Glass container precision thermal control forming equipment and preparation method

Abstract

The invention relates to the technical field of glass product forming and manufacturing, and discloses glass product precision thermal control forming equipment which comprises a forming main machine and is characterized by further comprising the following systems integrated on the forming main machine: an infrared material drop temperature control system arranged on a conveying path of glass material drops and used for controlling the temperature of the glass material drops; the non-contact radiation heating device is used for performing non-contact radiation heating and temperature homogenization on material drops; according to the embedded mold active temperature control system, a heat exchange element network is embedded in a mold, and the heat exchange element network is connected to an external program temperature control device and used for conducting independent temperature regulation and control on different areas of the mold. According to the invention, an infrared material drop precise temperature control system, an embedded mold active temperature control system and a whole-process atmosphere protection system are integrated, and a corresponding precise preparation process is matched, so that the difficulty in forming the large-size special-shaped amber glass bottle is systematically overcome, and an effective technical scheme is provided for producing a high-quality special glass packaging container.

Description

Technical Field

[0001] This invention relates to the field of glass product molding and manufacturing technology, specifically to a precision thermal control molding equipment for producing amber glass bottles and a corresponding preparation method. Background Technology

[0002] Amber-colored glass bottles are widely used in the packaging of high-end wines, cosmetics, pharmaceuticals, and chemical reagents due to their excellent light-blocking properties, beautiful appearance, and good chemical stability. As market demand shifts towards personalization and premiumization, higher requirements are being placed on glass bottle design, leading to a growing demand for large-sized, complex, and irregularly shaped amber-colored glass bottles (such as multifaceted, asymmetrical, and curved transition bottles).

[0003] However, the following technical bottlenecks are encountered when producing such products using traditional processes and equipment: 1. Uneven temperature of droplets: For large-sized droplets, due to their large volume and small specific surface area, significant temperature differences are easily generated between the inside and the surface of the droplet, and between the front and the back during the conveying and forming process. This uneven temperature will cause the glass material to flow inconsistently in the mold, resulting in defects such as uneven wall thickness, surface wrinkles, and cold spots. 2. Poor molding stability: The mold structure of complex irregular-shaped glass bottles is complex, and the flow path of glass material is long and variable, which easily causes severe friction with the mold wall, resulting in surface scratches and insufficient gloss. 3. Temperature control challenges caused by material characteristics: Amber glass, as a type of highly absorbent colored glass, has the characteristics of high absorption and low transmittance of infrared radiation. This means that in traditional heating or temperature control processes, infrared heat is strongly absorbed by the surface of the droplet and is difficult to effectively transfer to the core of the droplet, resulting in a temperature gradient structure of "hot outside and cold inside". This structure is very likely to cause defects such as uneven bottle wall thickness, surface streaks or shadows, and incomplete filling in some areas during the molding process, which seriously affects the optical quality, appearance and mechanical strength of the product.

[0004] Existing technologies typically make local adjustments by optimizing furnace temperature, adjusting mold air cooling, or extending overall annealing time. However, these methods are merely "stopgap measures" and cannot systematically and collaboratively solve the complex molding problems caused by the interplay of three factors: material properties (amber color), physical size (large size), and geometric shape (irregular shape). They lack a precise and coordinated temperature control solution for the entire process from material droplet preparation to final shaping. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a precision thermal control molding equipment and preparation method for amber glass bottles. This equipment and method systematically solve the problems of molding difficulties, surface defects, and uneven color caused by uneven material drop temperature, unbalanced heat transfer during the molding process, and oxidation discoloration in the production of large-sized irregular-shaped amber glass bottles through an integrated precision thermal management system, thereby significantly improving product yield, optical quality, and mechanical strength.

[0006] This invention proposes a precision thermal control molding device for amber-colored glass bottles, comprising a molding host (such as a rotary or row-type bottle making machine) and three collaborative control systems integrated on the molding host: The infrared droplet precision temperature control system is located between the outlet of the feeding channel and the inlet of the forming mold. It is used to perform non-contact temperature control on the falling glass droplets. It includes a short-wave near-infrared heating module, a mid- and far-infrared heat equalization module, and a closed-loop control unit based on thermal imaging. An embedded mold active temperature control system has a thermal barrier coating on the surface of the mold cavity and a network of heat exchange elements embedded in the mold body that connects to an external programmable temperature-controlled liquid circulation system, for independent and dynamic temperature management of different areas of the mold. A sealed atmosphere protection system is used to form and maintain an inert gas protective atmosphere at the droplet delivery and forming stations to prevent the glass material from oxidizing and discoloring at high temperatures.

[0007] A method for preparing amber-colored glass bottles using the above-described equipment includes the following steps: S1. Ingredient preparation and melting: Weigh the raw materials according to the amber glass formula, and melt, clarify and homogenize them in a glass melting furnace at 1500-1700℃. S2, Precision temperature control of material droplets: The homogenized molten glass is conveyed through the feeding channel and sheared into droplets of a predetermined weight; During the droplet's descent, the infrared droplet precision temperature control system is activated. First, short-wave near-infrared light is used for rapid pulse heating to raise the overall temperature of the droplet (especially its interior). Then, mid- and far-infrared light is used for scanning and homogenization to eliminate the surface temperature gradient, ultimately resulting in a droplet with a highly uniform temperature. S3, Precision blow molding: The temperature-controlled material droplets are fed into a preheated primary mold for degassing to form the bottle mouth and initial blank; The blank is then transferred into the forming mold, and the embedded mold active temperature control system is activated. Based on the geometric features of the bottle's three-dimensional model (such as wall thickness distribution), the temperature field of each area of ​​the mold is dynamically adjusted. At the same time, combined with high-pressure blowing, the precise shaping of the irregular bottle is completed. During this process, the sealed atmosphere protection system maintains a stable inert atmosphere throughout.

[0008] S4. Precision Annealing: The formed glass bottle is sent into an annealing furnace and subjected to a precision annealing curve that matches the wall thickness distribution of the bottle to completely eliminate internal stress and obtain the finished product.

[0009] The precision thermal control forming equipment and preparation method for glass containers proposed in this invention have the following beneficial effects: (i) By using a dual-band synergistic temperature control strategy of "short-wave near-infrared (penetrating heating) + mid-far-infrared (surface uniform heating)", the problem of "external heat and internal cold" caused by the strong absorption of infrared radiation by amber glass is effectively overcome, and the overall temperature gradient of large-size droplets is controlled within an extremely narrow range (such as ±3℃), laying a crucial thermodynamic foundation for subsequent uniform flow and molding. (ii) By combining the embedded heat pipe array with the programmable temperature-controlled liquid circulation system, and by independently controlling the temperature of different areas of the mold (such as strong cooling for thick-walled areas and heat preservation for thin-walled areas or seam lines), an "active" temperature field management that is highly matched with the product geometry is achieved, which significantly improves the flowability and filling uniformity of glass material in complex cavities and reduces surface defects. (iii) The inert atmosphere (such as nitrogen) protection throughout the process effectively prevents the oxidation of colorants (such as iron, sulfur, etc.) in the high-temperature glass material, ensuring that the amber glass bottle has a full, uniform color and no thermal color difference or streaks. (iv) The synergistic effect of the above three systems fundamentally solves a series of core problems in the molding of large-sized irregular amber glass bottles. Practice shows that the application of this invention can significantly improve product yield, improve wall thickness uniformity, and obtain high-quality products with high surface smoothness (e.g., 60° gloss ≥95), low internal stress, and excellent mechanical strength.

[0010] Additional aspects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the precision thermal control molding equipment provided by the present invention; Figure 2 A schematic diagram of the finished amber-colored glass bottle prepared according to the present invention; Figure 3 A schematic diagram of the bottom of the amber-colored glass bottle prepared according to the present invention; Detailed Implementation

[0012] Embodiments of the present invention are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar symbols denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0013] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0014] Example: Preparation of a 3.785L amber-colored, narrow-mouthed, wide-bellied irregularly shaped glass bottle This embodiment aims to produce a such... Figure 2 and Figure 3 The amber-colored glass bottle shown has a narrow mouth and a wide belly. The shoulder and body are decorated with patterns. The maximum diameter of the bottle body is about 1.5 times the diameter of the bottom. The outer surface is curved. The mouth is long and narrow with a single ear. The mouth is threaded. The inner wall of the bottom is thick and has a pattern along the edge.

[0015] I. Equipment Configuration Adopting such Figure 1 The precision thermoforming equipment shown is based on a rotary bottle-making machine with a speed set to four sets of dual-drip production modes. Around this main machine, three core systems are integrated, as follows: (1) An infrared droplet precision temperature control system, fixedly installed above the turntable, precisely positioned on the arc segment between the material droplet feeding station and the initial mold blowing station, including: 1. Short-wave near-infrared rapid heating module: Using a high-power short-wave infrared tube, when the initial mold carrying the droplet passes by as the turntable rotates, the module is triggered to irradiate the moving droplet with a pulse for 1-3 seconds. Utilizing the strong penetrating ability of short-wave infrared, the core temperature of the droplet is rapidly increased. 2. Mid-to-far infrared precision heat equalization module: Employs a mid-wave infrared heater. It activates immediately after short-wave heating to perform a 1-2 second scanning heat equalization process, addressing the temperature difference between the upper and lower surfaces of the material droplet due to contact with the feeder, focusing on homogenizing the surface temperature. 3. Closed-loop control unit: Integrated high-resolution thermal imager (temperature measurement range 500-1500℃) to scan the temperature field of the droplet in real time. The control system dynamically adjusts the power and action time of the two heating modules based on the feedback temperature distribution data to ensure that the overall temperature gradient of the droplet is precisely controlled within ±3℃ when it falls into the primary mold.

[0016] (2) An embedded mold active temperature control system is made of high-strength, high-thermal-conductivity beryllium copper alloy. A porous zirconia thermal barrier coating with a thickness of 100-150µm is sprayed onto the mold cavity surface to reduce instantaneous heat exchange between the mold and the high-temperature glass material, and to reduce friction. This includes... 1. Embedded temperature control network: A micro heat pipe array is embedded in the key area inside the mold. The evaporation end of the heat pipe is buried near the mold cavity wall, while the condensation end is connected to the rotary joint located at the central spindle of the turntable through a ring-shaped pipe network distributed inside the turntable. 2. External programmable temperature-controlled fluid circulation system: Heat transfer oil is introduced into the rotary joint through a static pipeline. This system consists of at least two independent temperature control loops, and the temperature control accuracy of the entire system is ±2℃. Cooling circuit: The heat transfer oil temperature is set to 500-600℃ and connected to the mold heat pipe array (e.g., 2-4 sets) corresponding to the thick-walled areas such as the bottom of the bottle to actively enhance cooling of the area, promote rapid glass solidification, and prevent shrinkage and depression; Insulation circuit: The heat transfer oil temperature is set to 700-800℃ and connected to the mold heat pipe array (e.g., 2-4 sets embedded) corresponding to thin-walled or easily heat-dissipating areas such as the bottle body seam line. This provides active insulation for the area, ensuring that the glass material flows and fills fully, and preventing the seam line from being obvious or not fully filled.

[0017] (3) Sealed atmosphere protection system: An arched transparent sealing cover is used to completely seal the entire forming station on the turntable (from the receiving of the material droplets to the removal of the bottle). Nitrogen gas with a purity of >99.99% is continuously and uniformly introduced from multiple points on the top or side wall of the cover, with the flow rate controlled at 20-25m³. 3 / h, keeping the oxygen concentration inside the sealed enclosure below 100ppm, providing inert atmosphere protection for high-temperature glass materials throughout the process.

[0018] II. Preparation Method and Steps S1. Melting, clarifying and homogenizing: The raw materials are precisely weighed according to the amber glass (brown soda-lime glass) formula and put into the glass melting furnace. They are melted at a high temperature of 1540℃ and then fully clarified and homogenized at 1450℃ to obtain a glass melt with uniform composition and no bubbles. S2. Droplet preparation and precise temperature control: After being further homogenized through the feeding channel, the molten glass is sheared into droplets weighing approximately 1500g each at a feeding temperature of 1180℃. The droplets fall and move with the initial mold through the infrared droplet precision temperature control system station. The system is started according to the aforementioned parameters, first heating the droplets with short-wave pulses, then heating them with mid- and far-infrared homogenization, and finally outputting droplets with highly uniform temperature. S3, Precision blow molding: After temperature adjustment, the material droplets fall into the preheated initial mold and undergo a gas-expelling operation to form the bottle mouth and preliminary blank. The initial mold is flipped to transfer the blank into the forming mold. The embedded mold active temperature control system starts working according to the preset program of the three-dimensional digital model of the irregular bottle. At the same time, it cools the thick-walled area and keeps the thin-walled area warm. Then, vacuum assistance is started and a high pressure of 22.8 Bar is applied for blowing. With the assistance of a dynamically optimized temperature field, the glass material precisely fills the complex cavity and completes the bottle shape. The entire S3 step is carried out in an inert environment created by the sealed atmosphere protection system. S4, Precision Annealing: After initial cooling, the glass bottles are sent to an annealing furnace and subjected to a customized precision annealing curve: the temperature gradient of the holding zone is set to 560℃→505℃→425℃→325℃, and then naturally cooled. The annealing furnace is 10 meters long and the total holding time is about 120 minutes. This curve matches the complex wall thickness distribution of the bottle body to ensure that the internal stress is completely and uniformly eliminated.

[0019] The 3.785L amber-colored irregularly shaped glass bottle prepared using the equipment and method of this invention exhibits the following excellent properties: 1. Wall thickness uniformity: Significantly superior to products made using traditional processes, with no areas that are too thick or too thin; 2. Surface quality: Smooth and flawless, free from defects such as wrinkles, cold spots, and scratches; gloss measurement value at 60° reaches 95 or above. 3. Color: The amber color is full, uniform, and consistent, without any color difference or heat-induced streaks caused by uneven temperature or oxidation. 4. Internal quality: Tested by a stress meter, the internal stress level is extremely low, and the product has high mechanical strength.

[0020] In summary, this invention systematically overcomes the molding challenges of large-sized, irregularly shaped amber glass bottles by integrating three major systems: infrared droplet precision temperature control, embedded mold active temperature control, and full-process atmosphere protection, and matching them with corresponding precision manufacturing processes. This provides an effective technical solution for the production of high-quality special glass packaging containers.

[0021] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A precision thermal control forming device for glass containers, comprising a forming main unit, characterized in that, It also includes the following systems integrated into the molding host: An infrared droplet temperature control system is configured on the glass droplet conveying path to perform non-contact radiant heating and temperature homogenization of the droplets. An embedded mold active temperature control system has a heat exchange element network embedded in the mold. The heat exchange element network is connected to an external programmable temperature control device for independent temperature control of different areas of the mold. A sealed atmosphere protection system is used to form and maintain a protective atmosphere at at least part of the molding station.

2. The precision thermal control forming equipment for glass containers according to claim 1, characterized in that, The infrared droplet temperature control system includes at least one first-band heating unit and at least one second-band heating unit. The first-band heating unit is used to heat the droplet as a whole, and the second-band heating unit is used to homogenize the temperature of the droplet surface.

3. The precision thermal control forming equipment for glass containers according to claim 1, characterized in that, The mold cavity surface of the active temperature control system is provided with a thermal barrier coating.

4. The precision thermal control forming equipment for glass containers according to claim 1, characterized in that, The heat exchange element is a micro heat pipe, a micro channel, or a combination thereof.

5. The precision thermal control forming equipment for glass containers according to claim 1, characterized in that, The external programmable temperature control device of the embedded mold active temperature control system includes at least two independent temperature control loops, which are used to apply different temperature control strategies to different functional areas of the mold.

6. The precision thermal control forming equipment for glass containers according to claim 1, characterized in that, The sealed atmosphere protection system includes a sealing cover and an inert gas supply device, the sealing cover covering at least the droplet receiving and blow molding station.

7. The precision thermal control forming equipment for glass containers according to claim 1, characterized in that, The forming machine is a rotary bottle making machine or a row-and-column bottle making machine.

8. A method for preparing a glass container, using the precision thermal control forming equipment for glass containers as described in any one of claims 1-7, characterized in that, Includes the following steps: S1: Melt, clarify and homogenize the glass batch to obtain molten glass; S2: The molten glass is formed into droplets, and the temperature of the droplets is regulated by the infrared droplet temperature control system during the droplet transport process; S3: The regulated material droplet is fed into the mold. Under the protective atmosphere provided by the sealed atmosphere protection system, the mold temperature field is regulated by the embedded mold active temperature control system, and the material droplet is formed into a product through the blowing process. S4: Anneal the molded product.

9. The preparation method according to claim 8, characterized in that, In step S2, the temperature control includes: firstly, using first-band radiation to heat the droplet as a whole, and then using second-band radiation to homogenize the temperature of the droplet surface.

10. The preparation method according to claim 8, characterized in that, In step S3, the control of the mold temperature field includes: actively cooling the part of the mold corresponding to the thick-walled area of ​​the product according to the three-dimensional geometric model of the product, and actively heat-preserving the part corresponding to the thin-walled area or structural feature line of the product.

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