Apparatuses for holding and conveying glass articles

In embodiments, a conveyor apparatus can include a conveyor ribbon having a length, a width, a thickness less than the width, and a plurality of receiving apertures located along the length and extending through the thickness of the conveyor ribbon. The plurality of receiving apertures are dimensioned to receive and hold a plurality of glass articles. A conveyor drive and guidance system directs the conveyor ribbon along a predefined conveyor path. The predefined conveyor path can include an immersion section and a drain section. The immersion section can be oriented to direct the conveyor ribbon into and out of an immersion station and the conveyor ribbon is rotated about a horizontal axis in the drain section after being directed out of the immersion station.

BACKGROUND

Field

The present specification generally relates to apparatuses for holding glass articles during processing and, more specifically, to conveyor ribbon apparatuses for holding glass articles during processing.

Technical Background

Historically, glass has been used as a preferred material for many applications, including food and beverage packaging, pharmaceutical packaging, kitchen and laboratory glassware, and windows or other architectural features, because of its hermeticity, optical clarity and excellent chemical durability relative to other materials.

However, use of glass for many applications is limited by the mechanical performance of the glass. In particular, glass breakage is a concern, particularly in the packaging of food, beverages, and pharmaceuticals. Breakage can be costly in the food, beverage, and pharmaceutical packaging industries because, for example, breakage within a filling line may require that neighboring unbroken containers be discarded as the containers may contain fragments from the broken container. Breakage may also require that the filling line be slowed or stopped, lowering production yields. Further, non-catastrophic breakage (i.e., when the glass cracks but does not break) may cause the contents of the glass package or container to lose their sterility which, in turn, may result in costly product recalls.

One root cause of glass breakage is the introduction of flaws in the surface of the glass as the glass is processed and/or during subsequent filling. These flaws may be introduced in the surface of the glass from a variety of sources including contact between adjacent glass articles and contact between the glass and equipment, such as handling and/or filling equipment.

Accordingly, a need exists for alternative apparatuses for holding and conveying glass articles during processing to mitigate glass breakage while allowing for access with the interior and exterior regions of the glass articles with processing fluids, such as molten salt for ion-exchange or the like.

SUMMARY

According to one embodiment, a conveyor apparatus may hold and convey articles during processing. The conveyor apparatus can include a conveyor ribbon having a length, a width, a thickness less than the width, and a plurality of receiving apertures located along the length and extending through the thickness of the conveyor ribbon. The plurality of receiving apertures are dimensioned to receive and hold a plurality of articles. A conveyor drive and guidance system can direct the conveyor ribbon along a predefined conveyor path. The predefined conveyor path can include an immersion section and a drain section. The immersion section can be oriented to direct the conveyor ribbon into and out of an immersion station and the conveyor ribbon is rotated about a horizontal axis in the drain section after being directed out of the immersion station. The plurality of receiving apertures may each have a keyhole shape with a first portion having a first diameter and a second portion having a second diameter. The first portions are dimensioned for receiving articles and the second portions are dimensioned for retaining articles. The thickness of the conveyor ribbon may be from about 150 micrometers to about 400 micrometers.

In another embodiment, a conveyor apparatus may be part of an ion-exchange system. The ion-exchange system includes an immersion tank (e.g. an ion-exchange tank) for containing liquid (e.g. molten salt) and a conveyor ribbon with a length, a width, a thickness less than the width, and a plurality of receiving apertures located along the length and extending through the thickness of the conveyor ribbon. A conveyor drive and guide system is included and is engaged with and directs the conveyor ribbon through an immersion tank section and a drain section. The conveyor ribbon extends through at least a portion of the immersion tank in the immersion tank section and is rotated about a horizontal axis in the drain section. Each of the plurality of receiving apertures may have a keyhole shape with a first portion that has a first diameter and a second portion that has a second diameter. The first portions are dimensioned for receiving articles (e.g. glass articles) into the conveyor ribbon and the second portions are dimensioned for retaining articles in the conveyor ribbon. The conveyor ribbon may include a top ribbon with a plurality of top ribbon apertures and a bottom ribbon with a plurality of bottom ribbon apertures. The top ribbon is translatable with respect to the bottom ribbon such that the plurality of top ribbon apertures and the plurality of bottom ribbon apertures align to form the plurality of receiving apertures extending through the thickness of the conveyor ribbon. The conveyor ribbon may have an open position and a lock position. In the open position, the plurality of top ribbon apertures are coaxial with the plurality of bottom ribbon apertures and provide a first opening. In the lock position, the plurality of top ribbon apertures are offset from the plurality of bottom ribbon apertures and provide a second opening. The first opening is dimensioned for receiving articles into the conveyor ribbon and the second opening is dimensioned for retaining articles within the conveyor ribbon. The top ribbon may have a thickness from about 50 micrometers to about 75 micrometers and the bottom ribbon may have a thickness from about 150 micrometers to about 400 micrometers.

In yet another embodiment, a method for processing a plurality of glass articles includes loading and retaining a plurality of glass articles into a plurality of receiving apertures of a conveyor ribbon. The conveyor ribbon extends along a predefined conveyor path that includes an ion-exchange tank section and a drain section. The conveyor ribbon extends through at least a portion of an ion-exchange tank in the ion-exchange tank section and is rotated about a horizontal axis in the drain section. The conveyor ribbon is directed along the ion-exchange tank section of the predefined conveyor path and the plurality of glass articles are submerged in the ion-exchange tank containing molten salt. The conveyor ribbon is directed from the ion-exchange tank section to the drain section and the conveyor ribbon with the plurality of glass articles is rotated about a horizontal axis such that molten salt is drained from the plurality of glass articles. The predefined conveyor path may extend through a plurality of ion-exchange tanks and the conveyor ribbon may be directed along the predefined conveyor path and through the plurality of ion-exchange tanks.

Additional features and advantages of the apparatuses for holding and retaining glassware during processing described herein 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.

DESCRIPTION OF EMBODIMENTS

Reference will now be made in detail to embodiments of conveyor ribbons and conveyor apparatuses for holding and retaining articles during processing, 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. One embodiment of a conveyor apparatus for holding and retaining articles during processing is schematically depicted inFIG. 1. The conveyor apparatus generally includes a conveyor ribbon that holds and retains a plurality of articles. The conveyor ribbon has a plurality of apertures (FIGS. 1-10) which allow for the plurality of articles to be loaded into the conveyor ribbon at a loading station. The articles are loaded into the conveyor ribbon by a portion of an article passing through the conveyor ribbon such that a top portion of the article is held on one side of the conveyor ribbon and a body of the article is held on an opposite side of the conveyor ribbon. A conveyor ribbon drive and guidance system directs the conveyor ribbon with the plurality of articles through an immersion section and a drain section. In the immersion section the articles are immersed in a liquid for a predetermined amount of time. Upon exiting the immersion section, the conveyor ribbon drive and guidance system directs the conveyor ribbon with the plurality of articles through the drain section which rotates the glass articles about a horizontal axis and allows for liquid within or on the articles to drain. The conveyor ribbon with the plurality of articles then proceeds to another station, e.g. another immersion section, a washing section, etc., before the articles are removed from the conveyor ribbon at an unloading station and the conveyor ribbon returns back to the loading station to receive additional articles to be processed. Various embodiments of apparatuses for holding and conveying glass articles during processing will be described in further detail herein with specific reference to the appended drawings.

As noted herein, the breakage of glass articles during processing and/or filling is a source of product loss and may lead to process inefficiencies and increased costs. Additionally, cosmetic flaws in glass articles are also undesirable to users. Strengthening of glass articles can assist in mitigating breakage. Glass articles can be strengthened using a variety of techniques, including chemical and thermal tempering. For example, chemical tempering, sometimes called ion-exchange strengthening, can be used to strengthen glass articles through the introduction of a layer of compressive stress in the surface of the glass articles. The compressive stress is introduced by submerging the glass articles in a molten salt bath, sometimes referred to as an ion-exchange bath. As relatively small ions in the glass are replaced by relatively larger ions from the molten salt, a compressive stress is induced in the surface of the glass. During chemical tempering, glass articles, such as glass containers, may be mechanically manipulated to both fill and empty the glass articles of molten salt.

While chemical tempering improves the strength of the glass articles, mechanical manipulation of the glass articles during the strengthening process may introduce flaws in the surface of the glass. For example, contact between the glass articles and the fixturing, such as a magazine apparatus used to retain the glass articles during processing, may introduce flaws in the glass, particularly when the glass articles and the fixturing are initially submerged in the molten salt bath and/or when the fixturing and glass articles are withdrawn from the molten salt bath and rotated to empty the glass articles of molten salt. Specifically, as the glass articles are submerged they may be buoyant and thus be propelled upward relative to the fixturing. Moreover, after the ion-exchange process is complete, the fixturing and glass articles are withdrawn from the molten salt bath and the fixturing is rotated to empty the glass articles of molten salt contained within the interior volume of the glass articles. As the fixturing is rotated, the glass articles may abruptly collide with the fixturing. This blunt force impact between the glass articles and the fixturing may introduce flaws in the surface of the glass.

In most cases the flaws are superficial and are contained within the layer of surface compressive stress induced in the glass. This surface compressive stress prevents the flaws from growing into cracks. However, in extreme cases, the flaws may extend through the layer of surface compressive stress which may lead to breakage of the glass articles. In either case, the flaws may be visible to the unaided human eye and, as such, are undesirable.

The conveyor apparatuses for holding and conveying glass articles during processing described herein generally mitigate the introduction of flaws in the glass articles retained therein and limit the introduction of flaws to locations of the glass article which are less susceptible to breakage. The conveyor apparatuses with the conveyor ribbons described herein also have a relatively low thermal mass and surface area which mitigates the degradation of ion-exchange performance when the conveyor apparatuses are used to facilitate strengthening of the glass articles contained therein by ion-exchange.

With reference again toFIG. 1, a conveyor apparatus100with a conveyor ribbon110holding a plurality of articles900is depicted. The conveyor apparatus100includes a drive and guidance system200(FIGS. 13A and 13B) with a plurality of rollers210that direct the conveyor ribbon110along a predetermined processing path10. For example, the conveyor ribbon110can be directed to a loading station102where a plurality of articles900are loaded into the conveyor ribbon110(FIGS. 2-8). For example, the conveyor ribbon may include a top ribbon with apertures and a bottom ribbon with apertures (as depicted inFIGS. 4-6) that are temporarily shifted relative to each other such that the top ribbon apertures align with the bottom ribbon apertures thereby allowing a portion of an article900to pass through the top ribbon and bottom ribbon. The top ribbon is then returned to its original position relative to the bottom ribbon such that the top ribbon apertures are offset from the bottom ribbon apertures with a portion of a glass article positioned and held above the top ribbon and another portion of the glass article positioned and held below the bottom ribbon. The conveyor ribbon110with the plurality of articles900can be directed through a first turn180aand down into an immersion tank300containing liquid302by moving on first vertical (along Z axis) section182aof the processing path10. The conveyor ribbon110with the plurality of articles is directed through a second turn180bof the processing path10, proceeds along a horizontal (along X or Y axis) section184of the processing path10, and is directed through a third turn180cbefore moving up a second vertical section182bof the processing path10and exiting the immersion tank300. After exiting the immersion tank300, the conveyor ribbon110with the plurality of glass articles proceeds through a drain section190where the articles900are rotated about a horizontal axis192such that liquid302within an interior910(FIG. 3) or an exterior of the articles900can drain. In the embodiment depicted inFIG. 1, the processing path10through the drain section190is in the form of a loop to facilitate rotating the articles900about the horizontal axis192and thereby draining the liquid302from the interior910or exterior of the articles900.

The conveyor ribbon110and the plurality of articles900then proceed to an unloading station104where the articles900are removed from the conveyor ribbon110before the conveyor ribbon travels back to the loading station102where additional articles900are loaded into the conveyor ribbon110. For example, the conveyor ribbon110may have a top ribbon with apertures and a bottom ribbon with apertures as mentioned above and the top ribbon can is temporarily shifted relative to the bottom ribbon such that the top ribbon apertures align with the bottom ribbon apertures. Full alignment of the top ribbon apertures with the bottom ribbon apertures allows the glass article to be released, i.e., to pass back through the top ribbon and bottom ribbon. The conveyor ribbon110with the plurality of articles900can be directed through additional stations, e.g. a washing station, inspection station, etc., before reaching the unloading station104. It should be appreciated that the speed of the conveyor ribbon110allows for a given article900to be located within the immersion tank300for a desired amount of time. In embodiments, the articles900are glass articles, the immersion tank300is an ion-exchange tank and the liquid302is a molten salt. In such embodiments, the desired amount of time for a glass article to be immersed in the molten salt can be 1 hour, 2 hours, 4 hours, 8 hours, 12 hours, 24 hours, 36 hours, and any time period between. It should also be appreciated that the turns180a-180c, vertical sections182a-182b, etc., shown inFIG. 1are for illustrative purposes only and any number of turns, vertical sections, inclined sections, horizontal sections, etc., can be used in the conveyor apparatus100in order for the plurality of articles900to be processed.

Referring now toFIGS. 2A, 2B, and 3, one embodiment of a conveyor ribbon110for holding and conveying articles900during processing is schematically depicted. The conveyor ribbon110is substantially planar and has a top surface111a, a bottom surface111b, a width ‘W1’, a length ‘L’, and a thickness ‘t’. The thickness of the conveyor ribbon can be from about 150 micrometers to about 400 micrometers. The conveyor ribbon110holds and retains a plurality of articles900in a plurality of apertures112. Each aperture112may be shaped and sized to securely hold articles900having a particular form factor, such as round, rectangular, or the like. For example, the apertures112of the conveyor ribbon110may be shaped to retain round-form glass vials. An example of an article900in the form of a glass vial is schematically depicted in FIG.3. In this embodiment, the article900in the shape of a glass vial may generally include a body section902, a neck section904above the body section902, and an opening906leading through the neck section904and connected to an interior volume910. The body section902substantially surrounds the interior volume910of the article900with a bottom section914and sidewalls916. The neck section904generally connects the body section902with the opening906. The opening906may be surrounded by a collar908extending outward from the top of the neck section904of the article900. The body section902may have a curved bottom edge918and a curved area912adjacent the neck section904. Generally, the neck section904, body section902, and collar908may have a generally circular shaped cross section, each comprising an exterior diameter. In one embodiment, the diameter of the collar (dcinFIG. 3) is greater than the diameter of the neck section (dn, inFIG. 3) and the diameter of the body section (dbinFIG. 3) is greater than the diameter of the collar. The neck section904and collar908may generally be formed with a greater thickness than the balance of the article900and, as such, may be better able to withstand incidental damage, such as scuffing, scratching, or the like, without breakage compared to the balance of the article900. Accordingly, the conveyor ribbon110and apertures112are constructed to engage the article900in the neck section904and collar908.

In embodiments, the plurality of apertures112are in the form of a “keyhole” aperture with a first aperture section113and a second aperture section114. The first aperture section113is substantially round in shape and has a first dimension113athat is greater than the collar diameter dcand less than the body diameter db. As such, the collar908can slide through the first aperture section113but the body section902cannot slide through the first aperture section113. The second aperture section114is also substantially round and has a second dimension114awhich is less than the first dimension113aand the collar diameter dcbut larger than the neck diameter dn. The collar908of the article900can be passed through the first aperture section113of the aperture112such that the collar908is located above the top surface111a, the body section902is located below the bottom surface111b, and the neck section904is located within the aperture112. Then, the article900can be moved relative to the conveyor ribbon110in a direction towards the second aperture section114as illustrated by arrows2inFIG. 2B. When the neck section904, with the diameter dnless than the second dimension114a, moves from the first aperture section113to the second aperture section114, the edge of the second dimension114aof the second aperture section114prevents the collar908from passing back through the aperture112. In this manner, the article900is held by the conveyor ribbon110with the collar908located above the top side111aof the conveyor ribbon110, the body section902located below the bottom side111bof the conveyor ribbon110and the neck section904located within the second aperture section114of the aperture112. The plurality of articles900can be retained in the second aperture section114of the apertures112using a clip, tab, etc., which ensures that the articles900are held and retained by the conveyor ribbon110during processing of the articles900. Illustrative examples of holding and retaining the articles900in a reliable and secure manner are discussed below.

Referring now toFIGS. 4A and 4B, another embodiment of a portion of a conveyor ribbon110for holding and conveying a plurality of articles900is depicted. The conveyor ribbon110has a top ribbon110aand a bottom ribbon110b. The top ribbon110acan have a thickness from about 50 micrometers to about 75 micrometers and the bottom ribbon110bcan have a thickness from about 150 micrometers to about 400 micrometers. The top ribbon110ahas a pair of oppositely disposed side edges118and the bottom ribbon110bhas a pair of oppositely disposed side edges119. Both the top ribbon110aand the bottom ribbon110bhave a plurality of the apertures112between the pair of oppositely disposed side edges118and119, respectively, and extending along the length L of the conveyor ribbon110. The apertures112in the top ribbon110aand the apertures112in the bottom ribbon110bhave the first aperture sections113and the second aperture sections114, as described above with respect toFIGS. 2A and 2B. However, the apertures112in the bottom ribbon110bare rotated 180 degrees relative to the apertures112in the top ribbon110a.

The top ribbon110aand bottom ribbon110bof the conveyor ribbon110are translatable relative to one another in the length direction (along the X-axis) such that the conveyor ribbon110has an open position and a lock position. In the open position (not shown), the top ribbon110ais aligned with and extends over the bottom ribbon110bwith the first aperture sections113in the top ribbon110aaligned directly above (coaxial) with the first aperture sections113in the bottom ribbon110b. In the open position a plurality of apertures having the first dimension113aextend through the thickness t of the conveyor ribbon110(i.e., the apertures extend through both the top ribbon110aand the bottom ribbon110b). With the collar diameter dcbeing less than the first dimension113aof the aligned first aperture sections113, the collar908of the articles900can slide up through the aligned first aperture sections113of the top ribbon110aand bottom ribbon110b. In this manner, the articles900can be positioned with the collars908located above the top surface111aof the conveyor ribbon110, the body sections902located below the bottom surface111bof the conveyor ribbon110, and the neck sections904located within the first aperture sections113of the top ribbon110aand bottom ribbon110b. The conveyor ribbon110can be placed in the open position by translating/moving the top ribbon110arelative to the bottom ribbon110b, or vice-versa, such that the first aperture sections113of the top ribbon110aare aligned directly above (coaxial) the first aperture sections113of the bottom ribbon110b(not shown). For example, the top ribbon110amay have a different travel path than the bottom ribbon110b, the different travel paths of the top ribbon110aand bottom ribbon110bproviding a temporary shift of the top ribbon110arelative to the bottom ribbon110b. The temporary shift of the top ribbon110arelative to the bottom ribbon110baligns the first aperture sections113of the top ribbon110adirectly above (coaxial) the first aperture sections113of the bottom ribbon110b. The conveyor ribbon110can be placed in the lock position by reversing the temporary shift of the top ribbon110arelative to the bottom ribbon110bsuch that the second aperture sections114of the top ribbon110aare aligned directly above (coaxial) the second aperture sections114of the bottom ribbon110b(FIG. 4B). Movement of the top ribbon110arelative to the bottom ribbon110bto reverse the temporary shift moves the neck sections904of the articles900from the first aperture sections113of the top ribbon110aand the bottom ribbon110bto the aligned second aperture sections114of the top ribbon110aand bottom ribbon110b. The alignment of the second aperture sections114of the top ribbon110awith the second aperture sections114of the bottom ribbon110bprovides a plurality of receiving apertures115with a retaining dimension115a. In the embodiment depicted inFIG. 4B, the retaining dimension115ais equal to the second dimension114a. However, in other embodiments, the retaining dimension115amay not be equal to the second dimension114aso long as the collars908of the plurality of articles900cannot slide back through the receiving apertures115while the conveyor ribbon110is in the lock position. For example, the receiving apertures115can be elliptical in shape with the retaining dimension115abeing less than or greater than the second dimension114a.

Referring now toFIGS. 5A and 5B, another embodiment of a portion of a conveyor ribbon110for holding and conveying a plurality of articles900is depicted. The conveyor ribbon110is similar to the conveyor ribbon depicted inFIGS. 4A and 4B, except the top ribbon110ais translatable relative to the bottom ribbon110balong a width direction (along the Y-axis) of the conveyor ribbon110. The conveyor ribbon110includes the top ribbon110aand the bottom ribbon110b. The top ribbon110acan have a thickness from about 50 micrometers to about 75 micrometers and the bottom ribbon110bcan have a thickness from about 150 micrometers to about 400 micrometers. The top ribbon110ahas a pair of oppositely disposed side edges118and the bottom ribbon110bhas a pair of oppositely disposed side edges119. Both the top ribbon110aand the bottom ribbon110bhave a plurality of the apertures112between the pair of oppositely disposed side edges118and119, respectively, and extending along the length L of the conveyor ribbon110. The apertures112in the top ribbon110aand the apertures112in the bottom ribbon110bhave the first aperture sections113and the second aperture sections114, as described above with respect toFIGS. 4A and 4B. However, the apertures112in the bottom ribbon110band the apertures112in the top ribbon110aare arranged at 90 degrees relative to the apertures12inFIGS. 4A and 4B.

The top ribbon110aand bottom ribbon110bof the conveyor ribbon110are translatable relative to one another in the width direction (along the Y-axis) such that the conveyor ribbon110has an open position and a lock position. In the open position (not shown), the top ribbon110ais aligned with and extends over the bottom ribbon110bwith the first aperture sections113in the top ribbon110aaligned directly above the first aperture sections113in the bottom ribbon110b. In the open position a plurality of apertures having the first dimension113aextend through the thickness t of the conveyor ribbon110(i.e., the apertures extend through both the top ribbon110aand the bottom ribbon110b). With the collar diameter dcbeing less than the first dimension113aof the aligned first aperture sections113, the collar908of the articles900can slide up through the aligned first aperture sections113of the top ribbon110aand bottom ribbon110b. In this manner, the articles900can be positioned with the collars908located above the top surface111aof the conveyor ribbon110, the body sections902located below the bottom surface111bof the conveyor ribbon110, and the neck sections904located within the first aperture sections113of the top ribbon110aand bottom ribbon110b. The conveyor ribbon110can be placed in the open position by translating/moving the top ribbon110arelative to the bottom ribbon110bin the width direction (along the Y-axis), or vice-versa, such that the first aperture sections113of the top ribbon110aare aligned directly above the first aperture sections113of the bottom ribbon110b(not shown). For example, the top ribbon110amay have a different travel path than the bottom ribbon110b, the different travel paths of the top ribbon110aand bottom ribbon110bproviding a temporary shift of the top ribbon110arelative to the bottom ribbon110b. The temporary shift of the top ribbon110arelative to the bottom ribbon110baligns the first aperture sections113of the top ribbon110adirectly above the first aperture sections113of the bottom ribbon110b. The conveyor ribbon110can be placed in the lock position by reversing the temporary shift of the top ribbon110arelative to the bottom ribbon110bsuch that the second aperture sections114of the top ribbon110aare aligned directly above the second aperture sections114of the bottom ribbon110b(FIG. 5B). Movement of the top ribbon110arelative to the bottom ribbon110bto reverse the temporary shift moves the neck sections904of the articles900from the first aperture sections113of the top ribbon110aand the bottom ribbon110bto the aligned second aperture sections114of the top ribbon110aand bottom ribbon110b. The alignment of the second aperture sections114of the top ribbon110awith the second aperture sections114of the bottom ribbon110bprovides a plurality of receiving apertures115with a retaining dimension115a. In the embodiment depicted inFIG. 5B, the retaining dimension115ais equal to the second dimension114a. However, in other embodiments, the retaining dimension115amay not be equal to the second dimension114aso long as the collars908of the plurality of articles900cannot slide back through the receiving apertures115while the conveyor ribbon110is in the lock position. For example, the receiving apertures115can be elliptical in shape with the retaining dimension115abeing less than or greater than the second dimension114a.

Referring now toFIGS. 5C, 5D and 6, another embodiment of a conveyor ribbon110to hold and convey a plurality of articles900is depicted. The conveyor ribbon110has the top ribbon110aand the bottom ribbon110b. The top ribbon110aand the bottom ribbon110bboth have apertures116extending along their length. The apertures116are circular in form and each aperture116has a diameter116a. The diameter116ais greater than the collar diameter dcand less than the body diameter db.

The conveyor ribbon110with apertures116in the top ribbon110aand bottom ribbon110bhas an open position and a lock position. In the open position (not shown), the apertures116of the top ribbon110aare aligned directly above (coaxial) the apertures116of the bottom ribbon110b. The conveyor ribbon110can be placed in the open position by translating/moving the top ribbon110arelative to the bottom ribbon110bin the length direction (along the X-axis) or along the width direction (along the Y-axis), or vice-versa, such that the apertures116of the top ribbon110aare aligned directly above (coaxial) the apertures116of the bottom ribbon110b(not shown). For example, the top ribbon110amay have a different travel path than the bottom ribbon110b, the different paths of the top ribbon110aand bottom ribbon110bproviding a temporary shift of the top ribbon110arelative to the bottom ribbon110b. The temporary shift of the top ribbon110arelative to the bottom ribbon110baligns the apertures116of the top ribbon110adirectly above the apertures116of the bottom ribbon110b. With the apertures116of the top ribbon110aand bottom ribbon100bso aligned, the collars908of the articles900can slide up and through the aligned apertures116such that the collars908are located above the top surface111aof the conveyor ribbon110, the body sections902are located below the bottom surface111bof the conveyor ribbon110, and the neck sections904are located within the aligned apertures116of the top ribbon110aand bottom ribbon110b. The conveyor ribbon110can be placed in the lock position by reversing the temporary shift of the top ribbon110arelative to the bottom ribbon110bsuch that the openings provided by the aligned apertures116are reduced to receiving apertures117with retaining dimensions117a(FIG. 5D). The retaining dimension117ais less than the collar diameter dc, greater than the neck section diameter dnand less than the body section diameter db. Thus, as illustrated inFIG. 6, articles900are held and secured by the conveyor ribbon110with the top ribbon110ashifted relative to the bottom ribbon110bsuch that receiving apertures117with retaining dimensions117aare provided and the collar908is located above the top surface111aand the body section902is located below the bottom surface111bof the conveyor ribbon110.

Referring now toFIGS. 7A, 7B and 7C, another embodiment of the conveyor ribbon110is depicted. The conveyor ribbon110has a top ribbon110a, a bottom ribbon110band a plurality of receiving apertures120. Each receiving aperture120has a circular aperture124with an outer diameter124awithin the bottom ribbon110b. The outer diameter124ais greater than the collar diameter dc, greater than the neck section diameter dnand less than the body section diameter db, i.e. the outer diameter124aallows for the articles900to be received into the conveyor ribbon110. Each receiving aperture120also has at least one tab121from the top ribbon110aextending inwardly towards a center axis (not shown) of the circular aperture124. The bottom ribbon110bmay have thickness from about 50 micrometers to about 75 micrometers and the bottom ribbon110bmay have a thickness from about 150 micrometers to about 400 micrometers. The relatively thin top ribbon110aallows for the at least one tab121to elastically deform and serve as a retainer feature. In the embodiment depicted inFIG. 7A, a plurality of tabs121from the top ribbon110aextend inwardly towards the center axis of the circular aperture124and each of the tabs121have a distal end122. The distal ends122of the plurality of tabs121define a generally circular opening having an inner diameter120bwhich is less than the collar diameter dc. The openings between the distal ends122of the tabs121with the inner diameter120ballow for the collars908of glass articles to elastically deform the tabs121and serve as retainer features when the collars908are pushed through the openings such that the collars908of the articles900are located above the top surface111a, the body sections902are located below the bottom surface111band the neck sections904are located between the tabs121of the conveyor ribbon110, i.e. the tabs121allow for the articles900to be received and retained within the conveyor ribbon110.FIGS. 7A, 7B and 7Cdepict the conveyor ribbon110having the top ribbon110awith the tabs121. However, in other embodiments (not shown), a top ribbon is not required and the receiving apertures120and the tabs121can be formed from of a single ribbon. In the alternative, the tabs121can be separate components that are joined to a single ribbon containing the receiving apertures120such that the tabs121extend inwardly towards a central axis of the receiving apertures120and provide an opening with a diameter that is less than the collar diameter dc.

Referring toFIG. 8, the spacing between adjacent receiving apertures120(S1inFIGS. 7B and 8) is such that adjacent articles900do not contact each other when the conveyor ribbon110is inclined, e.g. in a vertical orientation. The spacing S1results in a minimum distance (d inFIG. 8) to be maintained between adjacent articles900during processing of the articles900. It should be appreciated that the spacing S1between adjacent receiving apertures120and the minimum distance d between adjacent articles900depicted for the conveyor ribbon110can also be present for the conveyor ribbon110with the apertures112(FIG. 2B) and the conveyor ribbon with the apertures116(FIG. 5C).

Referring now toFIG. 9, a conveyor ribbon130is shown with a width ‘W3.’ The width W3is sufficient for a plurality of apertures112to be formed through the conveyor ribbon130along the width W3. The apertures112shown inFIG. 9have the first aperture section113and the second aperture section114as depicted inFIG. 4A. However, it should be appreciated that the conveyor ribbon130with the width W3can have the circular apertures116as illustrated inFIGS. 5C and 5D. In addition, it should also be appreciated that the conveyor ribbon130can have a top ribbon130aand a bottom ribbon130bsuch that apertures112or apertures116can be aligned to provide the receiving apertures115or receiving apertures117as discussed above with reference toFIGS. 4A-6.

With reference toFIG. 10, a conveyor ribbon140has a width W4, the width W4allowing for a plurality of receiving apertures120to extend along the width W3of the conveyor ribbon140. It should be appreciated that the conveyor ribbon140can have a top ribbon140aand a bottom ribbon140b. In this manner, conveyor ribbons disclosed herein can hold and convey a plurality of articles900along the length of the conveyor ribbon or along the length and the width of the conveyor ribbon. It should be appreciated that all of the apertures112inFIG. 9and receiving apertures120inFIG. 10can have an article900held therein. The conveyor ribbons130or140can have a thickness from about 150 micrometers to about 400 micrometers. The top ribbons130a,140acan have a thickness from about 50 micrometers to about 75 micrometers and the bottom ribbons130b,140bcan have a thickness from about 150 micrometers to about 400 micrometers.

With reference now toFIG. 11, a conveyor ribbon150is depicted with a flange152that protects the collar908of a glass article during processing. The conveyor ribbon150has a top ribbon150aand a bottom ribbon150b. The top ribbon150acan have a thickness from about 50 micrometers to about 75 micrometers and the bottom ribbon150bcan have a thickness from about 150 micrometers to about 400 micrometers. The top ribbon150ahas a pair of flanges152. Each flange152has a first section152aextending from a top surface111aof the top ribbon150aand a second section152bextending from the first section152a. InFIG. 11the first section152ais depicted as vertical and the second section152bis depicted as horizontal. Other flange configurations can be used so long as the height of the flange152(flange height=hfinFIG. 11) is greater than the height of the collar908(collar height=hcinFIG. 11) that extends above the top surface111a. Also, the flange152can be part of the conveyor ribbon110(FIGS. 2-8), conveyor ribbon130(FIG. 9) and conveyor ribbon140(FIG. 10) such that collars908of glass articles held in the conveyor ribbons are protected from contact with processing equipment.

The apertures, tabs and flanges of the conveyor ribbons disclosed herein can be formed in or on a conveyor ribbon using conventional manufacturing techniques. For example, apertures, with and without tabs, in the conveyor ribbons can be formed by stamping, laser cutting, water jet cutting and the like. Tabs can be formed by stamping, laser cutting, water jet cutting, etc. Flanges can be integral with the ribbon and formed by a folding shear. In the alternative, flanges can be formed by stamping, laser cutting, water jet cutting, etc. and welded to the ribbon. The conveyor ribbon can be made from a metallic material that exhibits salt corrosion resistance, for example, Inconel 600, Hastelloy, 310 stainless steel, etc. It should be appreciated that the conveyor ribbons disclosed herein can have a thickness that provides a large glass weight to conveyer ribbon weight ratio (weight of glass/conveyer ribbon used to hold and retain glass during ion-exchange processing) compared to conventional ion-exchange processing equipment. For example, conveyor ribbons disclosed herein can provide a glass weight to glass handling equipment weight ratio of between 0.4-1.0, whereas conventional ion-exchange processing equipment provides a glass weight to glass handling equipment weight ratio of between 0.0001-0.001. Thicknesses of conveyor ribbons disclosed herein provide sufficient rigidity to bear the weight of glass articles held in the conveyor ribbons during processed and yet accommodate 120-150 millimeter (mm) radius turns along the processing path. In embodiments, thicknesses of conveyor ribbons range from 250-350 μm when a single conveyor ribbon is used to hold glass articles during processing. In other embodiments when a top conveyor ribbon and a bottom conveyor ribbon are used to hold glass articles during processing, the top conveyor ribbon has a thickness between 50-75 μm and the bottom conveyor ribbon has a thickness between 200-300 μm. It should be appreciated that larger glass to glass handling equipment weight ratios provided by the conveyor apparatuses with conveyor ribbons disclosed herein results in less volume and mass of glass handling equipment that must be heated in a pre-heat furnace or ion-exchange tank. Therefore, the conveyor apparatuses disclosed herein can provide increased energy efficiency in the ion-exchange process.

Referring now toFIGS. 12A and 12B, an embodiment of a drive and guidance system200that drives and guides the conveyor ribbon110is depicted. The drive and guidance system200includes a pair of rollers210spaced apart from one another on opposite sides of the conveyor ribbon110. Each of the rollers210can have an inner roller portion212having a radius r1and an outer surface213. Each of the rollers210also has a pair of spaced apart outer roller portions214having a radius r2and an outer surface215. The radius r2is greater than the radius r1. The inner roller portion212is disposed between the pair of spaced apart outer roller portions214. A channel216is located between the pair of spaced apart outer roller portions214. The outer surface213of the inner roller portion212is a side wall of the channel216. The conveyor ribbon110may be positioned between pairs of opposing rollers210such that the side edges118,119are positioned between the pair of spaced apart outer roller portions214and in contact with the outer surface213of the inner roller portion212. One or more of the pairs of oppositely disposed rollers210(FIG. 1) can be actively driven/rotated by a mechanical device (not shown) such as an electric motor. Also, one or more of the pairs of oppositely disposed rollers210can be free to rotate (i.e., not actively driven by a mechanical device) as the conveyor ribbon110passes through the rollers210. When the pair of oppositely disposed rollers210rotate as illustrated by the arrows6inFIG. 12A, friction between the oppositely disposed side edges118,119of the conveyor ribbon110and the outer surfaces213of the pair of oppositely disposed inner roller portions212results in a force being applied to the conveyor ribbon110thereby propelling the conveyor ribbon in a direction as illustrated by the arrow220. Through the use of a plurality of pairs of oppositely disposed rollers210, the drive and guidance system200drives the conveyor ribbon110in a desired direction and guides the conveyor ribbon along a desired path. For example, a plurality of oppositely disposed rollers210can drive the conveyor ribbon110along the predetermined processing path10as depicted inFIG. 1.FIGS. 12A and 12Bdepict the drive and guidance system200having rollers210that drive the top ribbon110aand the bottom ribbon110balong the same path. However, in other embodiments (not shown), a drive and guidance system can drive the top ribbon110aalong a slightly different path that then bottom ribbon110b, or vice-versa. For example, the drive and guidance system200may be configured to displace the top ribbon110arelative to the bottom ribbon110bin the width direction (along the Y-axis) or in the length direction (along the X-axis). The displacement of the top ribbon110arelative to the bottom ribbon110bcan provide a temporary shift of the top ribbon110arelative to the bottom ribbon110bin the width direction (along the Y-axis) or in the length direction (along the X-axis) as discussed with respect toFIGS. 4-6. The temporary shift of the top ribbon110arelative to the bottom ribbon110bcan place a portion of the conveyor ribbon110in the open position, e.g. during loading of glass articles900into the conveyor ribbon110, and the reversal of the temporary shift of the top ribbon110arelative to the bottom ribbon110bcan place the portion of the conveyor ribbon110in the open position in the lock position, e.g. for conveying glass articles900through an immersion tank.

With reference toFIG. 13, an embodiment of a conveyor apparatus103with the conveyor ribbon110and drive and guidance system is depicted in conjunction with a plurality of immersion tanks. The conveyor ribbon110of the conveyor apparatus103extends along a processing path into a first immersion tank300containing a first liquid302. The conveyor ribbon110extends along the processing path through the first turn180a, down into the first liquid302along the first vertical section182a, through the second turn180band along the horizontal section184. After passing through the horizontal section184, the conveyor ribbon110exits the first liquid302after the third turn180cand the second vertical section182b. After exiting the first liquid302and thus the first immersion tank300, the conveyor ribbon110passes through a first drain section190aand then proceeds to a second immersion tank310containing a second liquid312.

Upon reaching the second immersion tank310, the conveyor ribbon110with the plurality of articles900extends along the processing path through another first turn180a, down into the second liquid312along another first vertical section182a, through another second turn180band along another horizontal section184in the second immersion tank310. After passing through the horizontal section184, the conveyor ribbon110exits the second liquid312after the third turn180cand second vertical section182b. After exiting the second liquid312and thus the second immersion tank310, the conveyor ribbon110passes through a second drain section190band then proceeds to a third immersion tank320containing a third liquid322.

Upon reaching the third immersion tank320, the conveyor ribbon110with the plurality of articles900extends along the processing path through another first turn180a, down into the third liquid322along another first vertical section182a, through another second turn180band along another horizontal section184in the third immersion tank320. After passing through the horizontal section184, the conveyor ribbon110exits the third liquid322after the third turn180cand second vertical section182b. After exiting the third liquid322and thus the third immersion tank320, the conveyor ribbon110passes through a third drain section190cand then proceeds to an unloading station (not shown).

The first liquid302, second liquid312and third liquid322can be molten salts that have the same salt composition. In the alternative, the first liquid302, second liquid312and third liquid322can be molten salts that have different salt compositions. It should be appreciated that the first immersion tank300, second immersion tank310and third immersion tank320can be dimensioned such that articles900spend a predetermined amount of time in each immersion tank. For example, the first immersion tank300, second immersion tank310and third immersion tank320can be dimensioned such that articles900spend the same amount of time in each immersion tank bath. In the alternative, the first immersion tank300, second immersion tank310and third immersion tank320can be dimensioned such that glass articles spend different amounts of time in each immersion tank, e.g. the glass articles spend 1 hour in the first immersion tank300, 30 minutes in the second immersion tank310and 10 minutes in the third immersion tank320. It should also be appreciated that the first liquid302, second liquid312and third liquid322can each be maintained at a predetermined and desired temperature. For example, the first liquid302, second liquid312and third liquid322can be molten salts that are each maintained at the same temperature (e.g. 500+/−10° C.). In the alternative, the first liquid302, second liquid312and third liquid322can be molten salts that each maintained at a different temperature, e.g. the first liquid302can be maintained at 500+/−10° C., the second liquid312can be maintained at 480+/−10° C. and the third liquid322can each be maintained at 420+/−10° C.

Referring now toFIG. 14, in embodiments, a conveyor apparatus105for increasing the number of articles900processed in the immersion tank300for a given processing run is depicted. The conveyor apparatus105with the plurality of rollers210(not shown) guide and drive the conveyor ribbon110with a plurality of articles900into the immersion tank300containing the liquid302. The conveyor ribbon110with the plurality of articles900is driven and guided through the first turn180a, down into the liquid302along the first vertical section182aand through the second turn180b. However, instead of traveling along the horizontal section184as shown for the conveyor apparatus100(FIG. 1) and103(FIG. 13), the conveyor ribbon110with the plurality of glass articles is driven and guided through one or more loops186submerged in the liquid302. It should be appreciated that the one or more loops allow for a greater number of articles900to be processed in the immersion tank300per unit time. After passing through the one or more loops186, the plurality of articles900proceed to exit the liquid302by passing through the third turn180cand up the second vertical section182b. After exiting the liquid302and thus the immersion tank300, the conveyor ribbon110with the plurality of articles900pass through a drain section190and then proceed to an unloading station (not shown).

Referring now toFIGS. 15A-15C, in embodiments, a conveyor apparatus106is depicted for increasing the number of articles900processed in an immersion tank300for a given processing run. The conveyor apparatus106includes a first drum191and a second drum193. The conveyor apparatus106also includes the conveyor ribbon130(FIG. 9) with the pair of flanges152(FIG. 11) and a plurality of articles900.FIG. 15Adepicts the conveyor ribbon130with the plurality of articles900entering into an immersion tank300(e.g. an ion-exchange tank). The conveyor ribbon130with the plurality of articles900are wrapped around a circumference and along a length of the first drum191, and wind down the first drum191into a liquid302(e.g. molten salt). The conveyor ribbon130with the plurality of articles900are also wrapped around a circumference and along a length of the second drum193, and wind up the second drum193out of the liquid302. When the conveyor ribbon130with the plurality of articles900are wrapped around and winding down the first drum191and wrapped around and winding up the second drum193, the flanges152slide along the drums191,193as depicted inFIGS. 15B and 15C. The first drum191can rotate in a first direction, e.g. clockwise when looking along the −Z direction, in order to wind the conveyor ribbon130with articles900down into the immersion tank300, and the second drum193can rotate in a second direction, e.g. counter-clockwise in order to wind the conveyor ribbon130and articles900up out of the immersion tank300. The flanges152with the first section152aextending from the conveyor ribbon130and second section152bextending from the first section152aprevent the collars908from contacting and sliding against the first drum191and the second drum193. The first drum191and the second drum193can be tilted relative to the vertical axis to ensure better filling of the interior910of the articles900with liquid302in the immersion tank300and provide enhanced mixing within the immersion tank that can aid thermal and compositional uniformity within the liquid. It should be appreciated that only one drum or more than two drums can be used in a given immersion tank. In addition, the conveyor ribbon110(FIGS. 2-8) with the flanges152and the conveyor ribbon140(FIG. 9) with the flanges152can be used with one or more drums to process the articles900through one or more immersion tanks.

Referring now toFIG. 16, a conveyor apparatus108for batch processing of articles900in an immersion tank300containing a liquid302, e.g. an ion-exchange tank containing a molten salt, is depicted. The conveyor apparatus108includes the conveyor ribbon110, but only a portion of the conveyor ribbon110holds and retains the plurality of glass articles. The portion of the conveyor ribbon110holding and retaining the plurality of articles900is driven and guided by the plurality of rollers210(not shown) through the first turn180a, down the first vertical section182and through the second turn180b. Once the plurality of articles900are located within the liquid302at a desired location, e.g. along the horizontal section184, movement of the conveyor ribbon is stopped and the articles900are allowed to remain in the liquid302for a predetermined amount of time to facilitate ion-exchange. Then, the conveyor ribbon110with the plurality of articles900is driven and guided through the third turn180c, up the second vertical section182band through the drain section190before proceeding to an unloading station (not shown). In this manner, batch processing of the plurality of articles900in the immersion tank300is provided. It should be appreciated that portions of the conveyor ribbon110that do not hold and retain any articles900during a given batch processing run can have apertures within the conveyor ribbon that are empty. In the alternative, the conveyor ribbon110can have only certain portions along its length that have apertures, the remainder of the length of the conveyor ribbon110not having apertures to hold and retain articles900. It should also be appreciated that the conveyor ribbon130(FIG. 9) and the conveyor ribbon140(FIG. 10) can be used for batch processing of the glass articles in one or more immersion tanks.

Referring now toFIGS. 17 and 18, a method500for processing articles900(e.g. glass vials) using a conveyor ribbon110according to embodiments disclosed herein is shown. The method500includes forming tube stock1000into articles900at step502. The articles900are loaded into the conveyor ribbon110at a loading station102at step504. The conveyor ribbon with the articles900is directed to and through an immersion tank300(e.g. an ion-exchange tank) containing liquid302(e.g. molten salt) at step506. The immersion process at step508can include a preheat before entering the immersion tank300, immersion of the articles900into the immersion tank, passing the articles900through the liquid302in the immersion tank300such that the articles900are within the liquid302for a predetermined amount of time, and then removal of the articles900from the immersion tank300. The articles900removed from the immersion tank300are drained and then proceed to a dip or rinse at step510. The dip or rinse of the articles900can be provided by a plurality of nozzles610which spray water612onto and into the articles900or be provided by the conveyor ribbon110with the articles900proceeding through a rinse tank (not shown). It should be appreciated that the nozzles610and spray water612can also rinse the conveyor ribbon110. The articles900are unloaded from the conveyor ribbon110at an unloading station104at step512, transferred to a washing station at step514and washed at step516. Alternatively, the articles900can be washed prior to unloading from the conveyor ribbon110.

While the conveyor apparatuses and conveyor ribbons have been shown and described herein being used in conjunction with glass articles such as glass containers, glass vials, etc., it should be understood that the conveyor apparatuses and conveyor ribbons may be used to hold and retain various other types of glass articles including, without limitation, Vacutainers®, cartridges, syringes, ampoules, bottles, flasks, phials, tubes, beakers, vials or the like, including both round-form glass articles and non-round-form glass articles.

It should now be understood that the conveyor apparatuses and conveyor ribbons described herein may be used to hold and retain glass articles during processing. The conveyor apparatuses and conveyor ribbons may mitigate the introduction of flaws in the glass articles retained therein and limit the introduction of flaws to locations of the glass article which are more susceptible to breakage. The design of the conveyor apparatuses and ribbon apparatuses allow for continuous or batch ion-exchange processing of glass articles and also allows for sufficient contact between the glass articles and fluids, such as a salt bath, when the conveyor ribbon is submerged. The conveyor ribbons described herein also have a relatively low thermal mass and surface area which mitigates the degradation of ion-exchange performance.