This patent application discloses innovations related to glass container manufacturing and, more particularly, to glass gob feeders and loading of glass gobs from gob feeders into blank molds.
Soda-lime-silica glass and other types of glass are prevalent in the manufacture of glass containers. Molten glass used to make such articles can be conventionally prepared by reacting and melting a batch of glass-forming materials in a glass furnace. The batch of glass-forming materials is typically introduced into the furnace by being deposited into a pool of molten glass already in the furnace. In a conventional furnace, the batch is gradually melted into the pool by continuous application of heat. In a submerged combustion (SC) melting furnace, the batch is melted by injecting a combustible gas mixture that contains fuel and oxygen directly into the pool contained in a SC melter, typically though submerged burners mounted in the floor or in an immersed portion of the sidewalls of the melter. The combustible gas mixture autoignites and the resultant combustion products cause vigorous stirring and turbulence as they are discharged through the glass melt. The intense shearing forces experienced between the combustion products and the glass melt cause rapid heat transfer and particle dissolution throughout the molten glass compared to the slower kinetics of a conventional melting furnace.
After the batch has been melted within the furnace, the resulting molten glass is typically directed to a fining channel where bubbles are liberated from the molten glass and then downstream to a forehearth where the fined molten glass is thermally conditioned by being cooled to a suitable temperature for forming the molten glass into containers. A gob feeder located at a downstream end of the forehearth can be used to measure out and form predetermined amounts of molten glass known as “gobs.” The gob feeder usually includes two or more orifices through which gobs are fed down into and through “delivery” equipment, and to an “individual section” (IS) machine that usually includes two or more blank molds that form the glass gobs into parisons used to form glass containers.
The gob feeder typically controls the temperature and quantity of molten glass of the glass gobs and a rate at which the glass gobs are fed to the IS machine indirectly via the delivery equipment. But the delivery equipment requires use of lubricants and includes a complex arrangement of scoops, troughs, and deflectors of varying lengths and configurations, depending on proximity of each section of the IS machine to the gob feeder. The use of lubricants and variable delivery equipment contributes to variation in temperature distribution of the glass gobs, which can contribute to undesirable non-uniform wall thicknesses of glass containers produced from the glass gobs. Such non-uniformity necessitates use of container wall thicknesses that are greater than would otherwise be required.
The present disclosure embodies a number of aspects that can be implemented separately from or in combination with each other.
A glass feeding and forming system in accordance with one aspect of the disclosure includes a multiple gob feeder including feeder orifices laterally spaced apart from one another and having longitudinal orifice centerlines establishing gob falling axes. The system also includes a blank molding station disposed below the gob feeder and including blank molds laterally spaced apart from one another and having longitudinal blank mold centerlines establishing gob loading axes corresponding to the gob falling axes of the gob feeder.
In accordance with another aspect of the disclosure, there is provided a multiple gob feeder including a feeder vessel including outlets laterally spaced apart from one another and with outlet centerlines, and feeder orifices laterally spaced apart from one another and in communication with the feeder vessel and having orifice centerlines coaxial with the outlets of the feeder vessel and establishing gob falling axes. The feeder orifices include orifice pipes having pipe mounts, and pipe sleeves carried by the pipe mounts. The feeder orifices also include orifice tips having tip mounts mounted to the pipe mounts, and tip sleeves carried by the tip mounts.
In accordance with a further aspect of the disclosure, there is provided a multiple gob feeder including a feeder vessel including outlets with outlet centerlines, feeder orifices in communication with the feeder vessel and having orifice centerlines coaxial with the outlets of the feeder vessel and establishing gob falling axes. The feeder orifices include orifice pipes including orifice pipe sleeves and orifice pipe heaters to heat the orifice pipes. The feeder orifices also include orifice tips including orifice tip sleeves and orifice tip heaters to heat the orifice tips.
In accordance with an additional aspect of the disclosure, there is provided a method of loading glass gobs into a blank molding station of a glass forming machine. The method includes producing glass gobs falling from orifices laterally spaced apart from one another and along falling gob axes, and receiving the glass gobs into blank molds laterally spaced apart from one another and having blank mold centerlines corresponding to the falling gob axes.
In accordance with another aspect of the disclosure, there is provided a glass gob feeder orifice that includes an orifice pipe including an orifice pipe sleeve, a refractory collar around the orifice pipe sleeve, and an orifice pipe heater to heat the orifice pipe. The glass gob feeder orifice also includes an orifice tip below the orifice pipe and including an orifice tip sleeve, and an orifice tip heater to heat the orifice tip.
In general, and in accordance with at least one aspect of the present disclosure, an apparatus, system, and method are provided for loading a glass gob directly into at least one blank mold, preferably with no intervening delivery equipment in the form of scoops, troughs, and/or deflectors to move gobs from feeder centerlines inward or outward to blank mold centerlines. But such delivery equipment could be used, for example, to provide equal paths for gobs traveling to blank molds. Therefore, the apparatus, system, and method do not necessitate delivery equipment that requires lubrication and that is lengthy and involves prolonged contact between glass gobs and the delivery equipment, and thus do not require a large height difference between the glass feeder and the corresponding blank mold(s). As such, the temperature distribution of each glass gob delivered from the glass feeder to the blank mold(s) is more uniform thereby leading to more uniform wall thicknesses of glass containers produced from the glass gobs and, thus, thinner-walled lighter-weight containers can be produced. In accordance with another aspect of the present disclosure, a feeder orifice is heated to facilitate rapid temperature changes of the orifice for good weight control of gobs, and is of split configuration to heat an orifice tip to a higher temperature than an orifice pipe to prevent freezing of glass at the orifice tip and prevent concomitant undesired reduction in gob diameters at the orifice tip. The orifice is configured with a plurality of interchangeable tip sleeves having conduits of differently sized inner diameters to facilitate easy change out from one gob size to another.
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Preferably, the system 10 includes no gob delivery equipment in the form of scoops, troughs, and/or deflectors between the gob feeder 12 and the blank molds 18 to change direction of the falling gobs G away from their gob falling axes F. However, the blank side 16 may include gob funnels (not shown) that may be placed at an elevation about 2 mm or more above baffle matches of the blank molds 18 between the gob feeder 12 and the blank molds 18. Notably, a primary purpose of a gob funnel is to maintain a trajectory of a falling gob along a falling gob axis. The gob funnel does not redirect the glass gob away from the gob falling axis associated with its blank mold.
According to the present disclosure, a loading height between a glass line (or “metal line”) of a glass melting apparatus and a top of a blank mold machine bed can be reduced compared to conventional arrangements using delivery equipment in the form of scoops, troughs, and/or deflectors. Such conventional equipment typically requires a conventional loading height of about 6 meters to achieve a gob velocity sufficient to fully load a gob into a blank mold. In contrast, because there is little to no surface contact on gobs falling between the gob feeder 12 and the blank molds 18 according to the present disclosure, the gobs G can achieve velocity sufficient to fully load the gobs G into the blank molds 18 according to a reduced loading height of, for example, about 3 meters. As used herein, the term “about” means within plus or minus 15%. In other embodiments, the presently disclosed subject matter can be used to direct load blank molds 18 at conventional heights. Notably, the shape of the gobs G for direct loading is substantially different than gobs loaded into molds via conventional delivery equipment, because there is little to no stretching of the gobs G thru any delivery equipment.
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The orifice pipes 62 may include pipe mounts that may include mounting conduits 66 having upper ends that may be welded, fastened, or otherwise coupled to the orifice plates 54, and also having lower ends. The pipe mounts also may include upper mounting flanges 68 welded, fastened, or otherwise coupled to the lower ends of the mounting conduits 66. In other embodiments, any other pipe mounts suitable for mounting the orifice pipes 62 may be used. The orifice pipes 62 also may include refractory collars 70 carried in the mounting conduits 66, and upper refractory flanges 72 at lower ends of the refractory collars 70. The orifice pipes 62 also may include pipe sleeves 74 carried in the collars 70 and including pipe conduits 76 and pipe flanges 78 at lower ends of the pipe conduits 76. The orifice pipes 62 also may include one or more orifice pipe heaters 80, for example, induction heaters carried around the mounting conduits 66 and/or the refractory collars 70 to heat the orifice pipe sleeves 74 indirectly through the mounting conduits 66 and/or the refractory collars 74. The induction heaters may include elements wound helically around the pipe conduits 66.
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The orifice pipes 62 and tips 64 may include different heaters configured to heat the orifice pipes 62 and tips 64 to different temperatures. For example, the orifice tips 64 may heated to temperatures higher than that of the orifice pipes 62 in any suitable manner. Accordingly, the feeder orifices 32 may be split induction heated orifices that facilitates rapid temperature changes of the orifices 32 for good weight control of gobs, and permits heating the orifice tips 62 to a higher temperature than the orifice pipes 64 to prevent freezing of glass at the orifice tips 64 and concomitant undesired reduction in gob diameters at the orifice tips 64. As shown in
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Also disclosed is a method of loading one or more glass gobs into a glass forming machine. The method includes producing one or more glass gobs falling from one or more corresponding orifices—the orifices being laterally spaced apart from one another if more than one orifice is present—and along respective gob falling axes. The orifices have centerlines with orifice center distances. The one or more glass gobs are received into one or more corresponding blank molds, each of which has a blank mold centerline establishing a gob loading axis that corresponds to its corresponding gob falling axis. The blank molds have centerlines with blank mold center distances that may be equal to the orifice center distances. The step of producing the glass gob(s) may include stirring molten glass in a tubeless gob feeder using stirring needles laterally spaced apart from one another, and may further include heating a column of molten glass with an orifice pipe heater configured to heat an upper portion of the column of molten glass and with an orifice tip heater configured to heat a lower portion of the column of molten glass to a temperature higher than that of the upper portion of the column of molten glass. For example, the orifice pipe induction heater may be used to heat the upper portion of the column of molten glass, and the orifice tip induction heater may be used to heat the lower portion of the column of molten glass. The heating step may include inductively heating an orifice pipe indirectly through a refractory collar and inductively heating an orifice tip directly. In other embodiments, the step of producing the glass gob(s) may include heating the orifice tip(s) to a higher temperature than the orifice pipe(s). In either case of heating the tip(s) or the lower portion(s) of the column(s) of molten glass, the goal is to prevent freezing of glass at the tip(s) and concomitant undesired reduction in gob diameter at the tip(s).
A glass manufacturing system may include a gob feeder to produce falling gobs that fall along a glass gob loading axis, and a glass forming machine having a machine frame, and establishing a glass gob loading axis, a traversable blank side including a blank mold configured to form glass gobs into parisons and having a corresponding blank mold vertical axis, and a mold carriage movably carried on the machine frame and coupled to the traversable blank side to linearly translate the traversable blank side toward the glass gob loading axis to align the blank mold vertical axis with the glass gob loading axis and to linearly translate the traversable blank side away from the glass gob loading axis. The traversable blank mold section is movable below the gob feeder so that the blank mold receives the falling gobs directly from the gob feeder. Those of ordinary skill in the art would recognize that the traversable blank side may include multiple blank molds and blank mold axes, wherein the mold carriage movably carries the traversable blank side to translate it toward and away from corresponding glass gob loading axes. In a preferred embodiment, such a glass forming machine may be provided as disclosed in U.S. application Ser. No. 17/981,139, filed on Nov. 4, 2022, assigned to the assignee hereof, and the entire contents of which is incorporated herein by reference.
As used in herein, the terminology “for example,” “e.g.,” for instance,” “like,” “such as,” “comprising,” “having,” “including,” and the like, when used with a listing of one or more elements, is to be construed as open-ended, meaning that the listing does not exclude additional elements. Also, as used herein, the term “may” is an expedient merely to indicate optionality, for instance, of a disclosed embodiment, element, feature, or the like, and should not be construed as rendering indefinite any disclosure herein. Moreover, directional words such as front, rear, top, bottom, upper, lower, radial, circumferential, axial, lateral, longitudinal, vertical, horizontal, transverse, and/or the like are employed by way of example and not necessarily limitation.
Finally, the subject matter of this application is presently disclosed in conjunction with several explicit illustrative embodiments and modifications to those embodiments, using various terms. All terms used herein are intended to be merely descriptive, rather than necessarily limiting, and are to be interpreted and construed in accordance with their ordinary and customary meaning in the art, unless used in a context that requires a different interpretation. And for the sake of expedience, each explicit illustrative embodiment and modification is hereby incorporated by reference into one or more of the other explicit illustrative embodiments and modifications. As such, many other embodiments, modifications, and equivalents thereto, either exist now or are yet to be discovered and, thus, it is neither intended nor possible to presently describe all such subject matter, which will readily be suggested to persons of ordinary skill in the art in view of the present disclosure. Rather, the present disclosure is intended to embrace all such embodiments and modifications of the subject matter of this application, and equivalents thereto, as fall within the broad scope of the accompanying claims.
Number | Date | Country | |
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63313983 | Feb 2022 | US |