Patent Application
20230136691
Glass parts having unique shapes in high throughput manufacturing is highly desired. While there are some technologies in cutting and pressing individual parts, these methods can provide non-uniformities in the resulting parts and are not available in thinner cross-sectional part thicknesses.
Broadly, the present disclosure is directed towards systems and methods of making glass, glass ceramic, or ceramic parts having a thin (e.g. less than about 1 mm) cross-sectional wall thickness, unique shapes and/or surface patterning, with via holes extending through the part from one major surface to the other, with high volume throughput. More specifically, the present disclosure is directed towards various embodiments of a system configured to make perforated glass, glass ceramic, or ceramic parts with the system having various embodiments for its configuration and related methods of processing hot, flexible glass-containing materials (e.g. glass, glass ceramic, and/or ceramic materials with a unique configuration to provide advantaged, tailored, and/or uniquely shaped-parts (i.e. in near net shape and/or requiring minimal additional processing to result with the final part shape) at high volume manufacturing.
Multiple process and equipment configurations possible with this disclosure to manufacture perforated glass sheet will now be described:
In some embodiments, a 3-D isometric presentation of one machine and process configuration to manufacture perforated glass sheet. It includes three sets of rollers, an air turn guide, smooth flat surfaced conveyor molds and a specially designed pressure roller with a matrix of protruding pins covering the entire surface of the roller to be in contact with the glass.
A specially designed pressure roller with a matrix of protruding pins covering the entire surface of the roller to be in contact with the glass is positioned above the conveyor molds and pressured down onto the hot glass sheet to push the pins of the pin roller against the hot glass sheet to pinch the sheet between the pressure roller and the smooth flat top conveyor molds to create an entire matrix of flat bottomed pin holes in the glass sheet. The objective is to penetrate the glass sheet as far as possible with the pin roller pins such that only a thin web of glass remains between the tip of the pin and the flat mold side of the glass sheet.
The perforated sheet glass cools as it travels along the top surface of the conveyor and the temperature difference between the thick glass of the desired perforated glass and the thin glass of the thin pinch line causes a thermal stress along the thin pinch that self-separates the sheet into discrete parts by the end of the conveyor. The resulting product is a rectangular tile with a smooth surface on the bottom surface and a full matrix of flat-bottomed pin holes on the top surface.
In some embodiments, the desired product is a thin sheet of glass with a matrix of 0.010 inch (0.254 mm) diameter through-holes spaced approximately 0.062 inches (1.57 mm) apart at least a portion over the entire surface of the glass sheet being manufactured (to be used as a component of an acoustic tile assembly).
In some embodiments, the product is a thin sheet of glass with a matrix of 1 mm dimeter through-holes. In some embodiments, the desired product is a thin sheet of glass with a matrix of 0.75 mm dimeter through-holes. In some embodiments, the desired product is a thin sheet of glass with a matrix of 0.5 mm dimeter through-holes. In some embodiments, the desired product is a thin sheet of glass with a matrix of 0.25 mm dimeter through-holes. In some embodiments, the desired product is a thin sheet of glass with a matrix of 0.1 mm dimeter through-holes.
In one aspect, a method is provided, comprising: depositing a flexible glass-containing ribbon along a plurality of sequentially conveyed molds; rolling a pinch roller over the surface of the glass-containing ribbon, such that at least one pinch region is actuated in the glass ribbon as the glass ribbon is pinched between a pinch edge of the pinch roller and the surface of the mold; and rolling a pin roller over the surface of the glass-containing ribbon, cooling the glass ribbon, separating the glass ribbon along the pinch region into discrete glass parts.
In some embodiments, the perimetrical edge of the discrete glass part is defined by the pinch region, optionally in combination with the at least one of the edge of the glass ribbon.
In some embodiments, wherein the glass-containing ribbon is configured with an average cross-sectional thickness of 0.5 mm to 1 mm.
In some embodiments, the glass containing ribbon has an average cross-sectional thickness of 1 mm.
In some embodiments, the method further comprises removing a layer of glass to define a plurality of vias extending from the first major surface to the second major surface of the glass part.
In some embodiments, the plurality of perforations in the discrete glass part comprise 25-50% of the volume of the discrete glass part.
In some embodiments, the plurality of perforations comprises at least 15%; or at least 30%; or at least 40%; or at least 50%; or at least 60%; or at least 70% of the volume of the discrete glass part. In some embodiments, the plurality of perforations comprises not greater than 75%; or not greater than 60%; or not greater than 50%; or not greater than 30%; of the volume of the discrete glass part.
In some embodiments, the part is configured with a matrix of through-holes.
In some embodiments, the matrix of through holes are approximately 0.25 mm in diameter.
In some embodiments, wherein the matrix of through-holes are uniformly distributed across at least a portion of the part.
In some embodiments, the through-holes are spaced from one another in the matrix with a spacing of approximately 1.5-1.7 mm apart.
In some embodiments, the part is configured with a spacer and retained in a frame to define an architectural product.
In some embodiments, the architectural product comprises an acoustic tile.
In some embodiments, the rolling step comprises defining a glass ribbon comprising a plurality of closed bottom perforations extending from one major surface towards the second major surface.
In some embodiments, the closed bottom perforations extend at least 50% to 95% of the cross-sectional thickness of the portion of perforated glass-containing ribbon.
In some embodiments, the method comprises removing a thin web of glass which defines a bottom of each of the respective closed-bottom perforations in the part.
In some embodiments, the rolling step is before the removing step.
In some embodiments, the removing step comprises machining one of the first or second major surfaces to define a plurality of through-holes extending from the first major surface to the second major surface.
In some embodiments, the removing step comprises acid etching one of the first major surface or second major surface to define a plurality of through-holes extending from the first major surface to the second major surface. In some embodiments, the product is a thin sheet of glass with the matrix of holes having a spacing of diameter through-holes spaced approximately 5 mm to not greater than 0.5 mm apart from one another over at least a portion of the part. In some embodiments, the product is a thin sheet of glass with the matrix of holes having a spacing of diameter through-holes spaced approximately 3 mm to not greater than 1.5 mm apart from one another over at least a portion of the part. In some embodiments, the product is a thin sheet of glass with the matrix of holes having a spacing of diameter through-holes spaced approximately 1.5 mm to not greater than 0.75 mm apart from one another over at least a portion of the part.
In some embodiments, the product is a thin sheet of glass with the matrix of holes having a spacing of diameter through-holes spaced of 1.5 mm; or 1.25 mm; or 1 mm; or 0.75 mm; or 0.5 mm, or 0.25 mm apart from one another over at least a portion of the part. In some embodiments, the product is a thin sheet of glass with the matrix of holes having a spacing of diameter through-holes spaced of 5 mm; or 4 mm; or 3 mm; or 2 mm; or 1 mm apart from one another over at least a portion of the part.
In some embodiments, the matrix comprises a uniformly diameter holes.
In some embodiments, the matrix comprises a non-uniform diameter holes (i.e. with the flat-bottomed perforations having a mixture of 2 or more average dimensions).
In some embodiments, the perforated patterning of the glass parts is configured to be homogenous (i.e. uniformly spaced flat-bottomed perforated holes). In some embodiments, the perforated patterning of the glass parts is configured to be non-homogenous (i.e. intermittent and/or non-patterned spacing of the flat bottomed perforated holes on each final part).
As used herein, uniform means generally having a consistent cross-sectional thickness, where the cross-sectional thickness is within a predetermined range/variation. For example, for a cross-sectional thickness of 1 mm, a uniform cross-sectional thickness may be within about 10% of 1 mm, within about 5% of 1 mm, within about 3% of 1 mm, within about 1% of 1 mm; within about 0.5% of 1 mm.
A secondary machining/grinding operation or acid etching operation is necessary to remove the thin web of glass covering the closed bottom perforations placed into the glass with this process—to expose the 0.010 inch diameter holes that would then be exposed.
In some embodiments, a 3-D isometric presentation of one machine and process configuration to manufacture perforated glass sheet. It includes three sets of rollers, an air turn guide, smooth flat surfaced conveyor molds and a smooth surface pressure roller with a cross chop thin pinch blade.
The precision dimensioned sheet glass then passes through a specially designed pin roller pair where the pin roller is a specially designed roller with a matrix of protruding pins covering the entire surface of the roller to be in contact with the glass. It pinches the precision dimensioned sheet against the mating smooth surfaced roller to perforate the sheet to create an entire matrix of flat bottomed pin holes in the glass sheet. In some embodiments, the pin rollers are configured such that they penetrate the glass sheet as far as possible with the pin roller pins such that only a thin web of glass remains between the tip of the pin and the smooth roller side of the glass sheet.
This thin pinch defines where the perforated sheet will self separate at the end of the conveyor, but the thin pinch zone reheats instantaneously and
The newly perforated glass sheet then turns 90 degrees from the vertical to the horizontal around an air turn guide to place the perforated sheet onto the smooth flat top surface of the molds of the horizontal conveyor traveling beneath the roller system delivery.
The thin pinch blade mounted on the pressure roller pinches a line full across the delivered sheet to pinch the sheet glass thin between the pressure roller blade and the flat surface of the conveyor molds.
The perforated sheet glass cools as it travels along the top surface of the conveyor and the temperature difference between the thick glass of the desired perforated glass and the thin glass of the thin pinch line causes a thermal stress along the thin pinch that self separates the sheet into discrete parts by the end of the conveyor. The resulting product is a rectangular tile with a smooth surface on the bottom surface and a full matrix of flat-bottomed pin holes on the top surface.
In some embodiments, the product is a thin sheet of glass with a matrix of 0.010 inch diameter through holes spaced approximately 0.062 inches apart over the entire surface of the glass sheet being manufactured (to be used as a component of an acoustic tile assembly).
In some embodiments, a secondary machining/grinding operation or acid etching operation is necessary to remove the thin web of glass covering the closed bottom perforations placed into the glass with this process—to expose the 0.010 inch diameter holes that would then be exposed.
Through one or more embodiments of the present disclosure, the systems are configured to make tailored, thin walled, complex surface patterned and/or shaped, thin walled glass, glass ceramic, and/or ceramic products that are not possible with any other forming technology. One or more products of the present system are configured with unique and/or tailored features, including but not limited to: complex 3D geometries, textured surfaces, discrete two-dimensional shapes, and/or combinations thereof.
In one embodiment, the ribbon is a monolithic glass, ceramic, or glass-ceramic sheet.
In In one embodiment, the ribbon is a laminate.
In one embodiment, product characteristics include, as non-limiting examples: product thickness (cross-sectional thickness) less than 1 mm thick; product wall thickness (cross-sectional thickness) 1 mm to 3 mm thickness; products having a small corner radii (e.g. 1.5 mm radii) between side and bottom (edges or walls of product form); three-dimensional shapes more than 1-inch deep w/1 mm wall thickness (Cross-sectional thickness); three dimensional products with thin walls (less than 1 mm thick) and steep sidewalls ranging from 3 degrees to 7 degrees. In some embodiments, the resulting products do not need to be annealed. In some embodiments, the products do not have chill-wrinkled surface feature and/or shear mark in parts made from pressing from a gob.
Some non-limiting examples of products include: textured roof tile, consumer electronics forms; perforated glass sheet (acoustic sheet); three dimensional shaped products, eating utensils, dinnerware forms; among other applications.
In one embodiment, a method is provided, comprising: delivering a molten glass, ceramic, or glass-ceramic -containing material into a glass forming and sizing assembly, the assembly comprising at least one pair of forming and sizing rollers; processing the molten glass via the at least one pair of forming and sizing rollers to form a glass ribbon having a width and a thickness; imparting, via a pair of pinching rollers, at least one pinch region into the cross-sectional thickness of the glass ribbon to provide a pinched glass ribbon, wherein the pinch region is defined as a localized area of reduced cross-sectional thickness; directing (via a conveyor or via air bend) the pinched glass ribbon onto plurality of sequentially spaced mold surfaces; rolling a pressure roller over the pinched glass ribbon on the sequentially spaced mold surfaces to impart a characteristic into the pinched glass ribbon to form a glass ribbon product; and cooling, thereby separating the glass ribbon product along the pinch region into a plurality of discrete glass parts, each glass part having the imparted characteristic.
In some embodiments, the method includes: wherein the pair of pinching rollers comprises a first roller and a second roller, where the first roller is configured with a pinch portion (edge or raised ridge).
In some embodiments, the method includes: wherein the pair of pinching rollers comprises a first roller and a second roller, where the first roller is configured with a pinch portion (edge or raised ridge) and the second portion is configure with a pinch portion (edge or raised ridge),wherein the first pinch portion of the first roller and the second pinch portion of the second roller are configured to matingly engage and actuate a pinch region in the glass ribbon.
In some embodiments, the method includes: wherein the imparting step further comprises imparting a surface texture on at least one of a first major surface of the glass ribbon and the second major surface of the glass ribbon (via a first pattern on a first roller surface and/or a second pattern on a second roller surface).
In some embodiments, the method further comprises: exerting pressurized air on the second surface of the glass ribbon product and/or discrete glass parts via a glass removal assembly, to facilitate part separation and/or spacing along the pinch region. In some embodiments, the method further comprises directing a puff of gas towards the second surface of the glass ribbon product and/or discrete glass parts via a glass removal assembly, to facilitate part separation and/or spacing along the pinch region. In some embodiments, the method further comprises directing a stream (e.g. continuous stream) of gas towards the second surface of the glass ribbon product and/or discrete glass parts via a glass removal assembly, to facilitate part separation and/or spacing along the pinch region.
In some embodiments, the pinch region defines part perimeter, possibly in combination with ribbon edges (if not also pinched).
In some embodiments, the pinch region comprises: transverse separation of each discrete glass component.
In some embodiments, the pinch region comprises: transverse separation and axial separation of each discrete glass component.
In some embodiments, the pinch region comprises: axial separation of glass component from discontinuous edge portion/cullet (forming high strength, clean edge). In some embodiments, by fire polishing the pinch region a high strength, a clean edge can be formed in the discrete glass products.
In some embodiments, the method is configured to provide a part with at least one of: 2D asymmetrical edge part formation; 2D geometric perimetrical edge part formation; 2D non-perfect/non-concentric edge part formation; at least one characteristic (e.g. flatness, texture, pattern), and/or combinations thereof.
In some embodiments, each mold of the sequentially spaced molds is configured with a mold having a mold surface, a mold carrier box, and a removably attachable mechanical engagement to a conveyor belt.
In some embodiments, the conveyor is configured with a vacuum box which is in communication with a plurality of the molds and mold carrier boxes, such that the vacuum box, mold carrier, and mold are configured to draw a vacuum through the assembly.
In some embodiments, the method comprises: actuating a vacuum across a plurality of vacuum equipped molds to deform the pinched glass ribbon into the surface of each of the molds.
As a non-limiting example, a ribbon material means that the length is longer than the width. While the term ribbon is used, it's understood that sheet can also be processed according to one or more embodiments of the present disclosure. (i.e. where sheet has a larger cross-sectional area than ribbon, as a sheet would have similar length and cross-sectional thickness as the ribbon, but would be configured with a larger width than the ribbon).
As used herein, pinch means reducing the cross-sectional thickness of the ribbon material by a predetermined amount. As set forth herein, with a ribbon cross-sectional thickness of 1 mm (e.g. average cross-sectional thickness), a pinch region has a thickness range selected from at least 0.25 mm to not greater than 0.51 mm. As a non-limiting example, a pinch region has a reduced cross-sectional thickness of at least 25% of the cross-sectional thickness of the ribbon material to not greater than 75% of the cross-sectional thickness of the ribbon material. As a non-limiting example, a pinch region has a reduced cross-sectional thickness of at least 30% of the cross-sectional thickness of the ribbon material to not greater than 70% of the cross-sectional thickness of the ribbon material. As a non-limiting example, a pinch region has a reduced cross-sectional thickness of at least 40% of the cross-sectional thickness of the ribbon material to not greater than 75% of the cross-sectional thickness of the ribbon material.
In one embodiment, a method is provided, comprising: depositing a hot, flexible (e.g. taffy like configuration) glass-containing ribbon along a plurality of sequentially conveyed molds, wherein the glass ribbon comprises a thickness of not greater than 1 mm, further wherein the glass ribbon comprises a uniform thickness; rolling a pinch roller over the surface of the glass-containing ribbon, such that at least one pinch region is actuated in the glass ribbon as the glass ribbon is pinched between a pinch edge of the pinch roller and the surface of the mold; and cooling the glass ribbon, [e.g. whereby the compressive stresses between the pinch region and the adjacent pinch regions is configured to thereby] separating the glass ribbon along the pinch region into discrete glass parts.
In some embodiments, the perimetrical edge of the discrete glass part is defined by the pinch region, optionally in combination with the at least one of the edge of the glass ribbon.
In one embodiment, a method is provided, comprising: depositing a hot, flexible glass-containing ribbon along a plurality of sequentially conveyed molds, wherein the glass ribbon comprises a thickness of not greater than 1 mm, further wherein the glass ribbon comprises a uniform thickness, further wherein each mold is configured with a three-dimensional surface pattern; rolling a pressure roller over the surface of the glass-containing ribbon, such that at least one pressure roller is actuated in the glass ribbon as the glass ribbon is pressed between the three-dimensional surface of the mold and the pressure roller; and cooling the glass ribbon, to define a three dimensional patterned surfaced glass ribbon.
In one embodiment, the method comprises: cutting the glass ribbon into discrete parts (via laser processing, score edge break, machining, selective ablation, chemical ablation, and/or combinations thereof).
In one embodiment, the method comprises, utilizing a pinch roller during processing to define a pinch region in the ribbon material.
In one embodiment, a method is provided, comprising: depositing a hot, flexible glass-containing ribbon along a plurality of sequentially conveyed molds, wherein the glass ribbon comprises a thickness of not greater than 1 mm, further wherein the glass ribbon comprises a uniform thickness; rolling a pressure roller over the surface of the glass-containing ribbon, wherein the pressure roller has a surface defined with a three-dimensional pattern, such that at least one pressure roller is actuated in the glass ribbon as the glass ribbon is pressed between the three-dimensional surface of the mold and the three-dimensional surface pattern of the pressure roller; and cooling the glass ribbon, to define a three-dimensional patterned surfaced glass ribbon.
In one embodiment, a method is provided, comprising: depositing a hot, flexible glass-containing ribbon along a plurality of sequentially conveyed molds, wherein the glass ribbon comprises a thickness of not greater than 1 mm, further wherein the glass ribbon comprises a uniform thickness; further wherein each mold is configured with a first three-dimensional surface pattern; rolling a pressure roller over the surface of the glass-containing ribbon, wherein the pressure roller has a surface defined with a second three-dimensional pattern, such that at least one pressure roller is actuated in the glass ribbon as the glass ribbon is pressed between the first three-dimensional surface of the mold is imparted on the first glass ribbon surface and the second three-dimensional surface pattern of the pressure roller is imparted into the second glass ribbon surface; and cooling the glass ribbon, to define a three-dimensional surface patterned glass part having a cross-sectional wall thickness of not greater than 1 mm.
In one embodiment, a method is provided, comprising: depositing a hot, flexible glass-containing ribbon along a plurality of sequentially conveyed molds, wherein the glass ribbon comprises a thickness of not greater than 1 mm, further wherein the glass ribbon comprises a uniform thickness; further wherein each mold is configured with a three-dimensional part shape in its surface, with vacuum engaging portions; negatively pressurizing the cavity defined between the glass ribbon and the mold surface via the vacuum engaging portions, thereby forming the glass ribbon to the surface of the three-dimensional part shape; rolling a pressure roller over the surface of the glass-containing ribbon, such that the pressure roller is configured to engage the glass ribbon towards the mold (e.g. outer edges of the ribbon towards the outer edges of the mold, to enable vacuum forming of the glass ribbon to the mold surface pattern; and cooling the glass ribbon, to define a three-dimensional glass part having a cross-sectional wall thickness of not greater than 1 mm.
In some embodiments, the perimetrical edge of the discrete glass part is defined by the pinch region, optionally in combination with the at least one of the edge of the glass ribbon.
In some embodiments, molten glass delivery can be completed via crucible, via a round tube delivery (e.g. of continuous tank batch tank); or from a fishtail spreading orifice or slot delivery. In some embodiments, the slot delivery can be configured to supply a stream of monolithic sheet glass or a laminated sheet of glass to promote uniform edge-to-edge puddle in the tope set of the sheet forming rollers.
In some embodiments, the crucible is configured to deliver 3-5 pounds of molten glass (e.g. using a dam as an option to control the sheet width). In this embodiment, a plurality of mold cavities can be covered (e.g. 10-30) depending on the desired size and thickness of the resulting product forms. In some embodiments, the round tube delivery is configured to deliver glass at a desired viscosity (e.g. not less than 500 poise and not greater than 3000 poise), configured to the top set of rollers, with or without dams. The glass delivered from the tube forms a puddle of glass that flows outward from the exit at the tube exit at the center. The puddle width can be established to be a desired width by selecting the appropriate glass delivery flow rate (e.g. pounds per hour) plus the appropriate roller gap (millimertsers 0 and process speed (e.g. inches per second).
In some embodiments, a control system is utilized to configure/control/adjust one or more aspects of the systems and components, including: flow controls, pressure of air flowing through (positive or negative/vacuum), flow controls/roller coolant, coolant flow rate, air flow rate (for air bend/air turn), collet, synchronization of rollers with conveyor speed and/or pressure down roller speed, and combinations thereof, among other items.
In some embodiments, the ribbon deposition system is configured to create a hot, flexible (e.g. taffy like consistency) flat sheet from the molten material and deliver it to the conveyor. The ribbon deposition/ribbon processing system includes: at least one pair of rollers, two pairs of rollers, 3 pairs of rollers, or more. In some embodiments, the roller types used int eh rolling machine delivery system include: smooth surface stainless steel rollers (with or without contour); ceramic coated rollers (e.g. configured to exhibit low thermal conductivity); textured rollers; sculptured rollers (e.g. with pronounced 3D relief); thin pinch rollers (e.g. configured with protruding pinch edges for sheet separation and/or discrete part perimeter shaping); rollers with 3D pockets; rollers with special configurations (e.g. pin rollers to perforate the surface of the sheet); metallic rollers (e.g. Inconel, nickel-specialty alloy, high-temp composition rollers); ceramic coated materials (e.g. dense chrome oxide, polished to a mirror surface finish). Some non-limiting examples of ceramic-coated rollers include zirconia, chromia alumina (e.g. plasma-sprayed chromia alumina) and layered applications of each of the compositions).
In some embodiments, the pressure/push-down roller on the conveyor is configured to be driven by a motor (e.g. servo motor). The pressure/push-down roller can be configured as a smooth surface roller, a textured surface roller, a pinch roller, a pinch roller with textured surface, and combinations thereof.
In some embodiments, the conveyor includes: a roller chain, which can be modified by changing the length of the spacers separating the two sides of the conveyors, changing the length of the sprocket shafts, and changing the widths of the mold, mold carriers, and pressure roller subassembly.
In some embodiments, the conveyor includes a mold carrier/mold chain configured to retain a plurality of molds along the length of the conveyor (e.g. sequentially, in series).
In some embodiments, the mold can be configured as: a flat top surface, a flat mold with textured three-dimensional top surface, a vacuum-forming molds with 3D shapes (e.g. male shapes above the plane or female cavities below the plane, employ complex shapes); three dimensional shape with and sculptured/textured surface(s); three dimensional cavity with a pinch edge configured along the perimeter of the cavity, a mold with a pinch edge along one end of each mold carrier, and/or combinations thereof.
In one embodiment, molds can be cast ceramic molds (e.g. configured with very low thermal conductivity). In one embodiment, the mold is configured to be used at room temperature. In one embodiment, the mold is configured with cooling/cooled air or fluid.
Non-limiting examples of mold materials include: castable ceramic, room temperature curing silica ceramic (e.g. Cotronics Corporation, Rescor 750)), stainless steel, cast-iron, incramet 800 with a chromium oxide coating, among others.
In some embodiments, the pinch region is configured such that the ribbon material self-separates as it travels down the conveyor (and correspondingly continues to cool). For example, as the processed glass ribbon (or ceramic ribbon, or glass ceramic ribbon) continues to cool as it travels down the conveyor, the temperature difference between the thick glass of the product and the thin glass at the thin pinch location causes a thermal stress along the pinch region, which resultingly self-separates ribbon material along the pinch region such that the ribbon material is formed into discrete parts or components by the time it reaches the end of the conveyor.
Using one or more of the embodiments described herein, three dimensional forming of complex shaped products has been demonstrated at process speeds as high as 30 in/sec. For a five inch long product (e.g. handheld phone back), this processing speed equates to more than five pieces manufactured per second. Five pieces per second equals 300 pieces per minute equals 18,000 pieces per hour equals 432,000 pieces in a 24 hour day equals 157,680,000 pieces per 365 day year. At a conservative 64 percent select rate, this means that one machine system could create more than 100 million qualifying parts per.
In some embodiments, low viscosity glass (50-100 poise at delivery) is formed into ribbon material.
In some embodiments, vacuum forming of hot glass sheet (at a viscosity range of 100 to 10,000 poise) causes complete pull down of the hot sheet into the vacuum mold cavities and accurately duplicates the surface features of the mold (e.g. fine features).
Additional features and advantages will be set forth in the detailed description which follows and will be readily apparent to those skilled in the art from that description or recognized by practicing the embodiments as described herein, including the detailed description which follows, the claims, as well as the appended drawings.
It is to be understood that both the foregoing general description and the following detailed description are merely exemplary and are intended to provide an overview or framework to understanding the nature and character of the disclosure as it is claimed.
The accompanying drawings are included to provide a further understanding of principles of the disclosure, and are incorporated in, and constitute a part of, this specification. The drawings illustrate one or more embodiment(s) and, together with the description, serve to explain, by way of example, principles and operation of the disclosure. It is to be understood that various features of the disclosure disclosed in this specification and in the drawings can be used in any and all combinations. By way of non-limiting examples, the various features of the disclosure may be combined with one another according to the following aspects.
In some embodiments, one of the pinch rollers of
In some embodiments, one of the pinch roller of
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In the following detailed description, for purposes of explanation and not limitation, example embodiments disclosing specific details are set forth to provide a thorough understanding of various principles of the present disclosure. However, it will be apparent to one having ordinary skill in the art, having had the benefit of the present disclosure, that the present disclosure may be practiced in other embodiments that depart from the specific details disclosed herein. Moreover, descriptions of well-known devices, methods and materials may be omitted so as not to obscure the description of various principles of the present disclosure. Finally, wherever applicable, like reference numerals refer to like elements.
Next, the ribbon is directed through a pair of sizing rollers 218, including a first sizing roller and a second sizing roller. The sizing roller are configured to actuate on the glass ribbon surfaces (first major surface, second major surface, and first and second edges) to configure the glass in a uniform thickness (e.g. as measured across its length and width).
Following the sizing rollers, the uniform ribbon material is directed into a pair of pin rollers (a first pin roller and a second pin roller), wherein at least one surface of the pin rollers is configured with a plurality of raised protrusions thereon. In some embodiments, both the first pin roller and second pin roller are configured with a plurality of raised protrusions on their respective surfaces. As the uniform ribbon material travels through the pair of pin rollers, the extending protrusions actuate in at least one (or both) of the first and second ribbon material surfaces to impart indentations into the cross-sectional thickness of the ribbon material.
Next, the perforated, uniform ribbon material is directed into a pair of thin pinch rollers 224, including a first and second thin pinch roller. The thin pinch roller are configured to impart a plurality of pinch regions onto at least one of: the first major surface and the second major surface, with sufficient actuation of the glass ribbon between the pair of thin pinch rollers to pinch, but not separate, the glass ribbon. The plurality of pinches in the glass ribbon can be configured in various directions, based on the corresponding patterning of the thin pinch rollers 224.
In one embodiment, the plurality of thin pinches comprise a plurality of transverse pinches, where each transverse pinch is configured to extend from one edge to the other edge (e.g. across the width of the glass ribbon). The forming system is configured with a thin pinch component and conveyor 100.
In one embodiment, the plurality of thin pinches comprise a plurality of axial pinches, where each axial pinch is configured to extend in parallel with the direction that ribbon is conveyed (e.g. along at least a portion of the length of the ribbon). In one embodiment, the plurality of pinches are configured in an arcuate direction (e.g. angled across the linear dimension of the ribbon), such that the ribbon comprises a plurality of parallelograms (e.g.
parallel oriented lines) configured thin pinch regions.
In some embodiments, the thin pinch rollers 224 are configured to actuate at least one of: a transverse thin pinch, an axial thin pinch, arcuate thin pinch, and/or combinations thereof.
As shown in
Once the thinly pinched glass ribbon is directed out of the delivery and processing system 50, the thinly pinched glass ribbon is deposited along a plurality of conveyed molds 110. The conveyed molds are configured in a substantially horizontal direction, such that gravity assists in the thinly pinched glass ribbon laying atop the mold assemblies 110. Further, the timing of the directing the thinly pinched glass from the delivery and processing systems 50 to the conveyed molds 110 along the conveyor 108 can be synchronized, such that the thin pinch region is outside of the working surface of the mold assemblies 110 (e.g. outside the width of the mold or between mold assemblies in the sequence). The conveyor roller assembly 140 is configured with a conveyor pressure roller 144. The conveyor pressure roller actuates against an upper surface of the deposited glass ribbon, pressing the deposited glass ribbon in a flattened configuration against the mold assembly 110 and corresponding mold surface. The glass ribbon is thereby molded via the actuation between the mold surface and the conveyor pressure roller surface to define a plurality of molted glass ribbon portions. As the molded glass ribbon portions continue to travel along the conveyor 108, the glass continues to cool. The reduced temperature is sufficient to initiate a break of the glass along the thin pinch line, such that the molded glass ribbon separates into a plurality of molded glass components as the conveyor directs the molded glass components towards an exit of the conveyor 100. Optionally, a part removal module 160 is configured towards the exit of the conveyor such that the positive pressure actuator 162 is configured to blows air from the conveyor to facilitate lifting the plurality of molded glass parts from the conveyor and/or separating two or more molded glass parts from each other along the thin pinch line(s).
The thin ribbon deposition apparatus 200 includes a pair of forming rollers 212, including a first forming roller and a second forming roller. The forming rollers 212 are configured to direct a continuously delivered batch of molten material (e.g. glass, ceramic, and/or glass ceramic) into a ribbon. The ribbon is configured with two major surfaces, a first and second surface, and two corresponding edges, a first edge and second edge.
Next, the ribbon is directed through a pair of sizing rollers 218, including a first sizing roller and a second sizing roller. The sizing roller are configured to actuate on the glass ribbon surfaces (first major surface, second major surface, and first and second edges) to configure the glass in a uniform thickness (e.g. as measured across its length and width). Following the sizing rollers, the uniform glass ribbon is directed into a pair of thin pinch rollers 224, here the thin pinch rollers are configured with at least one texturizing pinch roller, including a first and second thin pinch roller.
The thin pinch rollers are configured to impart a plurality of pinch regions onto at least one of: the first major surface and the second major surface, with sufficient actuation of the glass ribbon between the pair of thin pinch rollers to pinch, but not separate, the glass ribbon. The plurality of pinches in the glass ribbon can be configured in various directions, based on the corresponding patterning of the thin pinch rollers 224.
In one embodiment, the plurality of thin pinches comprises a plurality of transverse pinches, where each transverse pinch is configured to extend from one edge to the other edge (e.g. across the width of the glass ribbon). The forming system is configured with a thin pinch component and conveyor 100.
In one embodiment, the plurality of thin pinches comprises a plurality of axial pinches, where each axial pinch is configured to extend in parallel with the direction that ribbon is conveyed (e.g. along at least a portion of the length of the ribbon). In one embodiment, the plurality of pinches are configured in an arcuate direction (e.g. angled across the linear dimension of the ribbon), such that the ribbon comprises a plurality of parallel oriented lines configured thin pinch regions.
In some embodiments, the thin pinch rollers 224 are configured to actuate at least one of: a transverse thin pinch, an axial thin pinch, arcuate thin pinch, and/or combinations thereof.
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The conveyor 100 is configured with a plurality of mold assemblies 110, sized to accept the thinly pinched, surface patterned glass ribbon. The mold assemblies 110 are configured in a spaced, sequential order, such that a mold assembly is adjacent to at least two other mold assemblies. The conveyor 100 is configured with a conveyor roller assembly 140, which includes a conveyor pressure roller 144.
Once the thinly pinched surface patterned glass ribbon is directed out of the delivery and processing system 50, the thinly pinched glass ribbon is deposited along a plurality of conveyed molds 110. The conveyed molds are configured in a substantially horizontal direction, such that gravity assists in the thinly pinched glass ribbon laying atop the mold assemblies 110. Further, the timing of the directing the thinly pinched glass from the delivery and processing systems 50 to the conveyed molds 110 along the conveyor 108 can be synchronized, such that the thin pinch region is outside of the working surface of the mold assemblies 110 (e.g. outside the width of the mold or between mold assemblies in the sequence). The conveyor roller assembly 140 is configured with a conveyor pressure roller 144 having a pinned surface, wherein the surface of the roller 144 is configured with a plurality of raised protrusions on its surface. The conveyor pressure roller 144 actuates against an upper surface of the deposited glass ribbon, pressing the deposited glass ribbon in a flattened configuration against the mold assembly 110 and corresponding mold surface 120, while also pressing the pinned roller surface/plurality of protrusions from the conveyor roller arm 144 onto the first surface of the ribbon material. The ribbon material is thereby molded via the actuation between the mold surface and the conveyor pressure roller surface to define a plurality of molted ribbon material portions on the lower surface of the ribbon material.
As the molded glass ribbon portions continue to travel along the conveyor 108, the glass continues to cool. The reduced temperature is sufficient to initiate a break of the glass along the thin pinch line, such that the molded glass ribbon separates into a plurality of surfaced patterned molded glass components as the conveyor directs the surface patterned molded glass components towards an exit of the conveyor 100. Optionally, a part removal module 160 is configured towards the exit of the conveyor 108 such that a positive pressure actuator 162 blows air from the conveyor to facilitate lifting the plurality of surface pattered molded glass parts from the conveyor and/or separating two or more surface patterned molded glass parts from each other along the thin pinch line(s).
The thin ribbon deposition apparatus 200 includes a pair of forming rollers 212, including a first forming roller and a second forming roller. The forming rollers 212 are configured to direct a continuously delivered batch of molten material (e.g. glass, ceramic, and/or glass ceramic) into a ribbon. The ribbon is configured with two major surfaces, a first and second surface, and two corresponding edges, a first edge and second edge.
Next, the ribbon is directed through a pair of sizing rollers 218, including a first sizing roller and a second sizing roller. The sizing roller are configured to actuate on the glass ribbon surfaces (first major surface, second major surface, and first and second edges) to configure the glass in a uniform thickness (e.g. as measured across its length and width). Following the sizing rollers, the uniform glass ribbon is directed into a pair of thin pinch rollers 224, here the thin pinch rollers are configured with at least one texturizing pinch roller, including a first and second thin pinch roller.
Following the sizing rollers, the uniform ribbon material is directed into a pair of pin rollers (a first pin roller and a second pin roller), wherein at least one surface of the pin rollers is configured with a plurality of raised protrusions thereon. In some embodiments, both the first pin roller and second pin roller are configured with a plurality of raised protrusions on their respective surfaces. As the uniform ribbon material travels through the pair of pin rollers, the extending protrusions actuate in at least one (or both) of the first and second ribbon material surfaces to impart indentations into the cross-sectional thickness of the ribbon material.
The thin pinch rollers are configured to impart a plurality of pinch regions onto at least one of: the first major surface and the second major surface, with sufficient actuation of the glass ribbon between the pair of thin pinch rollers to pinch, but not separate, the glass ribbon. The plurality of pinches in the glass ribbon can be configured in various directions, based on the corresponding patterning of the thin pinch rollers 224.
In one embodiment, the plurality of thin pinches comprise a plurality of transverse pinches, where each transverse pinch is configured to extend from one edge to the other edge (e.g. across the width of the glass ribbon). The forming system is configured with a thin pinch component and conveyor 100.
In one embodiment, the plurality of thin pinches comprise a plurality of axial pinches, where each axial pinch is configured to extend in parallel with the direction that ribbon is conveyed (e.g. along at least a portion of the length of the ribbon). In one embodiment, the plurality of pinches are configured in an arcuate direction (e.g. angled across the linear dimension of the ribbon), such that the ribbon comprises a plurality of parallel oriented lines configured thin pinch regions.
In some embodiments, the thin pinch rollers 224 are configured to actuate at least one of: a transverse thin pinch, an axial thin pinch, arcuate thin pinch, and/or combinations thereof.
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The conveyor 100 is configured with a plurality of mold assemblies 110, sized to accept the thinly pinched, surface patterned glass ribbon. The mold assemblies 110 are configured in a spaced, sequential order, such that a mold assembly is adjacent to at least two other mold assemblies. The conveyor 100 is configured with a conveyor roller assembly 140, which includes a conveyor pressure roller 144.
Once the thinly pinched surface patterned glass ribbon is directed out of the delivery and processing system 50, the thinly pinched glass ribbon is deposited along a plurality of conveyed molds 110. The conveyed molds are configured in a substantially horizontal direction, such that gravity assists in the thinly pinched glass ribbon laying atop the mold assemblies 110. Further, the timing of the directing the thinly pinched glass from the delivery and processing systems 50 to the conveyed molds 110 along the conveyor 108 can be synchronized, such that the thin pinch region is outside of the working surface of the mold assemblies 110 (e.g. outside the width of the mold or between mold assemblies in the sequence). The conveyor roller assembly 140 is configured with a conveyor pressure roller 144. The conveyor pressure roller 144 actuates against an upper surface of the pinned pinched ribbon material, pressing the deposited glass ribbon in a flattened configuration against the mold assembly 110 and corresponding mold surface 120. The ribbon material is thereby molded via the actuation between the mold surface and the conveyor pressure roller surface to define a plurality of molted ribbon material portions on the lower surface of the ribbon material.
As the molded glass ribbon portions continue to travel along the conveyor 108, the glass continues to cool. The reduced temperature is sufficient to initiate a break of the glass along the thin pinch line, such that the molded glass ribbon separates into a plurality of surfaced patterned molded glass components as the conveyor directs the surface patterned molded glass components towards an exit of the conveyor 100. Optionally, a part removal module 160 is configured towards the exit of the conveyor 108 such that a positive pressure actuator 162 blows air from the conveyor to facilitate lifting the plurality of surface pattered molded glass parts from the conveyor and/or separating two or more surface patterned molded glass parts from each other along the thin pinch line(s).
The glass delivery system 60 provides molten material (e.g. glass, ceramic or glass ceramic material) into the glass processing system 70. The glass processing system 70 includes: forming rollers 212 (first forming roller and second forming roller); sizing rollers 218 (first sizing roller and second sizing roller), and pinching rollers 224 (first pinching roller and second pinching roller).
The forming rollers 212 are configured to form a hot, flexible ribbon material (e.g. glass ribbon material, ceramic ribbon material, or glass ceramic ribbon material) from the molten material delivered. Once formed, the ribbon material is sized to the appropriate width and thickness (e.g. uniform thickness) via the sizing rollers 218.
Once the ribbon is formed and sized, the pinch rollers 224 are configured to provide a pinch in the ribbon material, thus creating a pinch region in the ribbon material. The pinch region is configured to define the boundary between: the part and cullet, between discrete parts, and/or combinations thereof. The pinch region, together with the glass ribbon of initial cross-sectional thickness is configured to be processed downstream as a unitary piece (e.g. ribbon material +pinch region), continuously directed from glass deliver 60 to ribbon deposition system 200, including: forming rollers 212, sizing rollers 218 and thin pinch 224 rollers. The glass processing system 50, as depicted, illustrates the rollers (roller deposition system 200) configured in a gravity-assisted and/or vertical configuration.
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The conveyor roller assembly 140 is configured with at least one roller. The at least one roller is configurable as: a pinch roller 146 (with corresponding pinch edge(s) 148), a pressure roller 144, a pressure roller (e.g. having a smooth surface), a pressure roller having a three-dimensional surface pattern 150 (e.g. micro pattern or macro pattern), and/or combinations thereof.
The conveyor roller assembly 140 is configured with a frame 142 comprising a motor, the roller 138, and accompanying optional hydraulic components (e.g. configured to promote engagement between the roller and the ribbon material). The conveyor 100 is configured with a wheeled frame assembly, which is configured to be adjustable relative to the location of the glass processing system 40. The controller roller assembly 140 roller engages with a first surface of the ribbon material, such that the pinched ribbon material is engaged between the mold surface 120 and the roller 138. Depending on the configuration of the pressure arm roller 138 and/or mold surface 120 (or mold carrier 114), the pinched ribbon material undergoes further processing as it is transported along the conveyor.
While the ribbon is travelling through the ribbon processing system 40 and conveyor system 100, the ribbon is slowly cooling. Once cooled sufficiently, the compressive stresses created between the pinch region and the adjacent portions (e.g. with a cross-sectional thickness corresponding to the majority of the ribbon material) are high enough to cause the ribbon material to separate along the pinch region. The resulting separation along the pinch region creates discrete parts and/or cullet, depending on the configuration of the pinch region(s) and resulting product shape/dimension.
After forming discrete parts from the thinly pinched glass ribbon, the parts can be vacuum lifted off of the conveyor or removed from the mold(s) as the mold reaches the end of the conveying portion (e.g. while the molds are still horizontal, prior to being lifted/positioned into a vertical upright position). The parts can undergo further downstream processing. For example, the edges of the part defined by pinch region separation, can undergo fire polishing to smooth the edges. Alternative processing includes: mechanical processing, acid etch, laser processing, and/or combinations thereof.
Also, the conveyor supports are adjustable vertically as well—also allowing the distance to be adjustable between the ribbon deposition system 200 and the conveyor system 100.
In some embodiments, one of the pinch rollers 146 of
In some embodiments, one of the pinch roller 146 of
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The conveyor apparatus 100 further includes a plurality of mold assemblies 110 having a mold body and a mold carrier 116, where the mold carrier 116 is configured to attach the mold assemblies to the conveyor belt 108. The conveyor roller assembly provides a trimming roller 146 configured with a trim edge 148. As the trim edge 148 actuates with the ribbon material, the roller 146 also actuates with a trim edge 116 on the corresponding mold surface to provide a trim edge on the first surface and a trim edge on the second surface of the glass ribbon. Also, the vacuum engaging portions 132 provide a negative pressure between the lower surface of the ribbon material and the mold surface, forming the ribbon to the shape of the mold body.
Directional terms as used herein—for example up, down, right, left, front, back, top, bottom—are made only with reference to the figures as drawn and are not intended to imply absolute orientation.
Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification.
As used herein, the singular forms “a,” “an” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a “component” includes aspects having two or more such components, unless the context clearly indicates otherwise.
Many variations and modifications may be made to the above-described embodiments of the disclosure without departing substantially from the spirit and various principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.
This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Application No. 63/003,014 filed Mar. 31, 2020, and U.S. Provisional Application No. 63/119,334 filed Nov. 30, 2020, the content of each of which is incorporated herein by reference in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2021/024943 | 3/30/2021 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63003014 | Mar 2020 | US | |
| 63119334 | Nov 2020 | US |
