Preheated Mounting with Thermal Insulation for Glass Bending
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Solution Overview
Problem
Current glass bending processes in the automobile industry face high operating costs and inconsistent quality due to significant heat loss and variable temperature control in the thermal bending process, leading to suboptimal glass pane production.
Innovation Solution
A method and device that utilize a transport device to rapidly move preheated mountings between the furnace inlet and outlet, incorporating thermal insulation and controlled heating to maintain optimal temperature and reduce energy loss, ensuring consistent glass bending quality and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mounting is heated to the desired temperature for glass bending, then the glass pane can be bent to the desired shape, but a large part of the heating output (approximately 20%) is consumed to heat the mounting, resulting in high operating costs
Solution Approach 1:
The mounting is preheated before the glass pane is placed on it, so that when the mounted glass pane enters the furnace, the mounting is already at or near the desired temperature. This preliminary heating action reduces the energy required during the actual bending process, as the furnace only needs to maintain temperature rather than heat the mounting from cold.
Solution Approach 2:
The mounting is inserted into an insulating housing that provides thermal insulation. This nested structure allows the mounting to retain heat more effectively, reducing heat loss to the surroundings and minimizing the energy required to maintain the desired temperature during the bending process.
2Productivity
If the mounting is reused after removing the bent glass pane, then mass production is enabled, but the temperature of the mounting drops, causing variable start temperatures and inconsistent thermal expansion
Solution Approach 1:
The mounting is preheated in the insulating housing before each use, ensuring that it starts at a consistent temperature regardless of how much time has elapsed since the previous bending operation. This preliminary heating action eliminates the variability in start temperature that would otherwise occur during reuse.
Solution Approach 2:
The system monitors the temperature of the mounting and adjusts the heating in the insulating housing to maintain a consistent start temperature. This feedback mechanism ensures that regardless of the dwelling time in the furnace or the specific configuration of the mounting, the temperature conditions for bending are always consistent, thereby ensuring uniform thermal expansion and bending quality.
3Productivity
If the mounting is transported back to the starting point after use, then the mounting can be reused for mass production, but heat is lost during transport and the mounting cools down
Solution Approach 1:
The mounting is placed inside an insulating housing during transport back to the starting point. This nested structure provides thermal insulation that reduces heat loss to the surroundings during transport, allowing the mounting to retain its temperature and be ready for reuse with minimal additional heating.
Solution Approach 2:
The insulating housing maintains the thermal state of the mounting continuously during transport and storage, ensuring that the heat gained during the bending process is not lost. This continuous insulation allows the mounting to be quickly reused without significant cooling, thereby maintaining productivity while minimizing energy loss.
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 solution significantly reduces energy consumption by approximately 20%, enhances the precision and quality of bent glass panes, and minimizes heat loss, making the process more economically viable and precise.
Implementation Method 1
subsequently, a thermal insulation is installed on the mounting
Implementation Method 2
a glass pane is mounted on a suitable mounting and is heated—e.g., to 650° C.
Implementation Method 3
effects of the thermal expansion of the mounting become perceptible
Data Source
AI summary
A method for bending a glass pane in a furnace, wherein the furnace has an inlet and an outlet, includes providing a glass pane on a mounting, wherein the mounting is preheated, introducing the mounted glass pane into the inlet of the furnace for bending, discharging the bent, mounted glass pane out of the outlet of the furnace, withdrawing the bent, mounted glass pane from the mounting, installing thermal insulation on the mounting, returning the mounting and the thermal insulation using a transport device, removing the thermal insulation prior to renewed mounting, wherein the aforementioned steps are carried out again in a cyclical manner.