WO2023204920A1 - Récipients en verre à stries colorées par utilisation d'injection de calcin - Google Patents
Récipients en verre à stries colorées par utilisation d'injection de calcin Download PDFInfo
- Publication number
- WO2023204920A1 WO2023204920A1 PCT/US2023/015767 US2023015767W WO2023204920A1 WO 2023204920 A1 WO2023204920 A1 WO 2023204920A1 US 2023015767 W US2023015767 W US 2023015767W WO 2023204920 A1 WO2023204920 A1 WO 2023204920A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- glass
- molten glass
- flow
- cullet
- forehearth
- Prior art date
Links
- 239000011521 glass Substances 0.000 title claims abstract description 172
- 239000006063 cullet Substances 0.000 title claims abstract description 111
- 238000002347 injection Methods 0.000 title description 2
- 239000007924 injection Substances 0.000 title description 2
- 239000006060 molten glass Substances 0.000 claims abstract description 205
- 239000000463 material Substances 0.000 claims abstract description 49
- 230000001143 conditioned effect Effects 0.000 claims abstract description 48
- 238000000034 method Methods 0.000 claims abstract description 47
- 238000002844 melting Methods 0.000 claims abstract description 38
- 230000008018 melting Effects 0.000 claims abstract description 38
- 239000000758 substrate Substances 0.000 claims abstract description 19
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 13
- 238000004519 manufacturing process Methods 0.000 claims abstract description 12
- 239000000203 mixture Substances 0.000 claims abstract description 12
- 239000000126 substance Substances 0.000 claims abstract description 10
- 239000000377 silicon dioxide Substances 0.000 claims abstract description 7
- 230000003750 conditioning effect Effects 0.000 claims description 49
- 239000007787 solid Substances 0.000 claims description 19
- 239000002245 particle Substances 0.000 claims description 18
- 239000005361 soda-lime glass Substances 0.000 claims description 16
- 238000007599 discharging Methods 0.000 claims description 5
- 238000010008 shearing Methods 0.000 claims 1
- 238000001816 cooling Methods 0.000 description 11
- 239000002994 raw material Substances 0.000 description 10
- 238000002485 combustion reaction Methods 0.000 description 9
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 description 8
- 238000005816 glass manufacturing process Methods 0.000 description 8
- 238000000137 annealing Methods 0.000 description 7
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 4
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 4
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 4
- 229910052681 coesite Inorganic materials 0.000 description 4
- 229910052906 cristobalite Inorganic materials 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 235000012239 silicon dioxide Nutrition 0.000 description 4
- 229910052682 stishovite Inorganic materials 0.000 description 4
- 239000010936 titanium Substances 0.000 description 4
- 229910052905 tridymite Inorganic materials 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 239000003086 colorant Substances 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
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- 238000011144 upstream manufacturing Methods 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 235000019738 Limestone Nutrition 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
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- 229910002092 carbon dioxide Inorganic materials 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
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- 230000007423 decrease Effects 0.000 description 2
- 239000006025 fining agent Substances 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000007496 glass forming Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000006028 limestone Substances 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 2
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 2
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 235000017550 sodium carbonate Nutrition 0.000 description 2
- 229910000029 sodium carbonate Inorganic materials 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 229910052691 Erbium Inorganic materials 0.000 description 1
- 229910052693 Europium Inorganic materials 0.000 description 1
- 229910052688 Gadolinium Inorganic materials 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910052777 Praseodymium Inorganic materials 0.000 description 1
- 239000006004 Quartz sand Substances 0.000 description 1
- BUGBHKTXTAQXES-UHFFFAOYSA-N Selenium Chemical compound [Se] BUGBHKTXTAQXES-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- 229910052770 Uranium Inorganic materials 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- 229910052785 arsenic Inorganic materials 0.000 description 1
- RQNWIZPPADIBDY-UHFFFAOYSA-N arsenic atom Chemical compound [As] RQNWIZPPADIBDY-UHFFFAOYSA-N 0.000 description 1
- 230000003190 augmentative effect Effects 0.000 description 1
- 229910052788 barium Inorganic materials 0.000 description 1
- DSAJWYNOEDNPEQ-UHFFFAOYSA-N barium atom Chemical compound [Ba] DSAJWYNOEDNPEQ-UHFFFAOYSA-N 0.000 description 1
- 238000000071 blow moulding Methods 0.000 description 1
- 229910052793 cadmium Inorganic materials 0.000 description 1
- BDOSMKKIYDKNTQ-UHFFFAOYSA-N cadmium atom Chemical compound [Cd] BDOSMKKIYDKNTQ-UHFFFAOYSA-N 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 235000017168 chlorine Nutrition 0.000 description 1
- 125000001309 chloro group Chemical class Cl* 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 230000006835 compression Effects 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000012809 cooling fluid Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 229910021488 crystalline silicon dioxide Inorganic materials 0.000 description 1
- 239000003712 decolorant Substances 0.000 description 1
- FZFYOUJTOSBFPQ-UHFFFAOYSA-M dipotassium;hydroxide Chemical compound [OH-].[K+].[K+] FZFYOUJTOSBFPQ-UHFFFAOYSA-M 0.000 description 1
- 239000010459 dolomite Substances 0.000 description 1
- 229910000514 dolomite Inorganic materials 0.000 description 1
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 1
- OGPBJKLSAFTDLK-UHFFFAOYSA-N europium atom Chemical compound [Eu] OGPBJKLSAFTDLK-UHFFFAOYSA-N 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 230000009969 flowable effect Effects 0.000 description 1
- 235000019000 fluorine Nutrition 0.000 description 1
- 125000001153 fluoro group Chemical group F* 0.000 description 1
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 1
- 230000009477 glass transition Effects 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000011133 lead Substances 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- 239000010955 niobium Substances 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 150000002823 nitrates Chemical class 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 239000006069 physical mixture Substances 0.000 description 1
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 1
- 239000002243 precursor Substances 0.000 description 1
- 239000002265 redox agent Substances 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 238000003303 reheating Methods 0.000 description 1
- 239000004576 sand Substances 0.000 description 1
- 229910052711 selenium Inorganic materials 0.000 description 1
- 239000011669 selenium Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 239000002893 slag Substances 0.000 description 1
- 229910052712 strontium Inorganic materials 0.000 description 1
- CIOAGBVUUVVLOB-UHFFFAOYSA-N strontium atom Chemical compound [Sr] CIOAGBVUUVVLOB-UHFFFAOYSA-N 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 239000011593 sulfur Substances 0.000 description 1
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- JFALSRSLKYAFGM-UHFFFAOYSA-N uranium(0) Chemical compound [U] JFALSRSLKYAFGM-UHFFFAOYSA-N 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B5/00—Melting in furnaces; Furnaces so far as specially adapted for glass manufacture
- C03B5/16—Special features of the melting process; Auxiliary means specially adapted for glass-melting furnaces
- C03B5/173—Apparatus for changing the composition of the molten glass in glass furnaces, e.g. for colouring the molten glass
Definitions
- the present disclosure is directed to glass container manufacturing and, more specifically, to methods for creating unique streaks of color in glass containers by introducing colored cullet into the glass flow within a forehearth of a glass furnace.
- Glass containers are typically manufactured by melting a batch material in a furnace or melter, fining and conditioning the molten glass to remove gas bubbles and thermally homogenize the glass, respectively, and then individually forming the containers in a glass forming machine such as, for example, an individual section forming machine that includes a blank mold and a blow mold.
- Soda-lime-silica glass which has a chemical composition that includes 60 wt% to 80 wt% SiC>2, 8 wt% to 18 wt% Na2 ⁇ D, and 5 wt% to 15 wt% CaO based on the total weight of the glass — is the predominant glass from which glass containers are formed.
- the batch material used to produce molten soda-lime-silica glass includes two components: (1) virgin raw materials such as sand, soda ash, limestone and other materials that contribute one or more SiCh. Na2O, CaO, and other desired chemical components to the glass when melted and reacted together, and (2) previously-formed glass known as “cullet.” While cullet may be obtained from a variety of sources, the cullet used in glass container manufacturing operations oftentimes includes post-consumer recycled glass obtained from recycling operations and/or post-industrial recycled glass including waste glass from the same or a different glass plant.
- Cullet is substituted for a portion of traditional virgin raw materials in the batch material to lower the amount of energy consumed and reduce the carbon footprint associated with each manufactured glass container.
- the addition of cullet to the batch material conserves energy since, in cullet, the endothermic chemical reactions required to produce glass have already been completed, meaning that less energy is required to remelt cullet than is required to melt the quantity of constituent virgin raw materials needed to produce a corresponding amount of molten glass.
- the use of cullet also preserves resources; indeed, any cullet that is added to the batch material necessarily conserves virgin raw materials, which is aided by the fact that the cycle of forming, recycling, and remelting glass can occur infinitely.
- remelting cullet reduces the amount of carbon dioxide produced for a given quantity of glass since less virgin raw materials, which tend to be carbonates that release CO2 when melted, arc included in the batch material. Still further, the inclusion of cullet in the batch material lowers the melting temperature of the batch material and renders the resultant molten glass less corrosive. In that regard, the operational life of certain equipment, most notably the furnace or melter, can be extended.
- Glass manufacturers may wish to visibly mark glass containers that have been formed from a batch material containing cullet or, perhaps more specifically, from a batch material that includes some minimum amount of cullet. In this way, the purchasers of the glass containers and the general public at large can easily discern that the containers have been manufactured in an ecologically-friendly way.
- a glass container manufacturing process is disclosed that results in the glass substrate of an as-formed glass container having randomized streaks of color. These streaks of color uniquely indicate that the glass container has been formed at least in part from cullet and serve to visually distinguish the glass container from those produced by other manufacturers.
- the streaks of color are a permanent and intrinsic feature of the glass, the color streaks cannot be tampered with or removed from the glass container after the container leaves the manufacturing plant.
- the visually distinctive and fashionable streaks of color are created from cullet that is separate from the cullet included in the batch material. As such, the process of creating the streaks of color does not compromise the eco-friendly nature of the glass container.
- the present disclosure relates to a method for manufacturing glass containers that include random streaks of color.
- the colored streaks are deliberately integrated into the glass substrates of the containers to signify that the glass has been formed from a batch material that includes cullet.
- the colored streaks which can assume any of a wide variety of contours and colors, are created within the glass containers by introducing colored cullet into the flow of molten glass moving through a forehearth that receives molten glass from an upstream furnace or melter and discharges conditioned molten glass to downstream container forming equipment.
- the colored cullet may be introduced in solid form, in a molten form, or a combination of solid form and a molten form.
- the colored cullet produces colored striations within the conditioned molten glass leaving the forehearth that ultimately manifest themselves as streaks of color within glass containers formed from the conditioned molten glass. Tn addition to creating the streaks of color, the cullet added to the flow of molten glass absorbs heat and cools the flow of molten glass in the forehearth, which can reduce the flow of cooling air that needs to be fed into the forehearth in order to condition the glass to a certain viscosity and thermal homogeneity.
- a method of manufacturing a glass container includes several steps.
- One step of the method involves melting a batch material, which contains cullet, to produce molten glass having a soda-lime- silica chemical composition.
- Another step of the method involves delivering a flow of molten glass to a forehearth that comprises an elongated housing and a glass feeder appended to the elongated housing.
- the elongated housing defines a conditioning compartment, and the flow of molten glass flows through the conditioning compartment of the forehearth from an inlet to an outlet along a flow direction and then enters a spout chamber of the glass feeder.
- Yet another step of the method involves conditioning the flow of molten glass within the conditioning compailment of the forehearth including reducing a temperature of the flow of molten glass such that the temperature of the flow of molten glass at the outlet of the conditioning compartment is less than the temperature of the flow of molten glass at the inlet of the conditioning compartment.
- Still another step of the method involves introducing colored cullet into the flow of molten glass, which produces colored striations that do not fully mix and assimilate into the flow of molten glass.
- Another step of the method involves discharging an output of conditioned molten glass from the glass feeder of the forehearth. And yet another step of the method involves forming a glass container from the output of conditioned molten glass.
- the glass container comprises a glass substrate that defines the shape of the container and includes random streaks of color.
- a method of manufacturing a glass container includes several steps.
- One step of the method involves introducing a batch material, which contains cullet, into a melting chamber of a glass furnace.
- the batch material is, specifically, introduced onto a molten glass bath that comprises soda- lime- silica glass and melts into the molten glass bath.
- Yet another step of the method involves flowing the molten glass bath from the melting chamber of the glass furnace to a fining chamber of the glass furnace through a submerged throat.
- Still another step of the method involves delivering a flow of molten glass from the fining chamber of the glass furnace to a forehearth connected to the glass furnace.
- the forehearth includes an elongated housing and a glass feeder appended to the elongated housing.
- the elongated housing defines a conditioning compartment, and the flow of molten glass flows from an inlet of the conditioning compartment to an outlet of the conditioning compartment along a flow direction and then enters the glass feeder.
- Another step of the method involves conditioning the flow of molten glass within the conditioning compartment including reducing a temperature of the flow of molten glass such that the temperature of the flow of molten glass at the outlet of the conditioning compartment is less than the temperature of the flow of molten glass at the inlet of the conditioning compartment.
- Another step of the method involves introducing colored cullet into the flow of molten glass.
- the colored cullet comprises solid cullet particles that produce colored striations within the flow of molten glass.
- Still another step of the method involves discharging at least one gob of conditioned molten glass from the glass feeder of the forehearth.
- Still another step of the method involves forming a glass container from the gob of conditioned molten glass.
- the glass container comprises a glass substrate that defines the shape of the container and includes and axially-closed base and a circumferential wall extending from a periphery of the axially-closed base. Additionally, at least the circumferential wall of the glass substrate includes integral random streaks of color.
- FIG. 1 is a cross-sectional view of a glass container that includes random streaks of color according to practices of the method described in the present disclosure
- FIG. 2 is a perspective view of a glass container that includes random streaks of color according to practices of the method described in the present disclosure
- FIG. 3 is a cross-sectional view of a glass-making furnace that may be used according to practices of the method described in the present disclosure
- FTG. 4 is a magnified view of a forehearth that is connected to the glass-making furnace depicted in FIG. 3 and may be used according to practices of the method described in the present disclosure
- FIG. 5 is a cross-sectional view of the forehearth illustrated in FIGS. 3-4 taken along section line 5-5 (FIG. 4) according to one embodiment of the present disclosure.
- FIG. 6 is a flow chart that represents a process for forming glass containers from an outflow of conditioned molten glass discharged from the forehearth depicted in FIGS. 3-5 according to practices of the method described in the present disclosure.
- a glass container 10 that includes a glass substrate
- the glass substrate 12 includes an axially-closed base 14 and a circumferential wall 16.
- the circumferential wall 16 extends from a periphery of the axially-closed base 14 and terminates in a mouth 18 that defines an entrance plane 20 to a containment space 22 defined by the axially-closed base 14 and the circumferential wall 16.
- the container 10 is marked with random streaks of color 24 that meander through at least a portion of the circumferential wall of the glass substrate 12.
- the random streaks of color 24 are essentially colored portions of the glass substrate 12 that arc integral with and contrast visually with a native portion 26 of the glass substrate 12 that does not contain the streaks of color 24.
- the streaks of color 24 can be the same color or different colors and, due to the fact that the streaks or color 24 are an intrinsic feature of the glass — meaning the streaks of color 24 cannot be indestructibly separated from the native portion 26 of the glass substrate 12 — the streaks of color 24 constitute permanent and unique visual markings that are entirely within the control of the glass container manufacturer.
- cullet that is separate from the cullet included in the batch material is used to create the streaks of color 24.
- the disclosed method is depicted in FIGS. 3-6 and involves introducing colored cullet 28 into a flow of molten glass 30 moving through a forehearth 32.
- the flow of molten glass 30 traveling through the forehearth 32 is produced from a batch material 34 (FIG. 3) upstream of the forehearth 32 in a furnace or melter.
- a batch material 34 FIG. 3
- the temperature of the flow of molten glass 30 increases and its viscosity decreases, and the flow of molten glass 30 is thermally homogenized, in a process known as glass conditioning.
- an output conditioned molten glass 36 is discharged from the forehearth 32, preferably from a glass feeder 38 as at least one gob of conditioned molten glass 40, and is delivered to downstream glass container forming machines.
- the colored cullet 28 is introduced into the flow of molten glass 30, the colored cullet melts if not already in molten form (i.e., if introduced as solid particles) and the molten cullet flows, but does not fully mix and assimilated into the glass 30 before being discharged from the forehearth 32 within the output of conditioned molten glass 36.
- the non-assimilated flows of melted colored cullet forms colored striations within the flow of molten glass 30 and the output of conditioned molten glass 36, which eventually become the random streaks of color 24 within the glass container 10 formed from the conditioned molten glass 34.
- FIG. 3 one particular embodiment of a glass-making system
- the furnace 44 includes a housing 46 constructed from refractory materials that defines a melting chamber 48, a fining chamber 50, and a throat 52 that separates the melting and fining chambers 48, 50.
- a molten glass bath 54 having a glass level surface 56 partially fills the melting and fining chambers 48, 50, and fully fills the throat 52, and the batch material 34 is introduced into the molten glass bath 54 within the melting chamber 48 to feed the glass bath 54 with glass.
- the molten glass bath 54 flows from the upstream melting chamber 48 and into the downstream fining chamber 50 through the throat 52, which is submerged below the level surface 56 of the molten glass bath 54 and establishes fluid communication between the melting and fining chambers 48, 50.
- a melting chamber combustion zone 58 is present within the melting chamber 48 above the molten glass bath 54 and an fining chamber combustion zone 60 is present within the fining chamber 50 above the molten glass bath 54.
- a relatively large quantity of the molten glass — typically 30 tons to 1000 tons — is contained in the furnace 10 to support a glass residence time within the melting and fining chambers 48, 50 that ranges from 8 hours to 72 hours.
- the molten glass that comprises the molten glass bath 54 may be soda-lime-silica glass.
- a batch inlet 62 is defined in the housing 46 and provides an entrance to the melting chamber 48 for the delivery of the batch material 34 onto the molten glass bath 54.
- the batch material 34 is distributed over the glass level surface 56 of the molten glass bath 54 as a batch blanket 64 that melts and reacts to form glass that mixes into the molten glass bath 54 over time with the aid of convective flow currents 66.
- a glass outlet 68 is also defined in the housing 46 and provides an exit from the fining chamber 50 through which the flow of molten glass 30 is pulled from the molten glass bath 54 to supply the forehearth 32.
- the flow of molten glass 30 supplied to the forehearth 32 is typically considered “fined” glass that meets a prescribed specification for bubble content.
- a plurality of overhead burners 70 is mounted in the housing 46 within the melting chamber 48. Each of these overhead burners 70 discharges a combustion flame into the melting chamber combustion zone 58 above the molten glass bath 54. These combustion flames heat the glass bath 54 to facilitate melting and reacting of the batch material 34.
- the molten glass bath 54 may be maintained within a temperature range of 1200°C to 1550°C in the melting chamber 48.
- a plurality of overhead burners 72 may be mounted in the housing 46 within the fining chamber 50.
- Each of these overhead burners 72 discharges a combustion flame into the refining chamber combustion zone 60 above the molten glass bath 54. These combustion flames allow the molten glass bath 54 to cool at a controlled rate in the fining chamber 50 to help facilitate the ascension and removal of entrained gas bubbles from the glass. During operation of the glass-making furnace 44, the molten glass bath 54 may be maintained within a temperature range of 1450°C to 1150°C in the fining chamber 50.
- the forehearth 32 is fluidly connected to the fining chamber 50 of the glass-making furnace
- the forehearth 32 includes an elongated housing 74 and the glass feeder 38 appended to the housing 74.
- the elongated housing 74 comprises a trough 76 and a roof 78 as shown best in FIGS 4-5.
- the trough 76 defines an elongated channel 80 along which the flow of molten glass 30 flows in a flow direction F, and the trough 76 and the roof 78 together define an interior conditioning compartment 82 that includes the elongated channel 80 and an open space 84 above the flow of molten glass 30.
- the elongated housing 74 further defines an inlet 86 to and an outlet 88 from the conditioning compartment 82 that arc spaced apart along the flow direction F of the elongated channel 80.
- the flow of molten glass 30 is received from the furnace 44 into the conditioning compartment 82 of the forehearth 32 through the inlet 86, flows from the inlet 86 to the outlet 88 of the conditioning compartment 82 along the flow direction F, and exits the conditioning compartment 82 through the outlet 88.
- the flow of molten glass Upon exiting the conditioning compartment 82, the flow of molten glass enters the glass feeder 38 of the forehearth 32, which delivers the output of conditioned molten glass 36.
- the glass feeder 38 includes a spout 90 having a spout bowl 92 and a bottom orifice plate 94 that together define a spout chamber 96.
- the spout chamber 96 fluidly communicates with the conditioning compartment 82 of the forehearth 32 via the outlet 88 and the portion of the flow of molten glass 30 contained within the spout chamber 96 is conditioned molten glass as it has already navigated through the conditioning compartment 82.
- the spout 90 also includes at least one plunger 98 that reciprocates relative to the orifice plate 94 to control the flow of conditioned molten glass through an aligned orifice 100 in the orifice plate 94 as a stream of conditioned molten glass.
- the stream of conditioned molten glass may be sheared just below the orifice plate 94 such that the output of conditioned molten glass 36 discharged from the forehearth 32 is in the form of at least one individual gob of conditioned molten glass 40.
- Each glass gob 40 discharged from the glass feeder 38 of the forehearth 32 can be formed into a glass container.
- the forehearth 32 may include plurality of overhead burners 102 mounted in burner blocks contained in the roof 78 of the elongated housing 74. These burners 102 are spaced apart along the flow direction F of the flow of molten glass 30 and are configured to laterally discharge combustion flames into the open space 84 of conditioning compartment 82 above the flow of molten glass 30. Additionally, the forehearth 32 may include air ducts 104 that deliver cooling air into the open space 84 of the conditioning compartment 82 above the flow of molten glass 30 in any of a variety of flow patterns.
- Heat exchange conduits 106 that communicate a heating fluid or a cooling fluid may also be defined in the trough 76 to help control the temperature of the flow of molten glass 30.
- the flow of molten glass 30 is hottest in the center towards a top surface 108 of the glass since that portion of the flow of molten glass 30 is furthest from the walls of the trough 76.
- the plurality of overhead burners 102 are usually directed to heat the portions of the flow of molten glass 30 that flow adjacent to the walls of the trough 76, and the cooling air is directed to simultaneously cool the central portion of the flow of molten glass 30.
- the forehearth 32 is operated to reduce a temperature T of the flow of molten glass 30 along the flow direction F from a first temperature Ti at the inlet 86 of the conditioning compartment 82 to a second temperature T2 at the outlet 88 of the conditioning compartment 82 and within the spout chamber 96 to achieve a glass viscosity appropriate for downstream glass forming operations.
- the first temperature Ti of the flow of molten glass 30 may range from 1100°C to 1450°C and the second temperature T2 of the flow of molten glass 30 may range from 1050°C to 1200°C.
- the flow of molten glass 30 is more thermally homogenized (i.e., has a smaller temperature gradient) at the second temperature T2.
- a pair of laterally spaced projections 110a, 110b that run parallel to the flow direction F may extend downwardly from the roof 78 of the elongated housing 74 to divide the open space 84 above the flow of molten glass 30 into a central section and two side sections.
- the central and two side sections help ensure that heat is delivered from the burners 102 and cooling air is delivered from the air ducts 104, respectively, to the corresponding portions of the flow of molten glass 30.
- the colored cullet 28 may be introduced into the forehearth 32 either in the elongated housing 74 or the glass feeder 38.
- auxiliary inlet 112 is additionally defined in the elongated housing 74 of the forehearth 32 between the inlet 86 and the outlet 88 to allow the colored cullet 28 to be selectively introduced into the flow of molten glass 30.
- the auxiliary inlet 112 may be a single opening that provides access to the conditioning compartment 82 and the flow of molten glass 30 or it may collectively be several such openings.
- the colored cullet 28 may be added into the flow of molten glass 30 as solid particles or as molten cullet that has been pre-melted outside of the forehearth 32.
- the auxiliary inlet 112 receives the colored cullet 28 from an auxiliary feeder that can meter solid particulate material or molten cullet.
- the quantity of the colored cullet 28 supplied by the auxiliary feeder may be delivered to a guide 1 14, which is arranged in feeding communication with or extends through the auxiliary inlet 112 to introduce the colored cullet 28 into the flow of molten glass 30.
- the colored cullet 28 may be unicolored or multicolored depending on the desired appearance of the streaks of color 24.
- the auxiliary inlet 112 is located in the forehearth 32 so that the colored cullet will flow but will not become fully mixed and assimilated into the flow of molten glass 30.
- the colored cullet is flowable, typically at a viscosity of 10 3 Pa*s or less, either by being premelted into molten cullet prior to being entered into the forehearth 32 or by being added as solid particles into the flow of molten glass 30 and then melting within the glass into molten cullet.
- the colored cullet introduced into the flow of molten glass 30 within the conditioning compartment 82 of the forehearth 32 includes solid cullet particles.
- the auxiliary inlet 112 is positioned so that the solid cullet particles have enough time to melt into molten cullet and flow within the flow of molten glass 30 but not so much time that the molten cullet disbands and becomes assimilated into the flow of molten glass 30 such that it loses its distinctive band. If the colored cullet 28 includes premelted molten cullet, the colored cullet can be introduced into the flow of molten glass 30 closer to the glass feeder 38 since the premelted molten cullet would not have to initially melt like the solid cullet particles.
- the colored cullet if comprised of premelted molten cullet, can even be introduced into the flow of molten glass 30 contained in the spout chamber 96; that is, the premelted molten cullet may be introduced directly into the conditioned molten glass portion of the flow of molten glass 30 within the spout chamber 96 of the spout 90.
- the glass container 10 is formed from the gob of conditioned molten glass 40 and cooled to a temperature below the glass-transition temperature of the glass, the colored striations 116 become fixed within the glass substrate 12 of the container 10 as the visibly-perceptible streaks of color 24.
- the colored cullet 28 may absorb heat from the flow of molten glass 30, especially if the colored cullet 28 is added as solid particles that absorb heat when melting and becoming less viscous, which can in turn reduce the quantity of cooling air that needs to be input to the forehearth 32 to properly condition the flow of molten glass 30 as it moves forward down the elongated channel 80 of the trough 76.
- the best opportunity for realizing a savings in the demand for cooling air occurs when the colored cullet is introduced into the middle third of the top surface 108 of the flow of molten glass 30 since, as discussed above, the central portion of the glass is where the cooling air is commonly directed.
- the batch material 34 is introduced into the melting chamber 48 of the furnace 44 and is distributed over the glass level surface 56 of the molten glass bath 54 as the batch blanket 64.
- the batch material 34 melts, flows, and mixes into the molten glass bath 54 as assisted by the convective flow currents 66 that are present within the molten glass bath 54 and the radiant heat provided by the overhead burners 70 within the melting chamber 48.
- the batch material 34 is formulated to produce soda-lime- silica glass, which has a chemical composition that includes 60 wt% to 80 wt% SiCh, 8 wt% to 18 wt% Na2O, and 5 wt% to 15 wt% CaO, or more narrowly 70 wt% to 75 wt% SiCh, 12 wt% to 15 wt% Na2O, and 9 wt% to 13 wt% CaO, based on the total weight of the glass.
- the chemical composition of soda-lime- silica glass may include other oxide and non-oxide materials including aluminum oxide (AI2O3), magnesium oxide (MgO), potassium oxide (K2O), carbon, sulfates, nitrates, fluorines, chlorines, and/or elemental or oxide forms of one or more of iron, arsenic, antimony, selenium, chromium, barium, manganese, cobalt, nickel, sulfur, vanadium, titanium, lead, copper, niobium, molybdenum, lithium, silver, strontium, cadmium, indium, tin, gold, cerium, praseodymium, neodymium, europium, gadolinium, erbium, and uranium.
- AI2O3 aluminum oxide
- MgO magnesium oxide
- K2O potassium oxide
- carbon sulfates, nitrates, fluorines, chlorines, and/or elemental or oxide forms of one or more of iron,
- the sum total of those additional materials is preferably 10 wt% or less, or more narrowly 5 wt% or less, based on the total weight of the glass.
- the batch material 34 may be a physical mixture of virgin raw materials and, optionally, cullet (i.e., recycled glass) and/or other glass precursor oxides that provide a source of SiO2, Na2O, and CaO in the correct proportions along with any of the other components of the glass listed below in Table 1.
- the batch material 34 may include raw materials such as quartz sand (crystalline SiO2), soda ash (Na2COs), and limestone (CaCOs) in the quantities needed to provide the requisite proportions of SiO2, Na2O, and CaO, respectively.
- Other raw materials may of course be included in the batch material 34 to contribute one or more of SiO2, Na2O, CaO, and possibly other oxide and/or non-oxide materials.
- the batch material 34 may include anywhere from 10-90 wt% cullet, with an amount ranging from 10 wt% to 70 wt% being typical, to help conserve energy and reduce the carbon footprint associated with each manufactured glass container. Additionally, the batch material 34 may include secondary materials that provide the soda-lime- silica glass with colorants, decolorants, and/or redox agents, and in some instances may include chemical fining agents.
- the exact recipe of the batch material 34 may vary depending on the virgin raw materials used and the proportion of cullet included in the batch material 34 relative to the other materials.
- the molten glass bath 54 flows from the melting chamber 48 to the fining chamber 50 through the submerged throat 52.
- gas bubbles that are released into the glass when the batch material 34 is melted are removed through fining processes.
- the fining process begins in the melting chamber 48 as the larger of the entrained gas bubbles quickly ascend through the molten glass bath 54 and burst when the reach the glass level surface 56. This process may be augmented by fining agents that are optionally included in the batch material 34.
- the concentration of entrained gas bubbles in the molten glass bath 54 is further reduced in the fining chamber 50 on the other side of the throat 52.
- entrained gas bubbles continue to rise out of the molten glass bath 54 and glass bath 54 is also slowly cooled as the glass flows towards the forehearth. This cooling increases the solubility of certain gasses within the glass, allowing smaller entrained gas bubbles that do not escape the molten glass bath 54 to dissolve back into the glass.
- the removal of gas bubbles from the molten glass bath 54 is desired and promoted by thermal and/or chemical assistance to ensure the finished glass container 10 does not contain commercially unacceptable bubbles within the glass substrate 12.
- the flow of molten glass 30 is pulled into the forehearth 32, more specifically the conditioning compartment 82, from the fining chamber 50.
- the flow of molten glass 30 flows through the conditioning compartment chamber 82 along the elongated channel 80 from the inlet 86 to the outlet 88.
- the flow of molten glass 30 is reduced in temperature along the way from its first temperature Ti at the inlet 86 to its second temperature T2 at the outlet 88 by the combined application of heat from the plurality of overhead burners 102 and the flow of cooling air from the air ducts 104 and becomes more thermally homogenized as well.
- the flow of molten glass 30, which at this point comprises conditioned molten glass enters the spout chamber 96 of the spout 90 of the forehearth 32.
- the colored cullet 28 is introduced into the flow of molten glass 30 moving through the forehearth 32 via the auxiliary inlet 112 in the embodiment shown in FIGS. 3-5.
- the colored cullet 28 produces the colored striations 116 within the flow of molten glass 30, which are shown generically in FIG. 4. If the colored cullet 28 includes solid cullet particles, for example, those particles melt to form molten cullet that flows but does not fully mix and assimilate into the flow of molten glass 30 to produce the colored striations 116, as described above.
- the molten cullet 28 includes premelted molten cullet, on the other hand, the molten cullet simply flows but does not fully mix and assimilate into the flow of molten glass 30 to produce the colored striations 116.
- the color of the colored striations 116 is controllable and is derived from the color(s) of the colored cullet 28 and the color of the glass within the flow of molten glass 30.
- the particular color of the colored striations 116 — and the color of the streaks of color 24 that are eventually created in the glass container 10 — can be managed by presorting the cullet particles included in the colored cullet 28 by particle size and color so that the introduction of the colored cullet 28 into the flow of molten glass 30 will predictably result in striations 116 of an expected color when integrated into a bulk color associated with the flow of molten glass.
- the flow of molten glass 30 enters the spout chamber 96 of the spout 90 and, within the spout chamber 96, provides a source of conditioned molten glass.
- the reciprocating movement of the plunger 98 controls the flow of a stream of conditioned molten glass out of the spout 90 through the orifice plate 94 and the conditioned molten glass gob 40 that is sheared from the stream of conditioned molten glass may be formed into the glass container 10.
- the glass container 10 may be formed from the conditioned molten glass gob 40 by a standard container forming process such as the one represented in FIG. 6.
- the container forming process referred to in FIG. 6 includes a forming step 130 and an annealing step 132.
- the conditioned molten glass gob 40 is delivered into a blank mold of a glass container forming machine. Once in the blank mold, the conditioned molten glass gob 40, which is comprised of conditioned molten glass having the colored striations 116, is pressed or blown in substep 130a into a parison or preform that includes a tubular wall. The parison is then transferred from the blank mold into a blow mold of the glass container forming machine.
- the blow mold is closed and the parison is rapidly outwardly blown in substep 130b into the glass container 10 with the shape and contour of the glass substrate 12 matching the contour of the mold cavity.
- the parison is typically outwardly blown into the glass container 10 using a compressed gas such as compressed air.
- a compressed gas such as compressed air.
- Other approaches may of course be implemented to form the glass container 10 in the forming step 130 besides the press-and-blow and blow-and-blow forming techniques including, for instance, compression or other molding techniques.
- the glass container 10 is then removed from the blow mold and placed on a conveyor or other transport device.
- the glass container 10 is then reheated, if necessary, and cooled at a controlled rate in the annealing step to relax thermally-induced strain within the glass substrate 12.
- the glass container 10 may be annealed in an annealing lehr or by another suitable approach.
- the glass container 10 is heated in a reheating substep 132a to a temperature above the annealing point of the soda-lime- silica glass, if necessary, and is then slowly cooled in a cooling substep 132b at a rate of l°C/min to 10°C/min to a temperature below the strain point of the soda-lime-silica glass.
- the annealing point of soda-lime-silica glass usually lies within the range of 510°C to 550°C and the strain point of soda- lime- silica glass usually lies within the range of 470°C to 500°C.
- any of a variety of coatings may be applied to the surface of the glass container 10 either before (hot-end coating(s)) or after (cold-end coating(s)) annealing.
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Abstract
Un procédé de fabrication d'un récipient en verre, comprend la fusion par lots d'un matériau (34), qui contient un calcin, pour produire un verre fondu ayant une composition chimique de silicate sodo-calcique. Un flux de verre fondu (30) est envoyé à un avant-corps (32) et conditionné à l'intérieur de l'avant-corps, ce qui comprend la réduction d'une température (T) du flux de verre fondu, d'une première température (T1) du flux de verre fondu à une seconde température (T2) du flux de verre fondu. En outre, le procédé comprend l'introduction d'un calcin coloré (28) dans le flux de verre fondu, ce qui produit des stries colorées (116) à l'intérieur du flux de verre. Un produit obtenu à partir du verre fondu conditionné (36) est évacué de l'avant-corps, et un récipient en verre (10) est formé à partir du verre fondu conditionné. Le récipient en verre possède un substrat de verre (12), qui contient des stries colorées (24) disposées au hasard.
Applications Claiming Priority (4)
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US202263331934P | 2022-04-18 | 2022-04-18 | |
US63/331,934 | 2022-04-18 | ||
US17/836,198 US20230331615A1 (en) | 2022-04-18 | 2022-06-09 | Color streaked glass containers using cullet injection |
US17/836,198 | 2022-06-09 |
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WO2023204920A1 true WO2023204920A1 (fr) | 2023-10-26 |
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PCT/US2023/015767 WO2023204920A1 (fr) | 2022-04-18 | 2023-03-21 | Récipients en verre à stries colorées par utilisation d'injection de calcin |
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Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB401710A (en) * | 1932-04-19 | 1933-11-20 | James A Jobling & Company Ltd | Improvements in or relating to the manufacture of glass |
JP2002234735A (ja) * | 2001-01-31 | 2002-08-23 | Toyo Glass Co Ltd | 色筋模様入りガラス製品の製造方法 |
FR3068691A1 (fr) * | 2017-07-06 | 2019-01-11 | Verescence France | Procede et installation de formation d'une paraison destinee a la fabrication d'un article en verre et procede de fabrication d'un article en verre a partir d'une telle paraison |
-
2023
- 2023-03-21 WO PCT/US2023/015767 patent/WO2023204920A1/fr unknown
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB401710A (en) * | 1932-04-19 | 1933-11-20 | James A Jobling & Company Ltd | Improvements in or relating to the manufacture of glass |
JP2002234735A (ja) * | 2001-01-31 | 2002-08-23 | Toyo Glass Co Ltd | 色筋模様入りガラス製品の製造方法 |
FR3068691A1 (fr) * | 2017-07-06 | 2019-01-11 | Verescence France | Procede et installation de formation d'une paraison destinee a la fabrication d'un article en verre et procede de fabrication d'un article en verre a partir d'une telle paraison |
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