Interlocking Refractory Liner for Fusion Draw Glass Stability
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Solution Overview
Problem
In fusion draw glass manufacturing, existing technologies face challenges in maintaining stability and rigidity at high temperatures and protecting glass streams from environmental contamination, particularly due to the brittleness of materials used in high-temperature applications and the need for effective thermal control.
Innovation Solution
A refractory liner structure with an interlocking design using refractory materials like silicon carbide, featuring dovetail joints and an optional adhesive seal, is situated between the muffle housing and the fusion draw isopipes to control thermal properties and prevent contamination, providing superior mechanical stability and structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If refractory materials are used for high-temperature applications, then thermal resistance and stability are improved, but brittleness and susceptibility to tensile loads increase
Solution Approach 1:
The refractory liner is divided into multiple segments or blocks that can be assembled together. This segmentation allows the structure to accommodate thermal expansion and contraction without developing excessive tensile stresses, while maintaining high-temperature stability. The modular design also facilitates installation and replacement without requiring the entire liner to be removed.
Solution Approach 2:
Different regions of the refractory liner are designed with varying material compositions or densities to optimize local performance. Areas subject to higher thermal gradients or mechanical stresses receive enhanced material properties, while other regions are optimized for thermal insulation. This local differentiation allows the liner to withstand high temperatures while managing brittleness through targeted material enhancement.
2Object-affected harmful factors
If a sealed liner structure is used to protect glass streams from contamination, then protection from environmental contamination is improved, but heat loss and thermal control become more challenging
Solution Approach 1:
The refractory liner acts as an intermediary barrier between the glass streams and the external environment. It provides a sealed protective layer that prevents contamination while its refractory properties ensure thermal insulation. The liner's design includes features such as sealed joints and appropriate thickness to maintain thermal efficiency while providing effective contamination protection.
Solution Approach 2:
The liner structure utilizes composite refractory materials that combine different properties in a single system. These composite materials provide both the sealing capability needed for contamination protection and the thermal insulation properties needed to minimize heat loss. The composite structure may include layers with different densities or compositions optimized for either protection or thermal management.
3Stability of the object's composition
If the liner structure is made rigid for structural integrity, then stability at high temperatures is improved, but mechanical stability under thermal stress decreases
Solution Approach 1:
The liner structure incorporates dynamic characteristics that allow it to adapt to thermal conditions. This may include expansion joints, flexible sealing mechanisms, or material compositions that change properties with temperature. The structure maintains rigidity when needed for integrity but can flex or expand to accommodate thermal stress, preventing catastrophic failure and maintaining reliability under varying thermal loads.
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 refractory liner structure ensures maximum material loading in shear and bearing, minimizes tensile loads, and maintains structural integrity at high temperatures, while preventing heat loss and external contamination, thereby enhancing the quality and consistency of the glass production process.
Implementation Method 1
the liner is situated between an outer muffle housing and an internal chamber including the fusion draw isopipes to control thermal properties
Implementation Method 2
protecting the draw glass streams from ambient internal environmental contamination
Data Source
AI summary
An interlocking structure including: a top panel; a first wall and second wall; a first brace and a second brace each having interlocks that interlock with complementary interlocks on the top panel and at least one of the first and second walls. The structure can optionally have an additional interlocking joint, for example, a boss and via, between the top panel and contact point(s) or contact regions of each wall, and the interlocking joint can optionally have an adhesive seal to lock the optional interlocking joints. Also disclosed is a method of making the liner article and methods for using the article for forming glass, as defined herein.