Selective glass batching methods for improving melting efficiency and reducing gross segregation of glass batch components

Abstract

A method of controlling reaction paths of glass batch components added to a resident glass melt is provided, including the steps of providing a plurality of raw material batch components according to a batch recipe, selectively combining a portion of the batch components into a first combination material having a melting temperature in a range of 60 to 90% of a resident melt temperature (K) and a viscosity.sup.3 a melt viscosity/100, and selectively combining another portion of the batch components into a second combination material having a reaction temperature in a range of 60 to 100% of the resident melt temperature, the second combination material being capable of forming an intermediate compound via a solid state reaction before reacting with the glass melt. The first and second combination materials and any remaining batch components are mixed and introduced into a glass melter.

1 - 73 . (canceled)  
   
   
       74 . A method of increasing the efficiency of glass batch melting, comprising: 
 (a) dividing the raw material components of a glass batch into at least a first portion having a first composition and a second portion having a second, different composition;    (b) forming the first portion into first discrete reaction members, each respective first reaction member having substantially the first composition;    (c) forming the second portion into second discrete reaction members, each respective second reaction member having substantially the second composition;    (d) mixing the first and second discrete reaction members and any remaining raw material components to form a mixture; and    (e) reacting the mixture to yield a glass.    
   
   
       75 . The method of  claim 74  wherein the first composition has a first melting temperature, wherein the second composition has a second melting temperature, and wherein the first melting temperature is within two hundred degrees Celsius of the second melting temperature.  
   
   
       76 . The method of  claim 74  wherein the first composition has a first viscosity at about the first melting temperature; wherein the second composition has a second viscosity at about the second melting temperature; wherein the melted mixture has a melt viscosity; wherein the first viscosity is greater than about one percent of the melt viscosity; and wherein the second viscosity is greater than about one percent of the melt viscosity.  
   
   
       77 . The method of  claim 76  wherein at least one of the first viscosity and the second viscosity is greater than about the melt viscosity.  
   
   
       78 . The method of  claim 74  wherein at least one of the first portion and the second portion participates in solid state reactions prior to (e).  
   
   
       79 . The method of  claim 74  wherein at least one of the first portion and the second portion forms an intermediate composition prior to (e).  
   
   
       80 . A method of melting a mixture of oxides to produce molten glass, comprising: 
 (a) placing a first composition of oxides into a furnace;    (b) placing a second composition of oxides into the furnace;    (c) mixing the first and second compositions of oxides to yield a uniform blend of members of the first composition and the second composition;    (d) melting the first composition form a first liquid having a first liquid viscosity; and    (e) liquifying the second composition to yield a substantially homogeneous molten glass having a molten glass viscosity.    
   
   
       81 . The method of  claim 80  wherein (e) further comprises melting the second composition.  
   
   
       82 . The method of  claim 81  wherein (d) and (e) occur within a temperature range of about 200 degrees Celsius.  
   
   
       83 . The method of  claim 80  wherein the first liquid has a viscosity of at least about 0.1 percent that of the molten glass viscosity.  
   
   
       84 . The method of  claim 80  wherein the first liquid has a viscosity greater than the molten glass viscosity.  
   
   
       85 . The method of  claim 80  wherein the first composition of oxides substantially has the form of pelletized members.  
   
   
       86 . The method of  claim 80  wherein the first composition of oxides substantially has the form of a frit.  
   
   
       87 . The method of  claim 80  wherein the first composition of oxides is substantially prereacted.