Trough design for the overflow fusion process by numerical simulation

Computational modelling of the over flow fusion process used to manufacture flat glass for use in TFT-LCDs was conducted. A model experiment using water glass flow as a simulant for molten glass was conducted and compared with the results of computational modelling. The experiment proved that the Flow3D (TM) package was suitable for the modelling of molten glass flow. The numerical simulation results for molten glass flow over the trough during the overflow fusion process indicated that the radius on the top edges and tip angle at the bottom of the trough were two very important dimensions, especially the design of tip angle. Only if the tip angle was reduced near to 20 degrees could steady flow and good merging and fusion of molten glass be obtained. The flow velocity and viscosity of molten glass were also important process parameters for obtaining a steady flow profile and uniform thickness.