WO2013157477A1 - ガラス板の製造装置および製造方法 - Google Patents
ガラス板の製造装置および製造方法 Download PDFInfo
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- WO2013157477A1 WO2013157477A1 PCT/JP2013/060923 JP2013060923W WO2013157477A1 WO 2013157477 A1 WO2013157477 A1 WO 2013157477A1 JP 2013060923 W JP2013060923 W JP 2013060923W WO 2013157477 A1 WO2013157477 A1 WO 2013157477A1
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- glass
- glass ribbon
- barrel head
- ribbon
- sro
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B18/00—Shaping glass in contact with the surface of a liquid
- C03B18/02—Forming sheets
- C03B18/04—Changing or regulating the dimensions of the molten glass ribbon
- C03B18/06—Changing or regulating the dimensions of the molten glass ribbon using mechanical means, e.g. restrictor bars, edge rollers
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
- Y02P40/57—Improving the yield, e-g- reduction of reject rates
Definitions
- the present invention relates to an apparatus and a manufacturing method for manufacturing a thin glass plate according to the float bath method.
- glass substrates for flat panel displays such as liquid crystal displays and plasma displays have been increased in size and thickness.
- a float method is known in which a float bath in which a molten metal such as metallic tin is stored is used and a molten glass is thinly stretched in the horizontal direction on the molten metal.
- a molten glass is floated on the molten metal of the float bath to ensure a necessary thickness according to the purpose, and a strip-shaped glass ribbon can be formed by drawing the molten glass in the horizontal direction.
- a glass substrate having a desired size can be obtained by cutting the glass ribbon into a required size.
- this float method in order to manufacture a glass substrate that has been increased in size and thickness as described above, it is called a top roll that pulls both ends in the width direction of the glass ribbon on the molten metal of the float bath. And forming a thin glass ribbon by stretching the glass ribbon to both ends in the width direction. A thin glass ribbon is slowly cooled and then cut into a required size, followed by polishing and washing, whereby a target glass substrate can be obtained.
- large and thin glass substrates are produced in large quantities, and large glass substrates having a thickness of about 0.7 mm and a length and width of several meters are produced as glass substrates.
- a large amount of portable information terminal devices have been manufactured.
- a liquid crystal panel applied to the portable information terminal device a liquid crystal panel using a glass substrate having a thickness of about 0.7 mm is used.
- FIG. 8 shows an example of a float bath used in the float process.
- This float bath 100 is provided with a bottom bath 102 having a molten metal 101 such as molten tin inside, and a melt is formed on the inlet side of the bottom bath 102.
- Molten glass 103 flows in from the furnace hearth.
- the molten glass 103 is stretched to a target width on the molten metal 101 by a plurality of top rolls 105 and gradually cooled to form a glass ribbon 106 having a required width and thickness.
- a top roll 105 applied to this type of float bath 100, a barrel head 105A formed in a disk shape as shown in FIG.
- the barrel head 105A shown in FIG. 9 adjusts the width of the molten glass 103 by causing the outer peripheral blades 105a and 105a to bite into the edge portion 103a of the molten glass 103 while applying an outward tensile force to the edge portion 103a.
- the width and thickness of the ribbon 106 can be adjusted.
- glass substrates tend to be made thinner and the use of a glass substrate having a thickness of about 0.3 mm as a glass substrate for a panel of a portable information terminal device has been studied from the beginning. Yes. Further, there is a demand for further thinning of glass substrates for flat panel displays.
- the molten glass 103 immediately after being poured into the float bath 100 and being expanded cannot be easily pulled because it is liquid at high temperature, but the molten glass 103 moves from the upstream region to the downstream region of the float bath 100. As it is gradually cooled and the viscosity gradually increases, the molten glass 103 having increased viscosity can be pulled and expanded by the barrel head 105A.
- FIG. 10 is a diagram for explaining a state in which the barrel head 105A is pressed from above with a strong force against the edge portion 103a of the molten glass 103.
- FIG. 10 When the barrel head 105A is strongly pressed against the edge portion 103a of the molten glass 103 shown in FIG. 10A as shown in FIG. 10B, the edge portion 103a sinks deeply in proportion to the pressing force of the barrel head 105A. It is transformed into a U-shaped bag shape. If the deformed glass is solidified in this bag state, there is a problem that a locally deformed portion 110 called a straw having a T-shaped cross section is generated as shown in FIG.
- the cross section may be deformed into an S shape as shown in FIG.
- a locally deformed portion 111 called a straw is generated that is deformed so that the deformed portion overlaps the upper bag portion 111a and the lower bag portion 111b.
- molten metal may be caught inside the glass as shown by arrows a and b in FIG.
- the generation of the locally deformed portions 110 and 111 is conspicuous in a thin glass plate, particularly when a glass plate having a thickness of 1 mm or less is manufactured by the float method like the glass substrate for a display device described above. There is a problem to do.
- the present inventor has made various studies on a technique for producing a thin glass ribbon of 1 mm or less by forming molten glass by a float process.
- the inventors When forming a ribbon, the inventors have found that the position where the barrel head applies tension can be devised to suppress the occurrence of a locally deformed portion called a straw, and the present invention has been achieved. It is an object of the present invention to provide a manufacturing apparatus and a manufacturing method that can manufacture a glass ribbon without causing a local deformation portion when forming a thin glass ribbon by a float process, and contribute to stable production of a glass plate. To do.
- the present invention includes a float bath for storing molten metal, forming a glass ribbon by moving a molten glass from an upstream area to a downstream area of the molten path, wherein a molten glass moving path is formed on the molten metal.
- a plurality of pairs of top rolls disposed on both sides in the width direction of the movement path from the upstream area to the downstream area of the movement path in the float bath, the top rolls on both sides in the width direction of the movement path of the molten glass.
- Width of the nip margin indicating the distance between the nearest edge of the pressing position and the glass ribbon barrel head with respect to the glass ribbon, a manufacturing device of the small glass plate on the downstream side of the upstream side.
- a region where the logarithm of the viscosity of the glass ribbon is 5.29 to 6.37 dPa ⁇ s is used as a middle flow region, and the relationship between the widths of the nip margins of a plurality of barrel heads provided in the middle flow region is as described above.
- the present invention relates to a glass plate manufacturing apparatus that satisfies the above relationship.
- the position of the line stripe formed by the barrel head upstream from the specific barrel head is more than the position of the line stripe formed by the specific barrel head pressing the glass ribbon.
- the present invention relates to an apparatus for manufacturing a glass plate formed on the inner side of a glass ribbon.
- the present invention relates to a glass plate manufacturing apparatus in which a glass ribbon formed by the float bath has a thickness of 1 mm or less.
- This invention relates to the manufacturing apparatus of the glass plate to which the alkali free glass which has the following compositions is applied as said molten glass in the mass percentage display of an oxide basis.
- SiO 2 50 to 73%
- Al 2 O 3 10.5 to 24%
- B 2 O 3 0 to 12%
- SrO: 0 to 24% BaO: 0 to 13.5%
- ZrO 2 0 to 5%.
- This invention relates to the manufacturing apparatus of the glass plate to which the alkali free glass which has the following compositions is applied as said molten glass in the mass percentage display of an oxide basis.
- This invention relates to the manufacturing apparatus of the glass plate to which the alkali free glass which has the following compositions is applied as said molten glass in the mass percentage display of an oxide basis.
- SiO 2 54 to 73% Al 2 O 3 : 10.5 to 22.5%
- B 2 O 3 0 to 5.5%
- the present invention relates to a method of manufacturing a glass plate in which a glass ribbon is manufactured by moving a molten glass along a moving path of a molten glass provided on the molten metal, from an upstream area to a downstream area of the moving path.
- the top roll is A barrel head that applies an outward tensile force to the widthwise end of the glass ribbon that is conveyed from the upstream region to the downstream region along the movement path, and a plurality of barrel heads provided in the midstream area of the movement path are
- the width of the nip which indicates the distance between the pressing position of the barrel head against the glass ribbon and the nearest edge of the glass ribbon, is made smaller on the downstream side than on the upstream side to reduce the glass Process for producing a glass plate for applying a tensile force to both ends of the emissions related.
- the relationship between the widths of the nip margins of a plurality of barrel heads provided in the middle flow region is defined as a region where the logarithm of the viscosity of the glass ribbon is 5.29 to 6.37 dPa ⁇ s. It is related with the manufacturing method of the glass plate concerned.
- the position of the line streak formed by the barrel head upstream of the specific barrel head from the position of the line streak formed by pressing the glass ribbon by the specific barrel head The present invention relates to a method for manufacturing a glass plate formed on the inner side of a ribbon.
- This invention relates to the manufacturing method of the glass plate which uses the alkali free glass which has the following compositions in the mass percentage display of an oxide basis as said molten glass.
- SiO 2 50 to 73%
- Al 2 O 3 10.5 to 24%
- B 2 O 3 0 to 12%
- SrO: 0 to 24% BaO: 0 to 13.5%
- ZrO 2 0 to 5%.
- This invention relates to the manufacturing method of the glass plate which uses the alkali free glass which has the following compositions in the mass percentage display of an oxide basis as said molten glass.
- This invention relates to the manufacturing method of the glass plate which uses the alkali free glass which has the following compositions in the mass percentage display of an oxide basis as said molten glass.
- SiO 2 54 to 73% Al 2 O 3 : 10.5 to 22.5%
- B 2 O 3 0 to 5.5%
- the nip margin of the barrel head installed in the middle stream region.
- the width of the glass ribbon is gradually reduced from the upstream side to the downstream side of the middle basin, and the glass ribbon position pressed by the downstream barrel head from the position of the glass ribbon pressed by the upstream barrel head is set to the glass ribbon. Therefore, the downstream barrel head extends a portion closer to the edge than the end of the glass ribbon extended by the upstream barrel head.
- the downstream barrel head pulls the edge side from the deformed portion of the glass ribbon outward.
- the glass ribbon can be molded while correcting the deformed portion of the glass ribbon.
- a thin glass ribbon can be obtained without causing a local deformation portion called a straw in the glass ribbon in the midstream region.
- transformation part is cut
- the glass ribbon in the middle basin of the float bath tends to cause a local deformation part called a straw, but the above-mentioned barrel head is used for the molten glass in the middle basin, and a tensile force is applied to the edge. Therefore, the amount of deformation in the thickness direction can be reduced on the end side of the glass ribbon, and a thin glass ribbon without a local deformation portion can be obtained.
- This glass ribbon cracks, chips, etc. There can be obtained a thin glass plate having a target dimension of 1 mm or less.
- FIG. 1 is a schematic diagram showing the overall configuration of the glass plate manufacturing apparatus according to the first embodiment of the present invention.
- FIG. 2 is a configuration diagram illustrating an example of an arrangement state of top rolls provided in the manufacturing apparatus.
- FIG. 3 is a configuration diagram illustrating a main part of an example of an arrangement state of top rolls provided in the manufacturing apparatus.
- 4 shows a barrel head applied to a top roll provided in the manufacturing apparatus,
- FIG. 4 (a) is a sectional view of a reference barrel head,
- FIG. 4 (b) is a front view of a multistage barrel head,
- FIG. 4C is a cross-sectional view of the multistage barrel head.
- FIG. 5 is a perspective view of a multistage barrel head provided in the manufacturing apparatus.
- FIG. 5 is a perspective view of a multistage barrel head provided in the manufacturing apparatus.
- FIG. 6 is a graph showing the state of viscosity at each temperature for an example of molten glass supplied to the production apparatus.
- FIG. 7 is a graph showing an example of the compressive stress distribution at the end of the glass ribbon supplied to the float bath.
- FIG. 8 is a schematic plan view showing an example of a float bath provided with a conventional top roll.
- FIG. 9 is a cross-sectional view showing an example of a state in which a barrel head provided on a conventional top roll is pushed into an end portion of a glass ribbon.
- FIG. 10 shows the relationship between the end of the molten glass and the conventional barrel head.
- FIG. 10 (a) is a sectional view showing the end of the glass ribbon
- FIG. 10 (b) is the barrel at the end of the glass ribbon.
- FIG. 10C is a cross-sectional view showing an example of a locally deformed portion (straw) having an S-shaped cross section formed on the end side of the glass ribbon.
- FIG. 11 is a cross-sectional view showing an example of a T-shaped locally deformed portion formed on the end side of the glass ribbon.
- FIG. 12 is a cross-sectional view showing an example of a locally deformed portion having an S-shaped cross section formed on the end side of the glass ribbon.
- FIG. 1 shows a schematic configuration of a glass plate manufacturing apparatus according to a first embodiment of the present invention.
- a glass plate manufacturing apparatus (float bath) 1 according to the present embodiment is a refractory furnace having a substantially rectangular shape in plan view.
- the bathtub 2 is composed of a refractory bottom structure, side walls, and an upper structure. In FIG. 1, only the bottom structure is illustrated in a plan view.
- the upper structure side of the bathtub 2 is provided with accessory equipment such as a gas supply pipe such as a non-oxidizing gas and a temperature controller, and the atmosphere of the bathtub 2 can be controlled to a non-oxidizing gas atmosphere.
- accessory equipment such as a gas supply pipe such as a non-oxidizing gas and a temperature controller, and the atmosphere of the bathtub 2 can be controlled to a non-oxidizing gas atmosphere.
- the temperature of the space portion can be controlled to a target temperature.
- an inlet portion 5 for supplying the molten glass G onto the molten metal 3 from the forehearth of the glass melting furnace provided in the previous step is provided on the left end side of the bathtub 2.
- An outlet 6 is formed at the end of the bathtub 2 opposite to the side where the inlet 5 is provided, and a plurality of transport rolls 7 are arranged outside the outlet 6 to form a slow cooling line 7A.
- a moving path 8 having a rectangular shape in plan view for forming the molten glass G is defined on the molten metal 3 from the inlet portion 5 to the outlet portion 6.
- the molten glass G flows from the inlet portion 5 onto the molten metal 3 along the movement path 8, the molten glass G is expanded to the required thickness and width to form a molten glass ribbon 9. It is gradually cooled and moved to the outlet portion 6 side to form a glass ribbon 10 as a band-like final form having a uniform width, and this glass ribbon 10 is discharged from the outlet portion 6 to the slow cooling line 7A side. .
- the planar shape of the bathtub 2 is formed in a rectangular shape
- the movement path 8 partitioned on the molten metal 3 in the bathtub 2 is also rectangular, but the plane of the movement path 8 is The shape is not limited to a rectangular shape, and any shape that matches the planar shape of the bathtub 2 is possible.
- the molten glass G supplied from the inlet portion 5 is stretched in the width direction by the above-described plurality of top rolls 11 to form the above-described molten glass ribbon 9 in the downstream region (the outlet portion 6).
- the belt-shaped glass ribbon 10 having a predetermined width is finally obtained.
- 16 top rolls 11 are arranged at predetermined intervals from positions for starting to expand the width of the molten glass G on both ends in the width direction of the movement path 8. It is arranged with a gap.
- These 16 top rolls 11 will be distinguished by attaching symbols A 0 to A 15 for the sake of convenience, and individual arrangements will be described.
- the first-stage top roll 11A 0 to the fifteenth top roll A 15 includes a reference barrel head 18 described later. It is considered as a top roll.
- the fifth top roll 11A 5 to the tenth top roll 11A 10 may be a top roll provided with a multistage barrel head 14 described later instead of the reference barrel head 18. it can.
- the first-stage top roll 11A 0 to the fifteenth top roll A 15 are configured to include a rotary shaft 17 shown in FIG. 4A and a reference barrel head 18 integrated at the tip thereof.
- the mechanism for rotationally driving each rotating shaft 17 and the mechanism for moving the rotating shaft 17 are omitted in FIGS. 1 and 2, but the rotating shaft 17 passes through the side wall of the bathtub 2 and extends to the outside of the bathtub 2.
- a rotary drive device and a moving device are provided outside the bathtub 2.
- a moving device of the rotating shaft 17 as an example, a moving device in which a rotary driving device such as a motor is provided on a moving carriage provided movably along a rail member laid outside the position where the bathtub 2 is installed is applied. it can.
- rotational driving devices and moving devices are the same as top roll driving devices and moving devices provided in a general float bath, and the rotary shaft 17 is, for example, rotationally driven in both ends of the movement path 8 in the width direction. It is arranged to be movable in the width direction of the movement path 8 on the side. In FIG. 1 to FIG. 3, these rotary drive devices and moving devices are omitted, and only the tip end side of the rotary shaft 17 and the reference barrel head 18 attached thereto are shown.
- the reference barrel head 18 includes a two-stage (two rows) outer peripheral blade 19 on the outer peripheral wall 20 a of the rotary drum 20.
- Both the rotary shaft 17 and the reference barrel head 18 have a hollow structure, and a hollow portion 17a formed inside the rotary shaft 17 and a hollow portion 20b formed inside the rotary drum 20 are communicated with each other.
- a cooling water supply pipe 17 b is provided inside the rotary shaft 17, and a cooling water return flow path 17 c is formed in a gap between the supply pipe 17 b and the inner peripheral wall of the rotary shaft 17.
- cooling water is supplied from the supply pipe 17b to the hollow portion 20b of the rotating drum 20, and the cooling water is recovered through the return flow path 17c, thereby cooling the rotating shaft 17 and the rotating drum 20 from the inside thereof. It is configured to be able to. In addition, you may change suitably the cross-sectional shape of the hollow part 20b so that a water flow may circulate efficiently.
- the outer peripheral blade 19 of the reference barrel head 18 has a plurality of quadrangular pyramid-shaped cutting edges in two stages (two rows) along the outer peripheral wall 20a of the thin cylindrical rotating drum 20. Is formed continuously. Since these outer peripheral blades 19 are formed in the circumferential direction of the rotary drum 20 with the same pitch with each blade edge having the same shape, a two-stage in which one row of outer peripheral blades 19 that make a round of the rotary drum 20 is formed as a whole. It is structured.
- the end face wall 20c on the side connected and integrated with the rotary shaft 17 side and the end face wall 20d on the front end side of the reference barrel head 18 are formed in a flat plate shape. The end wall 20c may be inclined obliquely outward from the center of the barrel head.
- the fourth top roll 11A 4 gradually cools the molten glass G flowing from the inlet portion 5 into the moving path 8 on the molten metal 3 and the viscosity starts to rise and is in a molten state. It is installed with respect to the upstream area of the movement path 8 which is the glass ribbon 9. From the fifth top roll 11A 5 to the tenth top roll 11A 10 are installed in the middle region of the moving path 8, that is, the region where the glass ribbon 9 has a higher viscosity than the upstream region. . From the eleventh top roll 11A 11 of the structure to the fifteenth top roll 11A 15 are installed in the downstream area of the moving path 8, that is, in the area where the viscosity of the glass ribbon 9 is higher than the middle flow area. ing.
- the width of the nip margin of each of the fifth top roll 11A 5 to the tenth top roll 11A 10 installed in the midstream region is determined from the upstream reference barrel head 18. Also, the width of the nip margin is such that the downstream reference barrel head 18 is gradually narrowed.
- FIG. 3 representatively shows the fifth top roll 11A 5 to the eighth top roll 11A 8 in the middle basin. The reference barrel head 18 of the fifth top roll 11A 5 is placed on the upper surface of the glass ribbon 9.
- the distance a from the pressed position to the edge of the nearest glass ribbon 9, in other words, the distance a from the position pressed to the upper surface of the glass ribbon 9 to the edge of the glass ribbon 9 along the rotation axis 17 Is defined as the width of the nip allowance.
- the width of the margin and the width of the nip margin of the eighth top roll 11A8 are set so as to decrease sequentially in this order.
- the width of the nip margin of the ninth top roll 11A 9 and the width of the nip margin of the tenth top roll 11A 10 are also successively reduced following these. Is set to
- the widths of the nip margins of the fifth top roll 11A 5 to the tenth top roll 11A 10 in the middle basin are arranged so as to be sequentially reduced.
- the width of the nip margin of the arbitrary top roll 11 on the downstream side may be made smaller than the arbitrary top roll 11 on the upstream side, so the fifth top roll 11A 5 to the tenth top roll 11A 10 , the width of the nip margin may be sequentially reduced in any number of two or more top rolls 11. Therefore, for example, the width of the nip margin may be decreased for every other top roll 11 and may be decreased intermittently.
- the width of the nip margin is sequentially reduced from the upstream side to the downstream side
- the width of the nip margin may be sequentially reduced from the upstream side to the downstream side among the plurality of top rolls 11.
- the multi-stage barrel head 14 includes six stages (six rows) of outer peripheral blades 15 on the outer peripheral wall 16a of the rotary drum 16 as shown in FIGS. 4 (b), (c), and FIG.
- Both the rotary shaft 13 and the multistage barrel head 14 have a hollow structure, and a hollow portion 13a formed inside the rotary shaft 13 and a hollow portion 16b formed inside the rotary drum 16 are communicated with each other.
- a cooling water supply pipe 13 b is provided inside the rotary shaft 13, and a cooling water return flow path 13 c is formed in a gap between the supply pipe 13 b and the inner peripheral wall of the rotary shaft 13.
- the cooling water is supplied from the supply pipe 13b to the hollow portion 16b of the rotating drum 16, and the cooling water is recovered through the return flow path 13c, whereby the rotating shaft 13 and the rotating drum 16 are connected from the inside thereof. It is configured to be cooled.
- the outer peripheral blade 15 of the multi-stage barrel head 14 has a number of quadrangular pyramid-shaped cutting edges of six stages (see FIGS. 4B, 4C, and 5) along the outer peripheral wall 16a of the cylindrical rotary drum 16. (6 rows). Since these outer peripheral blades 15 are formed in the circumferential direction of the rotating drum 16 with the same pitch with each blade edge having the same shape, six rows of outer peripheral blades 15 that make one row around the rotating drum 16 are formed in total. It is structured.
- the end face wall 16c on the side connected and integrated with the rotary shaft 13 side and the end face wall 16d on the front end side of the multistage barrel head 14 are formed in a flat plate shape.
- the outer peripheral blade 15 formed in the multistage barrel head 14 is not limited to a six-stage structure, and may have any number of stages of three stages, four stages, five stages, or seven stages or more. However, if the number of stages is increased more than necessary, the glass ribbon 9 is unnecessarily cooled. Therefore, it is desirable that the number of stages is such that the glass ribbon 9 is not overcooled, and the number of stages is 3 or more, for example, about 4 to 8. *
- FIG. 6 shows a state in which a general non-alkali glass molten glass changes in viscosity as the temperature decreases and becomes hard and becomes a glass ribbon.
- the region where the common logarithm of the viscosity ( ⁇ ) of the glass ribbon 9 is less than 5.29 is the upstream region of the movement path 8, and the common logarithm of the viscosity of the glass ribbon 9 is 5.29.
- the region of ⁇ 6.37 can be defined as the midstream region of the movement path 8, and the region where the common logarithm of the viscosity of the glass ribbon 9 exceeds 6.37 can be defined as the downstream area of the movement path 8.
- the region where the logarithm of the viscosity of the glass ribbon 9 is 5.29 to 6.37 corresponds to the region where the viscosity ( ⁇ ) of the glass ribbon 9 is 10 5.29 to 10 6.37 dPa ⁇ s. .
- the top rolls 11A 0 to 11A 15 are not directed parallel to the width direction of the glass ribbon 9, but are inclined with a slight angle.
- the moving direction of the glass ribbon 9 in the moving path 8 (the direction parallel to the side wall of the bathtub 2 from the inlet portion 5 toward the outlet portion 6) is the Y-axis direction, and the moving path 8
- An XY coordinate system defining the width direction as the X-axis direction is assumed, and a plane including the outer peripheral blades 19 of each row of the reference barrel head 18 or a plane including the outer peripheral blades 19 of each row of the reference barrel head 18 is assumed. .
- the plane 19a including the outer peripheral blades 19 aligned in the circumferential direction of the reference barrel head 18 shown in FIG. 2 or the plane including the outer peripheral blades 19 aligned in the circumferential direction of the reference barrel head 18 is the Y axis.
- it is inclined in plan view so as to have an inclination angle ( ⁇ ) of about 0 to 16 °.
- ⁇ inclination angle
- the outer peripheral blade 19 of the reference barrel head 18 or the outer peripheral blade 19 of the reference barrel head 18 is pressed against the glass ribbon 9 almost vertically from above.
- the rotary shafts 13 and 17 of the barrel heads 14 and 18 are movable so that the barrel heads 14 and 18 can be pressed against the end of the glass ribbon 9 by moving up and down while being arranged almost horizontally. Is provided.
- the inclination angle is gradually increased from the first top roll 11A 1 to each gradually increasing angle.
- the barrel head is arranged, the inclination angle is increased to the maximum inclination angle in the middle basin, and the inclination angle is gradually decreased in the reference barrel head 18 of the top roll in the downstream area.
- the tilt angle is set to 0 °.
- the inclination arrangement state of each barrel head is not limited to the example described here, and any inclination arrangement having the maximum inclination angle may be employed in the reference barrel head 18 provided in the midstream area.
- the molten glass G is supplied from the inlet portion 5 to the moving path 8 on the molten metal 3 to be spread and provided in plural.
- the glass ribbon 9 is pressed against the both ends in the width direction while pressing the molten glass ribbon 9 using the reference barrel head 18 to adjust the width and thickness of the glass ribbon 9 to the final.
- a glass ribbon 10 having a target width can be obtained.
- a glass plate can be obtained by cutting this glass ribbon 10 to a target size in a subsequent cutting step of the slow cooling line 7A.
- the outer peripheral blade 19 having a two-stage structure is pressed against the end of the glass ribbon 9 in the width direction.
- the glass ribbon 9 is expanded by rotating the reference barrel head 18 of each of the top rolls so that necessary tensile forces are applied outwardly to both ends in the width direction of the glass ribbon 9 in the upstream region, the midstream region, and the downstream region. can do.
- the reference barrel head downstream of the upstream reference barrel head 18 with respect to the width of the nip allowance of each of the fifth top roll 11A 5 to the tenth top roll 11A 10 The width of the nip is such that 18 is gradually reduced.
- FIG. 3 shows the fifth top roll 11A 5 to the eighth top roll 11A 8 in the middle basin.
- Each of the top rolls 11A 5 to 11A 8 moves the individual rotating shaft 17 along the arrows T 5 to T in FIG.
- a tensile force having a desired size is applied to the end of the glass ribbon 9 to expand the width of the glass ribbon 9.
- the locus of the line streak drawn on the upper surface of the glass ribbon 9 by the upstream reference barrel head 18 (the reference barrel head 18 with the cutting edge of the outer peripheral blade 19 pressed against the upper surface of the glass ribbon 9.
- the trajectory of the streak drawn on the upper surface of the glass ribbon 9 by the reference barrel head 18 on the downstream side of the trajectory of the streak imprinted on the upper surface of the glass ribbon 9 by the rotation of the glass ribbon 9 is closer to the edge of the glass ribbon 9 It is drawn at the position. That is, as shown in FIG. 3, the streak A 6 drawn by the sixth top roll 11A 6 is closer to the edge of the glass ribbon 9 than the streak A 5 drawn by the fifth top roll 11A 5 .
- the streak A 7 drawn by the seventh top roll 11A 7 is drawn at a position closer to the edge of the glass ribbon 9 than the streak A 6 drawn by the sixth top roll 11A 6. .
- the line marks A 5 to A 10 are formed intermittently at intervals so as to gradually approach the edge of the glass ribbon 9.
- the fifth top roll 11A 5 on the upstream side presses the end of the glass ribbon 9 and pulls the pressing portion outward
- the sixth top roll 11A 6 on the downstream side is the glass.
- the cross sections of the state in which the end portion of the ribbon 9 is pressed and the pressed portion is pulled outward are shown in the region surrounded by the two-dot chain line in FIG.
- the fifth top roll 11 ⁇ / b> A 5 located on the upstream side in the midstream region is in a position where a tensile force is applied to the outside while deforming the end of the glass ribbon 9 in a convex shape downward.
- the position where the sixth top roll 11A 6 on the downstream side applies the tensile force to the outside with respect to the end of the glass ribbon 9 is the outer position of the glass ribbon 9, so Even if the top roll 11A 5 has formed a deep recess 9A in the glass ribbon 9, if the sixth top roll 11A 6 on the downstream side exerts a tensile force on the outside of the end of the glass ribbon 9, this Since the tensile force is applied in the direction in which the concave portion 9A is stretched and disappeared, the concave portion 9A can be eliminated or reduced.
- the glass ribbon 9 can be formed while sequentially eliminating the recesses 9A that are to occur at the end of the ribbon 9. Therefore, even when trying to manufacture an extremely thin glass ribbon 9 such as 1 mm or less as compared with the conventional apparatus, a local deformation portion called a straw does not occur on the end side in the width direction of the molten glass G.
- the molten glass G thinly stretched using the top rolls 11A 1 to 11A 15 is gradually cooled as it moves from the upstream area to the downstream area of the movement path 8 to increase its hardness. It becomes the glass ribbon 10 of a fixed width and thickness, reaches the outlet 6 and is conveyed to the slow cooling line 7A side in the subsequent process.
- a local deformation portion is not generated in the glass ribbon 10 that has been conventionally transported to the slow cooling line 7A while a local deformation portion called a straw is formed. Therefore, there is no possibility that the glass ribbon 10 breaks in the slow cooling line 7A.
- a cutting line (not shown) is installed in the subsequent process of the slow cooling line 7A, a glass plate having a desired size is obtained by cutting and folding the glass ribbon 10 after the slow cooling to a required size. be able to. Since the local deformation
- the reference barrel head 18 having a two-stage structure is used for the holding amount of the glass ribbon 9 (the amount by which the molten glass G is deformed in the thickness direction). Can be shallower than the case.
- the multi-stage barrel head 14 has the width direction end of the glass ribbon 9.
- the amount of deformation in the thickness direction (pressing margin) is reduced. Therefore, compared with the conventional apparatus in which a strong tensile force is applied to the glass ribbon 9 with a two-stage outer peripheral blade in the middle stream region, the molten glass G
- the local deformation part called a straw does not arise in the width direction edge part side of this.
- the glass ribbon 9 in the upstream region has a low viscosity and it is difficult to apply a strong tensile force from the beginning, so the reference barrel head 18 may be used.
- the glass ribbon 9 in the downstream region has a high viscosity and is almost in a hard state. Even if it is pressed, the amount of deformation in the thickness direction is small.
- the arrangement relationship of the reference barrel heads 18 in the middle basin is specially arranged as shown in FIG. 3, but the necessary number of barrel heads provided in the middle basin is defined as the multistage barrel head 14 in FIG.
- the reference barrel head 18 having the arrangement shown in FIG.
- the arrangement of the reference barrel head 18 shown in FIG. It can also be provided. By adopting such an arrangement configuration, it is possible to more effectively prevent a locally deformed portion called a straw.
- the number of the multistage barrel heads 14 provided in the middle stream is not particularly defined in the present embodiment, and a necessary number of the glass ribbons 10 having a final thickness can be provided. Further, the total number of reference barrel heads 18 provided in the entire region from the upstream region to the downstream region is not limited by the example of the present embodiment, and the number necessary for forming the glass ribbon 10 having a target thickness is not limited. Install it.
- any of non-alkali glass, soda lime glass, mixed alkali glass, borosilicate glass, or other glass may be used.
- the use of the manufactured glass product is not limited to flat panel display use, architectural use, and vehicle use, and includes various other uses. In particular, alkali-free glass for flat panel displays that requires high quality is preferred.
- an alkali-free glass having the following composition in the oxide-based mass percentage display can be used.
- SiO 2 50 to 73%, preferably 50 to 66%
- Al 2 O 3 10.5 to 24%
- B 2 O 3 0 to 12%
- SrO: 0 to 24% BaO: 0 to 13.5%
- ZrO 2 0 to 5%.
- an alkali-free glass having the following composition can be used in the oxide-based mass percentage display.
- SiO 2 58 to 66%
- Al 2 O 3 15 to 22%
- B 2 O 3 5 to 12%
- CaO 0 to 9%
- SrO 3 to 12.5%
- BaO 0 to 2%
- MgO + CaO + SrO + BaO 9 to 18%
- ZrO 2 0 to 5%.
- an alkali-free glass having the following composition can be used in the oxide-based mass percentage display.
- SiO 2 54-73% Al 2 O 3 : 10.5 to 22.5%
- B 2 O 3 0 to 5.5%
- CaO 0-9%
- SrO 0 to 16%
- BaO 0 to 2.5%
- FIG. 6 is a graph showing an example of the relationship between the temperature and viscosity of an alkali-free glass.
- a glass ribbon When a glass ribbon is formed, each molten glass at a temperature of about 1110 ° C. to 1120 ° C. is formed and the temperature is gradually lowered. The relationship of the viscosity in temperature is shown.
- the region in front of the region where the common logarithm of the viscosity ( ⁇ ) of the glass ribbon 9 is 5.29 dPa ⁇ s is the upstream region, and the common logarithm of the viscosity of the glass ribbon 9 is 5.29 to 6.37 dPa.
- the region of s can be divided into the middle flow region, and the region where the common logarithm of the viscosity of the glass ribbon 9 exceeds 6.37 dPa ⁇ s can be distinguished from the downstream region, the upstream region and the downstream region as described in the above embodiment It is possible to provide the reference barrel head 18 and the multistage barrel head 14 in the middle stream area.
- the molten glass having the viscosity characteristics shown in FIG. 6 is applied to a molding apparatus provided with 16 reference barrel heads shown in FIGS. 1 and 2, and the width is about 80 inches (about 2.28 m) to about 110 inches (about 3 inches). 0.05 m), and a glass ribbon having a thickness of 0.3 mm was produced. The width of the following nip margin was set for the seventh top roll to the ninth top roll.
- the top roll L-0 is the first stage, the first top roll L-1 to the fifteenth top roll L-15.
- the barrel heads of the top rolls of L-0 to L-3 are inclined stepwise from 0 ° to 15 °, and the top rolls of L-4 to L-8 are inclined.
- An inclination angle condition of 12 to 15 ° is given to the barrel head, and the inclination of the top roll barrel heads up to L9-L-13 is gradually reduced to 0 ° for the top rolls after L-11. did.
- Nip width of the seventh top roll 155 mm
- the width of the nip margin of the eighth top roll 140 mm
- Nip width of the 9th top roll 120mm
- Nip width of the seventh top roll 125 mm
- the width of the nip margin of the eighth top roll 140 mm
- the width of the nip margin of the ninth top roll 155 mm
- FIG. 7 shows the stress distribution at the pressing position of each barrel head at the end of the glass ribbon when the reference barrel head is provided on all the top rolls shown above and the glass ribbon is formed as the arrangement of the comparative case described above. It is a figure which shows the result of having calculated
- the technology of the present invention can be widely applied to apparatuses and methods for producing glass plates used in display glass, optical glass, medical glass, architectural glass, vehicle glass, and other general glass products.
- G ... Molten glass, 1 ... Manufacturing apparatus (float bath), 2 ... Bath, 3 ... Molten metal, 5 ... Inlet part, 6 ... Outlet part, 7 ... Conveyance roll, 7A ... Slow cooling line, 8 ... Movement path, 9 Glass ribbon, 10 ... Glass ribbon, 11 ... Top roll, 11A 0 to 11A 15 ... Top roll, 13 ... Rotating shaft, 14 ... Multi-stage barrel head, 16 ... Rotating drum, 17 ... Rotating shaft, 18 ... Reference barrel head, 20 ... Rotating drum, 30 ... Multi-stage barrel head, a ... Width of nip allowance.
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Abstract
Description
この種のガラス基板の製造方法の一例として、金属スズなどの溶融金属を貯留したフロートバスを用い、溶融金属の上に水平方向に溶融ガラスを薄く引き延ばして成形するフロート法が知られている。このフロート法によれば、溶融ガラスをフロートバスの溶融金属上に浮かせることで目的に応じた必要な厚みを確保し、この溶融ガラスを水平方向に引き出すことで帯状のガラスリボンを成形できる。このガラスリボンを必要な大きさに切断することで目的の大きさのガラス基板を得ることができる。
このフロート法に従い、上述のように大型化と薄型化が進められているガラス基板を製造するには、フロートバスの溶融金属上にガラスリボンの幅方向両端部を外側に引っ張るトップロールと称される成形装置を設け、ガラスリボンをその幅方向両端側に引き延ばして薄型化する方法が採用されている。薄く引き延ばしたガラスリボンを徐冷後に必要な大きさに切断し、研磨および洗浄を行うことで目的のガラス基板を得ることができる。このフロート法に従い、大型かつ薄型のガラス基板が大量に生産されており、ガラス基板として厚さ0.7mm程度、長さと幅が数mに達する大型のガラス基板が生産されている。
この種のフロートバス100に適用されているトップロール105の一例として、図9に示すように円盤状に形成され、その外周に鋸刃状の外周刃105aを2段に備えたバレルヘッド105Aを備えたトップロールが知られている。(特許文献1参照)
図9に示すバレルヘッド105Aは、外周刃105a、105aを溶融ガラス103のエッジ部103aに食い込ませつつエッジ部103aに外向きの引張力を作用させ、溶融ガラス103の幅を調整することによりガラスリボン106の幅と厚さを調整することができる。
従来、フロートバス100に流し込まれて拡げられた直後の溶融ガラス103は、高温で液状であるために、簡単に引っ張ることはできないが、溶融ガラス103はフロートバス100の上流域から下流域に移動するにつれて徐冷され、徐々に粘性が高くなるので、粘性が高くなった溶融ガラス103をバレルヘッド105Aにより引っ張り、拡げることができる。
しかし、流れ方に引張力が作用された溶融ガラス103には縮まろうとする性質があるため、溶融ガラス103を薄くしようとすればするほど、より強い力でガラスを押さえ付け、強い引張力を作用させる必要がある。
図10は、溶融ガラス103のエッジ部103aに対し強い力で上からバレルヘッド105Aを押し付けた状態を説明するための図である。
図10(a)に示す溶融ガラス103のエッジ部103aに対し図10(b)に示すようにバレルヘッド105Aを強く押し付けると、エッジ部103aがバレルヘッド105Aの押しつけ力に比例して深く沈み込むようにU字形の袋状に変形する。仮に、この袋状態のまま変形したガラスが固まると、図11に示すように断面T字形のストローと称される局所変形部110が生成する問題がある。
前記局所変形部110、111を有したままガラスリボンを切断工程において切断すると、目的の大きさのガラス板に切り折りする場合において、目的の切断位置や方向と異なる位置や方向に割れを誘発するので、ガラス板の安定生産を阻害するおそれがある。前記局所変形部110、111が生成されるのは、薄いガラス板において顕著であり、特に上述の表示装置用ガラス基板のように厚さ1mm以下のガラス板をフロート法により製造する場合に顕在化する問題がある。
本発明は、フロート法により薄いガラスリボンを成形する場合、局所変形部を生じさせることなくガラスリボンを製造することができ、ガラス板の安定生産に寄与する製造装置と製造方法の提供を目的とする。
本発明は、特定の前記バレルヘッドが前記ガラスリボンを押圧して形成する線条痕の位置より、当該特定のバレルヘッドよりも上流側のバレルヘッドにより形成された線条痕の位置が、前記ガラスリボンの内側寄りに形成されるガラス板の製造装置に関する。
本発明は、前記フロートバスにより成形されるガラスリボンの厚さが1mm以下であるガラス板の製造装置に関する。
SiO2:50~73%、Al2O3:10.5~24%、B2O3:0~12%、MgO:0~8%、CaO:0~14.5%、SrO:0~24%、BaO:0~13.5%、MgO+CaO+SrO+BaO:9~29.5%、ZrO2:0~5%。
本発明は、前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスが適用されるガラス板の製造装置に関する。
SiO2:58~66%、Al2O3:15~22%、B2O3:5~12%、MgO:0~8%、CaO:0~9%、SrO:3~12.5%、BaO:0~2%、MgO+CaO+SrO+BaO:9~18%、ZrO2:0~5%。
本発明は、前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスが適用されるガラス板の製造装置に関する。
SiO2:54~73%
Al2O3:10.5~22.5%
B2O3:0~5.5%
MgO:0~8%
CaO:0~9%
SrO:0~16%
BaO:0~2.5%
MgO+CaO+SrO+BaO:8~26%
本発明は、前記特定のバレルヘッドが前記ガラスリボンを押圧して形成する線条痕の位置より、当該特定のバレルヘッドよりも上流側のバレルヘッドが形成する線条痕の位置を、前記ガラスリボンの内側寄りに形成するガラス板の製造方法に関する。
SiO2:50~73%、Al2O3:10.5~24%、B2O3:0~12%、MgO:0~8%、CaO:0~14.5%、SrO:0~24%、BaO:0~13.5%、MgO+CaO+SrO+BaO:9~29.5%、ZrO2:0~5%。
本発明は、前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いるガラス板の製造方法に関する。
SiO2:58~66%、Al2O3:15~22%、B2O3:5~12%、MgO:0~8%、CaO:0~9%、SrO:3~12.5%、BaO:0~2%、MgO+CaO+SrO+BaO:9~18%、ZrO2:0~5%。
本発明は、前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いるガラス板の製造方法に関する。
SiO2:54~73%
Al2O3:10.5~22.5%
B2O3:0~5.5%
MgO:0~8%
CaO:0~9%
SrO:0~16%
BaO:0~2.5%
MgO+CaO+SrO+BaO:8~26%
この結果、中流域のガラスリボンにおいてストローと称される局所変形部を生じさせることなく薄いガラスリボンを得ることができる。そして、局所変形部を生じていないガラスリボンを後工程において切断してガラス板とするので、割れや欠けなどを生じることなく、目的の寸法のガラス板を得ることができる。
以下、添付図面を参照して本発明に係るガラス板の製造装置の第一実施形態について説明するが、本発明は以下に説明する実施形態に制限されるものではない。
図1は本発明に係るガラス板の製造装置の第一実施形態の概略構成を示すもので、本実施形態のガラス板の製造装置(フロートバス)1は、平面視略長方形状の耐火物炉からなる浴槽2と、この浴槽2の内部に収容されている金属スズなどの溶融金属3と、浴槽2の内部に複数配置されているトップロール11を備えている。
浴槽2は、耐火物製の底部構造と側壁と上部構造からなるが、図1では底部構造のみを平面視した状態で描いている。浴槽2の上部構造側には、非酸化性ガスなどのガス供給管や温度調節器などの付属設備が設けられ、浴槽2の雰囲気を非酸化性ガス雰囲気に制御でき、溶融金属3の上の空間部分の温度を目的の温度に制御できるようになっている。
浴槽2において入口部5から出口部6にかけて溶融金属3の上には、溶融ガラスGを成形するための平面視長方形状の移動経路8が区画されている。
この移動経路8に沿って溶融金属3の上に入口部5から溶融ガラスGが流入されると、溶融ガラスGが必要な厚さと幅に拡げられて溶融状態のガラスリボン9とされた状態で徐々に冷却されて出口部6側に移動され、幅が均一化された帯状の最終形態としてのガラスリボン10が形成され、このガラスリボン10が出口部6から徐冷ライン7A側に排出される。本実施形態において、浴槽2の平面形状が長方形状に形成されているので、浴槽2の内部において溶融金属3上に区画される移動経路8も長方形状にされているが、移動経路8の平面形状は長方形状に限らず、浴槽2の平面形状に合わせた任意の形状が可能である。
これらトップロール11のうち、初段のトップロール11A0~第15番目のトップロールA15(即ちトップロール11A15は初段のトップロール11Aoから数えると16番目)が後に説明する基準バレルヘッド18を備えたトップロールとされている。なお、本実施形態においては、第5番目のトップロール11A5~第10番目のトップロール11A10として、基準バレルヘッド18に代えて後に説明する多段バレルヘッド14を備えたトップロールとすることもできる。
各回転軸17を回転駆動する機構と回転軸17を移動させる機構については、図1と図2において略されているが、回転軸17は浴槽2の側壁を貫通して浴槽2の外側にまで略水平に延出され、浴槽2の外側に回転駆動装置と移動装置が設けられている。回転軸17の移動装置については、一例として浴槽2を設置した位置の外側に敷設したレール部材に沿って移動自在に設けられた移動台車にモーターなどの回転駆動装置が設けられた移動装置を適用できる。これらの回転駆動装置や移動装置は一般的なフロートバスに設けられているトップロールの駆動装置や移動装置と同等であり、回転軸17は例えば回転駆動された状態で移動経路8の幅方向両端側において移動経路8の幅方向に移動自在に配置されている。図1~図3においてはこれらの回転駆動装置や移動装置は略し、回転軸17の先端側とそこに取り付けられている基準バレルヘッド18のみを示している。
前記第5番目のトップロール11A5から、第10番目のトップロール11A10は、前記移動経路8の中流域、即ち、ガラスリボン9が上流域よりも粘度が高くなる領域に対し設置されている。
前記構造の第11番目のトップロール11A11から、第15番目のトップロール11A15は、前記移動経路8の下流域、即ち、ガラスリボン9の粘度が中流域より更に高くなる領域に対し設置されている。
この定義に従い、ニップ代の幅について、第5番目のトップロール11A5のニップ代の幅と、第6番目のトップロール11A6のニップ代の幅と、第7番目のトップロール11A7のニップ代の幅と、第8番目のトップロール11A8のニップ代の幅がこの順で順次小さくなるように設定されている。なお、図3では略しているが、更に、第9番目のトップロール11A9のニップ代の幅と、第10番目のトップロール11A10のニップ代の幅も同様にこれらに続いて順次小さくなるように設定されている。
図6に示す粘度の変化を示す状態において、ガラスリボン9の粘度(η)の常用対数が5.29未満の領域を移動経路8の上流域、ガラスリボン9の粘度の常用対数が5.29~6.37の領域を移動経路8の中流域、ガラスリボン9の粘度の常用対数が6.37を超える領域を移動経路8の下流域と定義できる。なお、ガラスリボン9の粘度の対数が5.29~6.37の領域とは、ガラスリボン9の粘度(η)が105.29~106.37dPa・sの領域に対応している。
本実施形態の製造装置1において、第5番目のトップロール11A5~第10番目のトップロール11A10のそれぞれのニップ代の幅について、上流側の基準バレルヘッド18よりも下流側の基準バレルヘッド18の方が順次小さくなるようなニップ代の幅となっている。図3に中流域の第5番目のトップロール11A5~第8番目のトップロール11A8を示すが、各トップロール11A5~11A8は個々の回転軸17を図3の矢印T5~T8方向に移動させることでガラスリボン9の端部に目的の大きさの引張力を印加し、ガラスリボン9の幅を拡張する。
また、下流側に設けられている以降のトップロール11A7~11A10についても同様の作用をなすので、本実施形態に示すトップロール11A5~11A10の配置であるならば、中流域においてガラスリボン9の端部に生じようとする凹部9Aを順次解消しつつガラスリボン9を成形できる。
よって、従来装置に比べ、1mm以下などのように極めて薄いガラスリボン9を製造しようとした場合であっても溶融ガラスGの幅方向端部側にストローと称される局所変形部を生じない。
また、徐冷ライン7Aの後工程には図示略の切断ラインが設置されているので、徐冷後のガラスリボン10を必要な大きさに切り折りすることによって目的の大きさのガラス板を得ることができる。この切断ラインに送るガラスリボン10に局所変形部を生成していないので、切り折りする切断の際に切断不良箇所を生じるおそれが無く、生産性の向上に寄与する。
このため、本実施形態では中流域の基準バレルヘッド18の配置関係を図3に示すように特別な配置としたが、中流域に設けるバレルヘッドの必要な個数を多段バレルヘッド14として、図3に示す配置とした基準バレルヘッド18と一部置き換えて共用することも可能である。
この点に鑑み、中流域においてガラスリボン9に強い引張力を作用させてガラスリボン9を引き延ばすので、中流域において図3に示す基準バレルヘッド18の配置を採用した上に、多段バレルヘッド14を設けることも可能となる。このような配置構成とすることにより、より効果的にストローと称される局所変形部を生じないようにできる。
また、上流域~下流域の全域に設ける基準バレルヘッド18の全個数についても本実施形態の例に規制される訳ではなく、目的の厚さのガラスリボン10を成形するために必要な数を設置すればよい。
従って、無アルカリガラス、ソーダライムガラス、混合アルカリ系ガラス、またはホウケイ酸ガラス、あるいは、その他のガラスのいずれであってもよい。また、製造されるガラス製品の用途は、フラットパネルディスプレイ用、建築用や車両用に限定されず、その他の各種用途が挙げられる。特に高品質が求められるフラットパネルディスプレイ用の無アルカリガラスが好ましい。
SiO2:50~73%好ましくは50~66%、Al2O3:10.5~24%、B2O3:0~12%、MgO:0~8%、CaO:0~14.5%、SrO:0~24%、BaO:0~13.5%、MgO+CaO+SrO+BaO:9~29.5%、ZrO2:0~5%。
前記溶融ガラスGに好適なガラスとして、歪点が高く溶解性を考慮する場合は、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いることができる。
SiO2:58~66%、Al2O3:15~22%、B2O3:5~12%、MgO:0~8%、CaO:0~9%、SrO:3~12.5%、BaO:0~2%、MgO+CaO+SrO+BaO:9~18%、ZrO2:0~5%。
前記溶融ガラスGに好適なガラスとして、特に高歪点を考慮する場合は、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いることができる。
SiO2:54~73%、
Al2O3:10.5~22.5%、
B2O3:0~5.5%、
MgO:0~8%、
CaO:0~9%、
SrO:0~16%、
BaO:0~2.5%、
MgO+CaO+SrO+BaO:8~26 %。
図6に示すようにガラスリボン9の粘度(η)の常用対数が5.29dPa・sとなる領域の手前の領域を上流域、ガラスリボン9の粘度の常用対数が5.29~6.37dPa・sの領域を中流域、ガラスリボン9の粘度の常用対数が6.37dPa・sを超える領域を下流域と区分けすることができるので、上述した実施形態で説明したように上流域と下流域に基準バレルヘッド18を設け、中流域に多段バレルヘッド14を設けることができる。
第7番目のトップロールから第9番目のトップロールについて以下のニップ代の幅に設定した。
各トップロールの傾斜角度θについては、L-0~L-3のトップロールのバレルヘッドについて0゜~15゜まで段階的に傾斜を付与し、L-4~L-8までのトップロールのバレルヘッドについて12~15゜の傾斜を付与し、L9-L-13までのトップロールのバレルヘッドについて段階的に傾斜を少なくしてL-11以降のトップロールについて0゜とする傾斜角度条件とした。
第8番目のトップロールのニップ代の幅:140mm
第9番目のトップロールのニップ代の幅:120mm
以上の条件にて厚さ0.3mmのガラスリボンを24時間生産したところ、ストローと称される局所変形部を生じることなくガラスリボンの生産が可能であり、このガラスリボンを徐冷して切り折りすることで厚さ0.3mmのガラス板を生産することができた。
第7番目のトップロールのニップ代の幅:125mm
第8番目のトップロールのニップ代の幅:140mm
第9番目のトップロールのニップ代の幅:155mm
以上の条件のようにニップ代の幅を下流側のトップロール程大きくして厚さ0.3mmのガラスリボンを生産したところ、連続的にストローと称される局所変形部を生じた。
以上の対比から、中流域に設ける複数のトップロールのニップ代の幅について、下流側のニップ代の幅ほど小さくすることが有効であると判明した。
図7に示す結果から、No.4(L-4)~No.11(L-11)の各トップロールについて各位置のガラスリボンに作用する応力分布の状態を解析した結果、本発明者が想定しているストローと称される局所変形部が発生すると予想される鎖線で示す境界値Rに対し、No.5(L-5)~No.10(L-10)の位置において顕著な応力分布となるので、このシュミュレーション結果から見ても、中流域のトップロールについてニップ代を調整することが有効であることが分かる。
Claims (13)
- 溶融金属が蓄えられ、該溶融金属上に溶融ガラスの移動経路が形成され、該移動経路の上流域から下流域にかけて溶融ガラスを移動させてガラスリボンを成形するためのフロートバスと、このフロートバス内の移動経路の上流域から下流域にかけて移動経路の幅方向両側に配設された複数対のトップロールとを備え、
前記トップロールが、溶融ガラスの移動経路の幅方向両側に個々に水平方向に延在された回転軸と、該回転軸の先端側に取り付けられ、前記移動経路に沿って上流域から中流域を経て下流域に搬送されるガラスリボンの幅方向端部に押し付けられるバレルヘッドを備え、
前記ガラスリボンに押し付けられて該ガラスリボンの幅方向端部に外向きの引張力を作用させる前記移動経路の中流域の複数のバレルヘッドは、前記ガラスリボンに対するバレルヘッドの押圧位置とガラスリボンの直近端縁との距離を示すニップ代の幅が、上流側よりも下流側において小さいガラス板の製造装置。 - 前記ガラスリボンの粘度の対数が5.29~6.37dPa・sの領域を中流域として、この中流域に設けられている複数のバレルヘッドのニップ代の幅の大小関係が前記の関係を満足する請求項1に記載のガラス板の製造装置。
- 特定の前記バレルヘッドが前記ガラスリボンを押圧して形成する線条痕の位置より、当該特定のバレルヘッドよりも上流側のバレルヘッドにより形成された線条痕の位置が、前記ガラスリボンの内側寄りに形成される請求項1または2に記載のガラス板の製造装置。
- 前記フロートバスにより成形されるガラスリボンの厚さが1mm以下である請求項1~3のいずれか一項に記載のガラス板の製造装置。
- 前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスが適用される請求項1~4のいずれか一項に記載のガラス板の製造装置:
SiO2:50~73%、
Al2O3:10.5~24%、
B2O3:0~12%、
MgO:0~8%、
CaO:0~14.5%、
SrO:0~24%、
BaO:0~13.5%、
MgO+CaO+SrO+BaO:9~29.5%、及び
ZrO2:0~5%。 - 前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスが適用される請求項1~4のいずれか一項に記載のガラス板の製造装置:
SiO2:58~66%、
Al2O3:15~22%、
B2O3:5~12%、
MgO:0~8%、
CaO:0~9%、
SrO:3~12.5%、
BaO:0~2%、
MgO+CaO+SrO+BaO:9~18%、及び
ZrO2:0~5%。 - 前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスが適用される請求項1~4のいずれか一項に記載のガラス板の製造装置:
SiO2:54~73%、
Al2O3:10.5~22.5%、
B2O3:0~5.5%、
MgO:0~8%、
CaO:0~9%、
SrO:0~16%、
BaO:0~2.5%、及び
MgO+CaO+SrO+BaO:8~26%。 - 溶融金属の上に設けた溶融ガラスの移動経路に沿って溶融ガラスを移動させつつ成形してガラスリボンを製造するガラス板の製造方法において、
前記移動経路の上流域から下流域にかけて移動経路の幅方向両端側に配設した複数対のトップロールによりガラスリボンの両端部に外向きの引張力を作用させて厚さ1mm以下のガラスリボンを製造する際、
前記トップロールは、前記移動経路に沿って上流域から下流域に搬送されるガラスリボンの幅方向端部に外向きの引張力を作用させるバレルヘッドを備え、
前記移動経路の中流域に設けられた複数のバレルヘッドは、前記ガラスリボンに対するバレルヘッドの押圧位置とガラスリボンの直近端縁との距離を示すニップ代の幅を、上流側よりも下流側において小さくしてガラスリボンの両端部に引張力を作用させるガラス板の製造方法。 - 前記ガラスリボンの粘度の対数が5.29~6.37dPa・sの領域を中流域としてこの中流域に設けられている複数のバレルヘッドのニップ代の幅の大小関係を前記の関係とする請求項8に記載のガラス板の製造方法。
- 前記特定のバレルヘッドが前記ガラスリボンを押圧して形成する線条痕の位置より、当該特定のバレルヘッドよりも上流側のバレルヘッドが形成する線条痕の位置を、前記ガラスリボンの内側寄りに形成する請求項8または9に記載のガラス板の製造方法。
- 前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いる請求項8~10のいずれか一項に記載のガラス板の製造方法:
SiO2:50~73%、
Al2O3:10.5~24%、
B2O3:0~12%、
MgO:0~8%、
CaO:0~14.5%、
SrO:0~24%、
BaO:0~13.5%、
MgO+CaO+SrO+BaO:9~29.5%、及び
ZrO2:0~5%。 - 前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いる請求項8~10のいずれか一項に記載のガラス板の製造方法:
SiO2:58~66%、
Al2O3:15~22%、
B2O3:5~12%、
MgO:0~8%、
CaO:0~9%、
SrO:3~12.5%、
BaO:0~2%、
MgO+CaO+SrO+BaO:9~18%、及び
ZrO2:0~5%。 - 前記溶融ガラスとして、酸化物基準の質量百分率表示において、以下の組成を有する無アルカリガラスを用いる請求項8~10のいずれか一項に記載のガラス板の製造方法:
SiO2:54~73%、
Al2O3:10.5~22.5%、
B2O3:0~5.5%、
MgO:0~8%、
CaO:0~9%、
SrO:0~16%、
BaO:0~2.5%、及び
MgO+CaO+SrO+BaO:8~26%。
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