Disk Roll Base Material Composition for Glass Production
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Solution Overview
Problem
The production of disk rolls for plate glass requires expensive heat-resistant inorganic fibers, and existing methods are inefficient in terms of water filtration time, necessitating a cost-effective and efficient solution for producing a disk roll suitable for glass production.
Innovation Solution
A disk roll base material comprising 5-9 wt% ceramic fibers, 20-40 wt% kibushi clay, 2-20 wt% bentonite, and 40-60 wt% mica, with ceramic fibers containing 30-70 wt% alumina and 30-70 wt% silica, and optional pulp and starch, is used to create a sheet through aqueous slurry formation and water filtration, followed by forming ring-like disk materials into a roll-like laminate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive heat-resistant inorganic fibers are used to ensure heat resistance and strength, then the disk roll can withstand high temperatures, but the production cost increases significantly
Solution Approach 1:
The patent uses a composite material system combining ceramic fibers (5-9 wt%), kibushi clay (20-40 wt%), bentonite (2-20 wt%), and mica (40-60 wt%). This composite approach allows the disk roll to achieve the required heat resistance and strength through synergistic material interactions rather than relying solely on expensive heat-resistant inorganic fibers, thereby reducing production cost while maintaining reliability
Solution Approach 2:
The patent optimizes the compositional parameters of the base material, specifically controlling the weight percentages of ceramic fibers (5-9 wt%) and adjusting the ratios of clay, bentonite, and mica. By precisely controlling these compositional parameters, the disk roll achieves adequate heat resistance with reduced fiber content, lowering the cost while maintaining necessary performance
2Ease of manufacture
If traditional water filtration methods are used to produce the disk roll base material, then the aqueous slurry can be processed, but the water filtration time is excessively long, reducing production efficiency
Solution Approach 1:
The patent modifies the compositional parameters of the aqueous slurry by incorporating specific ratios of kibushi clay, bentonite, and mica alongside ceramic fibers. These compositional changes affect the filtration characteristics of the slurry, enabling faster water removal and shorter filtration times while maintaining the integrity and quality of the base material
Solution Approach 2:
The base material formulation creates a porous structure through the combination of ceramic fibers and clay minerals. This porous network facilitates efficient water drainage during filtration, reducing filtration time while maintaining the mechanical strength and heat resistance required for disk roll application
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
This composition allows for the production of an inexpensive disk roll with balanced heat resistance, strength, and hardness, reducing the need for expensive fibers and improving efficiency in glass production while maintaining effective performance.
Implementation Method 1
mixing water, the ceramic fibers, kibushi clay, bentonite and mica to produce an aqueous slurry; and flowing the aqueous slurry in a forming chamber or a forming mold, followed by water filtration to produce a sheet
Data Source
AI summary
A base material for a disk roll, the base material including:5 to 9 wt % of ceramic fibers, 20 to 40 wt % of kibushi clay, 2 to 20 wt % of bentonite and 40 to 60 wt % of mica.