Disk Roll Base Material Using Layered Silicates for Wear Resistance
Solution Overview
Problem
Current disk rolls for glass production lack sufficient compressive strength and wear resistance, particularly when handling larger glass sheets, leading to potential damage and powder fall during transportation.
Innovation Solution
A base material for disk rolls containing layered silicates with interlayer distances exceeding 10 angstroms, combined with inorganic fibers and clay, is used to enhance compressive strength and wear resistance, preventing damage and powder fall during glass transportation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional base materials (mill board, planar compact) are used for disk rolls, then the structure is simple and easy to manufacture, but the compressive strength and wear resistance are insufficient for handling larger glass sheets
Solution Approach 1:
The patent uses composite base materials consisting of inorganic fibers (such as alumina fibers, silica fibers) combined with binders and fillers to create a material with enhanced compressive strength and wear resistance. This composite structure allows the disk roll to handle larger glass sheets while maintaining manufacturability through established composite material processing techniques.
2Temperature
If heat resistant inorganic fiber, mica, or clay is contained in the disk roll to respond to heat resistance demands, then heat resistance is improved, but the compressive strength and wear resistance are still insufficient
Solution Approach 1:
The patent combines heat resistant inorganic fibers with specific binders and fillers in a composite structure, where the fiber network provides both heat resistance and mechanical strength. The synergistic combination of materials allows simultaneous achievement of high temperature resistance and enhanced compressive strength beyond what single materials can provide.
Solution Approach 2:
The patent optimizes the composition ratios, fiber diameter, length, and arrangement parameters of the inorganic fibers along with binder and filler content to achieve the desired balance between heat resistance and compressive strength. By carefully controlling these parameters, the material properties are tuned to meet both thermal and mechanical requirements.
3Productivity
If the disk roll transports belt-like glass melt for a long time, then productivity is maintained, but wear resistance is insufficient leading to powder fall and glass damage
Solution Approach 1:
The composite base material structure with interlocked inorganic fibers and binders creates a highly wear-resistant surface that can withstand continuous contact with glass melt. This structure prevents powder fall and maintains surface integrity over extended operation periods, ensuring both high productivity and reliability simultaneously.
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 base material provides improved compressive strength and wear resistance, reducing glass damage and powder fall, enabling the production of high-quality glass sheets with reduced flaws.
Implementation Method 1
the layered silicate contains two or more kinds of minerals having an interlayer distance exceeding 10 angstroms
Implementation Method 2
when different kinds of minerals come into contact, catching is generated between minerals, and generation of worn chips (so-called powder dropping) during wearing may be suppressed
Data Source
AI summary
A base material for a disk roll containing a layered silicate, in which the layered silicate is constituted to contain two or more kinds of minerals having an interlayer distance exceeding 10 angstroms. A base material for a disk roll is excellent in the compressive strength and wear resistance thereby.