioning the thermal control path 253 such that the projection 309 of the thermal control path 253 is circumscribed by the footprint 301 permit simultaneous control of the flow rate, viscosity, and/or temperature of a first stream 211 of molten material 121 and a second stream 212 of molten material 121 (e.g., using a single thermal control device, using a single row of thermal control devices).
  • the thermal control device 251 can comprise one or more of a gas nozzle, an electric heater, or a laser. Although one type of thermal control device is shown in any given figure, it is to be understood that a combination of different types of thermal control devices can be combined. For example, a plurality of electric heaters may be operated simultaneously with a plurality of gas nozzles in the same glass manufacturing apparatus.
  • the thermal control device can comprise the illustrated gas nozzle 501.
  • the gas nozzle 501 may extend into and/or may be offset a distance from the wall passage 249.
  • an outer end of the gas nozzle 501 may partially extend through the wall passage 249 although the end the of the gas nozzle 501 may extend entirely through the wall passage 249 or may be positioned a distance outside of the wall passage 249 without any portion of the gas nozzle 501 extending through the wall passage 249.
  • a tube 503 may be positioned within the wall passage 249.
  • the thermal control device e.g., gas nozzle 501
  • the thermal control path 253 may at least partially extend through the tube 503.
  • the thermal control path 253 may be aligned with the tube 503.
  • the thermal control device 251 can comprise a plurality of gas nozzles.
  • the plurality of gas nozzles can be arranged (e.g., in a row) along a flow direction 208 of the flow passage 207 (see FIG. 4). In further embodiments, as shown in FIG.
  • the gas nozzle 501 can be configured to eject gas 507 from the gas nozzle 501 to travel along the thermal control path 253.
  • the gas 507 can comprise, for example, one or more of air, nitrogen, helium, argon, and carbon dioxide.
  • the gas 507 can be provided by a gas supply, for example, one or more of a pump, a cannister, a cartridge, a boiler, a compressor, and a pressure vessel.
  • the thermal control device 251 can comprise an electric heater 601.
  • a single electric heater may be provided although a plurality of electric heaters may be provided in further embodiments to allow a heat profile to be generated along the length of the slot.
  • the thermal control device can comprise a plurality of electric heaters (e.g., electric heaters 601a, 601b, 601c, and 601d).
  • the plurality of electric heaters can be arranged (e.g., in a row) along the flow direction 208 of the flow passage 207 (see FIG. 4).
  • an electric heater (e.g., electric heater 601a) of the plurality of electric heaters can be operated independently of another electric heater (e.g., electric heater 601b) of the plurality of electric heaters.
  • a thermal insulator e.g., thermal insulator 903a
  • a first electric heater e.g., electric heater 601a
  • a second electric heater e.g., electric heater 601b
  • the thermal insulator (e.g., thermal insulator 903a) can be positioned between an adjacent pair of electric heaters (e.g., electric heater 601a, electric heater 601b) of the plurality of the electric heaters.
  • the thermal insulator (e.g., thermal insulator 903a) may extend from the exterior surface 245 of the housing 240.
  • each thermal insulator 903a, 903b, and 903c can be attached to the housing 240 and extend from the exterior surface 245 of the housing 240. Attaching the thermal insulator to the housing can help further help control the heating through each slot by the heating element associated with that slot.
  • the thermal insulator e.g., thermal insulator 903a
  • the thermal insulator extending from the exterior surface 245 of the housing 240 can be positioned between an adjacent pair of electric heaters (e.g., electric heater 601a, electric heater 601b) of the plurality of the electric heaters.
  • a thermal insulator e.g., thermal insulator 903a
  • extending from the exterior surface 245 of the housing 240 may be positioned between each adjacent pair of electric heaters of the plurality of electric heaters.
  • the electric heater 601 is configured to emit (e.g., radiate) heat.
  • heat may be generated when electricity is circulated through the electric heater 601 as indicated by the arrow 603 in FIG. 6.
  • heat radiated from the electric heater 601 may travel along the thermal control path 253.
  • the electric heater 601 may be designed to quickly tune in the desired heat output to quickly modify the heat being supplied to the molten material. For instance, in some embodiments the heater may be designed to be rotated about an axis to immediately change the radiative heat being supplied to the molten material exiting the slot of the pipe.
  • the electric heater 601 may comprise a coil extending along a plane including a length 605a (see FIG. 6) and a width 605b (see FIG. 9) that is less than the length 605a.
  • the wall passage 249 can also comprise a slot including a length 607a and a width 607b that is less than the length.
  • the width 607b can extend in the flow direction 208 of the flow passage 207 although the length 607a may extend in the flow direction 208 of the flow passage 207 in further embodiments.
  • the electric heaters 601 may be positioned in an aligned position as shown by 601a in FIG. 6 and 601b, 601c, and 601d in FIG. 9, wherein the length 605a of the coil of the electric heater and the length 607a of the wall opening 249 extend in the same direction. In such position, the thermal control path 253 of the electric heater 601 can be fully exposed to the underlying molten material through the slot to permit maximum heating of the molten material.
  • the electric heater 601 may be at least partially rotated about an axis in direction 609 to at least partially misalign the length 605a of the electric heater 601 with the length 607a of the wall opening 249.
  • the electric heater 601a shown in FIG. 6 may be rotated from the aligned position shown in FIG. 6 (e.g., by 90 degrees) where the length 605a of the electric heater 601a is aligned with the length 607a of the wall opening to the misaligned position shown in FIG. 9, where the length 605a of the electric heater 601a extends in the direction of the width 607b of the wall opening 249.
  • the housing wall 241 of the housing 240 blocks relatively more radiative heat transfer from the electric heater 601a that would otherwise be blocked in the aligned position shown in FIG. 6. Allowing modification of the transfer by rotating the electric heater can provide the technical benefit of immediately reducing the radiative heat transfer being supplied by the electric heater without the need to wait for the heating element to cool off to modify heat transfer radiating from the heating element.
  • the electric heater 601 may comprise a metal or a refractory material (e.g., ceramic).
  • metals include chromium, molybdenum, tungsten, platinum, platinum, rhodium, iridium, osmium, palladium, ruthenium, gold, and combinations (e.g., alloys) thereof.
  • Additional exemplary embodiments of metals include nickel-chromium alloys (e.g., ni chrome), iron-chromium-aluminum alloys, and platinum alloys as described above.
  • Exemplary embodiments of ceramics include silicon carbide, chromium disilicide (CrSh), molybdenum disilicide (MoSh), tungsten disilicide (WSh), lanthanum chromite, alumina, barium titanate, lead titanate, zirconia, yttrium oxide, and combinations thereof.
  • the electric heater 601 can comprise platinum or a platinum alloy.
  • the electric heater 601 can comprise silicon carbide.
  • the electric heater 601 can comprise molybdenum disilicide.
  • the electric heater 601 can comprise lanthanum chromite.
  • the thermal control device 251 can comprise a laser (e.g., laser diode 701, laser 801, laser 1001).
  • the laser can comprise a gas laser, an excimer laser, a dye laser, or a solid-state laser.
  • gas lasers include helium, neon, argon, krypton, xenon, helium-neon (HeNe), xenon-neon (XeNe), carbon dioxide (CO2), copper (Cu) vapor, gold (Au) vapor, cadmium (Cd) vapor, ammonia, hydrogen fluoride (HF), and deuterium fluoride (DF).
  • Example embodiments of excimer lasers include chlorine, fluorine, iodine, or dinitrogen oxide (N2O) in an inert environment comprising argon (Ar), krypton (Kr), xenon (Xe), or a combination thereof.
  • Example embodiments of dye lasers include those using organic dyes such as rhodamine, fluorescein, coumarin, stilbene, umbelliferone, tetracene, or malachite green dissolved in a liquid solvent.
  • Example embodiments of solid-state lasers include crystal lasers, fiber lasers, and laser diodes. Crystal-based lasers comprise a host crystal doped with a lanthanide or a transition metal.
  • Example embodiments of host crystals include yttrium aluminum garnet (YAG), yttrium lithium fluoride (YLF), yttrium orthoaluminate (YAL), yttrium scandium gallium garnet (YSSG), lithium aluminum hexafluoride (LiSAF), lithium calcium aluminum hexafluoride (LiCAF), zinc selenium (ZnSe), ruby, forsterite, and sapphire.
  • YAG yttrium aluminum garnet
  • YLF yttrium lithium fluoride
  • YAL yttrium orthoaluminate
  • YSSG yttrium scandium gallium garnet
  • LiSAF lithium aluminum hexafluoride
  • LiCAF lithium calcium aluminum hexafluoride
  • ZnSe zinc selenium
  • ruby forsterite, and sapphire.
  • Example embodiments of dopants include neodymium (Nd), titanium (Ti), chromium (Cr), iron (Fe), erbium (Er), holmium (Ho), thulium (Tm), ytterbium (Yb), dysprosium (Dy), cerium (Ce), gadolinium (Gd), samarium (Sm), and terbium (Tb).
  • Example embodiments of solid crystals include ruby, alexandrite, chromium fluoride, forsterite, lithium fluoride (LiF), sodium chloride (NaCl), potassium chloride (KC1), and rubidium chloride (RbCl).
  • Laser diodes can comprise heterojunction or PIN diodes with three or more materials for the respective p-type, intrinsic, and n-type semiconductor layers.
  • Example embodiments of laser diodes include AlGalnP, AlGaAs, InGaN, InGaAs, InGaAsP, InGaAsN, InGaAsNSb, GalnP, GaAlAs, GalnAsSb, and lead (Pb) salts.
  • Some laser diodes can represent exemplary embodiments because of their size, tunable output power, and ability to operate at room temperature (e.g., about 20°C to about 25°C).
  • fiber lasers comprise an optical fiber further comprising a cladding with any of the materials listed above for crystal lasers or laser diodes.
  • the laser e.g., laser diode 701, laser 801, laser 1001 is configured to emit a laser beam comprising a wavelength.
  • the laser e.g., laser diode 701, laser 801, laser 1001 may be operated such that the wavelength of the laser beam is reduced by half (i.e., frequency doubled), reduced by two-thirds (i.e., frequency tripled), reduced by three-fourths (i.e., frequency quadrupled), or otherwise modified relative to a natural wavelength of a laser beam produced by the laser.
  • the wavelength of the laser beam may be about 760 nanometers (nm) or more, about 900 nm or more, about 980 nm or more, about 5,000 nm or less, about 4,000 nm or less, about 3,000 nm, or less, about 1,700 nm or less, about 1,660 nm or less, about 1,570 nm or less, about 1,330 nm or less, or about 1,100 nm or less.
  • the wavelength of the laser beam may be in a range from about 760 nm to about 5,000 nm, from about 760 nm to about 4,000 nm, from about 760 nm to about 3,000 nm, from about 760 nm to about 1,700 nm, from about 760 nm to about 1,660 nm, from about 760 nm to about 1,570 nm, from about 760 nm to about 1,330 nm, from about 760 nm to about 1,100 nm, from about 900 nm to about 5,000 nm, from about 900 nm to about 4,000 nm, from about 900 nm to about 3,000 nm, from about 900 nm to about 1,700 nm, from about 900 nm to about 1,660 nm, from about 900 nm to about 1,570 nm, from about 900 nm to about 1,330 nm, from about 900 nm to about 1,100 nm, from about
  • Exemplary embodiments of a laser diode capable of producing a laser beam with a wavelength within the aforementioned ranges include an AlGaAs, an InGaAsP, an InGaAsN laser diode.
  • Exemplary embodiments of a laser (other than a diode laser) (e.g., laser 801, laser 1001) capable of producing a laser beam with a wavelength within the aforementioned ranges include a He-Ne gas laser, an Ar gas laser, an iodine excimer laser, a Nd-doped YAG solid-state laser, a Nd-doped YLF solid-state laser, a Nd- doped YAP solid-state laser, a Ti-doped sapphire solid-state laser, a Cr-doped LiSAF solid-state laser, a chromium fluoride solid-state laser, a forsterite solid-state laser, a LiF solid-state laser, and a NaCl solid-state laser.
  • a laser other than a diode laser
  • laser 801, laser 1001 capable of producing a laser beam with a wavelength within the aforementioned ranges include a He-Ne gas laser, an Ar gas laser, an iod
  • Exemplary embodiments of a laser that can produce a laser beam with a wavelength within the aforementioned ranges when frequency-doubled include a XeNe gas laser, a HF gas laser, a Ho-doped YAG solid-state laser, an Er-doped YAG solid-state laser, a Tm-doped YAG solid-state laser, a KC1 solid-state laser, a RbCl solid-state laser, and an AlGaln laser diode.
  • a laser e.g., laser diode 701, laser 801, laser 1001
  • a laser e.g., laser diode 701, laser 801, laser 1001
  • Exemplary embodiments of a laser e.g., laser 801, laser 1001 that can produce a laser beam with a wavelength within the aforementioned ranges when frequency-tripled include a HeNe gas laser, a DF gas laser, and a Pb salt laser diode.
  • the laser e.g., laser diode 701, laser 801, laser 1001
  • the molten material 121 may comprise an absorption depth at a wavelength of a laser beam.
  • an absorption depth of a material is defined as a thickness of the material at which an intensity (e.g., power, power density) of a laser beam decreases to 36.8 % (i.e., 1/e) of an initial intensity of the laser beam.
  • an absorption depth of the laser beam in the molten material 121 at a wavelength of the laser beam can be about 50 pm or more, about 500 pm or more, about 1,000 pm or more, about 2,000 pm or more, about 5,000 pm or more, about 10,000 pm or less, about 5,000 pm or less, or about 2,000 pm or less.
  • an absorption depth of the laser beam in the molten material 121 at a wavelength of the laser beam can be in a range from about 50 pm to about 10,000 pm, from about 500 pm to about 10,000 pm, from about 1,000 pm to about 10,000 pm, from about 2,000 pm to about 10,000 pm, from about 5,000 pm to about 10,000 pm, from about 50 pm to about 5,000 pm, from about 500 pm to about 5,000 pm, from about 1,000 pm to about 5,000 pm, from about 2,000 pm to about 5,000 pm, from about 50 pm to about 2,000 pm, from about 500 pm to about 2,000 pm, from about 1,000 pm to about 2,000 pm, or any range or subrange therebetween.
  • a mirror e.g., mirror 803, polygonal mirror 1003 can be configured to reflect the laser beam emitted from the laser (e.g., laser 801, 1001) so that the laser beam impinges the molten material 121 at a location 315 (see FIG. 3) where the thermal control path 253 intersects the molten material 121.
  • the mirror e.g., mirror 803, polygonal mirror 1003 is configured to be rotatable such that can be configured to reflect the laser beam emitted from the laser (e.g., laser 801, 1001) scans the footprint 301 (see FIG. 3).
  • the mirror 803 can be rotatable using a galvanometer 805.
  • the galvanometer 805 can be configured to rotate in a first direction 807.
  • rotating the mirror 803 with the galvanometer 805 in a first direction 807 may cause the laser beam to scan a length of the pipe 201 (e.g., slot 203) in a direction substantially opposite to the flow direction 208 (see FIG. 4).
  • the galvanometer 805 can be configured to rotate in a second direction 809 opposite the first direction 807.
  • rotating the mirror 803 with the galvanometer 805 in a second direction 809 may cause the laser beam to scan a length of the pipe 201 (e.g., slot 203) in a direction substantially parallel to the flow direction 208 (see FIG. 4).
  • the galvanometer can be configured to alternate between rotating in both a first direction 807 and rotating in a second direction 809 opposite the first direction 807.
  • the mirror can comprise a polygonal mirror 1003.
  • the polygonal mirror 1003 can comprise a plurality of reflective surfaces.
  • the polygonal mirror 1003 may be rotated by a motor 1005 to rotate in a first direction 1007 about a rotation axis 1009 of the polygonal mirror 1003.
  • rotating the polygonal mirror 1003 with the motor 1005 in a first direction 1007 may cause the laser beam to scan a length of the pipe 201 (e.g., slot 203) in a direction substantially opposite to the flow direction 208 (see FIG. 4).
  • a length of the pipe 201 e.g., slot 203
  • the motor 1005 may optionally be operated by a control device 1015 (e.g., programmable logic controller) configured to (e.g., “programmed to”, “encoded to”, “designed to”, and/or “made to”) send command signals along communication line 1017 to the motor 1005 to rotate, in some embodiments, at a substantially constant angular velocity about the rotation axis 1009 of the polygonal mirror 1003.
  • a control device 1015 e.g., programmable logic controller
  • the laser e.g., laser 801, 1001
  • the laser can be configured to produce a pulsed laser beam.
  • the laser 1001 may be optionally operated by a control device 1011 (e.g., programmable logic controller) configured to (e.g., “programmed to”, “encoded to”, “designed to”, and/or “made to”) send command signals along communication line 1013 to the laser.
  • control device 1011 or 1015 and corresponding communication line 1013 or 1017 can be combined with the laser 801 and/or galvanometer 805 in FIG. 8, respectively.
  • a laser beam is emitted from the laser 801 or 1001, reflected by a mirror (e.g., mirror 803, polygonal mirror 1003), and travels along the thermal control path 253 through the wall passage 249 to scan a length of the pipe 201 (e.g., slot 203).
  • the length scanned may be about 10% or more, about 25% or more, about 50% or more, about 100% or less, about 75% or less, or about 50% or less of the length 401 of the slot 203 (see FIG. 4).
  • the length scanned as a percentage of the length 401 of the slot 203 see FIG.
  • the length scanned may be substantially equal to the length 401 of the slot 203 (see FIG. 4).
  • the shape of the wall passage 249 may correspond to the arc swept out the laser beam traveling along the thermal control path 253 after reflecting off the rotating mirror (e.g., mirror 803, polygonal mirror 1003).
  • the laser e.g., laser diode 701
  • the optical fiber 703 can comprise a first end 705 and a second end 707 opposite the first end 705.
  • the laser can comprise a laser diode 701 optically coupled to a first end 705 of the optical fiber 703, and the second end 707 of the optical fiber can face the slot 203.
  • the optical fiber 703 may partially extend through the wall passage 249.
  • the first end 705 may not extend through or into the wall passage 249.
  • the first end 705 may be spaced a distance outside of the wall passage 249 without the optical fiber 703 extending within the wall passage 249. In further embodiments, the first end 705 may be positioned within the interior region 247 with the optical fiber 703 extending through the wall passage 249.
  • the optical fiber 703 can comprise a plurality of optical fibers 703a-d. In further embodiments, each optical fiber of the plurality of optical fibers 703a-d can comprise a first end 705a-d optically coupled to a laser (e.g., lasers 701a-d).
  • each optical fiber of the plurality of optical fibers 703a-d can comprise a second end 707a-d facing the slot 203.
  • one or more of the plurality of optical fibers 703a-d can partially extend through the wall passage 249a- d, be positioned within the interior region 247 or outside the interior region 247.
  • the length of an optical fiber is defined as the distance between a first point at the first end 705 of the optical fiber 703 and a second point at the second end 707 of the optical fiber 703 when the optical fiber 703 is straightened so that it is aligned with an elongated axis and the first point and the second point are as far apart as possible.
  • the first point and the second point are as far apart as possible.
  • the optical fiber 703 can comprise a plurality of optical fibers 703a-d that can each include a length defined as the distance between a first end 705a-d of an optical fiber of the plurality of optical fibers 703a-d and a second end 707a-d of the corresponding optical fiber 703a-d when the optical fiber 703a-d is straightened so that it is aligned with an elongated axis.
  • the length of the optical fiber 703 (e.g., the length of an optical fiber of the plurality of optical fibers 703a-d) may be about 100 mm or more, about 1 m or more, about 2 m or more, about 5 m or more, about 1,000 m or less, about 50 m or less, about 30 m or less, about 20 m or less, or about 10 m or less.
  • the length of the optical fiber 703 may be in a range from about 100 mm to about 1,000 m, from about 100 mm to about 50 m, from about 100 mm to about 30 m, from about 100 mm to about 20 m, from about 100 mm to about 10 m, from about 1 m to about 1,000 m, from about 1 m to about 50 m, from about 1 m to about 30 m, from about 1 m to about 20 m, from about 1 m to about 10 m, from about 2 m to about 30 m, from about 2 m to about 20 m, from about 2 m to about 10m, or from about 5 m to about 10 m.
  • all the optical fibers of the plurality of optical fibers 703a-d may comprise substantially the same length. In other embodiments, at least one of the optical fibers of the plurality of optical fibers 703a-d may comprise a different length than another optical fiber of the plurality of optical fibers.
  • the optical fiber 703 (e.g., each optical fiber of the plurality of optical fibers 703a-d) can comprise a core (e.g., center) comprising an optical material.
  • a width of the core of an optical fiber is defined as a distance between a first point at a second end of the optical fiber and a second point at the second end of the optical fiber, where the first point and the second point comprise the same material as the center of the second end of the fiber and the first point and the second point are as far apart as possible.
  • the width of the core of an optical fiber can be equal to the diameter when the core of the second end of the optical fiber is circular.
  • the width of the core of the optical fiber 703 can be about 1 pm or more, about 5 pm or more, about 9 pm or more, about 50 pm or more, about 62.5 pm or more, about 550 pm or less, about 490 pm or less, about 400 pm or less, about 360 pm or less, about 255 pm or less, or about 145 pm or less.
  • the width of the core of the optical fiber 703 can be in a range from about 1 pm to about 550 pm, from about 1 pm to about 490 pm, from about 1 pm to about 400 pm, from about 1 pm to about 360 pm, from about 1 pm to about 255 pm, from about 1 pm to about 145 pm, from about 5 pm to about 550 pm, from about 5 pm to about 490 pm, from about 5 pm to about 255 pm, from about 9 pm to about 550 pm, from about 9 pm to about 490 pm, from about 9 pm to about 400 pm, from about 9 pm to about 360 pm, from about 9 pm to about 250 pm, from about 9 pm to about 144 pm, from about 50 pm to about 550 pm, from about 50 pm to about 490 pm, from about 50 pm to about 400 pm, from about 50 pm to about 144 pm, from about 62.5 pm to about 550 pm, from about 62.5 pm to about 550 pm, from about 62.5 pm to about 490 pm, from about 62.5 pm to about 400 pm, from about 62.5 pm to about 144 pm
  • the optical material in the core of the optical fiber 703 may comprise sapphire, fused silica, quartz, or a combination thereof.
  • the optical material may be doped with an optical amplifier such as erbium (Er), ytterbium (Yb), neodymium (Nd), or germanium dioxide (GeO?).
  • the optical fiber 703 may comprise a cladding surrounding the core.
  • the cladding may comprise a lower refractive index than a refractive index of the core.
  • the cladding may comprise fused silica, quartz, sapphire, or gas, for example, air, nitrogen, or argon.
  • the cladding may comprise any of the material listed above for laser diodes or crystal lasers. Doping, cladding, or a combination of the two may be desirable to modify the amplitude of a laser beam being transmitted by the optical fiber 703 (e.g., the optical fiber may be a fiber laser).
  • the core of the optical fiber 703 may comprise a circular cross-section.
  • An optical fiber with a core comprising a circular cross-section can provide the laser beam exiting the second end 707 of the optical fiber 703 with a smooth (e.g., homogenous and symmetric) intensity profile.
  • the first end 705 of the optical fiber 703 may comprise a circular cross-section
  • the second end 707 of the optical fiber 703 may comprise a circular cross-section.
  • Providing the optical fiber 703 with a circular cross-section can, in some embodiments, be used with a wall passage 249 and/or tube 503 (see FIG. 5) with a circular cross-section.
  • the laser e.g., laser diode 701
  • the laser can comprise a plurality of lasers 701a-d. In some embodiments, there may be 1 or more, 2 or more, 4 or more, 9 or more, 100 or less, 50 or less, 40 or less, 30 or less, or 20 or less lasers in the plurality of lasers.
  • the number of lasers in the plurality of lasers can be from 1 to 100, from 1 to 50, from 1 to 40, from 1 to 30, from 1 to 20, from 2 to 100, from 2 to 50, from 2 to 40, from 2 to 30, from 2 to 20, from 4 to 100, from 4 to 50, from 4 to 40, from 4 to 30, from 4 to 20, from 9 to 100, from 9 to 50, from 9 to 40, from 9 to 30, or from 9 to 20.
  • FIG. 1 as shown in FIG.
  • the number of lasers in the plurality of lasers 701a-d may be equal to the number of optical fibers in the plurality of optical fibers 703a-d, and each laser of the plurality of lasers 701a-d can be optically coupled to a corresponding optical fiber of the plurality of optical fibers 703a-d. In some embodiments, although not shown, the number of lasers of the plurality of lasers may be less than the number of optical fibers of the plurality of optical fibers. As shown, in some embodiments, each laser of the plurality of lasers 701a-d can be optically coupled to the first end 705a-d of a respective optical fiber 703a-d.
  • each corresponding laser of the plurality of lasers 701a-d can be transmitted into the first end 705a-d of the optical fiber 703a-d, through the length of the optical fiber 703a-d, and out the second end 707a-d of the corresponding optical fiber of the plurality of optical fibers 703a-d.
  • each laser of the plurality of lasers 701a-d can be optically coupled to each corresponding first end 705a-d of the optical fiber of the plurality of optical fibers 703a-i without a lens or other optics positioned therebetween.
  • a lens or other optical component can be placed between the laser 701a-d and the first end 705a-d of the optical fiber 703a-d to direct the laser beam to the core (e.g., center) of the first end 705a-d of the optical fiber 703a-d. It can be desirable to direct the laser beam to the core of the first end 705a-d of the optical fiber 703a-d, which can reduce an attenuation (i.e., loss of intensity) of the laser beam while the laser beam is transmitted from the first end 705a-d to the second end 707a- d of the optical fiber 703a-d.
  • a focal length of the lens can be chosen to desirably couple the laser beam from the laser 701a-d into the first end 705a-d of the optical fiber 703a-d based on properties (e.g., a diameter of a portion of the core, a numerical aperture) of the optical fiber 703a-d, and properties (e.g., divergence) of the laser 701a-d, and the distance from the laser 701a-d to the lens as well as the distance from the lens to the first end 705a-d of the optical fiber 703a-d.
  • properties e.g., a diameter of a portion of the core, a numerical aperture
  • properties e.g., divergence
  • the lens may be a spherical lens, which can be desirable if the laser 701a-d (e.g., a laser diode) generates a homogenous (i.e., no astigmatism) laser beam.
  • the lens may be aspheric (e.g., elliptical) correct any astigmatism of the laser beam.
  • optically coupling the laser 701a-d to the first end 705a-d of the optical fiber 703a-d may comprise a beam splitter and a relay fiber.
  • An exemplary embodiment of a beam splitter can be a fiber optical coupler that acts as a beam splitter for a laser beam within an optical fiber or a relay fiber.
  • Other example embodiments of a beam splitter can act on a laser beam outside of an optical fiber or a relay fiber and comprise a metal-coated mirror (e.g., half-silvered mirror), or a pellicle, or a waveguide. It is to be understood that a beam splitter can be used with any of the embodiments discussed above.
  • the distance of the lens to the first end 705a-d of the optical fiber 703a-d may be varied to control a fraction of the laser beam coupled into the optical fiber 703a-d.
  • the optical fibers 703a-d can comprise single-mode optical fibers. In some embodiments, the optical fibers 703a-d can comprise multi-mode fibers. In some embodiments, although not shown, a purge gas (e.g., any of the gases listed for the gas nozzle) can be circulated to reduce (e.g., mitigate, prevent) condensation on optical elements associated with the laser.
  • a purge gas e.g., any of the gases listed for the gas nozzle
  • a power density and/or size of the laser beam impinging on a portion of the molten material 121 can be achieved in a wide range of ways such as one or more of: adjusting a position of the second end 707 of the optical fiber 703, the type of optical element, or a position of the optical element.
  • a width of a laser beam impinging on a portion of molten material 121 is defined as the distance between a first point on the molten material 121 impinged by the laser beam and a second point on the molten material 121 impinged by the laser beam with an intensity of about 13.5 % (i.e., 1/e 2 ) of a maximum intensity of the laser beam at a location on the molten material 121, where the first point and the second point are as far apart as possible.
  • the maximum width of the laser beam can be about 100 pm or more, about 500 pm or more, about 1 mm or more, about 5 mm or more, about 10 mm or more, about 30 mm or less, or about 15 mm or less. In some embodiments, the maximum width of the laser beam can be in a range from about 100 pm to about 30 mm, from about 100 pm to about 15 mm, from about 500 pm to about 30 mm, from about 500 pm to about 15 mm, from about 1 mm to about 30 mm, from about 1 mm to about 15 mm, from about 5 mm to about 30 mm, from about 5 mm to about 15 mm, from about 10 mm to about 30 mm, or any range or subrange therebetween.
  • an area of the molten material 121 impinged by a laser beam is defined as a portion of the molten material 121 impinged by the laser beam with an intensity of about 13.5 % (i.e., 1/e 2 ) of a maximum intensity of the laser beam, where the area is measured at a surface of the molten material 121 closest to the second end 707 of the optical fiber 703.
  • the power of a laser beam is the average power of the laser beam transmitted from a second end 707 of an optical fiber 703 as measured using a thermopile.
  • a power of the laser beam can be controlled by controlling optical elements between the laser (e.g., laser diode 701) and the second end 707 of the optical fiber 703.
  • a power of the laser beam can be controlled by adjusting the parameters of the laser (e.g., electrical current or voltage, optical pumping conditions).
  • a power density of a laser beam is the power of the laser beam divided by the area of the molten material 121 impinged by the laser beam, as defined above.
  • the power density of the laser beam can be about 1 watt/centimeter 2 (W/cm 2 ) or more, about 5 W/cm 2 or more, about 10 W/cm 2 or more, about 2,000 W/cm 2 or less, about 1,000 W/cm 2 or less, about 500 W/cm 2 or less, about 100 W/cm 2 or less, or about 50 W/cm 2 or less.
  • the power density of the laser beam can be in a range from about 1 W/cm 2 to about 2,000 W/cm 2 , from about 1 W/cm 2 to about 1,000 W/cm 2 , from about 1 W/cm 2 to about 500 W/cm 2 , from about 1 W/cm 2 to about 100 W/cm 2 , from about 1 W/cm 2 to about 50 W/cm 2 , from about 5 W/cm 2 to about 2,000 W/cm 2 , from about 5 W/cm 2 to about 1,000 W/cm 2 , from about 5W/cm 2 to about 500 W/cm 2 , from about 5 W/cm 2 to about 100 W/cm 2 , from about 5 W/cm 2 to about 50 W/cm 2 , from about 10 W/cm 2 to about 2,000 W/cm 2 , from about 10 W/cm 2 to about 1,000 W/cm 2 , from about 10 W/cm 2 to about 500 W/cm 2 , from about 1 W
  • Methods of manufacturing glass from a quantity of molten material 121 using any of the glass manufacturing apparatus 100 discussed above can include flowing the molten material 121 along a flow direction 208 of a flow passage 207 defined by of the pipe wall 205 of a pipe 201.
  • a slot 203 can extend through the pipe wall 205.
  • the slot 203 can comprise a footprint 301 that can be circumscribed by the outer periphery 303 of the slot 203.
  • Methods can further include flowing the molten material 121 through the footprint 301 of the slot 203 from the flow passage 207 of the pipe 201.
  • Methods can further comprise operating a thermal control device 251.
  • the thermal control device 251 can comprise one or more of a gas nozzle, an electric heater, and a laser (e.g., laser diode).
  • the thermal control device 251 can define a thermal control path 253.
  • the projection of the thermal control path 253 can intersect the footprint 301 and can circumscribe the footprint 301.
  • Methods can further comprise adjusting a temperature of the molten material 121 at a location 315 where the thermal control path 253 intersects the molten material 121.
  • the location 315 can be located entirely within a projection 317 of the footprint 301 extending outwardly from the slot 203 in an outward direction 319 perpendicular to the flow direction 208.
  • adjusting the temperature of the molten material 121 at the location 315 can comprise decreasing the temperature of the molten material 121.
  • operating the thermal control device 251 can comprise ejecting gas 507 from a gas nozzle 501. Decreasing the temperature of the molten material 121 at the location 315 can increase the viscosity of the molten material 121 at the location; thereby decreasing the mass flow rate of the molten material 121 at the location.
  • adjusting the temperature of the molten material 121 at the location 315 can comprise increasing the temperature of the molten material 121.
  • operating the thermal control device 251 can comprise circulating electricity through an electric heater 601 as shown by arrow 603.
  • methods can further comprise rotating the electric heater about an axis in direction 609 to adjust the radiative heat transfer applied by the electric heater, thereby tuning the temperature and corresponding viscosity and mass flow of the molten material at the location 315.
  • operating the thermal control device 251 can comprise emitting a laser beam from a laser (e.g., laser diode 701, laser 801, laser 1001).
  • the laser beam can comprise an absorption depth in the molten material 121 that can be within the ranges discussed above (e.g., from about 50 pm to about 10 mm).
  • the laser beam can comprise a wavelength that can be within the ranges discussed above (e.g., from about 760 nm to about 5,000 nm).
  • methods can further comprise scanning the laser beam across a length of the slot 203. In even further embodiments, as shown in FIGS.
  • methods can comprise reflecting the laser beam emitted from the laser (e.g., laser diode 701, laser 801, laser 1001) off a mirror (e.g., mirror 803, polygonal mirror 1003).
  • methods can comprise rotating the mirror (e.g., mirror 803, polygonal mirror 1003) using a galvanometer 805.
  • the mirror can comprise a polygonal mirror 1003. Increasing the temperature of the molten material 121 at the location 315 can decrease the viscosity of the molten material 121 at the location. Increasing the temperature of the molten material 121 at the location 315 can increase the mass flow rate of the molten material 121 at the location.
  • methods can further comprise flowing a first stream 211 of molten material 121 from a location 315, where the thermal control path 253 intersects the molten material 121, in a first direction along a first outer surface 223 of the forming device 140.
  • methods can further comprise flowing a second stream 212 of molten material 121 from the location 315 in a second direction along a second outer surface 224 of the forming device 140.
  • methods can comprise converging the first stream 211 of molten material 121 and the second stream 212 of molten material 121 to form a glass ribbon 103.
  • the glass ribbon 103 can traverse along draw direction 154 at about 1 millimeter per second (mm/s) or more, about 10 mm/s or more, about 50 mm/s or more, about 100 mm/s or more, or about 500 mm/s or more, for example, in a range from about 1 mm/s to about 500 mm/s, from about 10 mm/s to about 500 mm/s, from about 50 mm/s to about 500 mm/s, from about 100 mm/s to about 500 mm/s, and all ranges and subranges therebetween.
  • the glass separator 149 (see FIG. 1) can then separate the glass sheet from the glass ribbon 103 along the separation path 151.
  • the separation path 151 can extend along the width “W” of the glass ribbon 103 between the first outer edge 153 and the second outer edge 155. Additionally, in some embodiments, the separation path 151 can extend perpendicular to the draw direction 154 of the glass ribbon 103. Moreover, in some embodiments, the draw direction 154 can define a direction along which the glass ribbon 103 can be drawn from the forming device 140.
  • the glass ribbon 103 can be drawn from the root 235 with a first major surface 215 of the glass ribbon 103 and a second major surface 216 of the glass ribbon 103 facing opposite directions and defining a thickness 227 (e.g., average thickness) of the glass ribbon 103.
  • the thickness 227 of the glass ribbon 103 can be about 2 millimeters (mm) or less, about 1.5 mm or less, about 1.2 mm or less, about 1 mm or less, about 0.5 mm or less, about 300 micrometers (pm) or less, or about 200 pm or less, although other thicknesses may be provided in further embodiments.
  • the thickness 227 of the glass ribbon 103 can be about 100 pm or more, about 200 pm or more, about 300 pm or more, about 600 pm or more, about 1 mm or more, about 1.2 mm or more, or about 1.5 mm or more, although other thicknesses may be provided in further embodiments.
  • the thickness 227 of the glass ribbon 103 can be in a thickness range from about 100 pm to about 2 mm, from about 200 pm to about 2 mm, from about 300 pm to about 2 mm, from about 600 pm to about 2 mm, from about 1mm to about 2 mm, from about 100 pm to about 1.5 mm, from about 200 pm to about 1.5 mm, from about 300 pm to about 1.5 mm, from about 600 pm to about 1.5 mm, from about 1 mm to about 1.5 mm, from about 100 pm to about 1.2 mm, from about 200 pm to about 1.2 mm, from about 600 pm to about 1.2 mm, or any range or subrange of thicknesses therebetween.
  • Exemplary molten materials which may be free of lithia or not, comprise soda lime molten material, aluminosilicate molten material, alkali- aluminosilicate molten material, borosilicate molten material, alkali-borosilicate molten material, alkali-alumniophosphosilicate molten material, and alkali- aluminoborosilicate glass molten material.
  • a molten material 121 may comprise, in mole percent (mol %): S1O2 in a range from about 40 mol % to about 80%, AI2O3 in a range from about 10 mol % to about 30 mol %, B2O3 in a range from about 0 mol % to about 10 mol %, ZrCh in a range from about 0 mol% to about 5 mol %, P2O5 in a range from about 0 mol % to about 15 mol %, T1O2 in a range from about 0 mol % to about 2 mol %, R2O in a range from about 0 mol % to about 20 mol %, and RO in a range from 0 mol % to about 15 mol %.
  • R2O can refer to an alkali metal oxide, for example, LhO, Na 2 0, K2O, Rb 2 0, and CS2O.
  • RO can refer to MgO, CaO, SrO, BaO, and ZnO.
  • a molten material 121 may optionally further comprise in a range from about 0 mol % to about 2 mol % of each of Na 2 S0 4 , NaCl, NaF, NaBr, K2SO4, KC1, KF, KBr, AS2O3, Sb 2 0 3 , Sn02, Fe20 3 , MnO, Mhq2, Mh0 3 , Mh2q 3 , Mh 3 q4, Mh2q7.
  • the glass ribbon 103 and/or glass sheets formed from the may be transparent, meaning that the glass ribbon 103 drawn from the molten material 121 can comprise an average light transmission over the optical wavelengths from 400 nanometers (nm) to 700 nm of about 85% or greater, about 86% or greater, about 87% or greater, about 88% or greater, about 89% or greater, about 90% or greater, about 91% or greater, or about 92% or greater.
  • Embodiments of the disclosure herein can provide the technical benefits of adjusting the mass flow rate, viscosity, and/or temperature of molten material leaving a slot of a pipe of a forming device using a thermal control device.
  • Embodiments of the disclosure can provide localized control and/or adjustment of the mass flow rate, viscosity, and/or temperature of the molten material.
  • the location where the mass flow rate, viscosity, and/or temperature of molten material can be controlled may be entirely within a projection of a footprint defined by an outer periphery of the slot.
  • the heating device or multiple heating devices may be provided (e.g., see FIGS.
  • any of the embodiments of the disclosure to allow adjustment of the heating profile along the length 401 of the slot 203 to provide a desired temperature profile along the location 315 and thereby provide a desired viscosity and corresponding mass flow rate profile of the molten material at the location 315. Adjusting the mass flow rate profile can provide for a desired thickness profile of the glass ribbon being drawn from the forming device. Additionally, acting on the molten material leaving the slot can reduce the need for additional thermal control later in the glass manufacturing process. A design of the slot can be used to reduce the region where the thermal control device acts on the molten material.
  • Embodiments comprising thin pipe walls can reduce the thermal mass of the forming device around the location where the thermal control device acts on the molten material, which can increase the effect of the thermal control device.
  • adjusting the mass flow rate, viscosity, and/or temperature of the molten material can also permit simultaneous control of both a first stream of molten material and a second stream of molten material.
  • Providing the forming device within an interior region of a housing can reduce (e.g., minimize, prevent) uncontrolled heat loss and/or thermal currents from impacting the quality of the glass ribbons produced while increasing the localization of the effect of the thermal control device.
  • Providing a passage through the wall of the housing can allow a thermal control device positioned at least partially positioned outside of the interior region to act on the molten material.
  • Providing the passage with a tube can further reduce uncontrolled heat loss and/or thermal current as well as permit adjustment (e.g., repositioning, removal, insertion, replacement) of the thermal control device.
  • Providing thermal insulators extending from an exterior surface of the wall of the housing can further localize the effect of the thermal control device.
  • the term “about” means that amounts, sizes, formulations, parameters, and other quantities and characteristics are not and need not be exact, but may be approximate and/or larger or smaller, as desired, reflecting tolerances, conversion factors, rounding off, measurement error and the like, and other factors known to those of skill in the art. Ranges can be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, embodiments include from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint and independently of the other endpoint.
  • substantially is intended to note that a described feature is equal or approximately equal to a value or description.
  • a “substantially planar” surface is intended to denote a surface that is planar or approximately planar.
  • substantially similar is intended to denote that two values are equal or approximately equal. In some embodiments, “substantially similar” may denote values within about 10% of each other, for example, within about 5% of each other, or within about 2% of each other.

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PCT/US2020/044828 2019-08-12 2020-08-04 Glass manufacturing apparatus and methods WO2021030097A1 (en)

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US20030037569A1 (en) * 2001-03-20 2003-02-27 Mehran Arbab Method and apparatus for forming patterned and/or textured glass and glass articles formed thereby
US20100319403A1 (en) * 2008-02-27 2010-12-23 Asahi Glass Company, Limited Vacuum degassing apparatus and vacuum degassing method for molten glass
WO2018052833A1 (en) * 2016-09-13 2018-03-22 Corning Incorporated Apparatus and method for processing a glass substrate

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TWI591026B (zh) * 2011-11-30 2017-07-11 康寧公司 用於自連續移動之玻璃帶移除邊緣部分之設備及方法
JP5921742B2 (ja) * 2014-03-29 2016-05-24 ＡｖａｎＳｔｒａｔｅ株式会社 ガラス板の製造方法、及び、ガラス板の製造装置
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CN107428581A (zh) * 2015-03-30 2017-12-01 安瀚视特控股株式会社 玻璃衬底的制造方法
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4466818A (en) * 1981-06-16 1984-08-21 U.S. Philips Corporation Double crucible method of fabricating optical fibers
US20010039814A1 (en) * 2000-05-09 2001-11-15 Pitbladdo Richard B. Sheet glass forming apparatus
US20030037569A1 (en) * 2001-03-20 2003-02-27 Mehran Arbab Method and apparatus for forming patterned and/or textured glass and glass articles formed thereby
US20100319403A1 (en) * 2008-02-27 2010-12-23 Asahi Glass Company, Limited Vacuum degassing apparatus and vacuum degassing method for molten glass
WO2018052833A1 (en) * 2016-09-13 2018-03-22 Corning Incorporated Apparatus and method for processing a glass substrate

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