High-precision traction roller for high-generation liquid crystal glass substrate and preparation method thereof

Abstract

The application provides a high-precision traction roller for high-generation liquid crystal glass substrates and a preparation method thereof, and relates to the technical field of glass processing. The traction roller comprises a roller shaft, a heat-resistant fiber traction roller body with an outer dense and inner sparse radial density gradient, a center pressing disc, and an edge limiting pressing ring with a micro-limiting tooth groove. A nano precursor bonding interface is arranged between adjacent fiber discs. A thermal expansion self-adaptive transition layer is arranged between the roller shaft and the roller body. An intelligent sensing array is embedded in the roller body. During preparation, the following steps are sequentially performed: transition layer pre-assembly, hierarchical disc stacking, full-end-face tool locking, gradient compaction, three-stage sintering and solidification, and demolding finishing. The application realizes uniform pressure on the full end face of the fiber blank and circumferential limiting, solves the problems of insufficient edge compaction and interlayer peeling in traditional single-center pressure, improves the uniformity of the roller body density, the interlayer bonding strength, and the high-temperature concentricity, and meets the continuous production requirements of G8.5 and above high-generation production lines.

Description

Technical Field

[0001] This invention relates to the technical field of high-generation glass processing, specifically to a high-precision traction roller for high-generation liquid crystal glass substrates and its preparation method. Background Technology

[0002] In the overflow pull-down forming process of high-generation LCD glass substrates, the annealing furnace traction mechanism is the core component that ensures stable transmission, uniform thickness, and precise shape of the high-temperature glass strip. The traction roller, as the core actuator of the traction mechanism, flexibly contacts the high-temperature glass strip, achieving constant-speed traction and posture correction through roller surface friction. Its roller surface precision, roller density uniformity, high-temperature resistance, and wear resistance directly affect the finished glass substrate quality, production yield, and production line uptime. With the development of display panels towards larger sizes, ultra-thinner profiles, and higher precision, high-generation production lines are characterized by high traction speeds, large glass widths, and stringent forming conditions, placing higher technical demands on the forming precision, structural uniformity, high-temperature creep resistance, and batch-to-batch wear consistency of the traction roller.

[0003] Currently, traction rollers for high-generation LCD glass substrates are generally manufactured using a heat-resistant fiber preform molding and sintering process. This involves stacking multiple layers of heat-resistant fiber discs, axially pressing, and then sintering at high temperatures. This material possesses excellent high-temperature resistance, insulation, and wear resistance, making it suitable for the high-temperature working environment of annealing furnaces. It meets the basic production requirements for continuous traction of glass substrates and is currently the mainstream manufacturing solution in the industry. Traditional forming fixtures mainly use a single central pressure plate axial pressure structure, applying a pressing load only to the central area of ​​the fiber preform to complete the preform shaping. This process is simple, cost-effective, and widely used in the mass production of conventional traction rollers.

[0004] Traditional single-center pressure structures can only effectively compact the center of the billet, resulting in insufficient pressure on the edges and uneven overall stress distribution. During the pressing process, forming defects such as edge turning, delamination, and edge bursting are prone to occur, leading to poor outer diameter accuracy of the roller after sintering, low edge density, and difficulty in ensuring the overall density uniformity of the roller. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a high-precision traction roller for high-generation liquid crystal glass substrates and its preparation method, thus solving the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions.

[0007] A high-precision traction roller for high-generation liquid crystal glass substrates includes:

[0008] The roller shaft is a rigid support shaft.

[0009] The heat-resistant fiber traction roller body, sleeved on the outside of the roller shaft, is formed by stacking and pressing multiple layers of heat-resistant fiber discs and sintering them at high temperature. Its outer cylindrical surface is a high-precision traction working surface that directly contacts the glass substrate. The heat-resistant fiber traction roller body has a gradient distribution structure with decreasing density from the outside to the inside along the radial direction. Its radial cross section consists of an outer ultra-dense layer and an inner loose buffer layer from the traction working surface inward. A nano-scale ceramic precursor bonding thin layer is provided between the bonding interfaces of two adjacent layers of heat-resistant fiber discs to solidify the multiple layers of heat-resistant fiber discs into an integral structure.

[0010] The central pressure plates are arranged in pairs and respectively abut against the central areas on both sides of the axial direction of the heat-resistant fiber traction roller body;

[0011] Edge limiting pressure rings are arranged in pairs and respectively abut against the outer edge area of ​​the axial end face of the heat-resistant fiber traction roller. Their inner rings fit and match the outer ring of the central pressure plate. The two edge limiting pressure rings are locked together by fasteners arranged evenly in the circumference to form a full-end face covering pressing fixture. The outer diameter of the edge limiting pressure ring is larger than the outer diameter of the heat-resistant fiber disc.

[0012] Specifically, the outer ultra-dense layer is an annular region of the heat-resistant fiber traction roller with a thickness not exceeding 3.5 mm from the outer cylindrical surface inward. This region has the highest fiber compaction and a porosity of ≤1.2%.

[0013] The inner loose buffer layer is the area between the inner wall surface of the heat-resistant fiber traction roller body that mates with the roller shaft and the outer boundary of the outer ultra-dense layer, and the porosity of this area is 4% to 6%.

[0014] The heat-resistant fiber disc matrix of the inner loose buffer layer is uniformly doped with closed-cell hollow ceramic microspheres with a particle size of 5-20 μm and a doping mass ratio of 3%-5%; the outer ultra-dense layer is a pure fiber matrix without particle doping.

[0015] Specifically, the nanoscale ceramic precursor bonding thin layer is a nano-silica precursor bonding coating with a thickness of 0.5–1.5 μm.

[0016] Specifically, an annular thermal expansion adaptive transition layer is provided between the inner wall of the heat-resistant fiber traction roller and the outer wall of the roller shaft. The thermal expansion adaptive transition layer is made of a composite sintered material of ceramic fiber and boron nitride, and its coefficient of thermal expansion is between that of the roller shaft metal material and the heat-resistant fiber traction roller body material. The thermal expansion adaptive transition layer has a uniform radial clearance of 0.05 to 0.15 mm with the roller shaft at room temperature, and the gap is filled with high-purity boron nitride thermally conductive and lubricating filler. The two axial ends of the thermal expansion adaptive transition layer and the end face of the central pressure plate adopt an elastic floating abutment structure.

[0017] Specifically, the inner circumferential side of the edge limiting pressure ring is uniformly provided with rectangular micro-limiting grooves, the groove depth is 1-2mm and the spacing is 8-12mm.

[0018] Specifically, the heat-resistant fiber traction roller body has a miniature high-temperature sensing unit array embedded in the axial and circumferential directions, including temperature sensors, pressure sensors and wear monitoring sensors; the leads of each sensor are led out along the internal channel of the roller shaft and connected to an external data acquisition and processing system.

[0019] A method for manufacturing a high-precision traction roller for a high-generation liquid crystal glass substrate includes the following steps:

[0020] S1. Transition layer pre-installation: A thermal expansion adaptive transition layer is installed at a predetermined position on the outside of the roller shaft. The transition layer and the roller shaft have a pre-reserved radial gap at room temperature and are filled with thermally conductive lubricating filler.

[0021] S2. Pre-treatment and stacking of the green body: Prepare graded heat-resistant fiber discs with hollow ceramic microspheres on the inside and pure fibers on the outside; uniformly coat the surface of each heat-resistant fiber disc with a nano-silica precursor bonding coating so that the precursor penetrates into the gap between the fiber surface layers; sequentially stack the heat-resistant fiber discs of each grade on the outside of the transition layer, and stack them in a sparse-inside-dense-outside-layer manner to form a gradient green body, and embed a high-temperature sensing unit array during the stacking process;

[0022] S3. Tooling assembly: Assemble a central pressure plate and an edge limiting pressure ring with micro-limiting tooth groove on both sides of the blank, and pre-tighten and position it by circumferential fasteners;

[0023] S4. Gradient compaction and sintering: First, the billet is pre-pressed and leveled with low pressure of 0.8-1.2MPa, and then the pressure is increased to 3.5-4.0MPa for overall compaction; the billet is treated with a three-stage gradient sintering combined with a rapid cooling process.

[0024] S5. Demolding and finishing: After cooling, the tooling is disassembled without damage, and the outer circle of the roller is turned and ultra-precision ground to obtain a high-precision traction roller finished product.

[0025] Specifically, the heat-resistant fiber discs with inner hollow ceramic microspheres are doped with 5-20 μm closed-cell hollow ceramic microspheres at a mass ratio of 3%-5%, while the outer dense layer is undoped; the micro-limiting grooves are 1-2 mm deep and 8-12 mm apart; the rapid cooling process includes cooling to below 600°C at a cooling rate of ≥10°C / min after sintering.

[0026] Specifically, the three-stage gradient sintering temperatures are 280–320℃ for low-temperature drying, 650–700℃ for medium-temperature bonding, and 950–1000℃ for high-temperature setting.

[0027] This invention provides a high-precision traction roller for high-generation liquid crystal glass substrates and its manufacturing method. Compared with the prior art, it has the following advantages:

[0028] 1. This invention features a radial density gradient structure with a sparse inner layer and a dense outer layer. The inner layer is doped with hollow ceramic microspheres, while the outer layer employs a pure fiber dense structure. Combined with zoned compaction and gradient sintering processes, the performance adaptability of the roller body is optimized. The outer ultra-dense layer has high compaction and low porosity, ensuring the wear resistance and dimensional stability of the traction working surface. The loose buffer layer on the inner side can buffer high-temperature deformation, suppress uneven wear and creep differences in the roller body, stabilize the cylindricity and coaxiality of the roller surface, ensure uniform glass belt traction speed, and improve the problems of uneven substrate thickness and board warping.

[0029] 2. This invention sets a nano-silica precursor bonding thin layer at the bonding interface of each fiber disc, forming a continuous covalent bonding interface after sintering, thus solidifying the multi-layer fiber discs as a whole. Compared with the traditional stacked and compacted structure, this effectively improves the interlayer bonding strength of the roller, prevents interlayer peeling and detachment during high-temperature use, and enhances the overall structural integrity and service life of the roller.

[0030] 3. This invention employs a combination of a central pressure plate and an edge-limiting pressure ring with micro-limiting toothed grooves to achieve uniform pressure application across the entire end face of the blank and circumferential limiting of the outer edge. This solves the problems of insufficient edge compaction and uneven stress caused by traditional single-center pressure application, effectively avoiding forming defects such as blank flanging, delamination, and edge bursting. It also improves the outer diameter accuracy and overall density uniformity of the roller, increasing forming yield and batch consistency. Furthermore, the modular tooling allows for non-destructive disassembly and assembly, preventing damage to the roller's working surface during demolding.

[0031] 4. This invention incorporates a thermal expansion adaptive transition layer. By matching the thermal expansion coefficients of the roller shaft and roller body, and in conjunction with a room-temperature gap fit structure, it effectively compensates for high-temperature deformation differences, reduces assembly stress and operational eccentricity, and improves the high-temperature coaxiality and operational stability of the roller body. Combined with a three-stage gradient sintering and limited-rate rapid cooling process, it can stably lock the radial gradient structure of the roller body, avoiding gradient failure caused by high-temperature homogenization, ensuring the long-term service accuracy of the traction roller, and adapting to the high-precision continuous production requirements of high-generation LCD glass substrates. Attached Figure Description

[0032] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0033] Figure 1 A structural diagram of the high-precision traction roller for high-generation liquid crystal glass substrates of the present invention is shown;

[0034] In the picture:

[0035] 100. Roller shaft;

[0036] 200. Heat-resistant fiber traction roller body; 201. Outer ultra-dense layer; 202. Inner loose buffer layer.

[0037] 300, center pressure plate;

[0038] 400, Edge limiting pressure ring; 401, Micro-limiting tooth groove;

[0039] 500, Annular thermal expansion adaptive transition layer;

[0040] 600. Miniature high-temperature sensor unit array. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0042] This invention provides a high-precision traction roller for high-generation liquid crystal glass substrates, such as... Figure 1 As shown, it includes:

[0043] Roller 100 is a rigid support shaft used for torque transmission and overall assembly;

[0044] A heat-resistant fiber traction roller body 200 is sleeved outside the roller shaft. It is formed by stacking and pressing multiple layers of heat-resistant fiber discs and sintering them at high temperature. Its outer cylindrical surface is a high-precision traction working surface that directly contacts the glass substrate. The heat-resistant fiber traction roller body has a gradient distribution structure with decreasing density from the outside to the inside along the radial direction. Its radial cross section consists of an outer ultra-dense layer 201 and an inner loose buffer layer 202 from the traction working surface inward. A nano-scale ceramic precursor bonding thin layer is provided between the bonding interfaces of two adjacent layers of heat-resistant fiber discs. During the high-temperature sintering process, the precursor can crystallize in situ to form Si-O-Si. A covalently bonded interface consolidates multiple fiber discs into an integrated structure: the outer ultra-dense layer is an annular region of no more than 3.5 mm in thickness from the outer cylindrical surface of the heat-resistant fiber traction roller, where the fiber compaction is highest and the porosity is ≤1.2%; the inner loose buffer layer is the region from the inner wall of the heat-resistant fiber traction roller that mates with the roller shaft to the inner boundary of the outer ultra-dense layer, where the porosity is 4%–6%; the heat-resistant fiber disc matrix of the inner loose buffer layer is uniformly doped with closed-cell hollow ceramic microspheres with a particle size of 5–20 μm and a doping mass ratio of 3%–5%; the outer ultra-dense layer is a pure fiber matrix without particle doping.

[0045] The central pressure plate 300 is arranged in pairs and abuts against the central areas of the two axial sides of the heat-resistant fiber traction roller body to transmit axial pressing load.

[0046] Edge limiting pressure rings 400 are arranged in pairs, respectively abutting against the outer edge areas of the axial end faces of the heat-resistant fiber traction roller. Their inner rings fit and match the outer ring of the central pressure plate. The two edge limiting pressure rings are locked together by fasteners evenly arranged around the circumference, forming a full-end-face covering pressing fixture. The fasteners adopt multiple sets of bolt assemblies, evenly spaced around the circumference of the edge limiting pressure rings. The two edge limiting pressure rings on both sides are locked and fixed by tie bolts. The preload pressure can be evenly adjusted during assembly. With the cooperation of the central pressure plate for limiting pressure, it can completely cover the entire end face of the fiber blank, realizing synchronous and uniform pressure on the central area and the outer edge area of ​​the blank. It avoids the problems of insufficient edge compaction and uneven stress caused by traditional single center pressure, and effectively avoids forming defects such as edge flipping, edge bursting, and delamination of the blank during the pressing process. The overall bolt-locking split fixture structure is firmly assembled and positioned. After sintering and cooling, the bolt assembly can be directly loosened to complete the fixture disassembly. There is no need to knock or scratch the working surface of the roller, realizing non-destructive disassembly. The outer diameter of the edge limiting pressure ring is larger than the outer diameter of the heat-resistant fiber disc, ensuring that the entire end face of the fiber blank is completely within the tooling pressing coverage area. The inner circumferential side of the edge limiting pressure ring is uniformly provided with rectangular micro-limiting grooves 401, with a groove depth of 1-2 mm and a spacing of 8-12 mm. These grooves form a circumferential limiting constraint on the outer edge of the fiber blank during pressing, preventing radial movement or outer edge flipping of the fiber disc under axial pressure. Simultaneously, multiple grooves are evenly distributed circumferentially, ensuring uniform force on the outer edge of the fiber blank in the circumferential direction, avoiding localized stress concentration that could lead to blank eccentricity or forming distortion. This groove structure, combined with the axial main pressure of the central pressure plate, forms a dual constraint mechanism of axial compaction and circumferential anti-movement. Both the central pressure plate and the edge limiting pressure ring are made of high-temperature alloy material, possessing structural strength and dimensional stability under high-temperature conditions. The heat-resistant fiber traction roller is made of carbon fiber or ceramic fiber-based composite material, possessing high-temperature resistance, high wear resistance, and creep resistance, making it suitable for continuous traction conditions in high-temperature annealing furnaces.

[0047] The aforementioned central pressure plate, edge limiting pressure rings, and circumferential fasteners together constitute a full-face covering pressing fixture. In the assembled state, the central pressure plate abuts against the central area of ​​the fiber preform's end face, and the edge limiting pressure rings abut against the outer edge area of ​​the fiber preform's end face. The inner ring of the edge limiting pressure rings circumferentially fits and matches the outer ring of the central pressure plate, forming a continuous, uninterrupted covering end face. When the edge limiting pressure rings on both sides are tightened with tie bolts, the tightening force is transmitted through the edge limiting pressure rings to the outer ring of the central pressure plate, giving the central pressure plate axial thrust, thus achieving synchronous pressure on the center and outer edge. This mechanical transmission path ensures that the entire end face of the fiber preform is under isobaric pressure, without stress bias, fundamentally eliminating the structural defects of pressure attenuation and low density at the outer edge of the preform when applying pressure with a traditional single central pressure plate.

[0048] In addition, in this invention, the nanoscale ceramic precursor bonding thin layer is a nanoscale silica precursor bonding coating with a thickness of 0.5 to 1.5 μm. The nanoscale ceramic precursor bonding thin layer is uniformly coated and penetrates into the gap between the surface layers of the heat-resistant fiber disc, and after sintering, a continuous Si-O-Si covalent bonding interface is formed.

[0049] An annular thermal expansion adaptive transition layer 500 is provided between the inner wall of the heat-resistant fiber traction roller body 200 and the outer wall of the roller shaft 100. The thermal expansion adaptive transition layer is made of a composite sintered material of ceramic fiber and boron nitride, and its coefficient of thermal expansion is between that of the roller shaft metal material and the heat-resistant fiber traction roller body material. At room temperature, the thermal expansion adaptive transition layer has a uniform radial clearance of 0.05 to 0.15 mm with the roller shaft, and the clearance is filled with high-purity boron nitride thermally conductive and lubricating filler. The two axial ends of the thermal expansion adaptive transition layer are elastically floating and abutting against the end face of the central pressure plate. The structure is designed with a thermal deformation allowance; it can adaptively compensate for high-temperature deformation differences to ensure the concentricity of the roller body; for example, a disc spring washer assembly is set between the axial end face of the transition layer and the inner end face of the central pressure plate. This assembly maintains an axial compression preload stroke of 0.2 to 0.5 mm at room temperature, forming an axial floating gap and reserving thermal deformation allowance; when the annealing furnace is heated to the working temperature (600 to 800°C), the thermal expansion difference between the roller shaft and the transition layer can be adaptively compensated by further compression or release of the disc spring, avoiding thermal stress concentration and roller deformation caused by rigid connection.

[0050] The heat-resistant fiber traction roller body 200 has a miniature high-temperature sensing unit array 600 embedded in its interior along the axial and circumferential directions, including a temperature sensor, a pressure sensor, and a wear monitoring sensor; the leads of each sensor are led out along the internal channel of the roller shaft and connected to an external data acquisition and processing system; the temperature sensor is a miniature thin-film thermocouple, the pressure sensor is a fiber optic strain sensor, and the wear monitoring sensor is an embedded resistance wear monitoring line, which can monitor the working condition and wear degree of the roller body in real time.

[0051] This invention includes a dedicated forming fixture, consisting of a central pressure plate, edge limiting pressure rings, and circumferential fasteners. This fixture achieves uniform pressing across the entire end face during the sintering and forming stage of the roll body blank. After the product is formed, this fixture component is retained in the traction roller structure as a permanent part of the traction roller, and is used in conjunction with a hydraulic pressing mechanism and a high-temperature sintering furnace. The fixture bears the axial main pressing pressure through the central pressure plate, while the edge limiting pressure rings simultaneously limit and assist in pressing the outer edge of the blank, achieving uniform pressure densification across the entire fiber blank from the center to the outer edge. This solves the problems of insufficient edge compaction and uneven stress caused by traditional single-center pressing, ensuring uniform density, dimensional stability, and excellent shape and position accuracy of the sintered roll body.

[0052] A method for manufacturing a high-precision traction roller for a high-generation liquid crystal glass substrate includes the following steps:

[0053] S1. Transition layer pre-installation: A thermal expansion adaptive transition layer is installed at a predetermined position on the outside of the roller shaft. The transition layer and the roller shaft have a pre-reserved radial gap at room temperature and are filled with thermally conductive lubricating filler.

[0054] S2. Pre-treatment and stacking of the green body: Prepare graded heat-resistant fiber discs with hollow ceramic microspheres on the inside and pure fibers on the outside; uniformly coat the surface of each heat-resistant fiber disc with a nano-silica precursor bonding coating so that the precursor penetrates into the gap between the fiber surface layers; sequentially stack the heat-resistant fiber discs of each grade on the outside of the transition layer, and stack them in a sparse-inside-dense-outside-layer manner to form a gradient green body, and embed a high-temperature sensing unit array during the stacking process;

[0055] S3. Tooling Assembly: Assemble a central pressure plate and an edge limiting pressure ring with micro-limiting tooth grooves on both sides of the billet. Pre-tighten and position them with circumferential fasteners. Make the inner ring of the edge limiting pressure ring fit tightly with the outer ring of the central pressure plate to achieve full end face coverage of the billet. Use circumferentially evenly arranged bolts to evenly pre-tighten the edge limiting pressure rings on both sides to complete the overall positioning of the tooling.

[0056] S4. Gradient Compaction and Sintering: A hydraulic mechanism is used to pre-press and level the billet at a low pressure of 0.8–1.2 MPa, then the pressure is increased to 3.5–4.0 MPa for overall compaction, maintaining the tooling constraint. The billet with tooling is then fed into a high-temperature sintering furnace. The axial pressure load of the tooling is maintained throughout the heating and heat preservation sintering process, with constraint maintained only during the cooling stage until gradient locking is completed. This prevents fiber springback at high temperatures from causing density relaxation of the roller body and degradation of the radial gradient structure. A three-stage gradient sintering process combined with rapid cooling is used to form a covalent bonded overall structure between layers and lock the radial density gradient. The three-stage gradient sintering temperatures are 280–320℃ for low-temperature drying, 650–700℃ for medium-temperature bonding, and 950–1000℃ for high-temperature setting.

[0057] The inner fiber discs are doped with rigid, closed-cell hollow ceramic microspheres. During axial pressing, these microspheres form a rigid support, preventing compaction and maintaining a stable porosity of 4%–6%. The outer structure is undoped pure fiber, lacking rigid support. Under the same pressure of 3.5–4.0 MPa, the fiber gaps are fully closed, achieving a high-density, low-porosity structure. Combined with full-end-face isobaric tooling pressing, pressure holding throughout sintering, and rapid cooling to lock the holes, a fixed radial density gradient with a denser outer layer and a looser inner layer is ultimately formed, preventing high-temperature homogenization failure.

[0058] S5. Demolding and finishing: After the roller has cooled naturally to room temperature in the furnace, remove it, loosen the fasteners and disassemble the edge limiting pressure ring and the center pressure plate in sequence to complete the tooling disassembly without damage; turn and ultra-precision grind the outer circle of the roller to obtain a high-precision traction roller finished product.

[0059] In the above method: the heat-resistant fiber discs doped with hollow ceramic microspheres on the inner side are doped with 5-20 μm closed-cell hollow ceramic microspheres at a mass ratio of 3%-5%, while the outer dense layer is undoped; the micro-limiting grooves have a depth of 1-2 mm and a spacing of 8-12 mm; the rapid cooling process includes: cooling to below 600℃ at a cooling rate of ≥10℃ / min after sintering to suppress high-temperature homogenization diffusion and lock the gradient structure. The thermal expansion coefficient of the adaptive transition layer is between that of the roller shaft metal material and the heat-resistant fiber traction roller material. The gap at room temperature facilitates assembly and demolding, and under high-temperature conditions, it can adaptively compensate for the thermal expansion difference between the roller shaft and the roller body, dynamically correcting the concentricity of the roller body.

[0060] The overall structure and manufacturing process of this invention are compatible with overflow pull-down molding production lines for high-generation ultra-thin liquid crystal glass substrates of G8.5, G10 and above, which can meet the needs of high-speed, wide-format, and high-precision continuous traction production. It has fewer molding defects, high product precision, and good batch consistency, and has good industrial application value.

[0061] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this document.

[0062] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the systems, devices, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0063] In the embodiments provided herein, it should be understood that the disclosed systems, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the couplings or direct couplings or communication connections shown or discussed may be indirect couplings or communication connections through some interfaces, apparatuses, or units, or they may be electrical, mechanical, or other forms of connection.

[0064] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of the embodiments described herein, depending on actual needs.

[0065] Furthermore, the functional units in the various embodiments of this document can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit.

[0066] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this paper, in essence, or the part that contributes to the prior art, or all or part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this paper. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory, random access memory, magnetic disks, or optical disks.

[0067] This document uses specific embodiments to illustrate the principles and implementation methods of this document. The descriptions of the embodiments above are only for the purpose of helping to understand the methods and core ideas of this document. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of this document. Therefore, the content of this specification should not be construed as a limitation of this document.

Claims

1. A high-precision traction roller for high-generation liquid crystal glass substrates, characterized in that, include: The roller shaft is a rigid support shaft. The heat-resistant fiber traction roller body is sleeved outside the roller shaft. It is formed by stacking and pressing multiple layers of heat-resistant fiber discs and sintering them at high temperature. Its outer cylindrical surface is a high-precision traction working surface that directly contacts the glass substrate. The heat-resistant fiber traction roller body has a gradient distribution structure with decreasing density from the outside to the inside along the radial direction. Its radial cross section consists of an outer ultra-dense layer and an inner loose buffer layer from the traction working surface inward. A nano-scale ceramic precursor bonding thin layer is provided between the bonding interfaces of two adjacent layers of heat-resistant fiber discs to solidify the multiple layers of heat-resistant fiber discs into an integral structure. The central pressure plates are arranged in pairs and respectively abut against the central areas on both sides of the axial direction of the heat-resistant fiber traction roller body; Edge limiting pressure rings are arranged in pairs and respectively abut against the outer edge area of ​​the axial end face of the heat-resistant fiber traction roller. Their inner rings are fitted and matched with the outer ring of the central pressure plate. The two edge limiting pressure rings are locked together by fasteners arranged evenly in the circumference to form a full-end face covering pressing fixture. The outer diameter of the edge limiting pressure ring is larger than the outer diameter of the heat-resistant fiber disc.

2. The high-precision traction roller for high-generation liquid crystal glass substrates according to claim 1, characterized in that: The outer ultra-dense layer is an annular region of no more than 3.5 mm in thickness from the outer cylindrical surface to the inner surface of the heat-resistant fiber traction roller. This region has the highest fiber compaction and a porosity of ≤1.2%. The inner loose buffer layer is the area between the inner wall surface of the heat-resistant fiber traction roller body that mates with the roller shaft and the outer boundary of the outer ultra-dense layer, and the porosity of this area is 4% to 6%. The heat-resistant fiber disc matrix of the inner loose buffer layer is uniformly doped with closed-cell hollow ceramic microspheres with a particle size of 5-20 μm and a doping mass ratio of 3%-5%; the outer ultra-dense layer is a pure fiber matrix without particle doping.

3. The high-precision traction roller for high-generation liquid crystal glass substrates according to claim 1, characterized in that: The nanoscale ceramic precursor bonding thin layer is a nano-silica precursor bonding coating with a thickness of 0.5–1.5 μm.

4. The high-precision traction roller for high-generation liquid crystal glass substrates according to claim 1, characterized in that: An annular thermal expansion adaptive transition layer is provided between the inner wall of the heat-resistant fiber traction roller and the outer wall of the roller shaft. The thermal expansion adaptive transition layer is made of a composite sintered material of ceramic fiber and boron nitride, and its coefficient of thermal expansion is between that of the roller shaft metal material and the heat-resistant fiber traction roller body material. The thermal expansion adaptive transition layer has a uniform radial clearance of 0.05 to 0.15 mm with the roller shaft at room temperature, and the gap is filled with high-purity boron nitride thermally conductive and lubricating filler. The two axial ends of the thermal expansion adaptive transition layer adopt an elastic floating contact structure with the end face of the central pressure plate.

5. The high-precision traction roller for high-generation liquid crystal glass substrates according to claim 1, characterized in that: The inner circumferential side of the edge limiting pressure ring is uniformly provided with rectangular micro-limiting grooves, the groove depth is 1-2mm and the spacing is 8-12mm.

6. The high-precision traction roller for high-generation liquid crystal glass substrates according to claim 1, characterized in that: The heat-resistant fiber traction roller body has a miniature high-temperature sensing unit array embedded in its interior along the axial and circumferential directions, including temperature sensors, pressure sensors, and wear monitoring sensors; the leads of each sensor are led out along the internal channel of the roller shaft and connected to an external data acquisition and processing system.

7. A method for manufacturing a high-precision traction roller for a high-generation liquid crystal glass substrate, characterized in that, The method for preparing the high-precision traction roller according to any one of claims 1 to 6 includes the following steps: S1. Transition layer pre-installation: A thermal expansion adaptive transition layer is installed at a predetermined position on the outside of the roller shaft. The transition layer and the roller shaft have a pre-reserved radial gap at room temperature and are filled with thermally conductive lubricating filler. S2. Pre-treatment and stacking of the green body: Prepare graded heat-resistant fiber discs with hollow ceramic microspheres on the inside and pure fibers on the outside; uniformly coat the surface of each heat-resistant fiber disc with a nano-silica precursor bonding coating so that the precursor penetrates into the gap between the fiber surface layers; sequentially stack the heat-resistant fiber discs of each grade on the outside of the transition layer, and stack them in a sparse-inside-dense-outside-layer manner to form a gradient green body, and embed a high-temperature sensing unit array during the stacking process; S3. Tooling assembly: Assemble a central pressure plate and an edge limiting pressure ring with micro-limiting tooth groove on both sides of the blank, and pre-tighten and position it by circumferential fasteners; S4. Gradient compaction and sintering: First, the billet is pre-pressed and leveled with low pressure of 0.8-1.2MPa, and then the pressure is increased to 3.5-4.0MPa for overall compaction; the billet is treated with a three-stage gradient sintering combined with a rapid cooling process. S5. Demolding and finishing: After cooling, the tooling is disassembled without damage, and the outer circle of the roller is turned and ultra-precision ground to obtain a high-precision traction roller finished product.

8. The method for preparing a high-precision traction roller for a high-generation liquid crystal glass substrate according to claim 7, characterized in that: The inner heat-resistant fiber discs doped with hollow ceramic microspheres contain 5-20 μm closed-cell hollow ceramic microspheres with a mass ratio of 3%-5%, while the outer dense layer is undoped. The micro-limiting tooth groove has a depth of 1-2 mm and a spacing of 8-12 mm; the rapid cooling process includes: cooling to below 600℃ at a cooling rate of ≥10℃ / min after sintering.

9. The method for preparing a high-precision traction roller for a high-generation liquid crystal glass substrate according to claim 7, characterized in that: The three-stage gradient sintering temperatures are 280–320℃ for low-temperature drying, 650–700℃ for medium-temperature bonding, and 950–1000℃ for high-temperature setting.

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