Glass shaping apparatus and methods

Abstract

Disclosed are apparatuses for shaping a glass structure, the apparatuses having a plurality of rib members, each rib member comprising at least one void and at least one shaping edge; and at least one support member. The apparatuses can further comprise a shaping member and/or a guide member and/or a shaping groove. Also disclosed herein are methods for shaping a glass structure, the methods comprising positioning the glass structure on a shaping apparatus and heating the glass structure to shape the glass structure.

What is claimed is: 
     
         1 . A method for shaping a glass structure comprising heating a glass structure disposed on a shaping apparatus, and shaping the glass structure,
 wherein the shaping apparatus comprising a plurality of rib members, one or more rib members comprising at least one void and at least one shaping edge; at least one support member connecting at least two rib members; and a shaping member proximate one or more of the shaping edges of the rib members, the shaping member having at least one first curvature that substantially matches at least one first curvature of the shaping edges.   
     
     
         2 . The method of  claim 1 , wherein the heating comprises heating the glass structure to the softening temperature of the glass material. 
     
     
         3 . The method of  claim 2 , wherein the shaping comprises applying a vacuum or weight to the shaping member and/or glass structure. 
     
     
         4 . The method of  claim 1 , wherein the shaping apparatus comprises:
 (a) an array of rib members, each of the rib members comprising a plurality of voids and at least one shaping edge; and   (b) at least one support member extending through at least a portion of at least one void in a direction transverse to a vertical axis of the array of rib members,   wherein the shaping edges of at least two of the rib members collectively form a non-planar surface.   
     
     
         5 . The method of  claim 4 , wherein the shaping member is disposed on the non-planar surface of the array of rib members, and substantially conforms to the shape of the non-planar surface of the array of rib members. 
     
     
         6 . The method of  claim 1 , wherein the shaping apparatus comprises:
 a plurality of rib members comprising at least one void and at least one shaping edge;   at least one guide member connected to at least one rib member, said at least one guide member comprising at least one shaping edge,   at least one support member connecting at least two rib members and/or at least two guide members; and   a shaping member.   
     
     
         7 . The method of  claim 1 , wherein the rib members comprise metal chosen from steel, stainless steel, cold rolled steel, and aluminium. 
     
     
         8 . The method of  claim 1 , wherein the rib members have a thickness ranging from about 0.1 to about 5 mm. 
     
     
         9 . The method of  claim 1 , wherein the shaping member comprises metal foils, metal fabrics, glass fabrics, ceramic fabrics, metal papers, glass papers, ceramic papers, and combinations thereof. 
     
     
         10 . The method of  claim 1 , further comprising at least one vacuum chamber configured to apply vacuum conditions to a portion of the shaping member,
 wherein a portion of the shaping member comprises through-holes.   
     
     
         11 . The method of  claim 1 , wherein at least one of the support members comprises a curved shaping edge configured to impart a second curvature to the shaping member. 
     
     
         12 . The method of  claim 11 , wherein the first curvature and the second curvature extend in substantially perpendicular directions. 
     
     
         13 . The method of  claim 1 , wherein the shaping apparatus further comprises an insert disposed between the rib members and configured to impart a three-dimensional shape to the shaping member. 
     
     
         14 . The method of  claim 1 , wherein heating the glass structure comprises heating to a softening point of the glass structure. 
     
     
         15 . The method of  claim 3 , wherein applying weight to the shaping member and/or glass structure comprises applying a weight to an end of a glass structure that does not contact the shaping apparatus prior to heating. 
     
     
         16 . The method of  claim 3 , wherein the weight comprises a material that is non-reactive during heating. 
     
     
         17 . The method of  claim 3 , wherein the weight comprises a material that is capable of effecting the desired application of weight to the glass structure without imparting damage the glass structure. 
     
     
         18 . The method of  claim 17 , wherein the weight comprises a metal foam. 
     
     
         19 . The method of  claim 1 , wherein the shaped glass structure has a length of 1 mm or greater, and comprises a radius of curvature that is within +/−0.2 mm of a target radius of curvature. 
     
     
         20 . The method of  claim 1 , wherein the glass structure comprises a thickness ranging from about 0.5 mm to about 5 mm.