Apparatus for production of curved glass and method for manufacturing same

A production apparatus making continuously curved crystalline glass as a cover or container includes a melting device, a drainage device, a molding device, and a crystallizing device. The melting device melts glass raw material to form a glass melt. The drainage device drains the glass melt to the molding device. The molding device includes a rotating table and a plurality of molding molds thereon. Each molding mold can be moved toward or away from the drainage device by the rotating table. Each molding mold has a molding cavity. At least one part of the molding cavity includes a plane, and at least one part of the molding cavity includes a curved surface to extrude the glass melt with such different surface forms. The crystallizing device crystallizes the curved glass member to achieve the curved crystallized glass member. A method for manufacturing such glass is also provided.

FIELD

The subject matter herein generally relates to a glass production.

BACKGROUND

Crystalline glass, also known as glass-ceramic, has low expansion, high temperature resistance, thermal shock resistance, and high transparency. It is widely used in electronic materials for Computer, Communication, and Consumer Electronic (3C) purposes, astronomical telescopes, tableware, high temperature resistance windows, and so on.

Non-flat glass used in 3C electronic products generally requires a small size and thinness. Conventional crystalline glass products are produced as large glass plates or large-sized glass blocks/bricks. When applied to 3C electronic products, the glass-ceramic products may need to be cut into small pieces, and then the small pieces of the glass-ceramic are thermoformed to achieve curved glass.

DETAILED DESCRIPTION

FIG. 1illustrates a glass production apparatus100configured to continuously prepare a curved crystalline glass member. The glass production apparatus100can include a melting device10, a drainage device20, a molding device30, a transferring device40, and a crystallizing device50. The melting device10can be configured to melt a glass raw material to prepare a glass melt (not shown). The drainage device20can be configured to drain the glass melt prepared by the melting device10to the molding device30. The molding device30can be configured to make the glass melt to prepare a curved glass member200as shown inFIG. 2. The transferring device40can be configured to transfer the curved glass member200to the crystallizing device50. The crystallizing device50can be configured to crystallize the curved glass member200to prepare a curved crystalline glass member (not shown). The curved crystalline glass member prepared by the glass production apparatus100of this disclosure can be applied to a mobile phone, used as a front and a rear cover plate, as a protective glass of a watch, as an instrument panel protection glass on a vehicle, as a protective glass of a wearable device, or for other purposes.

In the embodiment, the glass raw material can consist of a silicon dioxide having a mass fraction of 50%-60%, an aluminum oxide having a mass fraction of 10%-20%, a magnesium oxide having a mass fraction of 5%-10%, a titanium dioxide having a mass fraction of 2%-10%, an antimony trioxide having a mass fraction 0-2%, and an additive having a mass fraction of 5%-15%. The titanium dioxide acts as a nucleating agent to increase crystallinity of the curved crystalline glass member. The antimony trioxide acts as a clarifying agent to increase the clarity of the glass melt. The additive can be selected from one or more of sodium fluoride and magnesium fluoride. The additive can be used to improve a thermal stability of the curved crystalline glass member.

The melting device10has functions of heating, stirring, and filtration clarification, and is capable of melting the glass raw material at a temperature of about 1300 degrees centigrade to about 1600 degrees Celsius to prepare a clear glass melt.

In the embodiment, the melting device10can include a base11, a melting furnace12, and a heating member13. The melting furnace12can be positioned on the base11. A crucible (not shown) can be positioned in the melting furnace12. The crucible can be configured to receive the glass raw material and the glass melts. The crucible can be made of corundum. The heating element13can be inserted into the melting furnace12to heat the melting furnace12.

In the embodiment, the melting furnace12can further include a stirring mechanism (not shown) configured to stir the glass melt in the crucible to remove air bubbles.

In the present embodiment, the melting furnace12can further include a filtering mechanism (not shown) configured to filter the glass melt in the crucible to remove unmelted impurities in the glass melt.

In the embodiment, the melting furnace12can further include a sensor (not shown) configured to sense the volume or mass of the glass melt in the crucible, thus the melting furnace12controls the quantity of glass melt to flow to the drainage device20.

The drainage device20can include a drainage tube21, a temperature sensor, and a temperature controlling mechanism (not shown). The drainage tube21can be positioned on the melting furnace12and adjacent to a bottom of the melting furnace12(not shown). The drainage tube21can communicate with the melting furnace12to drain the glass melt into the molding device30.

A section of an opening211of the drainage tube21can be designed to be a predetermined shape according to a desired shape and a size of the curved glass member200, thus ensuring that the glass melt is completely filled into the molding mold of the molding device30. In the embodiment, the opening211of the drainage tube21has an elliptical cross section, thus a filling rate of the glass melt in the molding mold of the molding device30can be 95% or more. In other embodiments, the opening211of the drainage tube21can have a rectangular cross section to enable the filling rate of the glass melt in the molding mold of the molding device30to be more than 90%.

In the least one embodiment, the cross section of the opening211of the drainage tube21can be other polygonal shape according to a desired shape and a size of the curved glass member200.

The opening211of the drainage tube21and the molding mold of the molding device30have a predetermined height in a perpendicular direction to simultaneously cool the glass melt flowing into the molding mold of the molding device30. A temperature of the glass melt flowing into the molding mold can be 700 to 850 degrees Celsius.

In the embodiment, the drainage tube21can be made of a platinum or a platinum alloy.

The temperature sensor and the temperature controlling mechanism can be positioned on the drainage tube21. The temperature sensor can be configured to detect a temperature of the drainage tube21. The temperature controlling mechanism can be configured to adjust a temperature of the drainage tube21to a preset temperature to slowly and uniformly cool the glass melt in the drainage tube21.

The molding device30can include a supporting table31, a rotary table32, a plurality of molding molds33, and a manipulator34. The supporting table31can be adjacent to the drainage device20. The rotary table32can be substantially circular. The rotary table32can be positioned on the supporting table31. The plurality of molding molds33can be provided on the rotary table32and uniformly distributed in a circumferential direction of the rotary table32. The rotary table32can move each molding mold33toward to or away from the opening211of the drainage tube21. Each molding mold33can be configured to curvedly mold the glass melt to prepare the curved glass member200.

In the embodiment, referring toFIG. 2andFIG. 4, each molding mold33can be a hot press molding mold or a hot pressing and heat absorbing composite molding mold. Each molding mold33can include a female mold331and a male mold332engaged with the female mold331. A molding cavity333can be defined between the female mold331and the male mold332. At least one portion of the molding cavity333can include a plane surface and at least one portion of the molding cavity333can include a curved surface to prepare the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt. The manipulator34can be positioned on the supporting table31. The manipulator34can be configured to separate the male mold332from the female mold331or to engage the male mold332to the female mold331to open or close the molding mold33.

The male mold332of each molding mold33acting as the hot press molding mold can be made of graphite or platinized cemented carbide. The male mold332can prepare a curved glass member by applying pressure to the glass melt received in the female mold331.

The female mold331of each molding mold33acting as the hot pressing and heat absorbing composite molding mold can be made of graphite or a porous ceramic material. The female mold331can be connected to a vacuum generator (not shown). The male mold332can press the glass melt received in the female mold331, and the glass melt being vacuum-adsorbed by the female mold331prepares the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

In at least one embodiment, referring toFIG. 3, each molding mold33can also be a heat absorbing molding mold. Each molding mold33can be made of graphite or porous ceramic material. A molding cavity333can be defined in the molding mold33. At least one portion of the molding cavity333can include a plane surface and at least one portion of the molding cavity333can include a curved surface to receive the glass melt. Each molding mold33can be connected to a vacuum generator (not shown). Each molding mold33can adsorb the glass melt to the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

In the embodiment, the molding device30can further include a temperature controlling mechanism, a gas protection mechanism, and a controller (not shown). The temperature controlling mechanism can be configured to preheat each molding mold33to a preset temperature of 700 to 850 degrees Celsius. The gas protection mechanism can be configured to protect each molding mold33during molding process and cooling process in a protective atmosphere. The controller can be configured to control the temperature controlling mechanism and the gas protection mechanism.

The transferring device40can include a robot arm41and a suction member42. The robot arm41can be arranged adjacent to the supporting table31of the molding device30. The suction member42can be positioned on an end of the robot arm41. The robot arm41can move the suction member42. The suction member42can be configured to get the curved glass member200received in a molding mold33and to release the curved glass member200to the crystallizing device50.

The crystallizing device50can include a transferring mechanism51and a crystallizing furnace52. The transferring mechanism51can be configured to transfer the curved glass member200into the crystallizing furnace52. The crystallizing furnace52can be configured to crystallize the curved glass member200to achieve a curved crystalline glass member (not shown).

FIG. 5shows a flowchart of a glass manufacturing method of the glass production apparatus to continuously prepare a curved crystalline glass member (not shown).

Referring toFIG. 1toFIG. 5, the glass manufacturing method in a first embodiment can include the following processes.

S101: a glass raw material is prepared.

Specifically, the silicon dioxide having a mass fraction of 50%, the aluminum oxide having a mass fraction of 20%, the magnesium oxide having a mass fraction of 10%, the titanium oxide having a mass fraction of 10%, the trioxide having a mass fraction of 1%, and the additive having a mass fraction of 9% can be mixed to prepare the glass raw material.

S102: the melting device10melts the glass raw material to prepare a glass melt.

Specifically, the glass raw material is placed into the crucible of the melting furnace12of the melting device10and is subjected to a high-temperature by the heating member13. The stirring mechanism stirs the glass melt in the crucible, and the filtering mechanism filters the glass melt in the crucible during the high-temperature melting process. A temperature of the high-temperature melting treatment is about 1300 degrees Celsius.

S103: the drainage device20drains the glass melt into a molding mold33of the molding device30.

Specifically, the temperature controlling mechanism of the drainage device20adjusts a temperature of the drainage tube21to 900 degrees Celsius to slowly and uniformly cool the glass melt in the drainage tube21. The temperature controlling mechanism of the molding device30preheats each molding mold33to about 700 degrees. The drainage device20drains the glass melt into a molding mold33of the molding device30, and a temperature of the glass melt flowed into the molding mold33is about 700 degrees Celsius.

S104: each molding mold33of the molding device30prepares the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

Specifically, the gas protection mechanism of the molding device30protects each molding mold33acting as the hot press molding mold during molding process and cooling process in a protective atmosphere. The manipulator34places the male mold332on a female mold331. The male mold332of each molding mold33is pressured to 0.3 of standard atmospheric pressure and is held for 10 minutes. Then each molding mold33cools to room temperature. Finally, the manipulator34separates the male mold332from the female mold331.

It can be understood that the gas protection mechanism of the molding device30protects each molding mold33acting as heat absorbing molding mold during molding process and cooling process in a protective atmosphere. Each molding mold33is evacuated by the vacuum generator (not shown) at one standard atmospheric pressure and held for 10 minutes. Then each molding mold33cools to room temperature to prepare the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

It can be understood that the gas protection mechanism of the molding device30protects each molding mold33acting as the hot pressing and heat absorbing composite molding mold during molding process and cooling process in a protective atmosphere. The manipulator34places the male mold332on a female mold331. The male mold332of each molding mold33is pressured to 0.2 of standard atmospheric pressure and held for 10 minutes. Simultaneously, the female mold331of each molding mold33is evacuated by the vacuum generator (not shown) at one standard atmospheric pressure and held for 10 minutes. Then each molding mold33cools to room temperature. Finally, the manipulator34separates the male mold332from the female mold331to prepare the curved glass member200.

S105: the transferring device40gets the curved glass member200received in the molding mold33and releases the curved glass member200to the crystallizing device50.

Specifically, the robot arm41of the transferring device40drives the suction member42to get the curved glass member200received in the molding mold33and to release the curved glass member200to the transferring mechanism51of the crystallizing device50.

S106: the crystallizing device50crystallizes the curved glass member200to prepare a curved crystalline glass member (not shown).

Specifically, the transferring mechanism51of the crystallizing device50transfers the curved glass member200into the crystallizing furnace52of the crystallizing device50. The crystallizing furnace52performs crystallization heating treatment on the curved glass member200. The crystallization heating treatment employs a temperature-step controlling system. The temperature controlling system is that, in the first stage, the crystallizing furnace52is heated to 680 degrees at a rate of 10 degrees/min, and held for 2 hours. In the second stage, the crystallizing furnace52is further heated to 800 degrees at a rate of 10 degrees/min and held for 4 hours. Finally, the crystallized furnace52is cooled to room temperature to achieve a curved crystalline glass member (not shown).

The glass manufacturing method in second embodiment can include the following processes.

S201: a glass raw material is prepared.

Specifically, the silicon dioxide having a mass fraction of 55%, the aluminum oxide having a mass fraction of 15%, the magnesium oxide having a mass fraction of 5%, the titanium oxide having a mass fraction of 8%, the trioxide having a mass fraction of 2%, and the additive having a mass fraction of 15%, can be mixed to prepare the glass raw material.

S202: the melting device10melts the glass raw material to prepare a glass melt.

Specifically, the glass raw material is placed into the crucible of the melting furnace12of the melting device10and is subjected to high-temperature by the heating member13. The stirring mechanism stirs the glass melt in the crucible, and the filtering mechanism filters the glass melt in the crucible during a high-temperature melting process. A temperature of the high-temperature melting treatment is about 1500 degrees Celsius.

S203: the drainage device20drains the glass melt into a molding mold33of the molding device30.

Specifically, the temperature controlling mechanism of the drainage device20adjusts a temperature of the drainage tube21to 900 degrees Celsius to slowly and uniformly cool the glass melt in the drainage tube21. The temperature controlling mechanism of the molding device30preheats each molding mold33to 750 degrees. The drainage device20drains the glass melt into a molding mold33of the molding device30, and a temperature of the glass melt flowing into the molding mold33is 800 degrees Celsius.

S204: each molding mold33of the molding device30prepares the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

Specifically, the gas protection mechanism of the molding device30protects each molding mold33acting as the hot press molding mold during molding process and cooling process in a protective atmosphere. The manipulator34places the male mold332on a female mold331. The male mold332of each molding mold33is pressured to 0.5 of standard atmospheric pressure and is held for 15 minutes. Then each molding mold33cools to room temperature. Finally, the manipulator34separates the male mold332from the female mold331.

It can be understood that the gas protection mechanism of the molding device30protects each molding mold33acting as heat absorbing molding mold during molding process and cooling process in a protective atmosphere. Each molding mold33is evacuated by the vacuum generator (not shown) at 1.5 standard atmospheric pressure and held for 20 minutes. Then each molding mold33cools to room temperature to prepare the curved glass member200by simultaneously mold planar and curved surfaces for the glass melt.

It can be understood that the gas protection mechanism of the molding device30protects each molding mold33acting as the hot pressing and heat absorbing composite molding mold during molding process and cooling process in a protective atmosphere. The manipulator34places the male mold332on a female mold331. The male mold332of each molding mold33is pressured to 0.4 of standard atmospheric pressure and held for 15 minutes. Simultaneously, the female mold331of each molding mold33is evacuated by the vacuum generator (not shown) at 1.5 standard atmospheric pressure and held for 15 minutes. Then each molding mold33cools to room temperature. Finally, the manipulator34separates the male mold332from the female mold331to prepare the curved glass member200.

S205: the transferring device40gets the curved glass member200received in the molding mold33and then releases the curved glass member200to the crystallizing device50.

Specifically, the robot arm41of the transferring device40drives the suction member42to get the curved glass member200received in the molding mold33and then release the curved glass member200to the transferring mechanism51of the crystallizing device50.

Step S206: the crystallizing device50crystallizes the curved glass member200to prepare a curved crystalline glass member (not shown).

Specifically, the transferring mechanism51of the crystallizing device50transfers the curved glass member200into the crystallizing furnace52of the crystallizing device50. The crystallizing furnace52performs crystallization heating treatment on the curved glass member200. The crystallization heating treatment employs a step-temperature controlling system. The temperature-step controlling system is that, in the first stage, the crystallizing furnace52is heated to 730 degrees at a rate of 10 degrees/min, and held for 3.5 hours. In the second stage, the crystallizing furnace52is further heated to 850 degrees at a rate of 10 degrees/min and held for 7 hours. Finally, the crystallized furnace52is cooled to room temperature to achieve a curved crystalline glass member (not shown).

The glass manufacturing method in third embodiment can include the following processes.

S301: a glass raw material is prepared.

Specifically, the silicon dioxide having a mass fraction of 60%, the aluminum oxide having a mass fraction of 10%, the magnesium oxide having a mass fraction of 10%, the titanium oxide having a mass fraction of 10%, the trioxide having a mass fraction of 10%, and the additive having a mass fraction of 10%, can be mixed to prepare the glass raw material.

S302: the melting device10melts the glass raw material to prepare a glass melt.

Specifically, the glass raw material is placed into the crucible of the melting furnace12of the melting device10and is subjected to high-temperature by the heating member13. The stirring mechanism stirs the glass melt in the crucible, and the filtering mechanism filters the glass melt in the crucible to during the melting process. A temperature of the high-temperature melting treatment is 1600 degrees Celsius.

S303: the drainage device20drains the glass melt into a molding mold33of the molding device30.

Specifically, the temperature controlling mechanism of the drainage device20adjusts a temperature of the drainage tube21to 900 degrees Celsius to slowly and uniformly cool the glass melt in the drainage tube21. The temperature controlling mechanism of the molding device30preheats each molding mold33to 850 degrees. The drainage device20drains the glass melt into a molding mold33of the molding device30, and a temperature of the glass melt flowing into the molding mold33is 850 degrees Celsius.

S304: each molding mold33of the molding device30prepares the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

Specifically, the gas protection mechanism of the molding device30protects each molding mold33acting as the hot press molding mold during molding process and cooling process in a protective atmosphere. The manipulator34places the male mold332on a female mold331. The male mold332of each molding mold33is pressured to 0.6 of standard atmospheric pressure and is held for 20 minutes. Then each molding mold33cools to room temperature. Finally, the manipulator34separates the male mold332from the female mold331to prepare the curved glass member200.

It can be understood that the gas protection mechanism of the molding device30protects each molding mold33acting as heat absorbing molding mold during molding process and cooling process in a protective atmosphere. Each molding mold33is evacuated by the vacuum generator (not shown) at 2 standard atmospheric pressure and held for 25 minutes. Then each molding mold33cools to room temperature to prepare the curved glass member200by simultaneously molding planar and curved surfaces on the glass melt.

It can be understood that the gas protection mechanism of the molding device30protects each molding mold33acting as the hot pressing and heat absorbing composite molding mold during molding process and cooling process in a protective atmosphere. The manipulator34places the male mold332on a female mold331. The male mold332of each molding mold33is pressured to 0.5 of standard atmospheric pressure and held for 10 minutes. Simultaneously, the female mold331of each molding mold33is evacuated by the vacuum generator (not shown) at 2 standard atmospheric pressure and held for 10 minutes. Then each molding mold33cools to room temperature. Finally, the manipulator34separates the male mold332from the female mold331to prepare the curved glass member200.

S305: the transferring device40gets the curved glass member200received in the molding mold33and releases same to the crystallizing device50.

Specifically, the robot arm41of the transferring device40drives the suction member42to get the curved glass member200received in the molding mold33and release the curved glass member200to the transferring mechanism51of the crystallizing device50.

Step S306: the crystallizing device50crystallizes the curved glass member200to prepare a curved crystalline glass member (not shown).

Specifically, the transferring mechanism51of the crystallizing device50transfers the curved glass member200into the crystallizing furnace52of the crystallizing device50. The crystallizing furnace52performs crystallization heating treatment on the curved glass member200. The crystallization heating treatment employs a temperature-step controlling system. The temperature controlling system is that, in the first stage, the crystallizing furnace52is heated to 780 degrees at a rate of 10 degrees/min, and held for 5 hours. In the second stage, the crystallizing furnace52is further heated to 900 degrees at a rate of 10 degrees/min and held for 10 hours. Finally, the crystallized furnace52is cooled to room temperature to obtain a curved crystalline glass member (not shown).

It can be understood that processes S105, S205, and S305can be removed without affecting the crystallizing of the curved glass member200by the crystallizing device50.

In other embodiment, the transferring device40can be omitted, the curved glass member200prepared by the molding device30can be directly transferred to the crystallizing device50by an operator.

In other embodiment, the supporting table31and the manipulator34can be omitted, each molding mold33can be directly opened or closed by an operator. In addition, each molding mold33can function as the heat absorbing molding mold without opening and closing.