U.S. patent application number 17/307315 was filed with the patent office on 2021-11-18 for glass molding apparatus including adjustable cooling nozzles and methods of using the same.
The applicant listed for this patent is CORNING INCORPORATED. Invention is credited to Allan Mark Fredholm.
Application Number | 20210355016 17/307315 |
Document ID | / |
Family ID | 1000005612866 |
Filed Date | 2021-11-18 |
United States Patent
Application |
20210355016 |
Kind Code |
A1 |
Fredholm; Allan Mark |
November 18, 2021 |
GLASS MOLDING APPARATUS INCLUDING ADJUSTABLE COOLING NOZZLES AND
METHODS OF USING THE SAME
Abstract
A molding apparatus for forming a glass article comprises a mold
shell comprising a cooling surface comprising at least a first zone
and a second zone; an adjustable nozzle system comprising a
mold-facing surface having a plurality of apertures sized to
receive a nozzle or a plug; a plurality of nozzles, each coupled to
one of the apertures to direct a stream of fluid onto the cooling
surface; and a fluid supply providing a fluid through the plurality
of nozzles. The fluid is jetted through the nozzles to impinge
against the first zone or the second zone of the cooling surface,
and a number of nozzles through which the fluid is jetted to
impinge against the first zone of the cooling surface is different
than a number of nozzles through which the fluid is jetted to
impinge against the second zone of the cooling surface.
Inventors: |
Fredholm; Allan Mark;
(Vulaines sur Seine, FR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CORNING INCORPORATED |
CORNING |
NY |
US |
|
|
Family ID: |
1000005612866 |
Appl. No.: |
17/307315 |
Filed: |
May 4, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63024068 |
May 13, 2020 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C03B 17/067
20130101 |
International
Class: |
C03B 17/06 20060101
C03B017/06 |
Claims
1. A molding apparatus for forming a glass article comprising: a
mold shell comprising a cooling surface and a glass contact
surface, wherein the cooling surface comprises at least a first
zone and a second zone; and an adjustable nozzle system comprising
a mold-facing surface having a plurality of apertures, sized to
receive a nozzle or a plug; a plurality of nozzles, each of the
plurality of nozzles coupled to and extending through a
corresponding one of the plurality of apertures and oriented to
direct a stream of fluid onto the cooling surface of the mold
shell; a fluid supply coupled to the adjustable nozzle system for
providing a fluid through the plurality of nozzles of the
adjustable nozzle system, wherein: the fluid is jetted through the
plurality of nozzles to impinge against the first zone or the
second zone of the cooling surface of the mold shell; and a number
of nozzles through which the fluid is jetted to impinge against the
first zone of the cooling surface of the mold shell is different
than a number of nozzles through which the fluid is jetted to
impinge against the second zone of the cooling surface of the mold
shell.
2. The molding apparatus according to claim 1, wherein the first
zone and the second zone are thermally isolated from one another by
a deflector extending outward from the cooling surface, a groove in
the cooling surface, or a combination thereof.
3. The molding apparatus according to claim 1, further comprising
at least one plug coupled to a corresponding one of the plurality
of apertures, wherein the at least one plug causes an amount of
fluid impinging against the first zone to differ from an amount of
fluid impinging against the second zone.
4. The molding apparatus according to claim 1, wherein the amount
of fluid impinging against the first zone is greater than an amount
of fluid impinging against the second zone.
5. The molding apparatus according to claim 1, wherein the fluid
supply provides fluid through an inlet in the adjustable nozzle
system, and the fluid exits the adjustable nozzle system through
two or more of the plurality of nozzles.
6. The molding apparatus according to claim 1, wherein: each of the
plurality of nozzles in the adjustable nozzle system is fluidly
coupled to a corresponding inlet of a plurality of inlets; the
fluid supply provides fluid through one or more of the plurality of
inlets; and the fluid exits the corresponding nozzle fluidly
coupled to each of the one or more of the plurality of inlets.
7. A molding apparatus for forming a glass article comprising: a
mold shell comprising a cooling surface and a glass contact
surface, the glass contact surface defining a cavity within the
mold shell for receiving a flow of molten glass, wherein the
cooling surface comprises at least a first zone and a second zone,
wherein the first zone and the second zone are thermally isolated
from one another; and an adjustable nozzle system comprising a
mold-facing surface having a plurality of apertures, sized to
receive a nozzle or a plug; a plurality of nozzles, each of the
plurality of nozzles coupled to and extending through a
corresponding one of the plurality of apertures and oriented to
direct a stream of fluid onto the cooling surface of the mold
shell; and a fluid supply coupled to the adjustable nozzle system
for providing a fluid through the plurality of nozzles of the
adjustable nozzle system, wherein: the fluid is jetted through the
plurality of nozzles to impinge against the first zone or the
second zone of the cooling surface of the mold shell; and a number
of nozzles through which the fluid is jetted to impinge against the
first zone of the cooling surface of the mold shell is different
than a number of nozzles through which the fluid is jetted to
impinge against the second zone of the cooling surface of the mold
shell.
8. The molding apparatus according to claim 7, wherein the cooling
surface comprises a deflector extending outward from the cooling
surface, and wherein the deflector redirects the fluid impinging
the first zone or the second zone to prevent the fluid from
contacting the other of the second zone or the first zone of the
cooling surface of the mold shell.
9. The molding apparatus according to claim 8, wherein the cooling
surface further comprises at least one groove between the first
zone and the second zone.
10. The molding apparatus according to claim 9, wherein the at
least one deflector extends outward from the cooling surface along
a longitudinal edge of the at least one groove.
11. The molding apparatus according to claim 7, wherein the cooling
surface comprises at least one groove between the first zone and
the second zone.
12. The molding apparatus according to claim 7, further comprising
at least one plug coupled to a corresponding one of the plurality
of apertures, wherein the at least one plug causes an amount of
fluid impinging against the first zone to differ from an amount of
fluid impinging against the second zone.
13. The molding apparatus according to claim 7, wherein the first
zone is disposed adjacent a glass inlet into which molten glass is
flowed and the second zone is disposed adjacent a glass outlet of
which a solid glass article is produced.
14. The molding apparatus according to claim 7, wherein the amount
of fluid impinging the first zone is greater than an amount of
fluid impinging the second zone.
15. The molding apparatus according to claim 7, wherein the fluid
supply provides fluid through an inlet in the adjustable nozzle
system, and the fluid exits the adjustable nozzle system through
two or more of the plurality of nozzles.
16. The molding apparatus according to claim 7, wherein: each of
the plurality of nozzles in the adjustable nozzle system is fluidly
coupled to a corresponding inlet of a plurality of inlets; the
fluid supply provides fluid through one or more of the plurality of
inlets; and the fluid exits the corresponding nozzle fluidly
coupled to each of the one or more of the plurality of inlets.
17. A method of cooling molten glass to form a glass article
comprising: flowing molten glass into a cavity defined by a cooling
surface of a mold shell, wherein the cooling surface comprises at
least a first zone and a second zone, wherein the first zone and
the second zone are thermally isolated from one another; supplying
fluid to an adjustable nozzle system comprising a mold-facing
surface having a plurality of apertures, each of the plurality of
apertures sized to receive one of a nozzle or a plug; and jetting
the fluid through the plurality of nozzles, each of the plurality
of nozzles coupled to and extending through a corresponding one of
the plurality of apertures and oriented to direct a stream of fluid
onto the cooling surface of the mold shell, to impinge against the
first zone to cause a first cooling intensity and to impinge
against the second zone of the cooling surface to cause a second
cooling intensity, the first cooling intensity and the second
cooling intensity drawing heat away from the molten glass, thereby
cooling the molten glass to form a glass article, wherein the
second cooling intensity is different from the first cooling
intensity.
18. The method of claim 17, wherein a number of the plurality of
nozzles directing a stream of fluid to impinge against the first
zone is greater than a number of the plurality of nozzles directing
a stream of fluid to impinge against the second zone.
19. The method of claim 17, wherein a temperature of the fluid
impinging against the first zone is less than a temperature of the
fluid impinging against the second zone.
20. The method of claim 17, wherein the cooling surface comprises a
deflector extending outward from the cooling surface, and wherein
the deflector redirects the fluid impinging the first zone or the
second zone to prevent the fluid from contacting the other of the
second zone or the first zone of the cooling surface of the mold
shell.
Description
[0001] This application claims priority under 35 USC .sctn. 119(e)
from U.S. Provisional Patent Application Ser. No. 63/024,068 filed
on May 13, 2020 which is incorporated by reference herein in its
entirety.
FIELD
[0002] The present specification generally relates to molds and,
more particularly, to molds for forming glass articles.
BACKGROUND
[0003] Conventional processes for forming glass articles may
include the use of at least one mold. Although various molding
technologies are available, a challenge common among many such
technologies is establishing an adequate heat extraction rate.
Inadequate heat extraction rates can lead to cosmetic defects in
the resultant glass article, such as wavy surfaces, and/or to
mechanical defects, such as cracks, when the mold is too cold.
Conversely, when the mold is too, glass may stick to the glass
contact surface of the mold.
[0004] Conventional molding processes typically rely on one or more
cooling types, such as fan blown air, compressed air, or water or
other liquid cooling. The use of water cooling is limited by the
temperature of the surface to be cooled, which must be between
about room temperature and about 140.degree. C. Although air
cooling is not temperature limited, heat transfer coefficients of
air cooling methods are limited to around 500 W/m.sup.2K, which is
well below the heat transfer coefficients of water cooling, which
can be up to around 10,000 W/m.sup.2K for forced convection regimes
or even higher for other regimes.
[0005] In addition, some molding applications have variable heat
extraction rate targets over the surface of the mold. For example,
some molding applications have areas that require a large amount of
heat removal as well as areas that require a relatively lower
amount of heat removal.
[0006] Accordingly, a need exists for molding apparatuses with
tunable heat extraction rates over a cooling surface of the
mold.
SUMMARY
[0007] Various embodiments described herein enable adjustment of
the heat extraction within a number of zones through the use of a
molding apparatus comprising a mold shell comprising a cooling
surface and a glass contact surface, an adjustable nozzle system
comprising a mold-facing surface having a plurality of apertures,
and a plurality of nozzles, each of which is coupled to and extends
through a corresponding one of the plurality of apertures. The
molding apparatus further includes a fluid supply coupled to the
adjustable nozzle system for providing a fluid through the
plurality of nozzles to impinge against a first zone or a second
zone of the cooling surface of the mold shell. A number of nozzles
through which a fluid is jetted to impinge against the first zone
of a cooling surface differs from a number of nozzles through which
a fluid is jetted to impinge against a second zone of the cooling
surface of the mold shell, thereby providing different cooling
rates at the first zone and the second zone.
[0008] According to a first aspect disclosed herein, a molding
apparatus for forming a glass article comprises a mold shell
comprising a cooling surface and a glass contact surface, wherein
the cooling surface comprises at least a first zone and a second
zone; an adjustable nozzle system comprising a mold-facing surface
having a plurality of apertures, sized to receive a nozzle or a
plug; a plurality of nozzles, each of the plurality of nozzles
coupled to and extending through a corresponding one of the
plurality of apertures and oriented to direct a stream of fluid
onto the cooling surface of the mold shell; and a fluid supply
coupled to the adjustable nozzle system for providing a fluid
through the plurality of nozzles of the adjustable nozzle system,
wherein: the fluid is jetted through the plurality of nozzles to
impinge against the first zone or the second zone of the cooling
surface of the mold shell; and a number of nozzles through which
the fluid is jetted to impinge against the first zone of the
cooling surface of the mold shell is different than a number of
nozzles through which the fluid is jetted to impinge against the
second zone of the cooling surface of the mold shell.
[0009] According to a second aspect disclosed herein, a molding
apparatus comprises the molding apparatus of the first aspect,
wherein the first zone and the second zone are thermally isolated
from one another by a deflector extending outward from the cooling
surface, a groove in the cooling surface, or a combination
thereof.
[0010] According to a third aspect disclosed herein, a molding
apparatus comprises the molding apparatus of the first or second
aspects, further comprising at least one plug coupled to a
corresponding one of the plurality of apertures, wherein the at
least one plug causes an amount of fluid impinging against the
first zone to differ from an amount of fluid impinging against the
second zone.
[0011] According to a fourth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the previous
aspects, wherein the amount of fluid impinging against the first
zone is greater than an amount of fluid impinging against the
second zone.
[0012] According to a fifth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the previous
aspects, wherein the fluid supply provides fluid through an inlet
in the adjustable nozzle system, and the fluid exits the adjustable
nozzle system through two or more of the plurality of nozzles.
[0013] According to a sixth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the first
through fourth aspects, wherein: each of the plurality of nozzles
in the adjustable nozzle system is fluidly coupled to a
corresponding inlet of a plurality of inlets; the fluid supply
provides fluid through one or more of the plurality of inlets; and
the fluid exits the corresponding nozzle fluidly coupled to each of
the one or more of the plurality of inlets.
[0014] According to a seventh aspect disclosed herein, a molding
apparatus for forming a glass article comprises: a mold shell
comprising a cooling surface and a glass contact surface, the glass
contact surface defining a cavity within the mold shell for
receiving a flow of molten glass, wherein the cooling surface
comprises at least a first zone and a second zone, wherein the
first zone and the second zone are thermally isolated from one
another; an adjustable nozzle system comprising a mold-facing
surface having a plurality of apertures, sized to receive a nozzle
or a plug; a plurality of nozzles, each of the plurality of nozzles
coupled to and extending through a corresponding one of the
plurality of apertures and oriented to direct a stream of fluid
onto the cooling surface of the mold shell; and a fluid supply
coupled to the adjustable nozzle system for providing a fluid
through the plurality of nozzles of the adjustable nozzle system,
wherein: the fluid is jetted through the plurality of nozzles to
impinge against the first zone or the second zone of the cooling
surface of the mold shell; and a number of nozzles through which
the fluid is jetted to impinge against the first zone of the
cooling surface of the mold shell is different than a number of
nozzles through which the fluid is jetted to impinge against the
second zone of the cooling surface of the mold shell.
[0015] According to an eighth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of the seventh aspects,
wherein the cooling surface comprises a deflector extending outward
from the cooling surface, and wherein the deflector redirects the
fluid impinging the first zone or the second zone to prevent the
fluid from contacting the other of the second zone or the first
zone of the cooling surface of the mold shell.
[0016] According to a ninth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of the seventh or eighth
aspects, wherein the cooling surface further comprises at least one
groove between the first zone and the second zone.
[0017] According to a tenth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the eighth or
ninth aspects, wherein the at least one deflector extends outward
from the cooling surface along a longitudinal edge of the at least
one groove.
[0018] According to an eleventh aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the seventh
through tenth aspects, wherein the cooling surface comprises at
least one groove between the first zone and the second zone.
[0019] According to a twelfth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the seventh
through eleventh aspects, further comprising at least one plug
coupled to a corresponding one of the plurality of apertures,
wherein the at least one plug causes an amount of fluid impinging
against the first zone to differ from an amount of fluid impinging
against the second zone.
[0020] According to a thirteenth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the seventh
through twelfth aspects, wherein the first zone is disposed
adjacent a glass inlet into which molten glass is flowed and the
second zone is disposed adjacent a glass outlet of which a solid
glass article is produced.
[0021] According to a fourteenth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the seventh
through thirteenth aspects, wherein the amount of fluid impinging
the first zone is greater than an amount of fluid impinging the
second zone.
[0022] According to a fifteenth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the seventh
through fourteenth aspects, wherein the fluid supply provides fluid
through an inlet in the adjustable nozzle system, and the fluid
exits the adjustable nozzle system through two or more of the
plurality of nozzles.
[0023] According to a sixteenth aspect disclosed herein, a molding
apparatus comprises the molding apparatus of any of the seventh
through fourteenth aspects, wherein: each of the plurality of
nozzles in the adjustable nozzle system is fluidly coupled to a
corresponding inlet of a plurality of inlets; the fluid supply
provides fluid through one or more of the plurality of inlets; and
the fluid exits the corresponding nozzle fluidly coupled to each of
the one or more of the plurality of inlets.
[0024] According to a seventeenth aspect disclosed herein, a method
of cooling molten glass to form a glass article comprises: flowing
molten glass into a cavity defined by a cooling surface of a mold
shell, wherein the cooling surface comprises at least a first zone
and a second zone, wherein the first zone and the second zone are
thermally isolated from one another; supplying fluid to an
adjustable nozzle system comprising a mold-facing surface having a
plurality of apertures, each of the plurality of apertures sized to
receive one of a nozzle or a plug; and jetting the fluid through
the plurality of nozzles, each of the plurality of nozzles coupled
to and extending through a corresponding one of the plurality of
apertures and oriented to direct a stream of fluid onto the cooling
surface of the mold shell, to impinge against the first zone to
cause a first cooling intensity and to impinge against the second
zone of the cooling surface to cause a second cooling intensity,
the first cooling intensity and the second cooling intensity
drawing heat away from the molten glass, thereby cooling the molten
glass to form a glass article, wherein the second cooling intensity
is different from the first cooling intensity.
[0025] According to an eighteenth aspect disclosed herein, a method
comprises the method of the seventeenth aspect, wherein a number of
the plurality of nozzles directing a stream of fluid to impinge
against the first zone is greater than a number of the plurality of
nozzles directing a stream of fluid to impinge against the second
zone.
[0026] According to a nineteenth aspect disclosed herein, a method
comprises the method of the seventeenth or eighteenth aspects,
wherein a temperature of the fluid impinging against the first zone
is less than a temperature of the fluid impinging against the
second zone.
[0027] According to a twentieth aspect disclosed herein, a method
comprises the method of any of the seventeenth through nineteenth
aspects, wherein the cooling surface comprises a deflector
extending outward from the cooling surface, and wherein the
deflector redirects the fluid impinging the first zone or the
second zone to prevent the fluid from contacting the other of the
second zone or the first zone of the cooling surface of the mold
shell.
[0028] Additional features and advantages will be set forth in the
detailed description, which follows, and in part will be readily
apparent to those skilled in the art from that description or
recognized by practicing the embodiments described herein,
including the detailed description, which follows, the claims, as
well as the appended drawings.
[0029] It is to be understood that both the foregoing general
description and the following detailed description describe various
embodiments and are intended to provide an overview or framework
for understanding the nature and character of the claimed subject
matter. The accompanying drawings are included to provide a further
understanding of the various embodiments, and are incorporated into
and constitute a part of this specification. The drawings
illustrate the various embodiments described herein, and together
with the description serve to explain the principles and operations
of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1A illustrates a molding apparatus including adjustable
cooling nozzles in a glass casting process in accordance with one
or more embodiments shown and described herein;
[0031] FIG. 1B illustrates the cooling surface of the molding
apparatus of FIG. 1A in greater detail in accordance with one or
more embodiments shown and described herein;
[0032] FIG. 1C illustrates the mold-facing surface of the
adjustable nozzle system shown in FIG. 1A including a plurality of
nozzles extending through the apertures in accordance with one or
more embodiments shown and described herein;
[0033] FIG. 2 illustrates an example adjustable nozzle system in
accordance with one or more embodiments shown and described
herein;
[0034] FIG. 3 illustrates another example adjustable nozzle system
in accordance with one or more embodiments shown and described
herein;
[0035] FIG. 4A illustrates an example adjustable nozzle system in
which some apertures have different diameters than other apertures
in the adjustable nozzle system in accordance with one or more
embodiments shown and described herein;
[0036] FIG. 4B illustrates an example adjustable nozzle system in
which nozzles having different diameters are adapted to fit
apertures of a constant diameter in accordance with one or more
embodiments shown and described herein;
[0037] FIG. 4C illustrates an example size adjuster used to couple
nozzles having smaller diameters with apertures having a larger
diameter in accordance with one or more embodiments shown and
described herein;
[0038] FIG. 5A illustrates an example fluid supply system for
supplying fluid to an adjustable nozzle system through a single
inlet in accordance with one or more embodiments shown and
described herein;
[0039] FIG. 5B illustrates an example fluid supply system for
supplying fluid to an adjustable nozzle system in which each nozzle
is provided fluid by a corresponding inlet in accordance with one
or more embodiments shown and described herein;
[0040] FIG. 5C illustrates an example fluid supply system for
supplying fluid to an adjustable nozzle system in which an inlet
provides fluid to all of the nozzles in a particular zone in
accordance with one or more embodiments shown and described
herein;
[0041] FIG. 6A illustrates a molding apparatus including adjustable
cooling nozzles in a glass pressing process in accordance with one
or more embodiments shown and described herein; and
[0042] FIG. 6B illustrates the molding apparatus of FIG. 6A with
the mold shell removed to expose the adjustable nozzle system in
accordance with one or more embodiments shown and described
herein.
DETAILED DESCRIPTION
[0043] Reference will now be made in detail to various embodiments
of molding apparatuses and methods of using the same, examples of
which are illustrated in the accompanying drawings. Whenever
possible, the same reference numerals will be used throughout the
drawings to refer to the same or like parts.
[0044] Ranges can be expressed herein as from "about" one
particular value, and/or to "about" another particular value. When
such a range is expressed, another embodiment includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by use of the
antecedent "about," it will be understood that the particular value
forms another embodiment. It will be further understood that the
endpoints of each of the ranges are significant both in relation to
the other endpoint, and independently of the other endpoint.
[0045] Directional terms as used herein--for example up, down,
right, left, front, back, top, bottom--are made only with reference
to the figures as drawn and are not intended to imply ab solute
orientation.
[0046] Unless otherwise expressly stated, it is in no way intended
that any method set forth herein be construed as requiring that its
steps be performed in a specific order, nor that with any apparatus
specific orientations be required. Accordingly, where a method
claim does not actually recite an order to be followed by its
steps, or that any apparatus claim does not actually recite an
order or orientation to individual components, or it is not
otherwise specifically stated in the claims or description that the
steps are to be limited to a specific order, or that a specific
order or orientation to components of an apparatus is not recited,
it is in no way intended that an order or orientation be inferred,
in any respect. This holds for any possible non-express basis for
interpretation, including: matters of logic with respect to
arrangement of steps, operational flow, order of components, or
orientation of components; plain meaning derived from grammatical
organization or punctuation, and; the number or type of embodiments
described in the specification.
[0047] As used herein, the singular forms "a," "an" and "the"
include plural referents unless the context clearly dictates
otherwise. Thus, for example, reference to "a" component includes
aspects having two or more such components, unless the context
clearly indicates otherwise.
[0048] FIG. 1A depicts a molding apparatus 100 for forming a glass
article in a casting process. The molding apparatus 100 includes a
mold shell 102 comprising a cooling surface 104 through which heat
is extracted from the glass article being formed and a glass
contact surface 106 that is in contact with the glass article being
formed. In embodiments, the glass contact surface 106 is thermally
coupled to the cooling surface 104. In embodiments, the glass
contact surface 106 defines a cavity 107 within the mold shell 102
for receiving a flow of molten glass 12. As shown in FIG. 1A, the
molten glass 12 flows into the cavity 107 of the mold shell 102
through an inlet end 109 and a glass article 14 exits the cavity
107 of the mold shell 102 through an outlet end 111. In
embodiments, the molding apparatus 100 may be incorporated into a
glass casting line 10 that also includes a glass delivery tube 16
for delivering the flow of molten glass 12 to the cavity 107 of the
mold shell 102 and one more pulling rollers 18 for pulling the
glass article 14 out of the molding apparatus 100. Other components
can be included in the glass casting line 10, as will be recognized
by those of ordinary skill in the art.
[0049] The mold shell 102 may be made of a material capable of
withstanding high temperatures, such as temperatures that are
encountered while forming the glass article. The material may be
one that will not react with (e.g., stick to) the glass under
forming conditions. Alternatively, the glass contact surface 106
may be coated with a coating material that will not react with
(e.g., stick to) the glass under forming conditions. For example,
in embodiments, the mold shell 102 is made of a non-reactive carbon
material, such as graphite, and the glass contact surface 106 is
highly polished to avoid introducing defects into the glass when
the glass contact surface 106 is in contact with the glass. As
another example, in embodiments, the mold shell 102 is made of a
dense ceramic material, such as silicon carbide, tungsten carbide,
and/or silicon nitride, and the glass contact surface 106 is coated
with a hard ceramic material, such as titanium aluminum nitride.
However, it should be understood that other materials are
contemplated and possible, including, but not limited to stainless
steel, bronze, and nickel alloys.
[0050] The cooling surface 104 includes two or more zones,
collectively referred to herein by reference number 108. Although
the embodiment shown in FIG. 1A includes twelve distinct zones, it
is contemplated that as few as two zones or as many as twenty-five
or more zones may be included in the cooling surface 104. The
number of zones can vary, for example, based on the surface area of
the cooling surface, the number of nozzles, the cooling fluid
employed, or the application in which the molding apparatus is
used.
[0051] In various embodiments, each zone 108a is thermally isolated
from each adjacent zone 108b, 108c, and 108d. The zones 108 can be
thermally isolated from one another by a deflector 110 extending
outward from the cooling surface 104, a groove 112 in the cooling
surface 104, or a combination thereof, as depicted in FIG. 1B. In
embodiments including deflectors 110 and grooves 112, the
deflectors 110 may be positioned around or adjacent the grooves
112, or the deflectors 110 and grooves 112 may be located in
different locations. In embodiments, such as the embodiment shown
in FIG. 1B, at least one deflector 110 extends outward from the
cooling surface along a longitudinal edge of a groove 112. As
specifically shown in FIG. 1B, a deflector 110 extends outward from
each longitudinal edge of each groove 112. However, other
orientations and combinations are possible and contemplated. For
example, although the embodiment shown in FIGS. 1A and 1B includes
both deflectors 110 and grooves 112, it is contemplated that
embodiments may include deflectors 110 and not grooves, or grooves
112 and not deflectors. Moreover, although the embodiment shown in
FIGS. 1A and 1B includes deflectors 110 and grooves 112 at each
interface between the zones, it is contemplated that embodiments
may include a different combination of deflectors and grooves. For
example, the cooling surface 104 may include a deflector 110 to
thermally isolate each zone 108a from a zone 108c that is
vertically adjacent (e.g., above/below), and a groove 112 to
thermally isolate the zone 108a from a zone 108b that is
horizontally adjacent (e.g., next to). Other arrangements are
possible and contemplated.
[0052] The molding apparatus 100 also includes an adjustable nozzle
system 114 having a mold-facing surface 116 having a plurality of
apertures, collectively referred to herein as apertures 118, as
depicted in FIG. 1C. Each of the apertures 118 is sized to receive
a nozzle or a plug, as will be described in greater detail below.
In embodiments, each of the apertures 118 includes interior
threading (not shown), which can enable the corresponding nozzle or
plug to be secured in place, although in embodiments, threading is
not included.
[0053] As shown in FIG. 1C, the molding apparatus 100 includes a
plurality of nozzles, collectively referred to herein as nozzles
120. Each of the nozzles 120 is coupled to and extends through a
corresponding one of the apertures 118, such that each nozzle 120a
extends through an aperture 118a in the mold-facing surface 116.
When coupled to the corresponding aperture, each of the nozzles 120
is oriented such that it can direct a stream of fluid onto the
cooling surface 104 of the mold shell 102.
[0054] In the embodiments described herein, the molding apparatus
100 further includes a fluid supply 122 coupled to the adjustable
nozzle system 114 for providing a fluid through the plurality of
nozzles 120. In embodiments, the fluid supply 122 is coupled to the
adjustable nozzle system 114 through tubing or piping, one or more
pumps, and other optional fluid delivery system components, such as
filters, valves, and the like. In embodiments, the fluid supply 122
may include or be coupled to at least one cooling device configured
to control a temperature of the fluid supplied to the nozzles 120.
For example, a heat sink, a thermoelectric cooler, or another type
of cooling device can be coupled to or positioned within the fluid
supply 122 to adjust the temperature of the fluid. In embodiments,
a thermostat is additionally coupled to the fluid supply 122 to
measure and/or monitor the temperature of the fluid supply 122. As
will be appreciated, the thermostat, cooling device, pump, and
other components of the fluid delivery system can be
communicatively coupled to a control unit (not shown) that directs
the operation of the fluid delivery system to enable fluid to be
supplied from the fluid supply 122 to the nozzles 120.
[0055] In embodiments, the fluid supplied to the nozzles 120 may be
any suitable liquid or gas. For example, the fluid may be an oil,
water, or other fluid composition that has high thermal capacity
and low viscosity. Although a wide variety of fluids are
contemplated and possible, in embodiments, the fluid is water.
[0056] The fluid supplied by the fluid supply 122 is jetted through
the nozzles 120 to impinge against the cooling surface 104 to
remove heat from the mold shell 102 that is imparted to the mold
shell 102 by the glass in contact with the glass contact surface
106 of the mold shell 102. When included, each deflector 110 is of
a size and shape to deflect fluid that has impinged the cooling
surface 104 away from the cooling surface 104 after impingement.
For example, fluid that has impinged the zone 108a is directed away
from the cooling surface 104 by deflector 110a such that the fluid
does not run down the cooling surface 104 and also contact zone
108c or other zones below zone 108a. Deflectors in other
orientations can block splash of the fluid during or after
impingement on the cooling surface 104, in addition to or as an
alternative to acting as a thermal shield between adjacent
zones.
[0057] In various embodiments, the cooling in each zone 108 is
individually controllable and varies from one zone to another.
Accordingly, in various embodiments, the fluid impinging against
the first zone causes a first cooling intensity and the fluid
impinging against the second zone causes a second cooling intensity
that is different from the first cooling intensity. As used herein,
the "cooling intensity" is represented by the magnitude of the heat
transfer coefficient of each zone. The different cooling
intensities can be generated, for example, by varying a number of
nozzles for each of the zones, varying a temperature of the fluid
for each of the zones, varying an amount of fluid impinging against
each of the zones, or combinations thereof. As used herein, when a
parameter is referred to as varying for each of the zones, it is
meant that the parameter for one zone is different than the
parameter for another, different zone, in contrast to the parameter
varying over the zone.
[0058] In embodiments in which the cooling intensity is varied by
varying a number of nozzles for each of the zones, it is
contemplated that the number of nozzles directing fluid toward each
zone of the cooling surface can be varied according to any one or
more of a number of ways. For example, the number of apertures 118a
in the adjustable nozzle system proximate a zone 108a may differ
from the number of apertures 118c in the adjustable nozzle system
proximate a zone 108c, as shown in FIG. 2. Alternatively or
additionally, in embodiments, the number of nozzles 120a through
which fluid is jetted to impinge against zone 108a differs from the
number of nozzles 120c through which fluid is jetted to impinge
against zone 108c. The number of nozzles 120 can vary because of a
differing number of apertures 118 for each of the zones 108a, 108c,
or because one or more of the apertures 118c does not include a
nozzle 120, as shown in FIG. 3.
[0059] In the embodiment shown in FIG. 3, the molding apparatus 100
includes at least one plug 300 that is coupled to a corresponding
aperture 118. The plug 300 causes an amount of fluid impinging
against the zone 108a to differ from an amount of fluid impinging
against the zone 108b by reducing the number of apertures available
for coupling with nozzles. The use of plugs 300 enables the number
of apertures 118 that are coupled to nozzles 120 and the number of
apertures 118 that are coupled to plugs 300 to be varied without
requiring the adjustable nozzle system to be replaced, retooled, or
the like. Instead, in order to increase the cooling intensity in a
particular zone, one or more plugs 300 can be removed from the
corresponding apertures 118 and a nozzle 120 can be coupled to each
open aperture 118.
[0060] Accordingly, in embodiments, each aperture 118 can be
coupled to either a nozzle 120 or a plug 300. To facilitate such
coupling, in embodiments in which the apertures 118 include
internal threading, each nozzle 120 and plug 300 includes
corresponding external threading 302 and is sized to be coupled
with an aperture 118. Similarly, in embodiments in which the
apertures 118 do not include internal threading, each nozzle 120
and plug 300 do not have external threading and may instead, for
example, have a substantially smooth exterior surface such that the
nozzle 120 or plug 300 slides into and out of the aperture 118.
[0061] The size and shape of the plug 300 are not limited, provided
the plug 300 reduces the amount of fluid, or even prevents fluid,
from passing through the aperture 118 to which it is coupled,
thereby reducing the amount of fluid impinging on the corresponding
zone 108c (not shown in FIG. 3) of the cooling surface. Similarly,
the size and shape of the nozzle 120 are not limited, provided the
nozzle 120 is operable to direct a stream of fluid onto the cooling
surface. For example, in embodiments, the nozzle 120 may be an
adjustable nozzle 120 through which the stream of fluid can be
adjusted. In embodiments, the nozzle 120 may be closed to prevent
fluid from flowing therethrough.
[0062] As set forth above, in embodiments, the cooling intensity
may also be varied between the different zones by varying an amount
of fluid impinging against each of the zones. The amount of fluid
can be varied as described above, such as by providing a different
number of nozzles through which fluid impinges a first zone as
compared to a number of nozzles through which fluid impinges a
second zone. However, the amount of fluid can be varied in a number
of other ways while the number of nozzles remains unchanged.
Enabling the amount of fluid to be adjusted without changing the
number of nozzles can enable embodiments to provide adjustable
cooling intensity during the forming of a glass article (e.g.,
while the molding apparatus is in use). For example, in
embodiments, one or more of the nozzles 120 may be an adjustable
nozzle 120 through which the stream of fluid can be adjusted. In
embodiments, the nozzle 120 may be partially or fully closed to
reduce or even prevent fluid from flowing therethrough.
[0063] In embodiments, one or more of the nozzles may be of a
different size than one or more other nozzles included in the
adjustable nozzle system. As shown in FIGS. 4A and 4B, for example,
nozzles 120a have a diameter D.sub.1 that is larger than a
corresponding diameter D.sub.2 of nozzles 120c. In some such
embodiments, such as shown in FIG. 4A, some apertures 118c (e.g.,
those corresponding to nozzles 120c) have a diameter D.sub.3 that
is larger than a corresponding diameter D.sub.4 of other apertures
118c (e.g., those corresponding to nozzles 120c). In other such
embodiments, such as shown in FIG. 4B, each of the apertures 118 in
the adjustable nozzle system has the same diameter Da that is sized
to receive the larger nozzles 120b, and the smaller nozzles 120c
can be coupled to the apertures through a size adjuster 400. As
shown in FIG. 4C, the size adjuster 400 has a wall 402 that defines
an inner diameter 404 that is sized to receive the smaller nozzle
120c and an outer diameter 406 that is sized to fit within the
aperture 118. Other methods of coupling the nozzles with the
apertures are contemplated and possible.
[0064] Additionally or alternatively, in embodiments, the amount of
fluid impinging against a zone 108 of the cooling surface 104 can
be varied by varying the amount of fluid provided to one or more
nozzles through an inlet 500 of the adjustable nozzle system, as
shown in FIGS. 5A, 5B, and 5C. In embodiments, the fluid supply
provides fluid to the adjustable nozzle system through the inlet
500, and the fluid exits the adjustable nozzle system through one
or more nozzles 120. The number of nozzles 120 that are fluidly
coupled with the inlet 500 can vary depending on the particular
embodiment. For example, a single inlet 500 can be coupled to all
of the nozzles 120 in the adjustable nozzle system through a common
plenum 502, as shown in FIG. 5A, or multiple inlets can be used to
provide fluid to all of the nozzles 120 through multiple plenums
502, as shown in FIGS. 5B and 4C. In embodiments, an inlet 500 can
provide fluid to, for example, one nozzle 120 (FIG. 5B), two or
more nozzles, all of the nozzles directing fluid to one zone (FIG.
5C), or all of the nozzles directing fluid to more than one, but
less than all, of the zones of the cooling surface. Embodiments in
which multiple inlets are used to provide fluid to the nozzles can
enable the flow of fluid to the nozzles to which a first inlet is
coupled to be controlled independently of the flow of fluid to the
nozzles to which a second inlet is coupled.
[0065] In embodiments, control through an inlet can be controlled
by increasing or decreasing a flow rate, including, for example,
stopping the flow of fluid through the inlet. In embodiments, the
flow (e.g., through the inlet, the nozzles, or both) can be
controlled to provide a pulsed flow of fluid. Additionally or
alternatively, in embodiments, the fluid provided through a first
inlet can have a temperature that is different than a temperature
of the fluid provided through a second inlet. Accordingly, as set
forth above, in embodiments, the cooling intensity may also be
varied between the different zones by varying a temperature of the
fluid for each of the zones.
[0066] For example, the fluid provided to one inlet to impinge on a
first zone 108a of the cooling surface can have a lower temperature
and/or increased flow rate than the temperature and/or flow rate of
the fluid provided to another inlet to impinge on a second zone
108c such that the cooling intensity of the first zone 108a is
greater than the cooling intensity of the second zone 108c. Thus,
referring back to FIG. 1A, the molding apparatus 100 can be cooled
at a greater intensity near the inlet end 109 of the mold shell 102
than near the outlet end 111 of the mold shell 102.
[0067] Although FIG. 1A depicts the molding apparatus 100 as being
incorporated into a glass casting line 10, it is contemplated that
various embodiments of the molding apparatus 100 can be used in
other glass forming methods, such as, by way of example and not
limitation, glass pressing methods, as shown in FIGS. 6A and 6B. In
FIG. 6A, the molding apparatus 100 is oriented such that the glass
is placed on the glass contact surface 106 of the mold shell 102
instead of being directed into a cavity defined by the mold shell
102 in the form of molten glass. FIG. 6B depicts the molding
apparatus 100 of FIG. 6A with the mold shell 102 removed to expose
the mold-facing surface 116 of the adjustable nozzle system 114. In
embodiments, each zone 108 extends along and lies within the same
substantially horizontal plane and deflectors 110 extend outward
from that plane. Accordingly, it is contemplated that although the
molding apparatus 100 is described herein with respect to certain
orientations, the molding apparatus 100 may be otherwise oriented
depending on the particular embodiment described herein and, in
particular, depending on the particular glass forming process in
which it is employed.
[0068] Having described various embodiments of glass molding
apparatuses in detail, methods of using the glass molding apparatus
will now be described. When used in a glass casting line 10, as
shown in FIG. 1, a flow of molten glass 12 is poured into the
cavity 107 of the mold shell 102 through a glass delivery tube 16.
The flow of molten glass 12 enters the inlet end 109 of the cavity
107, and heat is transferred from the molten glass 12 to the glass
contact surface 106. Fluid is supplied to the nozzles 120 by the
fluid supply 122, and the nozzles 120 direct the fluid to a
corresponding one of the zones 108 of the cooling surface 104.
[0069] The heat from the molten glass 12 is transferred from the
glass contact surface 106 to the cooling surface 104 via
conduction. The heat is then transferred from the cooling surface
104 to the fluid via convection as the fluid impinges the cooling
surface 104. Cooling can be adjusted by adjusting the temperature
or flow of the cooling fluid through one or more of the nozzles, or
by replacing one or more of the nozzles with a plug, depending on
the particular embodiment.
[0070] In the embodiment shown in FIG. 1, the glass contact surface
proximate zone 108a removes a greater amount of heat from the flow
of molten glass than the glass contact surface proximate zone 108b,
reducing the temperature of the flow of molten glass and enabling
the glass to solidify. As the glass solidifies, it is pulled
through the outlet end 111 of the cavity 107 by one or more pulling
rollers 18 as a glass article 14. The rate of speed of the pulling
rollers 18 can be adjusted by a control unit to draw the glass
article 14 from the molding apparatus 100 at a predetermined rate
to ensure that the glass resides in the cavity 107 for a sufficient
time to solidify. In embodiments, after it is pulled from the
molding apparatus 100, the glass article 14 is subjected to
additional processing, which may include, by way of example and not
limitation, cutting, rolling, and annealing.
[0071] When used in a glass pressing method, as shown in FIGS. 6A
and 6B, a flow of molten glass 12 is poured into the cavity 107 of
the mold shell 102. In embodiments, a plunger (not shown) is used
to apply pressure to the molten glass and to force the molten glass
into contact with the glass contact surface 106. Heat is
transferred from the molten glass 12 to the glass contact surface
106. Fluid is supplied to the nozzles 120 by the fluid supply 122,
and the nozzles 120 direct the fluid to a corresponding one of the
zones 108 of the cooling surface 104.
[0072] The heat from the molten glass 12 is transferred from the
glass contact surface 106 to the cooling surface 104 via
conduction. The heat is then transferred from the cooling surface
104 to the fluid via convection as the fluid impinges the cooling
surface 104. Cooling can be adjusted by adjusting the temperature
or flow of the cooling fluid through one or more of the nozzles, or
by replacing one or more of the nozzles with a plug, depending on
the particular embodiment.
[0073] In the embodiment shown in FIG. 6A, the glass contact
surface proximate zone 108a removes a greater amount of heat from
the flow of molten glass than the glass contact surface proximate
zone 108b, reducing the temperature of the flow of molten glass and
enabling the glass to solidify. Following solidification, the glass
article 14 is removed from the molding apparatus 100, according to
methods known and used in the art. In embodiments, after it is
removed from the molding apparatus 100, the glass article 14 is
subjected to additional processing, which may include, by way of
example and not limitation, cutting and annealing.
[0074] In various embodiments described herein, the molding
apparatus including an adjustable nozzle system enables heat
extraction during a glass molding step to be adjusted over the area
of the molding surface. In particular, the use of an adjustable
nozzle system as described in various embodiments enables fluid
impinged against a plurality of thermally isolated zones of a
cooling surface of a glass mold to be adjusted according to zone
such that one zone may be cooled at a rate that is different from a
rate of another zone. The number of nozzles, size of nozzles,
temperature of fluid passing through the nozzles, or speed of fluid
passing through the nozzles can be adjusted to control a cooling
intensity or heat extraction rate at each of the zones on the
cooling surface. Accordingly, a molding apparatus can be used in a
variety of molding processes, and can be tuned to provide a target
cooling intensity at different points on the glass contact surface,
such as a higher cooling intensity at areas proximate an inlet for
molten glass and a lower cooling intensity at areas proximate an
outlet for a solid glass article and may, in embodiments, be
adjusted during the glass forming process.
[0075] It will be apparent to those skilled in the art that various
modifications and variations can be made to the embodiments
described herein without departing from the spirit and scope of the
claimed subject matter. Thus, it is intended that the specification
cover the modifications and variations of the various embodiments
described herein provided such modification and variations come
within the scope of the appended claims and their equivalents.
* * * * *