Silica-Based Glass Refining via Low-Viscosity Precursor Melt
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Solution Overview
Problem
Conventional processes for producing silica-based glass are slow and energy-intensive due to the time-consuming process of refining molten glass to remove gas bubbles, which requires significant space and high energy input.
Innovation Solution
A process involving the formation of a low-viscosity sodium-calcium-silicate glass precursor melt under reduced pressure, where gas-releasing raw materials are added to promote gas release, followed by mixing with additional glass network formers and modifiers to achieve the desired glass melt composition, reducing viscosity and facilitating faster refining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional in-furnace refining process is used to remove gas bubbles from molten glass, then the glass product achieves desired purity, but the process requires significant time (24 hours) and high energy input
Solution Approach 1:
The patent applies preliminary action by pre-reacting glass network formers and modifiers to form a glass precursor melt with controlled viscosity (1-100 Pa·s) before the main refining process. This preliminary preparation creates a melt that is more amenable to rapid gas bubble removal, reducing the subsequent refining time from conventional 24 hours to significantly shorter durations while maintaining energy efficiency
Solution Approach 2:
The patent employs parameter changes by controlling the viscosity of the glass precursor melt within a specific range (1-100 Pa·s) through selective reaction of network formers and modifiers. This viscosity control optimizes the melt's ability to release gas bubbles during refining, enabling faster processing while achieving the required purity level
2Manufacturing precision
If conventional in-furnace refining process is used to remove gas bubbles from molten glass, then the glass product achieves desired purity, but the process consumes high energy input
Solution Approach 1:
The preliminary formation of glass precursor melt with optimized composition and viscosity reduces the energy required for the subsequent refining step. By preparing the melt in advance with appropriate properties, the system minimizes the energy input needed during the actual gas removal process while still achieving the required purity
Solution Approach 2:
Controlling the viscosity parameter of the glass precursor melt within 1-100 Pa·s optimizes the energy efficiency of the refining process. This parameter control allows gas bubbles to rise and be removed more easily, reducing the energy input required compared to conventional processes that operate with higher viscosity melts
3Productivity
If glass precursor melt with low viscosity (1-100 Pa·s) is formed and refined, then the refining time and energy input are reduced, but the process requires precise control of reaction conditions
Solution Approach 1:
The patent manages process control complexity by defining a specific viscosity range (1-100 Pa·s) for the glass precursor melt. This parameter specification provides clear control targets for the reaction conditions, making the process manageable despite the precision required. The viscosity range acts as a control window that guides the reaction parameters
4Ease of manufacture
If conventional batch materials are used directly in the furnace, then the process is simple, but the refining process is slow and energy-intensive
Solution Approach 1:
The patent introduces a preliminary step where glass network formers and modifiers are reacted to form a glass precursor melt before being introduced to the main furnace for refining. This additional preparation step improves refining efficiency by creating a melt with optimized properties, while the overall process remains relatively simple and can be integrated into existing glass manufacturing workflows
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 approach significantly reduces the energy input and time required for refining, enabling the production of silica-based glass with fewer gas bubbles and improved efficiency by promoting the release of gaseous reaction products and enhancing the rise of bubbles to the surface.
Implementation Method 1
refining the glass precursor melt under reduced pressure
Implementation Method 2
having a viscosity of not more than 30 Pa·s... Target viscosity preferably is less than 15 Pa·s, more preferably less than 8 Pa·s and most preferably not more than 3 Pa·s
Data Source
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AI summary
A process for making silica-based glass includes; (a) forming a glass precursor melt that includes glass network formers and glass network modifiers, the glass precursor melt being at a temperature in the range of 900C to I700C and heaving a viscosity of not more than 30 Pa-s, and (b) refining the glass precursor melt. Either or both steps (a) (b) can include stirring and/or be carried out under reduced pressure to enhance refining. The refined glass precursor melt preferably is mixed with additional materials including silica (SiO2) to form a silica-based glass melt.