See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/267710708

Influence of Isopipe Temperature on Glass Fusion for the Overflow Fusion

Process

Article

CITATIONS READS

2 2,865

2 authors, including:

Huey-Jiuan Lin
National United University
28 PUBLICATIONS   535 CITATIONS   

SEE PROFILE

All content following this page was uploaded by Huey-Jiuan Lin on 13 March 2015.

The user has requested enhancement of the downloaded file.

_______________This is just a simple text_____________
Influence of Isopipe Temperature on Glass Fusion for the Overflow
Fusion Process
Huey-Jiuan Lin, Wei-Kuo Chang
Department of Materials Science and Engineering, National United University,
1 Lein-Da, Kung-Ching Li, MiaoLi, Taiwan.
Abstract
The overflow fusion process was an important
method for the manufacture of glass sheet that is
currently used for the production of TFT/LCD display
devices. The design of forming apparatus is critical for
very high surface quality of glass to allow the successful
application of semiconductor type material. However,
there is only a little of researches had been presented in
the literatures, because of difficulties and expansions in
experiments. In this study, a numerical model for
simulation of molten glass flow through the isopipe
during overflow fusion process is carried out. An explicit
finite difference algorithm with surface tracking method
is been proposed. The effect of temperature of forming
apparatus and viscosity of molten glass on the flow
patterns during overflow is investigated. It is found that
the stability and flatness of sheet glass is influenced by
the temperature of forming apparatus and viscosity of
molten glass flow. Too high or low temperature will both
induce unsteady flow profile along the surface of isopipe.
A precise control of overflow temperature and
temperature distribution of isopipe is needed for
maintaining a stable flow along the isopipe as well as
after fusion.
Keywords: overflow fusion process, numerical
simulation, sheet glass
Introduction
The overflow fusion process is one of the basic
techniques used to produce glass sheets. Compared to
other sheet glass forming process, e.g. the float [1] and
slot down [2] processes, the overflow fusion process
produces glass sheets whose surface have superior
flatness and smoothness. As a result, the overflow fusion
process has become of particular importance in the
production of the glass substrates used in the
manufacture of liquid crystal displays (LCDs). The
overflow fusion process is described in detailed in
United States patent numbers 3,338,696 and 3,682,609,
by Stuart M. Dockerty.
One of the major advantage of the overflow fusion
process is that the surfaces of the resulting glass sheet are
pristine, having avoided any contact with refractory
material during forming. This eliminates the need for
1
further grinding and polishing of the glass surface.
However, the overflow fusion process is more difficult to
control the flow rate and viscosity of molten glass than
the other two methods. Since it solely relies on the
design of an apparatus called “isopipe”, for forming the
sheet glass. To acquire a good quality of glass sheet, the
design of isopipe becomes critical.
Practical difficulties, preventing one to detect or
measure the abnormalities in the flow patterns and
temperature distribution during real overflow fusion
process operation, necessitated a numerical simulation
method. Numerical modeling was a very powerful tool in
the study of glass melt and forming process. Reviewing
the literatures [3-8], it was noted that various models had
been suggested to predict fluid flow and heat transfer in
the glass melt furnace and succeeded. However, to the
best of author’s knowledge, the numerical modeling of
transport phenomena during overflow fusion process had
received very little attention in past. In US patent
3338696, a simple mathematical model was built and
conducted that the product of the glass flow, glass
viscosity and the tangent of the tilt angle of trough must
be a constant to make glass of uniform thickness for a
given trough. However, it was still the state of the art as
practiced today. It also did not consider the influence of
temperature (or viscosity). Recently, R.B. Pitbladdo
proposed several patents [3,9-10] to modify the forming
apparatus, including delivering system, forming
apparatus and downdrawing equipment etc. He also
suggested that the exact shape of isopipe could be
calculated by solving the Navier-Stokes equations using
any of a number of computational fluid dynamics (CFD)
software packages. However, he did not show simulation
results and design criteria in the patents.
To gain a better understanding of flow pattern and
temperature variation during the overflow fusion process,
the physical phenomena would be well studied.
Therefore, the aim of this study is to propose a
computational method with volume of fluid (VOF)
approach for tracking the waving of surface of molten
glass, to model the flow patterns and temperature
distribution for various designs of isopipe, and to obtain
the relationships among flow pattern and temperature
distribution of isopipe. Then, an optimized design of
isopipe could be achieved.
159
_______________This is just a simple text_____________

Physical Model overflows the top of isopipe, the temperature should be

high enough for low viscosity and good fluidity. At the
same time, when two streams of molten glass fused
A schematic diagram of overflow fusion process together at root, the temperature should be low enough to
was shown in Figure 1. The molten glass from the avoid breakage due to pulling force.
melting furnace, which must be of substantially uniform
temperature and chemical composition, fed a refining
device. The refining device thoroughly homogenized the
glass melt. The glass was then conducted through an
inlet pipe to the sheet forming apparatus which formed
by refractory material known as an “isopipe”. The inlet
pipe was preferably shaped to control the velocity
distribution of the incoming molten glass flow. After
filling the trough of isopipe, the molten glass overflowed
the top of the trough on both sides, thus forming two
sheets of glass that flowed downward and then inward
along the outer surfaces of the isopipe with wedge shape.
The two sheets met at the root of the isopipe, where they
fused together into a single sheet. The single sheet was
then fed to drawing equipment, which controlled the
thickness of the sheet by the rate at which the sheet was Figure 1 A schematic diagram of isopipe
drawn away from the root. The drawing equipment was
located well downstream of the root so that the single
sheet had cooled and became rigid before coming into Simulation Details
contact with the equipment. The surface quality was
obtained by having no contact between the glass which While the experimental work offered invaluable
formed the surface of the sheet and any metal or insight into the phenomena, there were limitations in the
refractory object. Strict controls were necessary during experimentation because of the high temperature and
overflowing and fusion period in order to obtain uniform closed system of overflow fusion process. Quantitative
thickness and surface quality glass. measurement of the velocity and temperature gradients in
the region of the isopipe were difficult. Therefore, to
extend our understanding of the molten glass flow
phenomena, we performed a series of simulations using a
CFD code. The Flow3D™ [12] software was a
commercially available finite difference code for solving
the complete Navier-Stokes and energy equations with
the VOF method. The capabilities of the code included
three dimensional, time dependent, couple fluid/heat
transfer and free surface tracking of complex nonlinear
flows. A brief summary of the mathematical formulation
for describing the motion and heat transfer of an
incompressible fluid was given below.

Governing equations
The continuity equation
r
∇ ⋅V = 0 (1)
r
The Navier-Stokes equation
∂V r r 1 μ (T ) 2 r σ (2)
+ (V ⋅ ∇)V = − ∇p + ∇ V + g + κ∇F
∂t ρ ρ ρ
Figure 1 A schematic diagram of overflow fusion process The energy equation
∂ r (3)
ρ (C pT ) + ρV ⋅ ∇(C pT ) = ∇ ⋅ (∇kT )
The details of isopipe were shown in Figure 2. It ∂t
r
contained a collection trough at upper portion and a Where V is the velocity vector, t is the time, g is
forming wedge block at lower portion. According the gravitational acceleration, p is the scalar pressure, ρ
mentions above, the profile of isopipe would control the is density, μ (T) is viscosity depending on temperature, σ
behavior of molten glass and as a result, it determined is the surface tension, and κ is the curvature of the free
the thickness and uniformity of glass sheet. In the surface, F is volume fraction of fluid in the surface cell.
previous paper [11], we have discussed the influence of T is the temperature, Cp is the heat capacity and k is the
geometry of isopipe and the viscosity of molten glass thermal conductivity.
under constant temperature. However, in general, the The fourth term in the right hand side of equation
temperature of the molten glass at the top is higher than (2) is the volume force induced by the surface tension,
that at the root of isopipe. When the molten glass nonzero only within free surface. It is developed by
2
160
_______________This is just a simple text_____________

Brackbill et al. [13], called the CSF (Continuum Surface glass is introduced from the top of the isopipe. The linear
Force) method. CSF method converts the interfacial temperature distribution of the isopipe is assumed and
surface force into a corresponding volume force, which increases from root to top at beginning.
can then be included in the Navier-Stokes equations.
When supplied with geometry definition, boundary and
initial conditions, equations (1) - (3) are solved by the
code utilizing a finite difference approach.

Treatments for the Free Surface Flow

With the VOF method [14], a field variable,
F(x,y,z,t), is designated for each computational element
to indicate the volume fraction of liquid in that particular
cell. The values of F in filled cells, partially filled cells,
and empty cells are given by unity, between zero and
unity, and zero, respectively. From the law of
conservation of mass, this function is governed by the
following equation:
∂F r
+ (V ⋅ ∇ ) F = 0
∂t
However, if this equation is solved by using
regular finite difference schemes, F is soon smeared due
to numerical diffusion and interfaces are no longer sharp.
A special, non-diffusive, often geometry-based technique
called donor-acceptor method is then necessary for the
advection of F in a way that the sharpness of the phase
interface is kept.
Thus, the implementation of the VOF advection
method consists of three steps:
(1) Approximate fluid interface in a cell with a planar
surface;
(2) Move the fluid volume according to the local
velocity field;
(3) Compute new fluid fraction values in the
computational cells.
Viscosity Evaluation
For non-Newtorian fluids the viscosity can be a
function of the strain rate and/or temperature. Because
the molten glass during overflow could be considered as
viscous flow, the viscosity is dependent on temperature
only. Therefore, the Carreau model used in Flow3D is
modified to the form of temperature-dependent in this
research.
⎡ ⎛ T* ⎞⎤
μ = μ 0 exp ⎢a⎜⎜ − c ⎟⎟⎥ (5)
⎣ ⎝T −b ⎠⎦
Where T is fluid temperature, T*, a, b, and c are constant.
The parameters are calculated by curve-fitting for
specific glass.
Figure 3 Simulation model in mm unit
(4)
Results and Discussion
The relationship of temperature-viscosity for
silicate glass [15] using in this research is fitted to
Carreau model. The value for each parameters in Carreau
model, μ0, a, b, c, and T*, is 500, 10.21, 43.22, 2.046 and
1700 respectively.
Influence of Temperature Distribution of Isopipe
The influence of isopipe with different temperature
distribution is investigated by using Flow3D. The initial
temperature and flow rate of molten glass are kept
constant, set as 1200oC and 5mm2/sec respectively.
Figure 4 shows the flow pattern and temperature
profile of molten glass flowing along the outer surface of
isopipe with temperature distribution of 1170 to 1270oC.
The color bar indicates the temperature range in K. The
molten glass flows downward smoothly and then inward
along the inclined surface of isopipe. The temperature of
glass front increases a little. When the molten glass flows
over the converging surface of the isopipe, the separate
flows reunite at root, and fuse together into a single sheet.
The glass sheet is about 1205oC when it leaves the
isopipe. The free surface of molten glass waves slightly,
as shown in Figure 4(b).

Implementation
The simulation of glass forming was a complex
problem. Its viscosity was strongly temperature
dependent, varied from ~10Pa.s to ~104Pa.s, and the
process involved large deformation. Due to the high
viscosity and numerical stability criteria, the time step
for calculation was very small. It would take a very long
time to simulate the overflow fusion process in three
dimensions. Assuming the overflow of molten glass is (a) (b)
uniform through the isopipe, half and two-dimensional
cross-section at central location of isopipe is considered Figure 4 Flow pattern and temperature profile for the
here as shown in Figure 3. A uniform flow of molten isopipe with temperature distribution of 1170 to 1270oC
3
161
_______________This is just a simple text_____________

Figure 5 shows the results when the temperature

distribution of isopipe is increased to 1290~1380oC. The
flow and temperature profile are more stable than the
results of Figure 4. The film thickness is also smaller
than that above because of high flowing temperature and
low viscosity, as shown in Figure 5(b). However, the
fused glass sheet became discontinuous as shown in
Figure 4(c). The temperature is about 1290oC when the
glass leaves the root of isopipe and the viscosity is lower
than 1000 poise.

(a) (b)

Figure 6 Flow pattern and temperature profile for the

isopipe with temperature distribution of 930 to 1050oC

Influence of initial temperature of molten glass

The effects of initial temperature of molten glass
are investigated under constant temperature distribution
of isopipe, 1170 to 1270oC. Figure 7 shows the results
when the initial temperature of molten glass is set as
(a) (b) 1400oC. The glass sheet departs from the surface when
flows over the converging surface of isopipe, as shown
in Figure 7(a), because of low viscosity and gravity. The
glass falls downward before arriving at the root of
iospipe and could not fuse with the other stream, as
shown in Figure 7(b).

(c)

Figure 5 Flow pattern and temperature profile for the

isopipe with temperature distribution of 1290 to 1380oC

Figure 6 shows the results with temperature

distribution of isopipe from 930 to 1050oC. It is found
that the temperature distribution of molten glass from
inner to free surface is not uniform. The glass contacted
with isopipe is almost stuck because of low temperature
as well as high viscosity. The outer glass with high
temperature flows as free falling stream and do not
merge with the other stream at root. The fused single
sheet glass could not form in this case.
(a) (b)
Figure 7 Flow pattern and temperature profile for the
molten glass with initial temperature of 1400oC
As the initial temperature of molten glass is
1000oC, Figure 8, the flowing profile is quite unstable.
The high viscosity due to low glass temperature causes
the immovable front of glass at beginning, as shown in
Figure 8(a). After fusion, the sheet thickness varies with
time also, as shown in Figure 8(b) and (c).

4
162
 _______________This is just a simple text_____________
(a) (b)
(c)
Figure 8 Flow patterns and temperature profiles for the
molten glass with initial temperature of 1000oC
From above results, it is found that the temperature
distribution of isopipe and initial molten glass
temperature are important parameters for stable flowing
and uniform thickness. The glass sheet with low
viscosity causing by high initial temperature or high
temperature distribution will flow smooth over the
converging surface of the isopipe, but discontinue when
leaving the isopipe. However, low initial temperature and
temperature distribution will produce unstable flow and
waving phenomena during overflow and fusion. The best
conditions are 1200oC molten glass with isopipe of
1170-1270oC temperature distribution in this study. This
result is also met with the suggestion in patent
WO03/055813. In fact, the suitable temperature profile is
dependent on the glass properties. It is necessary to
maintain the viscosity of glass at location where it leaves
the isopipe is at about 105 poises.
Conclusion
Through the numerical simulation, two-
dimensional modeling of the flow and temperature of
5
View publication stats
molten glass down the isopipe surface, moving along
inclined surface, merging and fusing at root and falling
freely in space is perform using Flow3D package. The
effects of molten glass temperature and isopipe
temperature distribution are investigated. It is found that
the stability and flatness of sheet glass was influenced by
the temperature of forming apparatus, and viscosity of
molten glass flow. Low temperature will induce unsteady
flow profile along the surface of isopipe. High
temperature will cause discontinuous flow. A precise
control of overflow temperature and temperature
distribution of isopipe is needed for maintaining a
suitable viscosity of glass located at root and a stable
flowing along the isopipe as well as after fusion.
Acknowledgements
The authors acknowledge the financial support
provided by the National Science Council Foundation,
under Grant 94-2216-E-239-003 and
95-2221-E-239-024.
References
1. N. Ban, T. Kamihori, H. Takamuku, J. Non-Cryst.
Solids 345&346 (2004) 777-781.
2. H. Kariya, United States Patent Number US6758064,
July 6, 2004.
3. R. B. Pitbladdo, United States Patent Number
US6895782, 2005.
4. R. Viskanta, J. Non-Cryst. Solids 177 (1994)
347-362.
5. T. Kamihori, M. Iga, S. Kakihara, H. Mase, J.
Non-Cryst. Solids 177 (1994) 363-371.
6. M. Prieto, J. Diaz, E. Egusquiza, Int. J. Therm. Sci.
41 (2002) 348-359.
7. P. Schill, J. Chmelar, J. Non-Cryst. Solids 345&346
(2004) 771-776.
8. E. Feulvarch, N. Moulin, P. Saillard, T. Lornage, J. M.
Bergheau, J. Materials Processing Technology,
164-165 (2005) 1197-1203.
9. R. B. Pitbladdo, United States Patent Number
US6748765, 2004.
10. R. B. Pitbladdo, United States Patent Number
US6990834, 2006.
11. H.J. Lin, F.Y. Hsu, W. K. Chang, Glass Technol.: Eur.
J. Glass Sci. Technol. A, 48 (2007) to be published.
12. Flow Science Inc., 683 Harkle Rd Suite A, Santa Fe,
NM 87505, U.S. http://www.flow3d.com.
13. J. U. Brackbill, D. B. Kothe, and C. Zemach, J. of
Comp. Phy., 100 (1992) 335-354.
14. C. Hirt and B. Nichols, J. Comp. Phy., 39 (1981) 201-
225.
15. H. Scholze, Glass Nature, Structure and Properties,
Springer-Verlag 1991, p.44225.
163