Glass Surface Lubricant Layer Formation via SO3 Catalyst
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Solution Overview
Problem
Existing glass manufacturing techniques face challenges in preventing scratches on non-alkali glass surfaces during the annealing process, as conventional methods require excessive SO2 gas, leading to increased production costs, environmental pollution, and equipment corrosion.
Innovation Solution
An apparatus that uses a SO2 supply unit, an O2 supply unit, and a catalyst retaining unit with a SO2 gas oxidation catalyst, such as V2O5, to generate SO3 gas, which forms a CaSO4 lubricant layer on the glass surface, reducing the need for excessive SO2 gas and minimizing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excessive SO2 gas is supplied to form a lubricant layer on non-alkali glass, then scratch resistance is improved, but production cost increases and environmental pollution worsens
Solution Approach 1:
The invention changes the chemical parameter of the glass composition by adding alkali metal oxide (5-20 wt%) to non-alkali glass. This compositional change enables the glass to react with SO2 gas to form a lubricant layer (glass sulfate) at lower SO2 consumption levels, thereby improving scratch resistance while reducing SO2 gas consumption and associated environmental pollution.
Solution Approach 2:
The invention performs preliminary modification of the glass composition by incorporating alkali metal oxide before the annealing process. This preliminary action prepares the glass surface to readily form a lubricant layer when exposed to SO2 gas, reducing the need for excessive SO2 supply during the annealing process and thereby lowering both cost and environmental impact.
2Reliability
If excessive SO2 gas is supplied to form a lubricant layer, then scratch resistance is improved, but equipment corrosion increases
Solution Approach 1:
By modifying the glass composition to include alkali metal oxide, the invention changes the chemical reactivity parameters of the glass. This enables effective lubricant layer formation at reduced SO2 concentrations, thereby protecting manufacturing equipment from excessive corrosion while maintaining scratch resistance.
3Ease of manufacture
If SO2 gas is supplied to alkali glass, then a lubricant layer forms easily, but non-alkali glass requires excessive SO2 gas for the same effect
Solution Approach 1:
The invention bridges the gap between alkali and non-alkali glass by partially modifying non-alkali glass composition with alkali metal oxide. This creates an intermediate state where the glass maintains its non-alkali characteristics while gaining the ability to form lubricant layers more efficiently, achieving ease of manufacture comparable to alkali glass with reduced SO2 consumption.
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 effectively prevents scratches on glass surfaces, reduces production costs, and extends the lifespan of manufacturing equipment by forming a sufficient lubricant layer with a smaller amount of SO2 gas, while maintaining high-quality glass production.
Implementation Method 1
a SO2 supply unit for supplying SO2 gas; an O2 supply unit for supplying O2 gas; a catalyst retaining unit for retaining a SO2 gas oxidation catalyst, the catalyst retaining unit receiving SO2 gas and O2 gas from the SO2 supply unit and the O2 supply unit to generate SO3 gas
Implementation Method 2
the formed sulphate serves as a lubricant layer since its film strength is higher than that of a glass, thereby preventing scratches from occurring at the lower surface of the glass
Data Source
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AI summary
An apparatus for forming a lubricant layer on the surface of a glass prevents scratches from occurring at the surface of a glass and decrease corrosion of glass manufacturing equipment and may be included in an annealing furnace or a glass manufacturing apparatus. The apparatus includes a SO2 supply unit for supplying SO2 gas, a O2 supply unit for supplying O2 gas, and a catalyst retaining unit for retaining a SO2 gas oxidation catalyst, the catalyst retaining unit receiving SO2 gas and O2 gas from the SO2 supply unit and the O2 supply unit to generate SO3 gas and supplying the generated SO3 gas to a glass.