US Patent Application for METHOD AND APPARATUS FOR PRODUCING THIN PERFORATED GLASS SHEET Patent Application (Application No. 20230136691 issued May 4, 2023) (2023)

COMMUNICATION IN RELATED ORDERS

This application claims the benefit of priority under 35 U.S.C. § 119 of US Interim Order No. 63/003,014 filed on Mar. 31, 2020 and US Provisional Order No. 63/119,334 filed Nov. 30, 2020, the contents of each of which are incorporated herein by reference in their entirety.

BOTTOM

Uniquely shaped pieces of glass in high performance construction are highly desirable. While some technologies exist for cutting and pressing individual parts, these methods can provide non-uniformities in the resulting parts and are not available at thinner cross-section thicknesses.

FIELD OF THE INVENTION

In general, the present disclosure is directed to systems and methods of manufacturing glass, glass-ceramic, or ceramic parts having a thin cross-sectional wall thickness (e.g., less than about 1 mm), unique shapes, and/or surface pattern, with through-holes extending through the section from one main surface to another, with high volume efficiency. More specifically, the present disclosure is directed to various embodiments of a system configured to manufacture perforated glass, glass-ceramic or ceramic parts with the system having various embodiments for its configuration and associated methods of processing hot, flexible glass-containing materials (e.g. , glass, glass-ceramic and/or ceramic materials uniquely shaped to provide advantageously shaped, custom and/or uniquely shaped parts (ie, near liquid form and/or requiring minimal additional processing to have a final part shape) high volume production .

SUMMARY

Multiple process and equipment configurations possible with this disclosure for making perforated glass sheets will now be described:

In some embodiments, a three-dimensional isometric representation of a machine and process layout for manufacturing perforated glass sheet. It includes three sets of rollers, an air swing guide, smooth and flat transfer molds, and a specially designed pressure roller with a series of protruding pins that cover the entire surface of the roller to stay in contact with the glass.

A specially designed pressure roller with a series of protruding pins covering the entire surface of the roller to contact the glass is placed over the conveyor molds and pressed against the hot glass sheet to force the pins of the pin roller onto on the hot glass. glass sheet to clamp the sheet between the pressure roller and the conveyor's smooth flat top dies to create a whole series of flat bottom holes in the glass sheet. The goal is to penetrate the glass plate as far as possible with the rollers so that only a thin sheet of glass remains between the tip of the pin and the flat side of the glass plate mold.

The perforated glass sheet cools as it travels along the top surface of the conveyor and the temperature difference between the thick glass of the desired perforated glass and the thin glass of the fine nip line causes a thermal stress along the thin handle that self-separates the Sheet into discrete pieces at the end of the conveyor. The resulting product is a rectangular tile with a smooth surface on the bottom surface and a full row of flat-bottomed dowel holes on the top surface.

In some embodiments, the desired product is a thin glass sheet having a 0.010 inch (0.254 mm) diameter array of through holes spaced about 0.062 inches (1.57 mm) apart over at least a portion of the entire surface of the glass sheet. manufactured (for use as a component of an acoustic tile set).

In some embodiments, the product is a thin sheet of glass with a 1 mm diameter array of through holes. In some embodiments, the desired product is a thin sheet of glass with 0.75 mm diameter through holes. In some embodiments, the desired product is a thin sheet of glass with an array of 0.5 mm diameter through holes. In some embodiments, the desired product is a thin sheet of glass with an array of 0.25 mm diameter through holes. In some embodiments, the desired product is a thin sheet of glass with an array of 0.1 mm diameter through holes.

In one aspect, a method is provided, which includes: depositing a flexible tape containing glass along a plurality of sequentially transported molds; winding a pressure roller over the surface of the glass-containing strip such that at least one pinch region engages the glass strip as the glass strip is compressed between a pressure edge of the pressure roller and the mold surface. and rolling a pin roller over the surface of the glass-containing strip, cooling the glass strip, separating the glass strip along the grip area into separate glass pieces.

In some embodiments, the peripheral edge of the discrete glass portion is defined by the pinch region, optionally in combination with at least one of the ends of the glass strip.

In some applications, where the glass-containing film is formed with an average cross-sectional thickness of 0.5 mm to 1 mm.

In some embodiments, the film containing glass has an average cross-sectional thickness of 1 mm.

In some embodiments, the method further comprises removing a layer of glass to define a plurality of paths extending from the first major surface to the second major surface of the glass portion.

In some embodiments, the plurality of perforations in the discrete glass portion comprise 25-50% of the volume of the discrete glass portion.

In some embodiments, the plurality of perforations comprises at least 15%. or at least 30%; or at least 40%; or at least 50%; or at least 60%; or at least 70% of the volume of the discrete glass section. In some embodiments, the number of perforations comprises no more than 75%. or not more than 60%; or not more than 50%; or not more than 30%; of the volume of the distinct glass part.

In some embodiments, the portion is formed with a series of through holes.

In some embodiments, the through-hole arrangement has a diameter of about 0.25 mm.

In some embodiments, wherein the through-hole arrangement is uniformly distributed over at least one portion of the portion.

In some embodiments, the through holes are spaced apart in the die by about 1.5-1.7 mm.

In some embodiments, the part is configured with a spacer and held in a frame to define an architectural product.

In some embodiments, the architectural product includes an acoustic tile.

In some embodiments, the laminating step includes defining a glass strip that includes a plurality of closed bottom perforations extending from one major surface to the second major surface.

In some embodiments, the closed-bottom perforations extend at least 50% to 95% of the cross-sectional thickness of the glass-containing portion of the perforated strip.

In some embodiments, the method includes removing a thin glass web defining a bottom from each of the respective closed bottom perforations in the part.

In some embodiments, the lamination step occurs prior to the stripping step.

In some embodiments, the removing step includes machining one of the first or second major surfaces to define a plurality of through holes extending from the first major surface to the second major surface.

In some embodiments, the removing step includes scoring one of the first major surface or the second major surface to define a plurality of through holes extending from the first major surface to the second major surface. In some embodiments, the product is a thin sheet of glass with the hole pattern having holes with a diameter of about 5 mm to no more than 0.5 mm apart in at least one portion of the component. In some embodiments, the product is a thin sheet of glass with the hole pattern having diameter holes spaced about 3 mm to no more than 1.5 mm apart in at least one portion of the component. In some embodiments, the product is a thin sheet of glass with the array of holes having a hole diameter spaced about 1.5 mm to no more than 0.75 mm apart in at least one portion of the component.

In some embodiments, the product is a thin sheet of glass with the array of holes having a hole spacing of 1.5 mm in diameter hole spacing. or 1.25 mm. or 1 mm; or 0.75 mm. or 0.5 mm, or 0.25 mm from each other on at least one part of the component. In some embodiments, the product is a thin sheet of glass with the hole pattern having a hole spacing of 5 mm diameter. or 4 mm? or 3mm? or 2mm? or within 1 mm of each other in at least one part of the component.

In some embodiments, the die includes holes of uniform diameter.

In some embodiments, the die includes holes of uneven diameter (ie, with the flat-bottomed holes having a mixture of 2 or more average sizes).

In some embodiments, the perforated pattern of the glass pieces is formed to be uniform (ie, evenly spaced, flat-bottomed perforations). In some embodiments, the perforated pattern of the glass pieces is configured to be non-uniform (ie, intermittent and/or non-patterned spacing of the flat bottom holes in each end piece).

As used herein, uniform generally means having a constant cross-sectional thickness, where the cross-sectional thickness is within a predetermined range/range. For example, for a cross-sectional thickness of 1 mm, a uniform cross-sectional thickness may be within about 10% of 1 mm, within about 5% of 1 mm, within about 3% of 1 mm, within about 1% of 1 mm? within about 0.5% of 1 mm.

A secondary machining/abrasive or etch job is required to remove the thin glass tissue covering the closed bottom perforations placed in the glass with this process - to expose the 0.010 inch diameter holes which will then be exposed.

In some embodiments, a three-dimensional isometric representation of a machine and process layout for manufacturing perforated glass sheet. It includes three sets of rollers, an air spin guide, flat smooth surface conveyor dies and a smooth surface pressure roller with a thin crosscut blade.

The precise sheet of glass is then passed through a pair of specially designed pin rollers, where the pin roller is a specially designed roller with a series of protruding pins that cover the entire surface of the roller to contact the glass. It presses the precisely sized sheet onto the smooth mating roller to punch the sheet to create a full row of flat-bottomed pin holes in the glass sheet. In some embodiments, the pin rollers are configured to penetrate the glass sheet as far as possible with the pin rollers so that only a thin sheet of glass remains between the tip of the pin and the smooth side of the roller. the glass sheet.

This fine pinch determines where the punched sheet will split at the end of the conveyor, but the fine pinch zone reheats immediately and

The fresh perforated glass sheet is then rotated 90 degrees from vertical to horizontal around a rotating air guide to place the perforated sheet on the flat top smooth surface of the horizontal transfer molds traveling under the delivery roller system.

The thin pinch blade mounted on the pressure roller squeezes a full line on the supplied sheet to clamp the thin glass sheet between the pressure roller blade and the flat surface of the carrier die.

The perforated glass sheet is cooled as it travels along the top surface of the conveyor, and the temperature difference between the thick glass of the desired perforated glass and the thin glass of the fine nip line causes a thermal stress along the fine grip that separates the sheet into discrete pieces at carrier's fee. The resulting product is a rectangular tile with a smooth surface on the bottom surface and a full row of flat-bottomed dowel holes on the top surface.

In some embodiments, the product is a thin glass sheet having a 0.010 inch diameter die through holes spaced approximately 0.062 inch apart across the entire surface of the glass sheet being manufactured (for use as a component of an acoustic tile assembly).

In some embodiments, a secondary machining/abrasion or etch operation is required to remove the thin glass mesh covering the closed bottom perforations placed in the glass by this process - to expose the 0.010 inch diameter holes which will then be exposed.

Through one or more embodiments of the present disclosure, the systems are configured to manufacture custom thin-wall glass, glass-ceramic and/or ceramic products, thin-wall, composite designs and/or cast, thin-wall glass, glass-ceramic and/or ceramic products. which are not possible with any other formatting technology. One or more products in this system are configured with unique and/or custom features, including but not limited to: complex three-dimensional geometries, textured surfaces, distinct two-dimensional shapes, and/or combinations thereof.

In one embodiment, the film is a monolithic sheet of glass, ceramic or glass-ceramic.

In one embodiment, the film is a laminate.

In one embodiment, the product characteristics include, as non-limiting examples: product thickness (cross-sectional thickness) thickness less than 1 mm. product wall thickness (section thickness) 1 mm to 3 mm thick. products with small corner radii (for example, a radius of 1.5 mm) between the side and the bottom (edges or walls of the product shape). 3D shapes greater than 1 inch deep with 1 mm wall thickness (cross-sectional thickness). 3D products with thin walls (less than 1 mm thick) and steep sidewalls ranging from 3 degrees to 7 degrees. In some embodiments, the resulting products need not be annealed. In some embodiments, the products do not have a wrinkled surface and/or a shear mark in parts made from a drop pressure.

Some non-limiting examples of products include: textured tiles, consumer electronics shapes. perforated sheet of glass (acoustic sheet). three-dimensional shaped products, cutlery, tableware moulds. among other applications.

In one embodiment, a method is provided, which comprises: providing a molten glass, ceramic or glass-ceramic material containing to a glass forming and sizing assembly, the assembly including at least one pair of forming and sizing rolls. processing the molten glass through at least one pair of forming and sizing rolls to form a glass strip of width and thickness; imparting, via a pair of pinch rollers, at least one pinch region to the cross-sectional thickness of the glass strip to provide a compressed glass strip, wherein the grip region is defined as a local region of reduced cross-section thickness; Directing (via a conveyor or air bending) the compressed glass strip to a plurality of successively spaced mold surfaces. rolling a pressure roll over the compressed glass strip on successively spaced mold surfaces to impart a feature to the compressed glass strip to form a glass strip product. and cooling, thereby separating the glass strip product along the grip area into a plurality of distinct glass pieces, each glass piece having the assigned characteristic.

In some embodiments, the method includes: wherein the pair of pinch rollers includes a first roller and a second roller, wherein the first roller is configured with a nose portion (raised edge or rib).

In some embodiments, the method includes: wherein the pair of pinch rollers includes a first roller and a second roller, wherein the first roller is configured with a nose portion (raised edge or rib) and the second portion is configured with a grip portion (raised edge or projection), wherein the first grip portion of the first roller and the second grip portion of the second roller are configured to engage respectively and drive a grip region on the glass strip.

In some embodiments, the method comprises: wherein the transmitting step further comprises transmitting a surface texture to at least one of a first major surface of the glass tape and the second major surface of the glass tape (via a first major surface of the glass tape) pattern in a first cylinder surface and/or a second pattern on a second cylinder surface).

In some embodiments, the method further comprises: applying compressed air to the second surface of the glass tape product and/or discrete glass pieces through a glass removal assembly, to facilitate segment separation and/or spacing along the clamping region. In some embodiments, the method further comprises directing a burst of gas to the second surface of the glass tape product and/or discrete pieces of glass through a glass removal assembly to facilitate separation of pieces and/or pieces along the pinch region. In some embodiments, the method further comprises directing a flow (e.g., continuous flow) of gas to the second surface of the glass tape product and/or discrete glass pieces through a glass removal assembly, to facilitate part separation and/or the distance along the clamp area.

In some embodiments, the clamping region defines the perimeter of the component, possibly in conjunction with the tape edges (if not also clamped).

In some embodiments, the grip region includes: transversely separating each discrete glass component;

In some embodiments, the grip region includes: transverse separation and axial separation of each discrete glass component.

In some embodiments, the gripping region includes: axial separation of the glass component from the broken edge glass segment/fragment (forming a high strength, clean edge); In some embodiments, by fire polishing the handle area, a clean, high strength edge can be formed on the discrete glassware.

In some embodiments, the method is configured to provide a component with at least one of: 2D asymmetric configuration of edge components; formation of 2D perimeter geometric blocks. formation of imperfect/non-concentric 2D edge segments. at least one characteristic (eg flatness, texture, pattern) and/or combinations thereof.

In some embodiments, each mold of the sequentially spaced molds is formed with a mold having a mold surface, a mold carrier, and a removable mechanical link on a conveyor belt.

In some embodiments, the conveyor is configured with a vacuum box in communication with a plurality of molds and mold transfer boxes such that the vacuum box, mold conveyor, and mold are configured to draw a vacuum through the set.

In some embodiments, the method includes: passing a vacuum through a plurality of vacuum-equipped molds to deform the compressed glass film on the surface of each of the molds;

As a non-limiting example, a ribbon material means that the length is greater than the width. While the term film is used, it is understood that the sheet may also be processed in accordance with one or more embodiments of the present disclosure. (ie where the sheet has a larger cross-sectional area than the strip, as a sheet will have a similar length and cross-sectional thickness to the strip, but will be formed with a greater width than the strip).

As used herein, compression means reducing the cross-sectional thickness of the tape material by a predetermined amount. As stated in this document, with a tape cross-sectional thickness of 1 mm (eg, average cross-sectional thickness), a pinch region has a selected thickness range of at least 0.25 mm to no more than 0.51 mm. As a non-limiting example, a grip region has a reduced cross-sectional thickness from at least 25% of the cross-sectional thickness of the tape material to no more than 75% of the cross-sectional thickness of the tape material. As a non-limiting example, a grip region has a reduced cross-sectional thickness from at least 30% of the cross-sectional thickness of the tape material to no more than 70% of the cross-sectional thickness of the tape material. As a non-limiting example, a grip region has a reduced cross-sectional thickness from at least 40% of the cross-sectional thickness of the tape material to no more than 75% of the cross-sectional thickness of the tape material.

In one embodiment, a method is provided which includes: depositing a hot, flexible film (eg, candy molding) containing glass along a plurality of sequentially conveyed molds, wherein the glass film comprises a thickness of no more than 1 mm, further where the glass strip is of uniform thickness. winding a pressure roller over the surface of the glass-containing strip such that at least one pinch region engages the glass strip as the glass strip is compressed between a pressure edge of the pressure roller and the mold surface. and cooling the glass ribbon, [e.g. wherein the compressive stresses between the pinch region and the adjacent pinch regions are formed to separate the glass strip along the pinch region into discrete glass pieces.

In some embodiments, the peripheral edge of the discrete glass portion is defined by the pinch region, optionally in combination with at least one of the ends of the glass strip.

In one embodiment, a method is provided comprising: depositing a hot, flexible tape containing glass along a plurality of sequentially conveyed dies, wherein the glass ribbon is no more than 1 mm thick, wherein the glass tape glass comprises a uniform thickness; however each mold is shaped with a 3D surface pattern. rolling a pressure roller over the surface of the glass-containing strip such that at least one pressure roller moves on the glass strip as the glass strip is pressed between the three-dimensional surface of the mold and the pressure roller; and cooling the glass strip to define a three-dimensional patterned surface strip.

In one embodiment, the method includes: cutting the glass ribbon into discrete pieces (via laser processing, etch edge breaking, machining, selective removal, chemical removal, and/or combinations thereof).

In one embodiment, the method includes using a pressure roller during processing to define an area of ​​pressure on the tape material.

In one embodiment, a method is provided comprising: depositing a hot, flexible tape containing glass along a plurality of sequentially conveyed dies, wherein the glass ribbon has a thickness of no more than 1 mm, wherein the glass tape glass comprises a uniform thickness; rolling a pressure roller over the surface of the glass-containing tape, wherein the pressure roller has a defined three-dimensionally patterned surface, such that at least one pressure roller moves on the glass tape as the glass tape is pressed between the three-dimensional surface of the mold and the 3D surface drawing of pressure roller. and cooling the glass strip to define a three-dimensional patterned surface strip.

In one embodiment, a method is provided comprising: depositing a hot, flexible tape containing glass along a plurality of sequentially conveyed dies, wherein the glass ribbon has a thickness of no more than 1 mm, wherein the glass tape glass comprises a uniform thickness; further wherein each mold is formed with a first three-dimensional surface pattern. rolling a pressure roller over the surface of the glass-containing tape, wherein the pressure roller has a defined surface with a second three-dimensional pattern, such that at least one pressure roller is actuated on the glass tape as the glass tape is pressed between the first three-dimensional surface pattern of mold pattern is transmitted to the first surface of the glass strip and the second three-dimensional surface pattern of the pressure roller is transmitted to the second surface of the glass strip. and cooling the glass strip to define a three-dimensional surface-patterned glass piece having a cross-sectional wall thickness of no more than 1 mm.

In one embodiment, a method is provided comprising: depositing a hot, flexible tape containing glass along a plurality of sequentially conveyed dies, wherein the glass ribbon has a thickness of no more than 1 mm, wherein the glass tape glass comprises a uniform thickness; further wherein each mold is formed with a three-dimensional portion shape on its surface, with portions engaging in the gap. By negatively pressing the cavity defined between the glass strip and the mold surface through the parts engaged in the gap, thus forming the glass strip on the surface of the three-dimensional part shape. roll a pressure roller over the surface of the glass ribbon so that the pressure roller is configured to engage the glass ribbon to the mold (eg outer edges of the tape to the outer edges of the mold to allow forming vacuum of the glass strip mold to the surface pattern of the mold and cooling of the glass strip, to define a three-dimensional glass part with a cross-sectional wall thickness not exceeding 1 mm.

In some embodiments, the peripheral edge of the discrete glass portion is defined by the pinch region, optionally in combination with at least one of the ends of the glass strip.

In some embodiments, delivery of molten glass may be accomplished through a crucible, via a round feed tube (eg, continuous batch tank). or from a fishtail spread hole or slot. In some embodiments, the slot distribution may be configured to provide a flow of monolithic glass sheet or laminated glass sheet to advance a uniform end-to-end dimple to the upper set of sheet forming rolls.

In some embodiments, the crucible is configured to deliver 3-5 pounds of molten glass (eg, using a barrier as an option to control sheet width). In this embodiment, a number of mold cavities (eg, 10-30) may be filled, depending on the desired size and thickness of the resulting product shapes. In some embodiments, the round tube supply is configured to provide glass of a desired viscosity (eg, not less than 500 Poise and not greater than 3000 Poise), configured for the upper set of rollers, with or without barriers. The glass released from the tube forms a pool of glass that flows out of the outlet to the outlet of the tube in the center. The width of the pit can be adjusted to the desired width by selecting the appropriate glass supply flow rate (eg pounds per hour) plus the appropriate roll gap (0mm) and process speed (eg inches per second).

In some embodiments, a control system is used to configure/control/adjust one or more aspects of the systems and components, such as: flow controls, airflow pressure (positive or negative/vacuum), flow controls/refrigerant cylinder, refrigerant flow, flow air (for air turn/air turn), handle, roller synchronization with conveyor speed and/or down pressure roller speed and combinations thereof, among other elements.

In some embodiments, the tape deposition system is configured to create a hot, flexible flat sheet (eg, caramel texture) from the molten material and deliver it to the conveyor. The film processing/film deposition system includes: at least one pair of rollers, two pairs of rollers, 3 pairs of rollers or more. In some embodiments, the types of rollers used in the delivery system of the laminating machine include: smooth surface (with or without contour) stainless steel rollers; ceramic coated cylinders (eg designed to exhibit low thermal conductivity). elasticized cylinders; carved cylinders (for example, with a strong 3D relief); Thin pressure rollers (eg, formed with raised pressure ends for sheet separation and/or discrete perimeter forming of sections). rolls with 3D pockets. rollers with special configurations (for example, pin rollers for perforating the sheet surface). metal rollers (eg Inconel, special nickel alloy, high temperature composition rollers). Ceramic-coated materials (eg dense chromium oxide, polished to a mirror-like surface finish). Some non-limiting examples of ceramic coated rollers include zirconium, chromium alumina (eg, plasma sprayed chromium alumina) and layered applications of each composition).

In some applications, the pressure roller on the conveyor is configured to be driven by a motor (eg, a servo motor). The pressure/push roller can be configured as a smooth surface roller, a textured surface roller, a pressure roller, a textured surface pressure roller, and combinations thereof.

In some embodiments, the conveyor includes: a roller chain, which can be modified by changing the length of the spacers separating the two sides of the conveyors, changing the length of the pinion shafts, and changing the mold widths, mold carriers, and a roller subassembly pressure.

In some embodiments, the conveyor includes a mold conveyor/mold chain configured to hold a plurality of molds along the conveyor (eg, sequentially, in series).

In some embodiments, the mold may be configured as: a planar top surface, a planar mold with a textured 3D top surface, void forming molds with 3D shapes (eg, male shapes above the plane or female cavities below the plane , use complex shapes); three-dimensional shape with sculpted/embossed surface(s); three-dimensional cavity with a clamping edge formed along the perimeter of the cavity, a mold with a clamping edge along one end of each mold carrier, and/or combinations thereof .

In one embodiment, the molds can be cast ceramic molds (eg, formed with very low thermal conductivity). In one embodiment, the mold is configured to be used at room temperature. In one embodiment, the mold is formed with air or cold/cooled fluid.

Non-limiting examples of mold materials include: fusible ceramic, room temperature curable silicon ceramic (eg, Cotronics Corporation, Rescor 750)), stainless steel, cast iron, chromium oxide coated incramet 800, among others.

In some embodiments, the grip area is configured so that the strip material is separated as it travels down the conveyor (and accordingly continues to cool). For example, as the processed glass film (or ceramic film or glass-ceramic film) continues to cool as it travels down the conveyor, the temperature difference between the thick product glass and the thin glass at the location of the thin grip causes stress across the region gripper, which results in automatic separation of the strip material along the gripper area so that the strip material is formed into discrete parts or components until it reaches the end of the conveyor.

Using one or more of the methods described herein, 3D formation of complex shaped products has been demonstrated at process speeds up to 30 in/sec. For a five-inch-long product (for example, a mobile phone), this processing speed equates to more than five parts being manufactured per second. Five parts per second equals 300 parts per minute equals 18,000 parts per hour equals 432,000 parts in a 24-hour period equals 157,680,000 parts per 365 days of the year. With a conservative selection rate of 64%, this means that a machine system can produce over 100 million certified parts per.

In some embodiments, low viscosity glass (50-100 pose as delivered) is formed into ribbon material.

In some embodiments, forming the hot glass sheet under vacuum (in a viscosity range of 100 to 10,000 poise) causes the hot sheet to be fully drawn into the cavities of the vacuum mold and accurately replicate the surface characteristics of the mold (for example, fine features).

Additional features and advantages will be set forth in the following detailed description and will be readily apparent to those skilled in the art from this description or will be recognized by practice of the embodiments described herein, including the following detailed description, the claims, as well as the attached drawings.

It is to be understood that both the foregoing general description and the following detailed description are exemplary only and are intended to provide an overview or context for understanding the nature and character of the disclosure as claimed.

The accompanying drawings are included to provide further understanding of the principles of the disclosure and are incorporated into and made a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain, by way of example, the principles and operation of the disclosure. It should be understood that various features of the disclosure disclosed in this specification and the drawings may be used in any and all combinations. By way of non-limiting examples, the various features of the disclosure may be combined with each other according to the following aspects.

In some embodiments, one of its pressure rollersSYK.8through8doplaced on the pressure rollers of the glass processing assembly.

In some embodiments, one of its pressure rollersSYK.8through8doare placed in the pressure cylinder of the transfer system.

Referring toFIGO.8ONE, a cutting roll having a handle edge configured as a perimeter of complex pattern (eg, non-circular, atypical and/or asymmetric) is depicted in accordance with one or more embodiments of the present disclosure.

Referring toFIGO.8si, a cutting roller having a gripping edge shaped as a circular perimeter is depicted in accordance with one or more embodiments of the present disclosure.

Referring toFIGO.8do, a cutting roller having a handle edge shaped as a double Y is depicted in accordance with one or more aspects of the present disclosure. As a non-limiting example, when used in tape material, the double Y is configured to define a boundary between two distinct sections while providing a collared edge (eg, corner cuts) along the corners of the component.

FIGO.9ONErepresents a schematic view of the pressure rollers of the glass processing system, according to one or more embodiments of the present disclosure.

As depicted inFIGO.9ONE, one of the two rollers is formed with a pinch end so that when the tape material is moved between the pinch rollers, a pinch area is defined on the tape material.

FIGO.9sirepresents a schematic view of the pressure rollers of the glass processing system, according to one or more embodiments of the present disclosure.

As depicted inFIGO.9si, each of the rollers is formed with a pinch end (so that the pinch ends correspond to each other's respective positions), so that when the tape material is moved between the pinch rollers, a pinch area is formed. defined in the tape material as two pinch rollers whose edges fit respectively in a corresponding proximal position.

FIGO.10ONEis a schematic top view of an embodiment of a tape material, in accordance with various aspects of the present disclosure.

FIGO.10siis a schematic side view of the tape material, in accordance with one or more aspects of the present disclosure.

FIGO.11ONEis a schematic top view of an embodiment of a tape material placed in the conveyor system, in accordance with various aspects of the present disclosure.

FIGO.11siis a schematic plan view of an implementation of a belt material mounted on the conveyor system wherein the die assemblies are each configured with a corresponding grip edge, in accordance with various aspects of the present disclosure.

FIGO.12ONE-12mrepresent various configurations of a roller that may be used in the pressure roller of the glass processing system and/or the pressure roller of the transfer system, in accordance with one or more aspects of the present disclosure.

FIGO.12ONEillustrates a schematic view of a pressure roller that may be used in the pressure roller of the glass processing system and/or the pressure roller of the transfer system, in accordance with one or more aspects of the present disclosure.

FIGO.12siillustrates a schematic view of a pressure roller that may be used in the pressure roller of the glass processing system and/or the pressure roller of the transfer system, in accordance with one or more aspects of the present disclosure.

FIGO.12doillustrates a schematic view of a pressure roller that may be used in the pressure roller of the glass processing system and/or the pressure roller of the transfer system, in accordance with one or more aspects of the present disclosure.

FIGO.12Heyillustrates a schematic view of a pressure roller that may be used in the pressure roller of the glass processing system and/or the pressure roller of the transfer system, in accordance with one or more aspects of the present disclosure.

FIGO.12millustrates a schematic view of a pressure roller that may be used in the pressure roller of the glass processing system and/or the pressure roller of the transfer system, in accordance with one or more aspects of the present disclosure.

FIGO.13illustrates a schematic side view of the conveyor assembly showing the vacuum ports, vacuum boxes formed under the mold assemblies, and the pusher mechanism formed at the end of the conveyor, in accordance with one or more embodiments of the present disclosure.

FIGO.14is a top perspective view of an embodiment of a conveyor assembly having a plurality of mold assemblies having planar surfaces, in accordance with one or more aspects of the present disclosure.

FIGO.15is a perspective top view of an embodiment of a conveyor assembly having a plurality of mold assemblies with complex three-dimensional shapes and a corresponding void forming configuration, in accordance with one or more aspects of the present disclosure.

FIGO.16ONEis a close-up perspective top view of the mold assembly used in the mold transfer system;FIGO.14, representing a planar mold, according to one or more embodiments of the present disclosure.

FIGO.16siis a close-up perspective top view of the mold assembly used in the mold transfer system;FIGO.15, representing a surface mold in three-dimensional shape, according to one or more embodiments of the present disclosure.

FIGO.16dois a close-up perspective top view of the mold assembly used in the mold transfer system;FIGO.18, representing a surface mold in three-dimensional shape, according to one or more embodiments of the present disclosure.

FIGO.17is a top perspective view of an embodiment of a conveyor assembly having a plurality of mold assemblies with complex three-dimensional shapes and a corresponding void forming configuration, in conjunction with a clamping edge on the mold assembly (e.g., to define a pinch area around the three-dimensional portion formed through a gap), according to one or more aspects of the present disclosure. The cut edge on the roll is set to synchronize with the cut edge on the perimeter of the mold (so that the two components work together in actuation timing to form the grip on the glass strip together).

FIGO.18A-Erepresent various embodiments of complex three-dimensional parts that can be made from a tape material having one or more aspects of the present disclosure.

FIGO.18ONEdescribes a view from above the plane (topFIGO.18ONE) e flat side view (bottomFIGO.18ONE), representing an implementation of a product formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the conveying system, in accordance with one or more aspects of the present disclosure.FIGO.18ONErepresents a product shaped as a food utensil (for example, a soup spoon).

FIGO.18siillustrates a plan view of an embodiment of a product formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the conveying system, in accordance with one or more aspects of the present disclosure.FIGO.18sirepresents a product formed as a round plate with a non-uniform edge (for example, scalloped edge).

FIGO.18doillustrates a plan view of an embodiment of a product formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the conveying system, in accordance with one or more aspects of the present disclosure.FIGO.18dorepresents a product formed as a non-round symmetrical plate with a non-uniform edge (for example, a matching perimeter edge).

FIGO.18Heyillustrates a plan view of an embodiment of a product formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the conveying system, in accordance with one or more aspects of the present disclosure.FIGO.18Heyrepresents a product formed as a symmetrical, geometric (rectangular) plate with an uneven border (for example, a matching perimeter border).

FIGO.18millustrates a plan view of an embodiment of a product formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the conveying system, in accordance with one or more aspects of the present disclosure.FIGO.18mdescribes a product shaped as symmetrical, geometric (oval) with a raised edge/wall of uneven height (damaged or scalloped wall).

FIGO.19illustrates a schematic perspective top view of an embodiment of the transfer system in accordance with one or more aspects of the present disclosure.

FIGO.20illustrates a schematic perspective top view of an embodiment of the transfer system in accordance with one or more aspects of the present disclosure.

FIGO.21depicts images of various views of product shapes made in accordance with one or more embodiments of the present disclosure.

FIGO.22illustrates a top perspective view of an embodiment of a perforated acoustic sheet, in accordance with one or more embodiments of the present disclosure.

FIGO.23illustrates a perspective top view of various embodiments of a perforated acoustic sheet in various configurations, in accordance with one or more embodiments of the present disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

In the following detailed description, for purposes of illustration and not limitation, exemplary embodiments are presented that disclose specific details to provide a thorough understanding of the various principles of the present disclosure. However, it will be apparent to one skilled in the art having the benefit of the present disclosure that the present disclosure may be applied to other embodiments that depart from the specific details disclosed herein. Further, descriptions of known apparatus, methods, and materials may be omitted so as not to obscure the description of various principles of the present disclosure. Finally, where applicable, like reference numbers refer to like items.

FIGO.1represents a schematic view of one embodiment of a glass processing system50having delivery and processing systems including: a melt supply device;60, depositing thin strips and thin pressure rollers, which then direct a thin strip of hot, flexible material with a plurality of thin grips into a downstream conveyor system100. The thin film deposition device200Includes a pair of shaping rollers212, including a first forming roll and a second forming roll. the forming rollers212are configured to direct a continuously supplied batch of molten material (eg glass, ceramic and/or glass ceramic) onto a ribbon. The tape is configured with two main surfaces, a first and a second surface, and two corresponding edges, a first edge and a second edge.

The film is then passed through a pair of sizing rollers.218, including a first sizing roller and a second sizing roller. The sizing roller is configured to operate on the surfaces of the glass strip (first major surface, second major surface, and first and second edges) to form the glass to a uniform thickness (eg, as measured across its length and width). .

After the collar rolls, the uniform tape material is directed to a pair of pin rolls (a first pin roll and a second pin roll), where at least one surface of the pin rolls is formed with a plurality of pin roll raised bumps. In some embodiments, both the first pin cylinder and the second pin cylinder are formed with a plurality of raised projections on their respective surfaces. As the uniform tape material travels through the pair of pin rolls, the extending protrusions act on at least one (or both) of the first and second tape material surfaces to impart notches to the cross-sectional thickness of the tape. .

The perforated, uniform tape material is then directed to a pair of fine pressure rollers.224, including a first and second thin pressure roller. The thin pressure roller is configured to provide a plurality of gripping areas on at least one of the first major surface and the second major surface, with sufficient engagement of the glass strip between the pair of thin pressure rollers to grip, but not separate, the glass tape. The number of tweezers on the glass tape can be configured in various directions, based on the corresponding design of the fine tweezer rollers224.

In one embodiment, the plurality of thin clamps includes a plurality of cross clamps, where each cross clamp is configured to extend from edge to edge (eg, across the width of the glass strip). The forming system is configured with a thin clamping element and a conveyor100.

In one embodiment, the plurality of thin grips includes a plurality of axial grips, wherein each axial grip is configured to extend parallel to the direction in which the tape is conveyed (eg, along at least a portion of the length of the tape). . In one embodiment, the plurality of handles are configured in an arcuate direction (e.g., at an angle along the linear dimension of the strip) so that the strip includes a plurality of parallel lines (e.g.,

parallel oriented lines) shaped thin clamping areas.

In some applications, thin pressure rollers224are configured to engage at least one of: a thin transverse handle, a thin axial handle, a thin arcuate handle, and/or combinations thereof.

as shown inFIGO.1, after the thin pressure rollers224act on the formed glass ribbon to deliver fine perforated ribbon material, the ribbon material is directed to a conveyor100. The Carrier100it has been formed with a number of sets of molds110, sized to accept thin compressed glass ribbon. the mold is set up110are formed in sequential order at a distance such that one set of molds is adjacent to at least two other sets of molds. The Carrier100configured with a conveyor roller assembly140, which includes a conveyor pressure roller144.

Once the finely compressed glass strip is routed out of the delivery and processing system50, the finely compressed glass ribbon is deposited along a plurality of transfer molds110. The transfer molds are placed in a substantially horizontal direction so that gravity assists the finely compressed glass strip placed over the mold assemblies.110. In addition, the delivery time of compressed thin glass from the delivery and processing systems50in the transfer moulds110along the conveyor108can be synchronized so that the fine clamping area is outside the working surface of the die sets110(for example, outside the mold width or between mold assemblies in a row). Conveyor roller assembly140It is configured with a conveyor pressure roller144. The conveyor pressure roller acts against an upper surface of the deposited strip, pressing the deposited strip into a flattened configuration against the mold assembly110and the corresponding mold surface. The glass slit is thus formed by engaging the surface of the mold and the surface of the pressure roller of the conveyor to define a plurality of portions of molten glass. As the cast glass film sections continue to travel along the conveyor108, the glass continues to cool. The reduced temperature is sufficient to cause a break in the glass along the thin grip line so that the molded glass strip separates into a plurality of molded glass components as the conveyor directs the molded glass components toward each other, to an exit of the carrier100. Optionally, a component removal unit160is configured towards the exit of the conveyor so that the positive pressure actuator162is configured to blow air from the conveyor to facilitate the lifting of the plurality of molded glass pieces from the conveyor and/or the separation of two or more molded glass pieces from one another along the fine pinch line(s).

FIGO.2represents a schematic view of one embodiment of a glass processing system50having delivery and processing systems including: a melt supply device;60, thin film deposition200, thin pressure rolls224, which then directs a thin ribbon of hot flexible material (eg, candy-like consistency) that has a plurality of fine tweezers to a downstream conveyor system100.

The thin film deposition device200Includes a pair of shaping rollers212, including a first forming roll and a second forming roll. the forming rollers212are configured to direct a continuously supplied batch of molten material (eg glass, ceramic and/or glass ceramic) onto a ribbon. The tape is configured with two main surfaces, a first and a second surface, and two corresponding edges, a first edge and a second edge.

The film is then passed through a pair of sizing rollers.218, including a first sizing roller and a second sizing roller. The sizing roller is configured to operate on the surfaces of the glass strip (first major surface, second major surface, and first and second edges) to form the glass to a uniform thickness (eg, as measured across its length and width). . Following the sizing rollers, the uniform glass ribbon is directed to a pair of fine pressure rollers.224, here the fine nip rolls are configured with at least one textured cut roll, including a first and second fine nip rolls.

The thin pressure rollers are configured to convey a plurality of grip areas on at least one of: the first major surface and the second major surface, with sufficient engagement of the glass strip between the pair of thin pressure rollers to grip, but not separately. the glass film. The number of tweezers on the glass tape can be configured in various directions, based on the corresponding design of the fine tweezer rollers224.

In one embodiment, the plurality of thin clamps includes a plurality of cross clamps, where each cross clamp is configured to extend from edge to edge (eg, across the width of the glass strip). The forming system is configured with a thin clamping element and a conveyor100.

In one embodiment, the plurality of thin grips includes a plurality of axial grips, wherein each axial grip is configured to extend parallel to the direction in which the tape is conveyed (eg, along at least a portion of the length of the tape). . In one embodiment, the plurality of clips is configured in an arcuate direction (eg, at an angle along the linear dimension of the tape) such that the tape includes a plurality of parallel oriented lines formed into thin clip regions.

In some applications, thin pressure rollers224are configured to engage at least one of: a thin transverse handle, a thin axial handle, a thin arcuate handle, and/or combinations thereof.

Also, as depicted inFIGO.2, the fine pressure rollers are configured such that at least one of the first fine pressure roller, the second fine pressure roller, or the first and second fine pressure rollers are configured with an embossed surface that imparts a three-dimensional patterned surface to the uniform glass strip. Thus, fine-textured pressing rollers are formed to make a fine compressed-textured glass film. The embossed surface is configured to transmit at least one of: a micropattern, a macropattern, to at least one of: a first glass strip surface and a second glass tape surface. Texture rollers, sizing rollers, fine pressure rollers and/or pressure rollers can be custom textured and/or sculpted. In some embodiments, if the shaping rolls are textured, the sizing rolls may be omitted.

as shown inFIGO.2, after the fine pinch, textured rolls224act on the formed glass ribbon to feed the compressed thin glass strip, the surface patterned thin pressed glass strip is optionally directed to a conveyor100through an air blower240. Optional air fan240is configured to direct the finely compressed surface patterned glass film from a substantially vertical direction with air rotation to an angular direction and/or a substantially horizontal direction, thereby facilitating the deposition of finely compressed surface patterned film on the surface of a plurality of die assemblies110. So the fan240is configured to facilitate reorientation of the glass position from one direction to another as it moves through the delivery and processing system50to the carrier100.

The Carrier100it has been formed with a number of sets of molds110, sized to accept glass film with a thin surface compression pattern. the mold is set up110are formed in sequential order at a distance such that one set of molds is adjacent to at least two other sets of molds. The Carrier100configured with a conveyor roller assembly140, which includes a conveyor pressure roller144.

Once the finely pressed glass ribbon patterned surface is routed out of the delivery and processing system50, the finely compressed glass ribbon is deposited along a plurality of transfer molds110. The transfer molds are placed in a substantially horizontal direction so that gravity assists the finely compressed glass strip placed over the mold assemblies.110. In addition, the delivery time of compressed thin glass from the delivery and processing systems50in the transfer moulds110along the conveyor108can be synchronized so that the fine clamping area is outside the working surface of the die sets110(for example, outside the mold width or between mold assemblies in a row). Conveyor roller assembly140It is configured with a conveyor pressure roller144which has a constant surface, where the surface of the cylinder144it is formed with a number of raised projections on its surface. Conveyor pressure roller144acts on an upper surface of the deposited glass film, pressing the deposited glass film into a flattened configuration against the mold assembly110and the corresponding mold surface120, while pressing the surface/set of projections of the conveyor arm pinch roller144on the first surface of the tape material. The tape material is thus cast by engagement between the die surface and the conveyor pressure roller surface to define a plurality of portions of molten tape material on the lower surface of the tape material.

As the cast glass film sections continue to travel along the conveyor108, the glass continues to cool. The reduced temperature is sufficient to cause a break in the glass along the thin grip line so that the molded glass strip separates into a plurality of surface-patterned molded glass components as the conveyor directs the molded glass components.100. Optionally, a component removal unit160is set for carrier output108so that a positive pressure actuator162blows air from the conveyor to facilitate lifting of the plurality of surface-patterned molded glass pieces from the conveyor and/or separating two or more surface-patterned molded glass pieces from each other along the thin clamping line(s).

FIGO.3represents a schematic view of one embodiment of a glass processing system50having delivery and processing systems including: a melt supply device;60, thin film deposition200, pin rollers combined with fine pressure rollers224, which then directs a thin ribbon of hot, flexible material that has a plurality of thin handles into a downstream conveyor system100.

The thin film deposition device200Includes a pair of shaping rollers212, including a first forming roll and a second forming roll. the forming rollers212are configured to direct a continuously supplied batch of molten material (eg glass, ceramic and/or glass ceramic) onto a ribbon. The tape is configured with two main surfaces, a first and a second surface, and two corresponding edges, a first edge and a second edge.

The film is then passed through a pair of sizing rollers.218, including a first sizing roller and a second sizing roller. The sizing roller is configured to operate on the surfaces of the glass strip (first major surface, second major surface, and first and second edges) to form the glass to a uniform thickness (eg, as measured across its length and width). . Following the sizing rollers, the uniform glass ribbon is directed to a pair of fine pressure rollers.224, here the fine nip rolls are configured with at least one textured cut roll, including a first and second fine nip rolls.

After the collar rolls, the uniform tape material is directed to a pair of pin rolls (a first pin roll and a second pin roll), where at least one surface of the pin rolls is formed with a plurality of pin roll raised bumps. In some embodiments, both the first pin cylinder and the second pin cylinder are formed with a plurality of raised projections on their respective surfaces. As the uniform tape material travels through the pair of pin rolls, the extending protrusions act on at least one (or both) of the first and second tape material surfaces to impart notches to the cross-sectional thickness of the tape. .

The thin pressure rollers are configured to convey a plurality of grip areas on at least one of: the first major surface and the second major surface, with sufficient engagement of the glass strip between the pair of thin pressure rollers to grip, but not separately. the glass film. The number of tweezers on the glass tape can be configured in various directions, based on the corresponding design of the fine tweezer rollers224.

In one embodiment, the plurality of thin clamps includes a plurality of cross clamps, where each cross clamp is configured to extend from edge to edge (eg, across the width of the glass strip). The forming system is configured with a thin clamping element and a conveyor100.

In one embodiment, the plurality of thin grips includes a plurality of axial grips, wherein each axial grip is configured to extend parallel to the direction in which the tape is conveyed (eg, along at least a portion of the length of the tape). . In one embodiment, the plurality of clips is configured in an arcuate direction (eg, at an angle along the linear dimension of the tape) such that the tape includes a plurality of parallel oriented lines formed into thin clip regions.

In some applications, thin pressure rollers224are configured to engage at least one of: a thin transverse handle, a thin axial handle, a thin arcuate handle, and/or combinations thereof.

Also, as depicted inFIGO.2, the fine pressure rollers are configured such that at least one of the first fine pressure roller, the second fine pressure roller, or the first and second fine pressure rollers are configured with an embossed surface that imparts a three-dimensional patterned surface to the uniform glass strip. Thus, fine-textured pressing rollers are formed to make a fine compressed-textured glass film. The embossed surface is configured to transmit at least one of: a micropattern, a macropattern, to at least one of: a first glass strip surface and a second glass tape surface.

The Carrier100it has been formed with a number of sets of molds110, sized to accept glass film with a thin surface compression pattern. the mold is set up110are formed in sequential order at a distance such that one set of molds is adjacent to at least two other sets of molds. The Carrier100configured with a conveyor roller assembly140, which includes a conveyor pressure roller144.

Once the finely pressed glass ribbon patterned surface is routed out of the delivery and processing system50, the finely compressed glass ribbon is deposited along a plurality of transfer molds110. The transfer molds are placed in a substantially horizontal direction so that gravity assists the finely compressed glass strip placed over the mold assemblies.110. In addition, the delivery time of compressed thin glass from the delivery and processing systems50in the transfer moulds110along the conveyor108can be synchronized so that the fine clamping area is outside the working surface of the die sets110(for example, outside the mold width or between mold assemblies in a row). Conveyor roller assembly140It is configured with a conveyor pressure roller144. Conveyor pressure roller144acts on an upper surface of the pinned tape material, pressing the deposited glass tape into a flattened configuration onto the mold assembly110and the corresponding mold surface120. The tape material is thus cast by engagement between the die surface and the conveyor pressure roller surface to define a plurality of portions of molten tape material on the lower surface of the tape material.

As the cast glass film sections continue to travel along the conveyor108, the glass continues to cool. The reduced temperature is sufficient to cause a break in the glass along the thin grip line so that the molded glass strip separates into a plurality of surface-patterned molded glass components as the conveyor directs the molded glass components.100. Optionally, a component removal unit160is set for carrier output108so that a positive pressure actuator162blows air from the conveyor to facilitate lifting of the plurality of surface-patterned molded glass pieces from the conveyor and/or separating two or more surface-patterned molded glass pieces from each other along the thin clamping line(s).

FIGO.4A-Erepresent various embodiments of a roll pin surface in accordance with one or more embodiments of the present disclosure.FIGO.4ONEdepicts an approximate partial side view of a cylinder having an attached surface and engaging a first surface of a glass strip to form a plurality of projections on the first surface. As depicted inFIGO.4ONE, the pin roll does not run through the full cross-sectional thickness of the tape material and the tape material is supported during clamping by the second roll on the pin roll assembly (shown here with a matching arched surface).

FIGO.4siillustrates another view of a pair of roll pins in accordance with one or more embodiments of the present disclosure. The first pin cylinder has a pinned surface that looks like a series of raised plateaus with flat tops, with the equivalent pin cylinder having spike-shaped pins that are shaped to travel on the edges of the plateau pin cylinder. . The ribbon material appears to be moving between the two rollers. Here, the perforations on the first side of the tape material are offset by the perforations on the second side of the tape material, and each side has different perforation dimensions.

FIGO.4doillustrates another view of a pair of roller pins in accordance with one or more embodiments of the present disclosure. Here, both pin rollers are formed with surface projections with corresponding tooth-shaped pins, so that the teeth of the first roller and the second roller are shaped to meet at a fixed point-to-point distance, creating notches in both first surface and second surface of the tape material which are symmetrical.

FIGO.4Heyis a close-up of a planar surface of the first surface of the glass film with tested surface attachment, showing compressed square cavities (for example, representing the surface of a Belgian waffle).

FIGO.4mis a partial close-up view of the dimensions of an embodiment of a pinned cylinder surface, in accordance with one or more embodiments of the present disclosure.

FIGO.5ONEillustrates a perspective top view of a product with a three-dimensional component shape (circular recesses recessed into the part). a surface texture/surface pattern. and a plurality of surface perforations, after post-treatment to remove glass from an inner end of a perforation, according to one or more embodiments of the present disclosure.

FIGO.5sirepresents a product with an elongated three-dimensional shape (asymmetric) transmitted to the workpiece, with a surface pattern and perforations formed by cylinders with transmitted pins, according to one or more modes of the present disclosure.

FIGO.6represents one aspect of the glassware processing system50, in accordance with one or more aspects of this disclosure. as shown inFIGO.6, a glass delivery system60, a glass processing system70, and a glass transport system100are depicted.

The glass delivery system60provides molten material (eg glass, ceramic or glass-ceramic material) to the glass processing system70. The glass processing system70includes: forming rollers;212(first forming roll and second forming roll). sizing rollers218(first sizing roller and second sizing roller) and pressure rollers224(first pressure roller and second pressure roller).

the forming rollers212are configured to form a hot, flexible strip material (eg, glass tape material, ceramic tape material, or glass ceramic tape material) from the supplied molten material. Once formed, the strip material is formed to the proper width and thickness (ie, uniform thickness) by sizing rolls.218.

Once the tape is formed and sized, the pressure rollers224are shaped to provide a pinch on the tape material, thereby creating a pinch area on the tape material. The grip area is configured to define the boundary between: the component and the glass shell, between distinct parts and/or combinations thereof. The pinch region, along with the original cross-sectional thickness glass ribbon, is configured to be processed downstream as a single piece (eg ribbon material + pinch region), which is continuously removed from the glass supply60for tape placement system200, including: roll forming212, sizing rolls218and fine pinch224rolls. The glass processing system50, as shown, depicts the rollers (roller deposit system200) is configured in a gravity-assisted and/or vertical configuration.

Referring toFIGO.6, the compressed film is routed through the glass processing system40in the glass transport system100through a bend of air240(eg bending air under pressure cylinders224and next to the conveyor belt108of the carrier100. the transport system100includes conveyor belt108, a multitude of mold sets110on the conveyor belt108and a pressure arm assembly140. The compressed ribbon material is passed through the air spin assembly240, from a vertical position to a generally horizontal position, and is deposited along the molds (mold surfaces120matching die sets110) not carrier100, where the compressed tape material undergoes further processing.

Conveyor roller assembly140is configured with at least one roll. At least one cylinder can be configured as: pressure cylinder146(with matching handle ends)148), a pressure cylinder144, a pressure roller (for example, with a smooth surface), a pressure roller with a three-dimensional surface pattern150(eg micro pattern or macro pattern) and/or combinations thereof.

Conveyor roller assembly140has been framed142which includes a motor, the cylinder138, and accompanying optional hydraulics (eg, configured to provide engagement between the roll and the tape material). The Carrier100is configured with a wheeled frame assembly configured to be adjustable relative to the position of the glass processing system40. The controller roller assembly140the roller is engaged with a first surface of the strip material such that the compressed strip material is engaged between the surface of the die120and the roll138. Depending on the configuration of the pressure arm cylinder138and/or mold surface120(or mold case114), the compressed tape material is further processed as it travels along the conveyor.

While the film is passing through the film processing system40and transportation system100, the film slowly cools down. Once sufficiently cooled, the compressive stresses generated between the pinch area and adjacent sections (eg, with a cross-sectional thickness corresponding to most of the strip material) are high enough to cause the strip material to separate along the bite area. The resulting separation along the pinch region creates distinct parts and/or hulls depending on the configuration of the pinch regions and the shape/dimension of the resulting product.

After discrete pieces of the finely compressed glass strip are formed, the pieces can be vacuum lifted from the conveyor or removed from the mold(s) as the mold reaches the end of the transport section (eg, while the molds are still horizontal , before being raised/placed in a vertical position). Parts can be further processed. For example, the edges of the section defined by the pinch area separation can be fire polished to smooth the edges. Alternative processing includes: machining, acid etching, laser processing and/or combinations thereof.

FIGO.7shows an enlarged view of a portion of the glass processing system and glass transfer systemFIGO.6. As depicted inFIGO.7, The Carrier100is configured so that the conveyor belt108with a multitude of mold sets110formed thereon may circulate around an upper (working) surface of the conveyor belt108, where glass tape is processed after the formed glass pieces are removed from the mold surfaces120on the conveyor belt108, the die sets and the conveyor belt travel back to the glass film loading zone, where the finely compressed glass film is directed back to the empty die sets110attached to the carrier108through an air curve240. The closest view of the ribbon delivery system200illustrates the pair of shaping rollers214arranged next to each other, the pair of sizing rollers218placed next to each other and the pair of thin pressure rollers224placed next to each other. In addition, the glass film deposition system200it is adjusted vertically through its frame210, thus shaping the distance between the ribbon drop system200and the transport system100.

In addition, the conveyor supports are also vertically adjustable - also allowing the distance between the ribbon drop system to be adjusted200and the transport system100.

FIGO.8ONE-8dorepresents three different embodiments for a pressure cylinder146having a handle edge148, in accordance with one or more aspects of this disclosure.

In some embodiments, one of the pressure rollers146ofSYK.8through8doplaced on pressure rollers146of the glass treatment set40.

In some embodiments, one of the pressure rollers146ofSYK.8through8doare placed on the pressure cylinder138conveyor pressure roller144within the transport system100.

Referring toFIGO.8ONE, a pressure cylinder146having a handle edge148configured as a perimeter of complex pattern (eg, non-circular, atypical and/or asymmetric) is depicted in accordance with one or more embodiments of the present disclosure.

Referring toFIGO.8si, a pressure cylinder146having a handle edge148configured as a circular perimeter is illustrated in accordance with one or more embodiments of the present disclosure.

Referring toFIGO.8do, a pressure cylinder146having a handle edge148shaped as a double Y is depicted in accordance with one or more aspects of the present disclosure. As a non-limiting example, when used in tape material, the double Y is configured to define a boundary between two distinct sections while providing a collared edge (eg corner cuts) along the corners of the finished piece.

FIGO.9ONEshows a schematic view of the pressure rollers224,226of the glass processing system40, according to one or more embodiments of the present disclosure.

As depicted inFIGO.9ONE, one of two rolls, the first roll224is shaped with a grip tip230, so that when the ribbon material passes between the pinch rollers (224m226), a pinch area is defined/pressed into the tape material.

FIGO.9sirepresents a schematic view of the pressure rollers (224,226) of the glass processing system40, according to one or more embodiments of the present disclosure.

As depicted inFIGO.9si, each of the cylinders (first pressure cylinder224, second pressure cylinder226) is formed with a pinch edge (first pressure roller224shaped with a pinch tip230, second pressure cylinder226shaped with a pinch tip232. In this configuration, the pinch edges (230,232) are set to match each other with the corresponding positions so that when the ribbon material is moved between the nose rollers (224,226), a pinch area is defined in the tape material as the two pinch edges (230,232) are respectively involved in a corresponding proximal position. Therefore, the glass film is transported by fine forceps which are actuated on its first major surface and opposite on its second major surface.

FIGO.10ONEis a schematic top view of an embodiment of a tape material10, in accordance with various aspects of this disclosure. film material10is formed as a continuous body and/or long member (for example, depending on how the glass is delivered, continuous or batch). the glass film10is formed with a first large surface16and a second main surface18and the corresponding first edge12and second edge14. When the glass is formed through the forming and sizing rolls, the rolls contact the first and second major surfaces of the ribbon to form the ribbon into a ribbon of corresponding thickness (eg, based on roll spacing/gap).

FIGO.10siis a schematic side view of the ribbon material;10, in accordance with one or more aspects of this disclosure. As disclosed in one or more embodiments herein, the carrier is configured to hold (via the plurality of die assemblies) the glass film10so that the second surface contacts the die sets. In this position, the first surface16faces the nose roller (eg, a roller configured to contact/communicate with the first surface of the ribbon material). The second large surface18facing the mold surface of the mold assembly.FIGO.10sialso describes the thickness of the cross-section38of the film material10.

FIGO.11ONEis a schematic side elevational view of a ribbon material embodiment;10mounted not transport system100, in accordance with various aspects of this disclosure. As depicted inFIGO.11ONE, the material of the film10is configured as a continuous body and/or long member (eg depending on how glass is delivered). The Carrier100generally represents the plurality of die sets110formed in order. the mold is set up110by the carrier100are configured for the glass film10so that on second surface18is in contact with the mold assembly110. In this position, the first surface16is facing up towards the conveyor roller assembly140and the corresponding cylinder placed in it. The roller is represented as a pinch roller arm146having a defined grip end148is set to contact the glass film10on its first surface16, activating a pinch area in the film10through the edge of the handle148no roll open146.

FIGO.11siis a schematic plan view of an embodiment of a ribbon material10mounted not transport system100where the mold sets110each shaped with a matching grip edge116, in accordance with various aspects of this disclosure. As depicted inFIGO.11si, the material of the film10is configured as a continuous body and/or long member (eg depending on how glass is delivered). The Carrier100is set to hold (through the multitude of mold sets110) in the glass fits10so that on second surface18is in contact with the mold sets. In this position, the first surface16is facing the cylinder which is configured as a pressure cylinder146with handle tip148. the pressure cylinder146acts on the first surface16outside too10, thus pressing the film10on the tip of the forceps116from each respective mold set. Also as a pressure roller146acts on the first surface of the film10, the edge of the handle148from the pressure roller146activates a fine tweezer on the first surface16outside too10. such as the pressure roller146works with clamping ends116two sets of molds110, the corresponding compressed tape is designed with a pinch area with a fine grip20on the first surface is placed in cooperation with a fine pinch on the second surface18(represented as the area around the edge of the handle116of mold assembly after the roll is activated.

FIGO.12ONE-12mrepresent various configurations of a roll, which can be used in the pinch roll of the glass processing system40and/or as shown here by reference numerals, in the pressure cylinder configured as a pressure cylinder146with handle tip148of the transport system100, in accordance with one or more aspects of this disclosure.

As depicted inFIGO.12ONE, pressure cylinder146is formed with two matching handle ends148which run circumferentially around the cylinder146, so that the clamping edges148define a pinch area adjacent to each of the first and second edges along the edges of the tape material. In one embodiment, as the processed tape material cools, the gripping area separates the product from the edges/fragments. Alternatively, as another embodiment, peripheral pinch edges are used to define rows of discrete segments formed from the tape material. the edge of the handle148depicted inFIGO.12ONEis shaped to provide thin axial grip areas on the mating tape material along the tape.

As depicted inFIGO.12si, pressure cylinder146is shaped with a grip tip148extending from one edge of the roll146on the other side of the roll148in an axial direction in the cylinder146. In one embodiment, as the processed tape material cools, the gripping area separates the product from the edges/fragments. Alternatively, as another embodiment, axial grip edges are used to define rows of discrete segments formed from the tape material. the edge of the handle148depicted inFIGO.12siis shaped to provide a thin transverse pinch area(s) in the mating tape material, extending from one end of the tape to the other end of the tape, across the entire width of the tape.

As depicted inFIGO.12do, pressure cylinder146is shaped with a grip tip148extending from one end of the cylinder to the other end of the cylinder in an axial direction. In addition, the surface of the cylinder is modeled with a standard 3D surface pattern.152modeled as a 3D micropattern158along the surface of the roll, which transmits the corresponding three-dimensional micropattern to the surface of the film material (for example, in the negative or mirror image). In one embodiment, as the processed surface patterned tape material cools, the grip area separates the product from the edges/glass shard. Alternatively, as another embodiment, pinch edges are used to define rows of discrete sections formed from the tape material.

As depicted inFIGO.12Hey, pressure cylinder146is formed with a pressure edge extending from one end of the pressure roller146at the other end of the pinch roller146in the axial direction. In addition, the surface of the cylinder is modeled with a three-dimensional surface pattern.152is configured as a macro pattern156(e.g. star shapes) along its surface, which transmits the corresponding three-dimensional macropattern to the surface of the film material (e.g. in the negative or mirror image). In one embodiment, as the processed surface patterned tape material cools, the grip area separates the product from the edges/glass shard. Alternatively, as another embodiment, pinch edges are used to define rows of discrete sections formed from the tape material.

As depicted inFIGO.12m, pressure cylinder146it is designed with multiple grip tips148, including at least two corresponding types of clamping ends148: Perimeter pinch edges (ie placed around the roll) and axial pinch edges (ie placed to extend from one end of the roll to the other). Thus, the tape material is provided with a plurality of pinch areas in a grid-like pattern. As the processed strip material cools, areas of pinching separate the product(s) from the edges/sections of the fragments. Alternatively, as another embodiment, peripheral pinch edges are used to define rows of discrete segments formed from the tape material.

FIGO.13represents a schematic cut away side view of the conveyor assembly100, which shows the vacuum coupling part132, vacuum boxes136molded under the mold sets110and component removal unit160, described as positive pressure actuators162configured with a number of thrust mechanisms to facilitate the removal of glass fragments formed at the end of the conveyor assembly100, according to one or more embodiments of the present disclosure. The Carrier100it is equipped with a plurality of vacuum boxes136, where each empty box136is configured to interact with a multitude of template sets110. During operation, vacuum is applied through the vacuum engagement section132(which is in communication with the vacuum box136), thereby drawing a vacuum/negative pressure to the surface of the mold, through the parts involved in the vacuum132, through the vacuum box136and out through the vacuum doors leaving the transport system100. Accordingly, the strip element is drawn to and/or deformed/formed on the surface of the mold by the negative pressure transmitted between the bottom surface of the glass strip and the surface of the mold through the vacuum engagement portions.132. The resulting tape material is formed into a three-dimensional shape corresponding to the three-dimensional shape of the three-dimensional mold surface of each respective mold assembly.110. Also, as shown inFIGO.13, the push-up mechanism160(component removal unit) is equipped with individual positive pressure ports (shown as162, positive pressure actuator), which act to push up the mold holes and push out the vacuum-formed 3D parts.

FIGO.14is a top perspective view of one embodiment of a conveyor assembly;100, where the multitude of molds congeal110are formed with planar surfaces in accordance with one or more aspects of the present disclosure.FIGO.14also describes some additional parts of the conveyor roller assembly140shaped with a pressure roller144and context142.

FIGO.15is a top perspective view of one embodiment of a conveyor assembly;100having a multitude of mold sets110with complex 3D shapes and corresponding vacuum configuration (represented via a vacuum port134), in accordance with one or more aspects of this disclosure. the mold is set up110they are formed with a mold body112(specifying the resulting shape and/or surface pattern printed on the bottom surface of the glass strip) and the plate114(the fixture is shaped to hold the mold body110on the conveyor belt108, to bind the mold110are formed in a sequential, spaced, and subtractive fixed-position relationship. Also pictured insideFIGO.15, transfer roller assembly140shown having a pressure cylinder144and context142.

FIGO.16ONEis a close-up perspective top view of the mold assembly;110no transport system is used100ofFIGO.14, representing a mold surface120shaped as a smooth, flat surface mold, according to one or more embodiments of the present disclosure.

FIGO.16siis a close-up perspective top view of the mold assembly;110no transport system is used100ofFIGO.15, representing a mold surface120shaped as a three-dimensional surface mold, according to one or more embodiments of the present disclosure. As illustrated, there are a multitude of parts involved under vacuum132(through holes) formed in the bottom of the mold assembly110. The vacuum coupling sections132are formed through the mold body112, so that the holes are shaped to draw a vacuum through the vacuum engaging portions132when actuated via vacuum and vacuum box136. In addition, the vacuum coupling sections132in the mold body112are configured to engage the parts removal unit at the end of the conveyor belt so that the positive pressure actuator can push air/positive pressure through the vacuum engagement sections132to direct pieces of glass away from the mold surface120.FIGO.16sialso shows a closer view of the mold base114, which is shaped to hold the mold body112for the conveyor belt; and the clamping end of the die carrier, which is configured to cooperate with the roller in the carrier roller assembly to drive a clamping area on the lower surface of the glazing strip.

FIGO.16dois a close-up perspective top view of the mold assembly;110is used in the transfer system, representing a surface mold in a three-dimensional shape (e.g., plate or bowl pattern), according to one or more embodiments of the present disclosure. As illustrated, there are a multitude of parts involved under vacuum132(through holes) formed in the bottom of the mold body112. The parts/holes of the vacuum link132are formed through the mold body112, so the holes are shaped to draw a gap through the holes132when activated via the vacuum and vacuum box, in accordance with various aspects of the present disclosure. In addition, the mold assembly110it is equipped with a mold holder114is shaped to secure the mold body112on the conveyor belt. The mold body is further shaped with a grip edge.116perimeter of the 3D shape in the body of the mold112, so that when the pressure roller engages the mold surface120, the pressure roller fits the clamping edge116and defines a pinch region around the 3D shaped portion (e.g., while the vacuum pulls/forms the tape material into the 3D mold shape, in accordance with one or more aspects of the present disclosure.

FIGO.17is a top perspective view of one embodiment of a conveyor assembly;100having a multitude of mold sets110with complex 3D shapes and corresponding void shaping, combined with a clamping edge on the mold assembly (e.g. to define a clamping area around the 3D part4formed via vacuum), in accordance with one or more aspects of the present disclosure. Referring toFIGO.17, the glass delivery unit60directs a molten charge of material (eg glass, ceramic or vitreous) into a film deposition system with a pair of forming rolls212, a pair of size cylinders and a rotating air240, to direct the tape material to a transfer device100.

the transport device100additionally includes a variety of mold sets110having a mold body and a mold carrier116, where the mold slot116configured to attach sets of molds to the conveyor belt108. The transfer roller assembly provides a cutting roller146shaped with a finished edge148. as an end point148it works with the material of the film, the cylinder146also acts as a tip116on the surface of the respective mold to provide a cutting edge on the first surface and a cutting edge on the second surface of the glass strip. In addition, the vacuum coupling sections132they provide negative pressure between the bottom surface of the strip material and the mold surface, forming the strip into the shape of the mold body.

FIGO.18A-Erepresent various embodiments of complex three-dimensional parts that can be made from a tape material having one or more aspects of the present disclosure.

FIGO.18ONEdescribes a view from above the plane (topFIGO.18ONE) e flat side view (bottomFIGO.18ONE), which represents an integration of a product24formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the transfer system, in accordance with one or more aspects of the present disclosure.FIGO.18ONEdepicts a product24shaped as a food utensil (eg soup spoon).

FIGO.18sirepresents a top view of an implementation of a product24formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the transfer system, in accordance with one or more aspects of the present disclosure.FIGO.18sidepicts a product24is shaped as a round plate with an uneven edge (eg scalloped edge).

FIGO.18dorepresents a top view of an implementation of a product24formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the transfer system, in accordance with one or more aspects of the present disclosure. FIG.18C stands for product24is shaped as a non-round symmetric plate with a non-uniform edge (eg matching perimeter edge).

FIGO.18Heyrepresents a top view of an implementation of a product24formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the transfer system, in accordance with one or more aspects of the present disclosure.FIGO.18Heydepicts a product24is shaped as a symmetrical, geometric (rectangular) slab with an uneven border (eg, matching perimeter border).

FIGO.18mrepresents a top view of an implementation of a product24formed by a vacuum mold assembly having a three-dimensional shape therein, in conjunction with the transfer system, in accordance with one or more aspects of the present disclosure.FIGO.18mdepicts a product24shaped as symmetrical, geometric (oval) with a raised border/wall of uneven height (peeled or scalloped wall).

FIGO.19represents a schematic top perspective view of an embodiment of the transfer system;100in accordance with one or more aspects of this disclosure. as shown inFIGO.19, the composite conveyor is configured to provide a three-dimensional vacuum formed shape with the corresponding three-dimensional shape mold assembly110. The resulting product24It can be used as glass, ceramic or glass ceramic tile. The resulting product may be used as a glass, ceramic or glass-ceramic tile, according to one or more embodiments of the present disclosure. as shown inFIGO.19, the conveyor belt108has a multitude of mold sets110molded into it, with a clamping area20defined between each adjacent set of dies, configured to define a grip area on the glass strip on its lower surface. the mold assembly110it is formed as a female mold with a toothed mold surface pattern.

FIGO.20represents a schematic top perspective view of an embodiment of the transfer system;100in accordance with one or more aspects of this disclosure. as shown inFIGO.20, the composite shape is defined as a male mold (defined as a raised pattern) in the mold assembly110and the tape material is rolled with a pressure roller with a matching surface profile to conform the tape material to the mold surface120(eg no gap formation). The 3D product24shown with the corresponding 3D mold assemblies. The resulting product may be used as a glass, ceramic or glass-ceramic tile, according to one or more embodiments of the present disclosure.

FIGO.21depicts images of various views of product shapes made in accordance with one or more embodiments of the present disclosure. In the upper left corner, an embodiment of the edge formed is shown, in accordance with one or more embodiments of the present disclosure. In the upper right corner, an embodiment of the region split along the tip of the handle is shown. In the lower left corner, the shaped edge is seen at a different angle than the upper left corner, according to one or more embodiments of the present disclosure. In the lower right corner, the handle end/part end is shown after post-processing (fire polishing) in accordance with various aspects of the present disclosure.

FIGO.22illustrates a top perspective view of an embodiment of a perforated acoustic sheet, in accordance with one or more embodiments of the present disclosure. Here, the acoustic sheet product is formed with a plurality of spacers, three-dimensional strips imparted to promote a stained glass likeness, perforations in the first surface of the acoustic sheet, and three-dimensional shapes recessed into the acoustic sheet, in accordance with one or more embodiments of the present disclosure.

FIGO.23depicts a perspective top view of various embodiments of a perforated acoustic sheet having various configurations, including alternating perforations with aligned ribs on a first surface of the acoustic sheet. a combined lateral and transverse checkerboard pattern with a surface texture with perforations carried into the surface texture and an acoustic foil with a raised center and corner edges to create a beveled edge with a hollow interior. according to one or more embodiments of the present disclosure.

Directional terms used herein—eg, up, down, right, left, forward, backward, up, down—are made with reference only to the figures as drawn and are not intended to indicate absolute orientation.

Unless otherwise expressly stated, in no way is it intended that any method set forth herein be construed as requiring that its steps be performed in any particular order. Accordingly, where a method claim does not actually recite an order to be followed by its steps, or does not expressly state in the claims or descriptions that the steps are to be limited to a particular order, an order is in no way intended to be inferred from every point of view. This applies to any possible unexpressed basis of interpretation, including questions of logic about the arrangement of steps or functional flow. simple meaning derived from grammatical organization or punctuation. the number or type of modes described in the descriptive report.

As used in this document, the singular forms "a", "an" and "the" include plural references unless the context clearly indicates otherwise. Thus, for example, a reference to an "ingredient" includes aspects with two or more of these elements unless the context clearly indicates otherwise.

Many variations and modifications may be made in the foregoing embodiments of the disclosure without materially departing from the spirit and various principles of the disclosure. All such modifications and variations are incorporated herein by this disclosure and are protected by the following claims.