Systems and methods for reducing glass breakage

Abstract

Systems, apparatus, and methods for reducing glass breakage due to condensation are provided herein. The system comprises a forming apparatus configured to form a glass ribbon extending downward therefrom. The system further comprises at least one set of rollers, positioned below a root and configured to receive a glass ribbon between them. The system further comprises an apparatus positioned vertically below the root. An apparatus comprising a porous material configured to split a first droplet into two or more droplets.

Description

[Technical Field]

[0001] Cross-reference of related applications This application claims the benefit of priority under § 119 of U.S. Patent Act to U.S. Provisional Application No. 63 / 455638, filed on 30 March 2023, the contents of which this Provisional Application is relied upon and incorporated in its entirety by reference herein.

[0002] Embodiments of this specification generally relate to the formation of sheet glass, and more specifically to reducing breakage within sheet glass caused by condensation formation during manufacturing processes, such as during an overflow down-draw fusion process. [Background technology]

[0003] Glass panels are used in a variety of applications, such as handheld devices, televisions, tablets, and computer displays. One method of producing glass for optical displays is the overflow downdraw process (also known as the fusion downdraw process). Molten glass flows over the forming trough of a glass forming apparatus, and the separate flows recombine at the root to form a glass ribbon.

[0004] As the glass ribbon develops, its thickness decreases under the forces of gravity and the tensile device. For example, a tensile rod (e.g., a roller) is positioned downstream of the root of the glass forming apparatus and is used to regulate the speed at which the glass ribbon leaves the root. This process helps to set the thickness of the finished glass ribbon. The tensile device is positioned far enough downstream so that the poor quality glass cools and becomes stiff enough to be pulled. As the glass ribbon descends from the root, it cools and becomes a solid elastic glass ribbon, which can then be cut to form individual glass sheets.

[0005] In addition to the cooling of the glass ribbon, the gases formed during the glass forming process also cool, resulting in condensation on various surfaces of the glass forming apparatus and surrounding manufacturing equipment. As the condensation hardens, it can form droplets, which may adhere directly to the glass ribbon and / or the tension rod (resulting in the droplets rotating with the tension rod and eventually coming into contact with the glass ribbon). These droplets can cause shattering or other forms of breakage within the glass ribbon and are therefore undesirable. [Overview of the Initiative]

[0006] This disclosure relates to improvements in apparatus, systems, and methods for removing condensed droplets from a glass ribbon formation process to prevent or limit breakage of the glass ribbon in various embodiments. Specifically, embodiments relate to splitting larger condensed droplets so that the resulting smaller droplets can be more easily removed or trapped before they come into contact with the tension rod.

[0007] Embodiments of the present disclosure relate to an apparatus having a porous material, which is positioned vertically below the route of a glass forming apparatus. The porous material is configured to split a first condensed droplet into a plurality of smaller droplets. The apparatus may include a device configured to blow air or a similar inert gas toward the plurality of smaller droplets so that the plurality of smaller droplets are directed toward away from the glass ribbon and the tension rod. Alternatively, the device may be configured to include a vacuum suction for drawing the plurality of smaller droplets toward away from the glass ribbon and the tension rod.

[0008] In some embodiments, the apparatus having a porous material may be positioned vertically below the route of the glass forming apparatus, and the catcher may be positioned vertically below the porous material. The catcher may capture multiple smaller droplets to prevent them from reaching the glass ribbon and / or tension rod.

[0009] In exemplary embodiments, a system is provided. The system comprises a molding apparatus configured to form a glass ribbon extending downward therefrom. The system further comprises at least one set of rollers positioned below a root and configured to receive a glass ribbon between them. The system further comprises an apparatus positioned vertically below the root. The apparatus comprises a porous material configured to split a condensed droplet into two or more droplets.

[0010] In some embodiments, the apparatus may be positioned vertically above at least one set of rollers. In some embodiments, the apparatus may further include at least one device for removing two or more droplets passing through a porous material. In some embodiments, at least one device utilizes vacuum suction to remove two or more droplets from the glass ribbon. In some embodiments, at least one device utilizes forced air to remove two or more droplets from the glass ribbon.

[0011] In some embodiments, the system may further include a catcher positioned below the porous material. The catcher may include a body configured to receive two or more droplets. In some embodiments, the catcher may include a shaft, a first extension, and a second extension. The first and second extensions may be attached to the shaft. The second extension may be spaced apart from the first extension so that the first extension is positioned adjacent to a first side of the glass ribbon, and the second extension is positioned adjacent to a second side of the glass ribbon, resulting in the glass ribbon flowing between the first and second extensions. In some embodiments, the porous material may include a first portion positioned vertically above the first extension and a second extension positioned vertically above the second extension.

[0012] In some embodiments, the porous material may have a median pore size of less than 2 mm. In some embodiments, the porous material may be configured to withstand temperatures of 1000°C. In some embodiments, the porous material may be a mesh. In some embodiments, the porous material may be a ceramic.

[0013] In some embodiments, the apparatus may consist of a first apparatus and a second apparatus. The first apparatus may be positioned adjacent to a first edge of the glass ribbon, and the second apparatus may be positioned adjacent to a second edge of the glass ribbon. The first edge of the glass ribbon may be on the opposite side of the second edge of the glass ribbon.

[0014] In another exemplary embodiment, a device is provided for reducing glass breakage caused by condensation droplets. The device comprises a porous material positioned vertically below the glass molded body and adjacent to the path of the glass ribbon during molding. The porous material is configured to break up droplets formed by condensation. The device further comprises a catcher positioned vertically below the porous material and configured to support the porous material.

[0015] In some embodiments, the catcher may comprise a shaft, a first extension, and a second extension. The first and second extensions may be attached to and spaced apart from the shaft. In some embodiments, the porous material may comprise a first portion positioned vertically above the first extension and a second porous material positioned vertically above the second extension. In some embodiments, the first and second extensions each define a distal end, and the porous material extends beyond at least one of the distal ends of the first extension to the distal end of the second extension.

[0016] In some embodiments, the apparatus may further include at least one pin attached to the catcher; at least one pin configured to secure a porous material within the catcher. In some embodiments, the apparatus may further include a storage feature positioned below the catcher. The catcher may be connected to a platform via a hinged connector such that the catcher rotates around the hinged connector when moved to a position in which the storage feature is stored. In some embodiments, the storage feature is a silicon carbide rod.

[0017] In some embodiments, the porous material may be a mesh. In some embodiments, the porous material may be a ceramic.

[0018] In yet another exemplary embodiment, a method is provided for reducing glass breakage due to condensation. The method includes positioning an apparatus comprising a porous material vertically below the root of a glass forming apparatus. The glass forming apparatus comprises a trough defining a first side and a second side. The first and second sides of the trough converge at the root so that molten glass flows over the trough, down the first and second sides, converges at the root, and forms a glass ribbon extending downward from there. The apparatus is configured to split condensed droplets into a plurality of droplets. The method further includes positioning at least one instrument below the apparatus. The method further includes operating the glass forming apparatus to produce a glass ribbon and operating at least one instrument to remove a plurality of droplets from the area around the glass forming apparatus.

[0019] In some embodiments, at least one device may use vacuum suction to remove multiple droplets from the glass ribbon. In some embodiments, at least one device may use forced air to remove multiple droplets from the glass ribbon.

[0020] Please refer to the attached drawing, but note that the drawing is not drawn to scale. [Brief explanation of the drawing]

[0021] [Figure 1] Illustrate a perspective view of an exemplary glass forming apparatus according to some embodiments discussed herein. [Figure 2A] Illustrate a schematic side view of an exemplary glass forming system according to some embodiments discussed herein. [Figure 2B] Illustrate a perspective view of an exemplary glass forming system according to some embodiments discussed herein. [Figure 2C] Illustrate a perspective view of an exemplary glass forming system according to some embodiments discussed herein. [Figure 3A] Illustrate an exemplary catcher for an apparatus according to some embodiments discussed herein. [Figure 3B] Illustrate an exemplary catcher for an apparatus according to some embodiments discussed herein. [Figure 4] Illustrate an exploded view of an exemplary apparatus according to some embodiments discussed herein. [Figure 5A] Illustrate a cross-sectional view taken along line A-A of the exemplary apparatus shown in FIG. 4 according to some embodiments discussed herein. [Figure 5B] Illustrate a cross-sectional view taken along line B-B of the exemplary apparatus shown in FIG. 4 according to some embodiments discussed herein. [Figure 6A] Illustrate a cross-sectional view of another exemplary apparatus taken along the cross-section of line A-A of FIG. 4 according to some embodiments discussed herein. [Figure 6B] Illustrate a cross-sectional view of another exemplary apparatus taken along the cross-section of line B-B of FIG. 4 according to some embodiments discussed herein. [Figure 7A] Illustrate a cross-sectional view of another exemplary apparatus taken along the cross-section of line A-A of FIG. 4 according to some embodiments discussed herein. [Figure 7B]A cross-sectional view of another exemplary apparatus, shown by the line BB in Figure 4, is illustrated in some embodiments discussed herein. [Figure 8A] Exemplary apparatuses according to some embodiments discussed herein are illustrated. [Figure 8B] Exemplary apparatuses according to some embodiments discussed herein are illustrated. [Figure 9] Side views of exemplary instruments for use in glass molding systems, according to some embodiments discussed herein, are provided. [Figure 10] A flowchart illustrating an exemplary method for reducing glass breakage due to condensation, according to some embodiments discussed herein, is provided. [Modes for carrying out the invention]

[0022] While not all, some exemplary embodiments are shown with reference to the accompanying drawings, some exemplary embodiments are not described more fully herein. In fact, the embodiments described and depicted herein should not be construed as limiting the scope, applicability, or configuration of this disclosure. Rather, these exemplary embodiments are provided so that this disclosure satisfies applicable legal requirements. Similar reference numbers refer to similar elements throughout.

[0023] Glass forming may involve several steps for preparing the glass and adjusting it to form into a sheet. A glass fusion apparatus may include several upstream steps (e.g., adjustment, melting, etc.) before the molten glass is introduced into the glass forming apparatus. Figure 1 illustrates a glass forming system 100 including a glass forming apparatus 105 and at least one set 120 of rollers (e.g., a tension rod). While fusion glass forming apparatuses are discussed herein, other glass forms, including slot draws, are also intended.

[0024] The glass forming apparatus 105 includes a trough 110 positioned within the upper surface of the glass forming apparatus 105, and a first side 111a and a second side 111b converging in the drawing direction along the route (e.g., bottom edge) 113 of the glass forming apparatus 105. Molten glass 131 delivered to the trough 110 overflows the wall of the trough 110, indicated by arrow 132, and descends along the first side 111a and the second side 111b as separate flows of molten glass 131. The separate flows of molten glass 131 merge along route 113 below route 113 to produce a single ribbon 130 of glass, which is then drawn downward along the draw direction from route 113 by gravity and / or by applying downward tension to the glass ribbon 130, such as by a set of at least one set of rollers 120, so as the molten glass 131 cools and the viscosity of the glass ribbon 130 increases, the dimensions of the glass ribbon 130 are controlled. Thus, the glass ribbon 130 undergoes a viscoelastic transition to an elastic state and acquires mechanical properties that give the glass ribbon 130 stable dimensional characteristics. In some embodiments, the glass ribbon 130 can be separated into individual glass sheets by a glass separator, while in other further embodiments, the glass ribbon 130 can be wound onto a spool and stored for further processing.

[0025] Before entering the trough 110, the molten glass 131 is heated and prepared to melt. The processing temperature in the upstream process can exceed, for example, 1000°C. During the preparation and processing steps, and even during the forming process discussed herein, volatile compounds evaporate, and the high temperature keeps the compounds in a gaseous state. However, the evaporated compounds may condense into droplets as they cool, particularly when they come into contact with relatively colder surfaces in the manufacturing process. These condensed droplets may then fall due to gravity and adhere to various surfaces, such as the newly formed glass ribbon 130 or at least one set 120 of rollers. Notably, if condensed droplets adhere to rollers, the rollers rotate and interact with the glass ribbon, thereby resulting in the condensed droplets coming into contact with the glass ribbon 130.

[0026] Returning to Figure 1, at least one set of rollers 120 may be positioned vertically below the route 113 of the glass forming apparatus 105. In some embodiments, at least one set of rollers 120 may be edge rollers (e.g., positioned adjacent to the first edge 135a and second edge 135b of the glass ribbon 130), tension rods, stub rolls, or other rollers. The rollers may be configured to guide the glass ribbon 130 and assist in forming the thickness and length of the glass ribbon 130. In particular, at least one set of rollers 120 or other surfaces below the glass forming apparatus 150 may be colder than the temperature applied to the glass forming apparatus 150. Therefore, condensation may form on and / or around the at least one set of rollers 120 from volatile compounds, falling onto the vertically lower set(s) of rollers, potentially causing breakage within the glass ribbon 130.

[0027] In some embodiments, the apparatus may be positioned vertically below the route 113 of the glass forming apparatus 105 to reduce and / or prevent breakage due to condensation. The apparatus may slow down and / or break up condensed droplets so that one or more smaller droplets are small enough not to eventually come into contact with the glass ribbon and / or cause glass breakage. In some embodiments, multiple smaller droplets may be removed from the glass ribbon area or held away from reaching the glass ribbon. Figures 2A–2C illustrate exemplary positioning and configuration of the apparatus 240, but any position of the apparatus below the glass forming apparatus 105 is intended herein.

[0028] Figure 2A illustrates a side view of an exemplary glass forming system 200. In some embodiments, the glass forming system 200 may comprise several sets of rollers positioned along a glass ribbon 235. In this regard, in some embodiments, a first set of rollers 220a may be located below the glass forming apparatus 210 over which the molten glass 232 flows to form the glass ribbon 235. In some embodiments, a flapper 217 may be positioned below the first set of rollers 220a. The flapper 217 is maintained at a lower temperature than the molten glass and may therefore be a source of condensed droplets, and consequently, an apparatus (such as the apparatus 240 in Figure 2B and other embodiments described herein) may be positioned below the flapper 217 to capture the condensed droplets and prevent them from adhering to the lower rollers (e.g., 220b, 220c, 220d, 220e). More specifically, the apparatus may be installed below a transition window 218. The transition window 218 may be a location where the temperature inside the glass forming system 200 is low enough for the glass ribbon 235 to solidify, and as a result, all condensed droplets that come into contact with the lower roller may cause fragmentation within the glass ribbon 235.

[0029] As discussed herein, with reference to Figure 2B, in some embodiments the apparatus 240 may comprise a porous material 242 configured to split condensed droplets into two or more droplets. In some embodiments the apparatus 240 may be positioned below the glass forming apparatus 205 (e.g., root 113 of the glass forming apparatus 105 in Figure 1), for example, between a set of edge rollers 221 and a second set of rollers 222. In particular, the apparatus 240 may be positioned between the downstream set of edge rollers 221 and the second set of rollers 222 of the glass forming apparatus 205, while the apparatus 240 may be positioned above any of the sets of rollers used in the glass forming process, as depicted in Figure 2A. For example, referring to Figure 2A, in some embodiments, the device may be positioned between at least one of the transition windows 218 and a second set of rollers 220b, between the second set of rollers 220b and a third set of rollers 220c, between the third set of rollers 220c and an optional fourth set of rollers 220d, or between an optional fourth set of rollers 220d and an optional fifth set of rollers 220e.

[0030] For illustrative purposes, the volatile compound may be in gaseous form when it enters the trough 210 of the glass forming apparatus 205. As the molten glass flows out of the trough 210 over the first side 211a and the second side 211b, as indicated by arrow 232, the molten glass and gaseous compound are exposed to a lower temperature than in the trough 210 and the upstream forming components. In this regard, all of the components (e.g., gas, molten glass, etc.) are cooled, which may result in the formation of condensation outside the trough 210. The condensed droplets then fall by gravity and adhere to the set of rollers 220, potentially causing fragmentation within the formed glass ribbon 230. Alternatively, the porous material 242 of the apparatus 240 may break the condensed droplet(s) into smaller droplets, which can be more easily captured, cleaned, or otherwise prevented from adhering to the set of rollers 220 (or directly to the glass ribbon 230).

[0031] As will be further described herein, the apparatus 240 may be configured such that a portion of the apparatus can be positioned adjacent to each surface (e.g., the front and back) of the glass ribbon 230 in order to capture all condensed droplets that could otherwise condense on the front and back surfaces of the glass ribbon 230.

[0032] In some embodiments, two or more devices 240 may be used for the system 200. As illustrated in Figure 2B, one device 240 is positioned around the first edge 235a of the glass ribbon 230, and a second device 240 is positioned around the second edge 235b of the glass ribbon 230. In other embodiments, multiple devices may be used between adjacent sets of rollers, as illustrated in Figure 2A.

[0033] In some cases, such as illustrated in Figure 2B, the system 200 may comprise a plurality of rollers, including a set of edge rollers 221 and a second set of rollers 222. In this configuration, in some embodiments, the device 240 may be positioned between the set of edge rollers 221 and the second set of rollers 222, but in some embodiments, the device 240 may be positioned above the set of edge rollers 221 and / or below the second set of rollers 222 (for example, to protect the downstream portion of the glass ribbon 230).

[0034] In some embodiments, one or more devices may be used to remove droplets from the area around the glass ribbon. In some embodiments, one or more devices may be used in conjunction with the apparatus and porous material to provide a beneficial condensation droplet removal system. Referring to Figure 2C, an exemplary configuration is illustrated in which a device 250 is included and positioned below the apparatus 240. The device 250 may comprise at least a first pipe 251 and a second pipe 252. In some embodiments, the device 250 may be positioned on the front side and the back side of the glass ribbon 230, respectively. The device 250 may be configured to interact with two or more droplets passing beneath the porous material 242. In some embodiments, the device 250 may be configured to discharge hot air from the device 250 to move two or more droplets away from the glass ribbon 230 and the set of tension rods 222. In other embodiments, the device 250 may be configured for vacuum suction. In such embodiments, vacuum suction can capture droplets generated from the porous material 242 and retain them within the apparatus 250. In some embodiments, the apparatus can both push the droplets away (e.g., using forced air) and suck them in (e.g., using vacuum suction). For example, a forced air pipe can push the droplets toward a vacuum suction pipe.

[0035] In some embodiments, the apparatus may include a catcher positioned below the porous material. The catcher may be configured to capture and contain droplets resulting from condensed droplets passing through the porous material. Figures 3A and 3B illustrate exemplary catchers 345, 345'.

[0036] The catcher 345 may include a shaft 346. The shaft 346 may be used to fix the catcher 345 in place around the glass ribbon so that it does not move vertically and / or horizontally (for example, within the glass ribbon). The catcher may include a first extension 347 and a second extension 348 extending from the shaft 346. The first extension 347 and the second extension 348 are spaced apart so as to form a gap 349 between them. In this regard, the catcher 345 may be positioned so that the glass ribbon flows within the gap 349 between the first extension 347 and the second extension 348.

[0037] In some embodiments, the first extension 347 and the second extension 348 may define a first thickness T1 as illustrated in Figure 3A. In this regard, each of the first extension 347 and the second extension 348 has an extension length L E The thickness may be uniform along the first extension 347 and the second extension 348, for example, the gap 349 has a constant gap thickness T. G This could result in the same outcome.

[0038] In other embodiments as illustrated in Figure 3B, the catcher 345' may include a first extension 347' and a second extension 348', which define a varying thickness. For example, the first extension 347' and the second extension 348' may define a first thickness T1 adjacent to the shaft 346 and an extension length L opposite the shaft 346. E A second thickness T2 can be defined at the end 361. To accommodate the change in thickness, in some embodiments, the distal ends 362 of the first extension 347' and the second extension 348' have a gap 349, and the extension length L E Along the same gap thickness T GIt can be inclined from the first thickness T1 to the second thickness T2 so as to define. In other embodiments, the distal ends of the first extension and the second extension can be parallel, and the inner edges of the first extension and the second extension can extend obliquely. In this regard, in some embodiments, the thickness T of the gap G is the extension length L E and can vary along it.

[0039] In some embodiments, the device can include a porous material, a catcher, and a hinged attachment that provides a robust device to assist in the management of condensate droplets to prevent or limit glass breakage from the condensate droplets. FIG. 4 illustrates an exploded view of a device 440 including a porous material 442, a catcher 445, a hinged attachment 460, and a rod 465.

[0040] In some embodiments, the porous material 442 can include a plurality of parts. Each part can be positioned around and along the edges of different surfaces (e.g., the front and back surfaces) of the glass ribbon. In some embodiments, the porous material 442 can include a first part 442a, a second part 442b, and optionally a third part 442c. The first part 442a and the second part 442b can be spaced apart such that a glass ribbon (e.g., 230 in FIG. 2A) flows between the first part 442a and the second part 442b. Therefore, the porous material can split the condensate droplets formed on either side of the glass ribbon.

[0041] In some embodiments, the porous material 442 can be a mesh. The mesh can be formed from wires that can withstand temperatures up to 1000 °C, up to 1100 °C, or even up to 1200 °C. In other words, the mesh can be exposed to continuous operating temperatures of 1000 - 1200 °C without significant degradation due to temperature. The mesh is less than 4 mm 2 less than 2 mm 2 less than, or even less than 1 mm 2An aperture size of less than a certain size can be defined. In some embodiments, the mesh may be a readily replaceable wire material. In this regard, the mesh may be inexpensive and easy to handle (e.g., cut to size).

[0042] In some embodiments, the mesh may be a "soft mesh." In this regard, the mesh may be easily deformable and bend when in contact with condensed droplets. The soft mesh may absorb and attenuate the velocity of the condensed droplets, thereby reducing the energy and velocity of the resulting two or more droplets.

[0043] In some embodiments, the porous material 442 may be a ceramic material. The ceramic material may contain multiple pores, each defining a depth, to split the condensed droplet and confine two or more resulting droplets. The ceramic material may be lightweight, replaceable, and able to withstand high temperatures such as those that occur during glass formation.

[0044] In some embodiments, the apparatus 440 may include a catcher 445 positioned below the porous material 442. The catcher 445 may include a first extension 447 and a second extension 448 spaced apart from each other. The catcher 445 may further include a shaft portion 446 (which may be referred to herein as a shaft) connected to each of the first extension 447 and the second extension 448.

[0045] The catcher may include a depth configured to receive and hold any and all of the two or more droplets formed when the condensed droplets engage with the porous material 442. In some embodiments, the catcher 445 may include varying depths so that the two or more droplets can be directed into the catcher 445, such as toward the back of the shaft portion 446.

[0046] As will be described herein, the catcher 445 may include pins 444 for fixing the position of the porous material 442 on the catcher 445. In some embodiments, the pins 444 may be positioned on each side of the first extension 447, the second extension 448, and the shaft portion 446. In other embodiments, one pin 444 may be used on each of the first extension 447 and the second extension 448.

[0047] In some embodiments, the catcher 445 may be configured to be retractable. Retractability may allow easy access to the glass ribbon (e.g., 130 in Figure 1) when the glass forming process is interrupted or when fragments form within the glass ribbon. In these cases, the broken portion of the glass ribbon can be removed from the system and the process can be restarted. Therefore, when the glass ribbon extends between the first extension 447 and the second extension 448 of the catcher 445, it may be beneficial to remove the apparatus 440, including the catcher 445, from the face of the broken glass ribbon before removing the broken glass ribbon from the glass ribbon. Since the glass fusion process is in progress, shorter downtime is desired, and therefore, the ability to quickly release the catcher 445 in any usable way to remove the broken glass ribbon and replace the apparatus 440, including the catcher 445, is desired.

[0048] In some embodiments, the device 440 may be additionally attached to a hinged attachment 460. The hinged attachment may comprise a platform 461 and a hinge 462 attached to the platform 461. In some embodiments, the hinge 462 may hinge a shaft portion 446 to the platform 461 such that when the hinge 462 is opened or unlocked, the catcher 445 rotates downward, and as a result, the glass ribbon (e.g., 230 in Figure 2B) is no longer positioned between the first extension 447 and the second extension 448. In some embodiments, the hinge 462 may be appropriately attached to the shaft portion 446. In some embodiments, the hinge 462 may be a high-temperature hinge.

[0049] The apparatus 440 may further include a rod 465. In some embodiments, the rod 465 may be attached to a porous material 442, to a catcher 445, or to a platform 461. The rod 465 may be configured to maintain the position of the apparatus 440 around the glass ribbon. In some embodiments, the rod 465 may provide stowability for the apparatus 440. In such embodiments, the rod 465 may be slidably attached to the bottom side of the platform 461 and may extend beyond the hinge 462 to the underside of the catcher 445. In some embodiments, the rod 465 may be positioned within a tube or sheath attached to the underside of the platform 461. In some embodiments, the rod 465 may be a silicon carbide rod or similar. The rod 465 may be capable of withstanding high temperatures while maintaining solidity and malleability.

[0050] To retract the device 440, the rod 465 can be pulled away from the catcher 445 and hinge 462 so that the rod 465 is below the platform 461. Since there is nothing to support the catcher 445 and the porous material 442, the catcher 445 and the porous material 442 can therefore rotate around the hinge 462 (e.g., by gravity) to the disengaged position. In some embodiments, the hinge 462 can be biased to the retracted position. To re-engage the device 440, the rod 465 can be placed back under the hinge 462 and catcher 445, thereby moving the device 440 back to the engaged position.

[0051] In some embodiments, the platform 461 may be a stainless steel plate, and more specifically, the platform 461 may be made from 330 stainless steel. The platform 461 may be able to withstand processing temperatures of, for example, 1000°C to 1300°C, 1075°C to 1225°C, or even 1125°C to 1175°C.

[0052] In some embodiments, rather than the first extension 447 and the second extension 448 being attached to a single shaft portion 446 and thereby defining a single device 440, in some embodiments the first extension 447 and the second extension 448 may be attached to separate shafts or shaft portions. In this regard, either the first extension 447 or the second extension 448 may be retracted while the other remains in the engaged position. This configuration may be beneficial if one side has a greater amount of condensation compared to the other. Therefore, one side may be left empty while the other side is engaged.

[0053] In some embodiments, the porous material 442 may be positioned to cover the catcher 445 and may extend slightly beyond the edge of the catcher 445. In this regard, there may not be any excess porous material 442 protruding from the catcher 445. In some embodiments, such as those illustrated in Figures 5A and 5B, the porous material 442 may extend slightly above the catcher 445, beyond the catcher. In some embodiments, the porous material 442 (e.g., mesh) may be curved to fit within the catcher 445. In some embodiments, the catcher 445 may be provided with pins 444 for holding and securing the porous material 442 to the catcher 445. The pins 444 may be used to control the position of the porous material 442 and to prevent the porous material 442 from coming into contact with a glass ribbon (e.g., 230 in Figure 2B). In some embodiments, such as those illustrated in Figure 5A, the shaft portion 446 may be provided with pins 444 on both sides of the shaft portion 446. In contrast, as illustrated in Figure 5B, each of the first extension 447 and the second extension 448 may have a pin 444 positioned inside the corresponding extension (for example, near the gap and glass ribbon). In some embodiments, the first extension 447 and the second extension 448 may have pins 444 both inside and outside.

[0054] In some embodiments, the porous material 442 may extend along the entire edge of the catcher 445. In this regard, referring to Figures 6A and 6B, the body portions 442a, 442c may be within the catcher 445, and the wing portion 442e may extend outward from the catcher 445. The wing portion 442e may provide additional coverage for splitting and capturing condensed droplets.

[0055] Figure 6A illustrates alternative configurations of the shaft portion 446 and porous material 442 of the catcher 445. The body portion 442c of the porous material 442 may be positioned within the thickness of the shaft portion 446, and the porous material 442 may define two wing portions 442e extending away from either edge of the shaft portion 446. In contrast, as illustrated in Figure 6B, the porous material 442a of the first extension 447 and the second extension 448 may comprise one wing portion 442e extending from the body portion 442a. The wing portion 442e may be positioned on the opposite side of the gap 449 that receives the glass ribbon (e.g., 230 in Figure 2B) so that the wing portion 442e does not come into contact with the glass ribbon.

[0056] In some embodiments, the porous material 442 may be welded to line and remain in place within the catcher 445. In this regard, referring to Figures 7A and 7B, the porous material 442 may be positioned to fit within the contour of the catcher 445. The porous material 442 may also be spot-welded to the catcher 445 as indicated by the circle 442f. In such embodiments, the porous material 442 may remain fixed to the catcher 445 by the spot welds 442f, and therefore pins (e.g., 444 in Figure 5A) may not be necessary. In some embodiments, two or more spot welds 442f may be formed around the catcher 445.

[0057] In some embodiments, the porous material may include different configurations within the catcher. Figures 8A and 8B illustrate exemplary devices 740, 740'. Each of the devices 740, 740' may comprise a porous material 742 disposed within a catcher 745. The catcher 745 may comprise a shaft 746, a first extension 747, and a second extension 748, as described with reference to Figures 3A and 3B. In some embodiments, such as that illustrated in Figure 8A, the porous material 742 may extend a certain length 742g beyond the edge 761 of the catcher 745. By extending the porous material 742, it may be possible to shorten the first extension 747 and the second extension 748 to reduce the weight of the catcher 745 and the material cost of the device 740. In some embodiments, the length 742g of the porous material extending beyond the end 761 may be reinforced to provide structure to the porous material 742. In this regard, reinforcement can prevent the porous material from bending, sagging, or similarly deforming when struck by condensation droplets.

[0058] In another embodiment illustrated in Figure 8B, the apparatus 740' may comprise multiple sections of porous material 742 within each of the first extension 747 and the second extension 748. In this regard, less porous material 742 may be used, which may, in some cases, allow for easier cleaning of the apparatus 740'.

[0059] In some embodiments, apparatus can be used to manipulate the movement of condensed droplets in a manufacturing process, including droplets that have passed through a porous material, depending on the system configuration. In this regard, in some embodiments, the condensed droplets before passing through the porous material may otherwise be too large to be manipulated by vacuum suction or forced air due to their volume and velocity.

[0060] Figure 8 illustrates a device 550 positioned around a glass ribbon 535. The device may include at least a first pipe 551 positioned near the glass ribbon 535 but not in contact with it. The device 550 may be positioned vertically below the apparatus having a porous material as described herein. In this way, all condensed droplets passing through the apparatus can be manipulated by the device 550.

[0061] In some embodiments, the first pipe 551 and the second pipe 552 may be configured to discharge hot air. The hot air may be discharged parallel to the side of the glass ribbon 535 (for example, into the page). In this regard, the hot air may force droplets away from the glass ribbon, such as toward a catcher (not shown). The droplets may then be received and held by the catcher.

[0062] In some embodiments, the first pipe 551 and the second pipe 552 may be made of metal, specifically stainless steel or the like. In this regard, the first pipe 551 and the second pipe 552 are formed from a material softer than glass. Therefore, the glass ribbon (e.g., 230 in Figure 2B) is not susceptible to damage by accidental contact, as the glass ribbon is harder than the first pipe 551 and the second pipe 552, and thus the first pipe 551 and / or the second pipe 552 would be scratched.

[0063] In some embodiments, hot air may flow continuously through the first pipe 551 and the second pipe 552. A constant flow may allow the system to function without sensors to determine when condensation droplets need to form and be discharged. In this regard, a continuous flow of hot air is a cost-effective way to move two or more droplets away from the glass ribbon 535.

[0064] In another embodiment, the first pipe 551 and the second pipe 552 may be configured for vacuum suction rather than air discharge. In this regard, one or more of the first pipe 551 and the second pipe 552 may be configured to draw one or more droplets into the pipe and hold the condensed droplets within the first pipe 551 and / or the second pipe 552.

[0065] In some embodiments, two or more fixtures 550 may be positioned around the glass ribbon 535. For example, each side of the glass ribbon (e.g., the front and back) may have two fixtures, one positioned adjacent to each edge (e.g., the first edge 135a and the second edge 135b in Figure 1). Thus, the fixtures may be positioned in locations where condensate is likely to form, such as to protect downstream surfaces, for example, at least one set 520 of rollers.

[0066] Example flowcharts (multiple examples allowed) Figure 10 is a flowchart illustrating exemplary methods 600 for reducing glass breakage due to condensation, according to some embodiments discussed herein. In operation 610, a device having a porous material is positioned vertically below the route of the glass forming apparatus. In operation 620, optionally, at least one device is positioned vertically below the apparatus. In operation 630, the glass forming apparatus is operated. Optionally, in operation 640, at least one device is operated. In some embodiments, the operation of at least one device may discharge hot air, or alternatively, the operation of at least one device may result in vacuum suction. As detailed herein, during the operation of the glass forming apparatus, condensation may form and drip onto the glass ribbon and / or onto one or more sets of rollers positioned below the route, thereby ultimately resulting in the condensation adhering to the glass ribbon during the rotation of the rollers. The apparatus (and, in some embodiments, the device) may be positioned to capture and / or direct the condensation away from one or more sets of glass ribbons and / or rollers.

[0067] In particular, the operations described above for Figure 10 are presented in a specific order, but they may be performed in a different order, and / or some of the operations may be performed simultaneously.

[0068] conclusion Those skilled in the art will readily understand that the present invention has broad utility and applicability. Many embodiments and adaptations of the present invention other than those described herein, as well as many variations, modifications, and equivalent arrangements, will be apparent from the present invention and its preceding description, or reasonably suggested by the present invention and its preceding description, without departing from the content or scope of the present invention. Thus, although the present invention has been described in detail herein in relation to its preferred embodiments, it should be understood that this disclosure is merely illustrative and illustrative of the present invention and is made solely for the purpose of providing a complete and effective disclosure of the present invention. The foregoing disclosure is not intended to limit the present invention or exclude any other such embodiments, adaptations, variations, modifications, and equivalent arrangements, nor should it be construed as such.

Claims

1. It is a system, A molding apparatus configured to form a glass ribbon extending downward therefrom, A set of rollers, at least one set of rollers positioned below the root and configured to receive the glass ribbon between them, A device positioned vertically below the aforementioned route, comprising a porous material configured to split a condensed droplet into two or more droplets, A system equipped with these features.

2. The system according to claim 1, wherein the device is positioned vertically above at least one set of rollers.

3. The system according to claim 1 or 2, wherein the apparatus further comprises at least one device configured to remove the two or more droplets passing through the porous material.

4. The system according to claim 3, wherein at least one of the instruments uses vacuum suction to remove the two or more droplets from the glass ribbon.

5. The system according to claim 3, wherein at least one of the devices uses forced air to remove the two or more droplets from the glass ribbon.

6. The system according to claim 1 or 2, wherein the apparatus further comprises a catcher positioned below the porous material, the catcher comprising a body configured to receive the two or more droplets.

7. The aforementioned catcher, The shaft and A first extension attached to the shaft, A second extension is attached to the shaft and spaced apart from the first extension, The system according to claim 6, comprising, wherein the first extension is positioned adjacent to the first side surface of the glass ribbon, and the second extension is positioned adjacent to the second side surface of the glass ribbon such that the glass ribbon flows between the first extension and the second extension.

8. The system according to claim 7, wherein the porous material comprises a first portion positioned vertically above the first extension and a second portion positioned vertically above the second extension.

9. The system according to any one of claims 1 to 8, wherein the porous material includes a median pore size of less than 2 mm.

10. The system according to any one of claims 1 to 9, wherein the porous material is configured to withstand 1000°C.

11. The system according to any one of claims 1 to 10, wherein the porous material is a mesh.

12. The system according to any one of claims 1 to 10, wherein the porous material is a ceramic.

13. The system according to any one of claims 1 to 12, wherein the apparatus includes a first apparatus and a second apparatus, the first apparatus being positioned adjacent to a first edge of the glass ribbon, the second apparatus being positioned adjacent to a second edge of the glass ribbon, and the first edge being on the opposite side of the second edge.

14. A device for reducing glass breakage, A porous material positioned vertically below the glass molded body and adjacent to the path of the glass ribbon during molding, configured to split droplets formed from condensation, A catcher positioned vertically below the porous material and supporting the porous material, A device equipped with the following features.

15. The aforementioned catcher, The shaft and A first extension attached to the shaft, A second extension is attached to the shaft and spaced apart from the first extension, The apparatus according to claim 14, comprising:

16. The apparatus according to claim 15, wherein the porous material comprises a first portion positioned vertically above the first extension and a second portion positioned vertically above the second extension.

17. The apparatus according to claim 15 or 16, wherein the first extension and the second extension each define a distal end, and the porous material extends beyond at least one of the distal end of the first extension or the distal end of the second extension.

18. The apparatus according to any one of claims 14 to 17, further comprising at least one pin attached to the catcher, wherein the at least one pin pierces the porous material and fixes it within the catcher.

19. The apparatus according to any one of claims 14 to 18, further comprising a storage feature positioned below the catcher, wherein the catcher is connected to a platform via a hinged connector, and the catcher is configured to rotate about the hinged connector when the storage feature is moved to a storage position.

20. The apparatus according to claim 19, wherein the storage feature comprises a silicon carbide rod.

21. The apparatus according to any one of claims 14 to 20, wherein the porous material includes a mesh.

22. The apparatus according to any one of claims 14 to 20, wherein the porous material includes ceramic.

23. A method to reduce glass breakage, Positioning a device comprising a porous material vertically below a glass molding apparatus, wherein the glass molding apparatus comprises a trough, the trough comprises a first side and a second side, the first side and the second side converge at a route such that molten glass flows over the trough, down the first side and the second side, converges at a route, and forms a glass ribbon extending downward from there, and the device is configured to split condensed droplets into a plurality of droplets; Positioning at least one device below the aforementioned device, The glass molding apparatus is operated to produce the glass ribbon, Activating at least one of the aforementioned devices to remove the plurality of droplets from the area around the glass molding apparatus, Methods that include...

24. The method according to claim 23, wherein the at least one of the devices uses vacuum suction to remove the plurality of droplets from the glass ribbon.

25. The method according to claim 23, wherein at least one of the devices uses forced air to remove the plurality of droplets from the glass ribbon.

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