Overlapping Flange Rings for Uniform Vessel Heating
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Solution Overview
Problem
Conventional flange designs for metallic vessels in glass manufacturing fail to distribute electric current uniformly, leading to hot spots and uneven heating of molten glass, which can cause equipment damage and processing inefficiencies, especially in large-scale operations where increased heat energy is required to maintain processing temperatures.
Innovation Solution
The development of flanges with a first ring comprising multiple portions of different thicknesses and materials, where the portions overlap edge-to-edge, directing electric current away from the shortest conduction path to the sides and bottom of the vessel, reducing current density at the top and preventing hot spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If external electrical heating elements are used to heat metallic vessels, then heating can be achieved, but the heating becomes insufficient at large-scale operations requiring higher heat energy
Solution Approach 1:
The patent replaces external electrical heating elements with direct current heating through the metallic vessel wall. Instead of using external heating elements that transfer heat through insulation, the invention establishes an electric current directly in the vessel wall itself, which generates heat internally through resistive heating. This substitution enables sufficient heating for large-scale operations by eliminating the limitations of external heating capacity.
Solution Approach 2:
The metallic vessel wall serves as an intermediary that conducts electric current and transforms electrical energy into thermal energy. The vessel wall acts as both the structural component and the heating element, mediating between the electrical power source and the molten glass, thereby enabling direct heating without external heating elements.
2Use of energy by stationary object
If electric current is applied to heat the vessel, then heating efficiency improves, but non-uniform current distribution causes hot spots and uneven heating
Solution Approach 1:
The patent applies different thicknesses of the metallic vessel wall at different locations to achieve uniform current distribution. The vessel wall is made thinner at locations where current density would naturally be high and thicker where current density would be low, creating local variations in electrical resistance that compensate for geometric effects and result in uniform heating throughout the vessel.
Solution Approach 2:
The invention changes the physical parameter of the vessel wall thickness to control current distribution. By varying the thickness parameter of the metallic wall, the electrical resistance is adjusted at different locations, thereby redistributing the current density to achieve uniform heating and eliminate hot spots.
3Temperature
If current density is increased at the top of the vessel, then heating at that location improves, but hot spots form causing equipment damage
Solution Approach 1:
The patent creates local quality variations in the vessel wall thickness to control current density distribution. The wall is made thinner at the top and bottom where higher current density is needed for heating, and thicker at the sides where lower current density prevents hot spots, thereby achieving both effective heating and equipment protection through localized structural modifications.
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 design ensures uniform heating of the vessel and molten glass, preventing equipment damage and improving processing efficiency by maintaining consistent temperature and viscosity, even at higher production volumes.
Implementation Method 1
heating the vessel and therefore the molten glass within the vessel
Implementation Method 2
establishing an electric current in the vessel itself that heats the vessel
Data Source
Figure 1
Figure 2~3A
Figure 3B~4
AI summary
Disclosed is an apparatus and method of making molten glass. The apparatus includes a vessel for conveying the molten glass and at least one flange configured to supply an electric current to the vessel through the flange, the flange including a first ring extending completely around the vessel in a closed loop, the first ring comprising a first portion including a first thickness and a second portion including a second thickness different from the first thickness, wherein the first portion and the second portion overlap in a plane of the flange such that at least a portion of the first portion is positioned between at least a portion of the second portion and the vessel wall, and neither the first portion nor the second portion extends completely around the vessel. Also disclosed is a method of making glass using the disclosed flange.