Abstract: Apparatus (26) and a method for forming heated glass sheets in a heated chamber (22) of a housing (20) includes an upper mold support assembly (28) for supporting an upper mold (38) within the heated chamber for cyclical vertical movement between upper and lower positions. A lower mold shuttle (50) supports a lower mold (36) for cyclical movement between an idle position horizontally spaced from the upper mold and a use position below the lower mold. The apparatus also includes a lower mold support assembly (60) to which the lower mold is cyclically transferred from the lower mold shuttle (50) to provide support thereof while permitting horizontal alignment with the upper mold upon each cycle of downward movement to form a heated glass sheet between the molds. The lower mold shuttle (50) is supported by vertically movable rollers (70) to provide the transfer between the lower mold shuttle and the lower mold support assembly (60).

Abstract: Apparatus (26) and a method for forming heated glass sheets in a heated chamber (22) of a housing (20) includes an upper mold support assembly (28) for supporting an upper mold (38) within the heated chamber for cyclical vertical movement between upper and lower positions. A lower mold shuttle (50) supports a lower mold (36) for movement between an idle position horizontally spaced from the upper mold and a use position below the lower mold. The apparatus also includes a lower mold support assembly (60) to which the lower mold is transferred from the lower mold shuttle (50) to provide support thereof while permitting horizontal alignment with the upper mold upon each cycle of downward movement to form a heated glass sheet between the molds. The lower mold shuttle (50) is supported by vertically movable rollers (70) to provide the transfer between the lower mold shuttle and the lower mold support assembly (60).

Abstract: A furnace (10) and method for heating conveyed glass sheets within a housing (12) includes forced convection heaters (24) spaced along the direction of conveyance both below and above a roll conveyor (20). Each forced convection heater (24) includes a gas burner assembly (32) generally adjacent one of the housing side walls and has an outlet (34) through which products of combustion are supplied to the housing heating chamber (18) at a location intermediate its side walls. A hot gas distributor (38) of each forced convection heater (24) includes an inlet (40) that is spaced from the outlet (34) of the gas burner assembly (32), and the hot gas distributor (38) has a suction fan (42) for drawing in heated products of combustion together with spent recirculating gas in the heating chamber (18) for mixing to provide heated gas that is distributed to the conveyed glass sheets.

Abstract: Apparatus (16) and a method for roll bending heated glass sheets includes a pair of sets of bending rolls (40) and a support and drive mechanisms (44) that supports and rotatively drives the bending rolls at progressively increasing inclinations within a heating chamber (32) of a roll bending station (18) to provide engagement and bending at opposite lateral sides of a conveyed glass sheet. The bending rolls (44) are positioned in their progressively inclined inclinations by cooperation of an elongated connector (60) and clamps (64) for providing securement to curved support ribs (48) of an associated frame at the adjacent lateral side of the roll bending station housing.

Abstract: Apparatus (26) and a method for forming heated glass sheets in a heated chamber (22) of a housing (20) includes an upper mold support assembly (28) for supporting an upper mold (38) within the heated chamber for cyclical vertical movement between upper and lower positions. A lower mold shuttle (50) supports a lower mold (36) for movement between an idle position horizontally spaced from the upper mold and a use position below the lower mold. The apparatus also includes a lower mold support assembly (60) to which the lower mold is transferred from the lower mold shuttle (50) to provide support thereof while permitting horizontal alignment with the upper mold upon each cycle of downward movement to form a heated glass sheet between the molds. The lower mold shuttle (50) is supported by vertically movable rollers (70) to provide the transfer between the lower mold shuttle and the lower mold support assembly (60).

Abstract: A furnace (10) and method for heating conveyed glass sheets within a housing (12) includes forced convection heaters (24) spaced along the direction of conveyance both below and above a roll conveyor (20). Each forced convection heater (24) includes a gas burner assembly (32) generally adjacent one of the housing side walls and has an outlet (34) through which products of combustion are supplied to the housing heating chamber (18) at a location intermediate its side walls. A hot gas distributor (38) of each forced convection heater (24) includes an inlet (40) that is spaced from the outlet (34) of the gas burner assembly (32), and the hot gas distributor (38) has a suction fan (42) for drawing in heated products of combustion together with spent recirculating gas in the heating chamber (18) for mixing to provide heated gas that is distributed to the conveyed glass sheets.

Abstract: A press bending station (12) for heated glass sheets includes a lower wheel bed (36) having a lower support (38) and wheel assemblies (40) with detachable connections (46) to a drive mechanism (48) of the lower support to provide rotational driving of a wheel (44) of each wheel assembly. An actuator (62) provides relative vertical movement that lifts a heated glass sheet received by the wheel bed (36) to provide press bending thereof between a lower press ring (52) and an upper press mold (58). The wheel bed (36) can have a curved shape or a flat shape. Connection and detachment of the wheel assemblies (40) facilitates switching from one production job to the next.

Abstract: A method for roll forming a heated glass sheet utilizes a forming conveyor (62) including forming rolls (66) that are pivotally moved upwardly between horizontal rolls (46) of a horizontal conveyor (44) on opposite sides of a centerline (C/L) of the horizontal conveyor to rollingly engage the heated glass sheet above a plane of conveyance of the horizontal conveyor at its centerline to roll form the glass sheet in cooperation with a forming press (80) having rotatable forming members (82) that rollingly engage the heated glass sheet from above. A second set of forming rolls (68) cooperates with the first set of forming rolls (66) to provide the roll forming. First and second sets of roll cradles (76,90) are mounted by pivotal supports (128,142) on associated first and second carriages (154,156) and moved by first and second actuators (78,92). Lateral movement of the carriages (154,156) provides versatility in the glass sheet shapes that can be formed.

Abstract: A glass sheet quench station (16) includes first and second quench sections (24 and 26) that cooperate with a three position shuttle (28) and a control (30) to transfer glass sheets through the quench station with partial quenching performed at the first quench station and completion of the quenching at the second quench section. This glass sheet quenching method with two stage quenching shortens the cycle time to provide increased production.

Abstract: A glass sheet quench station (16) includes first and second quench sections (24 and 26) that cooperate with a three position shuttle (28) and a control (30) to transfer glass sheets through the quench station with partial quenching performed at the first quench station and completion of the quenching at the second quench section. This glass sheet quenching method with two stage quenching shortens the cycle time to provide increased production.

Abstract: A press bending station (12) for heated glass sheets includes a lower wheel bed (36) having a lower support (38) and wheel assemblies (40) with detachable connections (46) to a drive mechanism (48) of the lower support to provide rotational driving of a wheel (44) of each wheel assembly. An actuator (62) provides relative vertical movement that lifts a heated glass sheet received by the wheel bed (36) to provide press bending thereof between a lower press ring (52) and an upper press mold (58). The wheel bed (36) can have a curved shape or a flat shape. Connection and detachment of the wheel assemblies (40) facilitates switching from one production job to the next.

Abstract: A system (10) and method for forming and quenching glass sheets with curvatures both along and transverse to a direction of conveyance includes a furnace (12) having an exit end (22) with a roll bending station (14), a press bending station located downstream from the exit end of the furnace and having a lower ring mold (46) and an upper press mold (48) operated by an actuator (50), and a quench station (18) that provides toughening of the formed glass sheet. The location of the roll bending station (14) with sets (30) of inclined bending rolls (32) having increasing inclinations along the direction of conveyance together with the external press station (16) and the quench station (18) provides the glass sheet forming without the necessity for excessive heating so that the glass is sufficiently hot upon quenching to provide the toughening.

Abstract: Apparatus (16) and a method for roll bending heated glass sheets includes a pair of sets of bending rolls (40) and a support and drive mechanisms (44) that supports and rotatively drives the bending rolls at progressively increasing inclinations within a heating chamber (32) of a roll bending station (18) to provide engagement and bending at opposite lateral sides of a conveyed glass sheet. The bending rolls (44) are positioned in their progressively inclined inclinations by cooperation of an elongated connector (60) and clamps (64) for providing securement to curved support ribs (48) of an associated frame at the adjacent lateral side of the roll bending station housing.

Abstract: A method for forming glass sheets is performed by a system (10) that includes a furnace (12) having a heating chamber (14) in which a topside transfer device (20) has a downwardly facing surface (22) to which vacuum and pressurized air are supplied to receive and support a heated glass sheet from a conveyor (16) without any direct contact. A forming station (24) located externally of the furnace has a vertically movable upper mold (28) whose temperature is not greater than 500° C. The upper mold (28) cooperates with a horizontally movable lower ring (34) that transfers the heated glass sheet from the topside transfer device (20) to the forming station under the control of a first actuator (40). A second actuator (42) moves the upper mold (28) downwardly to cooperate with the lower ring (34) in forming the glass sheet. The external forming station (24) includes heat loss reducing apparatus (43) for reducing heat loss of the hot glass sheet during the forming.

Abstract: A method for forming glass sheets is performed by a system (10) that includes a furnace (12) having a heating chamber (14) in which a vacuum platen (20) has a downwardly facing surface (22) to which a vacuum is supplied to support a heated glass sheet received from a conveyor (16). A forming station (24) located externally of the furnace has a vertically movable upper mold (28) whose temperature is not greater than 500° C. The upper mold (28) cooperates with a horizontally movable lower ring (34). A first actuator (39) moves the vacuum platen (20) vertically to transfer a heated glass sheet from the conveyor (16) to the lower ring (34) which is then moved by a second actuator (40) to the forming station (24). A third actuator (42) then moves the upper mold (28) downwardly to cooperate with the lower ring (34) in forming the glass sheet. The forming station (24) includes apparatus (43) for reducing heat loss of the glass sheet during the forming.

Abstract: A method for heated mold changing at a forming station (24) is performed by apparatus (32) in a heated chamber (22) where heated glass sheets are cyclically formed. A switching station (318) is located adjacent the forming station (24). An unloading station (320) and a mold preheating station (322) are each located adjacent the switching station. An unloading cart (324) is initially movable from the loading station (320) to the switching station (318) and then to the forming station (24) to receive one or more heated molds from the forming station and is subsequently moved from the forming station back through the switching station to the unloading station to permit unloading of each heated mold. A loading cart supports a second mold or a pair of molds for heating within the mold preheating station (322) and is movable from the mold preheating station to the switching station (318) and then to the forming station for mold loading.

Abstract: A glass sheet forming system (10) includes apparatus (12) having a forming station (22) for forming glass sheets by cooperation of a lower deformable roll forming conveyor (26) and an upper deformable roll forming press (32). The upper deformable roll forming press (32) includes upper deformable rolls (34) whose axes are located along a direction of conveyance between the axes of lower deformable rolls (28) of the lower deformable roll forming conveyor (26) in a manner that prevents leading glass edge curling as the lower conveyor and upper forming press are moved between flat and curved shapes to provide glass sheet forming.

Abstract: A glass sheet quench unit (22) and method for quenching formed glass sheets by quench gas jets (40) that define a uniformly repeating gas jet impingement pattern (44) that is an equilateral triangular pattern providing uniformly repeating quench cells (46) distributed over the formed glass sheet to be quenched as equilateral hexagonal quench cells. The resultant product is a formed and quenched glass sheet (G) that has oppositely facing surfaces between which glass stresses are uniformly distributed. A method for making the quench unit (22) is performed by initially forming nozzle openings (38) in an elongated nozzle strip (36′), thereafter forming the nozzle strip with a curved cross section, thereafter forming the nozzle strip with a curved shape along its elongated length to provide a curved nozzle cap, subsequently securing the curved nozzle cap to planar sides (30) of an associated nozzle feed row (28), and securing the sides (30) of the nozzle feed row to a plenum housing (24).

Abstract: A method for making a furnace for heating a glass sheet by lower electric resistance elements (50) supported by a furnace housing (12) below a roll conveyor (40) and by supplying a gas burner heated hot gas flow from a forced convection heater (56) that provides a dominant mode of external heat for heating the conveyed glass sheet from above. The furnace is manufactured by retrofitting an electric resistance heater type glass sheet furnace that initially has both lower and upper electric resistance elements (50) located below and above the roller conveyor (40). The lower electric resistance elements (50) are maintained while the upper electric resistance elements (50) are replaced with a gas burner forced convection heater (56).

Abstract: Apparatus (32) for handling hot glass sheets includes a roll conveyor (14) and a topside transfer platen (18) that overlap to provide assistance in the initial support of heated glass sheets by the topside transfer platen through the use of a vacuum and pressurized air respectively applied to first and second sets of holes (40, 42) in a downwardly facing surface (38) of the topside transfer platen.