Patent Application
20230286848
The present invention relates to a holding member, a glass manufacturing apparatus using the same, and a glass manufacturing method. The present invention claims the benefit of priority of Japanese Patent Application No. 2020-202124, filed on Dec. 4, 2020, the contents of which are incorporated in the present application by reference in designated countries that allow documents to be incorporated by reference.
For example, Patent Literature 1 discloses a method for manufacturing optical glass by using a laser levitation furnace. In such a laser levitation furnace, it is requested that a glass sample be stably levitated by using levitating gas.
A first aspect of the present invention is a holding member that is used in a glass manufacturing apparatus that cools down a glass raw material that has been levitated by gas and has been heated and melted, and manufactures glass, in which the holding member includes a gas injection surface that includes a plurality of injection ports from which the gas is injected, the gas injection surface includes a first region and a second region, the first region including first injection ports that are some injection ports of the plurality of injection ports, the second region including second injection ports that are different from the first injection ports from among the plurality of injection ports, the first region is located inside the second region, when the gas injection surface is viewed from a top, an area of the injection ports per unit area of the first region is smaller than the area of the injection ports per the unit area of the second region, the area of the injection ports per the unit area of the first region is a ratio of a total of cross-sectional areas of the first injection ports to the area of the first region when the gas injection surface is viewed from the top, and the area of the injection ports per the unit area of the second region is the ratio of the total of the cross-sectional areas of the second injection ports to the area of the second region when the gas injection surface is viewed from the top.
A second aspect of the present invention is a holding member that is used in a glass manufacturing apparatus that cools down a glass raw material that has been levitated by gas and has been heated and melted, and manufactures glass, in which the holding member includes a gas injection surface that includes a plurality of injection ports from which the gas is injected, the gas injection surface includes a first region and a second region, the first region including first injection ports that are some injection ports of the plurality of injection ports, the second region including second injection ports that are different from the first injection ports from among the plurality of injection ports, the first region is located inside the second region, when the gas injection surface is viewed from a top, the number of the injection ports per unit area of the first region is smaller than the number of the injection ports per the unit area of the second region, the number of the injection ports per the unit area of the first region is a ratio of the number of the first injection ports to an area of the first region when the gas injection surface is viewed from the top, and
the number of the injection ports per the unit area of the second region is the ratio of the number of the second injection ports to the area of the second region when the gas injection surface is viewed from the top.
A third aspect of the present invention is a holding member that is used in a glass manufacturing apparatus that cools down a glass raw material that has been levitated by gas and has been heated and melted, and manufactures glass, in which the holding member includes a gas introduction surface and a gas injection surface, the gas introduction surface including an introduction port from which the gas is introduced, the gas injection surface including a plurality of injection ports from which the gas that has been introduced from the gas introduction surface is injected, the gas injection surface includes a first region and a second region, the first region including first injection ports that are some injection ports of the plurality of injection ports, the second region including second injection ports that are different from the first injection ports from among the plurality of injection ports, the first region is located inside the second region, when the gas injection surface is viewed from a top, and the gas introduction surface has a protruding shape.
A fourth aspect of the present invention is a holding member that is used in a glass manufacturing apparatus that cools down a glass raw material that has been levitated by gas and has been heated and melted, and manufactures glass, in which the holding member includes a gas introduction surface and a gas injection surface, the gas introduction surface including an introduction port from which the gas is introduced, the gas injection surface including a first region and a second region, the first region including a plurality of injection ports from which the gas that has been introduced from the gas introduction surface is injected, the second region including an injection port from which the gas is injected, the first region is located inside the second region, when the gas injection surface is viewed from a top, the holding member includes a first portion and a second portion, the first portion being surrounded by a surface including a straight line that is perpendicularly drawn from the first region to the gas introduction surface, the second portion being surrounded by the surface including the straight line that is drawn from the second region to the gas introduction surface in a perpendicular direction, and a portion where a thickness of the first portion is greater than the thickness of the second portion is included, the thickness of the first portion being a length of the straight line that is drawn from a point in the first region to the gas introduction surface in a gravity direction, the thickness of the second portion being the length of the straight line that is drawn from the point in the second region to the gas introduction surface in the gravity direction.
A fifth aspect of the present invention is a holding member that is used in a glass manufacturing apparatus that cools down a glass raw material that has been levitated by gas and has been heated and melted, and manufactures glass, in which the holding member includes a gas introduction surface and a gas injection surface, the gas introduction surface including an introduction port from which the gas is introduced, the gas injection surface including a first region and a second region, the first region including a plurality of injection ports from which the gas that has been introduced from the gas introduction surface is injected, the second region including an injection port from which the gas is injected, the first region is located inside the second region, when the gas injection surface is viewed from a top, and an average thickness (K1) of the holding member between the first region and the gas introduction surface is greater than the average thickness (K2) of the holding member between the second region and the gas introduction surface.
A sixth aspect of the present invention is a glass manufacturing apparatus including the holding member described above.
A seventh aspect of the present invention is a glass manufacturing method including: a levitation process for blowing the gas onto the glass raw material from the injection ports of the holding member described above, and levitating the glass raw material; a melting process for melting the glass raw material by irradiating the glass raw material that has been levitated with a laser beam; and a cooling process for cooling down the glass raw material that has been melted.
Embodiments of the present invention (hereinafter referred to as the “present embodiments”) are described below. The present embodiments described below are examples for describing the present invention, and are not to be construed as limitations to the contents described below.
Note that in the drawings, the same element is denoted by the same reference sign, and a duplicate description is omitted. Furthermore, a positional relationship, such as up, down, left, or right, is based on the positional relationship illustrated in the drawings, unless otherwise specified. Moreover, a dimension ratio of the drawings is not limited to the illustrated ratio.
Furthermore, a term in combination with “rough” or “roughly” indicates the meaning of the term without “rough” or “roughly” within the common general knowledge of those skilled in the art, and also includes the meaning itself without “rough” or “roughly”, and vice versa. For example, the term “circle” is not combined with “rough”, but it is natural that the term also includes the meaning of a “rough circle”, unless contrary to the gist of the invention.
Furthermore, a “top view” or “viewed from the top” refers to a plane viewed from a direction that is defined as an upper surface of the holding member 102 described later, when stationarily placed on a horizontal plane that is orthogonal to a gravity direction with a concave surface 1020 of the holding member 102 facing upward.
Furthermore, a “sectional view” or “viewed in a cross section” refers to a cross section that passes through a center or the center of gravity of the concave surface 1020, when stationarily placed on the horizontal plane that is orthogonal to the gravity direction with the concave surface 1020 of the holding member 102 facing upward.
As illustrated in
In the glass manufacturing apparatus 1, the sample M that has been levitated above the holding member 102 that is disposed on a stage 101 is irradiated with the laser beam L to be heated in a non-contact manner. As a result of this, the sample M is melted, is formed into melt having a roughly spherical shape or a roughly ellipsoidal shape due to the surface tension of the sample M itself, and is levitated in this state. Then, the sample M is cooled down to be solidified, and is formed into optical glass.
The sample M is heated in a non-contact manner by irradiating the sample M with the laser beam L emitted from the laser light source 103, via a mirror 104 and a mirror 105. The temperature of the sample M that is heated due to irradiation with the laser beam L is monitored by the radiation thermometer 106. An output of the laser light source 103 is controlled by the computer 107 on the basis of temperature information relating to the sample M that has been monitored by the radiation thermometer 106. Furthermore, a state of the sample M is imaged by a CCD camera 108, and it is output to a monitor 109. Note that the laser light source 103 is not particularly limited, and examples include a carbon dioxide gas laser, a semiconductor laser, a fiber laser, a YAG laser, and the like.
A flow rate of gas to be fed into the holding member 102 is controlled by the gas flow rate regulator 110. Note that a type of gas is not particularly limited, and a publicly known type of gas can be appropriately employed. Specific examples of gas include oxygen, carbon dioxide, nitrogen, argon, air, and the like. Furthermore, a shape of a nozzle (not illustrated) that is connected to the holding member 102 is not particularly limited, and a publicly known method can be appropriately employed.
After the stably levitated sample M has been heated in a non-contact manner, the laser beam L is intercepted. As a result of this, melt (the sample M) is cooled down to be solidified, and optical glass is obtained.
As illustrated in
Furthermore, as illustrated in
Furthermore, it is preferable that the holding member 102 include a through-hole 1026 that connects the introduction port 1022 to the injection port 1024. Due to the through-hole 1026, gas that has been supplied from the introduction port 1022 that is provided on the second surface S2 is efficiently fed toward the injection port 1024 that is provided on the concave surface 1020 of the first surface S1. As an example, a cross section of a plane that is parallel to a gravity direction of the through-hole 1026 is a rectangle.
In addition, it can be said that the introduction port 1022 is an introduction port from which gas is introduced, and the injection port 1024 is an injection port from which gas is injected. In the present embodiment, for example, each of a plurality of injection ports 1024 that is included in the concave surface 1020 is connected to a single introduction port 1022.
In
In the present embodiment, all of the introduction ports 1022 are not always connected to all of the injection port 1024 by the through-holes 1026, and only some of the introduction ports 1022 may be connected to some of the injection port 1024 by the through-holes 1026.
Next, the disposition of the injection ports 1024 of the holding member 102 is further described.
In the example illustrated in
Stated another way, when viewed from the top, the concave surface 1020 concentrically includes a region of the first circle C1, and a region of the second circle C2 having the radius R2 that is larger than or equal to the radius R1 of the first circle C1, and is adjacent. The concave surface 1020 includes a first region P1, which is the region of the first circle C1, and a second region P2, which is an annular region obtaining by excluding the region of first circle C1 from the region of the second circle C2. The first region P1 is a region that includes the center or the center of gravity, when the concave surface 1020 is viewed from the top. In other words, the first region P1 is located on an inner side (closer to the center or closer to the center of gravity) of the concave surface 1020 relative to the second region P2. Note that the radius R2 of the second circle C2 may be equal to the radius R of the concave surface 1020. Stated another way, the concave surface 1020 may be constituted by the first region P1 and the second region P2.
The first region P1 is a region that is at least part of a roughly circular region for which a radius from the center point O is r or less, when the concave surface 1020 is viewed from the top. Note that r<R. Furthermore, the second region P2 is a region that is at least part of a roughly annular region for which the radius of an inner circumference is r or more, when the concave surface 1020 is viewed from the top.
It is preferable that the first region P1 be a roughly circular region for which the radius from the center point O is 0.2R (0.2 times as large as the radius R) or less, in comparison with the radius R of the concave surface 1020, when viewed from the top, and it is more preferable that the radius from the center point O be 0.1R or less. Furthermore, it is preferable that the radius R1 be 1 to 3 mm. It is more preferable that a lower limit value of the radius R1 be 1.5 mm, and it is more preferable that an upper limit value be 2.5 mm.
In the second region P2, when viewed from the top, in comparison with the radius R of the concave surface 1020, the radius R2 that corresponds to the radius of an outer circumference of the annular region may be equal to the radius R, it is more preferable that the radius R2 be 0.9R (0.9 times as large as the radius R), and it is more preferable that the radius R2 be 0.8R or less.
Furthermore, it is preferable that the radius R2 be 3 to 8 mm. It is more preferable that a lower limit value of the radius R2 is 4 mm, and it is more preferable that an upper limit value be 7 mm.
Note that it is sufficient if the second region P2 is located outside the first region P1, and the second region P2 may or may not be adjacent to the first region P1. A case where the regions are not adjacent to each other will be described later.
When viewed from the top, in a case where the concave surface 1020 has a circular shape, it is preferable that the radius R of the concave surface 1020 be 5 to 10 mm. It is more preferable that a lower limit of the radius R of the concave surface 1020 be 5.5 mm, and it is further preferable that the lower limit be 6.5 mm. It is more preferable that an upper limit of the radius R of the concave surface 1020 be 9.5 mm, and it is further preferable that the upper limit be 8.5 mm. The radius R of the concave surface 1020 falls under the range described above, and therefore the sample M can be more stably levitated, and as a result of this, a glass gob or optical glass having a larger size can be made. Here, the glass gob refers to agglomerated glass that has been directly molded from glass melt.
Note that in the present embodiment, a case where a shape of the concave surface 1020 of the first surface S1 when viewed from the top is a circular shape has been described, but this is not restrictive. For example, the shape of the concave surface 1020 of the first surface S1 when viewed from the top may be an ellipsoidal shape, or may be a polygon such as a rectangular shape. It is assumed that a “radius” in a case where the shape is not a perfect circle means a shortest diameter from the center of gravity.
When viewed in a cross section of the concave surface 1020, it is preferable that a maximum depth H of the concave surface 1020 be 4 to 10 mm. The maximum depth H described here of the concave surface 1020 refers to a distance from an opening of the concave surface 1020 to a deepest portion of the concave surface 1020. It is more preferable that a lower limit of the maximum depth H of the concave surface 1020 be 5 mm, and it is further preferable that the lower limit be 5.5 mm. It is more preferable that an upper limit of the maximum depth H of the concave surface 1020 be 6.5 mm, and it is further preferable that the upper limit be 6 mm. The maximum depth H of the concave surface 1020 falls under the range described above, and therefore the sample M can be more stably levitated, and as a result of this, a glass gob having a larger size can be made.
Furthermore, a shape of the concave surface 1020 when viewed in a cross section is not particularly limited, but from a viewpoint of more stably levitating the sample M, it is preferable that the shape be a semicircle or a semi-ellipsoid.
The holding member 102 is formed by using a non-porous material such as metal. The material of the holding member 102 is not particularly limited, but it is preferable that at least part of the entirety of the member include at least one kind selected from the group consisting of stainless steel (SUS), silicon carbide (SiC), alumina (Al2O3), zirconia (ZrO2), duralumin, copper (Cu), and carbon (C). These materials have high thermal shock resistance or wear resistance even at high temperature, and therefore even at high temperature at which laser-beam heating is performed, gas can be blown onto the sample M with higher precision, and the sample M can be stably levitated.
It is assumed that a method for obtaining the area W1 of the injection port 1024x per unit area of the first region P1 is as follows. The area of the first region P1 refers to an area of the first region P1 when the concave surface 1020 is viewed from the top, as illustrated in
the area is the total of cross-sectional areas of three injection ports 1024, the injection ports 1024a and b. Accordingly, W1 is expressed by Mathematical Formula (1) described below.
Area W1 of injection port 1024x per unit area of first region P1=total of cross-sectional areas of injection ports 1024x included in first region P1/area of first region P1 when viewed from top . . . (1)
Furthermore, a method for obtaining the area W2 of the injection port 1024y per unit area of the second region P2 is similar to the method of W1. The area of the second region P2 refers to an area of the second region P2 when the concave surface 1020 is viewed from the top, as illustrated in
Area W2 of injection port 1024y per unit area of second region P2=total of areas of injection ports 1024y included in second region P2/area of second region P2 when viewed from top . . . (2)
Moreover, it is preferable that Cross Section A-A′ be a cross section that is located in a lowest position when the concave surface 1020 is viewed from the side.
Furthermore, an area of the injection port 1024x or 1024y may be as follows. The area of the injection port 1024x or 1024y may be an area of the injection port 1024x or 1024y when the concave surface is viewed from the top.
The area W1 of the injection port 1024x per unit area of the first region P1 in the example illustrated in
W1<W2 (3)
is satisfied.
Furthermore, a ratio (W1/W2) of the area W1 of the injection port 1024x per unit area of the first region P1 to the area W2 of the injection port 1024y per unit area of the second region P2 is preferably 0.05 to 0.7. Furthermore, it is more preferable that a lower limit value of W1/W2 be 0.1, and it is more preferable that an upper limit value be 0.4.
In the present example, the injection ports 1024 included in the concave surface 1020 is configured as described above, and therefore a flow rate of gas per unit time from the injection ports 1024y provided in the second region P2 is higher than a flow rate of gas per unit time from the injection ports 1024x provided in the first region P1. This enables the sample M to be kept stably levitated near a target position of irradiation with the laser beam L (stable levitation).
Conventionally, for example, in the case of a method for manufacturing optical glass by using a container such as a crucible (this is also referred to as a container method or the like in some cases), it has been requested that glass forming capability be improved by containing a large amount of network former oxide such as SiO2, B2O3, P2O5, or GeO2. Therefore, in the case of glass composition in which a large amount of material that is not the network former oxide is contained, and a small amount of the network former oxide described above is contained, there is a problem in which crystallization (non-uniform nucleation) with a container-melt interface as a starting point occurs, and vitrification is difficult.
Furthermore, in a holding member used in a conventional levitation furnace method, gas is blown from a lower side of a sample. Because of a difficulty in keeping the sample stably levitated above the holding member (stable levitation), or the like, precise laser-beam irradiation heating is difficult, and there is a problem in which a large-sized glass gob fails to be made.
With respect to such problems, by using the holding member 102 according to the present embodiment, conditions of blowing gas onto the sample M can be controlled with high precision. As a result of this, a stable levitation state that could not be achieved conventionally can be maintained (high levitation stability), and a glass gob having a larger size can be made. Stated another way, high stable levitation capability contributes to precise irradiation heating using a laser beam, an increase in size of obtained optical glass (glass gob), uniformization of a component composition, or the like.
In some cases, a glass gob is used as a material of an optical lens of various optical devices, such as an objective for microscopes or a camera lens, and it is desired that a large-sized glass gob can be stably made. By using the holding member according to the present embodiment, such a request can be met.
Furthermore, it is assumed that the number of injection ports 1024x per unit area of the first region P1 is T1, and the number of injection ports 1024y per unit area of the second region P2 is T2.
A plurality of injection ports 1024 included in the concave surface 1020 illustrated in
In order to stably levitate the sample M, it is preferable that a radius of the injection port 1024x be 0.05 mm to 0.2 mm. Furthermore, it is more preferable that a lower limit value of the radius of the injection port 1024x be 0.1 mm, and it is more preferable that an upper limit value be 0.15 mm. Furthermore, it is preferable that a radius of the injection port 1024y be 0.2 mm to 0.5 mm. Furthermore, it is more preferable that a lower limit value of the radius of the injection port 1024y be 0.3 mm, and it is more preferable that an upper limit value be 0.4 mm.
Note that the number of injection ports 1024 in the present example is not limited to this. It is sufficient if the area W1 of the injection port 1024x per unit area of the first region P1 is smaller than the area W2 of the injection port 1024y per unit area of the second region P2, and for example, the number T1 of injection ports 1024x per unit area of the first region P1 may be greater than the number T2 of injection ports 1024y per unit area of the second region P2.
Furthermore, a single injection port 1024x that is larger than a single injection port 1024y of the second region P2 may be present in the first region P1. Similarly, a single injection port 1024y that is smaller than a single injection port 1024x of the first region P1 may be present in the second region P2.
T1<T2 (4)
is satisfied.
Furthermore, a ratio (T1/T2) of the number T1 of injection ports 1024x per unit area of the first region P1 to the number T2 of injection ports 1024y per unit area of the second region P2 is preferably 0.05 to 0.5. It is more preferable that a lower limit value of T1/T2 be 0.1, and it is more preferable that an upper limit value be 0.3.
For example, in a state where the holding member 102 is viewed in a cross section, in the first region P1 including the center point O of the concave surface 1020, through-holes can be disposed at long intervals, and at a position closer to an end of the concave surface 1020, the through-holes can be disposed at shorter intervals. By employing such a configuration, the relationship expressed by Mathematical Formula (4) can be satisfied.
In the present example, a certain number of injection ports 1024 that satisfies Mathematical Formula (4) are provided on the concave surface 1020, and the injection ports 1024 are formed in such a way that the area W1 of the injection port 1024x per unit area of the first region P1 is smaller than the area W2 of the injection port 1024y per unit area of the second region P2. Stated another way, in the present example, similarly to the example illustrated in
In the sample M that has entered into a melt state due to laser heating, deformation or vibration easily occurs when the sample M has received pressure of gas, in accordance with a reduction in viscosity or surface tension that has been caused by a rise in temperature. Moreover, as the volume or gross weight of the sample M increases, the sample M more easily receives an influence of empty weight or a gas flow, and therefore a degree of deformation or vibration of melt becomes more outstanding.
Accordingly, it is difficult to stably float up a large-sized sample M. However, by employing a configuration according to the present embodiment, a flow rate of gas per unit time in the second region is higher than a flow rate of gas per unit time in the first region, and therefore even the large-sized sample M can be kept stably levitated.
Note that an area of a single injection port 1024x of the first region P1 in the example illustrated in
Stated another way, in the example illustrated in
In the present example, similarly to the other example described above, a flow rate of gas per unit time from the injection ports 1024 provided in the second region P2 is higher than a flow rate of gas per unit time from the injection ports 1024 provided in the first region P1. Stated another way, the sample M can be kept stably levitated near a target position of irradiation with the laser beam L.
Note that the disposition of the injection ports 1024 is not limited to the positions described above and illustrated in
When viewed from the top, the concave surface 1020 concentrically includes the region of the first circle C1, the region of the second circle C2 having the radius R2 that is larger than or equal to the radius R1 of the first circle C1, and a region of a third circle C3 having a radius R3 that is larger than the radius R2 of the second circle C2, the first region P1 is the region of the first circle C1, and the second region P2 is an annular region obtained by excluding the region of the second circle C2 from the region of the third circle C3.
In the present example, in the first region P1, it is preferable that the radius R1 from the center point O be 3 mm or less, when the concave surface 1020 is viewed from the top. Furthermore, it is preferable that the radius R1 be 1 to 3 mm, it is more preferable that a lower limit value be 1.5 mm, and it is more preferable that an upper limit value be 2.5 mm.
In the second region P2, it is preferable that the radius R2 that corresponds to a radius of an inner circumference of the annular region be 3 to 5 mm, when the concave surface 1020 is viewed from the top. It is more preferable that a lower limit value of the radius R2 be 3.5 mm, and it is more preferable that an upper limit value of the radius R2 be 4.5 mm. It is preferable that the radius R3 that corresponds to a radius of an outer circumference of the annular region be 5 to 9 mm. It is more preferable that a lower limit value of the radius R3 be 5.5 mm, and it is further preferable that an upper limit value of the radius R3 be 8 mm. Moreover, it is preferable that the radius R2 be one to three times as large as the radius R1, and it is preferable that the radius R3 be 3.5 to 6 times as large as the radius R1.
Furthermore, the concave surface 1020 is a circular shape having the radius R, when viewed from the top.
It is preferable that the first region P1 be a circular region for which the radius R1 from the center point O is 0.2R (0.2 times as large as the radius R) or less, in comparison with the radius R of the concave surface 1020, when the concave surface 1020 is viewed from the top.
In the second region P2, when the concave surface 1020 is viewed from the top, it is preferable that the radius R2 from the center point O be 0.4R (0.4 times as large as the radius R) or more, in comparison with the radius R of the concave surface 1020, and it is more preferable that the radius R2 be 0.5R (0.5 times as large as the radius R) or more. Furthermore, it is preferable that the radius R3 from the center point O be 0.9R (0.9 times as large as the radius R) or less, and it is further preferable that the radius R3 be 0.8R (0.8 times as large as the radius R) or less.
As described in the present example, in a case where the first region P1 and the second region P2 are not adjacent to each other, similarly, the concave surface 1020 can be configured in such a way that a flow rate of gas per unit time from the injection ports 1024 provided in the second region P2 is higher than a flow rate of gas per unit time from the injection ports 1024 provided in the first region P1. This enables high levitation stability to be maintained.
The holding member 102 in which through-holes through which gas passes have been provided to extend in an upward/downward direction inside the member has been described above as an example. However, a holding member according to the present embodiment is not limited to such an aspect, and another aspect may be employed.
A porous material is included, and therefore gas supplied to an introduction port 1112 can be blown onto the sample M from an injection port 1114 via an internal hole structure. As described above, the through-hole described above may be a hole made of a porous material. Stated another way, it can be said that a hole that is a porous body of the holding member 111 is one aspect of the through-hole described above.
If a pore diameter of the porous body that constitutes the holding member 111 is too small, pressure loss increases, and gas fails to pass sufficiently.
Furthermore, if the pore diameter is too large, a surface shape including a concave surface 1110 becomes coarse. Accordingly, it is preferable that the pore diameter of the porous body that constitutes the holding member 111 be 1 to 100 μm. It is more preferable that a lower limit of the pore diameter be 5 μm, and it is further preferable that the lower limit be 9 μm. It is more preferable that an upper limit of the pore diameter be 50 μm, and it is further preferable that the upper limit be 20 μm.
The pore diameter of the porous body that constitutes the holding member 111 falls under the range described above, and therefore gas can be made to appropriately pass, and an influence on the surface shape of the concave surface 1110 can be reduced.
The density of the internal disposition of a pore structure of the holding member 111 is made non-uniform, and therefore gas can be blown in such a way that the relationship expressed by Mathematical Formula (3) or Mathematical Formula (4) is satisfied. Here, it is assumed that a portion of the holding member 111 that includes pores from which gas is supplied to the injection port 1114 included in the first region P1 is a portion Q1, and a portion of the holding member 111 that includes pores from which gas is supplied to the injection port 1114 included in the second region P2 is a portion Q2. For example, it is assumed that a porosity of the portion Q1 of the holding member 111 that corresponds to the first region P1 including a center point O of the concave surface 1110 of the first surface S1 is V1, and a porosity of the portion Q2 of the holding member 111 that corresponds to the second region P2 that is located outside the first region P1 is V2. Note that the porosity described here is a ratio of the volume of a space to the total volume of a substance.
In the present embodiment, the porosity V1 of the portion Q1 of the holding member 111 that corresponds to the first region P1 including the center point O of the concave surface 1110 of the first surface S1 is lower than the porosity V2 of the portion Q2 of the holding member 111 that corresponds to the second region P2 that is located outside the first region P1. Stated another way,
V1<V2 (5)
is satisfied.
As a result of a configuration in which the porosity V1 of the portion Q1 is lower than the porosity V2 of the portion Q2, the area W1 of the injection port 1114 per unit area of the first region P1 is smaller than the area W2 of the injection port 1114 per unit area of the second region P2. Stated another way, Mathematical Formula (3) described above is satisfied, and a flow rate of gas per unit time from the injection ports 1024y provided in the second region P2 is higher than a flow rate of gas per unit time from the injection ports 1024x provided in the first region P1. This enables the sample M to be kept stably levitated near a target position of irradiation with the laser beam L (stable levitation). Note that the number T1 of injection ports 1114 per unit area of the first region P1 can be made smaller than the number T2 of injection ports 1114 per unit area of the second region P2.
As a result of forming the holding member 111 by using a porous material, at least one of a plurality of injection ports 1114 included on the concave surface 1110 is connected to a plurality of introduction ports 1112. The portion Q1 of the holding member 111 corresponds to a plurality of injection ports 1114 provided in the first region P1, and includes poles or the introduction ports 1112 that are connected to the injection port 1114. Similarly, the portion Q2 of the holding member 111 corresponds to a plurality of injection ports 1114 provided in the second region P2, and includes poles or the introduction ports 1112 that are connected to the injection port 1114.
In the present embodiment, the introduction port 1112 is not always provided on the second surface S2. For example, gas may be introduced from a side surface of the holding member 111. In other words, a gas introduction surface including the introduction ports 1112 may be at least either a side surface S3 of the holding member 111 or the second surface S2 that is an opposite side of the concave surface 1110.
In addition, the holding member 111 according to the present embodiment can be formed by combining a porous body that is located in the portion Q1 and a porous body that is located in the portion Q2 that is different from the portion Q1. As another example, the holding member 111 is constituted by a single porous body, and the porous body can be formed in such a way that the portion Q1 and the portion Q2 are different in porosity from each other.
By employing the holding member 111 according to the present embodiment, a flow rate of gas per unit time from the injection ports 1114 provided in the second region P2 is higher than a flow rate of gas per unit time from the injection ports 1114 provided in the first region P1. This enables the sample M to be kept stably levitated near a target position of irradiation with the laser beam L (stable levitation).
The holding member 112 includes introduction ports 1122 and injection ports 1124, and is constituted by a non-porous portion 1126 and a porous portion 1128, and a through-hole is disposed between the non-porous portion 1126 and the porous portion 1128. Stated another way, a concave surface 1120 of the first surface S1 includes both a porous region and a non-porous region, and this enables a flow rate of gas to be controlled. As the non-porous portion 1126, a member that is not porous is used, and for example, stainless steel (SUS), silicon carbide (SiC), alumina, zirconia (ZrO2), duralumin, copper (Cu), carbon (C), various other metals, and the like can be used.
The non-porous portion 1126 corresponds to the first region P1 including a center portion of the concave surface 1120, and the porous portion 1128 corresponds to the second region P2 that is located outside the first region P1. Furthermore, the through-pole between the non-porous portion 1126 and the porous portion 1128 is treated as being located in the second region P2. In the holding member 112, a flow rate of gas per unit time from the injection ports 1124 provided in the second region P2 is higher than a flow rate of gas per unit time from the injection ports 1124 provided in the first region P1.
Note that in the present configuration example, similarly, the introduction ports 1122 are not always provided in the second surface S2, and gas may be introduced from the side surface S3 of the holding member 112.
The holding member 113 includes a member 1136 and a member 1138. A material of the member 1136 is not particularly limited. The member 1136 may be formed by using a porous material including the injection ports 1134, may be formed by using a non-porous material including the injection ports 1134, or may be formed by using a non-porous material that does not include the injection ports 1134. The member 1136 is provided in a position that corresponds to the first region P1 including a center point O of a concave surface 1130.
The member 1138 includes the injection port 1134, and injects, from the injection port 1134, gas that has been introduced from the introduction ports 1132. The member 1138 injects gas in the roughly horizontal direction. The member 1138 is provided in a position that corresponds to the second region P2 outside the first region P1. Note that the introduction port 1132 from which gas is introduced to the injection port 1134 may be located on a side surface of the holding member 113. Alternatively, the introduction port 1132 may be located in a lower portion of the holding member 113, and gas may be introduced to the injection port 1134 via a curved hollow member.
In the holding member 113, a flow rate of gas per unit time of the second region P2 is higher than a flow rate of gas per unit time of the first region P1.
By employing the present configuration, gas is blown onto the sample M from the roughly horizontal direction, and the sample M can be levitated more stably.
The member 1141 includes a concave surface 1140, and is a member that includes the first region P1 and the second region P2 on the concave surface 1140. The member 1141 may be any of the holding members 102, 111, and 112 described above. In the member 1141, the area W1 of the injection port 1134 per unit area of the first region P1 and the area W2 of the injection port 1134 per unit area of the second region P2 satisfy Mathematical Formula (3) described above.
The member 1149 is a member that is located in an upper portion of the concave surface 1140, and includes an injection port 1149a from which gas is injected in the roughly horizontal direction that is roughly orthogonal to the gravity direction. In addition to the member 1141, the injection port 1149a from which gas is injected in the roughly horizontal direction is included, and therefore the sample M can be levitated more stably.
Note that it is preferable that a process of levitating a sample by blowing gas onto the sample, and melting the sample by irradiating the sample with a laser beam in a gas levitation furnace be performed in a chamber in which pressure can be reduced, but this is not illustrated. By blowing gas onto the sample under reduced pressure, gas easily passes through a porous material or a through-hole of a holding member. As a result, even in a case where a flow rate of gas is small, high levitation stability can be obtained, and turbulence can be prevented from occurring. Furthermore, gas may be heated, and this can also prevent turbulence. Moreover, defocus of the laser beam L to be applied or scanning may be performed. By doing this, a sample can be uniformly heated, and levitation stability can be improved.
The holding member 121 according to the third embodiment includes the second surface S2 that serves as a gas introduction surface, and has a protruding shape, includes a portion J1 that is surrounded by a surface including a straight line that is drawn from the first circle C1 to the second surface S2 (or the side surface S3) in the gravity direction (in a perpendicular direction), and a portion J2 that is surrounded by a surface including a straight line that is drawn from the second circle C2 to the second surface S2 (or the side surface S3) in the gravity direction, and includes a portion in which a thickness of the portion J1, which is a length of a straight line that is drawn from a point in the first circle C1 to the second surface S2 (or the side surface S3) in the gravity direction, is greater than a thickness of the portion J2, which is a length of a straight line that is drawn from a point in the second circle C2 to the second surface S2 (or the side surface S3) in the gravity direction. Note that the portion J2 does not include the portion J1, as described in detail later. As an example, the second surface S2 has a tapered shape in which a portion near a center portion is roughly horizontal, and a circumference gradually becomes thinner in a downward direction toward the center portion. In
The holding member 121 in the present example is constituted by a porous body. By changing a thickness of the holding member 121, levitation stability of the sample M can be improved.
Here, in the holding member 121, it is assumed that a portion that is surrounded by a surface including a straight line that is drawn from the first circle C1 to the second surface S2 (or the side surface S3) in the perpendicular direction is the portion J1, and a portion excluding the portion J1 of a portion that is surrounded by a surface including a straight line that is drawn from the second circle C2 to the second surface S2 (or the side surface S3) in the perpendicular direction is the portion J2. The portion J1 is a portion of the holding member 121 that corresponds to the first region P1 including a center point O of a concave surface 1210 of the first surface S1, and the portion J2 is a portion of the holding member 121 that corresponds to the second region P2 that is located outside the first region P1.
Note that the perpendicular direction in the present example is a vertical direction in the case of being stationarily placed on a horizontal surface that is orthogonal to the gravity direction with the concave surface 1210 of the holding member 121 facing upward. For example, in a case where the second surface S2 is a roughly flat surface, the perpendicular direction is a direction that is perpendicular to the second surface S2.
For example, it is assumed that an average thickness of the portion J1 is K1, and an average thickness of the portion J2 is K2. Note that the average thickness described here is a value obtained by measuring a thickness at plural predetermined points, when viewed in a cross section, and calculating an average value of the thicknesses. In a case where it is assumed that a predetermined point on the concave surface 1210 is a start point, and a point at which a straight line that extends from the point in the perpendicular direction intersects the second surface S2 (or the side surface S3) is an end point, the thickness indicates a distance from the start point to the end point.
In the present embodiment, the average thickness K1 of the portion J1 of the holding member 121, when viewed in a cross section, is greater than the average thickness K2 of the portion J2 of the holding member 121. Stated another way,
K1>K2 (6).
In other words, in the present embodiment, the average thickness K1 of the holding member 121 between the first region P1 and the second surface S2, which is a gas introduction surface, is greater than the average thickness K2 of the holding member 121 between the second region P2 and the second surface S2 (or the side surface S3).
Furthermore, a ratio (K2/K1) of the average thickness K2 of the portion J2 to the average thickness K1 of the portion J1 is preferably 0.5 to 0.95. It is more preferable that a lower limit value of K2/K1 be 0.6, and it is more preferable that an upper limit value be 0.9.
Furthermore, in the present embodiment, it is assumed that a thickness of the holding member 121 at the center point O, when viewed in a cross section, is D1, and a thickness of the holding member 121 at an arbitrary point on the second region P2 is D2. D2 is configured in such a way that a shortest D2 is shorter than D1. Furthermore, a configuration in which a longest D1 is longer than D2 is employed.
By employing the present configuration, a difference in a length of a route through which gas passes is generated between the portion J1 relating to the first region P1 and the portion J2 relating to the second region P2, and a route relating to the portion J1 becomes longer than a route relating to the portion J2. As a result of this, a flow rate of gas that passes through the portion J2 is higher than a flow rate of gas that passes through the portion J1. Therefore, the sample M can be stably levitated near the center point O, and a glass gob having a larger size can be generated.
Note that the holding member 121 according to the third embodiment can be configured to satisfy Mathematical Formula (3) or Mathematical Formula (4) described above similarly to the holding members according to the first embodiment and the second embodiment.
In the holding member 122, similarly to the holding member 121, the second surface S2 has a protruding shape. Stated another way, the second surface S2 including the side surface S3 has a roughly truncated cone shape that gradually becomes wider in an upward direction. In the holding member 122, the average thickness K1 of the portion J1 of the holding member 121 that corresponds to the first region P1 including a center point O of a concave surface 1220 of the first surface S1, when viewed in a cross section, is greater than the average thickness of the portion J2 of the holding member 121 that corresponds to the second region P2 that is located outside the first region P1, similarly to the holding member 121.
Furthermore, in a case where it is assumed that a thickness of the holding member 122 at the center point O, when viewed in a cross section, is D1, and a thickness of the holding member 122 at an arbitrary point on the second region P2 is D2, D2 is configured in such a way that a shortest D2 is shorter than D1, similarly to the holding member 121.
In the present configuration, similarly, a flow rate of gas that passes through the portion J2 is higher than a flow rate of gas that passes through the portion J1. Therefore, the sample M can be stably levitated near the center point O, and a glass gob having a larger size can be generated.
Note that the holding member 122 in the present example can be configured to satisfy Mathematical Formula (3) or Mathematical Formula (4) described above, similarly to the holding members according to the first embodiment and the second embodiment.
In the holding member 123, similarly to the holding member 121 and the holding member 122, the second surface S2 has a protruding shape. More specifically, the second surface S2 of the holding member 123 includes a protrusion. A portion near a center portion of the second surface S2 is roughly horizontal. Furthermore, it is assumed that, in the second surface S2, a surface other than the portion near the center portion is the side surface S3.
For example, the protrusion can be formed by forming a portion located just below the first region P1 to be roughly horizontal, and forming the other portion to be recessed. Similarly to the example described above, it is assumed that a portion of the holding member 123 that corresponds to the first region P1 including a center point O of a concave surface 1230 of the first surface S1 is the portion J1, and a portion of the holding member 123 that corresponds to the second region P2 that is located outside the first region P1 is the portion J2. The average thickness K1 of the portion J1, when viewed in a cross section, is greater than an average thickness of the portion J2.
Furthermore, in the holding member 123, in a case where it is assumed that a thickness of the holding member 123 at the center point O, when viewed in a cross section, is D1, and a thickness of the holding member 123 at an arbitrary point on the second region P2 is D2, D2 is configured in such a way that a shortest D2 is shorter than D1, similarly to the holding members 121 and 122.
In the present configuration, similarly, a flow rate of gas that passes through the portion J2 is higher than a flow rate of gas that passes through the portion J1. Therefore, the sample M can be stably levitated near the center point O, and a glass gob having a larger size can be generated. Note that the holding member 123 in the present example can be configured to satisfy Mathematical Formula (3) or Mathematical Formula (4) described above, similarly to the holding members according to the first embodiment and the second embodiment.
In the holding member 124, similarly to the holding members 121, 122, and 123, the second surface S2 has a protruding shape. More specifically, the second surface S2 of the holding member 124 has a bowl shape in which a portion where a straight line that extends from a center point O in the perpendicular direction intersects the second surface S2 is the longest. In other words, the holding member 124 draws a rough parabola in which the second surface S2 is downwardly convex, when viewed in a cross section.
In the holding member 124 in the present example, similarly, the average thickness K1 of the portion J1 of the holding member 124, when viewed in a cross section, is greater than the average thickness of the portion J2 of the holding member 124.
Furthermore, in a case where it is assumed that a thickness of the holding member 124 at the center point O, when viewed in a cross section, is D1, and a thickness of the holding member 124 at an arbitrary point on the second region P2 is D2, D2 is configured in such a way that a shortest D2 is shorter than D1, similarly to the holding members 121, 122, and 123.
In the present configuration, similarly, a flow rate of gas that passes through the portion J2 is higher than a flow rate of gas that passes through the portion J1. Therefore, the sample M can be stably levitated near the center point O, and a glass gob having a larger size can be generated. Note that the holding member 124 in the present example can be configured to satisfy Mathematical Formula (3) or Mathematical Formula (4) described above, similarly to the holding members according to the first embodiment and the second embodiment.
A method for manufacturing optical glass according to the present embodiment includes a process of blowing gas onto the sample M from a gas injection portion of the holding member described above to levitate the sample M, and melting the sample M by irradiating the levitated sample M with the laser beam L in a gas levitation furnace, and a process of cooling down the molten sample M.
According to the method for manufacturing the optical glass according to the present embodiment, by using the holding member described above, a container does not come into contact with melt (the sample M), and non-uniform nucleation can be avoided at the maximum. Accordingly, a composition that could not be manufactured according to the container method (crucible melting), and contains a small amount of network former oxide or contains no network former oxide can also be vitrified. By employing such a manufacturing method, optical glass of a composition system that could not be vitrified conventionally can be manufactured. Accordingly, optical glass having a high refractive index and a high Abbe number can also be manufactured.
In addition, a flow rate of injection of gas into melt is higher in a peripheral portion than in a center point. Therefore, the melt can be stably levitated near the center point O, and a large-sized glass gob can be made. Specifically, it is preferable that its diameter be 6 mm or more, it is more preferable that the diameter be 6.5 mm or more, and it is further preferable that the diameter be 7 mm or more.
Optical glass obtained by using a manufacturing method according to the present embodiment has many advantages, as described above, and therefore the optical glass can be utilized as a glass material having a high refractive index and low dispersion or a wide-band transmissive material. Specific examples are described below.
Next, the examples described below are described, but the present invention is not limited to the examples described below.
For optical glass in each example, the glass manufacturing apparatus 1 illustrated in
Gas was fed from the gas flow rate regulator 110 connected to the holding member 121 under a condition of 2 to 3 L/minute. In addition, the holding member 121 was used, and therefore the average thickness K1 of the portion J1 of the first region P1, when viewed in a cross section, is greater than the average thickness K2 of the portion J2 of the second region P2.
Then, optical glass was made in conformity with the procedure described below. First, a raw material selected from an oxide, a hydroxide, a carbonate, a nitrate, a sulfate, and the like was weighted to form a predetermined chemical composition, and then the raw material was mixed in an alumina mortar. This raw material was uniaxially pressed at 20 MPa, and was molded into a cylindrical pellet. The obtained pellet was fired at 1000 to 1300° C. in an electric furnace, and was fired during 6 to 12 hours in the atmosphere, and a sintered compact was made. The obtained sintered compact was coarsely crushed, and 500 to 600 mg were collected, and were placed in a nozzle of the holding member. Then, carbon dioxide gas laser was applied from the above while oxygen gas was injected, and therefore the raw material was melted. The molten raw material was formed into a spherical shape or an ellipsoidal shape due to the surface tension of the raw material itself, and entered into a levitated state due to the pressure of blown gas. By intercepting a laser output in a state where the raw material had been completely melted, the raw material was cooled down, and a glass gob having a roughly spherical shape having a diameter of 6 mm or more was obtained. In the glass in each of the examples, visually recognizable volatilization was not confirmed during melting, and neither foam nor devitrification was confirmed.
(Making Glass Gob)
In each of the examples, in a case where a glass gob having a roughly spherical shape having a diameter of 6 mm or more could be made, the term “vitrification” is used.
(Measurement of Refractive Index and Abbe Number)
A refractive index of glass was measured by using a prism coupler (from Metricon, the model “2010/M”). A glass sample was polished, a polishing surface was brought into close contact with a single crystal rutile prism, an angle of total reflection at the time of making light of a measurement wavelength incident was measured, and a refractive index was obtained. Measurement was performed at three wavelengths, 473 nm, 594.1 nm, and 656 nm, each five times, and an average value was determined as a measurement value. Moreover, fitting according to a least-squares method was performed on the obtained actual measurement value by using the Drude-Voigt dispersion formula described below, and a refractive index and an Abbe number (vd) were calculated on a d-line (587.562 nm), an F-line (486.133 nm), and a C-line (656.273 nm).
(n: refractive index, m: electron mass, c: velocity of light, e: elementary charge, N: the number of molecules per unit volume, f: strength of vibrator, 2′: natural resonance wavelength, 2: wavelength)
Furthermore, the Abbe number (vd) is defied by the mathematical formula described below.
(nd: refractive index on d-line, nF: refractive index on F-line, nc: refractive index on C-line)
Each of compositions and physical property values in the respective examples is indicated in each table. Note that the content of each component is based on cationic % unless otherwise specified.
indicates data missing or illegible when filed
indicates data missing or illegible when filed
indicates data missing or illegible when filed
indicates data missing or illegible when filed
As is apparent from the above, it has been confirmed that by employing a manufacturing method in each of the examples, a large-sized glass gob can be stably made, and obtained optical glass has a high refractive index, low dispersion, and devitrification resistance at a high level.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020-202124 | Dec 2020 | JP | national |
This application is a continuation of International Application PCT/JP2021/044446, filed on Dec. 3, 2021, and claims priority to Japanese Patent Application No. 2020-202124, filed on Dec. 4, 2020, the contents of which are incorporated by reference herein in their entireties in designated states where the incorporation of documents by reference is approved.
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2021/044446 | Dec 2021 | US |
| Child | 18200681 | US |
