Heat-Resistant Pass Roll Felt for Zinc Winding Suppression
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Solution Overview
Problem
Existing pass rolls in hot-dip galvanized steel sheet manufacturing facilities face frequent thermal decomposition issues with phenol resin and rubber binder materials, leading to reduced productivity due to frequent maintenance needs and inconsistent suppression of zinc winding, which affects the quality of the galvanized steel sheets.
Innovation Solution
A pass roll with a heat-resistant felt layer made of fibers with a thermal decomposition temperature of 420°C or higher and a surface hardness evaluation index of more than 0.11 μm/N, preventing thermal decomposition and maintaining the suppression of zinc winding effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a phenol resin or rubber binder is used in the pass roll, then the initial suppression of zinc winding is effective, but the material thermally decomposes at high temperatures leading to frequent maintenance and reduced productivity
Solution Approach 1:
The patent changes the thermal parameter (decomposition temperature) of the pass roll material from phenol resin/rubber binder (decomposing below 400°C) to heat-resistant organic peroxide-cured resin (maintaining stability above 400°C). This parameter change allows the material to withstand the thermal environment near the galvanizing bath without decomposing, thereby maintaining zinc winding suppression functionality and reducing maintenance frequency.
Solution Approach 2:
The patent employs a composite material system consisting of heat-resistant organic peroxide-cured resin combined with specific inorganic fillers (such as alumina, silica, or magnesia) and fibrous materials. This composite structure provides both the high-temperature stability needed to prevent decomposition and the surface properties required for effective zinc winding suppression, resolving the contradiction between initial effectiveness and long-term durability.
2Area of stationary object
If the pass roll is placed near the exit side of the galvanizing bath to reduce facility size, then space is saved, but the pass roll surface temperature increases causing material decomposition
Solution Approach 1:
The patent addresses the temperature issue by changing the thermal stability parameter of the pass roll material. The heat-resistant organic peroxide-cured resin composite is specifically designed to maintain its physical and chemical properties at temperatures above 400°C, allowing the pass roll to be positioned close to the galvanizing bath exit without suffering from thermal decomposition, thus saving facility space while withstanding high temperatures.
3Ease of manufacture
If conventional materials are used in the pass roll, then manufacturing is easier and initial cost is lower, but the materials decompose thermally requiring frequent replacement
Solution Approach 1:
The patent develops a composite material system using heat-resistant organic peroxide-cured resin combined with inorganic fillers and fibrous materials. While the manufacturing process is slightly more complex than conventional materials, the composite structure provides exceptional thermal stability and mechanical properties, extending the service life of the pass roll significantly and reducing the frequency of replacement, thereby improving overall productivity.
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 heat-resistant felt layer ensures stable and prolonged suppression of zinc winding, reducing maintenance frequency and increasing productivity by maintaining the quality of hot-dip galvanized steel sheets.
Implementation Method 1
the heat-resistant felt layer has a thermal decomposition temperature of 420° C. or higher
Implementation Method 2
having a surface hardness evaluation index at 400° C. of more than 0.11 μm/N
Data Source
AI summary
A pass roll for a hot-dip galvanized steel sheet manufacturing facility, the pass roll includes: a roll body; and a heat-resistant felt layer covering the roll body, wherein the heat-resistant felt layer has a thermal decomposition temperature of 420° C. or higher and has a surface hardness evaluation index at 400° C. of more than 0.11 μm/N.