Heat-Resistant Roll Surface Smoothing for Glass Production
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Solution Overview
Problem
Conventional heat-resistant rolls used in sheet glass production have surfaces that are not sufficiently smooth and generate dust, which can contaminate the glass ribbon and affect the quality of the produced sheet glass.
Innovation Solution
A heat-resistant roll with a roll portion containing 5% or more clay, where the surface is ground and then subjected to a surface treatment in a wet state to smoothen and densify the surface, reducing dust generation and maintaining heat resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the roll surface is ground to improve smoothness, then surface smoothness is improved, but dust generation is not sufficiently reduced
Solution Approach 1:
The roll surface is ground in advance to create a smooth base surface, and then a clay-containing coating is applied before the roll undergoes heat treatment. This preliminary coating application ensures that the smooth surface structure is established before final use, preventing dust generation while maintaining smoothness.
Solution Approach 2:
A composite structure is created by applying a coating containing 5% or more clay onto the ground roll surface. The coating layer comprises clay particles embedded in a binder matrix, forming a composite material that combines the smoothness of the ground surface with the dust-resistant properties of clay.
2Object-generated harmful factors
If clay is added to the roll portion to reduce dust generation, then dust-generating property is improved, but heat resistance may be affected
Solution Approach 1:
The clay-containing coating is subjected to heat treatment at temperatures of 800°C or higher, which transforms the clay minerals and creates a chemically stable, heat-resistant surface layer. This parameter change (heat treatment) ensures the coating maintains its dust-resistant properties while achieving the required heat resistance for glass manufacturing applications.
Solution Approach 2:
Instead of manufacturing the entire roll from heat-resistant materials, a relatively simple clay-containing coating is applied to the roll surface. This coating serves as a protective layer that can be reapplied or renewed, providing an economical solution that maintains heat resistance while reducing dust generation.
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 method results in a highly smoothed and dense roll surface that effectively reduces dust generation and maintains heat resistance, enhancing the quality of sheet glass production for applications like liquid crystal and plasma displays.
Implementation Method 1
a grinding step of grinding a roll surface of the roll portion
Implementation Method 2
a surface treatment step of performing surface treatment of smoothening the ground roll surface in a wet state
Implementation Method 3
in the second step, the roll surface may be smoothened by rotating the roll portion while pressing a substrate against the wet roll surface
Data Source
AI summary
A heat-resistant roll with improved characteristics, a production method thereof, and a method of producing sheet glass using the heat-resistant roll. A method of producing a heat-resistant roll equipped with a roll portion containing 5% by weight or more of clay includes: a grinding step (S101) of grinding a roll surface of the roll portion; and a surface treatment step (S102) of performing surface treatment of smoothening the ground roll surface in a wet state.