Electrode Array Infrared Melting for Glass
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Solution Overview
Problem
Conventional electrical melting of glass and ceramics is inefficient due to significant heat losses resulting from the reliance on conduction and convection, requiring large shallow melt tanks with high surface areas.
Innovation Solution
A system with a plurality of co-planar elongate strip electrodes spaced closely within the melt tank, where current flows between adjacent electrodes to radiate heat primarily through infrared radiation, reducing reliance on conduction and convection and allowing for a smaller tank size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional direct electrical resistance melting is used, then the glass heating process is simple and clean, but heat losses are large due to reliance on conduction and convection requiring large shallow melt tanks
Solution Approach 1:
The single electrode is segmented into multiple elongate electrodes arranged in an array. This segmentation increases the total surface area for infrared radiation heating, improving heat transfer efficiency to the glass batch while reducing reliance on conduction and convection, thereby reducing heat losses.
Solution Approach 2:
The patent replaces the conventional conduction-based heating mechanism with infrared radiation heating. By arranging multiple electrodes to emit infrared radiation, the heating process transitions from mechanical/thermal conduction to electromagnetic radiation, significantly reducing heat losses and improving energy efficiency.
2Loss of energy
If conventional direct electrical resistance melting is used, then the heating process is straightforward, but large shallow melt tanks with large surface area are required increasing heat losses
Solution Approach 1:
The patent transitions from a two-dimensional surface heating approach to a three-dimensional volumetric heating approach. By arranging multiple elongate electrodes in an array throughout the melt tank, infrared radiation can be emitted from multiple directions and depths, heating the glass batch more efficiently without requiring a large tank surface area.
Solution Approach 2:
The patent changes the heating parameter from thermal conduction (requiring large surface area) to infrared radiation (effective at shorter distances). This parameter change allows efficient heating with a smaller tank surface area, as infrared radiation can penetrate and heat the glass batch directly without requiring extensive surface contact area.
3Use of energy by moving object
If conventional direct electrical resistance melting is used, then the process is simple to operate, but energy efficiency is low due to significant heat losses
Solution Approach 1:
The electrode is segmented into multiple elongate electrodes arranged in an array, increasing the total active heating surface area. This segmentation allows more efficient infrared radiation emission, improving energy efficiency by reducing heat losses while maintaining operational simplicity through standardized electrode modules.
Solution Approach 2:
The patent replaces conventional thermal conduction heating with infrared radiation heating. This substitution dramatically improves energy efficiency by directly heating the glass batch through electromagnetic radiation, minimizing heat losses to the tank walls and surrounding environment, while the modular electrode array maintains ease of operation.
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 significantly reduces heat losses and increases energy efficiency, enabling the production of glass or ceramic materials with reduced tank size and lower energy consumption compared to traditional direct electrical resistance methods.
Implementation Method 1
heat is radiated from the electrodes to materials located within the interior of the melt tank
Implementation Method 2
direct electrical resistance, where electrodes, usually molybdenum, are placed into molten glass and a current is passed between them. The electrical resistivity of the glass is higher than that in the electrical circuit causing the glass to heat between the electrodes
Data Source
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Figure 3a~3c
AI summary
A system for melting materials during the production of a glass or ceramic material is disclosed. A method for melting materials during the production o fa glass or ceramic material is also disclosed. The system comprises a melt tank having an interior with a width and a length;and an electrode array comprising a plurality of elongate electrodes each extending at least partially across the width of the interior of the melt tank in a direction substantially perpendicular to the length of the interior of the melt tank. Each electrode within the electrode array is spaced apart from an adjacent electrode within the electrode array by from about 5 mm to100 mm. The electrode array is configured such that during a heating operation, current flows between adjacent electrodes within the electrode array, such that heat is radiated from the electrodes to materials located within the interior of the melt tank.