Patent GB-1156319-A (GB)
Title: Improvements in or relating to the manufacture of Flat Glass
IPC: C03C1/00
Filed: 1965-10-22
Abstract: 1,156,319. Glass manufacture. PILKINGTON BROS. Ltd., D. G. LOUKES, and A. E. HAY. 12 Oct., 1966 [22 Oct., 1965], No. 44900/65. Heading C1M. Glass - forming materials in suitable proportions for constituting a particular glass are fed into a bath of molten metal maintained under controlled chemical and thermal conditions for synthesis of the glass, this glass then forming a layer on the surface of the molten metal from which it is removed. The materials may be in the form of elements which oxidize preferentially to the molten metal and oxidizing conditions are maintained, or in the form of elements which are more chemically reactive than the molten metal and compounds of which form glass. Alternatively, pre-reacted glass forming compounds such as oxides and/or sulphides may be added in finely divided form. The glass may include undissolved particles, for example, of alumina. Glass melting temperatures need not be as high as is usual and the resultant glass can be in the form of a thin film. The preferred metal is tin or tin alloy, particularly with copper, silver or nickel, one alloy given being 80% tin and 20% copper. A tin-free alloy given is 72% silver and 28% copper. The elements preferably are one of the group, silicon, boron, phosphorus; one or more of the group, sodium, potassium, barium, calcium, magnesium and where possible are added in the form of an alloy with the molten metal, e.g. Si, Na and Ca can each be added as 1% to 79% Sn, 20% Cu. The metal bath is then replenished by addition of pellets of the alloy. Alternatively, the elements can be continuously added by electrolysing compounds of the elements in contact with the molten metal. As shown, a bath 1 of 80% Sn, 20% Cu is contained in a tank structure 2, 3, 4, 5 and covered by roof 7 and walls 8, 9, 10 with ducts 17 through which a special atmosphere is introduced. Oxygen can be added, in controlled amounts, to the inert gas over the bath or only over the glass forming region. Alternatively, oxygen or nitrogen/oxygen or nitrogen/steam can be bubbled through the molten metal in this region. Temperature regulators 20, 21 are provided and a formed film 15 of glass is removed over a roller 13 to conveyer rollers 16. The glass forming elements, e.g. Si, Na and Ca are added to the molten metal by electrolysis of the salts Na, Cl, Ca, C1 2  and K 2 SiF 6  mixed with KCI and dissolved SiO 2 . The salts are contained in cells formed by a cross-wall 22 and partitions 23 between the wall 22 and front wall 4, and the cells communicate with the main body of the molten metal by an inlet channel 25 cut in the bottom of wall 22 and each cell separately has an outlet channel 26 cut into the top of wall 22 at the surface level 14 of the molten metal, the three channels 26 converging towards the centre of the bath 1. Vanes of paddle wheels 27 in each channel 26 dip into the surface level 14 of the molten metal and are driven to move the metal from the channels outward to the main bath and the molten metal is drawn through the channel 25 where it is directed by baffle walls 28 to flow through each cell. Each cell contains a layer 30 of one of the salts on top of the molten metal contained within a carbon barrier 31, with refractory lining, which prevents escape of the salt to the channel 26. Heaters 32 in channel 25 maintain the metal at the correct temperature. Each cell has a-' carbon electrode 33 dipping into the salt layer 30 and another carbon electrode 34 is immersed in the molten metal outside the cells and is insulated from and sealed into a side wall 3 of the tank. The electrodes 33, 34 are connected individually to power supplies, the electrodes 33 acting as anodes and electrodes 34 as cathodes. The supply of the Na, Ca, Si are therefore individually controlled to the prescribed concentrations. The glass is synthesized at about 1000 C. and collects as a layer 36 on the metal surface 14 and is removed as a thin film 15 of glass so light that it can be taken unharmed from the bath without any large degree of cooling or annealing. The side walls 3 are surfaced at 37 with graphite to prevent sticking. The salt layers 30 are replenished from hoppers 38 with shoots 39. The thin film 15 may, instead of passing the rollers 16, be drawn upwardly to an annealing lehr or passed on to a further metal bath.