Patent Application
20120159989
The present invention relates to a flat glass production apparatus and a process for producing a flat glass, and more particularly, it relates to a flat glass production apparatus and a process for producing a flat glass in which molten glass is formed into a glass ribbon by using tension rollers.
As processes for forming a glass ribbon, an up draw process, a down draw process, a fusion process and a tin float process are conventionally known, and in addition, a flat glass production apparatus in which molten glass supplied from a molten glass supply part is formed into a glass ribbon by using rollers has been proposed as disclosed in JP-A-2001-180949 (hereinafter referred to as the '949 publication) and JP-A-2006-28008 (hereinafter referred to as the '008 publication). It is noted that a glass ribbon herein means a plate-shaped glass continuous in the form of a ribbon obtained after substantially defining its shape from a state of low viscosity attained immediately after being carried out from a melting furnace.
In the flat glass production apparatus disclosed in the '949 publication or the '008 publication, molten glass is sandwiched between pressure rollers disposed above and below, and the molten glass is rolled out by the pressure of the rollers to be formed into a glass ribbon in a thin plate shape.
In the pressure rollers of the '949 publication, a circumferential face of its roll body is made of a roll base capable of containing water therein, and both end portions of each roller are made of a base not containing water, so that the water introduced into the roll base may be instantaneously vaporized from the roller circumferential face due to the heat of the molten glass. Therefore, a thin layer of a steam film is formed between the molten glass and the roller and a heat insulating barrier is formed by the thin layer of the steam film, and hence, the molten glass may be prevented from being abruptly cooled. Furthermore, since the thin layer of the steam film is formed between the molten glass and each of the rollers, the surfaces of the rollers may be prevented from directly coming into contact with the molten glass, which leads to an advantage that a contact trace, wrinkles and irregularities of the roller are never transcribed onto the face of the formed glass ribbon.
The pressure rollers of the '008 publication are basically the same in the structure as the pressure rollers of the '949 publication, and the gas pressure of a gas cushion of one of the rollers disposed above and below is adjusted so that a linear contact portion may be formed in parallel to the shaft of that roller between the roller and the molten glass.
At this point, the pressure rollers mean a pair of rollers disposed in the horizontal direction above and below a glass ribbon so that a plane formed by connecting the center shafts of the two rollers may be substantially vertical to a face of the glass ribbon and that the minimum distance between the circumferential faces of the two rollers may be substantially equal to an estimated ultimate thickness of the glass ribbon. When a pair of rollers are disposed in such positions, the glass ribbon is rolled out through roller pressures applied by the rollers disposed above and blow it. In other words, the flat glass production apparatuses described in the '949 publication and the '008 publication are similar to a production apparatus employing a roll out process of a rolling method.
In the production apparatuses of the '949 publication and the '008 publication using the pressure rollers, the rollers disposed above and below the glass ribbon are made to basically oppose linearly to the glass ribbon for rolling out the glass ribbon, and hence, an area for forming the glass ribbon into a thin plate is as small as a linear area, steam generated in this area is instantaneously dispersed, and it is difficult to stably hold a steam film in this area, resulting in a problem that irregularities of the faces of the rollers are transcribed onto the glass ribbon.
On the other hand, JP-A-2004-26534 (hereinafter referred to as the '534 publication) discloses a flat glass production apparatus including a pair of tension rollers and a glass ribbon forming device.
In the production apparatus of the '534 publication, a glass ribbon falling from a lip face of a glass melting furnace outlet is stretched and hung in the shape of an S between the pair of tension rollers for applying tension to the glass ribbon, and the glass ribbon with a formable temperature having passed through the pair of tension rollers is formed into a glass ribbon with a desired thickness by the glass ribbon forming device.
The tension rollers described in the '534 publication have substantially the same structure as the rollers disclosed in the '949 publication, and the glass ribbon is stretched and hung in the shape of an S between these tension rollers via a thin layer of a steam film. Furthermore, since the speed of the tension rollers is set to be higher than the speed of the glass ribbon running down, a fire polishing function is caused on the interface between the tension rollers and the glass ribbon, so as to fire polish the both faces of the glass ribbon passing between the tension rollers. In this manner, it is advantageously possible to eliminate a trace of transcription of the surface characteristics of the lip face or a trace of pulsation caused at the edge of the lip face having been formed on the face of the glass ribbon.
In other words, the tension rollers of the '534 publication are provided not for the purpose of forming the molten glass into a glass ribbon with an estimated ultimate thickness by themselves but for the purpose of fire polishing the face of the glass ribbon. The glass ribbon is formed into the ultimate thickness by the glass ribbon forming device disposed at a stage subsequent to the tension rollers. Therefore, the molten glass supplied to the tension rollers is adjusted to have a temperature higher than, for example, the molten glass of the '949 publication or the '008 publication so as not to be cooled down to an unformable temperature in passing through the tension rollers.
At this point, the tension rollers mean rollers disposed differently from the pressure rollers and disposed so that a glass ribbon may be stretched and hung on the rollers for applying tension to the glass ribbon in its moving direction. Since the rollers are thus disposed, the glass ribbon is stretched and hung around the circumferential faces of the tension rollers by a prescribed length, and hence, the glass ribbon opposes the rollers in a large opposing face so as to be effectively fire polished.
Furthermore, the glass ribbon forming device disclosed in the '534 publication includes a large number of supports formed to be capable of containing water therein, a supply device for supplying water to the supports, a belt conveyor for making the supports go around, and carriage driving rollers for carrying the formed glass ribbon.
The glass ribbon supplied from the tension rollers onto the supports is formed into a glass ribbon with an estimated ultimate thickness while moving together with the supports via a thin layer of a steam film formed between the supports and the glass ribbon. Furthermore, since the tension to pull the glass ribbon placed on the supports in the carrying direction is caused by friction resistance between the plural carriage driving rollers and the glass ribbon, when the number of revolutions of the carriage driving rollers is variable, the thickness of the glass ribbon to be formed may be controlled.
When the glass ribbon passing through the glass ribbon forming device is pulled in the carrying direction, the width of the glass ribbon is reduced due to the tension, and hence, there arises a problem that the width of the glass ribbon to be formed is smaller than a desired width and also the thickness is larger than a desired thickness.
JP-A-2002-47020 (hereinafter referred to as the '020 publication) discloses a forming device that overcomes the problem of the glass ribbon forming device of the '534 publication. The forming device of the '020 publication is a device for forming molten glass into a glass ribbon while keeping portions of a glass ribbon in the vicinity of its both ends along the widthwise direction in a shape to be difficult to shrink in the widthwise direction. Specifically, concave grooves are formed on both sides of a support and both end portions along the widthwise direction of a glass ribbon are allowed to bend into the concave grooves by its own weight, and thus, a flat portion of the glass ribbon is prevented from shrinking in the widthwise direction. This forming device has an advantage that a glass ribbon may be formed into a desired width and a desired thickness.
A flat glass production apparatus disclosed in the '020 publication, however, has a problem of increase in size of equipment because it needs the forming device of a large scale including a large number of supports, the supply device, the belt conveyor and a plurality of carriage driving rollers.
As described above, since the production apparatuses of the '949 publication and the '008 publication using the pressure rollers are the apparatuses for forming molten glass into a glass ribbon with an ultimate thickness by using the pressure rollers, there is no need to provide the forming device disclosed in the '534 publication or the '020 publication, and therefore, they have an advantage that the equipment is compact. However, the area for forming the glass ribbon into a thin plate is as small as a linear area, and hence it is difficult to stably keep the steam film in this area, which leads to the problem that the irregularities of the rollers are transcribed onto the glass ribbon.
On the other hand, the production apparatuses of the '534 publication and the '020 publication have the advantage that molten glass may be formed into a glass ribbon with a prescribed thickness, and furthermore, the production apparatus of the '020 publication has the advantage that a glass ribbon with a desired width and a desired thickness may be formed. However, these production apparatuses have the problem that the equipment is increased in its size because they need the large scale forming device.
The present invention was made in consideration of these circumstances, and an object of the invention is providing a flat glass production apparatus and a process for producing a flat glass in which molten glass may be formed into a glass ribbon with a desired width and a desired thickness and with a good surface quality as well as equipment may be made compact.
The present invention provides a flat glass production apparatus, including: a molten glass ribbon supply part supplying a continuous flow of molten glass to a forming part as a glass ribbon of a formable temperature; the forming part including a plurality of tension rollers for forming the glass ribbon of the formable temperature supplied from the molten glass ribbon supply part into a glass ribbon of an unformable temperature; and a carriage part carrying out the glass ribbon of the unformable temperature on a downstream side of the forming part, wherein: the plurality of tension rollers including: each of tension rollers is disposed to have shaft center thereof extending in a horizontal direction and perpendicularly to a moving direction of the glass ribbon; among the plurality of tension rollers, odd-numbered tension rollers from an upstream side along the moving direction of the glass ribbon are disposed on a lower face side of the glass ribbon and even-numbered tension rollers are disposed on an upper face side of the glass ribbon; with regard to an odd-numbered tension roller and an even-numbered tension roller adjacent on the downstream side out of the plural tension rollers, an uppermost position of a circumferential face of the odd-numbered tension roller is disposed at the same level as or at a higher level than a lowermost position of a circumferential face of the even-numbered tension roller, and a distance between the circumferential faces of the odd-numbered and even-numbered tension rollers adjacent to each other is larger than a thickness of the glass ribbon present therebetween; at least a tension roller disposed in a most upstream position among the odd-numbered tension rollers out of the plurality of tension rollers, at least a tension roller disposed in a most upstream position among the even-numbered tension rollers or at least two tension rollers disposed in a most upstream position among the odd-numbered and even-numbered tension rollers have, in both end portions thereof and along a circumferential direction, concave grooves for forming substantially convex portions in both end portions of the glass ribbon; and all the plurality of tension rollers or all the plurality of tension rollers excluding a first tension roller are steam generating tension rollers made of a roll base capable of containing a steam film forming agent therein and having a structure in which steam generated from the steam film forming agent contained in the roll base is supplied between a circumferential face of the tension roller and a face of the glass ribbon.
According to the flat glass production apparatus of this invention, when the molten glass is supplied from the molten glass ribbon supply part to the even-numbered and odd-numbered tension rollers disposed in the most upstream position out of the tension rollers of the forming part, the substantially convex portions are formed in both end portions along the widthwise direction of the glass ribbon due to its own weight or due to tension applied to the glass ribbon by the concave grooves formed in the both end portions of one or both of the tension rollers. Therefore, the glass ribbon is prevented from shrinking in the widthwise direction. Then, the glass ribbon is cooled to the unformable temperature while passing through the plural tension rollers disposed on the downstream side and is formed into the glass ribbon with a desired width and a desired thickness. Thereafter, the glass ribbon is directly carried out by the carriage part after passing through the forming part. Incidentally, the substantially convex portions of the both end portions of the glass ribbon may be disposed in positions slightly closer to the center of the glass ribbon from the edges thereof or may be disposed at the edges of the glass ribbon.
Specifically, when the tension rollers are used in accordance with the present invention, the disadvantages of the '949 publication and the '008 publication using the pressure rollers may be overcome, and in addition, owing to the concave grooves formed in the tension roller of the forming part, the molten glass may be formed into a glass ribbon with a desired width and a desired thickness. Furthermore, there is no need to use the forming device as described in the '534 publication and the '020 publication, and the glass ribbon having passed through the forming part is carried out by the carriage part with a simple structure, and therefore, equipment of the production apparatus may be compact.
Moreover, in each tension roller according to the present invention, a steam film forming agent, which is not gaseous in the vicinity of ordinary temperature and is gaseous at a glass transition temperature of the glass, is introduced in a liquid state into the roll base capable of containing the steam film forming agent, and tension is applied to the glass ribbon via a thin layer of a steam film formed through vaporization of the steam film forming agent with high heat of the glass ribbon. Therefore, since a heat insulating barrier is formed by the thin layer of the steam film between the glass ribbon and the tension roller, the molten glass may be prevented from being abruptly cooled as well as the face of the roll base is not brought into direct contact with the glass ribbon, and therefore, traces of contact with the face of the roll base or substantial irregularities of the face of the roll base are not transcribed to the face of the formed glass ribbon, resulting in forming a glass ribbon with a high quality.
Incidentally, a roller conveyor with a simple structure may be exemplified as the carriage part. Alternatively, when the glass ribbon is carried out in the substantially vertical direction, rollers in contact with the front and back faces of the glass ribbon may be exemplified.
Furthermore, one of the odd-numbered and even-numbered tension rollers having the concave grooves and disposed in the most upstream position corresponds to the odd-numbered tension roller when the substantially convex portions are formed in the both end portions of the glass ribbon by its own weight, or corresponds to the even-numbered tension roller when the substantially convex portions are formed by applying the tension (tensile force) to the glass ribbon. In general, the glass ribbon passes through the forming part with tension applied thereto by friction resistance between the carriage part and the glass ribbon, and when this tension is increased beyond a force for forming the substantially convex portions by its own weight, the substantially convex portions may be formed in the both end portions of the glass ribbon by the concave grooves of the tension roller disposed above.
In the flat glass production apparatus to this invention, the first tension roller may be a steam generating tension roller having the concave grooves.
In the flat glass production apparatus of this invention, the first tension roller may be a cooling roller cooled by a coolant introduced into a roll body thereof, and at least the tension roller disposed in the most upstream position out of the even-numbered tension rollers may have the concave grooves.
According to the present invention, merely the tension roller disposed in the most upstream odd-numbered position is the so-called cooling roller, whose roll body is cooled by a coolant introduced thereinto, and therefore, the glass ribbon is directly cooled when it is brought into sliding contact with the face of the roll body of the cooling roller. When the glass ribbon is thus directly cooled merely by the cooling roller disposed on the upstream side and on the lower face side, cooling power approximately three times as high as that attained by a tension roller that cools molten glass via the thin layer of the steam film may be attained. Therefore, while suppressing transcription of irregularities of the roller disposed on the lower face side of the glass ribbon by the tension rollers having the steam film and disposed on the downstream side, the number of tension rollers may be reduced, so that the apparatus may be made more compact.
Furthermore, in the flat glass production apparatus of this invention, when the first tension roller has the concave grooves, each of subsequent odd-numbered tension rollers has, or when the second tension roller has the concave grooves, each of subsequent even-numbered rollers has, end portions with a smaller diameter than a diameter of a center portion thereof.
In the flat glass production apparatus of this invention, an odd-numbered tension roller may have a shaft center disposed in a position lower than a position of a shaft center of an adjacent even-numbered tension roller.
In the flat glass production apparatus of this invention, each of the steam generating tension rollers may have, on a circumferential face thereof, a groove for allowing steam to escape.
The present invention provides a process for producing a flat glass by making a glass ribbon of a formable temperature pass between a plurality of tension rollers, each of which is disposed to have shaft center extending in a horizontal direction and perpendicularly to a moving direction of the glass ribbon, to be formed into a glass ribbon of an unformable temperature, wherein: the glass ribbon of the formable temperature is allowed to pass between the plurality of tension rollers, which are disposed alternately above and below the glass ribbon with a distance between circumferential faces of adjacent tension rollers set to be larger than a thickness of the glass ribbon present therebetween; substantially convex portions are formed in both end portions along a widthwise direction of the glass ribbon by a tension roller having concave grooves formed in both end portions thereof along a circumferential direction; and a steam generating tension roller is used as at least one of the plurality of tension rollers, and the glass ribbon is supported on the tension roller with steam disposed between the glass ribbon and a circumferential face of the steam generating tension roller.
In the process for producing a flat glass of this invention, the glass ribbon of the formable temperature may be first supported by a steam generating tension roller having the concave grooves and provided below the glass ribbon and may be next supported by a steam generating tension roller provided above the glass ribbon.
In the process for producing a flat glass of this invention, the glass ribbon of the formable temperature may be first supported and cooled by a cooling roller provided below the glass ribbon and may be next supported by a steam generating tension roller having the concave grooves and provided above the glass ribbon.
In the process for producing a flat glass of this invention, the glass ribbon of the formable temperature may be first supported by a steam generating tension roller having the concave grooves and provided below the glass ribbon and may be next supported by a steam generating tension roller having the concave grooves and provided above the glass ribbon.
In the process for producing a flat glass of this invention, the glass ribbon may have, in a position immediately before coming into contact with a first tension roller, a formable temperature corresponding to a viscosity of approximately 102.0 to 3.9 Pa·s, and have, in a position immediately after coming into contact with a final tension roller, an unformable temperature corresponding to a viscosity of approximately 106.4 Pa·s.
In the process for producing a flat glass of this invention, the steam generating tension roller may be rotated in a reverse direction to a moving direction of the glass ribbon, or when the steam generating tension roller is rotated in a forward direction, the steam generating tension roller may be rotated at a circumferential speed 1.1 times or more as high as a moving speed of the glass ribbon.
In the process for producing a flat glass of this invention, the glass ribbon of the unformable temperature may be annealed and cut thereafter.
The present invention provides a process for producing a flat glass, characterized in that the glass ribbon carried out from the carriage part of the aforementioned flat glass production apparatus is annealed and cut thereafter.
As described above, according to the flat glass production apparatus and the process for producing a flat glass of this invention, molten glass may be formed into a glass ribbon with a desired width and a desired thickness and the equipment may be made compact.
Furthermore, according to the flat glass production apparatus and the process for producing a flat glass of this invention, a flat glass with a high quality may be produced.
Now, preferred embodiments of a flat glass production apparatus and a process for producing a flat glass according to this invention will be described with reference to the accompanying drawings.
In this production apparatus 10, a glass melting furnace (molten glass supply part) 12, a forming device (forming part) 14 and a roller carriage device (carriage part) 16 are successively arranged along a direction from an upstream side to a downstream side of molten glass G. Furthermore, an annealing furnace 17 for annealing a formed glass ribbon is provided on the downstream side of the roller carriage part 16, and a cutting unit 100 for cutting the annealed glass ribbon is disposed on the downstream side of the annealing furnace. While passing through the annealing furnace 17, the glass ribbon is cooled down to substantially room temperature, and thereafter, the glass ribbon is cut into a prescribed size to be produced into a flat glass. In other words, a flat glass production apparatus of this embodiment is obtained by involving the annealing furnace 17 and the cutting unit 100 in the flat glass production apparatus 10. It is noted that the annealing furnace 17 and the cutting unit 100 may be any of known devices and their forms are not particularly specified.
The glass melting furnace 12 is a tank in which a prescribed glass material for a flat glass is molten, molten glass G having a viscosity and a temperature falling in suitable ranges for formation is prepared by controlling the melting temperature and the thus prepared molten glass G is stored. Since there is a correlation between the viscosity of the molten glass G and the temperature thereof, the viscosity of the molten glass G stored in the glass melting furnace 12 is controlled by adjusting the temperature of the molten glass G by using heating equipment. Furthermore, the glass is molten in the glass melting furnace 12 at a temperature in accordance with the glass composition, and in case of soda-lime glass, for example, at approximately 1450 to 1550° C. (corresponding to a viscosity of 100.7 to 1.0 Pa·s) for a sufficiently long period of time so as to get rid of a foam defect of the glass, fluctuation in the composition and other defects.
The molten glass G having been adjusted in the temperature and the viscosity by the glass melting furnace 12 is supplied in the form of a continuous molten glass flow from a lip face 13 disposed at an outlet of the glass melting furnace 12 to the forming device 14 as a glass ribbon of a formable temperature and is formed into a glass ribbon GL by the forming device 14.
Incidentally, assuming that soda-lime glass is used as the glass, for example, the temperature of the molten glass G supplied to the forming device 14 is preferably approximately 930 to 1200° C. corresponding to a viscosity of 102.0 to 3.9 Pa·s. When the temperature of the molten glass G falls in this range, the glass is sufficiently soft for starting the formation and hence the glass temperature is not too high. For controlling devitrification of glass, the molten glass G adjusted in temperature to approximately 1000 to 1100° C. (corresponding to a viscosity of 102.6 to 3.3 Pa·s) preferably supplied to the forming device 14. Although the glass melting furnace 12 employs a lip shape in its supplying part, it may employ a slit shape of the down draw process or a tub shape of the fusion process. In other words, the molten glass supply part of this invention is not particularly specified in its form as far as it may supply ribbon-shaped molten glass to the forming device 14.
The forming device 14 includes a plurality of tension rollers 18, 20, 22, 24 and 26, and the glass ribbon GL fallen from the lip face 13 of the glass melting furnace 12 is stretched and hung successively on these tension rollers 18 to 26.
At this point, each of the tension rollers 18, 20, 22, 24 and 26 is disposed to have their shaft center extending in the horizontal direction and perpendicularly to the moving direction of the glass ribbon GL. Furthermore, among the plural tension rollers, the odd-numbered tension rollers 18, 22 and 26 from the upstream side of the moving direction of the glass ribbon GL are disposed on the lower face side of the glass ribbon GL, and the even-numbered tension rollers 20 and 24 are disposed on the upper face side of the glass ribbon. Moreover, with regard to an odd-numbered tension roller and an even-numbered tension roller 18 and 20 or 22 and 24 disposed adjacently on the downstream side, the odd-numbered tension roller 18 or 22 is disposed to have the uppermost position of a circumferential face at the same level as or lower than the lowermost position of a circumferential face of the even-numbered tension roller 20 or 24, and the minimum distance between the circumferential faces of the odd-numbered tension roller and the even-numbered tension roller 18 and 20 or 22 and 24 adjacent to each other is larger than the thickness of the glass ribbon GL present between the circumferential faces. It is noted that the position of the shaft center of the odd-numbered tension roller 18 or 22 is preferably lower than the position of the shaft center of the adjacent even-numbered tension roller 20 or 24.
Furthermore, these tension rollers 18 to 26 are rotated in directions shown with arrows in
Taking the soda-lime glass as an example, a temperature corresponding to a viscosity of approximately 106.2 Pa·s is approximately 760° C., and in the forming device 14 of this embodiment, the length of the passage is set so that the temperature of the glass ribbon GL attained immediately after passing through the tension roller 26 may be approximately 750° C.
Accordingly, when the forming device 14 of this embodiment is employed, the glass ribbon GL of a temperature of approximately 930 to 1200° C. supplied to the first and second tension rollers 18 and 20 is cooled and formed into the glass ribbon GL while passing through the forming device 14 and is formed into the glass ribbon GL with an ultimate thickness of an unformable temperature of approximately 750° C. immediately after passing through the fifth tension roller 26. Incidentally, the length of the passage of the glass ribbon GL is appropriately set on the basis of the temperature of the glass ribbon GL, the length of a part of the glass ribbon GL stretched and hung on the tension rollers 18 to 26 (i.e., the length of a part of the glass ribbon opposing the tension rollers) and the number of the tension rollers. In other words, the number of the tension rollers is not limited to five as that illustrated in
The glass ribbon GL having been formed by the forming device 14 is carried out of the production apparatus 10 with its lower face in contact with a plurality of rollers 28 of the roller carriage device 16 disposed at a stage subsequent to the forming device 14. Since the glass ribbon GL having passed through the forming device 14 has been cooled to an unformable temperature, it may be carried in contact with the plural rollers 28 without transcribing irregularities of the surfaces of the rollers. It is noted that the rollers 28 are driven in directions of arrows by a rotation drive not shown. Furthermore, although the glass ribbon having been formed is taken out in a horizontal direction in
The tension rollers 18 to 26 of the forming device 14 are arranged above and below the passage of the glass ribbon so as to sandwich the passage so that each of their shaft centers 18A, 20A, 22A, 24A and 26A is disposed in substantially vertically to the moving direction of the glass ribbon GL and in the horizontal direction, so that the glass ribbon GL may pass in a zigzag manner in a side view.
Furthermore, as illustrated in
All of the tension rollers 18, 20, 22, 24 and 26 of Embodiment 1 are steam generating tension rollers that are made of a roll base capable of containing a steam film forming agent as described later and have a structure for supplying steam, generated from the steam film forming agent contained in the roll base, between the circumferential faces of the tension rollers and the face of the glass ribbon.
Next, the function of the flat glass production apparatus 10 having the aforementioned structure will be described.
When the molten glass G is supplied from the lip face 13 disposed at the outlet of the glass melting furnace 12 to the first and second tension rollers 18 and 20 disposed in the most upstream position in the forming device 14, the end portions along the widthwise direction of the glass ribbon GL run down by its own weight into the concave grooves 30 formed in the both end portions of the first tension roller 18, resulting in forming the substantially convex portions.
According to the production apparatus 10 for a glass ribbon having the aforementioned structure, since the tension rollers 18 to 26 are used, the disadvantages of the '949 publication and the '008 publication using the pressure rollers may be overcome. Furthermore, since the substantially convex portions are formed in the both end portions of the glass ribbon GL by the concave grooves 30 formed in the first tension roller 18 of the forming device 14, the molten glass G may be formed into the glass ribbon GL with a desired width and a desired thickness. Moreover, since the glass ribbon GL having passed through the forming device 14 is carried in a contact state by the roller carriage device 16 with a simple structure, there is no need to use the forming device as disclosed in the '534 publication or the '020 publication, and hence, an effect of compactness of equipment of the production apparatus may be attained.
Incidentally, in the forming device 14, in the case where the concave grooves 30 are formed in the first tension roller alone of the passage of the glass ribbon GL as illustrated in
This production apparatus 40 includes a glass melting furnace 12, a forming device 42, a roller carriage device 16, an annealing furnace 17 and a cutting unit 100.
Similarly to the forming device 14 of
At this point, each of the tension rollers 44, 46, 48, 50 and 52 is disposed with their shaft center extending in the horizontal direction and perpendicularly to the moving direction of the glass ribbon GL. Furthermore, among the plural tension rollers, the odd-numbered tension rollers 44, 48 and 52 from the upstream side of the moving direction of the glass ribbon GL are disposed on the lower face side of the glass ribbon GL, and the even-numbered tension rollers 46 and 50 are disposed on the upper face side of the glass ribbon. Moreover, with regard to an odd-numbered tension roller and an even-numbered tension roller 44 and 46 or 48 and 50 disposed adjacently on the downstream side, the odd-numbered tension roller 44 or 48 is disposed to have the uppermost position of a circumferential face at the same level as or lower than the lowermost position of a circumferential face of the even-numbered tension roller 46 or 50, and the minimum distance between the circumferential faces of the odd-numbered tension roller and the even-numbered tension roller 44 and 46 or 48 and 50 adjacent to each other is larger than the thickness of the glass ribbon GL present between the circumferential faces. It is noted that the position of the shaft center of the odd-numbered tension roller 44 or 48 is preferably lower than the position of the shaft center of the adjacent even-numbered tension roller 46 or 50.
Incidentally, although the tension roller 52 disposed in the most downstream position in the forming device 42 does not have an upper tension roller to be paired with, such an upper tension roller may be additionally provided. Furthermore, the length of a passage of the glass ribbon GL formed by these tension rollers 44 to 52 is also set so that the temperature of the glass ribbon GL attained immediately after passing through the tension roller 52 may be an unformable temperature corresponding to a viscosity of approximately 106.4 Pa·s or a temperature of approximately 750° C. Moreover, the tension rollers 44 to 52 are arranged above and below the passage of the glass ribbon so as to sandwich the passage and so that each of their shaft centers 44A, 46A, 48A, 50A and 52A is disposed in substantially vertically to the moving direction of the glass ribbon GL and in the horizontal direction, so that the glass ribbon GL may pass in a zigzag manner in a side view.
On the other hand, as illustrated in
In other words, in the flat glass production apparatus 40 of Embodiment 2, the tension F2 of the glass ribbon GL is larger than the tension F1 employed in the production apparatus 10 of
The tension rollers 46, 48, 50 and 52 of Embodiment 2 are steam generating tension rollers described later. On the other hand, the tension roller 44 may be a steam generating tension roller or may be a cooling roller described later.
Next, the function of the flat glass production apparatus 40 having the aforementioned structure will be described.
When the molten glass G is supplied from the lip face 13 disposed at the outlet of the glass melting furnace 12 to the tension rollers 44 and 46 disposed in the first and second positions in the forming device 42, the substantially convex portions are forcedly formed in the both end portions along the widthwise direction of the glass ribbon GL by the concave grooves 54 formed in the both end portions of the second tension roller 46 due to the tension F2 of the glass ribbon GL.
Accordingly, the flat glass production apparatus 40 also exhibits the same effects as those attained by the flat glass production apparatus 10 of
Incidentally, in the forming device 42, in the case where the concave grooves 54 are formed in the second tension roller 46 alone as illustrated in
Now, the structure of the steam generating tension roller will be described by exemplifying the tension roller 18.
In the tension roller 18, as illustrated in a cross-sectional view of
As a method for supplying the steam film forming agent to the tension roller 18, it may be supplied to a central cavity 72 formed between a rotating shaft 68 and an inner circumferential face 70 of the tension roller 18, so as to be permeated into the entire bases 60 and 62, or alternatively, a wet roll (not shown) may be provided in contact on a side of the tension roller 18 not facing the glass ribbon GL so as to allow the steam film forming agent having been supplied to the wet roll to transfer to the tension roller 18. Alternatively, a spray method in which the steam film forming agent is sprayed onto the face of the tension roller 18 by using a nozzle may be employed. What is important is that the steam film forming agent may be sufficiently contained in the bases 60 and 62 of the tension roller 18 by the method.
As the bases 60 and 62, any base made of a material or having a structure capable of a liquid therein, such as one made of, for example, a porous body or fibrous body, may be suitably used. In using a porous body, pores are preferably communicating pores. Furthermore, the porous body preferably has, on its surface, fine pores with a diameter of preferably 1 mm or less, more preferably 0.1 mm or less and further preferably 30 μm or less. Thus, the transcription of the pore shapes to the glass ribbon GL may be prevented. Moreover, the porous body is preferably made of a material with a high lyophilic property (for example, a hydrophilic property in case of water) against the steam film forming agent 64.
As a basic material for the bases 60 and 62, porous hydrophilic carbon is particularly suitably used, and apart from it, a polymer material derived from a natural product, such as cellulose, paper, wood or bamboo; a synthetic polymer-based material such as a thermoplastic resin, a thermosetting resin or a rubber; a carbon-based material or the like may be suitably used. Alternatively, a metal material such as iron, stainless steel or platinum, or a ceramic material including, as a principal component, a metal oxide, a metal carbide or a metal nitride such as aluminum oxide, zirconium oxide, silicon carbide or silicon nitride may be used. It is noted that a molded surface of the bases 60 and 62 may be very smooth excluding micro pores or fibrous irregularities, or may be provided with prescribed irregularities on the contrary.
As the steam film forming agent 64 to be used, any of various organic or inorganic substances that are liquid at ordinary temperature and gaseous at a glass transition temperature may be used. Furthermore, from the viewpoint of the operability in supplying it to the bases 60 and 62, one having a melting point of 40° C. or less and a boiling point at atmospheric pressure of preferably 50 to 500° C. and more preferably 300° C. or less is preferably used. More preferably, steam resulting from the vaporization of the steam film forming agent 64 is not chemically too reactive to harmfully affect the glass, has low toxicity and is nonflammable at a temperature where it is used, and a typical example of such a substance is water.
As described above, as the steam film forming agent 64, it is necessary to appropriately select a liquid that is instantaneously vaporized by the high heat of the glass ribbon GL so as to form the stable thin layer 66 of the steam film. The thermal conductivity of the thin layer 66 of the steam film formed through the instantaneous vaporization with high heat is extremely low as compared with the thermal conductivity of a liquid or a solid, and hence, a heat insulating environment for the glass ribbon GL may be formed. When the thickness of the thin layer 66 of the steam film is too small, the tension roller 18 may be brought to direct contact with the glass ribbon GL, a heat insulating barrier is insufficiently formed, and it is easily affected by the irregularities of the surface of the tension roller 18, and therefore, the thickness needs to be at least 10 μm or more and preferably 50 μm or more. Furthermore, when the thin layer 66 of the steam film is too thick, the pressure of the tension roller 18 is difficult to transfer, and therefore, the thickness is preferably 500 μm less and suitably 200 μm or less.
Moreover, although various substances may be used as the steam film forming agent 64 as described above, water is generally suitably used from the viewpoint of the operability, availableness, safety and the like. Also, when the bases 60 and 62 are made of a porous body, for preventing the transcription of the porous pattern to the glass ribbon GL, the circumferential speed of the tension roller 18 is preferably set to be approximately 1.1 times or more as high as the carrying speed of the glass ribbon GL, and more preferably, the rotation direction of the tension roller 18 is opposite to the carrying direction of the glass ribbon GL. When the circumferential speed of the tension roller 18 is approximately 1.1 times or more as high as the carrying speed of the glass ribbon GL, the renewal frequency of the steam film on the face of the glass ribbon is increased, and hence, the surface quality of the glass ribbon is improved. When the tension roller 18 is rotated in the opposite direction, this effect is further enhanced. Furthermore, since the tension roller 18 and the glass ribbon GL are not in direct contact with each other owing to the thin layer 66 of the steam film, the tension F1 causes no problem in carrying the glass ribbon GL.
When such a tension roller 18, that is, the steam generating tension roller, is used in the forming device 14, a heat insulating barrier is formed by the thin layer 66 of the steam film between the glass ribbon GL and the tension roller 18, and hence, the glass ribbon GL may be prevented from being rapidly cooled. Furthermore, since the circumferential faces of the bases 60 and 62 are not in direct contact with the glass ribbon GL, contact traces of the circumferential faces of the bases 60 and 62 or the irregularities of the circumferential faces of the bases 60 and 62 are never transcribed onto the face of the formed glass ribbon GL. Accordingly, when the tension roller 18 corresponding to the steam film generating tension roller is used, the glass ribbon GL with a high quality may be formed, and as a result, a flat glass obtained after passing through the annealing furnace 17 attains a high quality.
Incidentally, when all the tension rollers 20 to 26 disposed in the downstream side are steam generating tension rollers, the thin layer 66 of the steam film is formed between the upper and lower faces of the glass ribbon GL and the tension rollers 20 to 26, and therefore, the circumferential faces of the bases 60 and 62 of the tension rollers 20 to 26 are not in direct contact with the glass ribbon GL. Accordingly, contact traces of the circumferential faces of the bases 60 and 62 and the irregularities of the circumferential faces of the bases 60 and 62 are never transcribed onto the upper and lower faces of the formed glass ribbon GL, and hence, the glass ribbon GL with a high quality may be formed.
In the tension roller 44 corresponding to the cooling roller, a coolant is introduced into its roll body in a cylindrical shape, so as to cool the roll body. Therefore, the glass ribbon GL with high heat stretched and hung on the tension roller 44 is directly cooled by bringing it into sliding contact with the circumferential face of the roll body of the tension roller 44.
When the glass ribbon GL with the high heat obtained immediately after running down from the glass melting furnace is directly cooled by merely the tension roller 44 corresponding to the cooling roller, cooling power three times as large as that of the tension roller 18 (see
It is noted that the tension roller 44 may be a steam generating tension roller. In this case, although a high cooling effect as that attained by the cooling roller may not be attained, the quality of the lower face of the glass ribbon GL may be as high as that attained in Embodiment 1.
Specifically, this forming device 82 uses, as the first and second tension rollers disposed in the most upstream position, the tension rollers 18 and 46 having the concave grooves 30 and 54 in their both end portions. When the tension of the glass ribbon GL passing through the forming device 82 is appropriately adjusted, the substantially convex portions A are formed by the concave grooves 30 on the lower face of the glass ribbon GL and the substantially convex portions B are formed by the concave grooves 54. Incidentally, the substantially convex portion formed in each end portion of the glass ribbon may be disposed in a position slightly closer to the center of the glass ribbon from the edge of the glass ribbon as illustrated in
When the steam generated continuously between the tension roller 18 (46) and the glass ribbon GL remains therebetween, it easily leads to a problem that the glass ribbon GL is deformed (swollen) by the pressure caused by the remaining steam. Therefore, when the steam escape grooves 84 or 86 are formed on the circumferential face of the roll base 60 as illustrated in
Incidentally, comparing the steam escape groove 84 of
The glass ribbon GL formed by any of the flat glass production apparatuses and the flat glass producing processes described above may be used as a glass substrate for an FPD (flat panel display), glass sheet for building materials and glass sheet for the other uses.
Incidentally, although the soda-lime glass is exemplarily described in the embodiments, the invention is applicable to glass not including an alkaline component.
Although the present invention has been described in detail by referring to the specific embodiments, it will be obvious to those skilled in the art that various changes and modifications may be made without departing from the scope and the spirit of the invention. The present application is based on Japanese Patent Application filed on Jul. 9, 2009 (Japanese Laid-Open Patent Publication No. 2009-162752), the entire contents of which are herein incorporated by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-162752 | Jul 2009 | JP | national |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2010/061642 | Jul 2010 | US |
| Child | 13344898 | US |
