Disk Roll Wear Resistance via Composite Material Density
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Solution Overview
Problem
Existing disk rolls for glass production face challenges in wear resistance and contamination, requiring improvements to sustain long-term use without damaging the glass or introducing dust.
Innovation Solution
A disk roll composed of fired disks with specific density and composition, including 20-50% ceramic wool, 5-30% kibushi clay, 2-20% bentonite, and 20-45% filler such as mica, alumina, or calcined kaolin, which are mounted on a shaft and fired at temperatures between 300°C to 700°C to achieve optimal wear resistance and surface smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the disk roll uses conventional materials (inorganic wool, mica, clay) to transfer molten glass continuously, then the disk roll can maintain operation over time, but it exhibits poor wear resistance and generates dust contamination
Solution Approach 1:
The disk roll uses a composite material consisting of ceramic wool (30-70 wt%), kibushi clay (10-40 wt%), and filler (10-40 wt%). This composite structure combines the wear resistance of ceramic wool with the binding properties of kibushi clay and the filler materials, creating a material that resists wear and prevents dust generation while maintaining continuous operation capability
Solution Approach 2:
The invention changes the density parameter of the disk roll material to 1.20-1.50 g/cm³ by adjusting the composition and firing conditions. This density optimization ensures the material is dense enough to prevent dust generation and contamination while maintaining the necessary wear resistance for continuous glass transfer operations
2Reliability
If the disk roll is made with higher density to reduce wear, then wear resistance improves, but manufacturing complexity increases due to precise density control requirements
Solution Approach 1:
The invention establishes a target density range of 1.20-1.50 g/cm³ for the disk roll material. By defining this specific parameter range and providing corresponding composition guidelines (ceramic wool 30-70 wt%, kibushi clay 10-40 wt%, filler 10-40 wt%), the invention simplifies manufacturing control while ensuring adequate wear resistance
Solution Approach 2:
The invention applies different material properties to different components: ceramic wool provides wear resistance, kibushi clay provides binding and structural integrity, and filler materials adjust density and texture. This local quality assignment allows each component to contribute specifically to the overall performance within the target density range
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 disk roll exhibits excellent wear resistance and reduced dust formation, ensuring the glass production process is efficient and contamination-free, with improved hardness and thermal expansion compatibility.
Implementation Method 1
a plurality of disks that are mounted to the shaft, the plurality of disks mounted having been fired
Implementation Method 2
firing the plurality of disks so that the plurality of disks have a density of more than 1.20 g/cm3 and 1.50 g/cm3 or less
Data Source
AI summary
A disk roll includes a shaft, and a plurality of disks that are fitted to the shaft, the plurality of disks fitted having been fired, having a density of more than 1.20 g/cm3 and 1.50 g/cm3 or less, and including 20 to 50 wt % of ceramic wool, 5 to 30 wt % of kibushi clay, 2 to 20 wt % of bentonite, and 20 to 45 wt % of a filler, the filler being selected from mica, alumina, wollastonite, cordierite, and calcined kaolin.