OVERFLOW BRICK AND GROOVE BOTTOM CURVE DESIGN OPTIMIZATION METHOD THEREFOR

Abstract

Provided is a groove bottom curve design optimization method for an overflow brick, including: S1: obtaining a standard output of the overflow brick based on design parameters; S2: obtaining an initial groove bottom curve of the overflow brick based on the design parameters and the standard output; S3: obtaining a groove bottom curve of the overflow brick through straight line correction of the initial groove bottom curve based on a length of a splitting block; S4: obtaining an extreme thickness difference of a formed glass substrate through overflow simulation based on the groove bottom curve and the design parameters; and S5: when the extreme thickness difference is smaller than or equal to a preset threshold, processing the overflow brick using the groove bottom curve and the design parameters; and when the extreme thickness difference is greater than the preset threshold, adjusting the design parameters and repeating steps S1 to S4.

Claims

1. A groove bottom curve design optimization method for an overflow brick, comprising: S1: obtaining a standard output of the overflow brick based on design parameters of the overflow brick; S2: obtaining an initial groove bottom curve of the overflow brick based on the design parameters of the overflow brick and the standard output of the overflow brick; S3: obtaining a groove bottom curve of the overflow brick through straight line correction of the initial groove bottom curve of the overflow brick based on a length of a splitting block of the overflow brick; S4: obtaining an extreme thickness difference of a formed glass substrate through overflow simulation based on the groove bottom curve of the overflow brick and the design parameters of the overflow brick; and S5: when the extreme thickness difference of the formed glass substrate is smaller than or equal to a preset threshold, processing the overflow brick based on the groove bottom curve of the overflow brick and the design parameters of the overflow brick; and when the extreme thickness difference of the formed glass substrate is greater than the preset threshold, adjusting the design parameters of the overflow brick and repeating steps S1 to S4.

2. The groove bottom curve design optimization method for the overflow brick according to claim 1, wherein in the step S1, the design parameters of the overflow brick are obtained based on a production line and a product design, and comprise a groove inlet height, a groove inlet width, a length of an overflow surface, an inclination angle of an overflow weir, and a design output of the overflow brick.

3. The groove bottom curve design optimization method for the overflow brick according to claim 1, wherein in the step S1, the standard output of the overflow brick is obtained specifically by a method comprising: S101: calculating a fluid parameter A of an overflow of a glass in accordance with an equation (1): $\begin{array}{cc}A=\frac{\rho \times g}{3\times \eta },& \left(1\right)\end{array}$ where ρ represents a density of the glass, in unit of Kg/m.sup.3; g represents an acceleration of gravity, in unit of m/s.sup.2; and η represents a forming viscosity of the glass, in unit of poise; S102: calculating a surface tension parameter B of the glass in accordance with an equation (2):
B=Sin(j)  (2), where j represents a contact angle of the glass; S103: calculating a standard flow rate C per unit length of an overflow surface of the overflow brick in accordance with an equation (3): $\begin{array}{cc}C=\frac{Q_s}{2\times L},& \left(3\right)\end{array}$ where Q.sub.s represents the standard output of the overflow brick, in unit of kg/s; and L represents a length of the overflow surface, in unit of mm; S104: calculating an overflow height D of an overflow groove in accordance with an equation (4): $\begin{array}{cc}D=\sqrt[3]{\frac{C}{A\times B}};& \left(4\right)\end{array}$ S105: calculating a height-width ratio E of the overflow groove in accordance with an equation (5): $\begin{array}{cc}E=\frac{H+D}{W},& \left(5\right)\end{array}$ where H represents a groove inlet height of the overflow brick, and W represents an inlet width of the overflow groove of the overflow brick; S106: calculating a section function F of the overflow groove in accordance with an equation (6): $\begin{array}{cc}F=0.6274\times \tanh \left(\frac{\pi }{4\times E}\right)+0.002581893\times \tan h\left(\frac{3\times \pi }{4\times E}\right)+0.000257234;& \left(6\right)\end{array}$ S107: calculating the standard output Q.sub.s of the overflow brick in accordance with an equation (7):
Q.sub.s=A×tan ϕ×[W×(H+D).sup.3−2×F×(H+D).sup.4]  (7); and S108: obtaining the standard output Q.sub.s of the overflow brick by solving the equations (1) to (7) simultaneously.

4. The groove bottom curve design optimization method for the overflow brick according to claim 3, wherein the standard output Q.sub.s of the overflow brick is greater than the design output Q.sub.d of the overflow brick.

5. The groove bottom curve design optimization method for the overflow brick according to claim 3, wherein the contact angle of the glass is j=21.7°, and the forming viscosity of the glass is η=35000 poise.

6. The groove bottom curve design optimization method for the overflow brick according to claim 3, wherein the step S2 comprises: S201: dividing the length L of the overflow surface of the overflow brick into n equal portions each of which corresponds to a Z value of a groove bottom position, where the Z value is selected from discrete values from 0 to L with an equal interval of L/n, and n is greater than or equal to 5; and S202: obtaining a height h of the overflow groove of the overflow brick corresponding to the Z value corresponding to each of the n equal portions of the length L of the overflow surface of the overflow brick by solving the equations (1) to (8) simultaneously, and recording the height h, to obtain an initial groove bottom curve of the overflow brick:
2×C×(L−Z)=A×tan Ø.sub.0×[W×(h+D).sup.3−2×F×(h+D).sup.4]  (8), where Ø.sub.0 represents an inclination angle of an overflow weir of the overflow brick.

7. The groove bottom curve design optimization method for the overflow brick according to claim 6, wherein the step S3 comprises: S301: dividing, based on a length L.sub.0 of the splitting block of the overflow brick, the length L of the overflow surface of the overflow brick into two sections comprising a section from 0 to L−L.sub.0 and a section from L−L.sub.0 to L; S302: dividing the initial groove bottom curve of the overflow brick obtained in step S2 into two sections comprising a section from 0 to L−L.sub.0 and a section from L−L.sub.0 to L, wherein Z=Z.sub.L-L.sub.0 corresponds to the height of the overflow groove h=h.sub.L-L.sub.0, and Z=L corresponds to the height of the overflow groove h=0; and S303: connecting the height of the overflow groove h=h.sub.L-L.sub.0 corresponding to Z=Z.sub.L-L.sub.0 and the height of the overflow groove h=0 corresponding to Z=L into a straight line and performing a straight line correction on the straight line to obtain a groove bottom curve of the overflow brick.

8. The groove bottom curve design optimization method for the overflow brick according to claim 7, wherein the step S4 comprises: performing overflow simulation using fluid software FLUENT based on the groove bottom curve of the overflow brick and the design parameters of the overflow brick to obtain the extreme thickness difference Δ of the formed glass substrate.

9. The groove bottom curve design optimization method for the overflow brick according to claim 8, wherein the step S5 comprises: when the extreme thickness difference of the formed glass substrate is smaller than or equal to the preset threshold, processing the overflow brick based on the groove bottom curve of the overflow brick and the design parameters of the overflow brick; and when the extreme thickness difference of the formed glass substrate is greater than the preset threshold, adjusting an inlet width W of the overflow groove of the overflow brick and repeating the step S4, or adjusting the groove inlet height H of the overflow brick and repeating the steps S1 to S4, or adjusting the inlet width W of the overflow groove of the overflow brick and the groove inlet height H of the overflow brick and repeating the steps S1 to S4.

10. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 1.

11. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 2.

12. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 3.

13. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 4.

14. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 5.

15. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 6.

16. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 7.

17. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 8.

18. An overflow brick formed by processing based on design parameters of the overflow brick and a groove bottom curve of the overflow brick, wherein the design parameters and the groove bottom curve of the overflow brick are obtained by the groove bottom curve design optimization method according to claim 9.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0038] FIG. 1 is a structural schematic diagram illustrating an overflow system;

[0039] FIG. 2 is a structural schematic diagram illustrating an external appearance of an overflow brick;

[0040] FIG. 3 is a structural schematic diagram illustrating an overflow groove in an overflow brick;

[0041] FIG. 4 is a flow block diagram illustrating a groove bottom curve design optimization method for an overflow brick provided by the present disclosure; and

[0042] FIG. 5 illustrates an example of design optimization of a groove bottom curve of an overflow brick provided by the present disclosure.

REFERENCE NUMERALS

[0043] 1—Overflow brick; [0044] 2—Overflow groove; [0045] 3—Glass melt feeding device; [0046] 4—Root of overflow brick; [0047] 5—Splitting block; [0048] 6—Initial groove bottom curve of overflow brick; [0049] 7—Groove bottom curve of overflow brick.

DESCRIPTION OF EMBODIMENTS

[0050] In order to allow those skilled in the art to better understand the technical solutions of the present disclosure, the technical solutions in the embodiments of the present disclosure will be described clearly and completely below with reference to the accompanying drawings in the embodiments. Apparently, the embodiments described are only part of and not all of the embodiments of the present disclosure. All other embodiments obtained by those of ordinary skill in the art based on the embodiments in the present disclosure without inventive effort shall fall into the protection scope of the present disclosure.

[0051] It's noted that, the terms such as “first” or “second” in the description, claims, and drawings of the present disclosure are used for distinguish one from another, rather than providing a specific sequence or order. It should be understood that the data used in this way are interchangeable in suitable situations, so that the embodiments of the present disclosure described herein may be implemented in an order rather than those illustrated or described herein. Besides, terms such as “including”, “comprising”, “having” and any variant thereof are intended for a non-exclusive inclusion, for example, a process, method, system, product or apparatus including a series of steps or units is not necessarily limited to those steps or units listed explicitly, and may further include other steps or units that are not explicitly listed or are inherent to the process, method, system, product or apparatus.

[0052] The present disclosure will be described below with reference to the accompanying drawings.

[0053] Referring to FIG. 1, FIG. 1 is a structural schematic diagram illustrating an overflow system formed by connecting an overflow brick 1 and a glass melt feeding device 3. An overflow groove 2 is provided in the overflow brick 1. The bottom of the overflow brick 1 forms a root of the overflow brick 1. When a glass substrate is manufactured in a melt overflow method, the glass melt that has been molten by a glass melting furnace is supplied to the glass melt feeding device 3 in a melt overflow forming apparatus, and overflows along the overflow groove 2 from two sides of the overflow brick 1, to form a glass substrate below the root 4 of the overflow brick 1.

[0054] Referring to FIG. 2 and FIG. 3, FIG. 2 is a structural schematic diagram illustrating an external appearance of an overflow brick used in manufacture of the glass substrate by the overflow down drawing method, and FIG. 3 is structural schematic diagram illustrating the overflow groove in the overflow brick. The figures show some key structural design dimensions, including a groove inlet height H, a groove inlet width W, a length L of an overflow surface, an inclination angle Ø.sub.0 of an overflow weir, an overflow height of the overflow groove, a length L.sub.0 of a splitting block 5 of the overflow brick, and a height h of the overflow groove of the overflow brick. In practical manufacture, all overflow bricks include the above parameters, and also include a bottom curve of the overflow groove.

[0055] Referring to FIG. 4, FIG. 4 is a flow block diagram illustrating design optimization of the bottom curve of the groove in the overflow brick, including following steps: first determining the groove inlet height H of the overflow brick, the groove inlet width W, the length L of the overflow surface, the inclination angle Ø.sub.0 of the overflow weir, and a design output Q.sub.d, etc. based on the production line and the product design; then calculating a standard output Q.sub.s of the overflow brick; designing and calculating a groove bottom curve in conjunction with the overflow fluid parameters related with the viscosity and density of the glass, the surface tension parameter of the glass, and the overflow height related to the thickness of the overflowed glass on the overflow weir, etc.; and performing an overflow simulation using professional fluid software such as Fluent to validate and optimize the groove bottom curve, to make an initial extreme thickness difference Δ of the overflow brick meet the design objective. Particularly:

[0056] S1: a standard output of the overflow brick is obtained based on design parameters of the overflow brick.

[0057] Where, the design parameters of the overflow brick in step S1 are acquired from the production line and the product design, including the groove inlet height H, the groove inlet width W, the length L of the overflow surface, the inclination angle Ø.sub.0 of the overflow weir, and the design output Q.sub.d of the overflow brick.

[0058] The standard output of the overflow brick is obtained specifically in the following method.

[0059] S101: a fluid parameter A of the glass overflow is calculated in accordance with the equation (1):

[00006]$\begin{array}{cc}A=\frac{\rho \times g}{3\times \eta },& \left(1\right)\end{array}$

where, ρ represents the density of the glass in unit of Kg/m.sup.3; g represents the acceleration of gravity in unit of m/s.sup.2, and η represents a forming viscosity of the glass, in unit of poise, usually with a design value of 35000 poise, or other possible design values;

[0060] S102: a surface tension parameter B of the glass is calculated in accordance with the equation (2):

B=Sin(j)  (2),

where, j represents a contact angle of the glass, usually j=21.7°, and a different contact angle may be adopted, depending on the specific glass;

[0061] S103: a standard flow rate C per unit length of the overflow surface of the overflow brick is calculated in accordance with the equation (3):

[00007]$\begin{array}{cc}C=\frac{Q_s}{2\times L},& \left(3\right)\end{array}$

where, Q.sub.s represents the standard output of the overflow brick, in unit of kg/s; and L represents the length of the overflow surface, in unit of mm;

[0062] S104: an overflow height D of the overflow groove is calculated in accordance with the equation (4):

[00008]$\begin{array}{cc}D=\sqrt[3]{\frac{C}{A\times B}};& \left(4\right)\end{array}$

[0063] S105: a height-width ratio E of the overflow groove is calculated in accordance with the equation (5):

[00009]$\begin{array}{cc}E=\frac{H+D}{W},& \left(5\right)\end{array}$

where, H represents the groove inlet height of the overflow brick, and W represents the groove inlet width of the overflow brick;

[0064] S106: a section function F of the overflow groove is calculated in accordance with the equation (6):

[00010]$\begin{array}{cc}F=0.6274\times \tanh \left(\frac{\pi }{4\times E}\right)+0.002581893\times \tan h\left(\frac{3\times \pi }{4\times E}\right)+0.000257234;& \left(6\right)\end{array}$

[0065] S107: the standard output Q.sub.s of the overflow brick is calculated in accordance with the equation (7):

Q.sub.s=A×tan ϕ×[W×(H+D).sup.3−2×F×(H+D).sup.4]  (7);

[0066] S108: the standard output Q.sub.s of the overflow brick is obtained by solving the equations (1) to (7) simultaneously, where the standard output Q.sub.s of the overflow brick is greater than the design output Q.sub.d of the overflow brick.

[0067] S2: an initial groove bottom curve of the overflow brick is obtained based on the design parameters and the design of the standard output of the overflow brick.

[0068] S201: the length L of the overflow surface of the overflow brick is divided into n (n≥5) equal portions each of which corresponds to a Z value of a groove bottom position, where the Z value is selected from discrete values from 0 to L with an equal interval of L/n; and

[0069] S202: a height h of the overflow groove of the overflow brick corresponding to the Z value corresponding to each of the n equal portions of the length L of the overflow surface of the overflow brick is obtained by solving the equations (1) to (8) simultaneously, and is recorded, so as to obtain an initial groove bottom curve of the overflow brick:

2×C×(L−Z)=A×tan Ø.sub.0×[W×(h+D).sup.3−2×F×(h+D).sup.4]  (8)

where, Ø.sub.0 represents the inclination angle of the overflow weir of the overflow brick.

[0070] S3: a groove bottom curve of the overflow brick is obtained through straight line correction of the initial groove bottom curve of the overflow brick based on the length L.sub.0 of the splitting block of the overflow brick.

[0071] S301: the length L of the overflow surface of the overflow brick is divided, based on the length L.sub.0 of the splitting block 5 of the overflow brick, into two sections including a section from 0 to L−L.sub.0 and a section from L−L.sub.0 to L;

[0072] S302: the groove bottom curve of the overflow brick obtained in S2 is divided into two sections including a section from 0 to L−L.sub.0 and a section from L−L.sub.0 to L, in which Z=Z.sub.L-L.sub.0 corresponds to the height of the overflow groove h=h.sub.L-L.sub.0, and Z=L corresponds to the height of the overflow groove h=0; and

[0073] S303: the height of the overflow groove h=h.sub.L-L.sub.0 corresponding to Z=Z.sub.L-L.sub.0 and the height of the overflow groove h=0 corresponding to Z=L are connected into a straight line, and straight line correction is performed on the straight line to obtain a groove bottom curve of the overflow brick.

[0074] S4: overflow simulation is performed using fluid software FLUENT based on the groove bottom curve of the overflow brick and the design parameters of the overflow brick to obtain an extreme thickness difference Δ of the formed glass substrate.

[0075] S5: when the extreme thickness difference of the formed glass substrate is smaller than or equal to a preset threshold, the overflow brick is processed based on the groove bottom curve of the overflow brick and the design parameters of the overflow brick; and

[0076] when the extreme thickness difference of the formed glass substrate is greater than the preset threshold, the groove inlet width W of the overflow brick is adjusted and the step S4 is repeated, or the groove inlet height H of the overflow brick is adjusted and the steps S1 to S4 are repeated, or the groove inlet width W of the overflow brick and the groove inlet height H of the overflow brick are adjusted and the steps S1 to S4 are repeated.

[0077] In the method according to the present disclosure, firstly, the design parameters of the overflow brick 1 are determined based on the production line and the product design; a standard output of the overflow brick 1 is calculated, a groove bottom curve is calculated and designed in conjunction with the fluid parameter of the overflow related to the viscosity and density of the glass, the surface tension parameter of the glass, and the overflow height related to the thickness of the overflow on the overflow weir, etc., and then the groove bottom curve is validated and optimized through fluid software to finally make the initial extreme thickness difference of the overflow brick meet the design objective. The method effectively solves the problem of the fluctuation in thickness of the formed glass substrate, increases a production tolerance in design, makes the thickness of the formed glass substrate meet the requirements, and reduces the complexity in the adjustment of the process, thereby maintaining further stability of the production line.

[0078] Referring to FIG. 5, FIG. 5 illustrates an example of design optimization of a groove bottom curve of a reference overflow brick provided by the present disclosure. After the overflow brick is optimized, the groove inlet height H is 259.254 mm, the groove inlet width W is 200.032 mm, a length L of the overflow surface is 2973 mm, the inclination angle Ø.sub.0 of the overflow weir is 6.0°, and the design output Q.sub.d is 20 ton/day. The extreme thickness difference objective is less than 70 μm. The initial groove bottom curve 6 of the overflow brick and the groove bottom curve 7 of the overflow brick in FIG. 5 are simulated using fluid software FLUENT, with an extreme thickness difference of 68.52 μm totally meeting the design objective. In another example, after the overflow brick is optimized, the groove inlet height H is 265.308 mm, the groove inlet width W is 204.855 mm, the length L of the overflow surface is 2973 mm, the inclination angle Ø.sub.0 of the overflow weir is 6.0°, and the design output Q.sub.d is 22 ton/day. The extreme thickness difference objective is less than 70 μm. Through simulation using the fluid software FLUENT, the extreme thickness difference is 67.95 μm totally meeting the design objective.

[0079] The above content is only to illustrate the technical ideas of the present disclosure, and cannot be used to limit the protection scope of the present disclosure. Any modification made on the basis of the technical solutions in accordance with the technical ideas proposed by the present disclosure fall into the protection scope of the claims of the present disclosure.