Burner Module Knife-Edge Partitions for Uniform Glass Ribbon Deposition
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Solution Overview
Problem
Current methods for forming thin glass sheets and ribbons are limited, particularly in achieving uniformity and high surface quality, with float glass being impractical for ribbons and fusion draw processes restricted to soft glass compositions with high silica levels.
Innovation Solution
The introduction of burner modules comprising a burner gas inlet block, lower and upper flow plates, and a burner gas flow disperser with knife-edge partitions, which facilitate the deposition and sintering of glass soot particles onto a rotating drum to form uniform glass sheets and ribbons.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If float glass process is used, then thick glass sheets can be produced, but it is impractical for making thin glass ribbons
Solution Approach 1:
The invention changes the fundamental production parameters by using chemical vapor deposition instead of float glass process, enabling continuous production of thin glass ribbons that can be spooled into rolls, whereas float glass is only suitable for thicker sheets
Solution Approach 2:
The invention replaces the mechanical float glass process with a chemical deposition process (OVD or VAD) followed by sintering, which allows for precise control of thin glass ribbon formation and continuous production suitable for spooling
2Length of moving object
If fusion draw process is used, then thin glass ribbons can be produced, but it is limited to soft glass compositions with high silica levels and high softening point
Solution Approach 1:
The invention changes the material parameters by using chemical vapor deposition with various silicon-containing precursors, enabling production of glass ribbons with different compositions including those with lower softening points, whereas fusion draw is restricted to high silica soft glass
Solution Approach 2:
The invention allows for composite glass compositions by using different silicon precursors and additives in the vapor deposition process, creating glass ribbons with tailored properties, whereas fusion draw is limited to relatively simple high-silica compositions
3Manufacturing precision
If silica ingots are produced by batch flame-hydrolysis and then cut, ground and polished, then silica glass substrates can be obtained, but it is impractical for glass ribbons
Solution Approach 1:
The invention implements continuous production by using continuous vapor deposition onto a moving substrate followed by continuous sintering, eliminating the batch processing steps of cutting, grinding and polishing required for ingot-based methods
Solution Approach 2:
The invention replaces mechanical cutting, grinding and polishing operations with chemical vapor deposition and thermal sintering processes, achieving high surface quality through controlled deposition rather than mechanical removal of material
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
This approach enables the production of thin, uniform glass sheets and ribbons with high surface quality, overcoming the limitations of existing methods by providing a modular and efficient process for glass formation, allowing for the use of various silicon-containing precursor materials and achieving superb uniformity in glass thickness and surface roughness.
Implementation Method 1
depositing a plurality of glass soot particles generated via the disclosed burner modules on a deposition surface of a rotating drum to form a soot sheet
Implementation Method 2
sintering at least a part of the soot sheet into densified glass by heating the part of the moving soot sheet to a sintering temperature
Data Source
AI summary
A burner module comprising a burner gas inlet block, a lower flow plate, an upper flow plate, a burner gas flow disperser, and a burner gas discharge block. The burner gas inlet block, the burner gas flow disperser, and the burner gas discharge block each comprising a plurality of channels separated by partitions. The partitions of the burner gas flow disperser and the burner gas discharge block comprising a knife edge. The upper flow plate and the lower flow plate each comprising a plurality of pressure holes in fluid communication with the plurality of channels. Additionally, the method of forming a glass sheet or ribbon using the disclosed burner module and a glass sheet or ribbon formed using the method.