Patent Application
20120144864
The present invention relates to a method and a device for manufacturing a glass sheet.
A method called a fusion process is conventionally known as a manufacturing method of a high-quality glass sheet (for example, see Patent Document 1). The fusion process is a method in which molten glass is run down along both side surfaces of a molded body with a cross section of a wedge shape converging downward and also the molten glass is joined and integrated just under a lower edge part of the molded body and while cooling an integrated sheet-shaped glass ribbon, the glass ribbon is drawn downward, thereby molding in a predetermined thickness. In the glass ribbon after molding, both ends in a width direction of the glass ribbon are cut off and the remaining center in the width direction is used as a glass sheet which is a product.
Normally, at least a pair of rollers is arranged under the molded body. The pair of rollers is rotated and driven by a driving device such as a motor, and pinches and downward delivers the end in the width direction of the glass ribbon. The glass ribbon is thicker than a predetermined thickness just under the lower edge part of the molded body, and is thinly drawn by a downward drawing force. As the force by which the glass ribbon is drawn downward, own weight of the glass ribbon can be used in addition to rotation torque acting on the glass ribbon from the pair of rollers.
Patent Document 1 proposes that a load acting on each roller from a glass ribbon should be detected to control a rotational speed of each roller based on a detection result in order to maintain the force by which the glass ribbon is drawn downward constant when own weight the glass ribbon varies steadily depending on cutting etc. of the glass ribbon.
Patent Document 1: JP-T-2008-501605 (Paragraph [0029])
Incidentally, when a pinching force acting on the end in the width direction of the glass ribbon by a pair of rollers (hereinafter called a roller pair) is too weak, the roller pair slips on the glass ribbon, so that it becomes difficult to equally draw the glass ribbon. Also, when the pinching force is too strong, an excessive load is applied to the end in the width direction of the glass ribbon, so that the glass ribbon may break.
Also, a proper range of the pinching force tends to vary depending on molding conditions. This tendency is remarkable as a thickness of a glass sheet becomes thin, and is particularly remarkable since rigidity of the glass sheet becomes remarkably low when the thickness of the glass sheet is 0.3 mm or less.
Here, the molding conditions refer to conditions of molding the glass sheet, and include, for example, material, size, arrangement of a molding furnace wall and a molded body constructing a manufacturing device of the glass sheet, or temperature distribution of the inside of the device in operation of the manufacturing device in addition to composition or thickness of the glass sheet, a force by which a glass ribbon is drawn downward, thickness of both ends in the width direction, temperature distribution or conveyance speed of the glass ribbon. Also, the molding conditions include, for example, a control method, the amount of heat generation, or arrangement of a heating element for increasing a temperature of the inside of a molding furnace.
However, in the conventional manufacturing method, a distance between the roller pair was fixed and it was difficult to adjust the pinching force, so that it was difficult to handle a change in the molding conditions. As a result, it was difficult to continuously mold the glass sheet with an average thickness of 0.3 mm or less.
The invention has been implemented in view of the problem described above, and an object of the invention is to provide a method and a device for manufacturing a glass sheet capable of easily handling a change in a molding condition and continuously molding a glass sheet with an average thickness of 0.3 mm or less.
In order to solve the above-mentioned problem, the present invention relates to a method for manufacturing a glass sheet, the method comprising:
running down molten glass along both side surfaces of a molded body;
joining and integrating the molten glass just under a lower edge part of the molded body; and
pinching and downward delivering an end in a width direction of an integrated sheet-shaped glass ribbon by a roller pair, thereby drawing downward the glass ribbon and molding a center in the width direction of the glass ribbon to have an average thickness of 0.3 mm or less,
wherein a pinching force is adjusted in a range in which a ratio F/T of a pinching force F (unit: N) acting on the end in the width direction of the glass ribbon by rollers of the roller pair to an average thickness T (unit: mm) of the center in the width direction of the glass ribbon after molding satisfies a relation expressed by the following formula (1):
10 (N/mm)≦F/T≦300 (N/mm)
Also, the present invention relates to a device for manufacturing a glass sheet, comprising a molded body for joining and integrating molten glass run down along both side surfaces of the molded body just under a lower edge part; and a roller pair for pinching and downward delivering an end in a width direction of a sheet-shaped glass ribbon integrated by the molded body, in which the glass ribbon is drawn downwardly and a center in the width direction of the glass ribbon is molded to have an average thickness of 0.3 mm or less,
wherein the device has an adjusting unit for adjusting a pinching force in a range in which a ratio F/T of a pinching force F (unit: N) acting on the end in the width direction of the glass ribbon by rollers of the roller pair to an average thickness T (unit: mm) of the center in the width direction of the glass ribbon after molding satisfies a relation expressed by the following formula (I):
10 (N/mm)≦F/T≦300 (N/mm) (1).
According to the invention, a method and a device for manufacturing a glass sheet capable of easily handling a change in a molding condition and continuously molding the glass sheet with the average thickness of 0.3 mm or less can be provided.
A mode for carrying out the invention will hereinafter be described with reference to the drawings.
The molded body 11 is constructed of, for example, an alumina or zirconia refractory. The molded body 11 has a cross section of a wedge shape converging downward. A recess 13 is formed in the upper portion of the molded body 11.
A molten glass supply pipe (not shown) is connected to the recess 13 of the molded body 11. Molten glass 12 supplied from this molten glass supply pipe to the inside of the recess 13 spills from an upper edge (that is, the upper edge of the molded body 11) 14 of the recess 13, and runs down along both side surfaces of the molded body 11, and joins and integrates just under a lower edge part 15 of the molded body 11. The integrating molten glass 12 forms the sheet-shaped glass ribbon 12A. The roller pairs 20 are installed under the molded body 11.
In an example shown in
In the glass ribbon 12A after molding, both ends in the width direction of the glass ribbon 12A are cut off and the remaining center in the width direction is used as a glass sheet which is a product.
The roller pairs 20 are rotated and driven by a driving device such as a motor, and pinch and downward deliver the end in the width direction of the glass ribbon 12A. The glass ribbon 12A is thicker than a predetermined thickness just under the lower edge part 15 of the molded body 11, and is thinly drawn by a downward drawing force. As the force by which the glass ribbon 12A is drawn downward, own weight of the glass ribbon 12A can be used in addition to rotation torque acting on the glass ribbon 12A by the roller pairs 20.
A static friction coefficient between the roller pairs 20 and the glass ribbon 12A is preferably 0.05 to 0.5. When the static friction coefficient is smaller than 0.05, the roller pairs 20 slip on the glass ribbon 12A and it becomes difficult to equally draw the glass ribbon 12A. On the other hand, when the static friction coefficient is larger than 0.5, an excessive load may be applied to the glass ribbon 12A when there is a deviation between a conveyance direction of the glass ribbon 12A and a direction in which the roller pairs 20 deliver the glass ribbon 12A.
The portion of the roller pairs 20 in contact with the glass ribbon 12A is formed of ceramic fiber or metal. In the case of being formed of the metal, the surface is finer than the case of being formed of the ceramic fiber, so that a foreign substance such as a cullet is resistant to adhering. As a result, the foreign substance can be inhibited from biting between the roller pairs 20 and the glass ribbon 12A. Also, in the case of being formed of the metal, the surface is finer than the case of being formed of the ceramic fiber, so that dust is resistant to occurring. As a result, a situation in which the occurring dust adheres to the glass ribbon 12A to cause a defect can be inhibited.
A pinching force F acting on the ends in the width direction of the glass ribbon 12A by the rollers 21a to 21h, 22a to 22h (provided that, the rollers 22e to 22h are not shown) of the roller pairs 20 acts in a direction orthogonal to a main surface of the glass ribbon 12A. Here, the pinching force F refers to respective sizes of pressing forces F1, F2 (see
Incidentally, when the pinching force F is too weak, the roller pairs 20 slip on the glass ribbon 12A, so that it becomes difficult to equally draw the glass ribbon 12A. Also, when the pinching force F is too strong, an excessive load is applied to the glass ribbon 12A, so that the glass ribbon 12A may break.
Also, a proper range of the pinching force F tends to vary depending on molding conditions. This tendency is remarkable as an average thickness of a glass sheet becomes thin, and is particularly remarkable since rigidity of the glass sheet becomes low when the average thickness of the glass sheet is 0.3 mm or less.
Here, the molding conditions refer to conditions of molding the glass sheet, and include, for example, states of components (the molded body 11, a furnace wall, a heating element, etc.) constructing the manufacturing device of the glass sheet in addition to composition or thickness of the glass sheet, a force by which the glass ribbon 12A is drawn downward, thickness of the end in the width direction, temperature distribution or conveyance speed of the glass ribbon 12A.
On the other hand, the manufacturing device of the glass sheet of the embodiment has an adjusting unit 31 for adjusting the pinching force F acting on the ends in the width direction of the glass ribbon 12A by the roller pairs 20. In addition, the adjusting unit 31 is installed one by one in each roller. The adjusting unit 31 adjusts the pinching force F in a range in which a ratio F/T of the pinching force F (unit: N) to an average thickness T (unit: mm) of the glass sheet satisfies a relation expressed by the following formula (I) when the average thickness T of the glass sheet is 0.3 mm or less. Consequently, a change in the molding conditions can be handled easily, and the glass sheet with the average thickness T of 0.3 mm or less can be molded continuously.
10 (N/mm)≦F/T≦300 (N/mm) (1)
When the ratio F/T is smaller than 10 N/mm, the pinching force F is too weak with respect to the average thickness T, so that the roller pairs 20 slip on the glass ribbon 12A, so that it becomes difficult to equally draw the glass ribbon 12A. As a result, a flow of the glass ribbon 12A may disconnect.
On the other hand, when the ratio F/T is larger than 300 N/mm, the pinching force F is too strong with respect to the average thickness T, so that the glass ribbon 12A may break.
In addition, an optimum value of the ratio FIT may vary depending on the molding conditions (for example, deterioration in a heating element (not shown) arranged in the molded body 11 or the periphery of the molded body 11) within the range of 10 N/mm to 300 N/mm. In this case, the ratio FIT can be optimized by the adjusting unit 31.
Next, a configuration of the adjusting unit 31 will be described with reference to
In the example shown in
The first bearings 33 rotatably support a first rotating shaft 23 of a first roller 21. The second bearings 34 rotatably support a second rotating shaft 24 of a second roller 22. The first bearings 33 and the second bearings 34 respectively include, for example, ball bearings. Outer rings of the first bearings 33 and the second bearings 34 are respectively supported in support stands (not shown) movably in a direction of moving near to or away from the glass ribbon 12A (in other words, a vertical plane 16 including a lower edge of the molded body 11). That is, the outer rings of the first bearings 33 and the second bearings 34 are supported in the support stands movably in the direction of moving near to or away from each other.
The first movable wall 35 and the second movable wall 36 are respectively supported in the support stands movably in the direction of moving near to or away from the glass ribbon 12A (in other words, the vertical plane 16). That is, the first movable wall 35 and the second movable wall 36 are supported in the support stands movably in the direction of moving near to or away from each other. The first movable wall 35 and the second movable wall 36 are formed of, for example, a metal material such as stainless steel, and are not particularly limited to the material.
The first elastic member 37 is interposed between the outer ring of the first bearings 33 and the first movable wall 35. The first elastic member 37 is constructed of, for example, a coil spring, and is interposed in a compressed state between the outer ring of the first bearings 33 and the first movable wall 35.
The second elastic member 38 is interposed between the outer ring of the second bearings 34 and the second movable wall 36. The second elastic member 38 is constructed of, for example, a coil spring, and is interposed in a compressed state between the outer ring of the second bearings 34 and the second movable wall 36.
The first elastic member 37 elastically urges the first roller 21 through the first bearings 33 in a direction of moving near to the glass ribbon 12A (in other words, the vertical plane 16). That is, the first elastic member 37 elastically urges the first roller 21 in the direction of moving near to the second roller 22.
The second elastic member 38 elastically urges the second roller 22 through the second bearings 34 in a direction of moving near to the glass ribbon 12A (in other words, the vertical plane 16). That is, the second elastic member 38 elastically urges the second roller 22 in the direction of moving near to the first roller 21.
An elastic urging force of the first elastic member 37 is determined by, for example, an elastic coefficient K1 of the first elastic member 37 or the amount of compression ΔX1 (not shown) from a natural state. An elastic urging force of the second elastic member 38 is determined by, for example, an elastic coefficient K2 of the second elastic member 38 or the amount of compression ΔX2 (not shown) from a natural state. The elastic coefficient K1 may be equal to or different from the elastic coefficient K2.
In the embodiment, the elastic urging force of the first elastic member 37 forms the pressing force F1 acting on the end in the width direction of the glass ribbon 12A by the first roller 21, and the elastic urging force of the second elastic member 38 forms the pressing force F2 acting on the end in the width direction of the glass ribbon 12A by the second roller 22. The size F of the pressing force F1 is equal to the size F of the pressing force F2 by the law of action and reaction.
Next, an operation of the adjusting unit 31 will be described with reference to
When the first movable wall 35 and the second movable wall 36 are fixed with respect to the vertical plane 16 after being moved in the direction of moving near to or away from each other manually or by a first driving device 39 and a second driving device 40 such as an air cylinder, the amounts of compression ΔX1, ΔX2 from the natural state change. As a result, the elastic urging forces of the first elastic member 37 and the second elastic member 38 change, and the pinching force F changes. Consequently, a change in the molding conditions can be handled easily.
Also, when the first movable wall 35 and the second movable wall 36 are fixed with respect to the vertical plane 16, the amounts of compression ΔX1, ΔX2 from the natural state change according to variations in thickness of the end in the width direction of the glass ribbon 12A. As a result, the elastic urging forces of the first elastic member 37 and the second elastic member 38 change, and the pinching force F changes. More specifically, when the end in the width direction of the glass ribbon 12A becomes thick, the amounts of compression ΔX1, ΔX2 from the natural state become large, so that the sizes of the elastic urging forces become large and the pinching force F becomes large. Also, when the end in the width direction of the glass ribbon 12A becomes thin, the amounts of compression ΔX1, ΔX2 from the natural state become small, so that the sizes of the elastic urging forces become small and the pinching force F becomes small. Consequently, the excessive pinching force F can be inhibited from being applied to the end in the width direction of the glass ribbon 12A.
In the example shown in
In the example shown in
On the other hand, in the example shown in
Next, an operation of the adjusting unit 31A will be described with reference to
When the first movable wall 35 is fixed with respect to the vertical plane 16 after being moved in a direction of moving near to or away from the glass ribbon 12A (in other words, the vertical plane 16) manually or by a first driving device 39 such as an air cylinder, the amount of compression ΔX1 from a natural state changes. As a result, an elastic urging force of the first elastic member 37 changes and the pinching force F changes. Therefore, also in this case, a change in the molding conditions can be handled easily.
Also, when the first movable wall 35 is fixed with respect to the vertical plane 16, the amount of compression ΔX1 from the natural state changes according to variations in thickness of the end in the width direction of the glass ribbon 12A. As a result, the elastic urging force of the first elastic member 37 changes and the pinching force F changes. Therefore, also in this case, the excessive pinching force F can be inhibited from being applied to the end in the width direction of the glass ribbon 12A.
In addition, in the examples shown in
Next, a driving control system of the roller pairs 20 will be described with reference to
In an example shown in
The third driving device 42 includes, for example, a motor, and rotates and drives the first rotating shaft 23 and the second rotating shaft 24 in the opposite direction mutually under control by a controller 43. Consequently, the first roller 21 and the second roller 22 rotate in the opposite direction mutually, and pinch and downward deliver the glass ribbon 12A.
The third driving devices 42 are installed one by one in plural roller pairs 20a to 20h. The plural third driving devices 42 are connected to one controller 43.
The controller 43 controls the plural third driving devices 42, and mutually associates respective rotational speeds of the plural roller pairs 20a to 20h and controls the rotational speeds, so that distribution of stress applied to the glass ribbon 12A by each of the plural roller pairs 20a to 20h can be optimized easily.
For example, when the respective rotational speeds of the plural roller pairs 20a to 20h are changed, the controller 43 can maintain a rotational speed ratio of the plural roller pairs 20a to 20h constant. Consequently, for example, when the respective rotational speeds of the plural roller pairs 20a to 20h are changed according to variations in the amount of molten glass supply, distribution of stress applied to the glass ribbon 12A can be optimized and the average thickness T of the glass sheet can easily be maintained constant.
In addition, in the example shown in
Next, adjustment of an angle and a position of the roller pairs 20 will be described again with reference to
A position of the end in the width direction of the glass ribbon 12A changes when the roller pair 20 is moved in a direction orthogonal to the vertical plane 16 while maintaining a distance between the roller pair 20 by moving the first movable wall 35 and the second movable wall 36 with respect to the support stands or moving the support stands manually or by the driving device such as the air cylinder as shown by two-dot chain lines in
Consequently, distribution of stress applied to the glass ribbon 12A changes, so that warpage of the glass ribbon 12A may be inhibited.
Also, consequently, the roller pair 20 can be moved in a proper position according to the molding conditions.
Angles θ between a horizontal plane and the first rotating shaft 23 and the second rotating shaft 24 change when the first rotating shaft 23 and the second rotating shaft 24 of the roller pair 20 are turned in a vertical direction by moving the support stands manually or by the driving device such as the air cylinder as shown by two-dot chain lines in
Consequently, a conveyance direction of the glass ribbon 12A and a direction in which each of the roller pairs 20 delivers the glass ribbon 12A can be adjusted. As a result, warpage of the glass ribbon 12A may be inhibited.
Also, consequently, each of the roller pairs 20 can be moved in a proper position according to the molding conditions.
The roller pair 20 moves away from the glass ribbon 12A when the roller pair 20 is moved in a direction away from the vertical plane 16 by moving the first movable wall 35 and the second movable wall 36 with respect to the support stands or moving the support stands manually or by the driving device such as the air cylinder as shown by dotted lines in
The unused roller pair 20 can be prevented from being damaged in the case of disturbing a flow of the glass ribbon 12A when the unused roller pair 20 is moved to the outside in the width direction of the glass ribbon 12A by moving the support stands manually or by the driving device such as the air cylinder as shown by dotted lines in
According to this embodiment as described above, the pinching force F is adjusted in the range in which the ratio F/T of the pinching force F (unit: N) acting on the end in the width direction of the glass ribbon by the rollers of the roller pair 20 to the average thickness T (unit: mm) of the glass sheet satisfies the relation expressed by the following formula (I) when the average thickness T of the glass sheet is 0.3 mm or less, so that a change in the molding conditions can be handled easily, and the glass sheet with the average thickness T of 0.3 mm or less can be molded continuously.
10 (N/mm)≦F/T≦300 (N/mm) (1)
Also, according to this embodiment, the pinching force F is changed according to variations in thickness of the end in the width direction of the glass ribbon 12A, so that the excessive pinching force F can be inhibited from being applied to the end in the width direction of the glass ribbon 12A.
Also, according to this embodiment, the angles θ between the horizontal plane and the first rotating shaft 23 and the second rotating shaft 24 of the roller pair 20 are adjusted, so that warpage of the glass ribbon 12A may be prevented. Also, the roller pair 20 can be moved in a proper position according to the molding conditions.
Also, according to the embodiment, the plural roller pairs 20a to 20h can be used selectively, and distribution of stress applied to the glass ribbon 12A can be adjusted.
Also, according to this embodiment, the unused roller pair 20 is moved to outside in the width direction of the glass ribbon 12A, so that the unused roller pair 20 can be prevented from being damaged in the case of disturbing a flow of the glass ribbon 12A.
Also, according to this embodiment, the respective rotational speeds of the plural roller pairs 20a to 20h are mutually associated and are controlled by one controller 43, so that distribution of stress applied to the glass ribbon 12A by the roller pairs 20 can be optimized easily.
For example, when the respective rotational speeds of the plural roller pairs 20a to 20h are changed, the rotational speed ratio of the plural roller pairs 20a to 20h can be maintained constant. Consequently, for example, when the respective rotational speeds of the plural roller pairs 20a to 20h are changed according to variations in the amount of molten glass supply, distribution of stress applied to the glass ribbon 12A can be optimized and the average thickness T of the glass sheet can easily be maintained constant.
Also, according to this embodiment, the portion of the roller pairs 20 in contact with the glass ribbon 12A is formed of metal, so that a foreign substance such as a cullet can be inhibited from adhering as compared with the case of being formed of ceramic fiber. Consequently, the foreign substance can be inhibited from biting between the roller pairs 20 and the glass ribbon 12A. Also, the portion of the roller pairs 20 in contact with the glass ribbon 12A is formed of metal, so that dust can be inhibited from occurring as compared with the case of being formed of ceramic fiber, and a situation in which the occurring dust adheres to the glass ribbon 12A to cause a defect can be inhibited.
Also, according to this embodiment, the static friction coefficient between the roller pair 20 and the glass ribbon 12A is 0.05 to 0.5, so that the glass ribbon 12A can be drawn equally and also, an excessive load can be inhibited from being applied to the glass ribbon 12A.
The embodiment of the invention has been described above in detail, but the invention is not limited to the embodiment described above, and various modifications and replacements can be made in the embodiment described above without departing from the scope of the invention.
For example, in the embodiment described above, the right and left rollers 21a to 21d, 21e to 21h have an independently rotatable configuration as shown in
The invention will hereinafter be described concretely by examples, but the invention is not limited to the following examples.
In Examples 1 to 12 and Comparative Examples 1 to 12, using the manufacturing device of the glass sheet shown in
O . . . The glass ribbon 12A could be molded continuously for five hours or more.
x . . . A flow of the glass ribbon 12A disconnected within five hours.
It is apparent from Table 1 that a flow of the glass ribbon 12A disconnects when the ratio F/T is more than 300 N/mm and when the ratio F/T is less than 10 N/mm. Also, it is apparent from Table 1 that the glass sheet can be molded continuously stably by adjusting the ratio F/T in the range of 10 N/mm to 300 N/mm according to molding conditions.
The invention has been described in detail with reference to the specific embodiment, but it is apparent to those skilled in the art that various changes or modifications can be made without departing from the spirit and scope of the invention.
The present application is based on Japanese patent application No. 2009-164346 filed on Jul. 13, 2009, and the contents of the patent application are hereby incorporated by reference.
According to the invention, a method and device for manufacturing a glass sheet capable of easily handling a change in a molding condition and continuously molding a glass sheet with an average thickness of 0.3 mm or less can be provided.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-164346 | Jul 2009 | JP | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2010/060905 | Jun 2010 | US |
| Child | 13349824 | US |
