TWI594958B - Method for producing pulling rolls for use in manufacturing sheet glass - Google Patents

Description

Method for manufacturing a drawing cylinder for making flat glass

The present application claims the benefit of priority to U.S. Provisional Application Serial No. 61/141,442, filed on Dec.

This disclosure relates to the fabrication of flat glass. More specifically, the present disclosure relates to a method of making a draw cylinder for making flat glass (for example, an overflow down-dip fusion process).

The draw cylinder is used to make flat glass to apply tension to the glass ribbon, which is formed from the glass ribbon and thus the glass ribbon controls the nominal flat thickness. For example, in an overflow down-draw process (see U.S. Patent Nos. 3,338,696 and 3,682,609 to Dockerty), the draw rolls can be placed on top of the molten tube or downstream of the root and are used to tune The rate at which the entire formed glass ribbon leaves the tube and thus determines the nominal thickness of the finished panel.

Successful pull rollers can meet several conflict criteria. First, the drum should be able to withstand the high temperatures associated with the newly formed glass for a significant period of time. The longer a drum can last in this environment, the better it is because the drum replacement reduces the amount of finished glass that can be manufactured by a given machine and thus increases the final cost of the glass.

Second, the drum should be capable of generating sufficient pulling force to control the thickness of the glass. In order not to damage the central portion of the belt that will become available glass, the drum can contact the belt only over a limited area of the belt edge. Therefore, only this area can be used to generate the pulling force. However, the force applied to the glass should not be too great as this may result in surface damage that can propagate into the available central portion of the belt. Therefore, the drum should strike a balance between applying too little force to the glass and applying too much force.

Third, the high density millboard material used in the construction of the draw rolls should be sufficiently rigid to withstand process damage due to, for example, cullet during manufacturing for extended periods of time.

Fourth, the draw rolls should not release excess particles because the particles can stick to the glass and form a surface defect called an onclusion. For glass that will be used in a desired application (for example, a substrate for a flat panel display) In other words, the impurity regions must be kept to a very low level because each impurity region will typically represent a defective region of the finished product (eg, one or more defective pixels). Due to the thermal environment in which the draw rolls operate, providing a material that can apply sufficient pull force to the glass ribbon without releasing particles at high temperatures is a difficult challenge.

The draw cylinder is preferably designed to be in contact with the outer edge of the ribbon, in particular in contact with the strip only in the region of the inside of the thickened bead that is present on the edge of the strip. A preferred configuration of the rollers is to use a disk of a heat resistant material (e.g., a high density fiberboard) that is mounted to the drive shaft. Examples of such a construction are found in U.S. Patent No. 3,334, 010 to Moore, U.S. Patent No. 4,533, 581 to Asaumi et al., and U.S. Patent No. 5,989,170, the entire disclosure of each of The specific purpose of the example of pulling the drum construction.

Existing traction rollers have not been able to fully meet the long-term competition criteria for high temperature service life, controlled force application, hardness and low pollution. Therefore, there is a need in the art to obtain a draw cylinder that achieves a higher level of performance than existing draw rolls.

The present disclosure relates to a method of manufacturing a draw cylinder for glass making.

In one aspect, the present disclosure provides a method for making a draw cylinder zone of a given length and diameter, the method comprising the steps of: selecting a set of heat resistant disks having a suitable outer diameter and combined weight, So that when the set of disks is set to fill the given length and a given diameter, the set of disks reaches a bulk density of from about 0.9 g/cm ³ to about 1.2 g/cm ³ ; Attaching to at least one first and one second assembly to the shaft, and positioning the first and second assemblies to apply a coaxial compressive force to the set of discs; and The disk is compressed to the given length such that at least a portion of the draw cylinder zone is adapted to contact a glass ribbon having a Shore D hardness of from about 30 to about 60 at about 25 °C.

Other aspects of the present disclosure will be set forth in part in the description of the appended claims and the claims. The advantages described below will be realized and obtained by the elements and combinations particularly pointed out in the appended claims. The above general description and the following detailed description are intended to be illustrative and not restrictive.

The accompanying drawings, which are incorporated in the claims of FIG

Figure 1 is a matrix diagram of the average drum hardness and working life of a draw cylinder.

Figure 2 illustrates the relationship between the change in overall density and the change in hardness of the durometer.

The present disclosure can be more readily understood by reference to the following detailed description, examples and claims claims However, it is to be understood that the present disclosure is not limited to the particular items and/or methods disclosed, and thus may be varied. It is also understood that the terminology used herein is for the purpose of the description

The disclosed subject matter can be used in the disclosed methods and compositions, in conjunction with the disclosed methods and compositions, in the preparation of the disclosed methods and compositions or materials, compounds, compositions and groups thereof. Share. These and other materials are disclosed herein, and it should be understood that when a combination, subset, interaction, group, etc. of such materials are disclosed, each individual and collective combination and the specific reference of the arrangement of such compounds may be It is not explicitly disclosed, but each specific reference is specifically covered and described herein.

The following description is provided as an illustration of the teachings of the present invention in the presently known embodiments of the invention. For this purpose, cooked It will be appreciated and appreciated by those skilled in the art that various modifications can be made in the various aspects of the embodiments of the invention described herein, while still obtaining the beneficial results of the invention. It will also be appreciated that some of the desired benefits of the present invention may be obtained by selecting some of the features of the present disclosure without the use of other features. Accordingly, those skilled in the art will recognize that many modifications and adaptations of the present invention are possible and in some cases may be desirable and are part of the disclosure. Accordingly, the description is to be construed as illustrative and not restricting.

As used herein, the singular forms "a", "an", "the" Thus, for example, reference to a "high density fiberboard" includes a plurality of aspects having two or more such high density fiberboards, unless the context clearly dictates otherwise.

Ranges may be expressed herein as "about" a particular value and/or to "about" another particular value. When this range is expressed, another aspect includes from a particular value and/or to another particular value. Similarly, when values are expressed as approximations by using the antecedent "about", it is understood that the particular value forms another aspect. It is further understood that the endpoints of each of the ranges are significant, whether relative to the other endpoint or independent of the other endpoint.

The reference to the weight fraction of a particular component of the composition or article in the scope of this patent specification and the final patent application Test, indicating the weight relationship expressed between parts of the composition or article and any other components in parts by weight. Thus, in a compound comprising 2 parts by weight of component X and 5 parts by weight of component Y, X and Y are present in a weight ratio of 2:5, and whether or not the compound contains additional components, X and Y All exist in this weight ratio.

As used herein, unless otherwise stated to the contrary, "wt.%" or "% by weight" of a component is based on the total weight of the composition comprising the component.

As used herein, "compressibility" refers to the relative volume change of a material in response to a applied pressure. For example, the compressibility of the draw cylinder refers to a change in the thickness of the assembled heat resistant disk or a change in the length of the assembled draw roller after application of a compressive axial force.

As used herein, "recovery" refers to the ability of a compressed material to expand after removal of an applied pressure. By way of example, the return of the draw cylinder refers to the expansion of the thickness of the high density fiberboard member after removal of an axial compression force or after elongation of the draw cylinder shaft by, for example, thermal expansion.

As briefly described above, an exemplary embodiment provides an improved method of making, for example, a draw cylinder that can be used to make flat glass. In various aspects described in detail below, an exemplary embodiment includes a method of making a draw cylinder having a predetermined bulk density. In various aspects, the draw rolls made by the methods disclosed herein can be expanded in the glass making system. Filled with the operation and improved glass quality. In other aspects, the draw rolls made by the methods disclosed herein achieve a higher degree of efficiency and consistency than conventional draw rolls.

Heat resistant disc

The draw rolls made by the methods of the present disclosure comprise a plurality of heat resistant disks. The particular shape, size and composition of any one or more of the plurality of heat resistant disks may vary depending, for example, on the intended application and operating conditions of the resulting draw rolls.

In various aspects, the heat resistant disk can comprise a planar material having an outer perimeter and a central aperture. The size and shape of the heat resistant disc can be any size and shape suitable for the draw cylinder. In one aspect, any one or more of the heat resistant disks are circular such that the disk on a pull cylinder will have a constant diameter when rotated about an axis. In this case, the diameter may be different for different draw rolls for different applications. In other aspects, the shape and/or outer perimeter of any one or more of the heat resistant disks can be varied along any particular draw roll such that the outer surface of the draw roll is undulating.

A heat resistant disk can also have a central aperture, for example, having an opening through which a shaft can be inserted. This hole allows a plurality of heat resistant disks to be mounted on the shaft in a face-to-face manner. The particular size and shape of the hole may vary depending on, for example, the configuration of the axis. In one aspect, the aperture of a heat resistant disk can match or substantially match the cross section of the shaft on which the heat resistant disk will be mounted. In another aspect, the aperture of a heat resistant disk can be associated with the axis on which the disk will be mounted. The cross section is different. In various aspects, the aperture of the heat resistant disk can be, for example, circular, square, pentagonal, hexagonal, diamond or elliptical. A heat resistant disc having matching or generally matching holes can be used to prevent sliding of the disc, for example, rotation of the disc about the shaft during operation. In various aspects, the outer surface of each heat resistant disk may form part of the outer surface of the draw cylinder. At least a portion of the outer surface of the draw cylinder is adapted to contact the glass plate.

The thickness of the heat resistant disk can vary, and can be any thickness suitable for use with a draw cylinder, and the present disclosure is not intended to be limited to any particular thickness of the heat resistant disk. In various aspects, the heat resistant disk can have a thickness from about 3 mm to about 10 mm, for example, can be about 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In other aspects, the heat resistant disk can have a thickness of less than about 3 mm or greater than about 10 mm.

The composition of the heat resistant disc can be any composition suitable for use in a draw cylinder. In one aspect, the heat resistant disk can comprise a high density fiberboard material. High density fiberboard materials are commonly used as thermal insulation materials in a variety of industries, including glass making. High density fiberboard articles are typically manufactured by producing a slurry of the desired component, using a rotating screening cylinder to effect absorption and dewatering of the components, and transferring the dehydrated components to a synthetic carpet gasket and It is then transferred to an accumulator drum (on which the layers of the slurry are accumulated on each other to a desired thickness). These accumulation layers can be cut, removed and formed into panels of the desired size for later Continue to use. After formation and during formation, the high density fiberboard slab can be compressed by a roller to impart a uniform thickness thereto. The resulting high density fiberboard plate can then be heated to remove residual moisture. Various compositions and methods for high density fiberboard fabrication are described in U.S. Patent Nos. 1,594,417, 1,678,345, 3,334, 010, 4,487, 631, and 5, 989,170. Those skilled in the art can readily determine the appropriate process conditions for making high density fiberboard articles.

In another aspect, the heat resistant disk can comprise citrate and clay. In another aspect, the heat resistant disk can comprise refractory ceramic fibers, such as aluminosilicate refractory fibers, silicates, mica, and clay (eg, kaolin clay). In still another aspect, the heat resistant disk may comprise a commercially available high density fiberboard material such as Nichias SD-115 (available from Nichias Corporation of Tokyo, Japan).

In one aspect, the heat resistant disc and/or the material from which the heat resistant disc is formed or cut may further comprise a functional component. In one aspect, the functional component comprises a cellulosic material, a starch material, a silicone or a mixture thereof. Functional components can be used for the formation of high density fiberboard articles. A functional component can be burned or decomposed during heating or during use of the high density fiberboard article at typical drawing drum operating temperatures. In one aspect, the functional component can be a processing aid (eg, processed wood pulp cellulose fibers). The functional component can also be a binder, for example, a cationic potato lake. Powder (e.g., Empresol N, available from American Key Products, Inc. of Kearney, New Jersey, USA), or the functional component can be a silicone, for example, an alkaline silicone solution (e.g., available from Naperville, Illinois, USA). LUDOX®-Nalco 1140 of Nalco Chemical Co.).

In another aspect, the heat resistant disk is substantially free of asbestos, unfibrillated material, and small crystalline cerium particles. In yet another aspect, the heat resistant disk can contain less than about 0.8 weight percent, less than about 0.3 weight percent titanium dioxide, or even no titanium dioxide.

In one aspect, the heat resistant disc can be fired and/or the material from which one or more heat resistant discs are cut prior to assembly to form the draw rolls, such that when exposed to the temperature at which the rolls are exposed At the time, the composition or size change is not substantially exhibited. For example, the heat resistant disk can be heated from a temperature of about 650 ° C to a temperature of about 1,000 ° C in a firing step, preferably from about 760 ° C to a temperature of about 1,000 ° C, and at least two The cycle of hours. Subsequently, the heat resistant disks can be cooled to ambient temperature and assembled to form a draw cylinder. The functional component (e.g., cellulose) present in the high density fiberboard material can be burned by heating in this firing step. Alternatively, the draw cylinder can be used without a firing step prior to assembly. If the high density fiberboard material forming the draw cylinder comprises a flammable functional component, The compression force of the assembled draw rolls may need to be adjusted to compensate for the burned functional components. Of course, other firing times and temperatures can also be used to implement the exemplary embodiments as long as the composition of the finished draw cylinder provided is stable at the operating temperature of the drum.

The hardness of the heat resistant disks can be any hardness suitable for the draw rolls. It should be noted that the hardness of the heat resistant disk may vary depending, for example, on the composition of the disk and the thermal history. The average hardness of the draw rolls comprising heat resistant discs can also vary. In one aspect, the draw rolls of the draw rolls comprising the heat-resistant disks produced by the methods disclosed herein have an average Shore D hardness at 25 ° C in the range of from about 30 to about 60, for example, about 30, 31, 33, 35, 37, 39, 41, 43, 45, 47, 49, 51, 53, 55, 57, 59 or 60; in the range from about 40 to about 60, for example, about 40, 42, 44, 46, 48, 50, 52, 54, 56, 58 or 60. In other aspects, the draw rolls of the draw rolls comprising the heat-dissipating disks produced by the methods disclosed herein may have an average Shore D hardness of less than about 30 or greater than about 60 at 25 ° C, and the disclosure is not intended to be limited Pull any specific hardness of the roller and/or heat resistant disc. In various aspects, the portion of the draw rolls suitable for contacting the glass ribbon can have a Shore D hardness of from about 30 to about 60 or a Shore D hardness of from about 40 to about 60 at 25 °C.

In various aspects, the nature of any one or more of the heat resistant disks may vary depending on whether the particular heat resistant disk is intended to contact the glass ribbon during operation. In one aspect, all of these The heat resistant discs comprise substantially the same composition and exhibit substantially the same properties. In another aspect, the heat resistant disks that are positioned such that they can contact the glass ribbon during operation can comprise different compositions as compared to the heat resistant disks that are not positioned to contact the glass ribbon and Presents different qualities.

Shaft and assembly

The shaft of the draw cylinder produced by the methods of the present disclosure may comprise any of the geometries and compositions suitable for use in the draw cylinder. In one aspect, the shaft contains a material that resists the typical thermal conditions during glass fabrication. In another aspect, the shaft is designed such that no or substantially no depression occurs during heating and operation. In one aspect, the shaft or a portion thereof may be coated with a heat resistant material, such as a CERAK M-720 black ceramic coating (distributed by Cetek Limited of Berea, Ohio, USA).

The draw rolls made by the methods disclosed herein may also include one or more assemblies positioned along the axis. The fittings may include a collar, a locking collar, a split collar, or other means capable of securing one or more heat resistant disks to the shaft. In one aspect, any device capable of applying an axial compression force to a plurality of heat resistant disks mounted on a shaft can be used.

In one aspect, the collar can be locked in place on the shaft by a buckle located in the groove in the shaft. In other aspects, other mechanisms known in the art can be used to The ring is attached to the shaft. In various aspects, each of a pair of fittings can be disposed on opposite sides of a shaft to which a plurality of heat resistant discs are mounted. In one aspect, each of the pair of assemblies is movable. In another aspect, one of the pair of assemblies is movable and the other can be permanently attached to the shaft and/or can be integrally formed as part of the shaft.

Depending on the desired configuration of a given draw cylinder, one or more regions of the heat resistant disk can be positioned along the axis. In various aspects, one, two, three or more individual regions of the heat resistant disk may be positioned along the axis, wherein each of the regions includes at least two assemblies, the at least two packages The fitting can apply an axial compression force to the heat resistant disc disposed between the fittings.

A pull roller shaft can further include one or more bearings or bearing surfaces positioned on one end of the shaft. The composition of the shaft and/or any of the assemblies attached to the shaft may vary depending on the intended application and operating conditions. In one aspect, the shaft can comprise a cast stainless steel alloy, such as cast HP 45 alloy, 330 stainless steel, or a combination thereof. In another aspect, a shaft or a portion of the shaft can comprise a composition that is different from the fitting or other portion of the same shaft. In a particular exemplary aspect, the shaft can comprise a cast HP 45 alloy, and the bearing attached to the shaft can comprise 330 stainless steel.

The particular shape and size of the shaft or any fitting attached to the shaft can vary. In various aspects, a shaft or a portion of the shaft may have a circle, a square, a pentagon, a hexagon, or an ellipse. The cross section of the shape. Other shapes are also possible and the disclosure is not intended to be limited to any particular shape or cross section. In another aspect, the diameter and/or cross-section may vary along the length of the shaft. In yet another aspect, the shaft can comprise any design and/or composition suitable for holding a plurality of heat resistant disks.

Pull roller configuration

It should be understood that various pull roller configurations are found in the literature and are suitable for making flat glass. U.S. Patent No. 6,896,646 describes the overall construction of a draw cylinder for glass sheet fabrication and a draw cylinder made of high density fiberboard material. The present disclosure is not limited to a particular pull roller configuration or arrangement, and one skilled in the art can readily select an appropriate pull roller configuration.

In one aspect, the draw cylinder can include a configuration in which a single region of the heat resistant disk extends to the length of the shaft or a portion of the shaft. The draw cylinder can include one or more portions that are particularly adapted to contact the glass plate, wherein the outer perimeter of the heat resistant disk in the portion extends from the axis a greater distance than the surrounding heat resistant disk. This configuration reduces the likelihood that particles from the draw rolls will become deposited on the glass plate as an impurity zone. In a full drum configuration, a single region of the heat resistant disk contains two portions that are adapted to contact the glass plate at different locations (eg, on opposite edges of the glass plate). In a short drum configuration, a single area of a heat-resistant disc mounted to a shaft is suitable for connection One of the edges of the glass plate is touched, and a separate short roller (having a separate shaft) can be used to contact the opposite edge of one of the glass plates.

In another aspect, the draw cylinder can comprise a bare shaft configuration in which two or more regions of the heat resistant disk adapted to contact the glass ribbon are separated by a region that does not include the axis of the disk. Each of the individual regions may have an assembly to secure the heat resistant disks in position and provide an axial compressive force to the heat resistant disks disposed between the assemblies.

Selection criteria and manufacturing

The present disclosure provides a method for selecting a draw roller component and for making a draw cylinder zone from the components. The pull cylinder zone may comprise the entire draw cylinder in the case of a full drum configuration or a short drum configuration, or may comprise a portion of the draw cylinder in the case of a bare shaft configuration. In one aspect, a method for making a draw cylinder zone includes the steps of: determining a target overall density for generating a draw cylinder zone and selecting a disk of a given weight for when the given weight is The target overall density is achieved when the disk is compressed to a set volume. For example, the set volume is defined by the desired length and diameter set by the finished draw cylinder zone.

In contrast, conventional methods of assembling high density fiberboard materials utilize a fixed number of heat resistant disks. Other conventional methods may include the steps of selecting a fixed number of disks and adjusting the compression; and adjusting the length accordingly to achieve the overall density of the assembled high density fiberboard material. Although these traditional methods can be applied to The filter cartridge is tested and suitable for other applications, but it is not ideally suited for use with a draw cylinder. For example, due to changes and variability in the materials from which the assembled high density fiberboard products are made, such conventional methods can result in excessive compression, unacceptable levels of hardness, and variations in consistency. Since the pulling cylinder has a fixed compression length, the adjustment of the compression length is not appropriate.

In one aspect, all or a portion of the heat resistant disks are fired and held for a period of time (eg, by heating to at least 700 ° C or at least 1,000 ° C), for example, prior to assembly on a draw cylinder ( For example, at least about two hours), substantially no change in composition and/or size is exhibited when it is exposed to the operating temperature. This firing step reduces the variability of the materials and the resulting draw rolls. If a firing step is performed, other firing temperatures and firing times may be utilized depending on the particular material and intended application, and the disclosure is not intended to be limited to any particular firing conditions.

In one aspect, the specific target weight of the heat resistant disc is determined to occupy a fixed volume on the draw cylinder shaft. The fixed volume is defined by the desired length and diameter of the finished draw cylinder zone. In this method, the actual number of heat resistant disks containing the target weight may vary.

In various aspects, the target overall density of the draw rolls can range from about 0.9 g/cm ³ to about 1.2 g/cm ³ . In one aspect, the target overall density of the draw rolls can vary depending on, for example, the particular configuration of the draw rolls. For example, in a particular aspect, the target overall density of the full drum configuration can range from about 1.025 g/cm ³ to about 1.05 g/cm ³ , for example, about 1.025 g/cm ³ , 1.03 g. ^{/ cm 3, 1.035g / cm 3} , 1.04g / cm 3, 1.045g / cm 3 or 1.05g / cm ^3. In another particular aspect, the target overall density of the bare shaft roller configuration can range from about 1.04 g/cm ³ to about 1.09 g/cm ³ , for example, about 1.04 g/cm ³ , 1.05 g/cm. ³ , 1.06 g/cm ³ , 1.07 g/cm ³ , 1.08 g/cm ³ or 1.09 g/cm ³ . In yet another particular aspect, the target overall density of the short roll configuration can range from about 1.07 g/cm ³ to about 1.09 g/cm ³ , for example, about 1.07 g/cm ³ , 1.08 g/cm ³ or 1.09g/cm ³ . In other aspects, the target overall density can be less than about 0.9 g/cm ³ or greater than about 1.2 g/cm ³ depending on the particular material of the construction and the intended application.

In addition to providing a target overall density, the predetermined target weight and/or weight range utilized to produce a heat-resistant disk having a set length and diameter of the draw rolls should be selected to provide one or more portions of the draw roll surface The portions have from about 30 to about 60 at 25 ° C (eg, about 30, 31, 33, 35, 37, 39, 41, 43, 45, 47, 49, 51, 53, 55, 57, 59) Or 60) or a Shore D hardness of from about 40 to about 60 (e.g., about 40, 42, 44, 46, 48, 50, 52, 54, 56, 58 or 60). In one aspect, one or more of the pull rollers having a target Shore D hardness value (eg, from about 30 to about 60) The portions may be portions of the draw rolls that are adapted to contact the glass ribbon during use. In another aspect, the hardness of each of the individual heat resistant disks can be from about 30 to about 60 after installation and compression. It should be understood that the hardness of any one or more of the heat resistant disks is before and/or after firing, and before and/or after installation, and before and/or after compressing to a particular volume on the draw cylinder shaft. Can vary.

The compression of any one or more of the individual heat resistant disks can result in different Shore D hardness values. The present disclosure is directed to achieving a Shore D hardness of from about 30 to about 60 on portions of the surface of the draw cylinder adapted to contact the glass ribbon. In one aspect, the stiffness of a portion of the draw cylinder or draw cylinder can vary depending on the particular overall length of the drum and the desired overall density of the diameter. For example, reducing the length of the draw cylinder zone while maintaining its diameter will increase the overall density and hardness of a given weight of material. The resulting increase in hardness can occur in a non-linear manner, such as shown in Figure 2.

The force used to compress a portion of the draw cylinder and achieve a particular hardness may also vary. In various aspects, the force can range from about 10,000 lbs to about 15,000 lbs. In other aspects, the force can be less than about 10,000 lbs or greater than about 15,000 lbs.

In one aspect, if any one or more of the heat resistant disks comprise a combustible or volatile component, the mesh should be adjusted The overall density is indicated to account for the loss of such flammable or volatile components after heating, and to provide a Shore D hardness of from about 30 to about 60 after heating.

This method of draw cylinder manufacturing provides a more consistent draw cylinder that reduces the undesirable effects of high density fiberboard material variations. In addition, consistency in manufacturing can be incorporated into the manufacturing process by utilizing the target weight of the disk material desired to produce volume (length and diameter) relative to a set number of disks. Further, if there is a need to move the hardness of the resulting draw rolls having the set length and diameter to another area, the process can be adjusted by, for example, changing the target weight.

Therefore, changes in target weight, overall density, and/or hardness will affect the remaining parameters. In various aspects, the target weight can be adjusted to impart a change to the overall density. For example, increasing the target weight for a set volume of material will increase the overall density. Similarly, when increasing the overall density of a set volume, greater compression is required to ensure that the disks of the desired weight are supplied within the set volume. For example, when attempting to supply an increased weight disc in a set volume, this increase in compression will result in a draw cylinder having increased stiffness.

The draw rolls prepared in accordance with the various methods of the present disclosure provide enhanced service life without applying excessive force to the glass ribbon or creating a high degree of particulate contamination. In the absence of external events (for example, the rupture of the glass ribbon), according to this disclosure The draw cylinders prepared for the present invention can exhibit a service life of more than 40 days, more than 75 days, or even more than 100 days.

Instance

To further illustrate the principles of the present disclosure, the following examples are presented to provide the general practitioner with a complete disclosure and description of how to make and evaluate high density fiberboard draw rolls fabricated in accordance with the methods disclosed herein. The following examples are intended to be purely exemplary of the present disclosure and are not intended to limit the scope of the disclosure. Efforts have been made to ensure accuracy with respect to numbers (eg, amounts, temperatures, etc.); however, some errors and deviations may occur. Unless otherwise indicated, parts are parts by weight, temperature is °C or ambient temperature, and pressure is at or near atmospheric.

Example 1 - Pulling drum life

In a first example, the draw drum life was evaluated as a function of hardness. As illustrated in Figure 1, when the average durometer hardness of a particular type of draw cylinder is about 41, the maximum draw drum life is achieved. When the average durometer hardness is about 44, the maximum average draw cylinder life occurs. The matrix diagram in Figure 1 illustrates the relationship between life and hardness of the durometer when the axes are interchanged.

Example 2 - Relationship between overall density and hardness

In a second example, a series of draw rolls were prepared and evaluated as detailed in Table 1 below. For the table 1 For each row, the sample heat resistant disk is compressed to a specific overall density. The durometer hardness of each of the compressed samples was determined at six points along the length of the drum and averaged.

The middle curve of Figure 2 illustrates the relationship between the average durometer of the material and the overall density. This relationship can be used to make the drum a specified durometer range by identifying the corresponding overall density range. The upper and lower limits for the display of this intermediate curve represent the predicted limits for future individual hardness values at each degree of overall density.

For example, as identified in Table 1, material A was tested at various degrees of overall density between 0.9 g/cm ³ and 1.2 g/cm ³ . The hardness of each of the compression disks was measured at six locations using a Shore D durometer and the average of the results was obtained.

The fit curve for the data is shown in Figure 2 along with a 95% prediction limit. The stretched display of the hardness of the Shore D durometer between such boundaries of a given overall density will show the expected change in the measured data.

Table 1

Example 3 - Comparison Example

In a comparative example, the assembled high density fiberboard article can be prepared to a fixed compression length. A plurality of heat resistant disks may be selected for the fixed length and the compressive force necessary to supply the disks to the fixed length. The different compressions required to supply the disks to the fixed length produce different hardnesses on the surface of the assembled high density fiberboard article.

In contrast, one aspect of the present invention includes selecting the weight of the heat resistant disk that achieves a target overall density when the heat resistant disks are disposed within a set volume of the draw rolls. As described in various embodiments herein, this method provides improved consistency and controlled hardness as compared to conventional methods and materials.

Various publications are referenced throughout this application. The disclosures of these publications are hereby incorporated by reference in their entirety in their entirety in their entirety in their entireties in the the the the the the the the the

Various modifications and variations can be made to the compounds, compositions and methods described herein. Other aspects of the compounds, compositions, and methods described herein will be apparent from the description of the <RTIgt; This patent specification and examples are intended to be exemplary.

For example, the invention may be practiced in one or more of the following aspects: According to a first aspect, a method for making a draw cylinder zone is provided, the draw cylinder zone comprising a given length And a given diameter, the method comprising the steps of: selecting a set of heat resistant disks having a suitable outer diameter and combined weight such that when the set of disks is set to fill the given length and the given diameter, The set of discs achieves an overall density of from about 0.9 g/cm ³ to about 1.2 g/cm ³ ; assembling the set of heat resistant discs onto a shaft; attaching at least one first and one second fitting to the shaft, And positioning the first and second fittings to apply a coaxial compressive force to the set of discs; and compressing the set of discs to the given length to enable contacting the draw barrel region of a glass ribbon At least a portion of it has a Shore D hardness of from about 30 to about 60 at about 25 °C.

According to a second aspect, the method of aspect 1, wherein the selection is used to achieve an overall density of from about 1.025 g/cm ³ to about 1.05 g/cm ³ .

According to a third aspect, the method of aspect 2 is provided wherein the draw cylinder zone has a full drum configuration.

According to a fourth aspect, the method of aspect 1, wherein the selection is used to achieve an overall density of from about 1.04 g/cm ³ to about 1.09 g/cm ³ .

According to a fifth aspect, the method of aspect 4 is provided, wherein the pull zone comprises a portion of a draw cylinder that includes a bare shaft configuration.

According to a sixth aspect, the method of aspect 1, wherein the selection is used to achieve an overall density of from about 0.9 g/cm ³ to about 1.09 g/cm ³ .

According to a seventh aspect, the method of aspect 6 is provided wherein the draw cylinder zone has a short roller configuration.

According to an eighth aspect, the method of aspect 1, wherein at least a portion of the set of heat resistant disks comprises aluminosilicate refractory fibers, silicates, mica and kaolin clay.

According to a ninth aspect, the method of aspect 1, wherein the step d) comprises the step of compressing the set of disks At least a portion of the draw cylinder zone adapted to contact a glass ribbon has a Shore D hardness of from about 40 to about 60 at about 25 °C.

According to a tenth aspect, the method of aspect 1, wherein the given diameter of the draw cylinder zone varies along a given length.

According to an eleventh aspect, the method of aspect 1, wherein the pulling cylinder zone comprises a first region of a pulling cylinder, and the pulling cylinder further comprises a second region on the shaft, wherein the first And each of the second regions includes at least two heat resistant disks positioned between the at least two assemblies.

According to a twelfth aspect, the method of aspect 11 is provided, wherein a portion of the axis between each of the first and second regions does not comprise a disk.

According to a thirteenth aspect, the method of aspect 1, wherein at least a portion of the heat resistant disks in the set has a central opening shaped to substantially match a cross section of the shaft.

According to a fourteenth aspect, a method of any one of aspect 1 to aspect 13 is provided, wherein the set of heat resistant disks are fired prior to assembly onto the shaft.

Claims (10)

A method for making a draw cylinder zone, the draw cylinder zone comprising a given length and a given diameter, the method comprising the steps of: a. selecting a set having a suitable outer diameter and a combined weight a heat resistant disk such that when the set of disks is set to fill the given length and the given diameter, the set of disks achieves an overall density from 0.9 g/cm ³ to 1.2 g/cm ³ ; b. Assembling the set of heat resistant disks onto a shaft; c. attaching at least one first assembly and second assembly to the shaft, and positioning the first and second assemblies to apply a coaxial compressive force To the set of disks; and d. compressing the set of disks to the given length such that at least a portion of the draw cylinder zone adapted to contact a glass ribbon has a Shore from 30 to 60 at 25 ° C (Shore) D hardness, and the average Shore D hardness of the draw cylinder is from 41 to 44. The method of claim 1, wherein the set of heat resistant disks are fired prior to assembly onto the shaft. The method of claim 1, wherein the selection is to achieve an overall density of from 1.025 g/cm ³ to 1.05 g/cm ³ and the draw cylinder zone has a full drum configuration. The method of claim 1, wherein the selection is to achieve an overall density of from 1.04 g/cm ³ to 1.09 g/cm ³ , and the pull-in region comprises a portion of a pull roller, the pull The drum includes a bare shaft configuration. The method of claim 1, wherein the selection is to achieve an overall density of from 0.9 g/cm ³ to 1.09 g/cm ³ and the draw cylinder zone has a short drum configuration. The method of claim 1, wherein at least a portion of the group of heat resistant disks comprises aluminosilicate refractory fibers, silicates, mica and kaolin clay. The method of claim 1, wherein the step d) comprises the step of compressing the set of disks such that at least a portion of the draw cylinder zone adapted to contact a glass ribbon has a temperature of from 40 to 60 at 25 °C. A Shore D hardness. The method of claim 1, wherein the pulling drum zone comprises a first region of a pulling cylinder, and the pulling cylinder further comprises a second region on the shaft, wherein the first region And each of the second regions includes at least two heat resistant disks positioned between the at least two assemblies. The method of claim 8 wherein a portion of the shaft between each of the first and second regions does not comprise a disk. For example, the method of claim 1 of the patent scope, wherein At least a portion of the heat resistant disks in the set have a central aperture that is shaped to substantially match a cross section of the shaft.