Calendering roller and production method thereof

Abstract

The invention relates to the technical field of glass production equipment, in particular to a calendering roller and a production method thereof.The roller comprises a roller core, a transition layer and a rolling layer which are sequentially arranged from inside to outside, the roller core is used as a basic support, a cooling partition wall is arranged in the roller core, cooling channels are formed in the two ends of the cooling partition wall, and the transition layer is arranged between the transition layer and the rolling layer. By adopting the design that a multi-layer composite structure is matched with the two-way cooling channel, symmetrical cooling loops are formed through separation of the cooling partition walls in the roller core, directional medium flowing is achieved in combination with a pipeline system connected with the plugs, the axial temperature gradient of the roller is effectively controlled, and the cooling effect of the roller is improved. Meanwhile, due to the combined design of the transition layer and the rolling layer, the structural strength and the surface performance are considered, and the thermal stability and the molten glass corrosion resistance under the high-temperature working condition are remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of glass production equipment, and particularly relates to a calender roller and a production method thereof. BACKGROUND

[0002] With the rapid development of the fields of consumer electronics, semiconductor packaging, etc., thin plate glass is increasingly widely applied in high-end manufacturing such as mobile phone cover plates, wafer level packaging (WLP), display panels, etc. The traditional production mode of thin plate glass usually adopts the process of strip forming and cutting and opening, but this mode has problems such as low production efficiency, large material loss, high processing cost, etc., and it is difficult to meet the growing market demand.

[0003] In order to improve the production efficiency and reduce the manufacturing cost, the one-time forming technology is widely applied, such as the slot down-draw method or the single-side overflow method and the roll forming, which can realize the continuous production of thin plate glass, reduce the subsequent cutting, grinding and other processes, and significantly improve the yield and capacity.

[0004] The continuous roll forming technology puts extremely strict comprehensive requirements on the performance of the roller material. Specifically, in the roll forming process, the purpose of the roller is to support (or lightly touch) the thin film of glass liquid to make it quickly cool and shape. The temperature of the glass melt is usually close to 1000°C, which poses a severe challenge to the high-temperature oxidation resistance of the roller material. Surface oxidation not only reduces the service life of the material, but also directly affects the surface quality of the glass product.

[0005] At the same time, the molten glass contains a large amount of alkali metal ions with strong chemical activity. These components will react with the surface of the roller, causing the material performance to deteriorate. More critically, the adhesion problem between the glass melt and the surface of the roller will seriously affect the forming uniformity, not only causing product thickness fluctuations and surface defects, but also significantly reducing production efficiency due to frequent shutdown for cleaning. Currently, the mainstream roller material adopts stainless steel (such as 316L) with a chrome plating or a sprayed metal ceramic coating to improve the oxidation resistance and corrosion resistance; however, the chrome plating layer generates chromium trioxide under long-term high temperature, which has a small wetting angle with the glass liquid, resulting in an increased adhesion tendency; while the ceramic coating may have micro-cracks, causing the glass liquid to penetrate and adhere, still requiring regular cleaning and maintenance or even replacement of the roller, which reduces the production efficiency.

[0006] In addition, the temperature of the middle part of the glass liquid film is usually greater than that of the edge part during the one-time forming process of the thin plate, causing the middle part to flow faster and the film thickness to be thinner than the edge part, resulting in a large thickness difference after cooling and forming the plate, which brings processing difficulties to the subsequent grinding and polishing processes. Therefore, it is necessary to regulate the uniformity of the transverse temperature field of the glass liquid film during the roll forming process to improve the quality of the thin plate. SUMMARY

[0007] The main purpose of the present application is to provide a calender roll and a production method thereof, aiming to solve the problem of short service life of the roll in the prior art, and on this basis, to improve the cooling effect of the roll and reduce the axial temperature difference of the roll by optimizing the structure of the internal cooling channel.

[0008] To achieve the above-mentioned purpose, the present application provides a calender roll, which comprises a roll core, a transition layer and a roll pressing layer arranged in sequence from inside to outside, the roll core is used as a basic support, the inside of the roll core is provided with a cooling partition wall, both ends of the cooling partition wall are provided with a cooling channel, the roll further comprises a plug, the plug is connected with the cooling channel, a pipeline is arranged in the cooling channel, one end of the pipeline is a cooling medium inlet, the other end of the pipeline is arranged in the cooling channel close to one side of the cooling partition wall, the pipeline is filled with flowing cooling medium, and the plug is used to close the cooling channel of the roll core.

[0009] Further, a flow guide groove is arranged in the cooling channel; a spoiler is arranged in the cooling channel, and a plurality of spoiler holes are arranged on the spoiler.

[0010] Further, a measurement hole is arranged on the roll core, and a temperature measurement assembly is arranged in the measurement hole, the temperature measurement assembly is used to monitor the temperature of the roll.

[0011] Further, the cooling medium inlet is provided with a flow monitoring assembly and an inlet temperature monitoring assembly, and the cooling medium outlet is provided with an outlet temperature monitoring assembly.

[0012] To achieve the above-mentioned purpose, the present application further provides a production method of a calender roll, which comprises the following steps: Taking the blank and polishing to obtain the roll core; Preparing a transition layer on the surface of the roll core; After the preparation of the transition layer is completed, rough grinding, fine grinding and polishing are sequentially performed on the transition layer; Preparing a roll pressing layer on the surface of the transition layer; After the preparation of the roll pressing layer is completed, the inspection and installation are completed.

[0013] Further, the preparation of the transition layer on the surface of the roll core comprises the following steps: preheating the roll core to 150-200 DEG C, and preparing the transition layer on the surface of the roll core by laser cladding; the thickness of the transition layer prepared by laser cladding ranges from 1mm to 2mm.

[0014] Further, the preparation of the roll pressing layer on the surface of the transition layer comprises the following steps: Preparing the roll pressing layer by plasma spraying or brazing the pre-prepared roll pressing layer sleeve to the surface of the transition layer.

[0015] Further, the preparation of the transition layer on the surface of the roller core by laser cladding further comprises the following steps: annealing at 550-650℃ for 2-4 hours.

[0016] Further, the preparation of the transition layer on the surface of the roller core comprises the following steps: Spraying the transition layer on the surface of the roller core, and the thickness of the sprayed transition layer is 0.3-0.5mm.

[0017] The present application adopts a multi-layer composite structure combined with a bidirectional cooling channel design, forms a symmetrical cooling loop by separating the roller core with an internal cooling partition wall, realizes directional medium flow by combining with the pipe system connected by the plug, effectively controls the axial temperature gradient of the roller, and the combination design of the transition layer and the roller layer takes into account the structural strength and surface performance, significantly improves the thermal stability and glass liquid corrosion resistance under high temperature working conditions. BRIEF DESCRIPTION OF DRAWINGS

[0018] Figure 1 Fig. 1 is a structural schematic diagram of the roller in Example 1 of the present application; Figure 2 Fig. 2 is a cross-sectional structural schematic diagram of the roller in Example 1 of the present application; Figure 3 Fig. 3 is a perspective structural schematic diagram of the roller in Example 1 of the present application; Figure 4 Fig. 4 is a local structural axial schematic diagram of the roller in Example 1 of the present application; Figure 5 Fig. 5 is a flow schematic diagram of the production method in Example 2 of the present application; Figure 6 Fig. 6 is a schematic diagram of the wetting angle of the Pt alloy and the glass in Example 3 of the present application.

[0019] REFERENCE SIGNS: 1-roller core, 2-transition layer, 3-roller layer, 4-measuring hole, 5-temperature measuring assembly, 6-flow monitoring assembly, 7-inlet temperature monitoring assembly, 8-cooling medium inlet, 9-outlet temperature monitoring assembly, 10-cooling medium outlet, 11-cooling partition wall, 12-cooling channel, 13-plug, 14-flow guide groove, 15-turbulence plate, 16-turbulence hole.

[0020] The implementation, functional features and advantages of the present application will be further described with reference to the embodiments and the accompanying drawings. DETAILED DESCRIPTION

[0021] With reference to the drawings and the embodiments of the present application, the technical solutions in the embodiments of the present application will be clearly and completely described. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments of the present application, all other embodiments obtained by those of ordinary skill in the art without creative efforts are within the scope of the present application.

[0022] It should be noted that all directional indications, such as upper, lower, left, right, front, back, and the like, used in the embodiments of the present application are only used to explain the relative position relationship, movement condition, and the like between components in a certain posture (as shown in the drawings), and if the certain posture changes, the directional indications also change accordingly.

[0023] In the present application, unless otherwise explicitly specified and limited, the terms "connection", "fixation", and the like should be understood in a broad sense, for example, "fixation" can be fixed connection, or detachable connection, or integral; can be mechanical connection, or electrical connection; can be direct connection, or indirect connection through an intermediate medium; can be internal communication of two elements or interaction relationship between two elements, unless otherwise explicitly limited. For those of ordinary skill in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0024] In addition, if the present application has descriptions involving "first", "second", and the like, the descriptions of "first", "second", and the like are only for the purpose of description, and cannot be understood as indicating or implying the relative importance of the indicated technical features or implicitly indicating the number of the indicated technical features. Therefore, the features limited by "first" and "second" can explicitly or implicitly include at least one of the features. In addition, the meaning of "and / or" appearing throughout the text includes three parallel solutions. For example, "A and / or B" includes A solution, or B solution, or A and B solution. In addition, the technical solutions of each embodiment can be combined with each other, but it must be based on the realization of those of ordinary skill in the art, and when the combination of technical solutions appears contradictory or unachievable, it should be considered that the combination of technical solutions does not exist, and is not within the scope of protection claimed by the present application.

[0025] Embodiment 1: As shown in the accompanying Figures 1 to 4As shown, the embodiment provides a calender roll, which comprises a roll core 1, a transition layer 2 and a roll pressure layer 3 arranged in sequence from inside to outside, the roll core 1 is used as a basic support, the inside of the roll core 1 is provided with a cooling partition wall 11, both ends of the cooling partition wall 11 are provided with a cooling channel 12, the roll further comprises a plug 13 connected with the cooling channel 12, a pipeline is arranged in the cooling channel 12, one end of the pipeline is a cooling medium inlet 8, the other end of the pipeline is arranged in the cooling channel 12 close to one side of the cooling partition wall 11, the pipeline is filled with flowing cooling medium, and the plug 13 is used to close the cooling channel of the roll core 1.

[0026] It should be noted that in the traditional continuous roll forming process of thin plate glass, when the high-temperature glass melt is in direct contact with the surface of the roll, the insufficient high-temperature oxidation resistance of the roll material leads to the rapid formation of the surface oxidation layer, the strong chemical active medium induces the corrosion reaction, and the imbalance of the wettability of the melt and the roll interface induces the adhesion effect, thereby causing the surface morphology of the roll to deteriorate. Since the intermediate temperature of the glass liquid film is usually higher than that of the two sides, the thickness tolerance of the formed thin plate exceeds the process standard, and even folding or pit defects appear on the surface.

[0027] In the face of the above problems, the present application first analyzes the root cause of the oxidation and corrosion of the roll surface, finds that the wettability of the traditional chromium plating layer with the glass liquid is too high under high temperature, and the microcracks of the ceramic coating aggravate the penetration of the melt. To extend the service life of the roll, a material that is stable in nature, not easy to oxidize and not easy to adhere to the glass liquid film at high temperature needs to be selected as the roll pressure layer 3, so platinum (Pt) or platinum alloy can be selected in the present application. In addition, in the actual production process, stainless steel is preferred as the roll core 1 for consideration of production cost; but since platinum cannot be directly welded with stainless steel, nickel-based alloy which can be connected with stainless steel and platinum at the same time is selected as the transition layer 2, thereby forming a gradient material system.

[0028] At the same time, in view of the problem that the intermediate temperature of the glass liquid film itself is high and the temperature of the two sides is low in the forming process, the present application sets a cooling partition wall 11 in the roll core 1 to form two symmetrical cooling channels 12, and makes the cooling medium with lower temperature enter the middle part of the roll first, so that the cooling effect of the middle part of the roll will be greater than that of the two ends, when the high-temperature glass liquid film contacts the surface of the roll, the horizontal temperature difference of the glass liquid film itself can be effectively balanced; in order to further improve the overall cooling effect and avoid the temperature of the roll pressure layer 3 being too high, the present application also uses structures such as flow guide grooves and turbulence plates to strengthen heat conduction, which can further reduce the risk of glass liquid film adhesion.

[0029] The multi-layer composite structure cooperates with the bidirectional cooling channel 12 design, the internal cooling partition wall 11 of the roller core 1 is separated to form a symmetrical cooling loop, and the pipe system connected by the plug 13 realizes directional medium flow, effectively controls the axial temperature gradient of the roller, and the combination design of the transition layer 2 and the roller pressing layer 3 considers the structural strength and surface performance, and significantly improves the thermal stability and glass liquid corrosion resistance under high-temperature working conditions.

[0030] The working process and principle of the present application are as follows: the roller includes a roller core 1, a transition layer 2 and a roller pressing layer 3 arranged from inside to outside. The roller core 1 serves as a basic support, and the internal cooling partition wall 11 is provided. The cooling partition wall 11 is provided with a cooling channel 12 at both ends. The roller further includes a plug 13 connected with the cooling channel 12 and serving as a sealing structure. The cooling channel 12 is provided with a pipe. One end of the pipe is a cooling medium inlet 8, and the other end is arranged in the cooling channel 12 close to one side of the cooling partition wall 11. The pipe is filled with flowing cooling medium. The plug 13 is used to close the cooling channel of the roller core 1. In some specific embodiments, the plug 13 is further connected with a rotary joint. The rotary joint is composed of the cooling medium inlet 8, a thin tube inside the roller core 1 and a cooling medium outlet 10, and forms an integral sealing structure.

[0031] The roller core 1 provides overall structural support. The transition layer 2 is used to realize good metallurgical bonding with the roller core 1 and the roller pressing layer 3. The transition layer 2 is also used to relieve thermal stress. The roller pressing layer 3 realizes corrosion resistance and anti-adhesion. The cooling partition wall 11 divides the cooling channel 12 into two parts to form a bidirectional cooling structure. The cooling medium enters the pipe from the inlet and flows out close to the cooling partition wall 11. After flowing along the cooling channel 12, the cooling medium is discharged from the outlet. The cooling medium with low temperature first enters the middle part of the roller. The cooling capacity of the middle part of the roller is greater than that of the end part. The glass liquid film itself has high temperature in the middle. When the glass liquid film contacts the roller, the lateral temperature difference can be balanced. This bidirectional cooling structure helps to uniformly and dynamically regulate the roller temperature field.

[0032] When the cooling medium flows in the pipe, heat exchange is performed with the pipe wall. The end of the pipe is arranged close to the cooling partition wall 11, so that the cooling medium first cools the central area of the roller. Then the cooling medium continues to absorb heat while flowing along the cooling channel 12. This flow path design can realize gradient cooling from inside to outside, which is beneficial to control the surface temperature distribution of the roller.

[0033] In some preferred embodiments, the roller cooling medium can be selected from water, air, liquid nitrogen and high-temperature resistant oil. The selection of the cooling medium is determined by the glass liquid flow rate of the roller pressing forming. When the flow rate is less than 3 tons / day, air or high-temperature resistant oil can be used. When the flow rate is greater than 3 tons / day and less than 20 tons / day, water or liquid nitrogen can be used.

[0034] The roll pressing layer 3 as a surface functional layer directly contacts with the high-temperature glass melt, and its corrosion resistance can resist the erosion of active components in the melt, and the anti-adhesion property reduces the adhesion of the glass liquid. The introduction of the transition layer 2 alleviates the stress between the roll pressing layer 3 and the roll core 1 due to the difference in the thermal expansion coefficient, and improves the stability of the overall structure. Through the synergistic effect of the above-mentioned multi-layer composite structure and the internal cooling system, the calender roll can maintain good surface performance and temperature uniformity in a high-temperature environment, thereby improving the forming quality and production efficiency of the thin plate glass. In some specific embodiments, the roll pressing layer 3 is made into a sleeve shape, the inner diameter of the sleeve is slightly larger than the outer diameter of the transition layer 2, and is brazed to the surface of the transition layer 2.

[0035] In some embodiments, the cooling partition wall 11 refers to a longitudinal partition structure arranged inside the roll core 1, which can be realized by welding or one-piece forming process with the same material as the roll core 1. The cooling partition wall 11 guides the cooling medium to form a bidirectional flow path, and realizes the axial temperature uniform distribution of the roll.

[0036] In some embodiments, the cooling channel 12 refers to a medium flow path arranged at both ends of the cooling partition wall 11, which can be formed into a through-hole structure by drilling. The diameter of the cooling channel 12 is not more than three-fourths of the diameter of the roll core 1 to ensure the structural strength, and the cooling medium is guided to form directional flow through the pipeline.

[0037] In some embodiments, the cooling medium inlet 8 refers to a medium input interface arranged at the end of the pipeline, which can be realized by a quick connector or a welded pipe. The inlet position close to the side of the cooling partition wall 11 can optimize the flow direction of the medium. It can be understood that the cooling medium outlet 10 is similar to the cooling medium inlet 8.

[0038] In the embodiment, the cooling channel 12 is provided with a flow guide groove 14; the cooling channel 12 is provided with a spoiler 15, and the spoiler 15 is provided with a plurality of spoiler holes 16.

[0039] It can be understood that the flow guide groove 14 guides the cooling medium to flow along the preset path, so that the medium forms a composite flow state of alternating laminar flow and turbulent flow in the channel cross section. When the cooling medium flows through the spoiler 15, the spoiler body blocks the main flow, forcing the fluid to form multiple jets through the spoiler holes 16, and the jets produce vortex mixing in the area behind the plate. The depth and spacing of the flow guide groove 14 cooperate with the hole diameter and arrangement density of the spoiler 15, so that the Reynolds number of the medium remains in the turbulent flow range of 4000 to 10000 within the flow velocity range.

[0040] Based on the above structure, the cooling efficiency is improved, the temperature distribution of the roller is more uniform, specifically, the flow guide groove 14 increases the heat exchange area and prolongs the residence time of the cooling medium in the channel, the spoiler plate 15 and the spoiler hole 16 break the laminar flow state of the cooling medium, and the overall performance of the cooling system is improved. The uniform temperature distribution helps to maintain the surface quality of the roller, reduces the deformation caused by thermal stress, and thus improves the quality stability of the calendered product.

[0041] In the embodiment, the roller core 1 is provided with a measuring hole 4, and the measuring hole 4 is provided with a temperature measuring assembly 5 for monitoring the temperature of the roller.

[0042] In some embodiments, the measuring holes 4 are uniformly distributed along the circumferential direction of the roller core 1, the inner walls of the holes are processed into a stepped structure to adapt to temperature sensors of different sizes, and the positions are close to the transition layer 2; the temperature measuring assembly 5 adopts an armored thermocouple or an infrared temperature measuring probe, is fixed in the measuring hole 4 through threads or flanges, and the end of the sensor can be adjusted as needed from the axial center of the roller to the end of the roller; the spacing of the measuring holes 4 is set in proportion to the diameter of the roller. Based on the above structure, the present application can monitor the temperature of each part of the roller in real time, provide accurate temperature data for the cooling system, help to optimize the cooling medium flow and temperature control, in addition, through monitoring the temperature distribution of the roller, local overheating phenomenon can be found in time to prevent the deformation or damage of the roller, thereby improving the service life of the roller and the stability of the calendering process, and ensuring the quality of the calendered product.

[0043] In some embodiments, the cooling medium inlet 8 is provided with a flow monitoring assembly 6 and an inlet temperature monitoring assembly 7, and the cooling medium outlet 10 is provided with an outlet temperature monitoring assembly 9.

[0044] It can be understood that when the cooling medium enters the pipeline from the inlet, the inlet temperature monitoring assembly 7 collects the initial temperature data in real time, and the flow monitoring assembly 6 synchronously records the instantaneous flow value. After the cooling medium flows through the cooling partition wall 11 area to absorb the heat of the roller core 1, the outlet temperature monitoring assembly 9 detects the temperature of the medium after the temperature rises; by calculating the temperature difference value between the inlet and the outlet, combined with the flow data, the heat exchange amount of the roller core 1 per unit time can be accurately obtained; when it is detected that the outlet temperature exceeds the set threshold value, the flow adjusting device automatically increases the flow of the cooling medium, so that the temperature field of the roller core 1 is maintained in a uniform state required for the glass liquid film to be shaped. By monitoring the flow and temperature of the cooling medium in real time, abnormal conditions of the cooling system can be found in time, such as insufficient flow or excessively high temperature. This helps to maintain the stable working temperature of the calendering roller and ensures the quality consistency of the calendered product. At the same time, by analyzing the difference between the inlet and outlet temperatures, the heat exchange efficiency of the roller can be evaluated to provide data support for optimizing the cooling system. In addition, these monitoring data can also be used for predictive maintenance to find potential equipment failures in advance, reduce unexpected downtime, and improve production efficiency.

[0045] In this embodiment, the length of the roller core 1 ranges from 300mm to 700mm, and the diameter of the roller ranges from 150mm to 250mm; the diameter of the cooling channel 12 is ≤3 / 4 of the roller core 1 diameter. When the length of the roller core 1 is controlled at 300mm, the cooling partition 11 can arrange at least two sets of independent cooling channels 12 along the axial direction to achieve segmented temperature control; when the length reaches 700mm, the cooling channel 12 adopts a spiral winding structure to make the cooling medium flow uniformly along the axial direction of the roller core 1. Through the above technical solution, the present invention achieves optimized design of the roller size. The reasonable range of the length of the roller core 1 and the diameter of the roller ensures the strength and rigidity of the roller, meeting the requirements of the calendering process. The limitation of the diameter of the cooling channel 12 ensures sufficient cooling effect without excessively affecting the overall structural strength of the roller. This design improves production efficiency and product quality while ensuring roller performance.

[0046] Example 2: As attached Figure 5 As shown, this embodiment provides a method for producing calendering rolls, the method comprising the following steps: The raw material is taken and polished to obtain roller core 1; A transition layer 2 is prepared on the surface of the roller core 1; After the transition layer 2 is prepared, it is subjected to coarse grinding, fine grinding and polishing in sequence; A roll-pressed layer 3 is prepared on the surface of transition layer 2; After the roll-pressed layer 3 is prepared, inspection and installation are completed.

[0047] It should be noted that after precision grinding, the roller core 1 forms a uniform microstructure, which is beneficial to the metallurgical bonding of the transition layer 2 material. During laser cladding, preheating the roller core 1 to 150-200℃ can reduce thermal stress, and the Ni-Cr-Fe alloy in the cladding layer forms a continuous solid solution structure, improving its resistance to high-temperature oxidation. The rough grinding process removes spheroidized particles from the surface of the cladding layer, and fine grinding and polishing form a nanoscale smooth surface, which increases the interfacial bonding strength during the subsequent deposition of the roll-formed layer 3 by 18%-22%. The porosity of the plasma-sprayed roll-formed layer 3 is less than 2%, effectively blocking the penetration of molten glass.

[0048] Through the above technical solutions, this invention achieves efficient production of calendering rolls. High-quality roll core 1 is obtained through grinding and polishing, laying the foundation for subsequent preparation. Laser cladding to prepare the transition layer 2 improves interlayer bonding strength and reduces the risk of interface peeling. Fine grinding of the transition layer 2 ensures surface flatness, which is beneficial for the uniform deposition of the roll-pressed layer 3. Plasma spraying to prepare the roll-pressed layer 3 has high efficiency and good coating quality. The final inspection and installation steps ensure the performance and reliability of the roll. This production method simplifies the process flow, improves production efficiency, and simultaneously guarantees the quality and performance of the calendering rolls.

[0049] In this embodiment, the preparation of the transition layer 2 on the surface of the roller core 1 includes the following steps: preheating the roller core 1 to 150℃-200℃, and preparing the transition layer 2 on the surface of the roller core 1 by laser cladding; the thickness range of the transition layer 2 prepared by laser cladding is 1mm-2mm.

[0050] It should be noted that during the preheating stage, a segmented temperature control device is used to uniformly heat the roller core 1 to 180℃±5℃ to reduce the cooling rate of the molten pool during the cladding process, thereby reducing the thermal stress generated during the cladding process. During laser cladding, the focused beam forms a molten pool on the surface of the rotating roller core 1 at a scanning speed of 0.8-1.2 mm / s, and the cladding powder is deposited layer by layer to a thickness of 1.5 mm under a protective atmosphere. During the annealing treatment, the roller core 1 with the transition layer 2 is placed in an inert gas furnace and heated to 600℃ at a rate of 10℃ / min and held for 3 hours to transform the dendritic structure inside the cladding layer into equiaxed crystals, eliminating about 85% of the residual stress.

[0051] Through the above technical solution, the present invention achieves a good bond between the transition layer 2 and the roll core 1, improving the overall strength and durability of the calendering roll. Simultaneously, by controlling the composition ratio of the cladding material, the oxidation and corrosion resistance of the transition layer 2 is enhanced, extending the service life of the calendering roll. Furthermore, preheating the roll core 1 and controlling the laser cladding parameters help reduce internal stress and defects in the transition layer 2, improving the surface quality and operational stability of the calendering roll.

[0052] In this embodiment, the preparation of the roll-pressed layer 3 on the surface of the transition layer 2 includes the following steps: The roll-pressed layer 3 is made into a sleeve shape, with the inner diameter of the sleeve slightly larger than the outer diameter of the transition layer, and is brazed to the surface of the transition layer 2.

[0053] It can be understood that in the plasma spraying process, the molten particles impact the surface of the transition layer 2 at high speed and undergo severe plastic deformation, and the mechanical interlocking occurs with the oxides on the surface of the transition layer 2 during the flattening process, forming an interface bonding with a gradient transition. In the brazing process, the liquid filler metal forms a continuous wetting layer between the rolled layer 3 and the transition layer 2, realizing the metallurgical bonding of the transition layer 2 and the rolled layer 3, wherein the layered structure formed by plasma spraying can block the crack propagation path, and the continuous interface formed by brazing can improve the thermal shock resistance.

[0054] In the present embodiment, the preparation of the transition layer 2 on the surface of the roller core 1 by laser cladding further comprises the following steps: annealing at 550-650°C for 2-4 hours.

[0055] After laser cladding, the transition layer 2 has non-equilibrium structure and residual thermal stress inside due to rapid cooling. During annealing, the atoms of the material obtain sufficient kinetic energy for diffusion, promoting the recovery of lattice distortion and eliminating residual stress. When the temperature reaches 550°C, the Ni-Cr-Fe alloy in the transition layer 2 begins to recover and recrystallize, and when the temperature rises to 650°C, the atomic diffusion rate is significantly improved, and the stress relief efficiency reaches a peak. Extending the annealing time to 4 hours can ensure uniform stress release in the thick cross-section area, while avoiding excessive grain size due to prolonged time. After annealing, the difference in the thermal expansion coefficient between the transition layer 2 and the rolled layer 3 is reduced, and the interface bonding strength is improved, thereby reducing the possibility of cracks or interface peeling of the rolled layer 3 due to thermal stress concentration during high-temperature rolling.

[0056] In the present embodiment, the preparation of the transition layer 2 on the surface of the roller core 1 comprises the following steps: Spraying on the surface of the roller core 1 to prepare the transition layer 2, and the thickness of the transition layer 2 prepared by spraying is 0.3-0.5mm.

[0057] It should be noted that after the roller core 1 is preheated to 150-200°C, the alloy powder is sprayed at high speed onto the surface of the roller core 1 by a spraying device to form a metallurgical bonding transition layer 2; during the spraying process, the powder particles melt at high temperature and impact the surface of the roller core 1, forming a layered stacking structure; by limiting the spraying thickness to 0.3-0.5mm, both the stress buffering effect of the transition layer 2 on the roller core 1 and the rolled layer 3 is ensured, and the risk of brittleness caused by too thick coating is avoided; after spraying is completed, the transition layer 2 is coarsely ground to remove the surface oxide layer, providing a flat base for subsequent preparation of the rolled layer 3; compared with laser cladding, this process reduces energy input, reduces the range of heat-affected zone, and shortens the processing cycle, meeting the requirements of thin plate glass rolling forming equipment for roller manufacturing efficiency and cost control.

[0058] In some embodiments, in the process of preparing the transition layer 2 by laser cladding, the content of Ni in the laser cladding material is 72%-75%, the content of Cr is 15%-18%, and the content of Fe is 8%-10%.

[0059] Embodiment 3: To make the technical solutions of the present application clearer, the specific structure and composition of the roller are described in detail. Specifically, the roller of the present application adopts a three-layer composite structure: the roller core 1 as a base support layer, nickel or nickel-based alloy as a transition bonding layer, and platinum or platinum alloy (Pt-Rh, Pt-Au, etc.) as a glass contact functional layer. The stainless steel roller core 1 serves as a basic support structure, which not only guarantees sufficient mechanical strength but also takes into account the economic efficiency of manufacturing cost. Its good heat resistance and dimensional stability can adapt to the high-temperature glass processing environment. The nickel or nickel-based alloy transition layer 2 is between the stainless steel and the platinum layer, which realizes reliable bonding of dissimilar materials by virtue of good metallurgical compatibility with stainless steel and excellent interdiffusion characteristics with platinum group metals. At the same time, the thermal stress problem under high-temperature working conditions is effectively alleviated through the transition of the thermal expansion coefficient of the intermediate layer. The platinum or platinum alloy functional layer (such as Pt-Rh, Pt-Au, etc.) that directly contacts the glass liquid has unique surface properties, which significantly reduces the adhesion tendency with the large wetting angle of the glass liquid, ensuring the surface quality of the formed sheet. At the same time, the inherent high-temperature oxidation resistance and corrosion resistance of platinum group materials avoid the generation of surface oxide scale and glass contamination, and still maintain stable forming precision and service life under severe working conditions. This composite structure design takes into account the requirements of mechanical properties, interface bonding and surface function, and is particularly suitable for the precision requirements of roll forming process for high-end products such as ultra-thin glass and optical glass.

[0060] The length of the calendering roller is not specifically limited in the present application and can be determined according to the width of the produced glass, preferably 300mm-700mm. The outer diameter of the calendering roller is usually 150mm-250mm. The calendering roller is usually used in pairs, and the glass flows in and out between the two rollers. The roller plays a role in cooling and calendering the glass liquid film, so that the glass is formed.

[0061] The cooling medium channel is provided inside the stainless steel roller core 1, and the diameter of the channel is ≤3 / 4 of the diameter of the roller core 1. The material of the roller core 1 includes one or more of SUS310S stainless steel (25Cr-20Ni), SUS316L stainless steel, Incoloy 800H (20Cr-32Ni), or Incoloy 801 (20Cr-32Ni-0.4Ti).

[0062] The internal cooling medium passage of the roll core 1 is divided into two zones, which are separated by a partition wall, and the cooling medium is introduced from the rotating joint thin pipe connected to the end of the roll core 1 and flows out from the periphery, which can ensure that the cooling medium with low temperature enters the axial center of the roll first, and the cooling effect on the middle part of the glass liquid film is greater than that on the edge part, so that the temperature difference between the middle part and the edge part of the glass liquid film (the temperature of the middle part is higher than that of the edge part) can be effectively reduced, and the structure can independently control the temperature of the two ends of the roll. The roll is provided with a cooling medium passage, temperature sensors are arranged at the inlet and outlet of the cooling medium, and a flow sensor is arranged at the inlet 8 of the cooling medium. Holes are drilled at the two ends of the roll wall, and thermocouples are inserted for temperature measurement, which approximately reflects the surface temperature of the calendering roll, and the insertion depth of the thermocouples can be adjusted according to the different widths of the glass thin plates.

[0063] In order to improve the cooling effect of the cooling medium in the roll core 1 on the surface of the roll, the cooling medium passage can be designed as Figure 3 or Figure 4 as shown in Figure 3 In order to increase the contact area between the cooling medium and the inner cavity of the roll core 1, a plurality of flow guide grooves 14 can be processed in the inner cavity of the roll, the cross-sectional shape of the flow guide grooves 14 can be other shapes in addition to semicircular shape, and the path of the flow guide grooves 14 can be spiral in addition to straight line; as shown in Figure 4 In order to prolong the residence time of the cooling medium in the inner cavity of the roll, destroy the laminar boundary layer at the same time, promote turbulence and thus improve the heat transfer coefficient, a spiral turbulence plate 15 can be arranged in the inner cavity of the roll core 1, and small holes can be punched on the turbulence plate 15. According to the length of the roll, one or more turbulence plates 15 can be arranged.

[0064] The nickel or nickel-based alloy transition layer 2 can be prepared on the surface of the stainless steel roll core 1 by spraying or laser cladding, the spraying thickness is 0.3-0.5mm, the laser cladding thickness is 1-2mm, and the cladding layer needs to be ground after laser cladding to make the surface smooth and flat. In order to eliminate the surface residual stress in the process of laser cladding, annealing treatment is needed. The intermediate layer material includes one or more of pure nickel, nickel-based alloy Inconel 600 (15Cr-8Fe-remaining Ni) or Haynes 214 (Ni-16Cr-4.5Al-3Fe), and it needs to be noted that the intermediate layer is prohibited to contain Si, Sb, S, C, P, As, Zn, Cd, Bi and other elements, because they are easy to form brittle compounds with platinum, thereby reducing the mechanical strength of the material.

[0065] The platinum or platinum alloy of the calendering process contacts the glass, and a sleeve composed of the roll-pressed layer 3 can be vacuum brazed to the surface of the nickel / nickel-based alloy transition layer 2 after plasma spraying and laser remelting, and the inner diameter of the sleeve composed of the roll-pressed layer 3 needs to be closely matched with the outer diameter of the intermediate layer. The material of the roll-pressed layer can be selected according to the wetting angle of different grades of glass at the forming temperature and the extrusion force of the calendering process. When the wetting performance of the roll-pressed layer material shows little difference (the difference in the wetting angle is ≤10°), the material with high hardness is preferred. When the wetting performance of the roll-pressed layer material shows great difference (the wetting angle is >10°), the material with a large wetting angle is preferred. The material of the roll-pressed layer includes one or more of pure platinum, strengthened platinum (T-1Pt), dispersed platinum (ZGS Pt), platinum-rhodium alloy (Pt-Rh5%-25%) or platinum-gold alloy (Pt-Au3%-5%). The comparison of the wetting angles of different Pt alloys and glass can be seen in Figure 6 .

[0066] The traditional coating (chromium plating, metal ceramic) is easy to peel off due to the large difference in the thermal expansion coefficient and low bonding strength, and the present application uniformly disperses the interface stress of each layer by the thermal expansion coefficient gradient (roll core 1> transition layer 2> functional layer) of the nickel / nickel-based alloy transition layer 2. The selection of the stainless steel roll core 1, the nickel / nickel-based alloy transition bonding layer and the platinum / platinum alloy calendering functional layer should consider the expansion coefficient (CTE), and the relationship of the expansion coefficients is: roll core 1> transition bonding layer> calendering functional layer, and the SUS310S stainless steel roll core 1+ laser cladding Haynes 214 alloy+ vacuum brazing 1mm thick Pt-Rh10% is preferred.

[0067] An example of a specific production method for the roll of the present application can be as follows: first, a cylindrical stainless steel roll core 1 is prepared, the surface of the roll core 1 is polished, and the cylindricality requirement is ≤0.03. A transition layer 2 of nickel / nickel-based alloy is prepared on the surface of the roll core 1 by using synchronous powder feeding type laser cladding. The roll core 1 is preheated to 150-200°C before laser cladding. It should be noted that the process parameters such as laser power, scanning speed, and powder feeding amount should be well controlled during the laser cladding process to avoid the formation of pores in the cladding layer. In order to eliminate the stress generated in the surface layer during the laser cladding process, stress relief annealing is required. The annealing temperature is set to 550-650°C, and the annealing time is 2-4 hours. After laser cladding, the transition layer 2 is subjected to rough grinding, fine grinding, and polishing, and the roughness Ra is ≤0.03. After finishing, the roll is bored at both ends, i.e. the thickness of the partition wall between the cooling medium channels in the middle of the roll is 20mm. After boring, plugs and variable-diameter cylinders are welded at both ends of the roll to facilitate connection with bearings and cooling medium pipelines. It should be noted that the coaxiality requirement is ≤0.02. The plugs 13 are installed, and in some embodiments, the plugs 13 are connected to the rotary joints formed by the cooling medium inlet 8, the cooling medium outlet 10, and the fine tubes inside the cooling channel 12 to form a sealed structure as a whole. After inserting flow monitoring and temperature detection devices into the cooling medium inlet and outlet pipelines, standard components can be used. The installation process forms a sealed cooling medium channel with the cooling medium inlet and outlet and the cylinder above them.

[0068] Based on the above, the calender roll with a three-layer composite structure produced in the present application has certain high-temperature strength and rigidity, meets the requirements of thin plate glass calendering forming, avoids peeling at the bonding interface, and ensures the bonding strength and surface quality under the action of internal stress during use. It can be understood that the process effect comparison of each layer of the calender roll is shown in the following table. During the calendering process of the three-layer composite structure roll, platinum or platinum alloy is in contact with high-temperature glass liquid. Platinum is not easy to oxidize and corrode in a high-temperature environment, and has a larger wetting angle with glass liquid, which is not easy to stick to the roll. The continuous roll forming working time can be close to the service life of the platinum smelting system, which is greatly improved compared with conventional rolls. The roll has a cooling medium channel inside, temperature sensors are arranged at the cooling medium inlet and outlet, and a flow sensor is arranged at the cooling medium inlet 8. The roll temperature can be adjusted by adjusting the cooling medium flow according to the actual forming needs. The cooling medium channel inside the roll is divided into two zones, and the cooling medium flow can be independently controlled. When the temperature on both sides of the glass liquid film is not uniform, the temperature of the roll can be adjusted to appropriately balance the temperature difference on both sides of the glass liquid film. The transverse thickness difference of the thin plate glass produced by roll forming using the roll with this structure can be ≤0.02mm.

[0069]

[0070] The above merely describes the preferred embodiments of the present application, and is not intended to limit the patent scope of the present application, and any equivalent structure or equivalent process conversion, or direct or indirect application in other related technical fields, which are made by using the content of the present application specification and drawings, are also included in the patent protection scope of the present application.

Claims

1. A calender roll characterized in that, The roller includes a roller core, a transition layer and a roller pressing layer arranged from inside to outside, the roller core is used as a basic support, the inside of the roller core is provided with a cooling partition wall, both ends of the cooling partition wall are provided with cooling channels, the roller further includes a plug, the plug is connected with the cooling channels, the cooling channels are provided with pipes, one end of the pipe is a cooling medium inlet, the other end of the pipe is arranged in the cooling channel close to the side of the cooling partition wall, the pipe is filled with flowing cooling medium, and the plug is used to close the cooling channel of the roller core.

2. A calender roll as claimed in claim 1, characterized in that The cooling channel is provided with a flow guide groove; the cooling channel is provided with a spoiler, and the spoiler is provided with a plurality of turbulence holes.

3. A calender roll as claimed in claim 1, characterized in that The roller core is provided with a measuring hole, and the measuring hole is provided with a temperature measuring assembly, which is used to monitor the temperature of the roller.

4. A calender roll as claimed in claim 1, characterized in that The cooling medium inlet is provided with a flow monitoring assembly and an inlet temperature monitoring assembly, and the cooling medium outlet is provided with an outlet temperature monitoring assembly.

5. A method of producing a calender roll, characterized by, The method is used for producing the calendering roller according to any one of claims 1 to 4, and the method comprises the following steps: The embryo material is polished to obtain the roller core; The transition layer is prepared on the surface of the roller core; After the preparation of the transition layer is completed, the transition layer is sequentially subjected to rough grinding, fine grinding and polishing; The roller pressing layer is prepared on the surface of the transition layer; After the preparation of the roller pressing layer is completed, the inspection and installation are completed.

6. A method of producing a calender roll as claimed in claim 5, characterized in that The transition layer is prepared on the surface of the roller core The roller core is preheated to 150-200 DEG C, and the transition layer is prepared on the surface of the roller core by laser cladding; the thickness of the transition layer prepared by laser cladding is 1-2 mm.

7. A method of producing a calender roll as claimed in claim 5, characterized in that The transition layer is prepared on the surface of the roller core The roller pressing layer is prepared by plasma spraying or the prefabricated roller pressing layer sleeve is brazed to the surface of the transition layer.

8. A method of producing a calender roll as claimed in claim 6, characterized in that After the transition layer is prepared on the surface of the roller core by laser cladding, the following step is further included: Annealing at 550-650 DEG C for 2-4 hours.

9. A method of producing a calender roll as claimed in claim 5, characterized in that The transition layer is prepared on the surface of the roller core The transition layer is prepared on the surface of the roller core by spraying, and the thickness of the transition layer prepared by spraying is 0.3-0.5 mm.

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