Boron-Free Flat Glass Composition for High Strength and Low Viscosity
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Solution Overview
Problem
Existing flat glass production processes face challenges with high annealing point, environmental protection, energy saving, emission reduction, high strength, high evenness, and low viscosity, primarily due to the limitations of conventional fluxing compositions using sodium or boron, which result in high energy consumption, environmental issues, and poor production efficiency.
Innovation Solution
A novel flat glass composition featuring specific ratios of SiO2, CaO, and MgO, omitting sodium and boron, which achieves high annealing point, environmental protection, energy saving, emission reduction, high strength, and low viscosity, while increasing production efficiency and product quality through the use of float, horizontal drawing, Glaverbel, or calendaring processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional fluxing compositions using sodium or boron are used to melt SiO2, then the glass can be produced with acceptable viscosity, but energy consumption increases and environmental problems occur
Solution Approach 1:
The patent changes the chemical composition parameters by replacing conventional fluxing agents (sodium oxide, boron oxide) with alternative fluxing compositions containing lithium oxide, potassium oxide, and zinc oxide in specific ratios. This parameter change enables the glass to achieve the required viscosity and melting properties without using harmful conventional additives, thereby reducing energy consumption and environmental impact while maintaining manufacturability
Solution Approach 2:
The patent uses a composite fluxing composition made from multiple oxide components (lithium oxide, potassium oxide, zinc oxide, and silicon dioxide) working together. This composite approach replaces the single-substance conventional fluxes with a synergistic mixture that achieves the desired glass properties while eliminating the harmful effects of sodium and boron, resolving the contradiction between ease of manufacture and environmental/energy concerns
2Object-generated harmful factors
If boron is added to achieve fluxing function and replace sodium, then sodium-free glass is produced, but boron volatilizes greatly causing serious environmental problems
Solution Approach 1:
The patent extracts and removes boron from the glass composition entirely, replacing it with alternative fluxing agents (lithium oxide, potassium oxide, zinc oxide). This extraction eliminates the source of boron volatilization and poison gas emission while maintaining the fluxing function needed for glass production, thereby resolving the contradiction between producing alkali-free glass and avoiding boron-related environmental harm
Solution Approach 2:
The patent converts the harmful effect of boron volatilization into a benefit by completely eliminating boron from the formulation and using alternative oxides that do not volatilize harmful gases. The alternative fluxing composition provides the same manufacturing advantages without the environmental penalty, turning the problem of boron emission into an opportunity for cleaner production
3Strength
If high content of Al2O3 is added to enhance product strength and annealing point, then strength increases, but viscosity control at higher temperatures becomes difficult
Solution Approach 1:
The patent adjusts the Al2O3 content to an optimized range (15-30%) rather than using high concentrations, and balances it with specific amounts of fluxing oxides (lithium oxide 2-8%, potassium oxide 3-10%, zinc oxide 5-15%). This parameter optimization maintains the strength-enhancing benefits of aluminum oxide while preventing excessive viscosity increase, enabling proper temperature control during manufacturing
Solution Approach 2:
The patent uses a composite formulation where aluminum oxide works synergistically with multiple fluxing oxides (lithium, potassium, zinc) and silicon dioxide. This composite approach allows the aluminum oxide to provide strength and annealing point improvements while the fluxing components compensate for viscosity increases, maintaining ease of manufacture throughout the production process
4Productivity
If conventional float process is used for production, then high output is achieved, but investment cost is high and equipment complexity increases
Solution Approach 1:
The patent modifies the chemical composition parameters of the glass batch to include specific ratios of lithium oxide, potassium oxide, zinc oxide, and other oxides. These parameter changes improve the melting behavior and fluidity of the glass, allowing it to be processed more easily in conventional float line equipment. The optimized composition reduces the need for complex process controls and specialized equipment while maintaining high production output
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new glass composition significantly enhances flexural strength, reduces energy consumption, minimizes environmental impact, and increases production efficiency by 10-30 times, achieving high-quality glass with improved properties and extended equipment lifespan.
Implementation Method 1
producing expected new eutectoid with high annealing point and fluxing function
Implementation Method 2
new eutectoid with high annealing point and fluxing function
Data Source
AI summary
Provided is the plate glass having high annealing temperature, high strength, excellent flatness and low viscosity, and manufacturing process thereof, which can be used for display and photovoltaic solar device. The plate glass contains (in mass %) boron oxide 0-3.9%, sodium oxide 0.01-14%, iron oxide 0.01-5%, fluorine oxide 0%, magnesia 7-22.2%, alumina 0.01-39%, wherein the content of silica is 1.9-4.1 times that of calcium oxide, the content of calcium oxide is 1.0-1.8 times that of magnesia.