Disk Roll Base Material Thermal Stress Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Disk rolls used for conveying large glass or metal plates experience increased conveyance time and temperature differences, leading to thermal stress and potential disk separation or cracking due to thermal expansion differences between the disk surface and core.
Innovation Solution
A process for producing ring-shaped disks with inorganic fibers having a wet volume of 300 mL/5 g or larger, low crystallinity, and an average diameter of 2-7 μm, combined with inorganic fillers like Kibushi clay and bentonite, to create a base material that maintains flexibility and strength, reducing thermal stress and enhancing spalling resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If disk rolls are used for conveying large glass or metal plates with increased area, then the conveyance capacity is improved, but the conveyance time per plate increases and the disks heat up to higher temperatures causing thermal stress
Solution Approach 1:
The patent changes the physical and chemical parameters of the disk material by using inorganic fibers with specific characteristics (wet volume ≥300 mL/5g, low crystallinity ≤70%, diameter 2-7 μm) and controlling the slurry composition. These parameter changes enable the disks to withstand longer conveyance times and higher temperatures without thermal cracking or separation from the shaft.
2Productivity
If the disks are rapidly cooled during periodic inspections, then the inspection efficiency is improved, but the disks thermally shrink and may separate from the metallic shaft or crack due to thermal stress
Solution Approach 1:
The patent utilizes thermal expansion principles by selecting inorganic fibers with low crystallinity (≤70%) that have favorable thermal expansion characteristics. These fibers allow the disk material to expand and contract more uniformly during rapid heating and cooling cycles, reducing thermal stress and preventing separation from the metallic shaft while maintaining reliability during frequent inspections.
3Ease of manufacture
If the disks are made with conventional inorganic fibers, then the manufacturing process is simple, but the disks have poor spalling resistance and are prone to cracking under thermal stress
Solution Approach 1:
The patent employs composite materials by combining inorganic fibers with specific properties (wet volume ≥300 mL/5g, low crystallinity ≤70%, diameter 2-7 μm) with inorganic fillers in a slurry matrix. This composite structure provides both ease of manufacture through conventional forming processes and enhanced spalling resistance and crack resistance under thermal stress conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting disk rolls exhibit improved spalling resistance and reduced risk of cracking, even under rapid cooling conditions, maintaining surface integrity and conveying efficiency.
Implementation Method 1
the disks thermally shrink before the metallic shaft, which has a high heat capacity, thermally shrinks. There is hence a fear that disk separation (the phenomenon in which a gap is formed between disks) may occur and the roll surface (conveying surface) may crack due to a thermal stress attributable to a temperature difference
Data Source
AI summary
A process for producing a base material for disks including forming a raw slurry material into a platy shape and drying the plate, the raw slurry material containing inorganic fibers which have a wet volume of about 300 mL/5 g or larger and which are amorphous or have a degree of crystallinity of about 50% or lower.