FORMING STATION AND METHOD FOR FORMING A HOT GLASS SHEET WITH TRANSVERSE CURVATURE
A glass sheet press forming station (32) and method for press forming hot glass sheets with transverse curvature is performed by initially limiting the central forming of a glass sheet (G) between its end portions upon pickup from a roll conveyor to an upper mold (38) and prior to press forming with an associated lower mold (66) to prevent central area optical distortion of the press formed glass sheet.
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This invention relates to a forming station and method for forming a hot glass sheet with transverse curvature having improved optics.
BACKGROUNDU.S. Pat. No. 4,661,141 Nitschke et al. discloses a glass sheet press bending system for bending hot glass sheets by conveying a hot glass sheet to below an upper mold that is moved downwardly to receive a hot glass sheet and provide support thereof by upwardly directed gas jets supplied from below a plane of conveyance of a roll conveyor and by a vacuum drawn at the upper mold, and the upper mold is then moved upwardly with the glass sheet supported thereon by contact with two thirds or more of the downwardly facing surface along the length of the glass sheet. When glass sheets are formed with transverse curvature, i.e., curvature in directions that cross each other without any straight line elements, the periphery of the glass sheet has excess glass that can cause excess pressure between the mold and the glass sheet at the center of the glass sheet and thereby result in undesirable optics both as to reflection and to transmission in the central viewing area of the glass.
In connection with the type of system disclosed by the aforementioned U.S. Pat. No. 4,661,141, see also U.S. Pat. No. 5,900,034 Mumford et al.; U.S. Pat. No. 5,906,668 Mumford et al.; U.S. Pat. No. 5,917,107 Ducat et al.; U.S. Pat. No. 5,925,162 Nitschke et al.; U.S. Pat. No. 6,032,491 Nitschke et al.; U.S. Pat. No. 6,079,094 Ducat et al.; U.S. Pat. No. 6,173,587 Mumford et al.; U.S. Pat. No. 6,418,754 Nitschke et al.; U.S. Pat. No. 6,718,798 Nitschke et al.; and U.S. Pat. No. 6,729,160 Nitschke et al.
SUMMARYAn object of the present invention is to provide an improved forming station for forming a hot glass sheet with transverse curvature.
In carrying out the above object, a forming station constructed according to the invention forms a hot glass sheet that has a pair of spaced end portions with distal extremities and that also has an intermediate portion extending between its end portions, and the forming station includes a housing having a heated chamber and also includes a roll conveyor for conveying the hot glass sheet into its heated chamber along a plane of conveyance. An upper mold of the forming station is located within the heated chamber above the roll conveyor and has a downwardly facing surface that has a downwardly convex shape with curvature in transverse directions, and the upper mold is movable between an upper position spaced above the roll conveyor and a lower position adjacent the roll conveyor. A vacuum source of the forming station is operable to draw a vacuum at the downwardly facing surface of the upper mold, and a gas lift jet array located below the roll conveyor in the forming station supplies upwardly directed gas lift jets that provide the sole impetus for lifting the glass sheet upwardly from the roll conveyor to the upper mold in its lower position and contacting the intermediate portion of the lifted glass sheet with the downwardly facing surface of the upper mold for less than 50% of the distance between the distal extremities of the end portions of the glass sheet, whereupon the upper mold and the glass sheet are moved upwardly to the upper position of the upper mold. A lower mold of the forming station has a ring shape that faces upwardly with a concave shape in transverse directions complementary to the downwardly convex shape of the downwardly facing surface of the upper mold, and the lower mold is movable horizontally within the heated chamber of the forming station at a location above the roll conveyor to below the upper mold in its upper position with the glass sheet supported on the upper mold by the gas lift jet array, whereupon the upper mold is moved downwardly and the vacuum source is operated to draw a vacuum at the downwardly facing surface of the upper mold and press form the glass sheet between the upper and lower molds to provide curvature of the glass sheet in transverse directions, and the upper mold is then moved upwardly to its upper position with the press formed glass sheet supported on the upper mold by the vacuum drawn at its downwardly facing surface. A delivery mold of the forming station is then moved to below the press formed glass sheet on the upper mold in its upper position whereupon the vacuum drawn at the upper mold by the vacuum source is terminated to release the glass sheet from the upper mold onto the delivery mold which is then moved out of the forming station for delivery of the press formed glass sheet. A controller of the forming station operates the roll conveyor, the upper mold, the vacuum source, the gas lift jet array, the lower mold, and the delivery mold to provide the press forming operation of the glass sheet and its delivery.
As disclosed, the controller of the forming station terminates the operation of the gas lift jet array providing the upwardly directed gas lift jets before completion of the press forming of the glass sheet between the upper and lower molds, and preferably the controller terminates the operation of the gas lift jet array providing the upwardly directed gas lift jets as the downward movement of the upper mold with the glass sheet supported thereon begins the press forming of the glass sheet between the upper and lower molds.
As disclosed, the gas lift jet array includes a pair of end portions for lifting the end portions of the glass sheet and a central potion for lifting the intermediate portion of the glass sheet, and the gas lift jet array also includes a control for controlling pressures of gas supplied to the end portions and to the central portion of the gas lift jet array.
In an alternate embodiment, the forming station includes a pair of positioners movable under the operation of the controller to blocking positions below the upper mold prior to operation of the gas lift jet array to limit upward movement of the end portions of the glass sheet toward the downwardly facing surface of the upper mold and thereby limit the extent of the intermediate portion of the glass sheet that contacts the downwardly facing surface of the upper mold, and the controller subsequently moving the pair of positioners from their blocking positions to unblocking positions to permit the subsequent press forming of the glass sheet between the upper and lower molds. As disclosed, the pair of positioners have respective pivotal connections providing support thereof on the upper mold for their movement between the blocking and unblocking positions under the operation of the controller.
The forming station as disclosed is used with a system having a quench station to which the delivery mold moves the press formed glass sheet for quenching under the operation of the controller.
Another object of the present invention is to provide an improved method for forming a hot glass sheet with transverse curvature.
In carrying out the immediately preceding object, the method is performed on a hot glass sheet that has a pair of spaced end portions with distal extremities and that also has an intermediate portion extending between its end portions, and the method commences by conveying the hot glass sheet on a conveyor into a heated chamber of a forming station to below an upper mold that is located above the conveyor and has a downwardly facing surface that has a downwardly convex shape with curvature in transverse directions. The upper mold is then moved downwardly from an upper position to a lower position adjacent the glass sheet on the conveyor and operation of a gas lift jet array provides upwardly directed lift jets as the sole impetus for lifting the glass sheet from the conveyor and contacting the intermediate portion of the glass sheet with the downwardly facing surface of the upper mold for less than 50% of the distance between the distal extremities of the end portions of the glass sheet, whereupon the upper mold and the glass sheet are moved upwardly to the upper position of the upper mold. A lower mold having a ring shape, that faces upwardly with a concave shape in transverse directions complementary to the downwardly convex shape of the downwardly facing surface of the upper mold, is then moved horizontally within the heated chamber to a location above the conveyor and below the upper mold in its upper position with the glass sheet supported on the upper mold, and the upper mold is then moved downwardly and a vacuum is drawn at the downwardly facing surface of the upper mold to press form the glass sheet between the upper and lower molds and provide curvature of the glass sheet in transverse directions, whereupon the upper mold is moved upwardly to its upper position with the press formed glass sheet supported on the upper mold by the vacuum drawn at its downwardly facing surface. Then, a delivery mold is moved to below the press formed glass sheet on the upper mold in its upper position whereupon the vacuum drawn at the upper mold is terminated to release the glass sheet from the upper mold onto the delivery mold which is then moved out of the forming station for delivery of the press formed glass sheet.
As disclosed, the method is performed by terminating the operation of the gas lift jet array before completion of the press forming of the glass sheet between the upper and lower molds, and preferably the operation of the gas lift jet array is terminated as the downward movement of the upper mold with the glass sheet supported thereon begins the press forming of the glass sheet between the upper and lower molds.
As disclosed, gas pressures that are respectively supplied to the end portions and to the intermediate portion of the glass sheet are controlled to limit the extent of the intermediate portion of the glass sheet that contacts the downwardly facing surface of the upper mold. More specifically, a lesser glass pressure is disclosed as being supplied to the end portions of the glass sheet than to the intermediate potion of the glass sheet, with the gas pressure supplied to the end portions of the glass sheet being 50 to 75% of the gas pressure supplied to the intermediate portion of the glass sheet.
In an alternate practice of the method, a pair of positioners are moved to blocking positions below the upper mold prior to operation of the gas lift jet array to limit upward movement of the end portions of the glass sheet toward the downwardly facing surface of the upper mold and thereby limit the extent of the intermediate portion of the glass sheet that initially contacts the downwardly facing surface of the upper mold, and the pair of positioners are subsequently moved from their blocking positions to unblocking positions to permit the subsequent press forming of the glass sheet between the upper and lower molds. As disclosed, the pair of positioners are moved between the blocking and unblocking positions about respective pivotal connections thereof on the upper mold.
After the press forming operation between the upper and lower molds, the press formed glass sheet is disclosed as being moved on the delivery mold from the forming station to a quench station for quenching.
In performing the preferred practice of the method, the operation of the gas lift jet array is terminated as the downward movement of the upper mold with the glass sheet supported thereon begins the press forming of the glass sheet between the upper and lower molds, and the press formed glass sheet is moved on the delivery mold from the forming station to the quench station for quenching.
The objects, features and advantages of the present invention are readily apparent from the detailed description of the preferred embodiments when taken in connection with the referenced drawings.
As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to practice the present invention.
With reference to
As illustrated in
A schematically indicated source of vacuum 50 is shown in
As schematically illustrated in
As illustrated in
Upon lifting the glass sheet from the roll conveyor 26 as shown in
A lower mold 66 of the forming station 30 has a ring shape as shown in
A controller 84 shown in
With reference to the flow chart of
In the preferred practice of the press forming operation described above, the operation of the gas lift jet array 54 providing the upwardly directed gas lift jets 58 shown in
With reference to
With reference to
As disclosed, the blocking members 122 have pivotal connections 124 to the upper mold 38 and, more specifically as shown in
All of the previously mentioned patents are assigned to the applicant of the present application and are hereby incorporated by reference.
While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.
Claims
1. A forming station for forming a hot glass sheet having a pair of spaced end portions with distal extremities and also having an intermediate portion extending between its end portions, the forming station comprising:
- a housing having a heated chamber;
- a roll conveyor for conveying the hot glass sheet into the heated chamber of the forming station along a plane of conveyance;
- an upper mold located within the heated chamber of the forming station above the roll conveyor and having a downwardly facing surface that has a downwardly convex shape with curvature in transverse directions, and the upper mold being movable between an upper position spaced above the roll conveyor and a lower position adjacent the roll conveyor;
- a vacuum source for drawing a vacuum at the downwardly facing surface of the upper mold;
- a gas lift jet array located in the forming station below the plane of conveyance of the glass sheet to supply upwardly directed gas lift jets that provide the sole impetus for lifting the glass sheet upwardly from the roll conveyor to the upper mold in its lower position and contacting the intermediate portion of the lifted glass sheet with the downwardly facing surface of the upper mold for less than 50% of the distance between the distal extremities of the end portions of the glass sheet, whereupon the upper mold and the glass sheet are moved upwardly to the upper position of the upper mold;
- a lower mold having a ring shape that faces upwardly with a concave shape in transverse directions complementary to the downwardly convex shape of the downwardly facing surface of the upper mold, the lower mold being movable horizontally within the heated chamber of the forming station at a location above the roll conveyor to below the upper mold in its upper position with the glass sheet supported on the upper mold by the gas lift jet array, whereupon the upper mold is moved downwardly and the vacuum source is operated to draw a vacuum at the downwardly facing surface of the upper mold and press form the glass sheet between the upper and lower molds to provide curvature of the glass sheet in transverse directions, and the upper mold then being moved upwardly to its upper position with the press formed glass sheet supported on the upper mold by the vacuum drawn at its downwardly facing surface;
- a delivery mold that is then moved to below the press formed glass sheet on the upper mold in its upper position whereupon the vacuum drawn at the upper mold by the vacuum source is terminated to release the glass sheet from the upper mold onto the delivery mold which is then moved out of the forming station for delivery of the press formed glass sheet; and
- a controller for operating the roll conveyor, the upper mold, the vacuum source, the gas lift jet array, the lower mold, and the delivery mold to provide the press forming of the glass sheet and its delivery.
2. A forming station as in claim 1 wherein the controller terminates the operation of the gas lift jet array providing the upwardly directed gas lift jets before completion of the press forming of the glass sheet between the upper and lower molds.
3. A forming station as in claim 2 wherein the controller terminates the operation of the gas lift jet array providing the upwardly directed gas lift jets as the downward movement of the upper mold with the glass sheet supported thereon begins the press forming of the glass sheet between the upper and lower molds.
4. A forming station as in claim 1 wherein the gas lift jet array includes a pair of end portions for lifting the end portions of the glass sheet and a central portion for lifting the intermediate portion of the glass sheet, and the gas lift jet array also includes a control for controlling pressure of gas supplied to the end portions and to the central portion of the gas lift jet array.
5. A forming station as in claim 1 further including a pair of positioners movable under the operation of the controller to blocking positions below the upper mold prior to operation of the gas lift jet array to limit upward movement of the end portions of the glass sheet toward the downwardly facing surface of the upper mold and thereby limit the extent of the intermediate portion of the glass sheet that contacts the downwardly facing surface of the upper mold, and the controller subsequently moving the pair of positioners from their blocking positions to unblocking positions to permit the subsequent press forming of the glass sheet between the upper and lower molds.
6. A forming station as in claim 4 wherein the pair of positioners have respective pivotal connections providing support thereof on the upper mold for their movement between the blocking and unblocking positions under the operation of the controller.
7. A forming station as in claim 1 that is used with a system having a quench station to which the delivery mold moves the press formed glass sheet for quenching under the operation of the controller.
8. A forming station for forming a hot glass sheet having a pair of spaced end portions with distal extremities and also having an intermediate portion extending between its end portions, the forming station comprising:
- a housing having a heated chamber;
- a roll conveyor for conveying the hot glass sheet into the heated chamber of the forming station along a plane of conveyance;
- an upper mold located within the heated chamber of the forming station above the roll conveyor and having a downwardly facing surface that has a downwardly convex shape with curvature in transverse directions, and the upper mold being movable between an upper position spaced above the roll conveyor and a lower position adjacent the roll conveyor;
- a vacuum source for drawing a vacuum at the downwardly facing surface of the upper mold;
- a gas lift jet array located in the forming station below the plane of conveyance of the glass sheet and having a pair of end portions and a central portion for providing upwardly directed gas lift jets that provide the sole impetus for lifting the glass sheet respectively at its pair of end portions and intermediate portion upwardly from the roll conveyor to the upper mold in its lower position and contacting the intermediate portion of the lifted glass sheet with the downwardly facing surface of the upper mold for less than 50% of the distance between the distal extremities of the end portions of the glass sheet, whereupon the upper mold and the glass sheet are moved upwardly to the upper position of the upper mold;
- a lower mold having a ring shape that faces upwardly with a concave shape in transverse directions complementary to the downwardly convex shape of the downwardly facing surface of the upper mold, and the lower mold being movable horizontally within the heated chamber of the forming station at a location above the plane of conveyance of the roll conveyor to below the upper mold in its upper position with the glass sheet supported on the upper mold by the gas lift jet array, whereupon the upper mold is moved downwardly and the vacuum source is operated to draw a vacuum at the downwardly facing surface of the upper mold and press form the glass sheet between the upper and lower molds to provide curvature of the glass sheet in transverse directions, and the upper mold then being moved upwardly to its upper position with the press formed glass sheet supported on the upper mold by the vacuum drawn at its downwardly facing surface;
- a delivery mold that is then moved to below the press formed glass sheet on the upper mold in its upper position whereupon the vacuum drawn by the vacuum source at the upper mold is terminated to release the glass sheet from the upper mold onto the delivery mold which is then moved out of the forming station for delivery of the formed glass sheet;
- a quench station to which the delivery mold moves the press formed glass sheet for quenching; and
- a controller for operating the roll conveyor, the upper mold, the vacuum source, the lift jet array, the lower mold, and the delivery mold and quench station to provide the press forming of the glass sheet and its delivery for quenching.
9. A forming station as in claim 8 wherein the controller terminates the operation of the gas lift jet array providing the upwardly directed gas lift jets as the downward movement of the upper mold begins the press forming of the glass sheet between the upper and lower molds.
10. A forming station as in claim 8 further including a pair of positioners pivotally movable on the upper mold under the operation of the controller to blocking positions below the upper mold prior to operation of the gas lift jet array to limit upward movement of the end portions of the glass sheet toward the downwardly facing surface of the upper mold and thereby limit the extent of the intermediate portion of the glass sheet that contacts the downwardly facing surface of the upper mold, and the controller subsequently pivotally moving the pair of positioners from their blocking positions to unblocking positions to permit the subsequent press forming of the glass sheet between the upper and lower molds.
11. A method for forming a hot glass sheet having a pair of spaced end portions with distal extremities and also having an intermediate portion extending between its end portions, the method comprising:
- conveying the hot glass sheet on a conveyor into a heated chamber of a forming station to below an upper mold that is located above the conveyor and has a downwardly facing surface that has a downwardly convex shape with curvature in transverse directions;
- moving the upper mold downwardly from an upper position to a lower position adjacent the glass sheet on the conveyor and operating a gas lift jet array to provide upwardly directed gas lift jets as the sole impetus for lifting the glass sheet from the conveyor and contacting the intermediate portion of the glass sheet with the downwardly facing surface of the upper mold for less than 50% of the distance between the distal extremities of the end portions of the glass sheet, and then moving the upper mold and the glass sheet upwardly to the upper position of the upper mold;
- then moving a lower mold having a ring shape, that faces upwardly with a concave shape in transverse directions complementary to the downwardly convex shape of the downwardly facing surface of the upper mold, horizontally within the heated chamber to a location above the conveyor and below the upper mold in its upper position with the glass sheet supported on the upper mold and subsequently moving the upper mold downwardly and drawing a vacuum at the downwardly facing surface of the upper mold to press form the glass sheet between the upper and lower molds and provide curvature of the glass sheet in transverse directions, whereupon the upper mold is moved upwardly to its upper position with the press formed glass sheet supported on the upper mold by the vacuum drawn at its downwardly facing surface; and
- then moving a delivery mold to below the press formed glass sheet on the upper mold in its upper position whereupon the vacuum drawn at the upper mold is terminated to release the glass sheet from the upper mold onto the delivery mold which is then moved out of the forming station for delivery of the press formed glass sheet.
12. A method for forming a hot glass sheet as in claim 11 wherein the operation of the gas lift jet array is terminated before completion of the press forming of the glass sheet between the upper and lower molds.
13. A method for forming a hot glass sheet as in claim 11 wherein the operation of the gas lift jet array is terminated as the downward movement of the upper mold with the glass sheet supported thereon begins the press forming of the glass sheet between the upper and lower molds.
14. A method for forming a hot glass sheet as in claim 11 wherein gas pressures are respectively supplied to the end portions and to the intermediate portion of the glass sheet and are controlled to limit the extent of the intermediate portion of the glass sheet that contacts the downwardly facing surface of the upper mold.
15. A method for forming a hot glass sheet as in claim 14 wherein a lesser gas pressure is supplied to the end portions of the glass sheet than to the intermediate portion of the glass sheet.
16. A method for forming a hot glass sheet as in claim 15 wherein the gas pressure supplied to the end portions of the glass sheet is 50 to 75% of the gas pressure supplied to the intermediate portion of the glass sheet.
17. A method for forming a hot glass sheet as in claim 11 wherein a pair of positioners are moved to blocking positions below the upper mold prior to operation of the gas lift jet array to limit upward movement of the end portions of the glass sheet toward the downwardly facing surface of the upper mold and thereby limit the extent of the intermediate portion of the glass sheet that initially contacts the downwardly facing surface of the upper mold, and the pair of positioners subsequently being moved from their blocking positions to unblocking positions to permit the subsequent press forming of the glass sheet between the upper and lower molds.
18. A method for forming a hot glass sheet as in claim 17 wherein the pair of positioners are moved between the blocking and unblocking positions about respective pivotal connections thereof on the upper mold.
19. A method for forming a hot glass sheet as in claim 11 wherein the press formed glass sheet is moved on the delivery mold from the forming station to a quench station for quenching.
20. A method for forming a hot glass sheet as in claim 11 wherein gas pressures are respectively supplied to the end portions and to the intermediate portion of the glass sheet and are controlled to limit the extent of the intermediate portion of the glass sheet that contacts the downwardly facing surface of the upper mold, a lesser gas pressure being supplied to the end portions of the glass sheet than to the intermediate portion of the glass sheet, wherein the operation of the gas lift jet array is terminated as the downward movement of the upper mold with the glass sheet supported thereon begins the press forming of the glass sheet between the upper and lower molds, and wherein after the press formed glass sheet is moved on the delivery mold from the forming station to a quench station for quenching.
Type: Application
Filed: Feb 6, 2014
Publication Date: Aug 6, 2015
Applicant: GLASSTECH, INC. (Perrysburg, OH)
Inventors: Dean M. NITSCHKE (Maumee, OH), David B. NITSCHKE (Perrysburg, OH)
Application Number: 14/174,245