System and apparatus for removing crystalline solids buildup on glass production equipment

Abstract

A system for removing devitrified crystals includes an edge guide of a glass forming instrument, wherein the edge guide adheres devitrified crystals at a plurality of locations; a burner; a first devitrification removal tool having a first shaft with a shaft, and a tip oriented at a first angle to the shaft; and a second devitrification removal tool having a second shaft with a shaft and a tip oriented at a second angle to the shaft, where the second angle is different from the first angle. The combustor and the first devitrification removal tool are operable to remove devitrification from a first location of the plurality of locations, and wherein the combustor and the second devitrification removal tool are operable to remove devitrification from a second location of the plurality of locations.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority under patent law to U.S. Provisional Application Serial No. 63 / 604,284, filed on November 30, 2023, the contents of which are relied upon and incorporated herein by reference in their entirety. Technical Field

[0003] The present disclosure relates to systems and apparatus for removing crystallized solid buildup on glass production equipment. More particularly, the present disclosure relates to systems and apparatus for efficiently and effectively removing crystallized solid buildup to reduce equipment downtime. Background Art

[0004] Glass production processes, such as molten-stretched glass processing, can produce glass in the form of a continuous strip. Production equipment is typically operated at elevated temperatures to allow glass to be formed to a desired width, thickness, and have other desired characteristics. After the molten glass composition moves downstream in the glass production process, devitrification may occur on multiple parts of the glass production equipment. Edge guides are an example part of the glass production equipment, which may be located at or near the forming body of the glass production system and may be susceptible to devitrification. During devitrification, the structure of the glass may become a crystalline solid, which may form and / or accumulate on the glass production equipment. This glass crystalline solid, also known as devitrification, may cause sheet attenuation, as well as a reduction in the total sheet width, poor bead quality, and process instability. Maintenance and / or other remedial processes need to be periodically implemented to remove the devitrification accumulated on the production equipment. However, existing maintenance processes are time-consuming and expensive, and may result in long periods of downtime. Therefore, improved methods and equipment are needed to remove the devitrification accumulated on the glass production equipment. Summary of the invention

[0005] The present disclosure provides apparatus and systems for removing crystallized solids from glass production equipment. The systems and apparatus and methods may include tools that can be used at various stages of crystallite removal to efficiently and effectively remove crystallite from edge directors of a glass production system.

[0006] In some embodiments, a system for removing crystallites may include: an edge guide of a glass forming instrument, wherein the edge guide has crystallites attached to it at a plurality of locations; a burner; a first crystallites removal tool, wherein the first crystallites removal tool has a first shaft with an axis, and a tip oriented at a first angle to the shaft; and a second crystallites removal tool, wherein the second crystallites removal tool has a second shaft with an axis, and a tip oriented at a second angle to the shaft, wherein the second angle is different from the first angle. The burner and the first crystallites removal tool are operable to remove crystallites from a first location of the plurality of locations, and wherein the burner and the second crystallites removal tool are operable to remove crystallites from a second location of the plurality of locations.

[0007] In one aspect, the first angle may be in a range of 90 degrees to 75 degrees, and the second angle may be in a range of 75 degrees to 45 degrees.

[0008] In another aspect, the first angle may be in a range of 75 degrees to 45 degrees, and the second angle may be in a range of 45 degrees to 10 degrees.

[0009] In another aspect, the burner and the first crystallite removal tool may be operated in tandem.

[0010] In another aspect, the system may include a second burner, wherein simultaneously, the burner and the first crystallite removal tool are operable to remove crystallites from the first of the plurality of locations, and wherein the second burner and the second tool are operable to remove crystallites from the second of the plurality of locations.

[0011] In another aspect, the burner is operable to apply a flame to the crystallite, and the flame comprises a flame length of at least 360 mm.

[0012] In another aspect, the system can include a mirror operable to reflect an image of the edge director for identifying a plurality of locations where crystallites adhere to the edge director. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present disclosure is best understood from the following detailed description when read in conjunction with the accompanying drawings. According to common practice, it is emphasized that the various features of the various drawings are not necessarily drawn to scale. On the contrary, the sizes of the various features may be arbitrarily expanded or reduced for clarity. The same reference numerals always represent the same features throughout the specification and drawings.

[0014] Figure 1 is a schematic illustration of an example glass forming apparatus according to the present disclosure.

[0015] Figure 2 It is along Figure 1 Schematic cross-sectional perspective view of the glass forming apparatus taken along line 2-2.

[0016] Figure 3 is an illustration of multiple views of an example edge director.

[0017] Figure 4 is an illustration of multiple views of an example director including a reflected view of an edge director.

[0018] Figure 5 is the location where the crystals accumulate Figure 4 Illustration of a view of an edge director.

[0019] Figure 6 is an illustration of a side view of an example edge director showing example stages of removing a devitrified crystal from the edge director according to some embodiments of the present disclosure.

[0020] Figure 7 is an illustration showing example stages of removing a crystallizer from an edge director according to some embodiments of the present disclosure.

[0021] Figure 8 It is shown that the crystallization from Figure 7 An illustration of another example stage of edge director removal.

[0022] Fig. 9 It is shown that the crystallization from Figure 7 An illustration of another example stage of edge director removal.

[0023] Fig.10 is an illustration of an example combustor that may be used in one or more methods of the present disclosure.

[0024] Fig.11 is an illustration of an example tool that may be used to remove crystallites in one or more methods of the present disclosure.

[0025] Fig.12 is a flow chart illustrating example steps for removing a crystallizer from an edge director according to some embodiments of the present disclosure. DETAILED DESCRIPTION

[0026] This description of exemplary embodiments is intended to be read in conjunction with the accompanying drawings, which are considered to be part of the entire written description. In the description, relative terms, such as "lower", "upper", "horizontal", "vertical", "above", "below", "up", "down", "top" and "bottom" and their derivatives (e.g., "horizontally", "downward", "upward", etc.) should be interpreted as referring to the orientation as described below or as shown in the accompanying drawings under discussion. These relative terms are for convenience of description and do not require the instrument to be constructed or operated in a specific orientation. Terms about attachment, coupling, etc., such as "connection" and "interconnection" refer to a relationship in which structures are fixed or attached to each other directly or indirectly through an intervening structure, as well as removable or rigid attachments or relationships, unless clearly described otherwise.

[0027] For purposes of the following description, it will be understood that the embodiments described below may contemplate alternative variations and embodiments. It will also be understood that the specific articles, compositions and / or processes described herein are exemplary and should not be considered limiting.

[0028] In the present invention, the singular forms "a", "an" and "the" include plural references, and references to specific numerical values ​​include at least the specific value, unless the context clearly indicates otherwise. When a value is expressed as an approximation, it will be understood that the specific value forms another embodiment by using the antecedent "about". As used herein, "about X" (wherein X is a numerical value) preferably refers to ±10% of the stated value, including the stated value. For example, the phrase "about 8" preferably refers to a value of 7.2 to 8.8, including 7.2 and 8.8. Where present, all ranges are inclusive and combinable. For example, when stating a range of "1 to 5", the stated range should be interpreted as including a range of "1 to 4", "1 to 3", "1-2", "1-2 and 4-5", "1-3 and 5", "2-5", etc. In addition, when a list of alternatives is provided positively, such a list can be interpreted as indicating that any of the alternatives can be excluded, such as by a reverse restriction in the attached claims. For example, when stating a range of "1 to 5", the stated range may be interpreted as including the situation whereby 1, 2, 3, 4 or 5 are excluded in reverse; thus, the statement of "1 to 5" may be interpreted as "1 and 3-5, but not 2", or simply "wherein 2 is not included". It is intended that any component, element, attribute or step that is positively stated herein may be explicitly excluded in the appended claims, regardless of whether such component, element, attribute or step is listed as an alternative or whether or not they are independently stated.

[0029] The present disclosure provides methods and apparatus that can be used to periodically remove crystallites that may have accumulated on portions of glass production equipment, such as edge directors. The methods and apparatus of the present disclosure include improved tools and methods to allow for faster and more complete removal of crystallites from edge directors than using existing methods and apparatus.

[0030] The methods and apparatus of the present disclosure can be implemented in various types of glass production lines that can produce various types of glass. Exemplary glasses can include, but are not limited to, aluminosilicates, alkali aluminosilicates, borosilicates, alkali borosilicates, aluminoborosilicates, alkali aluminoborosilicates, and other suitable glasses. Non-limiting examples of useful glasses include, for example, EAGLE GLASS from Corning Incorporated. IRIS TM and Glass. In some other embodiments, the glass may include other types of glass, such as high performance display (HPD) glass.

[0031] Reference will now be made in detail to embodiments of apparatus and methods for removing crystallized solids from glass production equipment and heating units for use in such apparatus and methods, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numerals are used throughout the drawings to refer to the same or like parts.

[0032] One embodiment of an apparatus for making glass is Figure 1 1 and generally indicated throughout by reference numeral 10. The apparatus generally includes a heating cartridge removably located at a port of a housing that surrounds the forming trough beneath an edge guide secured to the forming trough. Corning Incorporated further describes an apparatus for making glass and a replaceable heating cartridge for use in such an apparatus in U.S. Pat. No. 9,512,025 issued Dec. 6, 2016.

[0033] Reference now Figure 1 , schematically depicts one embodiment of a glass forming apparatus 10 for making glass, such as a glass ribbon 12. The glass forming apparatus 10 generally includes a melting tank 15 configured to receive a batch material 16 from a hopper 18. The batch material 16 may be introduced into the melting tank 15 by a batch delivery device 20 powered by a motor 22. An optional controller 24 may be provided to activate the motor 22, and a molten glass level probe 28 may be used to measure the level of the glass melt within the standpipe 30 and transmit the measured information to the controller 24.

[0034] The glass forming apparatus 10 may also include a clarifier tank 38, such as a clarifier tube, located downstream of the melting tank 15 and coupled to the melting tank 15 by means of a first connecting tube 36. A mixing tank 42, such as an agitation chamber, may also be located downstream of the clarifier tank 38. A delivery tank 46, such as a bowl, may be located downstream of the mixing tank 42. As depicted, a second connecting tube 40 couples the clarifier tank 38 to the mixing tank 42, and a third connecting tube 44 couples the mixing tank 42 to the delivery tank 46. As further shown, a downcomer 48 is positioned to deliver the glass melt from the delivery tank 46 to the inlet 50 of the forming vessel 60. As shown in FIG. Figure 1 As shown in FIG. 1 , melting tank 15 , fining tank 38 , mixing tank 42 , delivery tank 46 , and forming vessel 60 are examples of various glass melt stations that may be positioned in series along glass forming apparatus 10 .

[0035] The melting tank 15 is typically made of refractory materials, such as refractory (e.g., ceramic) bricks. The glass forming apparatus 10 may further include components typically made of platinum or platinum-containing metals (such as platinum rhodium, platinum iridium, and combinations thereof), but may also include refractory metals, such as molybdenum, palladium, rhenium, tantalum, titanium, tungsten, ruthenium, osmium, zirconium, and alloys thereof, and / or zirconium dioxide. The components containing platinum may include one or more of the first connecting pipe 36, the clarifying tank 38, the second connecting pipe 40, the riser 30, the mixing tank 42, the third connecting pipe 44, the delivery tank 46, the downcomer 48, and the inlet 50. The forming tank 60 may also be made of refractory materials and is designed to form the glass melt into the glass ribbon 12.

[0036] Figure 2 It is along Figure 1 2-2 of the glass forming apparatus 10. As shown, the forming trough 60 includes a forming wedge 62, which includes a pair of downwardly inclined forming surface portions 66a, 66b extending between opposite ends 64a, 64b of the forming wedge 62. The downwardly inclined forming surface portions 66a, 66b converge along a downstream direction 68 to form a root 70. A drawing plane 72 extends through the root 70. The glass ribbon 12 can be pulled in the downstream direction 68 along the drawing plane 72. The drawing plane 72 bisects the root 70 in a generally horizontal, longitudinal direction of the forming trough. However, it should be understood that the drawing plane 72 can extend in other orientations relative to the root 70.

[0037] In some embodiments, the forming trough 60 may include edge directors 80a, 80b that intersect the pair of downwardly inclined forming surface portions 66a, 66b. The edge directors help achieve the desired glass ribbon width and edge bead characteristics by directing the molten glass close to the root 70 of the forming trough 60. In some embodiments, the edge directors 80 may intersect both of the downwardly inclined forming surface portions 66a, 66b. Additionally or alternatively, in other embodiments, the edge directors may be located at each of the opposing ends 64a, 64b of the forming wedge 62. For example, as shown in FIG. Figure 1 As shown in , edge directors 80a, 80b may be located at each of the opposing ends 64a, 64b of the forming wedge 62, wherein each edge director 80a, 80b is configured to intersect both of the downwardly inclined forming surface portions 66a, 66b. As further shown, each edge director 80a, 80b may be substantially identical to one another. However, it should be understood that in alternative embodiments, the edge directors may have different configurations and / or geometries, depending on the specific characteristics of the glass forming apparatus. Additionally, it should be understood that various forming wedge and edge director configurations may be used in accordance with aspects of the present disclosure. For example, aspects of the present disclosure may be used in conjunction with forming wedge and edge director configurations as disclosed in U.S. Patent Nos. 3,451,798, 3,537,834, 7,409,839, and / or U.S. Provisional Patent Application No. 61 / 155,669, filed on February 26, 2009, each of which is incorporated herein by reference. Although Figure 1 and Figure 2 While one embodiment of a glass forming apparatus and forming trough is generally depicted, it should also be understood that aspects of the present disclosure may be used in conjunction with various other forming trough configurations and / or in conjunction with other edge director configurations.

[0038] Reference now Figure 3 , schematically depicts an embodiment of an edge director 80 that may be used in conjunction with aspects of the present disclosure. In the description that follows, the edge director 80 is described in more detail in conjunction with methods and tools for removing crystallites from the edge director 80. It should be understood that the description that follows may be used and or applied to the first edge director 80a and / or the second edge director 80b. The first edge director 80a and the second edge director 80b may be of the same or similar construction to each other. The use of the same edge director may be beneficial in providing a uniform glass ribbon. However, it should be understood that individual edge directors may also have different configurations and / or geometries to accommodate various glass forming apparatus and / or forming trough configurations.

[0039] In the example shown, the edge director can be located at or near the side of the root 70 and can be symmetrical about the drawing plane 72. The edge director 80 can be angled or curved as shown and can extend from the forming wedge to the edge director edge 306. Before or during the forming of the glass ribbon, as the molten glass moves downward during the pull process, the glass can move along the inner surface 302 of the edge director 80. The glass can crystallize or undergo devitrification to deposit devitrified crystals on the inner surface 302 of the edge director 80. Devitrified crystals that can form on the edge director 80 can compromise the quality of the glass ribbon formed by the glass production process. Devitrified crystals can, for example, cause hollow beads to form in the glass ribbon and / or increase the size or amount of the hollow beads. The hollow beads can cause cracks or other quality issues in the glass ribbon.

[0040] It may be necessary to periodically take the glass production process offline to remove crystallites that may form on the edge directors. However, such existing removal methods or tools often result in extended maintenance time and may often result in inadequate removal, such that crystallites remain on the edge directors 80 and / or continue to cause quality issues in the forming of the glass ribbon. The methods and apparatus of the present disclosure are an improvement over such existing methods. The methods and apparatus of the present disclosure allow crystallites removal to be performed more quickly than existing methods and allow for significant reductions in production equipment downtime.

[0041] During crystallite removal, an operator or operators may identify locations of crystallites that may form on edge director 80. Figure 3 As shown in , edge guide 80 may be divided into multiple sections 304 to identify locations where crystallites may form. Sections 304 may include a terminal (VE) section, an end (E) section, a second main (M2) section, a first main (M1) section, and a center (C) section. Labeling and / or organization of such sections may help an operator identify the location of crystallites and may lead to determining a recommended method and / or tool for removing the crystallites. For illustrative purposes, a straight view 310 of edge guide 80 includes section 304. Side view 320 is also shown and illustrates how difficult it may be for an operator to view the inner surface 302 of edge guide 80 because the operator will be located outside of side view 320 (to the right, in FIG. 1 ). Figure 3 As can be appreciated, due to the operating conditions of the glass production system and because of the curvature of edge director 80, it is difficult to see the edge director.

[0042] like Figure 4, an illustration of edge director 80 is shown. Front view 402 shows a front or front view of edge director 80. Also shown is a side view 406 of edge director 80. As explained above, edge director, and surface 408 of edge director 80 may be difficult to see in a manufacturing environment. An operator may use one or more tools to see edge director 80 to determine the location of crystallites that may form and / or accumulate on edge director 80. For example, an operator may use a reflector connected to an extension to see edge director 80. The glass production system may be used offline. An operator may be located at or near the outside of edge director 80, at a position to the right of edge director 80 in side view 406. The operator may extend the reflector to a position at or near surface 408 of edge director 80 and see edge director 80. Because the reflector is used at an angle, the reflected image may appear as Figure 4 4. The reflected view 404 is shown in FIG. The reflected view 404 can be used by an operator to view the location of the crystallites on the edge director 80.

[0043] Now turn to Figure 5 , shows an example edge director 80 with crystallites 510 accumulated at various locations. In the straight view 502, the crystallites 510 can be seen at the very edge portions of the edge director 80 and at or near the center portion. As shown in the side view 506, the operator can position the reflector 520 at a position to view the edge director 80 from the side. The reflector 520 can include a reflective portion 524 located at the distal end of the extension portion 522. The reflector 520 can be constructed of bright steel or other suitable metals, or allow for use in the environment of the glass production system. The operator can view the crystallites 510 in the reflective portion 524 to determine the location of the crystallites. The reflected view 504 shows an example reflected view of the edge director 80 and the crystallites 510. In this example reflected view 504, the edge director 80 is shown as it would appear during operation of the glass production system. As can be seen, the crystallites 510 prevent the glass 512 from flowing along the surface of the edge director 80 and are completely fused at the root 70 of the forming wedge. Crystallization 510 may increase the likelihood of quality issues in the glass ribbon as well as the size of hollow beads in the glass ribbon.

[0044] Reference now Figure 6, showing an example removal stage. In the example shown, an operator can use a removal tool 604 to remove a crystallization 510 from the surface of an edge guide 80. The operator can apply a flame 608 from a burner or a spray gun 606 to the crystallization 510. After heating the crystallization 510, the operator can use the removal tool 604 to remove the crystallization 510 from the surface of the edge guide 80. Alternatively, one operator or multiple operators can apply a flame 608 from a burner while using the removal tool 604 (e.g., operating the burner and the tool in tandem). As will be further explained below, after identifying the location of the crystallization 510 and selecting a preferred tool to remove the crystallization 510, the operator can perform this removal method. The burner 606 may include a nozzle 610 that generates a flame 608, and the flame length of the flame 608 is suitable for reaching the location of the crystallization 510 on the edge guide. Due to several advantages and improvements, the removal method is an improvement over existing methods.

[0045] First, the stage of crystallization removal can incorporate the use of one or more removal tools including preferred shapes and configurations to allow an operator to remove crystallization 510. Existing methods and instruments do not have specialized tools to allow removal of crystallization 510 at all locations on edge guide 80. Edge guide 80 has a specialized shape that may make removal difficult if normal or standard tools are used. The removal tool 604 of the present disclosure has a geometric shape and configuration to allow an operator to effectively and efficiently remove crystallization at various locations on edge guide 80.

[0046] Secondly, because of the improvement of burner 606, the system and instrument of the present disclosure are improvements to existing systems and instruments. Existing burners may have flame lengths that are not suitable for reaching all positions of edge guide 80. Such existing burner instruments may include nozzles that produce flame lengths (i.e., the length of the flame measured from the nozzle end to the end of the flame) in the range of about 250mm to 280mm. This flame length may not be enough to reach crystals that may be located at extreme positions on edge guide 80. The nozzle of burner 606 of the present disclosure may have an increased flame length. In some examples, the flame length of burner 606 described in the present disclosure may be in the range of about 340mm to about 380mm. In some instances, the flame length may be at least about 360mm. This flame length allows the operator to reach crystals 510 at all or substantially all positions on edge guide 80.

[0047] Third, the stage of crystallite removal may include simultaneous crystallite removal from both sides of the glass production equipment at the same time. As previously discussed, the glass production equipment may include an edge director 80 at each end of the forming wedge. The crystallite removal method may use multiple operators and / or teams of operators who may simultaneously remove crystallites from edge directors 80 located on opposite sides of the glass production system. In addition, the removal method may use standardized instructions and / or removal techniques that the operators may use to efficiently and effectively remove crystallites from edge directors 80.

[0048] Now turn to Figure 7 , example stages of a crystallizer removal method are shown and further explained. In this example, the crystallizer removal can be performed offline using a glass production device. The crystallizer removal can include multiple steps for crystallizer removal. The crystallizer removal can include removing the crystallizer 710 from the edge director in multiple stages, including starting at the end of the edge director 80 and then proceeding toward the center of the edge director 80. Figure 7 The first stage of crystallite removal is shown, where crystallite 710 is removed from the end (VE) portion and / or the end (E) portion of the edge director. The operator may use a reflector (not shown) to view the crystallite 710, as shown in the reflected view 704. If the operator identifies crystallite 710 located at the end (VE) portion and / or the end (E) portion, the operator may first remove the crystallite 710 located at these portions.

[0049] The operator may select a preferred tool 712 and apply the flame of a burner 714 to the crystallite 710 located at the end (VE) portion and / or the end (E) portion. While the crystallite is heated, the operator may move the tool 712 along the surface of the edge director 80 to remove the crystallite 710. The operator may use a reflector (not shown) during this procedure to help locate and remove the crystallite 710. The straight view 702, the side view 706, and the reflected view 704 are shown for illustration purposes to show the removal of the crystallite.

[0050] like Figure 8As shown in , crystallite removal can continue to remove crystallites 710 at locations toward the center of the edge guide 80. In this example, the crystallite 710 is located in the first main (M1) portion and the center (C) portion. As described above, crystallites 710 located in the end (VE) portion and / or the end (E) portion are removed. The crystallite 710 is removed in a manner similar to that explained above by applying a flame from a burner 714 and using a tool 812. In this removal step, the tool 812 may be a different tool from the tool 712 used in the earlier removal stage. The tool 812 may have different geometries that allow the operator to reach and remove the crystallite 710 at the first main (M1) portion of the edge guide 80. When removing the crystallite 710, the operator may use a combination of pulling and pushing actions to move the tool 812 along the edge guide 80 to remove the crystallite 710.

[0051] Reference now Fig. 9 , showing another straight view 902, a reflected view 904, and a side view 906 of the edge guide 80. An example stage is shown here in which a crystallizer 710 can be removed from the center portion of the edge guide 80. As shown, a crystallizer 710 located at or near the center (C) portion is targeted for removal. An operator can use a burner 714 to apply a flame to or near the crystallizer 710, and use a tool 912 to remove the crystallizer. Tool 912 can be the same as the tools 712, 812 used in other crystallizer removal stages, or have a different geometry. As described above, an operator can use a combination of push and pull actions to remove the crystallizer 710 from the edge guide 80.

[0052] Fig.10 An example burner 1000 is shown in FIG. The burner 1000 may include a nozzle 1002 configured to deliver a flame 1004 having a predetermined flame length (l). In some examples, the flame length may be adjustable and may deliver a flame length of at least 360 mm. The flame length may be configured to be at least long enough to reach crystallites located in all areas of the edge director. The burner 1000 may have various configurations and may be an oxy-fuel burner configured to produce a flame temperature suitable for melting crystallites on the edge director.

[0053] As explained above, the crystallization removal of the present disclosure may incorporate the use of a crystallization removal tool. Crystallization removal may include the use of multiple crystallization removal tools in different situations. In some examples, different crystallization removal tools are used to remove crystallization located at different portions of the edge director. Fig.11An example crystallite removal tool that can be used in crystallite removal of the present disclosure is shown. Tool 1102 includes a shaft 1108 and a removal end 1110. Removal end 1110 may include a tip 1116 positioned at a predetermined angle A1 to the axis of shaft 1108. In this example, tip 1116 may be oriented at an angle A1 in the range of about 90 degrees to about 75 degrees to the axis of shaft 1108. Tip 1116 may be pointed, and may also be flat to create an engagement surface for removal of crystallite. The configuration of tool 1102 may be configured to remove crystallite from the center (C) portion of the edge guide.

[0054] The crystallite removal tool may also include a tool configured similarly to tool 1104. Tool 1104 may be configured similarly to tool 1102 having a shaft 1108 and a removal end 1112. However, the tip 1118 of tool 1102 may be oriented differently relative to the axis of shaft 1108. In this example, the tip 1118 may be at an angle A2 relative to the axis of shaft 1108. Angle A2 may be in the range of about 75 degrees to about 45 degrees. Tool 1102 may have a more open orientation relative to shaft 1108 to allow an operator to easily and efficiently remove crystallizes from the main portion of the edge director, such as from the first main (M1) portion and / or the second main (M2) portion.

[0055] Tools for crystallite removal may also include tools configured similarly to tool 1106. Tool 1106 may be configured similarly to tool 1102 having a shaft 1108 and a removal end 1114. However, the tip 1120 of tool 1106 may be oriented differently relative to the axis of shaft 1108. In this example, tip 1120 may be at an angle A3 relative to the axis of shaft 1108. Angle A3 may be in the range of about 45 degrees to about 10 degrees. Tool 1106 may have a more open orientation relative to shaft 1108 to allow an operator to easily and efficiently remove crystallizes from end portions of an edge director, such as from a distal end (VE) portion and / or an end (E) portion.

[0056] In other examples, the tool may have a different configuration than that shown, and / or there may be additional versions of the tool having a tip at other angles relative to the shaft of the tool. The tool for removing crystallites may be made of a variety of suitable materials that can be used at the extreme operating temperatures required for crystallization removal, such as platinum, stainless steel, or other alloys or metals.

[0057] Reference now Fig.12, showing an example step group 1200 for removing crystallites from an edge director. Step group 1200 may include one or more of the steps described above, and / or include the use of one or more of the tools or burners described above. Although some of these elements may be used, it should be understood that step group 1200 is not limited to the embodiments described in the present disclosure.

[0058] Group 1200 may begin at step 1202. At step 1202, an operator may determine the location of a crystallite on an edge director. As may be appreciated, the glass production system may be used offline prior to step 1202. An operator may use a reflector or other visual aid. An operator may extend a reflector under an edge director and view a reflected view of the edge director. An operator may classify the location of the observed crystallite into one or more categories or sections of the edge director. The edge director may be divided into one or more predetermined sections. An operator may classify the observed crystallite into these predetermined sections, such as a terminal (VE) section, an end (E) section, a second main (M2) section, a first main (M1) section, and a center (C) section. In other examples, the edge director may be divided into other predetermined sections.

[0059] Once the crystallites are assigned or sorted into one or more of the predetermined portions, an operator may remove the crystallites in a predetermined order. In one example, an operator may not begin the removal process at the end of an edge director and work in a direction toward the center of the edge director.

[0060] In step 1204, the operator may remove the crystallization at the end portion of the edge director. The operator may apply a flame to the crystallization at the end portion. The operator may use the burner described above to apply the flame to the crystallization. The operator may then use a tool to remove the crystallization from the edge director. In one example, the operator may use a tool (such as tool 1106) to remove the crystallization from the end portion of the edge director. In other examples, other tools may be used. The operator may observe the removal to confirm that the crystallization is removed before moving to the next step of the removal process.

[0061] In step 1206, the operator may remove the crystallization from the main portion of the edge director. The operator may apply a flame to the crystallization at the main portion. The operator may use the burner described above to apply the flame to the crystallization. The operator may then use a tool to remove the crystallization from the edge director. In one example, the operator may use a tool (such as tool 1104) to remove the crystallization from the end portion of the edge director. In other examples, other tools may be used. The operator may observe the removal to confirm that the crystallization has been removed before moving to the next step.

[0062] In step 1208, the operator can remove the crystallization from the center portion of the edge director. The operator can apply a flame to the crystallization at the center portion. The operator can use the burner described above to apply the flame to the crystallization. The operator can then use a tool to remove the crystallization from the edge director. In one example, the operator can use a tool (such as tool 1102) to remove the crystallization from the end portion of the edge director. In other examples, other tools can be used. The operator can observe the removal to confirm that the crystallization has been removed before moving to the next step.

[0063] Upon completion, the crystallite has been removed from the edge guide. Prior to completion, the operator may confirm the removal of the crystallite. In some examples, step group 1200 may be performed simultaneously by multiple operators and / or multiple operator teams to remove the crystallite from opposite sides of the glass production system. Such simultaneous removal may further improve the efficiency and effectiveness of the method to minimize downtime of the glass production equipment.

[0064] The systems, tools and apparatus of the present disclosure were used to perform a crystallization removal process in an existing glass production system. The performance of the glass production system and the time required to perform crystallization removal were compared with existing crystallization removal techniques. The systems, tools and processes of the present disclosure showed significant improvements over existing systems and processes. The systems, tools and use stages of the present disclosure showed the ability to remove more than 95% of the crystallization accumulated on the edge guides. The total downtime required to perform crystallization removal as described in the present disclosure was significantly less than existing removal processes and systems. Existing removal processes and techniques require the glass production system to be used offline and have downtime ranging from 10 days to 2 days. The systems, tools and removal stages as described in the present disclosure reduce this required downtime to less than about 4 hours of downtime. Therefore, the downtime required for crystallization removal is improved by at least 50% compared to known processes, tools and systems.

[0065] The crystallization removal process also shows significant improvements in glass production. After performing the crystallization removal process, various significant improvements in glass ribbon properties were observed. In one example, after performing the crystallization removal, the total sheet width of the glass ribbon increased by about 19 mm. After the crystallization removal, the hollow bead situation in the glass ribbon was significantly reduced. In one example, it was observed that the glass ribbon exhibited hollow bead situations in the range of about 5 to 10 mm. After utilizing the crystallization removal system, tools and use stages of the present disclosure, the hollow bead situation was reduced to a range of about 0 mm to about 1 mm. In addition, the bead margin was increased by an amount of about 23 mm to about 25 mm.

[0066] As shown in this example, the systems, tools and apparatus of the present disclosure are significant improvements over existing processes and apparatus. The crystallite removal of the present disclosure requires significantly less downtime and results in significant improvements in the quality of the glass ribbon that can be produced from a glass production system.

[0067] The systems, tools, processes and stages of crystallization removal described herein or parts thereof may be embodied at least in part in the form of computer-implemented processes and instruments for practicing those processes. The disclosed systems, tools, processes and stages of crystallization removal may also be embodied at least in part in the form of tangible, non-transitory machine-readable storage media encoded with computer program code. The medium may include, for example, RAM, ROM, CD-ROM, DVD-ROM, BD-ROM, hard disk drive, flash memory, or any other non-transitory machine-readable storage medium, or any combination of these media, wherein when the computer program code is loaded into a computer and executed by the computer, the computer becomes an instrument for practicing the method. The systems, tools, processes and stages of crystallization removal may also be embodied at least in part in the form of a computer loaded with and executing a computer program code, so that the computer becomes an instrument for practicing the systems, tools, processes and stages of crystallization removal. When implemented on a general-purpose processor, the computer program code segment configures the processor to create a specific logic loop. The systems, tools, processes and stages of crystallization removal may alternatively be embodied at least in part in a digital signal processor formed by a dedicated integrated circuit for executing the method.

[0068] Although the subject matter has been described in terms of exemplary embodiments, it is not limited thereto. Rather, the appended claims should be interpreted broadly to encompass other variants and embodiments that may be made by one skilled in the art.

Claims

1. A system for removing crystallization, the system comprising: An edge director of a glass forming apparatus, wherein the edge director has crystallites adhered to it at a plurality of locations; Burner; a first devitrification removal tool having a first shaft with an axis and a tip oriented at a first angle to the shaft; as well as a second crystallization removal tool having a second shaft with an axis and a tip oriented at a second angle to the shaft, wherein the second angle is different from the first angle, wherein the burner and the first crystallite removal tool are operable to remove crystallites from a first location among the plurality of locations, and wherein the burner and the second crystallite removal tool are operable to remove crystallites from a second location among the plurality of locations.

2. The system of claim 1, wherein the first angle is in the range of 90 degrees to 75 degrees, and the second angle is in the range of 75 degrees to 45 degrees.

3. The system of claim 1, wherein the first angle is in a range of 75 degrees to 45 degrees, and the second angle is in a range of 45 degrees to 10 degrees.

4. The system of claim 1, wherein the burner and the first devitrification removal tool operate in tandem.

5. The system of claim 1, further comprising a second burner, wherein simultaneously, the burner and the first crystallite removal tool are operable to remove crystallites from the first of the plurality of locations, and wherein the second burner and the second tool are operable to remove crystallites from the second of the plurality of locations.

6. The system of claim 1, wherein the burner is operable to apply a flame to the crystallizer, the flame comprising a flame length of at least 360 mm.

7. The system of claim 1, further comprising a reflector operable to reflect an image of the edge director for identifying the plurality of locations where crystallites adhere to the edge director.

Images