CN104583150A - 圆盘辊及其基材 - Google Patents

圆盘辊及其基材 Download PDF

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CN104583150A
CN104583150A CN201380043165.0A CN201380043165A CN104583150A CN 104583150 A CN104583150 A CN 104583150A CN 201380043165 A CN201380043165 A CN 201380043165A CN 104583150 A CN104583150 A CN 104583150A
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ceramic fibre
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渡边和久
三原彻也
白鸟太一
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Nichias Corp
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Abstract

本发明涉及一种圆盘辊用基材，所述基材包含：5～9重量％的陶瓷纤维、20～40重量％的木节粘土、2～20重量％的膨润土和40～60重量％的云母。

Description

圆盘辊及其基材
技术领域
本发明涉及适用于平板玻璃的制造的圆盘辊及其基材。
背景技术
平板玻璃通过将玻璃熔融物连续地供给到装置中，使其自该装置以带状流下，在流下过程中冷却而使其固化来进行制造。圆盘辊起到一对拉伸辊的作用，用于夹持带状玻璃熔融物强制地向下方送出。平板形状玻璃除了上述下拉法以外，还可以通过浮法、轧平法(roll outmethod)、科尔伯恩法(Colburn method)等来进行制造。
圆盘辊通常是将硬纸板(millboard)(板状成型体、基材)冲裁成环状而制成圆盘材料，将多枚该圆盘材料嵌插至作为转轴的轴(shaft)制成辊状的层叠物，通过配置于两端的凸缘对整体进行加压固定而成的。圆盘材料的外周面起到玻璃熔融物的运送面的作用。
圆盘辊由于是运送带状玻璃熔融物的辊，因此，要求耐热性、柔软性、硬度，并且还要求不损伤玻璃表面，已知有含有耐热性无机纤维、云母、粘土的圆盘辊等(专利文献1～3)。
现有技术文献
专利文献
专利文献1：日本特表2010-510956
专利文献2：日本特开2009-132619
专利文献3：日本特开2004-299980
发明内容
然而，作为原料的无机纤维要求高的耐热性或强度，并且价格高。另外，由于从水性浆料通过滤水来进行制造，因此，为了高效地制造，寻求滤水时间短。
本发明的目的在于提供一种适于玻璃的制造并且能够高效地制造的廉价的圆盘辊及其基材。
本发明者们专心研究，其结果发现：如果以特定的组成，则即使降低高价格的耐热性无机纤维的含量也可以为适于平板玻璃的制造的圆盘辊，从而完成了本发明。
根据本发明，可以提供以下的圆盘辊用基材等。
1.一种圆盘辊用基材，其中包含：5～9重量％的陶瓷纤维、20～40重量％的木节粘土、2～20重量％的膨润土、和40～60重量％的云母。
2.如1所述的圆盘辊用基材，其中，上述陶瓷纤维包含30重量％以上且小于70重量％的氧化铝和大于30重量％且70重量％以下的二氧化硅。
3.如1或2所述的圆盘辊用基材，其中，上述陶瓷纤维的渣球为5重量％以下。
4.如1～3中任一项所述的圆盘辊用基材，其中，进一步包含纸浆和淀粉。
5.一种圆盘辊用基材的制造方法，其中，将含有30重量％以上且小于70重量％的氧化铝和大于30重量％且70重量％以下的二氧化硅的粗纤维脱硫，制造渣球为5重量％以下的陶瓷纤维；
将水、上述陶瓷纤维、木节粘土、膨润土和云母混合，制造水性浆料；
通过将水性浆料流入成型槽或成型模具，进行滤水，从而制造薄片。
6.一种圆盘辊，其中，包含由1～4中任一项所述的基材得到的环状圆盘材料。
7.一种圆盘辊的制造方法，其中，从1～4中任一项所述的基材冲裁出多个环状圆盘材料，
将上述多个环状圆盘材料嵌插于轴上，进行压缩，从而制成辊状层叠物。
8.一种玻璃的制造方法，其中，使用6所述的圆盘辊来运送玻璃熔融物，并冷却玻璃熔融物。
根据本发明，可以提供适于玻璃的制造且能够高效地制造的廉价的圆盘辊及其基材。
附图说明
图1是表示使用了圆盘辊的玻璃的制造方法的一个例子的图。
具体实施方式
本发明的圆盘辊用基材包含：陶瓷纤维(硅酸铝纤维等)、木节粘土、膨润土以及云母。
包含陶瓷纤维5～9重量％，优选包含6～9重量％，进一步优选包含7～8重量％。在陶瓷纤维小于5重量％时，成型为圆盘辊时耐热性降低；在陶瓷纤维超过9重量％时，由于导致填充前的圆盘材料的低密度化，因此，在调节为规定的填充密度时圆盘材料的体积增大，填充时的操作性降低。另外，如果陶瓷纤维的量多，则变得高价。
本发明中使用的陶瓷纤维通常包含氧化铝30重量％以上且小于70重量％，优选为40重量％以上且小于60重量％，进一步优选为45重量％以上且小于55重量％。另外，陶瓷纤维通常包含二氧化硅大于30重量％且70重量％以下，优选为大于40重量％且60重量％以下，进一步优选为大于45重量％且55重量％以下。纤维可以使用1种或者混合2种以上使用。
本发明中使用的陶瓷纤维优选只含5重量％以下的45μm以上的渣球(未纤维化物)，进一步优选只含2重量％以下。使用渣球多的纤维制造的圆盘辊有可能会损伤玻璃表面。渣球的大小通常为45～5000μm左右。原料陶瓷纤维可以通过以干式或湿式的方法进行脱硫来降低渣球。
陶瓷纤维的纤维直径通常为2～5μm左右。
基材包含木节粘土20～40重量％，优选为25～40重量％，进一步优选为28～38重量％。如果以该范围包含木节粘土，则表面润滑性(平滑性)变得良好。
包含膨润土2～20重量％，优选为2～15重量％，进一步优选为3～15重量％，更加优选为5～14重量％。如果不含膨润土，则固定·凝集不充分且滤水性变差。相反如果膨润土过多，则有浆料的粘性变高，滤水性变差。
为了提高圆盘辊对轴的热膨胀的跟随性而添加云母。由于嵌插圆盘材料的轴是金属制，因此，如果暴露于高温下，则该轴热膨胀而沿着轴方向伸展。此时，圆盘材料由于比金属热膨胀率低，因此不能跟随轴的伸展，圆盘材料彼此剥离。然而，云母形成极薄的层结构，如果被加热，则会发生结晶异变，此时有向层方向膨胀的倾向，通过该向层方向的膨胀从而圆盘材料对轴的热膨胀的跟随性提高。
作为云母，能够使用白云母(muscovite，K2Al4(Si3Al)2O20(OH)4)、黑云母、金云母(phlogopite，K2Mg6(SiAl)2O20(OH)4)、钠云母、锂云母(lepidolite)、氟金云母等，但是如果考虑上述的跟随性，则优选为白云母。
基材包含云母40～60重量％，优选为44～54重量％。在云母小于40重量％时，对轴的热膨胀的追随性变低；在大于60重量％时，难以使之均匀地分散在浆料中，担心圆盘基材的物性的变异性变大。
本发明的基材可以在不损害本发明的效果的范围内，在上述成分以外，还包含凝聚辅助剂、有机粘结剂。
作为有机粘结剂，优选有机纤维(纸浆)、淀粉。如果包含有机纤维(纸浆)，则能够表现压缩特性，其量例如能够为2～10重量％或5～10重量％。另外，如果包含淀粉，则能够表现圆盘材料的强度，其量例如能够为1～10重量％或1～4重量％。
本发明的基材作为无机成分，合计陶瓷纤维、木节粘土、膨润土、云母可以为85重量％以上、90重量％以上、95重量％以上、98重量％以上、99重量％以上、100重量％。
本发明的基材通过在上述的范围包含上述的成分，从而即使无机纤维的量少，也能够获得平衡良好地保持耐热性、强度、硬度的圆盘辊。
基材能够通过将包含无机纤维、木节粘土、膨润土、云母的水性浆料成型为板状并干燥来进行制造。此时，从高效方面出发，优选使用抄纸法。即，可以通过调制包含规定量的无机纤维、木节粘土、膨润土、云母、根据需要的凝聚辅助剂、有机粘结剂等的水性浆料，将该水性浆料用抄纸机成型为板状并干燥来得到基材。另外，基材的厚度能够适当设定，通常为2～10mm。
接着，说明圆盘辊的制造方法。通常从基材冲裁环状的圆盘材料，将多枚该圆盘材料嵌插于金属制(例如铁制)的轴，制成辊状的层叠物，经由配置于两端的凸缘自两端对整体进行加压，在对圆盘材料施加少许压缩的状态下用螺母等固定。根据需要进行烧成。然后，通过以成为规定的辊径的方式研磨圆盘材料的外周面，从而得到圆盘辊。
圆盘辊的形状有完全包覆辊(full cover roll)、悬臂辊、短柱辊(stubroll)。
例如，如图1所示，能够使用本发明的圆盘辊10，夹持玻璃熔融物100进行运送，使玻璃熔融物100冷却、固化来制造玻璃。
实施例
实施例1
[圆盘辊用基材的制作和评价]
调制配合有7重量％的陶瓷纤维(氧化铝40～60重量％、二氧化硅60～40重量％)、30重量％的木节粘土、10重量％的膨润土、45重量％的白云母、6重量％的纸浆、2重量％的淀粉的水性浆料，通过抄纸法抄制薄片(圆盘辊用基材)。
对于得到的基材，通过以下的方法进行特性的测定或评价。将结果示于表1中。
(1)滤水性
通过TAPPI式手抄抄纸机以滤水时间进行评价。
○：小于100秒，△：100～200秒，×：大于200秒
(2)薄片外观
○：良好，△：有粗糙，×：有龟裂
(3)加热收缩率
将圆盘辊用基材切成宽30mm、长150mm，在900℃下加热3小时后，测定其长度方向和厚度方向的长度，基于下述式子评价加热收缩率。
[(加热前的测定值－加热后的测定值)/加热前的测定值]×100
(4)原板的弯曲试验(弯曲强度和弯曲弹性模量)
将圆盘辊用基材在维持于900℃的加热炉中保持3小时后，自然冷却到室温。将加热前的基材和冷却后的基材切成宽30mm、长150mm的试验片，使用岛津制作所制造的“Autograph AG-100kND”，根据JISK7171评价弯曲强度和弯曲弹性模量。
(5)耐剥落性
从圆盘辊用基材上冲裁出外径60mm内径20mm的圆盘材料，在直径20mm的不锈钢制轴上以长度成为100mm、充填密度成为表1的值的方式做成辊，制作圆盘辊。
将该圆盘辊投入保持于900℃的电炉中，15小时后取出，急冷至室温25℃。然后，重复该加热和急冷的循环直至发生圆盘辊的开裂或圆盘分离，对发生了开裂或圆盘分离的循环数进行计数。
除了上述以外，还分别评价了耐剥落性试验前的圆盘材料的肖氏(Shore)D硬度和开裂后或圆盘分离后的(试验后)的圆盘材料的硬度。
(6)负荷变形量
从圆盘辊用基材冲裁出外径60mm内径20mm的圆盘材料，在直径20mm的不锈钢制轴上做成辊使得长度成100mm、充填密度成为表1的值，并制作圆盘辊。
对于该圆盘辊，用支架支撑轴的两端，通过压缩元件以1mm/分钟施加10kgf/cm的负荷于由圆盘材料构成的辊面上，测定此时的负荷变形量(室温)。
另外，将上述圆盘辊在900℃的加热炉中保持10小时，从加热炉中取出后，冷却至室温，针对这样得到的圆盘辊也用与上述同样的方法测定负荷变形量(900℃下10小时)。
参考例1
除了使用配合有30重量％的陶瓷纤维(氧化铝50重量％、二氧化硅50重量％)、20重量％的木节粘土、10重量％的膨润土、32重量％的白云母、6重量％的纸浆、2重量％的淀粉的水性浆料以外，其它与实施例1同样地制造基材和圆盘辊并进行评价。将结果示于表1中。
[表1]
由表1可知，实施例1的圆盘辊虽然纤维量少，但是具有与参考例1同等的在实用上没有问题的耐热性和强度。
工业上利用的可能性
本发明的圆盘辊能够用于平板玻璃、特别是液晶显示器、等离子体显示器、有机EL显示器的制造。
上述对几个本发明的实施方式和/或实施例进行了详细地说明，但是本领域技术人员在实质上不偏离本发明的新的教导和效果的情况下，容易在这些作为示例的实施方式和/或实施例中加入多种变化。因此，这些多种变化包含于本发明的范围中。
在此全部引用作为本申请的巴黎优先权基础的日本申请说明书的内容。

Claims (8)

1.一种圆盘辊用基材，其中，
包含：
5～9重量％的陶瓷纤维；
20～40重量％的木节粘土；
2～20重量％的膨润土；和
40～60重量％的云母。
2.如权利要求1所述的圆盘辊用基材，其中，
所述陶瓷纤维包含30重量％以上且小于70重量％的氧化铝和大于30重量％且70重量％以下的二氧化硅。
3.如权利要求1或2所述的圆盘辊用基材，其中，
所述陶瓷纤维的渣球为5重量％以下。
4.如权利要求1～3中任一项所述的圆盘辊用基材，其中，
进一步包含纸浆和淀粉。
5.一种圆盘辊用基材的制造方法，其中，
将含有30重量％以上且小于70重量％的氧化铝和大于30重量％且70重量％以下的二氧化硅的粗纤维脱硫，制造渣球为5重量％以下的陶瓷纤维；
将水、所述陶瓷纤维、木节粘土、膨润土和云母混合，制造水性浆料；
通过将水性浆料流入成型槽或成型模具，并进行滤水，从而制造薄片。
6.一种圆盘辊，其中，
包含由权利要求1～4中任一项所述的基材得到的环状圆盘材料。
7.一种圆盘辊的制造方法，其中，
从权利要求1～4中任一项所述的基材冲裁出多个环状圆盘材料，
将所述多个环状圆盘材料嵌插于轴上，进行压缩，从而做成辊状层叠物。
8.一种玻璃的制造方法，其中，
使用权利要求6所述的圆盘辊来运送玻璃熔融物，并冷却玻璃熔融物。
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