TWI577644B - Plate roll and its substrate - Google Patents

Plate roll and its substrate Download PDF

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TWI577644B
TWI577644B TW102128979A TW102128979A TWI577644B TW I577644 B TWI577644 B TW I577644B TW 102128979 A TW102128979 A TW 102128979A TW 102128979 A TW102128979 A TW 102128979A TW I577644 B TWI577644 B TW I577644B
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Taiwan
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weight
substrate
disk
mica
bentonite
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TW102128979A
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TW201408605A (zh
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Kazuhisa Watanabe
Tetsuya Mihara
Taichi Shiratori
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Nichias Corp
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    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/36—Reinforced clay-wares
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P19/00—Machines for simply fitting together or separating metal parts or objects, or metal and non-metal parts, whether or not involving some deformation; Tools or devices therefor so far as not provided for in other classes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
    • B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
    • B28B3/126—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material passing directly between the co-operating rollers
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B13/00—Rolling molten glass, i.e. where the molten glass is shaped by rolling
    • C03B13/16—Construction of the glass rollers
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B17/00—Forming molten glass by flowing-out, pushing-out, extruding or drawing downwardly or laterally from forming slits or by overflowing over lips
    • C03B17/06—Forming glass sheets
    • C03B17/061—Forming glass sheets by lateral drawing or extrusion
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
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    • C03B17/06—Forming glass sheets
    • C03B17/068—Means for providing the drawing force, e.g. traction or draw rollers
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    • 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
    • C03B35/181—Materials, coatings, loose coverings or sleeves thereof
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    • 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
    • C03B35/189—Disc rollers
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    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/04—Clay; Kaolin
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    • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
    • C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
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    • C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3427—Silicates other than clay, e.g. water glass
    • C04B2235/3463—Alumino-silicates other than clay, e.g. mullite
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    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
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    • Y10T29/00—Metal working
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    • Y10T29/49826—Assembling or joining

Description

盤型輥及其基材
本發明係關於適用於板玻璃之製造之盤型輥及其基材。
板玻璃係將玻璃熔融物連續供給於裝置中，自其裝置成帶狀地流下，藉由在流下中冷卻硬化而製造。盤型輥係作為一對拉伸輥發揮功能，係用於夾持帶狀玻璃熔融物且強制送出到下方而使用。平板形狀玻璃除了上述下拉法以外，亦可利用浮法、輥出(roll out)法、柯伯恩法(Colburn method)等製造。
盤型輥一般係將硬紙板(mill board)(板狀成型體，基材)沖壓成環狀之盤材以複數片嵌插在成為轉軸之軸上而成之輥狀之層合物，且透過配置於兩端之輪緣將全體加壓而固定者。盤材之外周面係發揮作為玻璃熔融物之運送面之功能。
盤型輥由於為運送帶狀玻璃熔融物者，故要求耐熱性、柔軟性、硬度以及不會傷及玻璃表面，含有耐熱性無機纖維、雲母、黏土之盤型輥等為已知(專利文獻 1~3)。
先前技術文獻 專利文獻
專利文獻1：特表2010-510956
專利文獻2：特開2009-132619
專利文獻3：特開2004-299980
然而成為原料之無機纖維要求高的耐熱性或強度相當昂貴。且，由於自水性漿液經濾水而製造，故就有效率製造而言，要求縮短濾水時間。
本發明之目的係提供一種適於玻璃之製造、可有效率地製造之便宜的盤型輥及其基材。
本發明人等積極研究之結果，發現若為特定組成，則即使減少昂貴之耐熱性無機纖維亦為適於板玻璃之製造之盤型輥，因而完成本發明。
依據本發明，係提供以下之盤型輥用基材等。
1.一種盤型輥用基材，其包含陶瓷纖維5~9重量%、木節黏土20~40重量%、膨潤土2~20重量%及雲母40~60重量%。
2.如1所記載之盤型輥用基材，其中前述陶瓷纖維包含氧化鋁30重量%以上且未達70重量%與二氧化矽超過30重量%且70重量%以下。
3.如1或2所記載之盤型輥用基材，其中前述陶瓷纖維之硬粒(shot)為5重量%以下。
4.如1~3中任一項所記載之盤型輥用基材，其進一步包含紙漿與澱粉。
5.一種盤型輥用基材之製造方法，其係使含氧化鋁30重量%以上且未達70重量%與二氧化矽超過30重量%且70重量%以下之粗纖維進行脫硫，製造硬粒為5重量%以下之陶瓷纖維，將水、前述陶瓷纖維、木節黏土、膨潤土與雲母混合，而製造水性漿液，使水性漿液流入成形槽或成形模中，藉由濾水，製造薄片。
6.一種盤型輥，其包含由如1~4中任一項所記載之基材所得之環狀盤材。
7.一種盤型輥之製造方法，其包含自1~4中任一項所記載之基材沖壓出複數個環狀盤材，將前述複數個環狀盤材嵌插於轉軸(shaft)上，經壓縮成為輥狀層合物。
8.一種玻璃之製造方法，其係使用如6所記載之盤型輥運送玻璃熔融物，使玻璃熔融物冷卻。
依據本發明，可提供一種適於玻璃之製造、可有效率地製造之便宜之盤型輥及其基材。
10‧‧‧盤型輥
100‧‧‧玻璃熔融物
圖1為顯示使用盤型輥之玻璃之製造方法之一例之圖。
本發明之盤型輥用基材包含陶瓷纖維(氧化鋁矽酸鹽纖維等)、木節黏土、膨潤土及雲母。
陶瓷纖維含5~9重量%，較好6~9重量%，更好7~8重量%。陶瓷纖維未達5重量%時，成形為盤型輥時耐熱性降低，超過9重量%時，導致填充前之盤型材之低密度化，故調整成特定之填充密度時，盤材之體積增加使填充時之作業性降低。且，陶瓷纖維之量多時變得昂貴。
本發明所使用之陶瓷纖維通常含30重量%以上且未達70重量%，較好40重量%以上且未達60重量%，更好為45重量%以上且未達55重量%之氧化鋁。且，陶瓷纖維通常含超過30重量%且70重量%以下，較好超過40重量%且60重量%以下，更好為超過45重量%且55重量%以下之二氧化矽。纖維可使用1種或混合2種以上使用。
本發明中使用之陶瓷纖維較好含5重量%以下，更好2重量%以下之45μm以上的硬粒(未纖維化物)。使用硬粒多之纖維製造之盤型輥會有傷及玻璃表面 之虞。硬粒之大小通常為45~5000μm左右。
陶瓷纖維之纖維徑通常為2~5μm左右。
基材含20~40重量%，較好25~40重量%，更好28~38重量%之木節黏土。以該範圍含木節黏土時，表面潤滑性(平滑性)變良好。
膨潤土係含2~20重量%，較好含2~15重量%，更好含3~15重量%，又更好含5~14重量%。不含膨潤土時，定著．凝聚不充分且濾水性變差。相反地，膨潤土太多時，漿液黏性變高而使濾水性變差。
雲母係為了提高盤材對軸心之熱膨脹之追隨性而添加。由於嵌插盤材之軸心為金屬製，故曝露於高溫時，該軸心經熱膨脹而沿軸方向延伸。此時，盤材之熱膨脹率比金屬低故無法追隨軸心伸長，會使盤材彼此剝離。另一方面，雲母係作成極薄層之構造，加熱時會引起結晶態轉變，但此時有於層方向膨脹之傾向，因向層方向之膨脹而提高盤材對軸心熱膨脹之追隨性。
雲母可使用白雲母(白雲母(muscovite)；K2Al4(Si3Al)2O20(OH)4)、黑雲母、金雲母(水鋁氟石(prosopite)：K2Mg6(SiAl)2O20(OH)4)、玄玻凝灰岩(palagonite)、鋰雲母(lepidolite)、氟合成雲母等，但考慮上述追隨性時，以白雲母較佳。
基材含有40~60重量%，較好44~54重量%之雲母。雲母未達40重量%時，對軸心熱膨脹之追隨性變 低，超過60重量%時難以均勻分散於漿液中，會有盤基材之物性偏差變大之顧慮。
本發明之基材在不損及本發明效果之範圍內，除上述成分以外，亦可含凝聚輔助劑、有機黏結劑。
有機黏結劑較好為有機纖維(紙漿)、澱粉。含有機纖維(紙漿)時可展現壓縮特性，其量可為例如2~10重量%，或5~10重量%。且，含澱粉時可展現盤材之強度，其量為例如1~10重量%，或1~4重量%。
本發明之基材之作為無機成分之陶瓷纖維、木節黏土、膨潤土、雲母合計可成為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%。
本發明之基材藉由以上述範圍含上述成分，即使無機纖維之量較少，亦可獲得均衡良好地保有耐熱性、強度、硬度之盤型輥。
基材可將含無機纖維、木節黏補、膨潤土、雲母之水性漿液成形為板狀，經乾燥而製造。此時，在效率上以使用造紙法較佳。亦即，可調製含特定量之無機纖維、木節黏土、膨潤土、雲母、視需要之凝聚輔助劑、有機黏結劑等之水性漿液，以造紙機將該水性漿液成形為板狀，經乾燥而獲得基材。又，基材之厚度可適當設定，一般為2~10mm。
接著，說明關於盤型輥之製造方法。通常，自基材沖壓環狀之盤材，將該盤材嵌插於複數片、金屬製 (例如鐵製)之軸心上成為輥狀之層合物，透過配置於兩端之輪緣，自兩端加壓全體且在對盤材施加若干壓縮之狀態以螺絲等固定。視需要進行燒成。接著，以成為特定輥徑之方式研磨盤材之外周面，獲得盤型輥。
盤型輥之形狀有全蓋式輥(full cover roll)、單側固定輥、短截輥(stub roll)等。
例如，如圖1所示，使用本發明之盤型輥10，夾持玻璃熔融物100進行運送，使玻璃熔融物100冷卻、硬化，可製造玻璃。
實施例 實施例1 [盤型輥用基材之製作與評價]
調配陶瓷纖維(氧化鋁40~60重量%、二氧化矽60~40重量%)7重量%、木節黏土30重量%、膨潤土10重量%、白雲母45重量%、紙漿6重量%、澱粉2重量%，調製水性漿液，以造紙法造成薄片(盤型輥用基材)。
針對所得基材藉以下方法進行特性之測定或評價。結果示於表1。
(1)濾水性
利用TAPPI式手工抄紙機，以濾水時間進行評價。
○：未達100秒，△：100~200秒，×：超過200秒
(2)薄片外觀
○：良好，△：有不均，×：有龜裂
(3)加熱收縮率
將盤型輥用基材切成寬度30mm、長度150mm，在900℃加熱3小時後，測定其線方向及厚度方向之長度，基於下述式評價加熱收縮率。
[(加熱前之測定值-加熱後之測定值)/加熱前之測定值]×100
(4)原板之彎曲試驗(彎曲強度及彎曲彈性率)
使盤型輥用基材保持於維持在900℃之加熱爐中3小時後，自然冷卻至室溫。由加熱前者及冷卻後之基材切出寬度30mm、長度150mm之試驗片，使用島津製作所製造之「Autograph AG-100kND」，以JIS K7171為準評價彎曲強度及彎曲彈性率。
(5)耐剝落(spalling)性
自盤型輥用基材沖壓外徑60mm內徑20mm之盤材，以成為長度100mm、填充密度為表1之值之方式填輥(roll build)於直徑20mm之不銹鋼製之軸心上，製作盤型輥。
將該盤型輥投入保持在900℃之電爐中，15小時後取出且急冷至室溫25℃。接著，重複該加熱及急冷之循環直到盤型輥發生龜裂或盤分離為止，且計算發生龜裂或盤分離之循環數。
除上述外，分別評價耐剝落試驗前之盤材之Shore D硬度，與龜裂後或盤分離後之(試驗後)之盤材之硬度。
(6)荷重變形量
自盤型輥用基材沖壓外徑60mm內徑20mm之盤材，以成為長度100mm、填充密度為表1之值之方式填輥於直徑20mm之不銹鋼製之軸心上，製作盤型輥。
該盤型輥以支架支持軸心之兩端，以壓縮元件，以1mm/分鐘對由盤材所成之輥面施加10kgf/cm之荷重，測定此時之荷重變形量(室溫)。
又，針對將上述盤型輥保持在900℃之加熱爐中10小時，自加熱爐取出後，冷卻至室溫者，與上述同樣測定荷重變形量(900℃ 10小時)。
參考例1
除使用調配陶瓷纖維(氧化鋁50重量%、二氧化矽50重量%)30重量%、木節黏土20重量%、膨潤土10重量%、白雲母32重量%、紙漿6重量%、澱粉2重量%之水性漿液以外，餘與實施例1同樣製造基材與盤型輥並進行評價。結果示於表1。
由表1可知，實施例1之盤型輥儘管纖維量少，但具有與參考例1同等之實用上沒有問題之耐熱性及強度。
[產業上之可利用性]
本發明之盤型輥可使用於板玻璃，尤其是液晶顯示器、電漿顯示器、有機EL顯示器之製造中。
上述已詳細說明本發明之實施形態及/或實施例，但熟悉本技藝者在實質上不脫離本發明之新穎教示及效果下，可容易地對該等例示之實施形態及/或實施例施加多種變更。據此，該等多種變更均包含於本發明之範圍中。
本申請案之成為巴黎優先權基礎之日本申請案說明書之內容已全文被援用。
10‧‧‧盤型輥
100‧‧‧玻璃熔融物

Claims (10)

  1. 一種盤型輥用基材，其係包含陶瓷纖維5~9重量%、木節黏土20~40重量%、膨潤土2~20重量%及雲母40~60重量%，且前述陶瓷纖維、前述木節黏土、前述膨潤土及前述雲母合計佔基材之92重量%以上。
  2. 如請求項1之盤型輥用基材，其中前述陶瓷纖維包含氧化鋁30重量%以上且未達70重量%與二氧化矽超過30重量%且70重量%以下。
  3. 如請求項1之盤型輥用基材，其中前述陶瓷纖維之硬粒(shot)為5重量%以下。
  4. 如請求項1或2之盤型輥用基材，其進一步包含紙漿與澱粉。
  5. 一種盤型輥用基材之製造方法，其係混合水、陶瓷纖維、木節黏土、膨潤土與雲母，在固體成分含量下陶瓷纖維5~9重量%、木節黏土20~40重量%、膨潤土2~20重量%及雲母40~60重量%，以使前述陶瓷纖維、前述木節黏土、前述膨潤土及前述雲母合計佔基材之92重量%以上之方式製造水性漿液，前述陶瓷纖維包含氧化鋁30重量%以上且未達70重量%與二氧化矽超過30重量%且70重量%以下，且45μm以上之硬粒為5重量%以下，使水性漿液流入成形槽或成形模中，藉由濾水，製造薄片。
  6. 一種盤型輥，其包含由如請求項1~4中任一項之基 材所得之環狀盤材。
  7. 一種盤型輥之製造方法，其包含自如請求項1~4中任一項之基材沖壓出複數個環狀盤材，將前述複數個環狀盤材嵌插於轉軸(shaft)上，經壓縮成為輥狀層合物。
  8. 一種玻璃之製造方法，其係使用如請求項6之盤型輥運送玻璃熔融物，使玻璃熔融物冷卻。
  9. 一種盤型輥用盤材，其係包含陶瓷纖維5~9重量%、木節黏土20~40重量%、膨潤土2~20重量%及雲母40~60重量%，且前述陶瓷纖維、前述木節黏土、前述膨潤土及前述雲母合計佔基材之92重量%以上。
  10. 一種盤型輥用盤材之製造方法，其係自如請求項1~4中任一項之前述盤型輥用基材沖壓出複數個環狀盤材。
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