TWI518018B - Production method of disc substrate and disc substrate and disc roll - Google Patents

Production method of disc substrate and disc substrate and disc roll Download PDF

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Publication number
TWI518018B
TWI518018B TW100117526A TW100117526A TWI518018B TW I518018 B TWI518018 B TW I518018B TW 100117526 A TW100117526 A TW 100117526A TW 100117526 A TW100117526 A TW 100117526A TW I518018 B TWI518018 B TW I518018B
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Taiwan
Prior art keywords
disc
sheet
inorganic
substrate
disk
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Application number
TW100117526A
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English (en)
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TW201200440A (en
Inventor
Kazuhisa Watanabe
Kouji Iwata
Masaaki Nakayama
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Nichias Corp
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Publication of TW201200440A publication Critical patent/TW201200440A/zh
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Publication of TWI518018B publication Critical patent/TWI518018B/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65H—HANDLING THIN OR FILAMENTARY MATERIAL, e.g. SHEETS, WEBS, CABLES
    • B65H27/00—Special constructions, e.g. surface features, of feed or guide rollers for webs
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
    • F16C13/00—Rolls, drums, discs, or the like; Bearings or mountings therefor
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B35/00—Transporting of glass products during their manufacture, e.g. hot glass lenses, prisms
    • C03B35/14—Transporting hot glass sheets or ribbons, e.g. by heat-resistant conveyor belts or bands
    • C03B35/16—Transporting hot glass sheets or ribbons, e.g. by heat-resistant conveyor belts or bands by roller conveyors
    • C03B35/18—Construction of the conveyor rollers ; Materials, coatings or coverings thereof
    • C—CHEMISTRY; METALLURGY
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    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
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    • C04B33/36—Reinforced clay-wares
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Description

碟片材及碟片材用基材之製造方法暨碟片輥筒
本發明，係關於將複數片環狀之碟片材插裝至旋轉軸，由該碟片材之外圓周面形成搬送面而成之碟片輥筒，暨上述碟片材及碟片材用基材之製造方法。
例如，碟片輥筒被使用於搬送從熔融爐流下之板玻璃，或搬送以退火爐加熱之不鏽鋼板等金屬板(例如，參照專利文獻1)。如圖1所示，此碟片輥筒10，係將複數片含有無機纖維或無機填充材之環狀之碟片材12插裝至成為旋轉軸之金屬製桿軸11而成為滾筒狀之積層物，經由配設於其積層物兩端之凸緣13對整體加壓且在對碟片材12施加若干之壓縮之狀態下藉由螺帽15加以固定者，而碟片材12之外圓周面作為搬送面而發揮功能。
關於如此之碟片輥筒，因為插裝碟片材12之桿軸11是金屬製，故當暴露於高溫下將使此桿軸11進行熱膨脹而沿著軸方向伸長。此時，碟片材12係相較於金屬為熱膨脹率較低之陶瓷製故不會跟隨桿軸11之延伸，而使得碟片材12彼此間剝離，會有發生碟片分離(碟片材之間產生隙縫之現象)之疑慮。又，由於起因於碟片材之外側(外圓周面)與內側(內部)之溫度差(熱膨脹差)的熱應力，而會有在輥筒表面(搬送面)發生龜裂之疑慮。為了迴避如此之不良狀況，很多會對碟片材調配雲母等鱗片狀物(例如，參照專利文獻1及2)。即，雲母，係由極薄的薄片狀構造所形成，在加熱時就會釋放出結晶水而引起晶體變形，此時會有朝層方向膨脹的傾向。藉由如此之雲母朝層方向之膨脹而期待能提高對於碟片材12之桿軸11之熱膨脹的追隨性。
[專利文獻1]日本特開昭58-156717號公報
[專利文獻2]日本特表2005-520774號公報
然而，如專利文獻1或2所記載之碟片輥筒，當碟片材之基材含有作為無機填充材之雲母時，因為雲母為鱗片狀物，故於其基材之成形步驟中，例如在平板狀的基材之內部有時會以指向與表面平行之狀態存在。其結果，雲母，係有時會指向與從平板狀之基材所衝切出之碟片材的表面平行，即與碟片輥筒之搬送面垂直。因此，當搬送面之摩耗持續進行，雲母之端面就會露出至搬送面，而由於露出之雲母之端面會有使玻璃板或金屬板之表面發生線狀傷痕之疑慮。如此之傷痕，雖然在現階段並不會特別成為問題，但隨著更進一步玻璃板或金屬板之高品質化的進行，就會有當作新的問題而被提出之疑慮。
又，近年來由於被搬送之玻璃板或金屬板大面積化使得每一片的搬送時間變長，與碟片材之接觸時間亦變長。因此，碟片材會成為比目前為止更高的高溫，在搬送前後，即與玻璃板或金屬板接觸時，與結束接觸後之溫度差有較到目前為止變大的傾向。又，在定期維修時亦相同，有被急遽冷卻的情形。因此，容易引起上述碟片分離或表面的龜裂。
本發明，係有鑑於上述問題而完成者，以提供不會使如玻璃板或金屬板之被搬送物之表面損傷，且即便是在被更急遽冷卻的情形亦不會發生碟片分離、或發生龜裂之碟片輥筒為目的。
為解決上述目的，本發明係提供下述內容。
(1)一種碟片材用基材之製造方法，其係用以形成將複數片環狀之碟片材插裝在旋轉軸，由該碟片材之外圓周面形成搬送面而成之碟片輥筒之上述碟片材，其中，將包含無機纖維、縱橫比1~25之無機填充材、及無機黏合劑之漿體原料成形為板狀並加以乾燥。
(2)如上述(1)所記載之碟片材用基材之製造方法，其中，上述無機填充材不含鱗片狀物。
(3)如上述(1)或(2)所記載之碟片材用基材之製造方法，其中，上述無機纖維之濕比容為300ml/5g以上，且非晶質或結晶化率為50%以下。
(4)如上述(1)至(3)所記載任一項之碟片材用基材之製造方法，其中，將上述漿體原料成形為板狀之方法為抽吸脫水成形。
(5)一種碟片材，其係將複數片環狀之碟片材插裝至旋轉軸，由該碟片材之外圓周面形成搬送面而成之碟片輥筒之上述碟片材，包含無機纖維、縱橫比1~25之無機填充材、及無機黏合劑。
(6)如上述(5)所記載之碟片材，其中，上述無機填充材不含鱗片狀物。
(7)一種碟片輥筒，其係將複數片上述(5)或(6)所記載之碟片材插裝在旋轉軸而成。
(8)如上述(7)所記載之碟片輥筒，其中，碟片材之填充密度為0.6~1.5g/cm3。
根據本發明，因未含有如雲母之鱗片狀物，故沒有使被搬送物之表面受到損傷之疑慮。
又，因為即使沒有含如雲母之鱗片狀物，在輥筒建立後亦可使碟片材中殘存較長之無機纖維，故可維持‧發揮無機纖維之彈性。其結果，因為可維持碟片材之高復原率，緩和/吸收起因於熱膨脹差之應力，所以即便在被急遽冷卻時，不會發生碟片分離、或發生龜裂，可獲得耐剝落性優異之碟片輥筒。
以下，關於本發明係參照圖式進行詳細說明。
(碟片材用基材)
本發明，係提供用以製造構成如圖1所示之碟片輥筒10之碟片材12的碟片材用基材。本發明之碟片材用基材，係將含有無機纖維、縱橫比1~25之無機填充材、及無機黏合劑之漿體原料成形為板狀並加以乾燥所獲得。在此，所謂縱橫比，係指在無機粉末中之最長直徑(最大徑長度)與最短直徑(最小徑長度)之比(最大徑長度/最小徑長度)，若為完全之球狀則縱橫比為1，若為針狀或纖維狀者，則為纖維長度與纖維直徑之比。在本發明中，當碟片材所含有之無機填充材之縱橫比為1~25時並沒有特別之限制，較佳的是1~20，更佳的是1~15。
於本發明中，無機填充材係以未含有雲母等鱗片狀物(鱗片狀礦物)為佳。另外，鱗片狀物為板狀物，最小徑長度為其厚度，如碟片輥筒所使用一般之雲母，厚度與最大徑長度之比(縱橫比)為40以上。如此之鱗片狀物，係在碟片材用基材之成形步驟中，因為有時會指向與基材之表面平行，在被組裝入碟片輥筒後，與基材之表面平行即有時會指向與碟片輥筒之搬送面垂直。其結果，當搬送面之摩耗持續進行，鱗片狀物之端面會露出於搬送面，會有因為所露出之鱗片狀物的端面使玻璃板或金屬板之表面發生線狀傷痕之疑慮。另外，於本說明書中所謂「不含鱗片狀物」，係意味著鱗片狀物，相對於水以外之固體含量在1.0wt%以下。
在本發明中，碟片材，係以不含縱橫比超過25之無機填充材為佳。即，碟片材，係以僅含有縱橫比為25以下之無機填充材作為無機填充劑為佳。
無機填充材，係為如雲母之鱗片狀物以外皆可，例如諸如氧化鋁、堇青石、燒成高嶺土、滑石、矽石之粒狀物、或諸如矽灰石、海泡石之針狀物皆可。尤其在其中，較佳的是氧化鋁、燒成高嶺土、矽灰石。此等係可單獨使用，亦可將兩種以上組合使用。另外，所謂燒成高嶺土，係指將高嶺土燒成使可塑性消失者，並無如下述無機黏合劑的作用。
如此之無機填充材，係越細微越可以抑制被搬送物表面之損傷，若為粒狀物，以使用平均粒徑在25μm以下的微粉末為佳，以使用20μm以下的微粉末為更佳，以使用15μm以下的微粉末為最佳，若為針狀物，以平均直徑80μm以下、平均長度1000μm以下為佳，以平均直徑60μm以下、平均長度800μm以下為更佳，以平均直徑40μm以下、平均長度600μm以下為最佳。即，在本發明中，無機填充材，係若是縱橫比1~未滿5之粒狀物，平均粒徑為0.1~25μm即可，較佳的是0.1~20μm，更佳的是0.1~15μm之粒狀物，若是縱橫比為5~25之針狀物，則平均直徑1~80μm、平均長度10~1000μm之針狀物即可，較佳的是平均直徑1~60μm、平均長度10~800μm之針狀物，更佳的是平均直徑1~40μm、平均長度10~600μm之針狀物。
於本發明中，以無機纖維之濕比容300ml/5g以上，且非晶質或結晶化率50%以下為佳。無機纖維有各種纖維長度者混合存在，本發明係以濕比容規定無機纖維之纖維長度。若使用如此之無機纖維，可期待確保習知，雲母所扮演加熱到結晶溫度以上時對桿軸的追隨性。
而且，濕比容，係由下述方法所計算出。(1)以具有小數點以下兩位數以上之精密度之磅秤量測乾燥過之纖維材料5g。(2)將所量測之纖維材料置入500g之玻璃燒杯。(3)將溫度20~25℃之蒸餾水400cc左右倒入(2)之玻璃燒杯，使用攪拌機以不切斷纖維材料之方式謹慎地攪拌，以分散開。此分散亦可使用超音波洗淨機。(4)將(3)之玻璃燒杯之內容物移到1000ml之量筒中，添加蒸餾水至刻度1000ml為止。(5)以手等塞住(4)之量筒口，以不會漏水之方式一邊注意一邊上下顛倒過來攪拌。反覆此動作10次。(6)攪拌停止後，於室溫下靜置，以目視測量經過30分鐘後之纖維沉積體積。(7)針對三個樣本進行上述操作，取其平均值作為測量值。
雖然濕比容越大纖維長度會變得越長，在本發明係使用300ml/5g以上之無機纖維，較佳的是400ml/5g以上，更佳的是500ml/5g以上。又，濕比容之上限值，係若在可獲得本發明之效果的前提下並沒有特別限制，例如在2000ml/5g以下即可，以1500ml/5g以下為佳，以1200ml/5g以下更佳。
一般的無機纖維，係因為為了做成漿體而在水中與無機填充材等攪拌混合，故於攪拌中被切斷，所得到之碟片材中之無機纖維係為纖維長度短者。因此，使用一般之無機纖維之碟片材係彈性低，無法追隨激烈的溫度變化而發生碟片分離、或龜裂。相對於此在本發明所使用之上述濕比容之無機纖維係為塊狀短纖維，即便在做成漿體時進行攪拌混合，亦可以比習知殘存較長之纖維長度，於所獲得之碟片材中亦因為調配有較長之無機纖維，故可維持‧發揮無機纖維之彈性。其結果，可緩和/吸收起因於熱膨脹差之應力，提高碟片輥筒之耐剝落性。
又，於本發明中，無機纖維係非晶質體，即結晶化率為0%，或結晶化率為50%以下。無機纖維，係因為其結晶化率變得越低纖維強度越優異，故即便在漿體中攪拌，或於輥筒建立步驟中施加壓縮力，無機纖維均成為難以曲折，可維持碟片材之復原力。其結果，可獲得強度高、復原率高之碟片材。為了使如此之效果成為確實，將無機纖維之結晶化率上限設為30%以下為佳，設為20%以下較佳，設為10%以下更佳。最佳的，為非晶質之無機纖維。
在本發明中，結晶化率，係藉由X射線繞射法測量即可，使用內標準法，製作高鋁紅柱石之校準曲線，以求取結晶化率。
再者，無機纖維之平均纖維直徑，係若可獲得本發明之效果則無特別限制，但諸如以平均纖維直徑為3~7μm，較佳為4~7μm之較粗之無機纖維為佳。如此之較粗之無機纖維係因為纖維強度優異，故即便是在漿體中攪拌，或於輥筒建立步驟中施加壓縮力，無機纖維均成為難以曲折，可維持碟片材之復原力。其結果，可提供強度高、復原率高之基材。
而且，無機纖維之組成，係若可獲得本發明之效果，則無特別限制，但較佳的是Al2O3：SiO2為60：40~99：1。如此之組成之無機纖維係被稱為氧化鋁纖維或高鋁紅柱石纖維，因為耐熱性高，故可將所獲得之碟片材之尺寸熱變化率壓低。尤其，是Al2O3：SiO2為70：30~80：20之高鋁紅柱石纖維係耐熱性、纖維強度、成本之平衡優異，而且，即便經過成形步驟、輥筒建立步驟亦可輕易維持較長之纖維長度而很適合使用在本發明中。
於本發明中，無機黏合劑若作為結合材而發揮功能，則其種類並無特別限制，但例如，可列舉諸如木節黏土或膨土、蛙目黏土等耐火黏土具有透過加熱而燒結之特性之黏土、或矽石溶膠或氧化鋁溶膠。尤其在其中，木節黏土，係因為透過燒結之黏合效果高、雜質亦較少所以較佳。
關於本發明之碟片材用基材，上述無機纖維、縱橫比1~25之無機填充材、及無機黏合劑之調配量，係若可以獲得所期待之效果，則無特別限制，但若含有無機纖維15~70質量%、無機填充材10~60質量%、無機黏合劑10~50質量%即可，以含有無機纖維25~60質量%、無機填充材15~55質量%、無機黏合劑15~45質量%為較佳，以含有無機纖維30~50質量%、無機填充材20~50質量%、無機黏合劑20~40質量%為更佳。當無機纖維少於15質量%，就會有無法獲得起因於無機纖維之彈性，在輥筒建立後會有無法得到如後述所期待之復原率的疑慮。又，當無機纖維多於70質量%，就會有難以使無機纖維均勻分散於漿體，或會有所得到之碟片材用基材之物理特性偏差變大、或耐磨耗性不佳之疑慮。
在本發明中，為了獲得碟片材用基材，係可透過將諸如上述無機纖維、縱橫比1~25之無機填充材、無機黏合劑作為原料之混合物調製成水性漿體後成形為板狀，並加以乾燥而製造。
雖然如此之水性漿體之組成並沒有限制，但若將水以外之固體含量設為100質量份時，只要含有無機纖維15~70質量份、無機填充材10~60質量份、無機黏合劑10~50質量份即可，而含有無機纖維25~60質量份、無機填充材15~55質量份、無機黏合劑15~45質量份較佳，含有無機纖維30~50質量份、無機填充材20~50質量份、無機黏合劑20~40質量份更佳。當無機纖維少於15質量份時，就無法獲得起因於無機纖維之彈性，會在輥筒建立後有無法得到如後述所期待之復原率的疑慮。又，當無機纖維多於70質量份時，就難以使無機纖維均勻分散於漿體中，會有所得到之碟片材用基材之物理特性偏差變大、或耐磨耗性不佳之疑慮。
水性漿體，係可進一步含有為了使成形性等特性提升之成形佐劑或蒙脫石粉末等去絮凝劑(deflocculating agent)。作為如此之成形佐劑，係可使用例如，藉由燒成碟片材12而從該碟片材12消失之有機材料或無機材料。作為有機材料，係可使用紙漿等有機纖維、澱粉、或合成樹脂之纖維或粒子等有機黏合劑。
如此之成形佐劑及去絮凝劑，只要視需要添加至水性漿體即可，當要添加時，若將水以外之固體含量設為100質量份時，1~20質量份即可，2~15質量份較佳，3~10質量份更佳。
成形方法，係可使用抄紙法(papermaking method)、或一邊將漿體供應至金網等成形模具之一面並從另一面進行抽吸之抽吸脫水成形法，但於使用如上述含有較長塊狀之短纖維之漿體進行成形時，因為漿體中之固體含量所凝集之絮凝物(floc)容易變大，而且過濾阻力容易降低故抽吸脫水成形法較為有利。然而，在無機纖維量較少時(例如，20質量%以下)，亦可採用抄紙法。抄紙法，係具有在成本面有利的優點。
成形後，進行乾燥可獲得碟片材用基材，但此碟片材用基材之密度，係只要能獲得本發明之效果並沒有特別限制，0.3~1.0g/cm3即可，以0.4~0.8g/cm3為佳，特別以0.45~0.7g/cm3更佳。此，係由於相對於作為碟片輥筒時之填充密度，碟片材之體密度越低則壓縮率越高，且碟片輥筒之復原力亦變得越佳。又，碟片材用基材之厚度，在抄紙法時係以2~10mm為適當，抽吸脫水成形法時係以10~35mm為適當。碟片材用基材之厚度，係當越厚時填充至桿軸的片數即可越少，於製造上有利。
(碟片材)
本發明，係亦提供由上述碟片材用基材衝切成環狀所獲得之碟片材。即，本發明之碟片材，係包含無機纖維、縱橫比1~25之無機填充材、及無機黏合劑。又，上述無機填充材係以不含鱗片狀物為佳。依據如此之構成，可以避免使在被搬送物的表面發生起因於如雲母之鱗片狀物之細微傷痕。再者，在無機纖維為非晶質或結晶化率50%以下時，平均纖維直徑3~7μm為佳，若更佳為4~7μm，可維持碟片材之高復原率，不僅當即使沒有如雲母之鱗片狀物亦可確保在加熱到結晶溫度以上時對於桿軸之追隨性，還可提高耐剝落性。具體而言，碟片材之復原率，為10~100%，以10~90%為佳，10~80%為較佳，更佳為20~70%、20~60%、20~50%。而且，在本發明中，碟片材之復原率，係可由將在直徑65mm、長度1000mm之不鏽鋼製桿軸，將外徑130mm、內徑65mm之碟片材以填充密度1.25g/cm3進行輥筒建立之碟片輥筒，一邊以900℃進行加熱一邊以旋轉速度5rpm旋轉150小時後，並冷卻至室溫25℃之後，以原本之長度除以解除施加於碟片材之壓縮力時所復原之長度來求得。
另外，於本發明中，雖然可如上述從板狀基材衝切出圓盤狀之碟片材，但亦可使用圓盤狀之成形模具藉由抽吸脫水成形直接獲得圓盤狀之基材(碟片材)。
又，在本發明中，可將碟片材12，在從基材被衝切出後進行燒成，以發揮碟片材中所含無機黏合劑的結合力，同時使有機成分消失，而得到經燒結之無機材料所構成之碟片材12。透過如此之燒成，就可以抑制起因於有機成分之被搬送物的表面之汙染。
(碟片輥筒)
本發明進一步，如圖1所示，係提供在為旋轉軸之金屬製桿軸，插裝複數片之上述碟片材作為輥筒狀之積層物，並從兩端以壓縮整體之狀態所固定之碟片輥筒。碟片材之填充密度，即在從兩側所壓縮之狀態下之密度，係若可得到本發明之效果時並無特別限制，0.6~1.6 g/cm3即可，以0.7~1.5 g/cm3為佳，特別以1.1~1.4 g/cm3為更佳。若為如此之填充密度，在不會傷及搬送物之同時，可成為耐剝落性良好之表面硬度，因為可將以上述本發明所得之基材的特性發揮至最大極限故為佳。
又，關於本發明之碟片輥筒，表面(搬送面)硬度，係若可得到本發明之效果時並沒有特別限制，但以橡膠硬度計D型硬度為25~65即可，亦可為30~60、35~55。如此之橡膠硬度計D型硬度，係例如以橡膠硬度計D型硬度計(高分子計器公司製「阿斯卡(ASKER)D型橡膠硬度計」)進行測量即可。
在本發明中，當使用滿足上述特定範圍之濕比容及結晶化率之無機纖維時，在建立起碟片材之後，將碟片輥筒予以燒成，使碟片材所含之有機成分消失為佳。即，滿足上述特定範圍之濕比容及結晶化率的無機纖維，係因反彈力過強，若於建立前進行燒成使得有機黏合劑等之成形佐劑消失，就很難僅利用無機黏合劑之約束力維持其形狀。
(實施例)
以下列舉試驗例進一步說明本發明，但本發明並不會因此而受任何限制。
如表1所示，將無機纖維、無機填充材及無機黏合劑添加至水中，經充分攪拌混合調製成漿體。另外，材料係使用下述者。高鋁紅柱石纖維：濕比容990ml/5g、平均纖維直徑5μm、結晶化率0%、Al2O3：SiO2為70：30~80：20；矽酸鋁纖維：濕比容20ml/5g、平均纖維直徑2.5μm、結晶化率0%、Al2O3：SiO2為45：55~55：45；黏土A：木節黏土；黏土B：硼土；白雲母：REPCO公司(Repco Inc.)製「M-60」縱橫比50、平均直徑105μm；氧化鋁：日本輕金屬公司製「A31」縱橫比1.5、平均粒徑5μm；燒成高嶺土：林化成公司製「SATINTONE W」縱橫比1.5、平均粒徑3μm；矽灰石A：林化成公司製「NYAD-400」縱橫比15、平均纖維直徑8μm、平均纖維長度120μm；矽灰石B：林化成公司製「NYAD-G」縱橫比15、平均纖維直徑40μm、平均纖維長度600μm；紙漿：Weigood of Canada Ltd製「HINTON」；澱粉：日澱化學公司製「Petrosize J」。
然後，透過抽吸脫水成形法或抄紙法將各漿體成形為板狀，經乾燥製作成碟片材用基材，並進行下述評估。結果合併記載於表1。
(1)尺寸熱變化率
由各碟片材用基材衝切出試驗片，以900℃加熱3小時之後，測量其直徑，由加熱前後之測量值求得長度方向(直徑方向)之尺寸熱變化率(%)。於本發明中，如此之尺寸熱變化率，以1%以下為佳，以0.7%以下為較佳，以0.5%以下為更佳。
(2)硬度
從各碟片材用基材衝切出外徑80mm之環狀碟片材，使寬度成為100mm，並成為所期望之填充密度在不鏽鋼製桿軸進行輥筒建立，於研磨搬送面後，測量搬送面表面之硬度(ShoreD)。又，以900℃加熱24小時後，進行相同之測量。
(3)耐剝落性
從各碟片材用基材衝切出外徑60mm之環狀碟片材，使寬度成為100mm，並成為所期望之填充密度在不鏽鋼製桿軸進行輥筒建立，置入保持在900℃的電氣爐中，經15小時後取出急遽冷卻至室溫25℃。接著，反覆如此之加熱‧急遽冷卻，並計算至發生碟片分離或龜裂為止的次數。在實用上，即使在經反覆如此之加熱‧急遽冷卻3次以上也沒發生碟片分離或龜裂時，可評估為耐剝落性優良。又，於本發明中，即使反覆上述加熱‧急遽冷卻5次以上亦沒有發生碟片分離或龜裂者較佳，8次以上為更佳。
(4)負重變形量
從各碟片材用基材衝切出外徑80mm之環狀碟片材，使寬度成為100mm，並成為所期望之填充密度在不鏽鋼製桿軸進行輥筒建立，於研磨搬送面後，施加1200N的負重並測量因負重所造成之變形量。又，以900℃加熱10小時之後，進行相同之測量。如此之負重變形量，若加熱前、以900℃加熱10小時後均為0.1mm以上，則可評估為在實用上沒有問題，於本發明中，係以0.15mm以上為佳，以0.20mm以上為更佳。
(5)被搬送物之損傷
從各碟片材用基材衝切出外徑80mm之環狀碟片材，使寬度成為100mm，並成為所期望之填充密度在不鏽鋼製桿軸進行輥筒建立，於研磨搬送面後，在900℃加熱爐中將不鏽鋼板對輥筒進行通板，觀察通板後不鏽鋼板的表面，確認有無50μm以上之傷痕。
由實施例與比較例1及2之比較，可知當使用雲母作為無機填充材時相對於損傷不鏽鋼板之表面，藉由使用雲母以外之縱橫比1~25之無機填充材，可以抑制表面所受之損傷。
又，由實施例1及實施例2之比較，可知當使用滿足上述特定範圍之濕比容及結晶化率之高鋁紅柱石纖維作為無機纖維時，可獲得耐剝落性等之熱特性優異之碟片輥筒。
雖詳細，且參照特定之實施態樣進行本發明之說明，但在不偏離本發明之精神與範圍之前提下，可施以各種修改或變化，係為本業者所清楚了解的。
本申請案，係根據2010年5月19日所申請之日本專利申請2010-115460，其內容係參照並取入於此。
10‧‧‧碟片輥筒
11‧‧‧金屬製桿軸
12‧‧‧碟片材
13‧‧‧凸緣
15‧‧‧螺帽
圖1係表示碟片輥筒之一例的概略圖。
10．．．碟片輥筒
11．．．金屬製桿軸
12．．．碟片材
13．．．凸緣
15．．．螺帽

Claims (12)

  1. 一種碟片材用基材之製造方法，其係用以形成使複數片之環狀碟片材插裝在旋轉軸，由該碟片材之外圓周面形成搬送面而成之碟片輥筒之上述碟片材的基材之製造方法，其中，將包含無機纖維、縱橫比1~25之無機填充材、及無機黏合劑，並且不含有雲母之漿體原料成形為板狀並加以乾燥；上述無機填充材係由氧化鋁、堇青石、燒成高嶺土、滑石、矽石、矽灰石及海泡石中選擇1種以上。
  2. 如申請專利範圍第1項之碟片材用基材之製造方法，其中，上述無機纖維之組成係Al2O3：SiO2為60：40~99：1。
  3. 如申請專利範圍第1項之碟片材用基材之製造方法，其中，上述無機纖維之濕比容為300ml/5g以上，且非晶質或結晶化率為50%以下。
  4. 如申請專利範圍第1至3項中任一項之碟片材用基材之製造方法，其中，將上述漿體原料成形為板狀之方法為抽吸脫水成形。
  5. 一種碟片材用基材，其係用以形成使複數片之環狀碟片材插裝在旋轉軸，由該碟片材之外圓周面形成搬送面而成之碟片輥筒之上述碟片材的基材，其包含無機纖維、縱橫比1~25之無機填充材、及無機黏合劑，並且不含有雲母；上述無機填充材係由氧化鋁、堇青石、燒成高嶺土、滑石、 矽石、矽灰石及海泡石中選擇1種以上。
  6. 如申請專利範圍第5項之碟片材用基材，其中，上述無機纖維之組成係Al2O3：SiO2為60：40~99：1。
  7. 一種碟片材，其係使複數片之環狀碟片材插裝在旋轉軸，由該碟片材之外圓周面形成搬送面而成之碟片輥筒之上述碟片材，其包含無機纖維、縱橫比1~25之無機填充材、及無機黏合劑，並且不含有雲母；上述無機填充材係由氧化鋁、堇青石、燒成高嶺土、滑石、矽石、矽灰石及海泡石中選擇1種以上。
  8. 一種碟片材之製造方法，其係由申請專利範圍第5或6項之碟片材用基材衝切出碟片材。
  9. 一種碟片輥筒，其係使複數片申請專利範圍第7項之碟片材插裝在旋轉軸而成。
  10. 如申請專利範圍第9項之碟片輥筒，其中，碟片材之填充密度為0.6~1.6g/cm3。
  11. 一種碟片輥筒之製造方法，其係使複數片申請專利範圍第7項之碟片材插裝在旋轉軸。
  12. 一種玻璃板或金屬板之搬送方法，係使用申請專利範圍第9或10項之碟片輥筒。
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JP5452752B1 (ja) 2013-02-07 2014-03-26 ニチアス株式会社 ディスクロール及びその基材
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JP6506226B2 (ja) 2016-08-25 2019-04-24 ニチアス株式会社 ディスクロール用基材及びその製造方法並びにディスクロール及びその製造方法
KR102440269B1 (ko) * 2022-03-10 2022-09-06 케이알에스티대한동방(주) 생체용해성 섬유를 포함하는 고온로용 롤디스크 및 내화성형체
KR102468065B1 (ko) 2022-08-29 2022-11-18 케이알에스티대한동방(주) 생체용해성 섬유가 포함된 판유리 제조용 롤 디스크, 그것으로 제작된 롤 및 그 롤 디스크의 제조방법

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CN102311010A (zh) 2012-01-11
US9040139B2 (en) 2015-05-26
TW201200440A (en) 2012-01-01
US20140173901A1 (en) 2014-06-26
KR20110127614A (ko) 2011-11-25
US20110287916A1 (en) 2011-11-24

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