Method and apparatus for manufacturing a glass ribbon

Abstract

The glass manufacturing apparatus includes a forming device, and the forming device includes a trough that extends along a trough axis between an inlet end and an opposite end of the forming device. The forming device includes a pair of dams. The forming device includes a diverter positioned within the trough for diverting molten material over at least one of the pair of dams. The diverter includes a first edge that contacts the bottom surface of the trough. The first edge includes an upstream diverter edge segment and a downstream diverter edge segment that is non-linear with the upstream diverter edge segment. The downstream diverter edge segment is positioned downstream from the upstream diverter edge segment. A method of manufacturing glass is provided.

Description

Technical Field

[0001] 〔Cross - Reference to Related Applications〕 This application claims the benefit of priority under "35 U.S.C.§119" of U.S. Provisional Patent Application No. 63 / 367,931, filed on July 8, 2022, which is incorporated herein by reference in its entirety and is relied upon for its content.

[0002] The disclosure of the present invention generally relates to a method for manufacturing a glass ribbon, and more specifically, to a method for manufacturing a glass ribbon using a forming device including a diverter.

Background Art

[0003] It is known to manufacture a glass ribbon using a forming device. Conventional forming devices are known to operate to draw a certain amount of molten material downward as a glass ribbon from the forming device. However, the flow rate of the molten material exiting the forming device can be difficult to control. The shape of the forming device can be contoured to achieve a desired flow rate. However, changing the shape of the forming device is inefficient and costly.

Summary of the Invention

Means for Solving the Problems

[0004] The following presents a simplified summary of the disclosure of the present invention to provide a basic understanding of some aspects described in the "Modes for Carrying Out the Invention".

[0005] Enumerate a method for manufacturing glass using a forming device. The forming device includes a trough into which a molten material is received. The trough is bounded by a pair of weirs and a bottom surface. The forming device can include a diverter positioned on the bottom surface. The forming device can include a diverter that can affect the flow rate of the molten material exiting the trough. Accordingly, based on the shape of the diverter, the flow rate of the molten material exiting the trough can be increased or decreased.

[0006] In an aspect, the glass manufacturing apparatus can include a forming device. The forming device includes a trough extending along a trough axis between an inlet end of the forming device and an opposite end opposite the inlet end. The forming device can include a pair of weirs. The forming device can include a diverter positioned within the trough to divert the molten material over at least one of the pair of weirs. The diverter can include a first edge that contacts the bottom surface of the trough. The first edge can include an upstream diverter edge segment and a downstream diverter edge segment that is non-linear with the upstream diverter edge segment. The downstream diverter edge segment is positioned downstream from the upstream diverter edge segment with respect to the flow direction of the molten material in the trough.

[0007] In an aspect, the bottom surface can be substantially planar and extend at least partially between the inlet end and the opposite end.

[0008] In an aspect, the diverter can further include a second edge that contacts the bottom surface. The second edge can include a second upstream diverter edge segment and a second downstream diverter edge segment that is non-linear with the second upstream diverter edge segment. The second downstream diverter edge segment is positioned downstream from the second upstream diverter edge segment.

[0009] In an aspect, the diverter can extend along a diverter axis between a first diverter end and a second diverter end. The first edge and the second edge can intersect at the first diverter end and branch toward the second diverter end.

[0010] In an aspect, the distance separating the first edge from the second edge can increase in a non-uniform ratio along the diverter axis from the first diverter end toward the second diverter end.

[0011] In an aspect, a second distance separating an upstream diverter edge segment from a second upstream diverter edge segment can increase at a first ratio along the diverter axis toward the second diverter end, and a third distance separating a downstream diverter edge segment from a second downstream diverter edge segment can increase at a second ratio along the diverter axis toward the second diverter end.

[0012] In an aspect, the first ratio can be higher than the second ratio.

[0013] In an aspect, the first ratio can be lower than the second ratio.

[0014] In an aspect, the height of the diverter from the bottom surface at the center of the diverter can increase in a non-uniform ratio along the diverter axis from the first diverter end toward the second diverter end.

[0015] In an aspect, the diverter can be homogeneous with the forming device.

[0016] In an aspect, the forming device can be formed of a ceramic material, and the diverter can include platinum.

[0017] In an aspect, the glass manufacturing apparatus can include a forming device, and the forming device can include a trough extending along a trough axis between an inlet end of the forming device and an opposite end opposite the inlet end. The forming device can include a bottom surface at least partially defining the trough and a pair of weirs extending from the bottom surface. The forming device can include a diverter positioned within the trough and configured to divert molten material over at least one of the pair of weirs. The diverter can extend along a diverter axis between a first diverter end and a second diverter end. The height of the diverter from the bottom surface at the center of the diverter can increase in a non-uniform ratio along the diverter axis from the first diverter end toward the second diverter end.

[0018] In an aspect, the diverter can further include a first surface positioned in a first plane and in contact with the bottom surface. The diverter can include a second surface positioned in a second plane and in contact with the bottom surface. The second surface can be attached to the first surface. The diverter can include a third surface positioned in a third plane that is non-planar with the first plane and in contact with the bottom surface. The third surface can be attached to the first surface. The diverter can include a fourth surface positioned in a fourth plane that is non-planar with the second plane and in contact with the bottom surface. The fourth surface can be attached to the second surface and the third surface.

[0019] In an aspect, the first surface and the third surface can be located on a first side of the diverter, and the second surface and the fourth surface can be located on a second side of the diverter opposite the first side.

[0020] In an aspect, the first surface can form a first angle with respect to the bottom surface, and the third surface can form a third angle with respect to the bottom surface. The first angle can be different from the third angle.

[0021] In an aspect, the second face can form a second angle with respect to the bottom face, and the fourth face can form a fourth angle with respect to the bottom face. The second angle can be different from the fourth angle.

[0022] In an aspect, a method of manufacturing glass can include directing a molten material along a flow direction within a trough of a forming device. The trough can include a bottom face and a pair of dams extending from the bottom face. The method can include flowing the molten material over the pair of dams. The method can include diverting the molten material at a first flow rate over the pair of dams at a first location of the trough when the molten material flows over a first portion of a diverter attached to the bottom face. The method can include diverting the molten material at a second flow rate different from the first flow rate over the pair of dams at a second location of the trough when the molten material flows over a second portion of the diverter. The second location can be positioned downstream from the first location with respect to the flow direction.

[0023] In an aspect, the method can include diverting the molten material at an upstream flow rate over the pair of dams at a location of the trough upstream from the first location with respect to the flow direction.

[0024] In an aspect, the first flow rate can be lower than the upstream flow rate, and the second flow rate can be higher than the upstream flow rate.

[0025] In an aspect, the first flow rate can be higher than the upstream flow rate, and the second flow rate can be lower than the upstream flow rate.

[0026] Additional features and advantages of aspects disclosed in this specification are set forth in the following detailed description, and some of these features and advantages will be apparent to those of ordinary skill in the art from that description, or will be recognized by practicing the aspects described in this specification, which includes the detailed description, the claims, and the accompanying drawings. It is to be understood that both the foregoing general description and the following detailed description are provided to present an overview or framework for understanding the nature and character of the aspects disclosed in this specification. The accompanying drawings are included to provide a further understanding and are incorporated into and constitute a part of this specification. These drawings illustrate various aspects of the disclosure of the present invention and, together with the description, explain the principles and operation thereof.

[0027] These and other features, aspects, and advantages will be better understood when the following detailed description is read in conjunction with the accompanying drawings.

Brief Description of the Drawings

[0028]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

DETAILED DESCRIPTION OF THE INVENTION

[0029] Hereinafter, aspects will be more fully described with reference to the accompanying drawings showing exemplary aspects. Whenever possible throughout the drawings, the same reference numbers are used to indicate the same or similar parts. However, the disclosure of the present invention can be embodied in many different forms and should not be construed as limited to these aspects shown in this specification.

[0030] As used herein, the term "about" means that a quantity, size, composition, parameter, and other quantities and characteristics are not exact or need not be exact, and may be approximate as necessary to reflect tolerances, conversion factors, rounding, measurement errors, etc., as well as other factors known to those skilled in the art and / or may be larger or smaller.

[0031] In this specification, ranges may sometimes be expressed as from "about" one value and / or to "about" another value. When expressing such a range, an aspect includes from one value to the other value. Similarly, when a value is expressed as an approximate value using the prefix modifier "about", it will be understood that the value forms another aspect. It will be further understood that each endpoint of a range is significant both when related to the other endpoint and when unrelated to the other endpoint.

[0032] Directional terms used in this specification, such as "upper", "lower", "right", "left", "front", "rear", "top", "bottom", "upper side", "lower side", etc., represent the orientation as depicted in the relevant figure and are not intended to imply an absolute orientation.

[0033] Unless otherwise specified, none of the methods described in this specification are to be construed as requiring that the steps be performed in a particular order, nor are they ever intended to require a particular orientation for any device. Accordingly, when a method claim does not actually enumerate the order in which the steps are to be followed, or when any apparatus claim does not actually enumerate the order or orientation for the individual components, or when the steps in the claims or in this specification are not otherwise specifically described as being limited to a particular order, or when the specific order or orientation for the components of the apparatus is not enumerated, it is never intended that the order or orientation be inferred in any respect. This applies to any implicit underlying matters considered in giving an interpretation that includes the logical part regarding the arrangement of steps, the operational flow, the order of components, or the orientation of components, the plain meaning derived from the grammatical construction or punctuation, and the number or type of aspects described in this specification.

[0034] As used in this specification, unless the context clearly dictates otherwise, the singular forms "a", "an", and "the" include plural referents. Thus, for example, when referring to "a" component, it includes embodiments having one or more such components unless the context clearly indicates otherwise.

[0035] In this specification, the words "exemplary", "example", and their various forms are used to mean acting as an example, instance, or embodiment. Any aspect or design described as "exemplary" or "example" in this specification should not be construed as being more preferable or advantageous than other aspects or designs. Furthermore, examples are provided only for the purpose of clarification and understanding, and are not intended to limit or restrict the subject matter of the disclosure of the present invention or its related parts in any way. Although it is considered that many alternative or additional examples of various ranges can be provided, it can be recognized that they can be omitted for the purpose of simplification.

[0036] As used in this specification, the terms "comprising" and "including", and their variants, should be construed as synonymous and non-limiting unless otherwise indicated. The recitation of elements preceding a transitional phrase such as "comprising" or "including" is a non-limiting recitation, and thus there may be elements other than those specifically recited within the recitation.

[0037] As used in this specification, the terms "substantially", "substantially", and their variants are intended to indicate that the characteristics being described are equal to or approximately equal to the value or description. For example, a surface that is "substantially planar" is intended to represent a planar or approximately planar surface. Furthermore, "substantially" is intended to indicate that two values are equal to or approximately equal. The term "substantially" may represent values within about 10% of each other, for example, within about 5% of each other or within about 2% of each other.

[0038] Modifications can be made to the disclosure of the present invention without departing from the scope or spirit of the claimed subject matter. Unless otherwise specified, terms such as "first" or "second" are not intended to imply a temporal, spatial, or ordering aspect, etc. Instead of such an intention, such terms are merely used as identifiers, names for features, elements, items, etc. For example, a first end and a second end generally correspond to end A and end B or two different ends.

[0039] The disclosure of the present invention relates to a glass manufacturing apparatus and method for producing a glass ribbon. Here, a method and apparatus for producing a glass ribbon from a glass material will be described below using exemplary embodiments. As shown in FIG. 1, in an embodiment, an exemplary glass manufacturing apparatus 100 can include a glass melting and delivery device 102 and a forming device 101 designed to produce a glass ribbon 103 from a certain amount of molten material 121. The glass ribbon 103 can include a central portion 152 positioned between opposing edge portions (e.g., edge beads) formed along its first outer edge 153 and second outer edge 155, and the thickness of the edge portions can be made greater than the thickness of the central portion. Further, in an embodiment, a separated glass ribbon 104 can be separated from the glass ribbon 103 along a separation path 151 by a glass separator 149 (e.g., a scribe needle, scoring wheel, diamond chip, laser, etc.).

[0040] In an embodiment, the glass melting and delivery device 102 can include a melting vessel 105 oriented to receive a batch material 107 from a storage bin 109. The batch material 107 can be introduced by a batch delivery device 111 powered by a motor 113. In an embodiment, an optional controller 115 can be actuated to start the motor 113 so as to introduce a desired amount of the batch material 107 into the melting vessel 105 as indicated by arrow 117. The melting vessel 105 can heat the batch material 107 to supply a molten material 121. In an embodiment, a melt amount probe 119 can be used to measure the liquid level of the molten material 121 in the standpipe 123, and the melt amount probe 119 can communicate measurement information to the controller 115 through a communication line 125.

[0041] In addition, in an aspect, the glass melting and delivery device 102 can include a first conditioning station that includes a fining vessel 127 positioned downstream from the melting vessel 105 and coupled to the melting vessel 105 through a first connecting conduit 129. In an aspect, the molten material 121 can be gravity-fed from the melting vessel 105 through the first connecting conduit 129 to the fining vessel 127. For example, in an aspect, gravity can drive the molten material 121 from the melting vessel 105 through the internal passage of the first connecting conduit 129 to the fining vessel 127. Further, in an aspect, bubbles can be removed from the molten material 121 by various techniques within the fining vessel 127.

[0042] In an aspect, the glass melting and delivery device 102 can further include a second conditioning station that includes a mixing chamber 131 positioned downstream from the fining vessel 127. The mixing chamber 131 can be used to provide a uniform composition of the molten material 121, thereby reducing or eliminating non-uniformities that may otherwise be present in the molten material 121 exiting the fining vessel 127. As shown, the fining vessel 127 can be coupled to the mixing chamber 131 through a second connecting conduit 135. In an aspect, the molten material 121 can be gravity-fed from the fining vessel 127 through the second connecting conduit 135 to the mixing chamber 131. For example, in an aspect, gravity can drive the molten material 121 from the fining vessel 127 through the internal passage of the second connecting conduit 135 to the mixing chamber 131.

[0043] In addition, in an aspect, the glass melting and delivery device 102 can include a third adjustment station including a delivery chamber 133 that can be positioned downstream from the mixing chamber 131. In an aspect, the delivery chamber 133 can be adjusted to supply the molten material 121 into the inlet conduit 141. For example, the delivery chamber 133 can act as a reservoir and / or flow controller for adjusting the molten material 121 and supplying its stable flow rate to the inlet conduit 141. As shown, the mixing chamber 131 can be coupled to the delivery chamber 133 through a third connecting conduit 137. In an aspect, the molten material 121 can be gravity-fed from the mixing chamber 131 through the third connecting conduit 137 to the delivery chamber 133. For example, in an aspect, gravity can drive the molten material 121 from the mixing chamber 131 through the internal passage of the third connecting conduit 137 to the delivery chamber 133. Further, as shown, in an aspect, a delivery pipe 139 can be arranged for delivering the molten material 121 to the forming device 101, for example, to the inlet conduit 141 of the forming device 101. The forming device 101 can include a trough (e.g., trough 201 shown in FIG. 2) extending along a trough axis 140 between an inlet end 142 of the forming device 101 and an opposite end 143 on the opposite side thereof. The inlet end 142 is the end of the trough 201 close to the inlet conduit 141 that receives the molten material 121. The opposite end 143 is the end farthest from the inlet conduit 141.

[0044] As an embodiment, the forming device 101 shown and disclosed below can be provided to melt-draw the molten material 121 from the bottom edge defined as the root 145 of the forming wedge 209 to produce the glass ribbon 103. For example, in an aspect, the molten material 121 can be fed from the inlet conduit 141 into the forming device 101. Next, the molten material 121 can be formed into the glass ribbon 103 based in part on the structure of the forming device 101. For example, as shown in the figure, the molten material 121 can be drawn along a draw path extending in the advancing direction 154 of the glass manufacturing apparatus 100 from the bottom edge (e.g., the root 145) of the forming device 101. In an aspect, the edge directors 163, 164 can guide the molten material 121 out of the forming device 101 and can partially define the width 108 of the glass ribbon 103. In an aspect, the width 108 of the glass ribbon 103 extends between the first outer edge 153 of the glass ribbon 103 and the second outer edge 155 of the glass ribbon 103.

[0045] In an aspect, the width 108 of the glass ribbon 103 extending between the first outer edge 153 of the glass ribbon 103 and the second outer edge 155 of the glass ribbon 103 is greater than or equal to about 20 millimeters (mm), for example, greater than or equal to about 50 mm, for example, greater than or equal to about 100 mm, for example, greater than or equal to about 500 mm, for example, greater than or equal to about 1000 mm, for example, greater than or equal to about 2000 mm, for example, greater than or equal to about 3000 mm, for example, greater than or equal to about 4000 mm. However, in an aspect, other widths smaller or larger than the above-mentioned widths can be provided. For example, in an aspect, the width 108 is in the range of about 20 mm to about 4000 mm, for example, in the range of about 50 mm to about 4000 mm, for example, in the range of about 100 mm to about 4000 mm, for example, in the range of about 500 mm to about 4000 mm, for example, in the range of about 1000 mm to about 4000 mm, for example, in the range of about 2000 mm to about 4000 mm, for example, in the range of about 3000 mm to about 4000 mm, for example, in the range of about 20 mm to about 3000 mm, for example, in the range of about 50 mm to about 3000 mm, for example, in the range of about 100 mm to about 3000 mm, for example, in the range of about 500 mm to about 3000 mm, for example, in the range of about 1000 mm to about 3000 mm, for example, in the range of about 2000 mm to about 3000 mm, for example, in the range of about 2000 mm to about 2500 mm, and it is possible to be in all ranges and partial ranges between these values.

[0046] FIG. 2 illustrates a cross-sectional perspective view of the forming device 101 along line 2-2 of FIG. 1. In an aspect, the forming device 101 can include a trough 201 oriented to receive the molten material 121 from the inlet conduit 141. For illustrative purposes, the cross-hatching of the molten material 121 has been removed from FIG. 2 for clarity. The forming device 101 includes a pair of dams 203, 204 that define an opening 224 within the trough 201. The forming device 101 can be substantially planar and include a bottom surface 225 that extends at least partially between an inlet end 142 and an opposite end 143 (e.g., as shown in FIG. 1). The bottom surface 225 can at least partially define the trough 201. For example, the bottom surface 225 extends along the bottom of the trough 201, and the pair of dams 203, 204 extend along opposite sides of the trough 201. In an aspect, the bottom surface 225 can be substantially planar and can form a right angle with the pair of dams 203, 204. In an aspect, the bottom surface 225 can be substantially planar. The bottom surface 225 can include opposing edges that extend along the trough axis 140 and contact the pair of dams 203, 204. In an aspect, the opposing edges can form a rounded shape with the pair of dams 203, 204 such that the intersection (e.g., at the opposing edges) between the bottom surface 225 and the pair of dams 203, 204 has a radius of curvature. The forming device 101 can further include a forming wedge 209 that includes a pair of downwardly inclined confluent surface portions 207, 208 that extend between opposing ends of the forming wedge 209. The pair of downwardly inclined confluent surface portions 207, 208 of the forming wedge 209 can converge along the travel direction 154 such that they intersect along the root 145 of the forming device 101 (e.g., the bottom edge of the forming wedge 209 where the downwardly inclined confluent surface portions 207 and 208 meet). The draw plane 213 of the glass manufacturing apparatus 100 can extend along the travel direction 154 through the root 145. In an aspect, the glass ribbon 103 can be drawn along the travel direction 154 along the draw plane 213. As shown, the draw plane 213 can bisect the forming wedge 209 through the root 145, but in an aspect, it can extend in other orientations with respect to the root 145.In an aspect, the glass ribbon 103 can move along a travel path 221 that can be coplanar with the draw plane 213 in the travel direction 154.

[0047] In addition to this, the molten material 121 can flow into the trough 201 of the forming device 101 in the flow direction 156 and can flow along the trough 201. Next, the molten material 121 can overflow from the trough 201 by flowing downward over the corresponding dams 203, 204 through the opening 224 and over the outer surfaces 205, 206 of the corresponding dams 203, 204. Next, each flow of the molten material 121 can flow along the downwardly inclined confluent surface portions 207, 208 of the forming wedge 209, and these flows can merge and be drawn from the root 145 of the forming device 101 where they fuse into the glass ribbon 103. Next, the glass ribbon 103 can be drawn along the travel direction 154. In an aspect, the glass ribbon 103 includes material in one or more states based on its vertical location, i.e., the distance from the root 145. For example, the glass ribbon 103 can include viscous molten material 121 at a first location and can include an amorphous solid in a glassy state (e.g., a glass ribbon) at a second location.

[0048] The glass ribbon 103 includes a first major surface 215 and a second major surface 216 that face each other and define the thickness 212 (e.g., average thickness) of the glass ribbon 103. In an aspect, the thickness 212 of the glass ribbon 103 can be less than or equal to about 2 millimeters (mm), less than or equal to about 1 millimeter, less than or equal to about 0.5 millimeter, e.g., less than or equal to about 300 micrometers (μm), less than or equal to about 200 micrometers, or less than or equal to about 100 micrometers, although other thicknesses can be provided in additional aspects. For example, in an aspect, the thickness 212 of the glass ribbon 103 can be in the range of about 20 micrometers to about 200 micrometers, about 50 micrometers to about 750 micrometers, about 100 micrometers to about 700 micrometers, about 200 micrometers to about 600 micrometers, about 300 micrometers to about 500 micrometers, about 50 micrometers to about 500 micrometers, about 50 micrometers to about 700 micrometers, about 50 micrometers to about 600 micrometers, about 50 micrometers to about 500 micrometers, about 50 micrometers to about 400 micrometers, about 50 micrometers to about 300 micrometers, about 50 micrometers to about 200 micrometers, about 50 micrometers to about 100 micrometers, about 25 micrometers to about 125 micrometers, and can be in a range that includes all ranges and sub-ranges of thicknesses between these values. Further, the glass ribbon 103 can include one or more of various compositions, such as soda-lime glass, borosilicate glass, aluminoborosilicate glass, alkali-containing glass, alkali-free glass, aluminosilicate, borosilicate, borosilicate, silicate, glass ceramic, or other glass-containing materials.In an aspect, the glass ribbon 103 can include one or more of lithium fluoride (LiF), magnesium fluoride (MgF2), calcium fluoride (CaF2), barium fluoride (BaF2), sapphire (Al2O3), zinc selenide (ZnSe), germanium (Ge), or other materials.

[0049] In an aspect, the glass separator 149 (see FIG. 1) can separate the glass ribbon 104 from the glass ribbon 103 along the separation path 151 to provide a plurality of separated glass ribbons 104 (i.e., a plurality of glass sheets). In an aspect, the longitudinal portion of the glass ribbon 104 can be wound around a storage roll. Next, the separated glass ribbon can be processed for a desired application, such as a display application. For example, the separated glass ribbon can be used in a wide variety of display applications and non-display applications including, but not limited to, liquid crystal displays (LCDs), electrophoretic displays (EPDs), organic light emitting diode displays (OLEDs), plasma display panels (PDPs), micro LED displays, mini LED displays, organic light emitting diode lighting, light emitting diode lighting, augmented reality (AR), virtual reality (VR), touch sensors, photovoltaic cells, foldable phones, or other applications.

[0050] Figure 3 shows a side view of the forming device 101 in the area of interest 3 of FIG. 1, where the forming device 101 includes a diverter 301 positioned within the trough 201. The diverter 301 can change the flow path of the molten material 121 over at least one of the pair of weirs 203, 204. In an aspect, the diverter 301 can be positioned adjacent to the opposite end 143 of the forming device 101 on the side opposite the inlet end 142. In an aspect, the diverter 301 can be positioned in contact therewith on the bottom surface 225. For example, the diverter 301 can be a separately formed structure that can be attached to the bottom surface 225 (e.g., by gravity, fasteners, welding, press-fitting, etc.). In this way, the bottom surface 225 can be substantially coplanar with the diverter 301 resting thereon. In an aspect, when attaching the diverter 301 to the forming device 101, the diverter 301 and the forming device 101 can include the same material or different materials. For example, when including different materials, the forming device 101 can be formed of a ceramic material and the diverter 301 can include platinum. The diverter 301 is not limited to being separately attached to the bottom surface 225. Instead, the diverter 301 and the forming device 101 can be, for example, a composite or one-piece formation where the diverter 301 is machined into the bottom surface 225 (e.g., by milling, grinding, etc.). In this way, the diverter 301 can be a uniform (one-piece) one where it and the forming device 101 include the same material.

[0051] In an aspect, the forming device 101 can be tilted such that the bottom surface 225 and / or the pair of dams 203, 204 can form an angle with respect to a horizontal plane perpendicular to the direction of gravity. For example, the bottom surface 225 can form a first angle 303 in the range of about +5 degrees to about -5 degrees or in the range of about 0 degrees to about -3 degrees with respect to the horizontal. In an aspect, the pair of dams 203, 204 (e.g., the upper surface) can form a second angle 305 in the range of about -3 degrees to about -8 degrees or in the range of about -6 degrees to about -7 degrees with respect to the horizontal. By tilting the forming device 101 such that the bottom surface 225 includes a negative gradient, the molten material 121 can flow under the influence of gravity from the inlet end 142 towards the opposite end 143.

[0052] In an aspect, the diverter 301 can include a body portion 307 and a deflector portion 309. The body portion 307 is in contact with and rests on the bottom surface 225. The deflector portion 309 can be positioned on the body portion 307 so as to be spaced apart at a distance from the bottom surface 225. In an aspect, the body portion 307 can be positioned partially or completely within the trough 201 and below the pair of weirs 203, 204. The deflector portion 309 can extend upwardly from the trough 201 such that its upper surface is above the pair of weirs 203, 204 and higher than the liquid level of the molten material 121. In an aspect, the body portion 307 can have a first height 312 that can be in the range of about 13 mm to about 51 mm or in the range of about 19 mm to about 32 mm or about 25 mm, which can be the maximum height. In an aspect, the deflector portion 309 can have a second height 314 that can be in the range of about 51 mm to about 102 mm or about 76 mm (e.g., between the upper portion of the body portion 307 and the upper portion of the deflector portion 309). However, the deflector portion 309 can be optional, and thus, in an aspect, the diverter 301 can include the body portion 307 without the deflector portion 309. The first height 312 of the body portion 307 can substantially correspond to the height between the bottom surface 225 and the upper portions of the pair of weirs 203, 204 at the end 143. Thus, at the end 143, the upper portion of the body portion 307 can be substantially at the same level as the upper portions of the pair of weirs 203, 204. In an aspect, the body portion 307 can include a first portion 311 and a second portion 313, and the first portion 311 is positioned upstream of the second portion 313 with respect to the flow direction 156 of the molten material 121.

[0053] Figure 4 shows a perspective view of the diverter 301. In an aspect, the diverter 301 can extend along a diverter axis 401 between a first diverter end 403 and a second diverter end 405. The diverter axis 401 can be substantially parallel to the trough axis 140 (e.g., shown in FIGS. 1 - 3) such that the first diverter end 403 is closer to the inlet end 142 than the second diverter end 405, and the second diverter end 405 is closer to the opposite end 143 than the first diverter end 403. The diverter 301 can include a first edge 409 and a second edge 411 that extend along the diverter axis 401 between the first diverter end 403 and the second diverter end 405. In an aspect, the first edge 409 can be non - parallel to the second edge 411 while the first edge 409 and the second edge 411 define the outermost boundary or perimeter of the diverter 301. The first edge 409 and the second edge 411 can contact the bottom surface 225. In an aspect, the first edge 409 can include an upstream diverter edge segment 415 and a downstream diverter edge segment 417 that are non - linear (non - linearly mismatched) with respect to each other. The upstream diverter edge segment 415 and the downstream diverter edge segment 417 are non - linear (non - linearly mismatched) such that they extend along different axes and are non - collinear and non - parallel. In an aspect, the upstream diverter edge segment 415 and the downstream diverter edge segment 417 intersect and contact at a location between the first diverter end 403 and the second diverter end 405, and the upstream diverter edge segment 415 can terminate at the first diverter end 403 and the downstream diverter edge segment 417 can terminate at the second diverter end 405. In an aspect, the downstream diverter edge segment 417 can be positioned downstream from the upstream diverter edge segment 415 with respect to the flow direction 156 of the molten material 121. In an aspect, due to the inclination and tilt of the bottom surface 225 with respect to the horizontal, the downstream diverter edge segment 417 can be positioned at a higher location than the upstream diverter edge segment 415.

[0054] In an aspect, the second edge portion 411 can include a second upstream diverter edge segment 421 and a second downstream diverter edge segment 423 that are non-linear (in a linearly inconsistent state) with respect to each other. The second upstream diverter edge segment 421 and the second downstream diverter edge segment 423 are non-linear (in a linearly inconsistent state), extend along different axes, and are non-collinear and non-parallel. In an aspect, the second upstream diverter edge segment 421 and the second downstream diverter edge segment 423 intersect and contact at a location between the first diverter end 403 and the second diverter end 405, and the second upstream diverter edge segment 421 can terminate at the first diverter end 403, and the second downstream diverter edge segment 423 can terminate at the second diverter end 405. In an aspect, the second downstream diverter edge segment 423 can be positioned downstream from the second upstream diverter edge segment 421 with respect to the flow direction 156 of the molten material 121. In an aspect, due to the inclination and tilt of the bottom surface 225 with respect to the horizontal, the second downstream diverter edge segment 423 can be positioned at a higher position than the second upstream diverter edge segment 421.

[0055] The diverter 301 can include a plurality of surfaces between the first edge 409 and the second edge 411. For example, the diverter 301 can include a first surface 431, a second surface 433, a third surface 435, and a fourth surface 437. The first surface 431 can include an upstream diverter edge segment 415 (e.g., in a state where the upstream diverter edge segment 415 forms an edge of the first surface 431), and thus, the first surface 431 can contact the bottom surface 225. In an aspect, the first surface 431 can be located in a first plane or can be non-planar. The second surface 433 can include a second upstream diverter edge segment 421 (e.g., in a state where the second upstream diverter edge segment 421 forms an edge of the second surface 433), and thus, the second surface 433 can contact the bottom surface 225. The second surface 433 can be located in a second plane or can be non-planar. In an aspect, the second surface 433 is attached to the first surface 431 in a state where the first surface 431 and the second surface 433 are attached at a first intersection confluence 441 extending along the first confluence axis 443.

[0056] The third face 435 can include the downstream diverter edge segment 417 (e.g., in a state where the downstream diverter edge segment 417 forms the edge of the third face 435), and thus, the third face 435 can contact the bottom face 225. The third face 435 can be located in the third plane or can be non-planar. The fourth face 437 can include the second downstream diverter edge segment 423 (e.g., in a state where the second downstream diverter edge segment 423 forms the edge of the fourth face 437), and thus, the fourth face 437 can contact the bottom face 225. The fourth face 437 can be located in the fourth plane or can be non-planar. In an aspect, the third face 435 is attached to the fourth face 437 in a state where the third face 435 and the fourth face 437 are attached at the second intersection junction 451 extending along the second confluence axis 453. In an aspect, the first intersection junction 441 and the second intersection junction 451 can contact and intersect at the confluence of the first face 431, the second face 433, the third face 435, and the fourth face 437. The first confluence axis 443 and the second confluence axis 453 can be non-linear (in a linearly inconsistent state) such that they are non-collinear and non-parallel. In an aspect, the first confluence axis 443 and the second confluence axis 453 can be located in the confluence plane 457 extending through the diverter 301 between the first diverter end 403 and the second diverter end 405.

[0057] In an aspect, the confluence plane 457 can bisect the diverter 301 such that the first surface 431 and the third surface 435 are located on the first side of the diverter 301 (e.g., the confluence plane 457), and the second surface 433 and the fourth surface 437 are located on the second side of the diverter 301 on the opposite side of the first side (e.g., the confluence plane 457). In an aspect, the diverter 301 is symmetric with respect to the confluence plane 457. For example, the first surface 431 and the third surface 435 on the first side of the confluence plane 457 are symmetric with the second surface 433 and the fourth surface 437 on the second side of the confluence plane 457. The third surface 435 can be attached to the first surface 431 in a state where the first surface 431 and the third surface 435 are attached at the third intersection confluence portion 461 extending along the third confluence axis 463. The fourth surface 437 can be attached to the second surface 433 in a state where the second surface 433 and the fourth surface 437 are attached at the fourth intersection confluence portion 467 extending along the fourth confluence axis 469. In an aspect, the third intersection confluence portion 461 and the fourth intersection confluence portion 467 can intersect at the intersection of the first intersection confluence portion 441 and the second intersection confluence portion 451. Thus, in an aspect, the first surface 431 and the second surface 433 can include three sides. For example, the first surface 431 is bounded by the upstream diverter edge segment 415, the first intersection confluence portion 441, and the third intersection confluence portion 461. The second surface 433 is bounded by the second upstream diverter edge segment 421, the first intersection confluence portion 441, and the fourth intersection confluence portion 467. The third surface 435 and the fourth surface 437 can include four sides. For example, the third surface 435 is bounded by the downstream diverter edge segment 417, the second intersection confluence portion 451, the third intersection confluence portion 461, and the second diverter end 405. The fourth surface 437 can be bounded by the second downstream diverter edge segment 423, the second intersection confluence portion 451, the fourth intersection confluence portion 467, and the second diverter end 405. In an aspect, the first portion 311 of the diverter 301 can include the first surface 431, the second surface 433, the upstream diverter edge segment 415, and the second upstream diverter edge segment 421.In an aspect, the second portion 313 of the diverter 301 can include a third face 435, a fourth face 437, a downstream diverter edge segment 417, and a second downstream diverter edge segment 423.

[0058] FIG. 5 shows a top view of the diverter 301 within the trough 201 along line 5-5 of FIG. 3. In an aspect, the first edge 409 and the second edge 411 can intersect at the first diverter end 403 and branch towards the second diverter end 405. For example, by intersecting at the first diverter end 403, the distance between the first edge 409 and the second edge 411 can be zero at the first diverter end 403. However, the distance 501 separating the first edge 409 and the second edge 411 can increase at a non-uniform rate along the diverter axis 401 from the first diverter end 403 towards the second diverter end 405. For example, the second distance 503 can separate the upstream diverter edge segment 415 and the second upstream diverter edge segment 421. Due to the non-parallelism of the upstream diverter edge segment 415 and the second upstream diverter edge segment 421, the second distance 503 is non-uniform and increases at a constant first rate along the diverter axis 401 from the first diverter end 403 towards the second diverter end 405. The third distance 505 can separate the downstream diverter edge segment 417 and the second downstream diverter edge segment 423. Due to the non-parallelism of the downstream diverter edge segment 417 and the second downstream diverter edge segment 423, the third distance 505 is non-uniform and increases at a constant second rate along the diverter axis 401 towards the second diverter end 405. In an aspect, the first rate can be different from the second rate. For example, the first rate can be higher than the second rate. In an aspect, the maximum width of the diverter 301 (e.g., along a direction perpendicular to the confluence plane 457) can be substantially equal to or slightly smaller than the width of the trough 201 between the weirs 203 and 204. In this way, at the second diverter end 405, the first edge 409 and the second edge 411 of the diverter 301 can be adjacent to and / or in contact with the weirs 203, 204.

[0059] FIG. 6 shows a side view of the diverter 301 in contact with the bottom surface 225 within the trough 201. In an aspect, the diverter can have a height 601 that increases from a first diverter end 403 to a second diverter end 405. For example, at the first diverter end 403, the height 601 of the diverter 301 can be zero, whereas at the second diverter end 405, the diverter 301 can have a maximum height (e.g., the first height 312). In an aspect, the height 601 of the diverter 301 from the bottom surface 225 at the center of the diverter 301 can increase at a non - constant rate along the diverter axis 401 from the first diverter end 403 towards the second diverter end 405. In an aspect, the center of the diverter 301 can include confluence intersections 441, 451 such that it comes to the mid - point between the edges 409 and 411. The diverter 301 can have a first height 603 between the bottom surface 225 and the first confluence intersection 441 and a second height 605 between the bottom surface 225 and the second confluence intersection 451. In an aspect, when the diverter 301 is machined into the forming device 101 (e.g., such that the diverter 301 and the bottom surface 225 are uniform and one - piece), the bottom surface 225 can extend along a plane (e.g., at a location upstream of the diverter 301), and these heights are measured between this plane and the diverter 301. In an aspect, the first height 603 can increase at a constant or non - constant first rate from the first diverter end 403 towards the second diverter end 405. In an aspect, the second height 605 can increase at a constant or non - constant second rate towards the second diverter end 405. In an aspect, the first rate is different from the second rate. For example, in FIG. 6, the first rate is higher than the second rate. The diverter 301 includes a length 611 along the diverter axis 401 between the first diverter end 403 and the second diverter end 405. In an aspect, the length 611 can be in the range from about 305 mm to about 760 mm or in the range from about 406 mm to about 508 mm.

[0060] Figures 7-8 show cross-sectional views of the diverter 301 at the first intersection and confluence section 441 and the second intersection and confluence section 451. For example, FIG. 7 shows a cross-sectional view of the third surface 435 and the fourth surface 437 along line 7-7 of FIG. 5. As shown in FIG. 7, the third surface 435 contacts the bottom surface 225 and extends along the third plane 701, and the fourth surface 437 contacts the bottom surface 225 and extends along the fourth plane 703. The third surface 435 is attached to the fourth surface 437 at the second intersection and confluence section 451, and the third plane 701 is non-planar with respect to the fourth plane 703. The third surface 435 can form a third angle 705 with the bottom surface 225, and the fourth surface 437 can form a fourth angle 707 with the bottom surface 225. In an aspect, the third angle 705 can be made substantially equal to the fourth angle 707 when, for example, the third surface 435 is symmetric with the fourth surface 437.

[0061] FIG. 8 shows cross-sectional views of the first surface 431 and the second surface 433 along line 8-8 of FIG. 5. The first surface 431 contacts the bottom surface 225 and is located within the first plane 801, and the second surface 433 contacts the bottom surface 225 and is located within the second plane 803. The first surface 431 is attached to the second surface 433 at the first intersection and confluence section 441, and the first plane 801 is non-planar with respect to the second plane 803. The first surface 431 can form a first angle 805 with the bottom surface 225, and the second surface 433 can form a second angle 807 with the bottom surface 225. In an aspect, the first angle 805 can be made substantially equal to the second angle 807 when, for example, the first surface 431 is symmetric with the second surface 433. In an aspect, due to the inclination between the first surface 431 and the third surface 435 (shown in FIG. 7 for example), the first angle 805 can be different from the third angle 705. Similarly, in an aspect, due to the inclination between the second surface 433 and the fourth surface 437 (shown in FIG. 7 for example), the second angle 807 can be different from the fourth angle 707.

[0062] Figs. 9 to 10 show cross-sectional views of the diverter 301 at the third intersection and confluence portion 461 and the fourth intersection and confluence portion 467. For example, Fig. 9 shows a cross-sectional view of the first surface 431 and the third surface 435 along line 9-9 of Fig. 4. Fig. 10 shows a cross-sectional view of the second surface 433 and the fourth surface 437 along line 10-10 of Fig. 4. In an aspect, the first plane 801 can be non-planar with respect to the third plane 701. For example, the first surface 431 can form an angle 901 smaller than about 180 degrees with the third surface 435, and for example, the angle 901 is in the range from about 135 degrees to about 170 degrees. In an aspect, the second plane 803 can be non-planar with respect to the fourth plane 703. For example, the second surface 433 can form an angle 1001 smaller than about 180 degrees with the fourth surface 437, and for example, the angle 1001 is in the range from about 135 degrees to about 170 degrees.

[0063] Fig. 11 shows an additional aspect of a diverter 1101 similar to the diverter 301, and common numbers between the diverter 301 and the diverter 1101 indicate common features. For example, the diverter 1101 can include the first surface 431, the second surface 433, the third surface 435, and the fourth surface 437, and can extend between the first diverter end 403 and the second diverter end 405. The diverter 1101 is positioned within the trough 201 in contact with the bottom surface 225 at substantially the same location as the diverter 301 shown in Fig. 3.

[0064] In an aspect, the diverter 1101 can include dimensions different from those of the diverter 301. For example, FIG. 12 shows a top view of the diverter 1101 within the trough 201. In an aspect, the first edge 409 and the second edge 411 can intersect at the first diverter end 403 and branch toward the second diverter end 405. For example, by intersecting at the first diverter end 403, the distance between the first edge 409 and the second edge 411 can be zero at the first diverter end 403. However, the distance 1201 separating the first edge 409 and the second edge 411 can increase at a non-uniform rate along the diverter axis 401 from the first diverter end 403 toward the second diverter end 405. For example, the second distance 1203 can separate the upstream diverter edge segment 415 and the second upstream diverter edge segment 421. Due to the non-parallelism of the upstream diverter edge segment 415 and the second upstream diverter edge segment 421, the second distance 503 is non-uniform and increases at a constant first ratio along the diverter axis 401 from the first diverter end 403 toward the second diverter end 405. The third distance 1205 can separate the downstream diverter edge segment 417 and the second downstream diverter edge segment 423. Due to the non-parallelism of the downstream diverter edge segment 417 and the second downstream diverter edge segment 423, the third distance 505 is non-uniform and increases at a constant second ratio along the diverter axis 401 toward the second diverter end 405. In an aspect, the first ratio can be different from the second ratio, for example, the first ratio can be lower than the second ratio.

[0065] FIG. 13 shows a side view of the diverter 1101 in contact with the bottom surface 225 within the trough 201. In an aspect, the diverter 1101 can have a height 1301 that increases from the first diverter end 403 to the second diverter end 405. For example, at the first diverter end 403, the height 1301 of the diverter 301 can be zero, whereas at the second diverter end 405, the diverter 1101 can have a maximum height (e.g., the first height 312 at the second diverter end 405). In an aspect, the height 1301 of the diverter 1101 from the bottom surface 225 can increase at a non-uniform rate along the diverter axis 401 from the first diverter end 403 towards the second diverter end 405. For example, the diverter 1101 can have a first height 1303 between the bottom surface 225 and the first intersection and confluence portion 441, and a second height 1305 between the bottom surface 225 and the second intersection and confluence portion 451. In an aspect, the first height 1303 can increase at a uniform or non-uniform first rate from the first diverter end 403 towards the second diverter end 405. In an aspect, the second height 1305 can increase at a uniform or non-uniform second rate towards the second diverter end 405. In an aspect, the first rate is different from the second rate. For example, in FIG. 13, the first rate is lower than the second rate.

[0066] The diverters 301, 1101 illustrated and described with reference to FIGS. 3 to 13 are not limited to the designs and shapes disclosed in this specification. For example, although the surfaces 431, 433, 435, 437 were illustrated as being substantially planar, in an aspect, one or more of the surfaces 431, 433, 435, 437 can include non-planar shapes, such as, for example, round, concave, or convex shapes. Further, although each of the intersection and confluence portions 441, 451, 461, 467 was illustrated as being substantially straight, in an aspect, one or more of the intersection and confluence portions 441, 451, 461, 467 can include non-straight shapes, such as, for example, round shapes. Further, although the diverters 301, 1101 were illustrated as including a first portion 311 and a second portion 313, in an aspect, the diverters 301, 1101 can have edges 409, 411 that branch at a ratio greater than two (as shown, for example, in FIGS. 5 and 12), and the intersection and confluence portions 441, 451 can increase in height at a ratio greater than two (as shown, for example, in FIGS. 6 and 13), and can include additional portions (for example, more than two). In an aspect, a non-straight or curved shape can include a plurality of lines having different gradients that form these shapes with respect to each other. Further, although the diverters 301, 1101 were illustrated as being substantially symmetric, in an aspect, the diverters 301, 1101 can be asymmetric with respect to the confluence plane 457.

[0067] FIG. 14 shows a plot of the mass change of the molten material 121 exiting the trough 201 (e.g., on the x-axis) against the position within the trough 201 (e.g., on the y-axis). When the mass change is zero, this corresponds to zero on the y-axis, but the flow rate is constant. When the mass change is positive, the flow rate increases. When the mass change is negative, the flow rate decreases. The mass change and position of the molten material 121 are illustrated in arbitrary units. Line 1401 represents the mass change from the diverter 301 shown in FIGS. 3-10, and line 1403 represents the mass change from the diverter 1101 shown in FIGS. 11-13. On the x-axis, the position ranges from 0 to 1. In this case, the zero position can represent the inlet end 142, the position of 1 can represent the opposite end 143, and a position between 0 and 1 can represent a position within the trough 201 between the inlet end 142 and the opposite end 143. A first location 1405 around the position 0.6 represents the molten material 121 passing over the first diverter end 403. A second location 1407 around the position 0.9 represents the molten material 121 passing over the third and fourth intersection junctions 461, 467. The second diverter end 405 is at the position of 1.

[0068] In an aspect, different mass changes of the molten material 121 exiting the trough 201 can be achieved depending on the diverters 301, 1101 positioned within the trough 201. For example, at a location 1409 upstream of the diverters 301, 1101 (e.g., between about 0 from the position 0), the mass change of the molten material 121 is approximately zero, indicating a substantially constant flow rate from the trough 201. When the molten material 121 reaches the diverters 301, 1101, the mass change can become either positive or negative. For example, referring to the line 1401 representing the diverter 301, the mass change can start and increase at a first location 1405 (e.g., the first diverter end 403). The mass change can continue to increase from the first location 1405 to a second location 1407 (e.g., from the first diverter end 403 to the third and fourth intersection junctions 461, 467). From the second location 1407 (e.g., from the third and fourth intersection junctions 461, 467 to the second diverter end 405), the mass change can decrease. The reason for the change between the first location 1405 and the second location 1407 lies in the shape of the diverter 301. For example, the second distance 503 can increase more rapidly than the third distance 505 (e.g., as shown in FIG. 5), and the first height 603 can increase more rapidly than the second height 605 (e.g., as shown in FIG. 6). In this way, the diverter 301 can provide a relatively rapid volume increase from the first diverter end 403. This volume increase can cause the molten material 121 to flow out of the trough 201 over the weirs 203, 204 at different flow rates.

[0069] Referring to line 1403 representing diverter 1101, the mass change can start and decrease at the first location 1405 (e.g., the first diverter end 403). The mass change can continue to decrease from the first location 1405 to the second location 1407 (e.g., from the first diverter end 403 to the third and fourth intersection junctions 461, 467). From the second location 1407 (e.g., from the third and fourth intersection junctions 461, 467 to the second diverter end 405), the mass change can increase. The reason for the change between the first location 1405 and the second location 1407 lies in the shape of the diverter 1101. For example, the second distance 1203 can increase more slowly than the third distance 1205 (e.g., as shown in FIG. 12), and the first height 1303 can increase more slowly than the second height 1305 (e.g., as shown in FIG. 13). In this way, the diverter 1101 can provide a relatively slow increase in volume from the first diverter end 403. This volume increase can cause the molten material 121 to flow out of the trough 201 at different flow rates over the weirs 203, 204.

[0070] Referring to FIGS. 3 and 14, the method can include diverting the molten material 121 at the upstream location 1409 of the trough 201 upstream of the first location 1405 with respect to the flow direction 156 so as to exceed the upstream flow rate by the pair of weirs 203, 204. At the upstream location 1409, the molten material 121 can flow over the pair of weirs 203, 204 and is considered not to be affected by the diverters 301, 1101 because the upstream location 1409 is upstream of the diverters 301, 1101. In an aspect, the method can include diverting the molten material 121 at the first location 1405 of the trough 201 at a first flow rate over the pair of weirs 203, 204 when the molten material 121 flows over the first portion 311 of the diverters 301, 1101 attached to the bottom surface 225. The first location 1405 can include the location where a plane perpendicular to the flow direction 156 intersects the first portion 311 and the pair of weirs 203, 204. As shown in FIG. 14, the first flow rate can be different from the upstream flow rate due to the molten material 121 flowing over the first portion 311 of the diverters 301, 1101. In an aspect, the method can include diverting the molten material 121 at the second location 1407 of the trough 201 positioned downstream from the first location 1405 with respect to the flow direction 156 at a second flow rate different from the first flow rate over the pair of weirs 203, 204 when the molten material 121 flows over the second portion 313 of the diverters 301, 1101. For example, the second location 1407 can include the location where a plane perpendicular to the flow direction 156 intersects the second portion 313 and the pair of weirs 203, 204. As shown in FIG. 14, the second flow rate can be different from the first flow rate because the molten material 121 flows over the second portion 313 of the diverters 301, 1101 and the second portion 313 includes a shape different from the first portion 311. In an aspect and as represented by the line 1403 corresponding to the change in mass from the diverter 1101, the first flow rate can be less than the upstream flow rate, and the second flow rate can be greater than the upstream flow rate. In an aspect and as represented by the line 1401 corresponding to the change in mass from the diverter 301, the first flow rate can be greater than the upstream flow rate, and the second flow rate can be less than the upstream flow rate.

[0071] The diverters 301, 1101 disclosed in this specification can provide several technical benefits. For example, the shape of the diverters 301, 1101 can result in different flow rates at locations upstream of the trough 201, and thus, the flow rate of the molten material 121 exiting the trough 201 can be controlled. In an aspect, at the end 143 of the trough 201, all of the molten material 121 has been diverted out of the trough 201 by the diverters 301, 1101, and thus, the flow rate at the end 143 of the trough 201 is zero. Further, since the diverters 301, 1101 can be positioned on the bottom surface 225 of any forming device to achieve a desired flow rate, the existing forming device may not need to be replaced or dimensionally adjusted. In an aspect, the dimensions of the existing forming device (such as the angles 303, 305, the dimensions of the trough 201, etc.) may be obtained, and the diverters 301, 1101 can be configured based on these dimensions to achieve a desired flow rate. Further, when the diverters 301, 1101 are formed separately from the forming device 101 (e.g., not a composite formed as a one-piece with the bottom surface 225), the bottom surface 225 may not need to be machined to the diverter shape. Instead, the bottom surface 225 can be substantially planar, and a substantially planar shape is relatively easy to manufacture, so the manufacturing cost of the forming device 101 can be reduced.

[0072] Although various aspects have been described in detail with respect to certain illustrative and specific examples, it should be understood that the disclosure of the present invention should not be considered limited to such examples, as many modifications and combinations of the features of the disclosure of the present invention are possible without departing from the following claims.

Claims

1. A glass manufacturing apparatus, A forming device, the forming device comprising a trough extending along the trough axis between an inlet end of the forming device and the opposite end opposite to the inlet end, Includes, The forming device is, One pair of weirs, A diverter positioned within the trough to divert the molten material beyond at least one of the pair of weirs, Includes, The aforementioned divertor is A first edge that contacts the bottom surface of the trough, the first edge comprising an upstream diverter edge segment and a downstream diverter edge segment that is nonlinear with respect to the upstream diverter edge segment, wherein the downstream diverter edge segment is positioned downstream of the first edge with respect to the flow direction of the molten material in the trough. including, Glass manufacturing equipment.

2. The glass manufacturing apparatus according to claim 1, wherein the bottom surface is substantially flat and extends at least partially between the entrance end and the opposite end.

3. The glass manufacturing apparatus according to any one of claims 1 to 2, wherein the diverter further includes a second edge that contacts the bottom surface, the second edge including a second upstream diverter edge segment and a second downstream diverter edge segment that is nonlinear with respect to the second upstream diverter edge segment, the second downstream diverter edge segment being positioned downstream of the second upstream diverter edge segment.

4. The glass manufacturing apparatus according to claim 3, wherein the diverter extends along the diverter axis between a first diverter end and a second diverter end, and the first edge and the second edge intersect at the first diverter end and branch toward the second diverter end.

5. The glass manufacturing apparatus according to claim 4, wherein the distance separating the first edge from the second edge increases at a non-constant ratio along the diverter axis from the first diverter end to the second diverter end.

6. The glass manufacturing apparatus according to claim 5, wherein the second distance separating the upstream diverter edge segment and the second upstream diverter edge segment increases by a first ratio toward the second diverter end along the diverter axis, and the third distance separating the downstream diverter edge segment and the second downstream diverter edge segment increases by a second ratio toward the second diverter end along the diverter axis.

7. The glass manufacturing apparatus according to claim 6, wherein the height of the diverter from the bottom surface at the center of the diverter increases at a non-constant ratio along the diverter axis from the first diverter end to the second diverter end.

8. A glass manufacturing apparatus, A forming device, the forming device comprising a trough extending along the trough axis between an inlet end of the forming device and the opposite end opposite to the inlet end, Includes, The forming device is, The trough is defined at least partially by a bottom surface and a pair of weirs extending from the bottom surface, A diverter positioned within the trough and configured to divert molten material beyond at least one of the pair of weirs, wherein the diverter extends along the diverter axis between a first diverter end and a second diverter end, and the height of the diverter from the bottom surface at the center of the diverter increases at a non-constant rate along the diverter axis from the first diverter end to the second diverter end, including, Glass manufacturing equipment.

9. The aforementioned divertor is A first surface that is in contact with the bottom surface and is located on the first plane, A second surface that contacts the bottom surface and is located on a second plane, and is attached to the first surface, A third surface that is in contact with the bottom surface and is located on a third plane that is not planar with the first plane, and is attached to the first surface, The fourth surface is in contact with the bottom surface and is located on a fourth plane that is not planar with the second plane, and is attached to the second surface and the third surface, This also includes, The glass manufacturing apparatus according to claim 8.

10. The glass manufacturing apparatus according to claim 9, wherein the first surface and the third surface are located on the first side of the diverter, and the second surface and the fourth surface are located on the second side of the diverter opposite to the first side.

11. A method for manufacturing glass, A step of directing molten material along the flow direction within a trough of a forming device, wherein the trough includes a bottom surface and a pair of weirs extending from the bottom surface, The steps include: flowing the molten material over the pair of weirs, As the molten material flows over the first portion of the diverter attached to the bottom surface, the step of diverting the molten material at a first flow rate beyond the pair of weirs at a first location in the trough, As the molten material flows over the second portion of the diverter, the step of diverting the molten material at a second location in the trough, over the pair of weirs, at a second flow rate different from the first flow rate, wherein the second location is positioned downstream from the first location with respect to the flow direction; A method that includes this.

12. The method according to claim 11, further comprising the step of diverting the molten material with an upstream flow rate over the pair of weirs at the location of the trough upstream from the first location with respect to the flow direction.

Images