Furnace Laser Heating for Glass Reshaping Cycle Time
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Solution Overview
Problem
The existing glass shaping processes in furnaces are hindered by long cycle times due to slow heating and cooling of semi-finished glass products, which limits control over the shaping process.
Innovation Solution
A device and method that utilize a furnace with a wall chamber, where semi-finished glass products are heated by convection and radiation, and specific areas are further heated with infrared laser radiation, allowing for controlled re-shaping. The furnace design includes a material-free opening for the laser beam, a sealing air flow nozzle to reduce heat loss, and multiple temperature zones for sequential processing, along with embossing dies and a positioning system for precise shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional heating methods are used in the furnace, then the semi-finished glass product can be heated uniformly, but the heating process is slow and cycle time is long
Solution Approach 1:
The heating process is segmented into two distinct phases: (1) conventional convective heating for uniform temperature distribution, and (2) localized laser heating for rapid temperature increase in specific areas. This segmentation allows each heating method to be optimized for its specific function, resolving the contradiction between uniform heating and fast heating.
Solution Approach 2:
Different heating qualities are applied to different parts of the glass product simultaneously. The bulk of the product receives gentle convective heating to maintain uniform temperature, while specific areas requiring shaping receive concentrated laser heating for rapid temperature increase. This local differentiation enables both uniformity and speed.
2Temperature
If the glass product is heated to high temperature for re-shaping, then the glass becomes sufficiently soft for shaping, but the mechanical strength decreases and control over shaping becomes difficult
Solution Approach 1:
Temperature and strength requirements are satisfied locally: the bulk of the glass product is maintained at lower temperatures where it retains mechanical strength and dimensional stability, while only the specific areas requiring shaping are heated to high temperatures to achieve the necessary softness for re-shaping.
Solution Approach 2:
Instead of heating the entire glass product to high temperature, only the necessary partial areas are heated excessively (to high temperature) for the duration needed to achieve shaping. This partial action minimizes the volume of glass exposed to high temperatures, preserving overall mechanical strength.
3Adaptability or versatility
If an opening is provided in the furnace wall for laser beam entry, then laser heating can be applied, but heat loss increases and energy efficiency decreases
Solution Approach 1:
The opening in the furnace wall is periodically closed with a shutter mechanism: open when laser heating is active, closed during other phases of the process. This periodic action allows the opening to serve its function when needed while minimizing heat loss during non-laser periods, resolving the contradiction between adaptability and energy efficiency.
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 cycle times, enhances control over the shaping process, improves temperature distribution, and reduces energy consumption while maintaining mechanical strength and quality of the glass products.
Implementation Method 1
the heating may be carried out by convection and radiation
Implementation Method 2
the heating may be carried out by convection and radiation
Implementation Method 3
the above mentioned partial areas may, for example, be heated with infrared laser radiation from a laser device
Implementation Method 4
the above mentioned partial areas may, for example, be heated with infrared laser radiation
Implementation Method 5
an emission of warm air otherwise occurs since the heated air in the furnace chamber rises up and can escape as if through a chimney. The sealing air flow can counteract this convective flow
Data Source
AI summary
A furnace (2) has at least one furnace chamber (20) delimited by a wall (25); at least one opening (5) is provided in the wall (25). The opening is provided with at least one nozzle (50), configured to generate a sealing air flow. A glass semi-finished product (4) can be introduced into the furnace chamber.