APPARATUS AND METHOD FOR FORMING THIN GLASS ARTICLES
20190218133 ยท 2019-07-18
Inventors
- Antoine Gaston Denis Bisson (Bois le Roi, FR)
- Allan Mark Fredholm (Vulaines sur Seine, FR)
- Vincent Guillard (Chevrainvilliers, FR)
Cpc classification
C03B13/00
CHEMISTRY; METALLURGY
C03B35/188
CHEMISTRY; METALLURGY
C03C10/00
CHEMISTRY; METALLURGY
C03C2204/00
CHEMISTRY; METALLURGY
C03B17/067
CHEMISTRY; METALLURGY
International classification
C03C10/00
CHEMISTRY; METALLURGY
C03B13/00
CHEMISTRY; METALLURGY
Abstract
Embodiments of a method of forming a glass article are disclosed. The methods include supplying a glass ribbon in a first direction and redirecting the glass ribbon to a second direction different from the first direction without contacting the glass ribbon with a solid material. The glass ribbon may exhibit a viscosity of less than about 10.sup.8 Poise and a thickness of about 1 mm or less. Embodiments of a glass or glass-ceramic forming apparatus are also disclosed. The apparatus may include a glass feed device for supplying a glass ribbon in a first direction and a redirection system disposed underneath the glass feed device for redirecting the glass ribbon to a second direction. In one or more embodiments, the redirection system comprising at least one gas bearing system for supplying a gas film to support the glass ribbon.
Claims
1.-13. (canceled)
14. A glass ribbon forming apparatus comprising: a glass feed device for supplying a glass ribbon in a first direction, at least a portion of the glass ribbon exhibiting a viscosity of less than about 10.sup.8 Poise; and a redirection system disposed underneath the glass feed device for redirecting the glass ribbon to a second direction, the redirection system comprising at least one gas bearing system for supplying a gas film for supporting the glass ribbon.
15. The glass ribbon forming apparatus of claim 14, wherein the at least one gas bearing system comprises one of: a curved support for providing an arcuate gas film that redirects the glass ribbon to the second direction, wherein the curved support is stationary or rotatable around a first axis in a direction in which the glass ribbon is supplied; and a horizontally disposed, planar support for providing a planar gas film that redirects the glass ribbon to the second direction.
16. The glass ribbon forming apparatus of claim 15, further comprising a second gas bearing system comprising a horizontally disposed, planar support for providing a planar gas film that supports the redirected glass ribbon in the second direction.
17. The glass ribbon forming apparatus of claim 14, further comprising a system comprising a sensor for detecting a shape of the redirection of the glass ribbon in communication with a speed control, wherein the sensor signals an increase or decrease to the speed control based on the shape of the redirection of the glass ribbon.
18. The glass ribbon forming apparatus of claim 17, wherein the sensor comprises an optical detector and the speed control is in communication with the at least one of the glass feed device and the at least one gas bearing.
19. (canceled)
20. A glass-ceramic formed according to a method comprising: supplying a glass ribbon in a first direction, at least a portion of the glass ribbon exhibiting a viscosity of less than about 10.sup.8 Poise; redirecting the glass ribbon to a second direction different from the first direction without contacting the glass ribbon with a solid material to provide a precursor glass ribbon exhibiting a thickness of about 1 mm or less in the second direction; and ceramming the precursor glass ribbon to form a glass-ceramic.
21. The glass ribbon forming apparatus of claim 14, wherein the at least one gas bearing system comprises a curved support for providing an arcuate gas film that redirects the glass ribbon to the second direction, wherein the curved support is stationary or rotatable around a first axis in a direction in which the glass ribbon is supplied.
22. The glass ribbon forming apparatus of claim 14, wherein the at least one gas bearing system comprises a horizontally disposed, planar support for providing a planar gas film that redirects the glass ribbon to the second direction.
23. The glass ribbon forming apparatus of claim 14, further comprising a forming body comprising a plurality of walls defining an open channel and overflowing the flowing molten glass over the walls of the forming body into two individual flows of molten glass that combine to form the glass ribbon.
24. The glass ribbon forming apparatus of claim 14, further comprising a forming body comprising an open slot.
25. The glass ribbon forming apparatus of claim 14, further comprising at least one pair of forming rolls.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
[0028] Reference will now be made in detail to the present preferred embodiment(s), examples of which are illustrated in the accompanying drawings. Whenever possible, the same reference numerals will be used throughout the drawings to refer to the same or like parts.
[0029] A first aspect of this disclosure pertains to a method for forming a glass sheet in which a glass ribbon is formed in a first direction (e.g., vertical) and redirected to a second direction different from the first direction (e.g., horizontal), while maintaining the surface quality of the glass ribbon. In some embodiments, the method includes redirecting the glass ribbon when the glass ribbon is viscous (e.g., has a viscosity less than about 10.sup.8 poise) and/or by completing the redirection of the glass ribbon along a turn or curve having a horizontal length of less than about 1.5 m. In one or more embodiments, the method includes redirection of the glass ribbon from a vertical or essentially vertical direction to a horizontal direction along a horizontal length of about 200 mm or less.
[0030] Known processes in which a glass ribbon is redirected from a vertical process to a horizontal process typically utilize higher viscosity glasses. For example, known processes and apparatus may use glasses with viscosities of greater than 10.sup.8 poise and such glasses may develop significant and undesirable elastic stresses during processing. Moreover, the higher viscosity glasses may still require use of an apparatus with a larger layout. For example, the radius of the turn or redirection may need to be great enough (e.g., greater than about 1.5 m) to enable redirection of the glass ribbon formed from higher viscosity glasses using an air bearing. Significant elastic stresses will therefore possibly develop. The embodiments of the methods described herein address these issues.
[0031] In one or more embodiments, the method includes supplying a glass ribbon in the first direction, where at least a portion of the glass ribbon exhibits a low viscosity. As used herein, low viscosity includes a viscosity of less than about 10.sup.8 poise, less than about 10.sup.7.8 poise, less than about 10.sup.7.6 poise, less than about 10.sup.7.4 poise, less than about 10.sup.7.2 poise, less than about 10.sup.7 poise and all ranges and sub-ranges therebetween. In one or more embodiments, the glass ribbon has a low viscosity that is greater than about 10.sup.6 poise.
[0032] The method may include supplying a glass ribbon in the first direction by a number of ways. As shown in
[0033] As shown in
[0034] In one or more alternative embodiments, supplying the glass ribbon may include forming the glass ribbon by a fusion forming process (not shown). In one or more specific embodiments, the method includes flowing molten glass from a forming body including an open channel (not shown) defined by a plurality of walls (not shown). The molten glass flows into the open channel and overflows the walls thereof, thereby separating into two individual flows of molten glass that flow over the converging forming surfaces (not shown). When the individual flows of molten glass are flowed vertically and are recombined to form a single ribbon of molten glass that descends from the forming body. In this manner, the method includes drawing the glass ribbon in a first direction, which may be vertical.
[0035] In one or more embodiments, the method includes redirecting the glass ribbon from a first direction to a second direction different from the first direction, without contacting the glass ribbon with a solid material. As shown in
[0036] As shown in
[0037] As shown in
[0038] In one or more embodiments, the method includes rotating the curved support 310 or providing a stationary curved support 310. The method may also include directing gas through the gas bearing 312 of the curved support in one direction (as shown in
[0039] As shown in
[0040] In the embodiment shown in
[0041] In one or more embodiments, the method may include modifying the speed (e.g., increased or decreased) of supplying the glass ribbon. In one or more embodiments, the method includes modifying the speed, without the use of a curved support. As shown in
[0042] With respect to the gas bearing(s) 312, 332, the curved support 310 and the horizontally disposed, planar support 330 may be formed at least partially from a pressurized, porous material through which the gas from the gas bearing is flowed. The porous material which may include graphite, ceramic, partially sintered metal, high temperature tolerant metal oxide(s), silicon carbide and other similar materials through which gas may be flowed at the recited pressures. The permeability of the porous material may be in the range from about 10.sup.15 m.sup.2 to about 10.sup.13 m.sup.2. The method may include supplying a gas to the porous material through a feed or a plurality of feeds as shown in
[0043] As shown in
[0044] In one or more embodiments, the method includes introducing a minimal or no tension to the glass ribbon during redirection. In one or more alternative embodiments, the method includes applying a tension to the glass ribbon during redirection to further reduce the thickness of the glass ribbon. The thickness may be reduced by up to about 20%, up to about 25%, or even up to about 30%. In one or more embodiments, the tension in the glass ribbon is created between supplying the glass ribbon along at least a portion of a curved support (e.g., 310) and supplying the glass ribbon to the horizontally disposed, planar support (e.g., 330).
[0045] In one or more embodiments of the method, redirecting the glass ribbon includes maintaining the temperature of the glass ribbon such that the glass ribbon exhibits a desired viscosity (e.g., less than about 10.sup.8 poise, about 10.sup.7.8 poise or less, about 10.sup.7.6 poise or less, about 10.sup.7.4 poise or less, about 10.sup.7.2 poise or less, about 10.sup.7 poise or less). In some embodiments, the method includes maintaining the temperature of the portion of the glass ribbon exhibiting a low viscosity, at the first temperature, as defined herein. The temperature of the glass ribbon or the portion of the glass ribbon exhibiting a low viscosity may be maintained by directing gas to glass ribbon, thus creating a gas bearing effect where the gas bearing and/or the gas film generated by the gas bearing have a temperature in the range from about 200 C. to about 400 C. Additionally or alternatively, the method may include controlling the environment and specifically controlling the temperature of the environment during at least the redirection.
[0046] In one or more embodiments, the redirected glass ribbon exhibits a thickness in the range from about 0.1 mm to about 5 mm, from about 0.1 mm to about 4 mm, from about 0.1 mm to about 3 mm, from about 0.1 mm to about 2 mm, from about 0.1 mm to about 1 mm, from about 0.5 mm to about 5 mm, from about 0.75 mm to about 5 mm, from about 1 mm to about 5 mm, from about 1.5 mm to about 5 mm, from about 0.1 mm to about 0.9 mm, from about 0.1 mm to about 0.8 mm, from about 0.1 mm to about 0.7 mm, from about 0.1 mm to about 0.6 mm, from about 0.1 mm to about 0.5 mm, and all ranges and sub-ranges therebetween. In some instances, the method includes reducing the thickness of the glass ribbon during redirection of the glass ribbon from the first direction to the second direction. In one variant, the method includes reducing the thickness of the glass ribbon by about 5%, about 10%, about 15%, about 20% or about 25% during redirection of the glass ribbon from the first direction to the second direction. In one or more alternative embodiments, the method includes substantially maintaining the thickness of the glass ribbon. In one variant, the method includes maintaining the thickness of the glass ribbon during redirection such that the glass ribbon in the second direction is no more than 5% less than the thickness of the glass ribbon in the first direction.
[0047] In one or more embodiments, the methods described herein can form and redirect a glass ribbon having a thickness of about 1 mm or about 1.1 mm, a width in the range from about 60 mm to about 70 mm at a speed of about 11 m/minute. In some embodiments, the glass ribbons were thus formed and redirected using a gas bearing system as described herein directing gas at the glass ribbon at a pressure of about 0.2 MPa. The resulting glass ribbon exhibits a superior flatness, is free of optical distortions and shows no visual damage indicating possible contact between the glass ribbon and a solid material.
[0048] The method according to one or more embodiments may include cooling the glass ribbon into a glass sheet. The embodiment shown in
[0049] A second aspect of the present disclosure pertains to a glass or glass-ceramic forming apparatus. In one or more embodiments, the apparatus includes glass feed device for supplying a glass ribbon exhibiting a viscosity of less than about 10.sup.8 poise in a first direction (e.g., vertical) and a redirection system for redirecting the glass ribbon to a second direction (e.g., horizontal). As shown in
[0050] As shown in
[0051] In one or more alternative embodiments, the glass feed system may include a fusion forming system (not shown). In one or more specific embodiments, the fusion forming system may include a melting furnace (not shown) for melting batch material to produce molten glass in communication with a fining vessel that heats the molten glass. The fusion forming system may include a stirring vessel (not shown) in communication with the fining vessel for homogenizing the molten glass and a forming body (not shown) in communication with the stirring vessel. The forming body may an open channel (not shown) defined by a plurality of walls (not shown), a pair of converging forming surfaces (not shown) that converge at a bottom of the forming body. In operation, the molten glass from the stirring vessel into the open channel of the forming body and overflows the walls thereof, thereby separating into two individual flows of molten glass that flow over the converging forming surfaces (not shown). When the individual flows of molten glass are flowed vertically and are recombined to form a single ribbon of molten glass that descends from the forming body. In this manner, fusing forming system provides a drawn glass ribbon in a first direction, which may be vertical.
[0052] The apparatus of one or more embodiments includes a redirection system disposed underneath the glass feed device for redirecting the glass ribbon to a second direction. In one or more embodiments, the redirection system includes at least one gas bearing system for supplying a gas film for supporting the glass ribbon during redirection. The at least one gas bearing system 310 may include a curved support 310 having an outer curved surface 314 for providing an arcuate gas film surface that redirects the glass ribbon to the second direction. In one or more embodiments, the curved support 310 may be rotatable around a first axis in a direction in which the glass ribbon is supplied. In one or more alternative embodiments, the curved support 310 may be stationary.
[0053] As shown in the embodiment of
[0054] In one or more embodiments, the apparatus includes system for monitoring the redirection of the glass ribbon. As shown in