Glass Hopper Nozzle Layout to Prevent Roll Sticking and Fold Marks
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Solution Overview
Problem
The existing glass production processes using horizontal calendering counter-rolls face issues of roll sticking and fold mark defects due to prolonged contact of glass melt with air, leading to uneven temperature and viscosity, which affects the quality of finished glass articles.
Innovation Solution
A hopper mechanism with a discharging nozzle divided into a thermally insulating section and a bare section, extending out of the relief opening, reduces the falling height and contact duration of the glass melt, maintaining uniform temperature and preventing blockage, thereby avoiding roll sticking and fold marks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the glass melt falls down into the counter-roll gap with a large height difference, then the material pool is formed, but the contact duration with air increases causing temperature non-uniformity and fold marks
Solution Approach 1:
The patent extracts the harmful effect of prolonged air contact by designing the discharging nozzle to extend directly into the counter-roll gap, eliminating the intermediate falling distance. The glass melt is delivered precisely at the target location, removing the unnecessary exposure time to air that causes temperature non-uniformity and fold marks.
Solution Approach 2:
The discharging nozzle acts as an intermediary component that bridges the gap between the material pool and the counter-roll gap. By extending the nozzle into the counter-roll gap, it serves as a conduit that delivers glass melt directly to the rolling interface, eliminating the need for free-fall and reducing air contact duration.
2Temperature
If the discharging nozzle is fully thermally insulated, then heat loss is reduced, but the glass melt may block in the nozzle
Solution Approach 1:
The patent applies local quality by providing thermal insulation only for the portion of the discharging nozzle that is not extending into the counter-roll gap. The exposed section remains bare to prevent blockage through controlled cooling, while the insulated section maintains temperature to ensure smooth flow. This localized differentiation of thermal properties resolves the contradiction between heat retention and blockage prevention.
3Device complexity
If conventional lip bricks and edge retaining bricks are used, then the calendering structure is simple, but material cooling and crystallization occur at edges
Solution Approach 1:
The patent replaces the conventional mechanical calendering system with lip bricks and edge retaining bricks with a streamlined system using a material pool and counter-rolls. This substitution eliminates the edge contact points that cause cooling and crystallization, while maintaining the essential calendering function through the counter-roll mechanism that applies uniform pressure without edge constriction.
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 design ensures a uniform glass material pool temperature, prevents roll sticking, and reduces calendering difficulties, resulting in high-quality glass articles with minimal defects.
Implementation Method 1
the discharging nozzle includes a thermally insulating section and a bare section connected to each other, where the thermally insulating section is provided in the relief opening
Implementation Method 2
the glass melt in a hopper falls down into a counter-roll gap, forming a material pool
Data Source
Figure 1
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AI summary
The present disclosure relates to the technical field of glass production. Disclosed are a hopper mechanism and a glass product production device. The hopper mechanism comprises a housing and a discharging hopper, the discharging hopper being arranged in the housing. The bottom of the housing is provided with a clearance opening. The discharging hopper is provided with a discharging nozzle, the discharging nozzle comprising a heat preservation section and an exposed section which are connected to each other, the heat preservation section being arranged in the clearance opening, the exposed section extending out of the clearance opening, and the height range of the exposed section being 20 mm to 50 mm. Compared with the prior art, the hopper mechanism provided by the present disclosure uses the heat preservation section arranged in the clearance opening and the exposed section extending out of the clearance opening, so that the hopper mechanism can effectively avoid the risk of sticking onto rollers during rolling processes and fold mark defects after rolling, thereby ensuring the forming quality of glass.