CN104649697B - 圆盘辊及其基材的制造方法 - Google Patents

圆盘辊及其基材的制造方法 Download PDF

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CN104649697B
CN104649697B CN201410831978.2A CN201410831978A CN104649697B CN 104649697 B CN104649697 B CN 104649697B CN 201410831978 A CN201410831978 A CN 201410831978A CN 104649697 B CN104649697 B CN 104649697B
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堀内修
渡边和久
中山正章
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Abstract

一种圆盘辊用基材的制造方法，该方法为调制水性浆料，将所述水性浆料成型并进行干燥，其中，所述水性浆料包含：25～50重量％的陶瓷纤维；5～30重量％的木节粘土；5～20重量％的膨润土；和25～45重量％的选自氧化铝、硅灰石和煅烧高岭土中的填充剂，并且不含云母。一种圆盘辊的制造方法，该方法为由基材冲裁多枚环状的圆盘材料，将所述圆盘材料嵌插于金属制的传动轴从而制成辊状的层叠物，经由配置于所述辊状的层叠物的两端的凸缘自两端对整体进行加压的状态下进行固定，其中，所述基材包含：25～50重量％的陶瓷纤维；5～30重量％的木节粘土；5～20重量％的膨润土；和25～45重量％的选自氧化铝、硅灰石和煅烧高岭土中的填充剂，并且不含云母。

Description

圆盘辊及其基材的制造方法
本申请是申请日为2012年4月24日、申请号为201280021479.6、发明名称为圆盘辊 及其基材的专利申请的分案申请。
技术领域
本发明涉及适用于制造平板玻璃的圆盘辊(Disk roll)及其基材的圆盘辊(Diskroll)及其基材的制造方法。
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，在流下中冷却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送出。
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传动轴(shaf)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，要求耐热性的同时，还要求不损伤玻璃表面的柔软性、硬度，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
发明所要解决的技术问题
然而，云母有可能容易划伤玻璃。另外，从原料的多样性或可替代性的观点考虑，寻求不以云母作为必须成分来制造圆盘辊。进一步，由于由水性浆料滤水来进行制造，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不以云母作为必须成分的圆盘辊及其基材的圆盘辊及其基材的制造方法。
解决技术问题的技术手段
根据本发明，提供以下的圆盘辊用基材的制造方法等。
1.一种圆盘辊用基材的制造方法，其中，所述制造方法为调制水性浆料，将所述水性浆料成型并进行干燥，所述水性浆料包含：25～50重量％的陶瓷纤维；5～30重量％的木节粘土；5～20重量％的膨润土；和25～45重量％的选自氧化铝、硅灰石和煅烧高岭土中的填充剂，并且不含云母。
2.一种圆盘辊的制造方法，其中，由基材冲裁多枚环状的圆盘材料，将所述圆盘材料嵌插于金属制的传动轴从而制成辊状的层叠物，经由配置于所述辊状的层叠物的两端的凸缘自两端对整体进行加压的状态下进行固定，所述基材包含：25～50重量％的陶瓷纤维；5～30重量％的木节粘土；5～20重量％的膨润土；和25～45重量％的选自氧化铝、硅灰石和煅烧高岭土中的填充剂，并且不含云母。
发明的效果
根据本发明的制造方法，能够提供不以云母作为必须成分的圆盘辊及其基材。
附图说明
图1是表示使用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、膨润土以及选自氧化铝、硅灰石、堇青石、煅烧高岭土中的填充剂。不含云母。
基材包含25～50重量％的陶瓷纤维，优选包含25～45重量％，更加优选包含30～40重量％。在陶瓷纤维小于25重量％时，耐热性、耐热冲击性降低；在陶瓷纤维超过50重量％时，由于圆盘材料体积密度变低体积变大，而操作性有可能变差。
本发明中使用的陶瓷纤维通常包含氧化铝40重量％以上且99重量％以下，优选为40重量％以上且80重量％以下，更优选为70重量％以上且80重量％以下，更加优选为70重量％以上且75重量％以下。另外，陶瓷纤维通常包含二氧化硅1重量％以上且60重量％以下，优选为20重量％以上且60重量％以下，更优选为20重量％以上且30重量％以下，更加优选为25重量％以上且30重量％以下。如果增加氧化铝，则耐热性增加。纤维也可以混合1种或2种以上使用。
基材包含木节粘土5～30重量％，优选为5～25重量％，更优选为5～20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。
膨润土包含2～20重量％，优选包含2～15重量％，更优选包含5～15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，则有可能浆料的粘性变高，滤水性变差。
本发明进一步包含氧化铝、硅灰石、堇青石或煅烧高岭土作为填充剂。本发明的基材也可以包含2种以上的这些填充剂。
基材包含25～45重量％的填充剂，优选包含28～42重量％。在填充剂小于25重量％时，组装后的辊的表面润滑性(平滑性)降低；在超过45重量％时，将基材冲裁成环状时的冲裁性有可能降低。
本发明的基材在不损害本发明的效果的范围内除了上述成分以外，还能够包含凝聚辅助剂、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6～10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，将陶瓷纤维、木节粘土、膨润土、填充剂合起来能够设为90重量％以上、95重量％以上、98重量％以上、99重量％以上、100重量％。
本发明的基材通过以上述的范围包含上述的成分，即使不含云母，也能够获得平衡良好地保持耐热性、强度、硬度的圆盘辊。
基材能够用抄纸法或一边将浆料向金属网等成型模具的一个面供给一边从另一个面进行抽吸的脱水成型法等进行制造。具体而言，可以通过调制含有规定量的陶瓷纤维、木节粘土、膨润土、填充剂、根据需要的凝聚辅助剂、有机粘结剂等的水性浆料，将该水性浆料成型并干燥来得到基材。厚度能够适当设定，通常为2～30mm。
接着，说明圆盘辊的制造方法。通常由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)的传动轴，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。根据需要进行烧制。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，得到圆盘辊。
在圆盘辊的构造中有用圆盘材料包覆传动轴整体的构造、圆盘材料包覆仅玻璃接触的部分的传动轴的构造、具有单一的轴的构造等。
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
[含有各种填充剂的圆盘辊用基材]
实施例1
调制含有耐火性无机纤维(氧化铝70重量％以上并且二氧化硅30重量％以下的莫来石纤维)30重量％、氧化铝32重量％、木节粘土20重量％、膨润土10重量％、纸浆6重量％和淀粉2重量％的水性浆料，通过抽吸脱水成型法成型干燥后的尺寸为200mm×200mm×6mm的圆盘辊用基材(硬纸板)。
对所得到的圆盘辊用基材，测定密度后，进行下述(1)～(8)的评价。将结果表示于表1。
(1)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。对于厚度方向的加热收缩率，由于如果收缩大则会发生圆盘间的分离，因此优选厚度方向的加热收缩率小。
[(加热前的测定值－加热后的测定值)/加热前的测定值]×100
(2)原板的弯曲试验(弯曲强度和弯曲模量)
将圆盘辊用基材在维持在900℃的加热炉中保持3小时后，自然冷却到室温。将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JIS K7171评价弯曲强度和弯曲模量。由于如果弯曲模量大则会使耐剥裂性降低，因此优选弯曲模量小。
(3)充填时的弯曲试验(弯曲强度和弯曲模量)
从圆盘辊用基材中切出宽30mm、长150mm的圆盘材料，用不锈钢板夹住该圆盘材料，进行压缩使其厚度成为10mm、密度成为1.35g/cm3，在经过压缩的状态下在维持于900℃的加热炉中保持10小时后，自然冷却到室温。冷却后，将释放了压缩力的样品作为测定样品，使用岛津制作所制造的“Autograph AG-100kND”，根据JIS K7171评价弯曲强度和弯曲模量。
(4)导热系数
将圆盘辊用基材切割，切出宽50mm、长100mm的圆盘材料，用SUS板夹住该圆盘材料，压缩至厚度成为10mm、密度成为1.35g/cm3，在压缩的状态下在维持于900℃的加热炉中保持10小时后，自然冷却至室温。冷却后，将释放了压缩力的样品作为测定样品，对样品的表面，按照JIS R2618的非稳态热线法，利用快速导热系数仪QTM-500(京都电子工业株式会社制造)在室温下测定导热系数。
(5)热膨张系数
从含有陶瓷纤维的圆盘辊用基材中冲裁出外径60mm内径20mm的圆盘材料，在不锈钢制的传动轴上以长度成为100mm、密度成为1.35g/cm3的方式成辊，在维持于900℃的加热炉中保持10小时后，自然冷却到室温。将冷却后的样品切成5×5×20mm，作为测定样品。使用理学电机工业株式会社制造的热机械分析装置“TMA8310”，在空气中以5℃/分钟的速度从室温升温至900℃测定热膨张系数。因为热膨张系数大使之对传动轴的追随性变大，所以优选热膨张系数大。
(6)压缩加热复原率
从含有陶瓷纤维的圆盘辊用基材中切出宽30mm、长50mm的圆盘材料，用不锈钢板夹住，以达到厚度20mm、密度1.35g/cm3的方式进行压缩，将固定后的物质作为样品。
将所得到的样品在600℃下加热5小时后，冷却到室温25℃，释放施加于圆盘材料的压缩力，将此时复原后的长度除以原始的长度求得复原率。另外，使所得到的圆盘辊在900℃下加热10小时，与上述同样地测定复原率。因为压缩加热复原率大使其对传动轴的热膨张的追随性良好，所以优选压缩加热复原率大。
(7)耐剥裂性
从圆盘辊用基材中冲裁出外径60mm内径20mm的圆盘材料，在直径20mm的不锈钢制传动轴上以长度成为100mm、充填密度成为1.35g/cm3的方式成辊，制作圆盘辊。
将该圆盘辊投入保持在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。优选耐剥裂性大。
除了上述以外，还分别评价了耐剥裂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。
(8)负荷变形量
从圆盘辊用基材中冲裁出外径60mm内径20mm的圆盘材料，在直径20mm的不锈钢制传动轴上以长度成100mm、充填密度成为1.35g/cm3的方式成辊，制作圆盘辊。
对于该圆盘辊，用架台支撑传动轴的两端，在由圆盘材料构成的辊面上通过压缩元件以1mm/分钟施加10kgf/cm的负荷，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，对于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)。负荷变形量由于与柔软度相关，所以优选负荷变形量大。
实施例2、3、参考例1
代替氧化铝，对于分别使用煅烧高岭土、硅灰石和堇青石的具有表1所示的组成的圆盘辊用基材分别进行抽吸脱水成型，用与实施例1同样的方法评价(1)～(8)的物性。将结果表示于表1中。
参考例2
对于代替氧化铝而使用白云母，作为耐火性无机纤维使用陶瓷纤维(氧化铝40～60重量％、二氧化硅60～40重量％)的具有表1所示的组成的圆盘辊用基材分别进行抄纸，用与实施例1同样的方法评价(1)～(8)的物性。将结果表示于表1中。可知实施例1～3、参考例1的基材具有原板的加热收缩等与参考例2的基材同等或更为优异的特性。
[表1]
[含有氧化铝的圆盘辊用基材]
实施例4－5
对于实施例1的圆盘辊用基材，改变无机纤维和木节粘土的含量，评价物性。具体来说，对于具有表2所示的组成的圆盘辊用基材分别进行抽吸脱水成型，用与实施例1同样的方法评价(1)～(8)的物性。将结果表示于表2中。可知包含氧化铝的基材特别是负荷变形量优异。
[表2]
[含有硅灰石的圆盘辊用基材]
实施例6－8
对于实施例3的圆盘辊用基材，改变无机纤维、木节粘土、纸浆的含量评价物性。具体来说，对于具有表3所示的组成的圆盘辊用基材分别进行抽吸脱水成型，用与实施例1同样的方法评价(1)～(8)的物性。将结果表示于表3中。
[表3]
工业上利用的可能性
本发明的圆盘辊能够用于平板玻璃、特别是液晶用玻璃或等离子体显示器用玻璃的制造。
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指教和效果的情况下，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，这些多种变化包含在本发明的范围中。
在此全部引用该说明书中记载的文献的内容。

Claims (2)

1.一种圆盘辊用基材的制造方法，其中，
所述制造方法为调制水性浆料，将所述水性浆料成型并进行干燥，
所述水性浆料包含：25～50重量％的陶瓷纤维；5～30重量％的木节粘土；5～20重量％的膨润土；和25～45重量％的选自氧化铝、硅灰石和煅烧高岭土中的填充剂，并且不含云母。
2.一种圆盘辊的制造方法，其中，
由基材冲裁多枚环状的圆盘材料，将所述圆盘材料嵌插于金属制的传动轴从而制成辊状的层叠物，经由配置于所述辊状的层叠物的两端的凸缘自两端对整体进行加压的状态下进行固定，
所述基材包含：25～50重量％的陶瓷纤维；5～30重量％的木节粘土；5～20重量％的膨润土；和25～45重量％的选自氧化铝、硅灰石和煅烧高岭土中的填充剂，并且不含云母。
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