Glass form and marking

A system for forming a glass panel includes a mixing apparatus for weighing and mixing glass particles and additives, an oven for melting and holding molten glass, a float chamber for floating molten glass thereover, an annealing lehr, and at least a nozzle for delivering compressed air at least of one of a first pressure and a second pressure.

FIELD

The present disclosure relates to glass panels, for example as used in automotive driver and passenger side windows, and more particularly to an improved glass form and markings for such glass panels.

BACKGROUND

Referring toFIG.1, by way of example, modern automotive driver and passenger side windows (e.g., window10) generally follow an inboard curved path to detent secondary sealing members (e.g., secondary sealing members12) to contact a primary seal (e.g., primary seal14) to ensure water does not enter the cabin of the automobile. In many applications, ensuring water does not enter the cabin of the automobile is accomplished by providing a small radius formed into the top of the glass panel to securely engage with the primary seal. Under many applications, the radius may be as small as less than or equal to about 2 millimeters to greater than or equal to about 1 millimeter. The radius provides smooth operation of the window when proceeding from an open to closed position as well as ensures water does not run off into the cabin of the automobile or into the sealing member.

Under conventional processes, the top glass bend radius is formed late in the glass making process. More specifically, a thin layer of molten glass is passed along a glass panel forming system into a lehr, where the molten glass is annealed. After annealing, the glass is cut to shape to form a glass panel. The glass panel is then heated to, or kept at, a temperature sufficient that the glass panel is capable of bending as desired without breaking or otherwise sacrificing ductility, strength, and/or other desired properties, and the glass panel engages with a heated metal press or an air press, which gently bends the glass panel into the shape and contour desired.

Such conventional processes are very slow and costly. For example, when metal presses are used, metal dies of a glass panel forming system may need to be changed depending on the resultant glass panel desired. Further, on occasion, the small radius into the top of the glass panel to form the seal may mistakenly be missing, or the glass panels may be mislabeled, which may not be discovered until a fully assembled vehicle undergoes final inspection.

These issues with forming glass panels that seal properly, among other issues with forming glass panels, are addressed by the present disclosure.

SUMMARY

In one form, a system for forming a glass panel includes a mixing apparatus for weighing and mixing glass particles and additives, an oven for melting and holding molten glass, a float chamber for floating molten glass thereover, an annealing lehr, and at least a nozzle for delivering compressed air at at least of one of a first pressure and a second pressure.

In variations of the system, which may be implemented individually or in combination: the at least a nozzle for delivering compressed air at the second pressure marks a dot matrix onto the glass panel; the dot matrix comprises an eight-combination marking system; the dot matrix comprises readable binary code; the at least a nozzle for delivering compressed air comprises a first nozzle system for delivering air at the first pressure and further comprising a second nozzle system for delivering air at the second pressure; the at least a nozzle for delivering compressed air delivers compressed air at the first pressure and the second pressure; the system further includes a cutter disposed between the annealing lehr and the at least a nozzle; the float chamber includes at least one of a molten tin bath, an air blower, and a ceramic roller.

In another form, a system includes an annealing lehr configured to anneal glass, a cutter configured to cut the annealed glass into a glass panel, and a nozzle configured to provide compressed air at a specified pressure to bend the glass panel to a specified radius.

In variations of the system, which may be implemented individually or in combination: the glass panel includes a dot matrix; the nozzle is configured to provide compressed air at a second specified pressure to form the dot matrix in the glass panel; the dot matrix comprises an eight-combination marking system; the dot matrix comprises readable binary code; the system further includes a float chamber configured to float molten glass toward the annealing lehr; the float chamber includes at least one of a molten tin bath, an air blower, and a ceramic roller; the system further includes an oven configured to melt and hold molten glass; a mixing apparatus configured to weigh and mix glass particles and additives into a glass mixture; an oven configured to melt the glass mixture into molten glass; a float chamber configured to float a layer of the molten glass toward the annealing lehr; a controller configured to actuate the nozzle to provide the compressed air.

DETAILED DESCRIPTION

Systems and methods for forming a glass panel are disclosed. The systems and methods exhibit several advantages over conventional systems and processes, including providing cost savings, better reliability that the glass panel is properly formed and labeled, and increased production speeds.

Referring toFIG.2, a glass panel forming system100includes a mixing apparatus105(shown schematically) for weighing and mixing glass particles and, optionally, additives. The composition of glass particles and any optional additives can be predetermined depending on the properties desired in a resultant glass panel.

After sufficient mixing, the glass mixture is introduced into oven110. The oven110is heated to a temperature sufficient to melt the glass mixture into molten glass and may be in the shape of a tank having a stirrer to ensure the glass mixture remains homogenous.

A portion of the molten glass travels from the oven110to form a thin layer of molten glass over float chamber120. The float chamber120may comprise molten tin, continuous air blowers, or ceramic rollers, or other devices that function to create a desirable thin glass profile. By way of example, when the float chamber120comprises a molten tin bath, the thin layer of molten glass floats over the molten tin bath. The thickness of the molten glass can depend on the characteristics desired in the formed glass panel.

The thin layer of molten glass floats over the float chamber120and the temperature of the thin layer of molten glass decreases as its distance relative to the oven110increases. Thus, as the thin layer of molten glass exits the float chamber120, the thin layer of molten glass may be in a semi-hard yet moldable state. The thin layer of molten glass proceeds into lehr130, where the glass is annealed as desired.

The annealed glass continues to travel through the lehr130towards cutters140, where annealed glass is cut into glass panels having a desired length and width. The glass panels are kept at a temperature sufficient to maintain their moldability. The glass panels are then transferred along rollers, air blowers, or the like.

After annealing and cutting, the temperature of the glass panel is maintained at or heated to a temperature such that the glass panel is moldable, and the glass panel162and a first nozzle system150are located relative with one another such that compressed air directed from the first nozzle system150bends a top bend radius155into the glass panel162, as shown inFIG.3A. By way of example, compressed air is directed from the first nozzle system150for greater than or equal to about 5 milliseconds to less than or equal to about 7 milliseconds, which forms on a top edge of the glass panel162a curvature radius of greater than or equal to about 1.5 millimeters to less than or equal to about 3 millimeters. In a variation, water jets or other media that are capable of deforming glass panels without sacrificing the resultant glass properties could also be used rather than compressed air. The pounds per square inch (PSI) from each nozzle of the first nozzle system150can be calculated such that a precise and equal bend is achieved with every glass panel. The number of nozzles of the first nozzle system150can depend upon the size of the glass panel, the properties of the glass panel, the radius of the glass panel desired, and the like. According to a variation, the first nozzle system150comprises at least three nozzles156,157, and158, for delivering localized precise compressed air.

After the top bend radius155is formed on the glass panel162, second nozzle system160and the glass panel162are located relative with one another such that compressed air directed from the second nozzle system160forms at least an indentation on the glass panel162at a desired location, such as near the curvature developed by the first nozzle system150. Compressed air directed from the second nozzle system160is directed at a pressure higher than compressed air blasted from the first nozzle system150, forming an indentation pattern165. The indentation pattern165formed by compressed air directed from the second nozzle system160mark the glass panel162, and those markings can be used to identify characteristics of the glass panel162, such as whether the glass panel162was tempered, the tint level of the glass panel162, whether the glass panel162was laminated, the amount of radius of the top bend radius155formed by the first nozzle system150, for which application the glass panel162was designed for, and the like.

According to a variation, the second nozzle system160forms a plurality of indentations that can be used to identify characteristics of the glass. Referring toFIG.3B, according to a variation, a first indentation166may be sized differently than subsequent indentations (e.g., second indentation167) following the first indentation166to identify a start location, and a final indentation168may be sized differently than indentations preceding the final indentation168to identify an end location. In this manner, the indentation pattern165can form identification markings, such as a binary code pattern, where a dot present between the start location and end location can represent a1and an absence of a dot between the start location and end location can represent a0. With such a pattern, a binary code pattern of three possible indentations (e.g., the first indentation166, the second indentation167, and the final indentation168) placed between a start location and an end location can provide an 8-combination marking system, where each combination represents a marking for identifying the characteristics of the glass panel. According to yet another variation, the start location could be one of the three possible indentations. According to yet another variation, the end location could be one of the three possible indentations. According to yet another variations, the start location could be one of the three possible indentations, and the end location could be one of the other three possible indentations. Rounded indentations should be used to avoid creating stress points in the glass panels. The pounds per square inch (PSI) from each nozzle of the second nozzle system160can be calculated such that a predetermined, desirable indentation pattern is achieved with every glass panel. By way of not limiting example, the PSI may be less than or equal to about 5 PSI, and in some aspects, less than or equal to about 2 PSI. The number of nozzles of the second nozzle system160can depend upon the indentation pattern desired. According to a variation, the first nozzle system150comprises at least three nozzles for delivering localized precise compressed air. According to a variation, the indentation pattern (e.g., indentation pattern165) is placed near the corner of the glass panel such that it is not readily identifiable by an end user but readily apparent to a trained technician or engineer having knowledge of the indentation patterns contemplated hereunder.

A controller170(shown in phantom) may be used to control either or both of the first nozzle system150and the second nozzle system160. The controller170can determine, as non-limiting examples, whether to operate the nozzles of the first nozzle system150or the second nozzle system160, at what PSI the nozzles should operate, and for what duration the nozzles should operate. In a response from the controller, the nozzles will perform accordingly. The controller170may be preprogrammed or used in connection with a graphical user interface. According to yet further variations, the controller170can control the position of the nozzles of the first nozzle system150and/or the nozzles of the second nozzle system160, such as by repositioning mechanical arms having the nozzles attached thereto. According to yet further variations, the controller170can control a rotatable member that acts to rotate the positioning of the glass panel162, thereby allowing the controller170to position the glass panel162in an appropriate arrangement with the nozzles of the first nozzle system150and/or the nozzles of the second nozzle system160.

Referring toFIG.4, a glass panel forming system200includes a mixing apparatus205(shown schematically) for weighing and mixing glass and, optionally, additives. The composition of glass particles and any optional additives can be predetermined depending on the properties desired in a resultant glass panel.

After sufficient mixing, the glass mixture is introduced into oven210. The oven210is heated to a temperature sufficient to melt the glass mixture into molten glass and may be in the shape of a tank having a stirrer to ensure the glass mixture remains homogenous.

A portion of the molten glass travels from the oven210to form a thin layer of molten glass over float chamber220. The float chamber220may comprise molten tin, continuous air blowers, or ceramic rollers, or other devices that function to create a desirable thin glass profile. By way of example, when the float chamber220comprises a molten tin bath, the thin layer of molten glass floats over the molten tin bath. The thickness of the molten glass can depend on the characteristics desired in the formed glass panel.

The thin layer of molten glass floats over the float chamber220and the temperature of the thin layer of molten glass decreases as its distance relative to the oven210increases. Thus, as the thin layer of molten glass exits the float chamber220, the thin layer of molten glass may be in a semi-hard yet moldable state. The thin layer of molten glass proceeds into lehr230, where the glass is annealed as desired.

The annealed glass continues to travel through the lehr230towards cutters240, where annealed glass is cut into glass panels having a desired length and width. The glass panels are kept at a temperature sufficient to maintain their moldability. The glass panels are then transferred along rollers, air blowers, or the like.

After annealing and cutting, the temperature of the glass panel is maintained at or heated to a temperature such that the glass panel is moldable, and the glass panel and nozzle system250are located relative with one another such that compressed air directed from the nozzle system250bends a top bend radius255into a glass panel262, as shown inFIG.5A. By way of example, compressed air is directed from the nozzle system250for greater than or equal to about 5 milliseconds to less than or equal to about 7 milliseconds, which forms on a top edge of the glass panel a curvature radius of greater than or equal to about 1.5 millimeters to less than or equal to about 3 millimeters. The PSI from each nozzle of the nozzle system250can be calculated such that a precise and equal bend is achieved with every glass panel. The number of nozzles of the nozzle system250can depend upon the size of the glass panel, the properties of the glass panel, the radius of the glass panel desired, and the like. According to a variation, the nozzle system250comprises at least three nozzles256,257, and258, for delivering localized precise compressed air.

After the top bend radius255is formed on the glass panel262, the nozzle system250and the glass panel262are located relative with one another, to the extent necessary, such that compressed air directed from the nozzle system250forms an indentation pattern265on the glass panel262at a desired location, such as near the curvature previously developed by the nozzle system250. Compressed air directed from the nozzle system250at this stage is blasted at a pressure higher than previously blasted. The indentation pattern265formed by compressed air directed from the nozzle system250mark the glass panel262, and those markings can be used to identify characteristics of the glass panel262, such as whether the glass panel262was tempered, the tint level of the glass panel, whether the glass panel262was laminated, the amount of radius of the top bend radius255formed by the nozzle system250, for which application the glass panel was designed for, and the like.

According to a variation, the nozzle system250forms a plurality of indentations that can be used to identify characteristics of the glass. Referring toFIG.5B, according to a variation, a first indentation266may be sized differently than subsequent indentations (e.g., second indentation267) following the first indentation266to identify a start location, and a final indentation268may be sized differently than indentations preceding the final indentation268to identify an end location. In this manner, the indentation pattern265can form identifications markings, such as a binary code pattern, where a dot present between the start location and end location can represent a1and an absence of a dot between the start location and end location can represent a0. With such a pattern, a binary code pattern of three possible indentations (e.g., the first indentation166, the second indentation167, and the final indentation168) placed between a start location and an end location can provide an 8-combination marking system, where each combination represents a marking for identifying the characteristics of the glass panel. According to yet another variation, the start location could be one of the three possible indentations. According to yet another variation, the end location could be one of the three possible indentations. According to yet another variations, the start location could be one of the three possible indentations, and the end location could be one of the other three possible indentations. Rounded indentations should be used to avoid creating stress points in the glass panels. The PSI from each nozzle of the nozzle system250can be calculated such that a predetermined, desirable indentation pattern is achieved with every glass panel. By way of not limiting example, the PSI may be less than or equal to about 5 PSI, and in some aspects, less than or equal to about 2 PSI. The number of nozzles of the nozzle system250can depend upon the indentation pattern desired. According to a variation, the nozzle system250comprises at least three nozzles for delivering localized precise compressed air. Not every nozzle that is active to form the curvature of the glass panel may be active to form the indentation patterns, or vice versa. According to a variation, the indentation pattern (e.g., indentation pattern265is placed near the corner of the glass panel such that it is not readily identifiable by an end user but readily apparent to a trained technician or engineer having knowledge of the indentation patterns contemplated hereunder.

A controller270(shown in phantom) may be used to control nozzle system250. The controller270can determine, as non-limiting examples, which nozzles to operate of nozzle system250, at what PSI the nozzles should operate, and for what duration the nozzles should operate. In a response from the controller270, the nozzles will perform accordingly. The controller270may be preprogrammed or used in connection with a graphical user interface. According to yet further variations, the controller270can control the position of the nozzles of nozzle system250, such as by repositioning mechanical arms having the nozzles attached thereto. According to yet further variations, the controller270can control a rotatable member that acts to rotate the positioning of the glass panel, thereby allowing the controller270to position the glass panel in an appropriate arrangement with the nozzles of nozzle system250.

Referring toFIG.6, a flowchart of a routine300for preparing a glass panel according to the present disclosure is provided. At302, raw material is weighed and mixed. The raw material includes glass and optionally includes additives, which can depend on the properties desired in a resultant glass panel. After sufficient mixing, at304, the glass mixture is introduced into an oven, which is heated to a temperature sufficient to melt the glass mixture into molten glass. The oven may have a stirrer to ensure the glass mixture remains homogenous. At306, a portion of the molten glass travels from the oven to form a thin layer of molten glass over a float chamber. At308, the thin layer of molten glass passes into a lehr, where the glass is annealed as desired. At310, the annealed glass is cut by cutters to form a glass panel. At312, a first nozzle system distributes localized compressed air over a portion of the glass panel to provide a top bend radius into the glass panel. At314, a second nozzle system distributes localized compressed air at a pressure higher than the air distributed by the first nozzle system to form small indentations in the glass panel.

Referring toFIG.7, a flowchart of a routine400for preparing a glass panel according to the present disclosure is provided. At402, raw material is weighed and mixed. The raw material includes glass and optionally includes additives, which can depend on the properties desired in a resultant glass panel. After sufficient mixing, at404, the glass mixture is introduced into an oven, which is heated to a temperature sufficient to melt the glass mixture into molten glass. The oven may have a stirrer to ensure the glass mixture remains homogenous. At406, a portion of the molten glass travels from the oven to form a thin layer of molten glass over a float chamber. At408, the thin layer of molten glass passes into a lehr, where the glass is annealed as desired. At410, the annealed glass is cut by cutters to form a glass panel. At412, a nozzle system distributes localized compressed air over a portion of the glass panel to provide a top bend radius into the glass panel. At414, the nozzle system distributes localized compressed air at a pressure higher than the air previously distributed by the nozzle system to form small indentations in the glass panel.

According to the systems and processes disclosed above, it is believed glass panels can be much more quickly and accurately formed, and that greater than or equal to about 750 glass panels can be formed per hour according to the present disclosure.

While the examples above have been directed to automobile passenger and driver side windows, it is contemplated that the methods and systems disclosed herein extend to the formulation of any glass panels where having identification marking and/or sealing is desirable, including sun roofs, moon roofs, windshields, and back windows.

Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, manufacturing technology, and testing capability.

The term code may include software, firmware, and/or microcode, and may refer to programs, routines, functions, classes, data structures, and/or objects. The term memory circuit is a subset of the term computer-readable medium. The term computer-readable medium, as used herein, does not encompass transitory electrical or electromagnetic signals propagating through a medium (such as on a carrier wave); the term computer-readable medium may therefore be considered tangible and non-transitory.