BACKGROUND ART Glass sheets are heated for processing such as forming, heat strengthening, or tempering, etc. Such heating is conventionally performed by either electric resistance-type furnaces or by forced convection furnaces. Prior electric resistance-type furnaces are disclosed by United States Patent Nos. 3,934,970 McMaster et al., 3,947,242 McMaster et al., and 3,994,711 McMaster, all of which have lower and upper housing portions that support electric resistance elements that provide radiant heating of glass sheets from below and above at their lower and upper surfaces during conveyance within a heating chamber of the furnace housing.

Prior forced convection furnaces are disclosed by the United States patents of Kenneth R. Kormanyos: 5,669,954; 5,672,191; 5,735,924; 5,762,677; and 5,792,232, all of which have lower and upper forced convection heaters that provide forced convection heating of conveyed glass sheets from below and above at top and bottom surfaces of the glass sheets.

Electric resistance furnaces for heating glass sheets are less expensive to initially manufacture than forced convection furnaces for heating glass sheets and also can be more easily controlled by less involved control apparatus. In addition, electric resistance furnaces for heating glass sheets also result in a greater percentage of the energy input being transferred into the glass for the heating. However, electrical energy is more expensive than natural gas heating and the radiant heating involved cannot efficiently heat low emission-coated glass. Furthermore, radiant heating cannot uniformly heat glass coated partially with paint bands or reflective

coatings used in the automotive industry because the coated area absorb more or less radiant heat than adjacent uncoated areas.

Forced convection furnaces for heating glass sheets are not as efficient as electric resistance furnaces since a certain volume of heated air must be continually removed from the furnace to make up for the volume of combusted gas that is being introduced. However, this loss in efficiency is offset by the lower cost of natural gas as compared to electrical energy such that the operational cost for forced convection furnaces are effectively less than for electric resistance furnaces.

DISCLOSURE OF INVENTION One object of the present invention is to provide an improved method for heating a glass sheet.

In carrying out the above object, the method for heating a glass sheet in accordance with the invention is performed by conveying the glass sheet along a direction of conveyance on rolls of a horizontal roll conveyor within a heating chamber of a furnace housing. Electrical power is supplied to electric resistance elements supported by a lower portion of the furnace housing below the rolls of the conveyor to heat the conveyed glass sheet from below. A hot gas flow heated by a gas burner is supplied and directed downwardly from an upper portion of the furnace housing to provide a dominant mode of external heat for heating the conveyed glass sheet from above.

The method has particular utility when an uncoated surface of a glass sheet faces downwardly and is supported by the conveyor and a coated surface thereof faces upwardly and is heated by the downwardly directed hot gas flow.

In the preferred practice of the method, the gas burner heated hot gas flow is delivered downwardly through hot gas distributors that are spaced along the direction of conveyance above the conveyor. This hot gas flow is preferably delivered to the hot gas distributors from a plenum housing having a supply blower

that is located within the plenum housing. The hot gas flow is most preferably provided to the plenum housing through an intake that extends laterally with respect to the direction of conveyance into the plenum housing at one lateral extremity thereof and internally through the plenum housing to the supply blower at another lateral extremity of the plenum housing.

Another object of the present invention is to provide an improved furnace for heating glass sheets.

In carrying out the immediately preceding object, a furnace constructed in accordance with the invention for heating glass sheets includes a furnace housing having lower and upper portions that cooperate to define a heating chamber. A roll conveyor of the furnace has horizontally extending conveyor rolls for supporting and conveying the glass sheets along a direction of conveyance through the heating chamber. An electric resistance heater of the furnace includes electric resistance elements supported by the lower housing portion below the rolls of the conveyor and to which electric power is supplied to heat the conveyed glass sheets from below. A forced convection heater of the furnace is supported by the upper housing portion and includes a gas burner for heating a hot gas flow that is directed downwardly to provide a dominant mode of external heat for heating the conveyed glass sheets from above.

In the preferred construction of the furnace for heating glass sheets, the forced convection heater includes hot gas distributors spaced along the direction of conveyance above the conveyor to deliver the hot gas flow downwardly to the conveyed glass sheets. This preferred construction of the forced convection heater includes a plenum housing that is supported within the heating chamber above the conveyor and includes an intake that receives a hot gas flow of mixed return air and products of combustion from the gas burner for flow to and through the hot gas distributors downwardly to the conveyed glass sheets. The preferred construction of the forced convection heater also includes a supply blower located internally within the plenum housing and further has the gas burner located at one lateral extremity of the furnace housing, with the plenum housing located at another lateral

extremity of the furnace housing, and with a mixing tube that delivers mixed return air and products of combustion from the gas burner to the plenum housing as the hot gas flow. The intake of the plenum housing is located at one lateral extremity of the plenum housing and extends internally through the plenum housing to deliver the hot gas flow to the supply blower within the plenum housing at another lateral extremity of the plenum housing.

Another object of the present invention is to provide an improved method for making a furnace for heating glass sheets.

In carrying out the immediately preceding object, the method for making a furnace for heating glass sheets in accordance with the invention is performed by providing a glass sheet roll conveyor furnace of the electric resistance heater type having a housing for supporting lower and upper electric resistance elements below and above a roll conveyor including conveyor rolls within the furnace. In making the furnace, the roll conveyor and a lower housing portion of the furnace are maintained for supporting electric resistance elements below the conveyor rolls such that electrical power supplied thereto provides heating from below of the glass sheets conveyed by the conveyor rolls. The furnace manufacturing also involves installing a gas burner forced convection heater within an upper housing portion above the roll conveyor to provide a dominant mode of external heat for heating the conveyed glass sheets from above.

In one preferred practice for making the furnace by what is essentially a retrofit operation as described above, an upper housing portion of the electric resistance heater type furnace is replaced with an upper housing portion that supports the gas burner forced convection heater above the roll conveyor.

The preferred practice for making the furnace is also performed by installing the gas burner forced convection heater with hot gas distributors spaced along a direction of conveyance of the furnace. This installation of the forced convection heater is performed with a gas burner on one lateral side of the furnace, with a mixing tube that mixes return air and products of combustion, and with a

plenum housing that is located at another lateral side of the furnace to receive the mixed return air and products of combustion from the mixing tube as a hot gas flow that is fed to the hot gas distributors. The preferred installation of the forced convection heater is also performed with the plenum housing having an intake that receives the mixed return air and products of combustion at one lateral side of the plenum housing, and with the plenum housing having a supply blower located therein at another lateral extremity of the plenum housing to provide pressurizing of the mixed return air and products of combustion as the hot gas flow.

The objects, features, and advantages of the present invention are readily apparent from the following detailed description of the best mode for carrying out the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF DRAWINGS FIGURE 1 is a partially broken away perspective view of a furnace constructed in accordance with the invention to perform the method thereof for heating glass sheets.

FIGURE 2 is a cross sectional view of the furnace taken along the direction of line 2-2 in Figure 1 to illustrate its construction.

FIGURE 3 is a partial sectional view taken along the direction of line 3-3 in Figure 2 to illustrate the manner in which conveyed glass sheets are heated from below by radiant energy from electric resistance elements and from above by forced convection hot gas flow that is directed downwardly.

FIGURE 4 is a perspective view illustrating the construction of hot gas distributors that provide the downwardly directed hot gas flow for performing the forced convection heating from above.

FIGURE 5 is a sectional view taken in the same direction as Figure 3 to illustrate the manner in which the heating can be performed on a glass sheet having a continuously coated surface such as a low emission coating that faces upwardly during the heating.

FIGURE 6 is a perspective view that illustrates the manner in which a glass sheet is conveyed with a coated surface thereof facing upwardly as illustrated by the peripheral paint band.

FIGURE 7 is a cross sectional view illustrating the manner in which the furnace can be made by providing an electric resistance furnace having a lower portion and an upper portion that is illustrated by solid line representation prior to being removed and replaced by another upper housing portion illustrated by phantom line representation for providing forced convection heating from above.

FIGURE 8 is a sectional view taken in the same direction as Figure 3 and illustrating another construction of the hot gas distributor.

FIGURE 9 is an elevational view taken along the direction of line 9-9 in Figure 8 to further illustrate that construction of the hot gas distributor.

FIGURE 10 is a bottom plan view taken along the direction of line 10-10 in Figure 8 to further illustrate that construction of the hot gas distributor.

FIGURE 11 is a sectional view taken in the same direction as Figure 8 illustrating another construction of the hot gas distributor.

FIGURE 12 is an elevational view taken along the direction of line 12-12 in Figure 11 to further illustrate that construction of the hot gas distributor.

FIGURE 13 is a bottom plan view taken along the direction of line 13-13 in Figure 11 to further illustrate that construction of the hot gas distributor.

BEST MODE FOR CARRYING OUT THE INVENTION With reference to Figure 1 of the drawings, a furnace for heating glass sheets in accordance with the invention is generally indicated by 10 and is operable to perform the glass sheet heating method of the invention as is hereinafter more fully described. Both the furnace and the method for heating glass sheets will be described in an integrated manner to facilitate an understanding of the different aspects of the invention.

With continuing reference to Figure 1 and additional reference to Figure 2, the furnace 10 includes a housing 12 having lower and upper housing portions 14 and 16 that cooperate to define a heating chamber 18 in which glass sheets are heated as is hereinafter more fully described. Furnace housing 12 includes a framework 20 having horizontal beams 22 and vertical posts 24 which as shown in Figure 2 support an insulated floor 26, insulated side walls 28, and an insulated ceiling 30. As illustrated in Figure 1, the factory floor 32 also supports the lower ends of vertical posts 34 whose upper ends have mounts 36 that support outwardly extending arms 38 of the upper housing portion 16 to provide support thereof over the lower housing portion 14.

With continuing reference to Figures 1 and 2, the furnace 10 also includes a roll conveyor 40 having horizontally extending conveyor rolls 42 for supporting and conveying glass sheets G (Figure 2) along a direction of conveyance that is identified by arrow A as illustrated in Figures 1 and 3. The conveyor rolls 42 have ends 44 that project outwardly through furnace side seals 46 and are rotatively driven by a continuous drive chain 47 to provide conveyor roll rotation and conveyance of the glass sheets within the heating chamber 18 of the furnace housing 12.

As illustrated in Figures 1 and 2, an electric resistance heater 48 of the furnace includes electric resistance elements 50 that are supported by the lower housing portion 14 below the rolls 42 of the conveyor 40 such that electrical power supplied thereto heats the conveyed glass sheets G from below. More specifically

as illustrated in Figure 2, the furnace floor 26 includes an upper floor member 52 that is cast from fused silica and includes T-shaped retainers 54 that receive the heating elements 50 which extend back and forth as illustrated in Figure 1 between the adjacent pairs of retainers. The radiant upward heat from the resistance elements 50 not only shines between the conveyor rolls 42 directly onto the lower surface of the glass sheet G, but also as illustrated best in Figure 3 also shines upwardly to the conveyor rolls 42 to provide radiant heating thereof which, in turn, heats the lower glass sheet surface primarily by radiation but also by conduction. The conveyor rolls 42 are preferably made from sinter bonded fused silica so as to have good resistance to thermal warpage.

As illustrated in Figures 1 and 2, the furnace 10 also includes a forced convection heater 56 that is supported by the upper housing portion 16 and for the most part located within the heating chamber 18 of the furnace housing. The forced convection heater includes gas burners 58 that are mounted by the furnace housing side wall 28 for heating a hot gas flow that, as illustrated by arrows 60 in Figure 3, is directed downwardly to provide a dominant mode of external heat for heating the conveyed glass sheets G from above.

In describing the heating provided by the forced convection heater 56 as being a"dominant mode"of external heat for heating the conveyed glass sheets from above, it should be appreciated that there can be other amounts of minimal heat provided to the conveyed glass sheets from above such as, for example, heat provided by electromagnetic beams that shine into the upper housing portion for detecting glass sheet location, localized heaters that may be utilized to provide localized heating of the conveyed glass sheets at abrupt bend locations, or other heating that is minimal in comparison to the primary heating provided by the forced convection.

As illustrated in Figures 1 and 3, furnace 10 also includes hot gas distributors 62 that are spaced along the direction of conveyance to deliver the downward hot gas flow illustrated by arrows 60 in Figure 3 and which permit the

hot gas after impinging with the upper glass sheet surface to flow back upwardly as illustrated by arrows 64.

As shown in Figure 2, each gas burner 58 is mounted on the furnace housing 12 at one lateral side thereof and has a nozzle end 66 located within the heating chamber 18 such that products of combustion thereof flow into the furnace to provide external heating as the forced convection previously described. Each burner 58 also has an associated mixing tube 68 mounted within the furnace heating chamber 18 by a mount 70 on the housing ceiling 30. The mixing tube 68 is open to the burner nozzle end 66 to receive the products of combustion and is also open to the heating chamber so as to receive return air as well. A plenum housing 72 of the forced convection heater 56 is associated with each burner 58 and its mixing tube 68 and is supported within the heating chamber 18 above the roll conveyor 40. This plenum housing 72 has an intake 74 that receives a hot gas flow of mixed return air and products of combustion from the gas burner 58 from the mixing tube 68 for flow to and through the hot gas distributors 62 downwardly to the conveyed glass sheets as previously described. The plenum housing 72 is located at another lateral side of the furnace housing 12 opposite the one lateral side thereof where the burner 58 is located, and a supply blower 76 is located within the plenum housing to pressurize the mixed return air and products of combustion received from the mixing tube 68 by the intake 74. More specifically, the intake 74 receives the mixed return air and products of combustion from the mixing tube 68 at one lateral side of the plenum housing 72 and extends internally through the plenum housing to deliver the hot gas flow to the supply blower 76 at another lateral extremity of the plenum housing.

From the supply blower 76, the pressurized hot gas flow flows through openings 78 for flow to the hot gas distributors 62.

As illustrated in Figures 3 and 4, the hot gas distributors 62 each include lower converging ends 80 made of formed sheet metal pieces 82 that have parallel nozzle portions 84 between which nozzle spacers 86 are located and secured in any suitable manner such as by fasteners or welds 88 best shown in Figure 4. The nozzle spacers 86 have curved upper ends that provide a converging entry into the

downwardly extending nozzle passages 89 through which the hot gas flows downwardly to provide the forced convection as previously described.

All of the components of the forced convection heater described above are preferably made from high temperature sheet metal such as a stainless steel of a high chromium content.

As shown in Figures 1 and 2, a baffle 90 is mounted on the one furnace side wall 28 adjacent the open end of the mixing tube 68 and prevents excessive drawing of cold ambient air into the furnace heating chamber 18 around the roll seals 46 through which the conveyor roll ends 44 project outwardly for the rotational driving as previously described. Within the furnace heating chamber 18, there is a slight pressure above atmosphere that is prevented from being excessive by exhaust ducts 92 on the furnace housing ceiling 30 at spaced locations shown in Figure 1 under the control of associated dampers 94.

The burners 58 as shown in Figure 2 provide a level of heating under the operation of associated controls 96 that include associated thermocouples 98 for sensing the temperature of the pressurized hot gas flow in the plenum housings 72 after being pressurized by the supply blowers 76 and just prior to being distributed by the hot gas distributors 62. Also, the supply blowers 76 are each driven by a drive shaft 100 that is driven by an unshown electric motor located externally of the heated furnace housing 12 and operated by an associated control 102 that can be coupled with the burner controls 96 in any suitable manner to provide coordination of the burner and blower operations.

As illustrated in Figure 5, the glass sheet G being heated can have a coating 104 such as of the low emission type of coating currently used on much architectural glass. Heating of this type of coated glass sheet for which the invention has particular utility is performed with a lower uncoated surface 106 of the glass sheet facing downwardly to be supported by the conveyor rolls 42 of the roll conveyor 40 and with the upper coated surface 108 thereof facing upwardly so as to be heated by the forced convection in the manner previously described.

As illustrated in Figure 6, the upper coated surface of the glass sheet G can also be provided by a paint band 110 that covers less than the entirety of the glass sheet such as its periphery as illustrated.

With reference to Figure 7, the furnace as previously described can be provided by retrofitting a glass sheet roll conveyor furnace of the electric resistance type as generally indicated by 10'. This furnace has electric resistance elements 50 supported on a housing 12'of the furnace below and above a roll conveyor 40 thereof. Both the roll conveyor 40 and the lower housing portion 14 of the furnace are maintained and have the same construction as the furnace previously described in connection with Figures 1-6. A gas burner forced convection heater is installed within the upper housing portion to provide the dominant mode of external heat for heating the conveyed glass sheets from above in the same manner previously described such that the upper electric resistance elements 50 above the roll conveyor are no longer utilized for the heating. Most preferably, the upper housing portion 12'of the furnace 10'is replaced with an upper housing portion 14 that has the same construction as previously described and supports a gas burner forced convection heater above the roll conveyor with the same construction as the previously described gas burner forced convection heater.

With reference to Figures 8-10 and 11-13, further embodiments of the hot gas distributors 62a and 62b are illustrated. With each of these embodiments, the banks of nozzle passages 89 are laterally spaced from each other from one bank to the other in an alternating relationship transverse to the direction of conveyance.

This construction of the nozzle banks provides uniformity of the heating provided by the hot gas to the upper surfaces of the glass sheets as they are conveyed for the heating.

As illustrated in Figures 8-10, the hot gas distributor 62a includes an inverted U-shaped housing 112 having a pair of housing members 114 of inverted L shapes with upper flanges 115 that are secured to each other in any suitable manner such as by welding. The inverted U-shaped housing 112 provided by the inverted L-shaped housing members 114 includes a pair of spaced side portions 116

and a connecting portion 118 extending between its side portions. The hot gas distributor 62a also includes a U-shaped cap 120 received within the inverted U- shaped housing 112 thereof and having a pair of spaced side portions 122 and a cap portion 124 extending between its side portions. The spaced side portions 116 of the inverted U-shaped housing 112 and the spaced side portions 122 of the U-shaped cap 120 of the hot gas distributor 62a cooperate to define the pair of nozzle bank passages 89 through which the hot gas jets are delivered for the downward hot gas flow to the conveyed gas sheets being heated.

The construction of the lower hot gas distributors 62a illustrated in Figures 8-10 is made entirely from formed sheet metal. More specifically, the inverted U-shaped housing 112 is provided by the pair of formed sheet metal housing members 114 and the side portions 116 of the housing are formed to cooperate with the spaced side portions 122 of the U-shaped cap 120 to define the pair of banks of nozzle passages 89 of the hot gas distributor 62. This forming of the side portions 116 of the inverted U-shaped housing 112 is provided by inward formations 126 that are vertically elongated and have upper rounded ends 128 as shown in Figure 9 such that the adjacent formations provide curved converging shapes at the entry end of each nozzle passage 89. Adjacent their ends 128, the formations 126 have round openings 130 that facilitate securement of the side portions 116 of the inverted U- shaped housing 112 to the side portions 122 of the U-shaped cap 120 such as by welding.

The construction of the hot gas distributor 62b illustrated in Figures 11-13 has an inverted U-shaped housing 112'whose side portions 116'and connecting portion 118'are unitary with each other in the same manner as the side portions 122'and cap portion 124'of the U-shaped cap 120'. However with this embodiment, nozzle spacers 86 located between the housing and cap side portions 116'and 122'cooperate therewith to define the pair of banks of nozzle passages 89 of the hot gas distributor. These nozzle spacers 86 have semicircular ends 128'that provide curved converging shapes at the entry ends of the nozzle passages 89.

While embodiments of the invention have been illustrated and described, it is not intended that these embodiments illustrate and describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention.