METHODS AND APPARATUS FOR HEAT TRANSFER BY CONDUCTION MORE THAN CONVECTION
20190039938 ยท 2019-02-07
Assignee
Inventors
- Dana Craig Bookbinder (Corning, NY)
- Jeffrey John Domey (Elmira, NY)
- John Christopher Thomas (Elmira, NY)
- Kevin Lee Wasson (Elmira, NY, US)
Cpc classification
C03B29/12
CHEMISTRY; METALLURGY
C03B25/093
CHEMISTRY; METALLURGY
B65G49/065
PERFORMING OPERATIONS; TRANSPORTING
International classification
C03B29/12
CHEMISTRY; METALLURGY
Abstract
Method and apparatus are provided for the controlled transport of glass sheets (13) or glass ribbons (15) undergoing heating and/or cooling (e.g., thermal tempering) by conduction more than convection. The controlled transport is achieved by applying a gas-based force (17,19,21) to the glass sheet (13) or glass ribbon (15). The gas-based force (17,19,21) can move the glass sheet (13) or glass ribbon (15) in a desired direction and/or cause it to acquire a desired orientation. The gas-based force (17,19,21) can also cause the glass sheet (13) or glass ribbon (15) to retain a desired position and/or a desired orientation. The gas-based force (17,19,21) can be applied to the glass sheet (13) or glass ribbon (15) continuously or intermittently. Systems for transitioning a glass sheet (13) or a glass ribbon (15) between a heating zone (27) and a quench zone (31) are also discussed.
Claims
1. A method for heating or cooling a glass sheet or a glass ribbon by conduction more than convection, the glass sheet or the glass ribbon having opposing major surfaces, the method comprising: (a) controlling movement of the glass sheet or the glass ribbon while the glass sheet or the glass ribbon is in and/or is passing through a gap in which pressure is applied to the opposing major surfaces of the glass sheet or the glass ribbon; and (b) heating or cooling the glass sheet or the glass ribbon by conduction more than convection while it is in and/or is moving through the gap; wherein step (a) comprises applying at least one gas-based force to the glass sheet or the glass ribbon which gas-based force has at least one non-zero component whose direction is parallel to a major surface of the glass sheet or the glass ribbon.
2. The method of claim 1 wherein in step (b) the glass sheet or the glass ribbon is cooled and the cooling thermally tempers the glass sheet or the glass ribbon.
3. The method of claim 1 wherein the gas-based force causes the glass sheet or the glass ribbon to move in a desired direction and/or to acquire a desired orientation.
4. The method of claim 1 wherein the gas-based force causes the glass sheet or the glass ribbon to retain a desired position and/or a desired orientation.
5. The method of claim 1 wherein the gas-based force is applied to the glass sheet or the glass ribbon continuously.
6. The method of claim 1 wherein the gas-based force is applied to the glass sheet or the glass ribbon intermittently.
7. The method of claim 1 wherein the gas-based force is applied to the glass sheet or the glass ribbon by a gas bearing that comprises gas bearing outlets that are slanted.
8. The method of claim 7 wherein the gas bearing comprises gas bearing outlets that are vertical.
9. The method of claim 1 wherein the gas-based force is applied to the glass sheet or the glass ribbon by at least one gas wall.
10. The method of claim 9 wherein the gas wall is oriented parallel to the direction of motion of the glass sheet or the glass ribbon through the gap.
11. The method of claim 10 wherein the gas-based force provides left-right alignment for the glass article or the glass ribbon.
12. The method of claim 9 wherein a plurality of glass sheets are in or passing through the gap and the gas wall is oriented transversely to a direction of motion of the glass sheets.
13. The method of claim 12 wherein the gas-based force provides speed control for the plurality of glass sheets.
14. The method of claim 13 wherein the speed control comprises temporarily bringing one or more of the plurality of glass sheets to rest.
15. The method of claim 12 wherein the gas-based force provides inter-piece spacing control for the plurality of glass sheets.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0021]
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[0036] The reference numbers used in the drawings, which are not to scale, refer to the following: [0037] 9 a glass sheet or a glass ribbon [0038] 11 a major surface of a glass sheet or a glass ribbon [0039] 13 a glass sheet [0040] 15 a glass ribbon [0041] 17 vector [0042] 19 vector [0043] 21 vector [0044] 23 gap [0045] 23a thicker gap [0046] 23b thinner gap [0047] 25 direction of motion of glass sheet or glass ribbon [0048] 27 heating zone [0049] 29 transition zone [0050] 31 quench zone [0051] 33 gas bearing [0052] 35 slanted outlet of gas bearing [0053] 37 vertical outlet of gas bearing [0054] 39 longitudinal gas wall [0055] 41 gas flow in longitudinal gas wall [0056] 43 side gas pressure system [0057] 45 side gas pressure nozzle [0058] 47 transverse gas wall [0059] 49 gas flow in transverse gas wall [0060] 51 nozzle of transverse gas wall [0061] 53 angle from horizontal [0062] 55 taper [0063] 57 one-sided support [0064] 59 burner [0065] 61 substrate [0066] 63 liquid metal or liquid salt [0067] 65 barrier [0068] 67 mechanical support [0069] 69 motion of mechanical support [0070] 71 top support of two-sided support [0071] 73 bottom support of two-sided support
DETAILED DESCRIPTION
[0072]
[0073] As shown in these figures, the systems can include a heating zone 27, a transition zone 29, and a quench zone 31, it being understood that the controlled transport methods and apparatus disclosed herein can be applied to all of the zones, only one of the zones, e.g., just the quench zone, or only two of the zones, e.g., just the heating and quench zones, as desired. Also, some embodiments may employ only one of the zones, e.g., only the heating zone if only heating is desired.
[0074] In general terms, heating zone 27 heats the glass article(s) to a temperature sufficient for thermal tempering, and quench zone 31 lowers the surface temperature of the article(s) at a rate sufficient to achieve a desired level of thermal tempering. As its name implies, transition zone 29 (when used) serves as an interface between the high temperatures of the heating zone and the low temperatures of the quench zone. As shown in
[0075]
[0076] When glass sheet(s) are being treated, the process can, for example, be characterized as a batch process, a semi-continuous process, or a continuous process. In a batch process, the glass sheet(s) can be moving at different speeds at different points in the process. For example, the glass sheet(s) can move through the heating zone at one speed or set of speeds, through the transition zone (when used) at another speed or set of speeds, and through the quench zone at still another speed or set of speeds. Likewise, for a semi-continuous process, the glass sheets can be moving at different speeds at different points in the process, with the spacings between glass sheets increasing and decreasing as the treatment takes place to avoid contact between the articles. As just one example, a given glass sheet can enter a zone and slow down or become stationary as a result of the application of a gas-based force, with the spacing to the next following glass sheet decreasing during the slow down or stationary period. The given glass sheet can then be accelerated by a gas-based force to restore the original spacing or some other spacing as appropriate.
[0077] For a glass ribbon, the process is continuous for any given ribbon. Nevertheless, the effects of different speeds can be achieved through adjustments in the lengths of the zones. Specifically, the effects of a higher speed can be achieved by a shorter zone (shorter residence time), and the effects of a slower speed by a longer zone (longer residence time). Such adjustments in the lengths of the zones can also be used with glass sheets if desired. Also, a combination of zone lengths and zone speeds can be used with glass sheets. In addition to speed considerations, zone lengths can change with the size of the glass sheets being processed, longer zones being used for longer glass sheets.
[0078] The temperature T of the glass article may be below, at, or above a desired T.sub.0 when the glass article enters the heating zone. If below, the temperature is raised to T.sub.0 or in some cases to T.sub.0+T to compensate for heat loss that may occur in the transition zone (when used). If the temperature of the glass article is already at T.sub.0 at the start of the heating zone, then the heating zone can maintain that temperature or, alternatively, raise it to T.sub.0+T. If the temperature is already at T.sub.0+T, the heating zone can maintain that temperature. Alternatively, if the temperature of the article is already at T.sub.0 (or, if desired, at T.sub.0+T), e.g., because it has been recently formed by, for example, a float or fusion process, the heating zone may be eliminated, with the article going directly to the transition zone (when used) or directly to the quench zone.
[0079] After leaving the heating zone (when used), the glass article can enter the transition zone (when used), which can serve to minimize adverse impacts to the glass article and/or the process as a result of the sharp change in temperature needed to achieve thermal tempering. The transition zone can also be used to change the thickness of gap 23 from that used in the heating zone to that used in the quench zone. For example, the gap may be thicker in the heating zone than in the quench zone. The transition zone can be used to provide a smooth transition between the gap dimensions.
[0080] Depending on its length and construction, the transition zone can use a gas bearing of the type shown in
[0081] If desired, the transition zone can in essence be eliminated with the glass article(s) passing directly from the heating zone to the quench zone. For example, the spacing between the heating zone and the quench zone can be less than about five times the thickness of the glass article. In connection with these embodiments, if the thickness of gap 23 is different in the heating and quench zones, the gap may be tapered (e.g., at a taper angle in the range of, for example, 0.001 to 90 degrees, with 90 degrees corresponding to a step change) in the region of the exit of the heating zone and/or in the region of the entrance to the quench zone.
[0082] If a transition zone is used and if vertical support in the transition zone is desired, the support can be either one-sided support where the supporting system acts from below the glass article or two-sided support where the supporting system acts both from above and from below the glass article. In either case, the magnitude of the upward force per unit area (upward pressure) needed to counteract the effect of gravity is small, as can be seen from the following calculation.
[0083] For a glass sheet having a density , a thickness d, and major surfaces of area A, the weight (W) of the glass sheet is:
W=g**A*d,
where g is the gravitational constant (g=9.8 meters/second.sup.2). The weight per unit area (W/A) is then:
W/A=g**d.
[0084] Representative densities for glass sheets (and ribbons) are in the range of 2400-2800 kg/meter.sup.3, and representative thicknesses are in the range of 0.1-12 millimeters. Accordingly, the upward pressure needed to counteract the force of gravity in the transition zone are on the order of 2-300 Pascal (0.0003-0.04 psi).
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[0088] Two-sided support can also be provided in a variety of ways.
[0089] Many of the systems used for one-sided support can also be used for two-sided support, with a second copy of the system (either identical or modified) used for the top support. For example, two-sided systems can be based on ultrasonic levitation, the Bernoulli principle, simple gas pressure, or the burner/substrate system of
[0090] As noted above, the more-heat-transfer-by-conduction-than-convection criterion is satisfied in quench zone 31 and may be satisfied in heating zone 27 and/or transition zone 29. When this criterion is satisfied, the flow of gas into gap 23 from gas bearing 33 is low. Consequently, the glass article(s) are in a low friction environment when in gap 23 and thus their motion can be controlled with relatively small gas-based forces. The following calculations illustrate the low force magnitudes associated with such a low friction environment.
[0091] We consider two representative cases, a higher force case and a lower force case. The higher force calculation is for a higher mass glass sheet undergoing a larger change (increase or decrease) in speed over a shorter time period, and the lower force case is for a lower mass glass sheet undergoing a smaller change in speed over a longer time period. For the higher mass sheet, we consider a 3 meter by 3 meter sheet having a thickness of 12 millimeters and a density of 2800 kg/meter.sup.3, and for the lower mass glass sheet, we consider a 25 millimeter by 25 millimeter glass sheet having a thickness of 1 millimeter and a density of 2400 kg/meter.sup.3. The masses for these two cases are 302.4 kilograms and 0.0015 kilograms, respectively. For the larger change in speed over the shorter time period, we consider a speed change of 1 meter/second in 0.1 seconds, and for the smaller change in speed over the longer time period, we consider a speed change of 0.001 meters/second over 1 second. In each case, we assume that a constant force is applied over the time period.
[0092] From Newton's laws, we can write: Ft=mv, where F is the gas-based force, t is the time over which the force acts, m is the mass of the glass sheet, and v is the change in speed. Evaluating this equation for the higher and lower force cases, we have forces of 3027 Newtons and 1.510.sup.6 Newtons, respectively. Including friction in the calculation has a minimal effect on these values, the frictional force for the higher mass glass sheet being only 3.0 Newtons for a coefficient of friction of 0.001 (a high estimate), and is much lower for the lower mass glass sheet.
[0093] Assuming the gas-based force acts on an edge of the glass sheet, these forces for the higher and lower force cases correspond to pressures of 84.1 kilopascal (12.2 psi) and 0.06 Pascal (8.710.sup.6 psi), respectively, which are readily achieved in practice. For a gas-based force applied to a major surface of a glass sheet, the angle at which the gas impacts the glass sheet comes into play, as well as the velocity of the gas leaving the outlets and the gas density. Computational fluid dynamics (CFD) can be used to calculate the tangential sheer force applied to the surface of the glass article for any particular arrangement of outlets and gap thicknesses and areas. For example, the commercially available ANSYS CFD software (ANSYS Inc., Canonsburg, Pa.) can be used for this purpose. In general terms, an individual outlet at an angle from horizontal in the range of approximately 30 can generate a tangential sheer force at least in the micro-Newton range for a flow velocity on the order of a few hundred meters/second. The number of outlets can then be adjusted to achieve the accelerations/decelerations of the glass article that are desired.
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[0098] When a gas wall is used, whether it be a longitudinal or a transverse wall, at least some of the gas flowing from the vertical outlets 37 of gas bearing 33 (and the slanted outlets 35, when used) will enter the gas flow which forms the wall, rather than exiting from the sides of the gas bearing as occurs in the absence of a gas wall(s). The gas flow in a gas wall, whether a longitudinal or traverse wall, will generally be at least 2-3 times the gas flow from a vertical outlet 37, the amount of flow being dependent on the magnitude of the gas-based force needed to achieve motion control (e.g., steering) of the glass article(s) at the location of the wall.
[0099] The gas used in the above embodiments, as well as in other embodiments, can have a variety of compositions. The gas can be one gas or a mixture of gases from different gas sources or the same gas source. Exemplary gases include air, nitrogen, carbon dioxide, helium or other noble gases, hydrogen and combinations thereof.
[0100] A variety of modifications that do not depart from the scope and spirit of the invention will be evident to persons having ordinary skill in the art from the foregoing disclosure. As just one example, as illustrated in