JP4920118B1 - Disc roll and its base material - Google Patents

Abstract

Disclosed are a disk roll and a base material which do not contain mica as an essential component.
A filler 25 to 25% by weight selected from ceramic fibers 25 to 50% by weight, Kibushi clay 5 to 30% by weight, bentonite 2 to 20% by weight, alumina, wollastonite, cordierite and calcined kaolin. An aqueous slurry containing 45% by weight or the like is prepared, and this slurry is molded and dried to obtain a disk roll substrate. The ceramic fiber is a fiber containing 40 to 99% by weight of alumina and 20 to 60% by weight of silica.
[Selection figure] None

Description

  The present invention relates to a disk roll suitable for production of plate glass and a base material thereof.

  The plate glass is produced by continuously supplying a glass melt to an apparatus, allowing the glass melt to flow down in a strip shape, and cooling and curing during the flow. The disc roll functions as a pair of pulling rolls, and is used to sandwich the glass melt and forcibly feed it downward.

  In general, a disc roll is a roll-like laminate in which a plurality of disc materials obtained by punching a millboard (plate-shaped molded body, base material) into a ring shape are inserted into a shaft serving as a rotating shaft, and flanges arranged at both ends are provided. The whole is pressed and fixed through. The outer peripheral surface of the disk material functions as a conveying surface for the glass melt.

  Since the disk roll transports the glass ribbon melt, it is required to have heat resistance and flexibility and hardness that do not damage the glass surface. Disk rolls containing heat-resistant inorganic fibers, mica, clay, etc. are known. (Patent Documents 1 to 3).

Special table 2010-510956 JP2009-132619A JP2004-299980

However, mica had easy fear scratch the glass. In addition, from the viewpoint of the diversity of raw materials and the possibility of substitution, it is required to manufacture disc rolls without using mica as an essential component. Furthermore, since it produces by filtering from aqueous slurry, in order to manufacture efficiently, it was calculated | required that the drainage time was short.
An object of the present invention is to provide a disc roll that does not contain mica as an essential component and a base material thereof.

According to the present invention, the following disk roll substrate and the like are provided.
1. 25 to 50% by weight of ceramic fibers,
Kibushi clay 5-30% by weight,
2-20% by weight of bentonite,
A base material for a disk roll containing 25 to 45% by weight of a filler selected from alumina, wollastonite, cordierite, and calcined kaolin.
2. 2. The disk roll substrate according to 1, wherein the ceramic fiber contains 40% by weight or more and 99% by weight or less of alumina and 60% by weight or less and 20% by weight or more of silica.
3. The base material for disk rolls according to 1 or 2, wherein the ceramic fiber contains 70 to 80% by weight of alumina and 30 to 20% by weight of silica.
4). Furthermore, the base material for disk rolls in any one of 1-3 containing a pulp and starch.
5. A disc roll containing the substrate according to any one of 1 to 4.
6). The glass melt is conveyed using the disk roll described in 5,
The manufacturing method of the glass which cools the said glass melt.

  ADVANTAGE OF THE INVENTION According to this invention, the disk roll which does not make mica an essential component, and its base material can be provided.

It is a figure which shows an example of the manufacturing method of glass using a disk roll.

  The base material for disk rolls of the present invention contains ceramic fibers (alumina silicate fibers and the like), a kibushi clay, bentonite, and a filler selected from alumina, wollastonite, cordierite, and calcined kaolin. Does not include mica.

  The substrate contains 25 to 50% by weight of ceramic fibers, preferably 25 to 45% by weight, more preferably 30 to 40% by weight. When the ceramic fiber is less than 25% by weight, the heat resistance and thermal shock resistance are lowered, and when the ceramic fiber is more than 50% by weight, the bulk density of the disk material becomes low and the bulk becomes high, which may deteriorate the workability.

  The ceramic fiber used in the present invention usually contains 40 to 99% by weight of alumina, preferably 40 to 80% by weight, more preferably 70 to 80% by weight, and even more preferably 70% by weight. More than 75 wt% is included. In addition, the ceramic fiber usually has a silica content of 1 to 60% by weight, preferably 20 to 60% by weight, more preferably 20 to 30% by weight, and even more preferably 25 to 30% by weight. Contains up to% by weight. As alumina increases, heat resistance increases. You may use a fiber 1 type or in mixture of 2 or more types.

  The base material contains 5 to 30 wt%, preferably 5 to 25 wt%, more preferably 5 to 20 wt% of Kibushi clay. When Kibushi clay is included in this range, the surface lubricity (smoothness) becomes good.

  Bentonite is contained in an amount of 2 to 20% by weight, preferably 2 to 15% by weight, more preferably 5 to 15% by weight. If bentonite is not included, fixing and agglomeration are insufficient and drainage is deteriorated. On the contrary, if there is too much bentonite, the viscosity of the slurry becomes high and the drainage may be deteriorated.

  The present invention further includes alumina, wollastonite, cordierite or calcined kaolin as a filler. The base material of the present invention may contain two or more of these fillers.

  The substrate contains 25 to 45% by weight, preferably 28 to 42% by weight of filler. If the filler is less than 25% by weight, the surface lubricity (smoothness) of the roll after assembly is lowered, and if it exceeds 45% by weight, the punching property when the substrate is punched into a ring shape may be lowered.

  The base material of the present invention can contain an agglomeration aid and an organic binder in addition to the above components as long as the effects of the present invention are not impaired.

  As the organic binder, organic fibers (pulp) and starch are preferable. When an organic fiber (pulp) is included, compression characteristics can be expressed, and the amount can be, for example, 2 to 10% by weight, or 6 to 10% by weight. Moreover, when starch is included, the intensity | strength of a disk material can be expressed and the quantity can be 1 to 10 weight% or 1 to 4 weight%, for example.

  The base material of the present invention includes 90% by weight, 95% by weight, 98% by weight, 99% by weight, and 100% by weight of ceramic fiber, Kibushi clay, bentonite, and filler as inorganic components. be able to.

  By including the above components in the above range, the substrate of the present invention can provide a disk roll that maintains a good balance of heat resistance, strength, and hardness even without mica.

  The base material can be manufactured by a papermaking method, a dehydration molding method in which a slurry is supplied to one surface of a molding die such as a wire net and suction is performed from the other surface. Specifically, an aqueous slurry containing a predetermined amount of ceramic fiber, kibushi clay, bentonite, filler, agglomeration aid, organic binder, etc., if necessary, is prepared, and this aqueous slurry is molded and dried. A material can be obtained. The thickness can be appropriately set, and is generally 2 to 30 mm.

Next, a method for manufacturing a disk roll will be described. Usually, a ring-shaped disc material is punched from a base material, and a plurality of the disc materials are inserted into a metal (for example, iron) shaft to form a roll-like laminate, and the whole from both ends via flanges arranged at both ends. Is fixed with a nut or the like with a slight compression applied to the disk material. Bake if necessary. And a disk roll is obtained by grinding the outer peripheral surface of a disk material so that it may become a predetermined roll diameter.
The structure of the disc roll includes a specification in which the entire shaft is covered with the disc material, a specification in which the shaft is covered with the disc material only in a portion where the glass contacts, a specification having a single shaft, etc. is there.

  As shown in FIG. 1, the glass roll 100 of the present invention is used to sandwich and convey the glass melt 100, and the glass melt 100 can be cooled and cured to produce glass.

[Various filler-containing disk roll base materials]
Example 1
30% refractory inorganic fiber (mullite fiber of alumina 70 wt% or more, silica 30 wt% or less), alumina 32 wt%, Kibushi clay 20 wt%, bentonite 10 wt%, pulp 6 wt% and starch 2 wt% An aqueous slurry was prepared, and a disk roll substrate (millboard) having dimensions after drying of 200 mm × 200 mm × 6 mm was formed by a suction dehydration molding method.
About the obtained base material for disk rolls, after measuring a density, the following (1)-(8) evaluation was performed. The results are shown in Table 1.

(1) Heat shrinkage The disk roll base material was cut into a width of 30 mm and a length of 150 mm, heated at 900 ° C. for 3 hours, measured for the length in the linear direction and the thickness direction, and heated based on the following formula: Shrinkage was evaluated. The heat shrinkage rate in the thickness direction is preferably smaller because the separation between the disks occurs when the shrinkage is large.
[(Measured value before heating−Measured value after heating) / Measured value before heating] × 100

(2) Bending test of original sheet (bending strength and bending elastic modulus)
The disk roll substrate was held in a heating furnace maintained at 900 ° C. for 3 hours, and then naturally cooled to room temperature. A specimen having a width of 30 mm and a length of 150 mm was cut out from the cooled substrate, and the bending strength and the flexural modulus were evaluated according to JIS K7171 using “Autograph AG-100kND” manufactured by Shimadzu Corporation. If the flexural modulus is large, the spalling resistance is lowered.

(3) Bending test during filling (bending strength and flexural modulus)
A disk material having a width of 30 mm and a length of 150 mm is cut out from a disk roll base material, and the disk material is sandwiched between stainless plates, compressed to a thickness of 10 mm, and a density of 1.35 g / cm ^3, and compressed. Was kept in a heating furnace maintained at 900 ° C. for 10 hours, and then naturally cooled to room temperature. After cooling, the sample released from the compressive force was used as a measurement sample, and bending strength and bending elastic modulus were evaluated according to JIS K7171 using “Autograph AG-100kND” manufactured by Shimadzu Corporation.

(4) Thermal conductivity A disk roll base material is cut out, a disk material having a width of 50 mm and a length of 100 mm is cut out, the disk material is sandwiched between SUS plates, and the thickness is 10 mm and the density is 1.35 g / cm ^3. And then kept in a heating furnace maintained at 900 ° C. in a compressed state for 10 hours, and then naturally cooled to room temperature. After cooling, the sample whose compression force is released is used as a measurement sample, and the surface of the sample is measured at room temperature by a rapid thermal conductivity meter QTM-500 (manufactured by Kyoto Electronics Industry Co., Ltd.) according to the unsteady hot wire method of JIS R2618. The thermal conductivity was measured.

(5) Coefficient of thermal expansion A disk material having an outer diameter of 60 mm and an inner diameter of 20 mm is punched from the ceramic fiber-containing disk roll base material, and roll-built so that the length is 100 mm and the density is 1.35 g / cm ³ on a stainless steel shaft. After being kept in a heating furnace maintained at 900 ° C. for 10 hours, it was naturally cooled to room temperature. The sample after cooling was cut into 5 × 5 × 20 mm and used as a measurement sample. Using a thermomechanical analyzer “TMA8310” manufactured by Rigaku Denki Kogyo Co., Ltd., the temperature was increased from room temperature to 900 ° C. in air at a rate of 5 ° C./min, and the thermal expansion coefficient was measured. A larger thermal expansion coefficient is preferable because followability to the shaft is increased.

(6) Compression heating recovery rate A disk material having a width of 30 mm and a length of 50 mm is cut out from a ceramic fiber-containing disk roll substrate, sandwiched between stainless plates, and compressed to a thickness of 20 mm and a density of 1.35 g / cm ^3. A fixed sample was used.
The obtained sample was heated at 600 ° C. for 5 hours, then cooled to room temperature 25 ° C., and the restored length when the compression force applied to the disk material was released was divided by the original length to obtain the restoration rate. It was. The obtained disk roll was heated at 900 ° C. for 10 hours, and the restoration rate was measured in the same manner as described above. A larger compression heating recovery rate is preferable for improving the followability of the shaft to thermal expansion.

(7) Spalling resistance A disk build having an outer diameter of 60 mm and an inner diameter of 20 mm is punched from a disk roll base material, and roll build so that the length is 100 mm and the packing density is 1.35 g / cm ³ on a stainless steel shaft with a diameter of 20 mm. Then, a disk roll was produced.
This disc roll was put into an electric furnace maintained at 900 ° C., taken out after 15 hours, and rapidly cooled to room temperature 25 ° C. This heating and rapid cooling cycle was repeated until a crack or disk separation occurred in the disk roll, and the number of cycles in which the crack or disk separation occurred was counted. Higher spalling resistance is preferable.
In addition to the above, the Shore D hardness of the disk material before the spalling resistance test and the hardness of the disk material after cracking or after disk separation (after the test) were evaluated.

(8) Amount of load deformation A disk material having an outer diameter of 60 mm and an inner diameter of 20 mm is punched from a disk roll base material, roll-built so that a 100 mm length filling density is 1.35 g / cm ³ on a stainless steel shaft having a diameter of 20 mm, A disk roll was produced.
The disk roll was supported at both ends of the shaft by a gantry, and a load of 10 kgf / cm was applied to the roll surface made of the disk material by a compressor at 1 mm / min, and the amount of load deformation (room temperature) at that time was measured.
Further, the disk roll was held in a heating furnace at 900 ° C. for 10 hours, taken out from the heating furnace, and then cooled to room temperature, the load deformation amount (900 ° C. for 10 hours) was measured in the same manner as described above. Since the amount of load deformation is related to softness, a larger one is preferable.

Example 2-4
Substrate for disk roll having the composition shown in Table 1 using calcined kaolin, wollastonite and cordierite, respectively, instead of alumina, was subjected to suction dehydration molding, and (1) to (8) in the same manner as in Example 1. ) Was evaluated. The results are shown in Table 1.

Reference example 1
Each of the disk roll base materials having the composition shown in Table 1 using white mica instead of alumina and ceramic fibers (alumina 40-60% by weight, silica 60-40% by weight) as the refractory inorganic fiber was made. The physical properties of (1) to (8) were evaluated in the same manner as in Example 1. The results are shown in Table 1. It turns out that the base material of Examples 1-4 has a characteristic equivalent to or better than the base material of Reference Example 1, such as heat shrinkage of the original plate.

[Alumina-containing disc roll substrate]
Example 5-6
About the base material for disk rolls of Example 1, physical property was evaluated by changing content of an inorganic fiber and Kibushi clay . Specifically, disk roll base materials having the compositions shown in Table 2 were respectively subjected to suction dehydration molding, and the physical properties (1) to (8) were evaluated in the same manner as in Example 1. The results are shown in Table 2. It can be seen that the substrate containing alumina is particularly excellent in load deformation.

[Base material for wollastonite-containing disc roll]
Example 7-9
About the base material for disk rolls of Example 3, physical properties were evaluated by changing the contents of inorganic fibers, Kibushi clay , and pulp. Specifically, disk roll base materials having the compositions shown in Table 3 were respectively subjected to suction dehydration molding, and the physical properties (1) to (8) were evaluated in the same manner as in Example 1. The results are shown in Table 3.

  The disc roll of the present invention can be used for production of plate glass, particularly glass for liquid crystal and glass for plasma display.

10 Disc roll 100 Glass melt

Claims (9)

25 to 50% by weight of ceramic fibers,
Kibushi clay 5-30% by weight,
2-20% by weight of bentonite,
Alumina, wollastonite, substrate disk roll comprising a filler 25-45% by weight selected from baked adult kaolin. The disk roll substrate according to claim 1, wherein the ceramic fiber contains 40 wt% or more and 99 wt% or less of alumina and 60 wt% or less and 1 wt% or more of silica.   The disk roll substrate according to claim 1 or 2, wherein the ceramic fibers contain 70 wt% or more and 80 wt% or less of alumina and 30 wt% or less and 20 wt% or more of silica.   The disk roll substrate according to any one of claims 1 to 3, wherein the filler is alumina.   The base material for disk rolls according to any one of claims 1 to 3, wherein the filler is wollastonite.   The disk roll substrate according to any one of claims 1 to 3, wherein the filler is calcined kaolin. Furthermore, the base material for disk rolls in any one of Claims 1-6 containing a pulp and starch. A disk roll comprising the base material according to claim 1 . The glass melt is conveyed using the disk roll according to claim 8 ,
The manufacturing method of the glass which cools the said glass melt.

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