阅读说明：本技术 耐热辊、其制造方法以及使用其的板状玻璃的制造方法 (Heat-resistant roll, method for producing same, and method for producing plate-shaped glass using same ) 是由 渡边和久 三原彻也 于 2014-08-22 设计创作，主要内容包括：一种耐热辊的制造方法,其中包括制作含有5重量％以上的粘土类矿物的辊部的辊部制作工序；研削上述辊部的辊表面的研削工序；在使研磨后的上述辊表面润湿的状态下进行平整的表面处理的表面处理工序；在经过上述表面处理后的辊表面上形成粘土类矿物的覆膜的粘土覆膜工序。(A method for manufacturing a heat-resistant roll, comprising a roll portion manufacturing step of manufacturing a roll portion containing 5 wt% or more of clay minerals; a grinding step of grinding the surface of the roller portion; a surface treatment step of performing a smooth surface treatment in a state where the surface of the roller after polishing is wetted; and a clay coating step of forming a coating of a clay mineral on the surface of the roll after the surface treatment.)

1. A method for manufacturing a heat-resistant roller, wherein,

the method comprises the following steps:

a roll part production step of producing a roll part containing 5 wt% or more of a clay mineral;

a grinding step of grinding the roll surface of the roll portion;

a surface treatment step of performing surface treatment on the ground roller surface, the surface treatment being to flatten the ground roller surface in a state of being wetted; and

a clay coating step of forming a coating of a clay mineral on the surface of the roll after the surface treatment.

2. The method for manufacturing a heat-resistant roller according to claim 1,

the swelling power of the clay mineral coating the surface is more than 15ml/2 g.

3. The method of manufacturing a heat-resistant roller according to claim 1 or 2,

the clay mineral coating the surface is more than 1 selected from bentonite, nodular clay and kaolin.

4. The method for producing a heat-resistant roller according to any one of claims 1 to 3,

in the clay coating step, a liquid containing a clay mineral is attached to the surface of the roll after the surface treatment, and the roll is dried to form a clay mineral coating film.

5. A method for manufacturing a heat-resistant roller, wherein,

the method comprises the following steps:

a roll part production step of producing a roll part containing 5 wt% or more of a clay mineral;

a grinding step of grinding the roll surface of the roll portion;

and a surface treatment step of performing a surface treatment of flattening the ground roll surface in a state in which the roll surface is wetted with a liquid containing a clay mineral, to form a coating film of the clay mineral on the roll surface.

6. The method for producing a heat-resistant roller according to claim 1 to 5,

in the surface treatment step, in which the surface treatment is performed in a wet state, the surface treatment is performed by performing a first step and then performing a second step,

wherein the first step is to wet the surface of the ground roller; the second step is to flatten the surface of the wetted roll.

7. The method for manufacturing a heat-resistant roller according to claim 6,

in the second step, the roll surface is flattened by pressing a base material on the wetted roll surface and rotating the roll portion.

8. The method for producing a heat-resistant roller as claimed in any one of claims 1 to 7,

in the surface treatment step, the base material after being wetted is pressed on the roller surface of the rotating roller portion, thereby performing the surface treatment.

9. The method for producing a heat-resistant roller according to any one of claims 1 to 8,

the coating amount of the clay mineral is 1m on average in terms of solid content²The surface area is 0.1g or more.

10. A heat-resistant roll, wherein the surface part of a roll part containing 5 wt% or more of a clay mineral is coated with the clay mineral.

11. The heat-resistant roller as claimed in claim 10,

the surface portion of the roll portion is more densified than the interior of the roll portion.

12. A heat-resistant roller, wherein,

the heat-resistant roll is produced by the method according to any one of claims 1 to 9.

13. The heat-resistant roll according to any one of claims 10 to 12,

the coating amount of the clay mineral is 1m on average in terms of solid content²The surface area is 0.1g or more.

14. A method for producing a plate-like glass, wherein,

use of the heat-resistant roller according to any one of claims 10 to 13 as a roller for conveyance.

Technical Field

The present invention relates to a heat-resistant roll, a method for producing the same, and a method for producing plate glass using the same, and more particularly, to improvement of heat-resistant roll characteristics such as low dusting.

Background

In the production of plate-shaped glass, heat-resistant rolls having roll portions are used to convey a glass ribbon in a molten state. In order to produce high-quality plate glass suitable for liquid crystal displays and plasma displays, it is necessary to reduce the adverse effect of the heat-resistant roll on the glass ribbon as much as possible.

In view of this, patent documents 1 to 3 propose grinding of the surface of the roll portion in the processing of the heat-resistant roll. Further, patent document 4 describes that the surface is ground and then leveled with water.

Documents of the prior art

Patent document

Patent document 1: japanese laid-open patent publication No. 2004-299980

Patent document 2: japanese patent laid-open publication No. 2007-269604

Patent document 3: japanese Kohyo publication No. 2005-520774

Patent document 4: japanese patent application laid-open No. 2010-095437

Disclosure of Invention

However, in the case of manufacturing high-quality and thin plate-like glass used in liquid crystal displays, plasma displays, and the like, high cleanness is required for the roller surface. Therefore, the heat-resistant roller is required to have further reduced dusting properties.

The present invention has been made in view of the above-described problems, and an object thereof is to provide a heat-resistant roll having a reduced dusting property on the roll surface, a method for producing the same, and a method for producing plate glass using the heat-resistant roll.

The present inventors have conducted special and repeated studies and, as a result, have independently found that: by forming a coating film of a clay-based mineral on the surface of the roll portion, the dusting property can be reduced without substantially changing the characteristics of the heat-resistant roll.

The present invention can provide the following method for manufacturing a heat-resistant roll.

1. A method of manufacturing a heat-resistant roller, comprising:

a roll part production step of producing a roll part containing 5 wt% or more of a clay mineral;

a grinding step of grinding the roll surface of the roll portion;

a surface treatment step of performing a surface treatment for smoothing the ground roll surface in a state of being wetted; and

a clay coating step of forming a coating of a clay mineral on the surface of the roll after the surface treatment.

2. The method for producing a heat-resistant roller as described in claim 1, wherein the clay-based mineral covering the surface has a swelling power of 15ml/2g or more.

3. The method for producing a heat-resistant roll according to claim 1 or 2, wherein the clay-based mineral coating the surface is 1 or more selected from bentonite, knar clay and kaolin.

4. The method for producing a heat-resistant roll according to any one of claims 1 to 3, wherein in the clay coating step, a liquid containing a clay mineral is adhered to the surface of the roll after the surface treatment, and the liquid is dried to form a coating of the clay mineral.

5. A method for manufacturing a heat-resistant roller, wherein,

the method comprises the following steps:

a roll part production step of producing a roll part containing 5 wt% or more of a clay mineral;

a grinding step of grinding the roll surface of the roll portion; and

and a surface treatment step of performing a surface treatment of flattening the ground roll surface in a state in which the roll surface is wetted with a liquid containing a clay mineral, to form a coating film of the clay mineral on the roll surface.

6. The method for manufacturing a heat-resistant roller as recited in any one of claims 1 to 5,

in the surface treatment step, in which the surface treatment is performed in a wet state, the surface treatment is performed by performing the first step and then performing the second step,

wherein the first step is to wet the surface of the ground roller; the second step is to flatten the surface of the wetted roll.

7. The method of manufacturing a heat-resistant roller as recited in claim 6, wherein,

in the second step, the roll surface is flattened by pressing a base material on the wetted roll surface and rotating the roll portion.

8. The method for manufacturing a heat-resistant roller as recited in any one of claims 1 to 7,

in the surface treatment step, the base material after wetting is pressed on the roller surface of the rotating roller portion, thereby performing the surface treatment.

9. The method for manufacturing a heat-resistant roller as recited in any one of claims 1 to 8,

the coating amount of the clay mineral is 1m on average in terms of solid content²The surface area is 0.1g or more.

10. A heat-resistant roll, wherein the surface part of a roll part containing 5 wt% or more of a clay mineral is coated with the clay mineral.

11. The heat-resistant roller according to claim 10, wherein a surface portion of the roller portion is more densified than an inside of the roller portion.

12. A heat-resistant roll produced by the method according to any one of 1 to 9.

13. The heat-resistant alloy as described in any of 10 to 12A roll, wherein the coating film amount of the clay mineral is 1m on average in terms of solid content²The surface area is 0.1g or more.

14. A method for producing a plate-like glass using the heat-resistant roller according to any one of 10 to 13 as a conveying roller.

The present invention can provide a heat-resistant roll having a reduced dusting property on the surface of the roll portion, a method for producing the same, and a method for producing plate glass using the same.

Drawings

Fig. 1 is an explanatory view for explaining an example of a heat-resistant roll according to an embodiment of the present invention.

Fig. 2 is an explanatory view showing an example of producing plate-like glass using the heat-resistant roll shown in fig. 1.

Fig. 3 is a schematic view showing main steps included in the method for manufacturing a heat-resistant roll according to embodiment 1 of the present invention.

Fig. 4 is an explanatory view showing an example of surface treatment using a base material in the method for manufacturing a heat-resistant roll according to embodiment 1 of the present invention.

Fig. 5 is a schematic view showing main steps included in the method for manufacturing a heat-resistant roll according to embodiment 2 of the present invention.

Detailed Description

Hereinafter, a heat-resistant roll, a method for manufacturing the same, and a method for manufacturing plate glass using the heat-resistant roll according to embodiments illustrated in the present invention will be described with reference to the drawings. In the present embodiment, an example in which the heat-resistant roller according to the present invention is realized as a disc roller having a plurality of disc members stacked on each other is mainly described, but the present invention is not limited to the present embodiment.

First, an outline of the disc roller according to the present embodiment and a method for manufacturing plate-shaped glass using the disc roller will be described. Fig. 1 shows an example of a disc roller 1. As shown in fig. 1, the disc roller 1 includes a cylindrical roller portion 10 extending in the longitudinal direction thereof.

The roll portion 10 is configured by stacking a plurality of disk members 11 containing 5 wt% or more of a clay mineral (hereinafter, also simply referred to as clay) in the longitudinal direction of the roll portion 10. That is, a plurality of disc members 11 constituting the roller portion 10 are fitted to a shaft portion 20 serving as a rotation shaft of the disc roller 1.

In the present invention, the surface of the roll portion 10 is further coated with a clay mineral. The clay mineral uniformly dispersed in the entire roll portion 10 may be the same as or different from the clay mineral coated on the surface.

The stacked plurality of disc members 11 are fixed in a state compressed in the longitudinal direction of the shaft portion 20 by flanges 21 and nuts 22 provided at both end portions of the shaft portion 20. Therefore, the surface of the roller portion 10 (hereinafter, referred to as "roller surface 12") is configured by connecting the outer circumferential surfaces of a plurality of disc members 11 stacked in a compressed state.

The structure of the disc roller is not limited to the structure in which the entire shaft is covered with the disc member as shown in fig. 1, and may be, for example, a structure in which the shaft is covered with the disc member only at a portion where glass contacts, a structure having a single shaft form, a structure in which the disc portion can be removed, or the like.

The disc roll 1 can be used as a conveying roll in the production of sheet glass. Fig. 2 shows an example of a disc roller 1 used as a conveying roller in manufacturing sheet glass. As shown in fig. 2, in a plate glass manufacturing apparatus (not shown), a pair of disc rollers 1 arranged in parallel is provided so as to be rotatable about the shaft portion 20. In addition, the disc 1 may be connected to a power generation device (not shown). In this case, the disc roller 1 may be rotated based on the power generated by the power generation device.

Then, the glass ribbon 30 conveyed in a molten state from the upstream side of the conveyance path is conveyed to the downstream side while being sandwiched by the pair of rotating roller portions 10. That is, in the example shown in fig. 2, the glass ribbon 30 is conveyed vertically downward (in the direction indicated by the arrow D shown in fig. 2). The flat glass can be produced by float method, roll-out method, Colburn method, or the like, in addition to the above-described downdraw method.

The glass ribbon 30 is slowly cooled by being conveyed by the disk roll 1. In fig. 2, only one pair of disc rollers 1 is shown, but 2 or more pairs of disc rollers 1 may be provided along the conveyance path.

The disc roll 1 may be used as a pulling roll for applying tension to the glass ribbon 30 in order to adjust the nominal sheet thickness of the sheet glass to be produced. The nominal sheet thickness of the sheet glass to be produced can be adjusted by the speed of drawing the glass ribbon 30 by the drawing rolls.

In this way, in the production of the plate-like glass, it is preferable that the roll surface 12 in contact with the glass ribbon 30 has characteristics such as heat resistance to withstand a high temperature equal to or higher than the melting temperature of the glass, crack resistance (crack resistance) to take out the roll immediately for a line failure or the like, flexibility of the glass ribbon 30 not to be in contact with, durability against a high temperature for a long time, and low dusting property not to contaminate the glass ribbon 30.

Here, the heat-resistant roll of the present invention is a roll having a heat shrinkage rate of 1% or less, as measured by the method described in examples.

Hereinafter, the disc roller 1 having such excellent characteristics and the method for manufacturing the same (hereinafter, referred to as "the present manufacturing method") will be described.

According to one embodiment of the present invention, the disc roller 1 is first assembled using a plurality of disc members 11. In the production of the disc member 11, first, an aqueous slurry is prepared, and a plate-like body (so-called "thick paper board") having a predetermined thickness is produced from the aqueous slurry.

The aqueous slurry is prepared in a composition according to the composition that the finally manufactured disk material 11 should have. That is, for example, the aqueous slurry contains clay minerals in an amount necessary to achieve a content of 5 wt% or more in the disc material 11 attached to the disc roll 1.

As the clay-based mineral, a mineral having a characteristic of being sintered by heating can be preferably used. The number of the compounds may be 1 or more than 2. Specifically, for example, a fire clay such as a knar clay or a frog clay (Potter's clay), bentonite, or kaolin may be used, and the fire clay may be preferably used. Among them, the knar clay is preferable because the bonding effect by sintering is high and the impurities are small.

The aqueous slurry may further contain an inorganic fiber or a filler. The inorganic fibers are not particularly limited as long as they are reinforcing materials for improving the strength of the disk member 11, and any kind of inorganic fibers may be appropriately selected and used, and 1 kind may be used alone or 2 or more kinds may be used in combination.

That is, for example, artificial inorganic fibers such as ceramic fibers, glass fibers, and rock wool fibers can be preferably used. More specifically, for example, alumina fibers, mullite fibers, silica-alumina fibers, and silica fibers having excellent heat resistance can be particularly preferably used.

The filler is not particularly limited as long as it contributes to improvement of the properties such as heat resistance and strength of the disc member 11, and any kind of filler may be appropriately selected and used, and 1 kind may be used alone or 2 or more kinds may be used in combination. That is, for example, inorganic fillers such as mica, wollastonite, sepiolite (sepiolite), silica, alumina, cordierite (cordiolite), and calcined kaolin may be used, and among these, mica having excellent characteristics such as high elasticity, lubricity, abrasion resistance, and heat resistance may be preferably used. Further, scaly silica or scaly alumina can be used, and particularly, scaly silica is preferable because it has high abrasion resistance. The scaly silica is preferably a 2-order aggregate formed by superposing scaly silica in parallel, or a 3-order aggregate formed by collecting a plurality of the 2-order aggregates. Specifically, the flaky 1 primary particles of the scaly silica are leaf-shaped silica secondary particles formed by orienting the flaky 1 primary particles in parallel between planes and overlapping a plurality of the flaky 1 primary particles. The lobed silica 2 primary particles may be further three-dimensionally agglomerated to form 3 primary particles. The 2 nd-order and 3 rd-order leaf-shaped particles are described in Japanese patent application laid-open Nos. 2006-143666 and 3795671.

The aqueous slurry may further contain an auxiliary agent for improving the properties such as moldability. As the auxiliary agent, for example, an organic material or an inorganic material which can be eliminated from the disc member 11 by firing the disc member 11 can be used. As the organic material, an organic binder such as pulp, starch, and fibers or particles of synthetic resin can be used.

The aqueous slurry prepared as a mixture of these raw materials is formed into a sheet and dried to produce a cardboard. The formation of the cardboard can be preferably performed by a papermaking method using a paper machine. The thickness of the thick paper sheet may be set to a desired value corresponding to the thickness of the disc member 11, and may be set to a range of 2 to 30mm, for example.

Then, a part of the cardboard sheet is punched into a disk shape, and the punched disk body is obtained as the disk member 11. In addition, a through hole for inserting the shaft portion 20 at the time of assembly is formed in the center of the disc member 11.

The disc member 11 may be a fired disc obtained by pressing a cardboard sheet, or may be a disc obtained by pressing a cardboard sheet without firing. After assembling the disc roll 1 having the plurality of disc members 11, the roll portion 10 including the plurality of disc members 11 may be fired. Further, the roll portion 10 may be fired after the surface treatment in the surface treatment step S20 described later is performed on the roll portion 10. The firing conditions are not particularly limited, and may be appropriately changed depending on the conditions such as the specification of the firing furnace, the volume density and the size of the disk member 11. That is, the firing temperature is not particularly limited, and may be, for example, in the range of 300 to 1000 ℃, preferably in the range of 400 to 900 ℃, and more preferably in the range of 500 to 800 ℃. The firing time is not particularly limited, and may be, for example, 1 to 24 hours.

In the case of manufacturing the fired disk material 11, the firing can eliminate the auxiliary agent such as the organic material contained in the cardboard. As a result, the disk member 11 made of the sintered inorganic material can be obtained. In addition, in the disc member 11 after firing, voids derived from the disappearance of a part of the material accompanying the firing can be formed.

The disc member 11 may be manufactured by die molding. That is, the disc member 11 can be manufactured, for example, by pouring a slurry prepared as a mixture of the above-described raw materials into a mold having a predetermined shape corresponding to the shape of the disc member 11, and performing suction dehydration molding. Alternatively, the disk material 11 containing the clay mineral may be produced by impregnating the surface of the disk molded by the mold with a clay slurry and drying the clay slurry.

The disc member 11 molded by the mold may be fired. The firing conditions such as the firing method, the firing period, the firing temperature, and the firing time are the same as those described above.

The disk member 11 thus obtained (disk member 11 after firing when firing is performed) contains 5 wt% or more of clay-based minerals. The content of the clay-based mineral is more preferably 10% by weight or more, and still more preferably 15% by weight or more.

On the other hand, the upper limit of the clay mineral content may be appropriately set in accordance with the characteristics required for the disc roll 1. That is, the content of the clay-based mineral is, for example, preferably 50 wt% or less, and more preferably 45 wt% or less. If the clay-based mineral content is high, problems such as the generation of cracks, the formation of cracks, and the separation of the plurality of disc members 11 are likely to occur in the roll portion 10, and the disc roll 1 may not exhibit its performance sufficiently.

Therefore, the content of the clay-based mineral in the disc roll 11 may be, for example, 5 to 50 wt%, preferably 10 to 30 wt%, and more preferably 10 to 43 wt%.

The clay-based mineral preferably contains a nodular clay and bentonite. The content of each of these is preferably 5 to 30% by weight, more preferably 7 to 25% by weight, and still more preferably 8 to 23% by weight.

The amount of the inorganic fiber or filler contained in the disc member 11 can be appropriately set according to the kind of these materials or the characteristics required for the disc roll 1. That is, the content of the inorganic fibers is, for example, preferably 20 to 50% by weight, more preferably 25 to 45% by weight, and still more preferably 30 to 43% by weight.

The content of the filler is, for example, preferably 5 to 50% by weight, more preferably 7 to 40% by weight, and still more preferably 10 to 35% by weight.

The clay mineral, the inorganic fiber, the filler and the organic binder can account for more than 90%, more than 95%, more than 98% or 100% of the disc roller.

The plurality of disc members 11 thus manufactured are sequentially fitted into the shaft portion 20. Further, the plurality of disc members 11 stacked along the shaft portion 20 may be fastened in the longitudinal direction of the shaft 20 by oil pressure or the like. Then, the plurality of disk members 11 in the compressed state are sandwiched by a pair of flanges 21 provided at both end portions of the shaft portion 20, and are further fixed by a pair of nuts 22. Further, after fitting the plurality of disc members 11 into the shaft portion 20, they may be fixed by the flange 21 and the nut 22 without being compressed.

In this way, the disc roller 1 including the roller portion 10 in which the plurality of disc members 11 are stacked can be assembled. By compressing and fixing the plurality of disc members 11 constituting the roller portion 10, the roller portion 10 can be solidified and densified more than the disc members 11 before being assembled.

The roller portion 10 is not limited to the plurality of disk members 11 stacked as described above. That is, the roll portion 10 may be formed into 1 cylindrical molded body containing 5 wt% or more of clay mineral, for example. The roller portion 10 may be formed by laminating a plurality of cylindrical molded bodies containing 5 wt% or more of a clay mineral along the shaft portion 20.

Such a cylindrical molded body can be produced, for example, by die molding using a raw material containing the above-described inorganic material as a main component, and in this case, the roll portion 10 can be produced as a cylindrical molded body by pouring a slurry prepared as a mixture of the above-described raw materials into a mold having a predetermined shape corresponding to the shape of the roll portion 10, and performing suction dehydration molding. In this case, the slurry before the mold is molded may contain a clay mineral in advance. Alternatively, the roll portion 10 containing the clay mineral may be manufactured by impregnating the clay slurry into the surface of the cylindrical molded body molded by the mold and drying the impregnated cylindrical molded body.

The roll portion 10 may be an inorganic fiber molded body containing a clay mineral between fibers. That is, the roll portion 10 may be formed by winding a sheet-like inorganic fiber molded body containing a clay mineral between fibers around the shaft portion 201 time or more, for example.

In this case, the roll portion 10 can be produced by impregnating the inorganic fiber molded body with clay slurry, for example. Specifically, for example, the roll portion 10 can be manufactured by impregnating inorganic fiber paper with clay slurry and then winding the inorganic fiber paper around the shaft portion 20. For example, an inorganic fiber paper containing a clay mineral may be manufactured by papermaking of a slurry containing the clay mineral, and the roll portion 10 may be manufactured using the inorganic fiber paper. The roll portion 10 may be produced by winding an inorganic fiber blanket around the shaft portion 20, impregnating the inorganic fiber blanket with clay slurry, and drying the impregnated inorganic fiber blanket.

These cylindrical shaped articles or inorganic fiber shaped articles may be fired. Further, after assembling the heat-resistant roll having the roll portion 10 including the plurality of disk members 11, the cylindrical molded body, or the inorganic fiber molded body as described above, the roll portion 10 may be fired. Further, the roll portion 10 may be subjected to surface treatment in the surface treatment step S20 described later, and then the roll portion 10 may be fired. In these cases, the firing conditions are not particularly limited, and may be appropriately changed depending on the conditions such as the specification of the firing furnace, the bulk density or size of the cylindrical molded article or the inorganic fiber molded article, and the like. The firing temperature and firing time were the same as described above.

The surface processing of the thus-produced roller will be described below with reference to the drawings. Fig. 3 shows the main steps included in embodiment 1 of the present manufacturing method. The right end shows the approximate appearance of the surface.

First, in the grinding step S10, the roll surface 12 of the disc roll 1 assembled in the assembling step is ground. That is, by grinding off a part of the roll surface 12 in a dry state, the roll surface 12 is smoothed, and the diameter of the roll portion 10 is adjusted. For example, as shown in fig. 1, the diameter of the roller portion 10 in the longitudinal direction may be adjusted to be constant.

In the present embodiment, the grinding step S10 includes a cutting step S12 and a polishing step S14.

First, the roll surface 12 is cut by a cutting device such as a capstan to remove relatively large irregularities on the roll surface 12 (cutting step S12). However, as shown in the right column of the figure, minute irregularities remain on the surface.

Next, the roll surface 12 is further polished by a polishing tool such as sandpaper to be planarized (polishing step S14). At this time, as shown in the right column of the figure, microparticles generated by grinding enter the concave portion.

The cutting step S10 may not be divided into the cutting step S12 and the polishing step S14, and the cutting and polishing may be performed in the same step, or either step may be omitted depending on the surface state.

Next, in the surface treatment step S20, the roll surface 12 ground in the grinding step S10 is subjected to a surface treatment, i.e., flattened in a wet state. In this embodiment, in the surface treatment step S20, water is first applied to the ground and dried roll surface 12 (water application step S22).

Although water is used in the present embodiment, any kind of liquid is not particularly limited as long as it can be immersed in the roll surface 12 and does not contain a solute, and 1 kind may be used alone or 2 or more kinds may be used in combination. That is, for example, water, ethanol, acetone, or other polar solvents can be preferably used, and among these, water is particularly preferably used from the viewpoint of ease of handling and the ability to effectively plasticize clay-based minerals.

Further, not limited to coating, a spraying device such as a sprayer may be used.

The roll surface 12 may be plasticized by wetting. That is, the fine particles constituting the roll surface 12 are solidified and strongly bound in a dry state, but are softened in a wet state and relatively easily deformed or moved.

Then, in the surface treatment step S20, an external force is further applied to the wetted roll surface 12 to flatten the roll surface 12 (flattening step S24). I.e. for example wiping the wetted roll surface 12 and applying a shear force in a direction along the roll surface 12.

In this way, a portion of the microparticles that make up the roll surface 12 can be made to move along the roll surface 12. As a result, the unevenness of the roller surface 12 can be reduced.

That is, for example, as shown in the right column of the figure, the fine particles constituting the convex portions of the roll surface 12 are moved along the roll surface 12 and embedded in the concave portions of the roll surface 12, thereby smoothing the roll surface 12.

In addition, by applying a force to press the roller surface 12, the microparticles constituting the roller surface 12 can also be more densely packed. That is, since the fine particles can move while being shifted from each other on the wetted roll surface 12, the fine particles can be rearranged and refilled so as to be in a more uniformly dispersed state by a load of an appropriate pressing force. As a result, the roller surface 12 can be densified.

The water application step S22 and the leveling step S24 may be performed while rotating the roller unit 10.

The surface treatment step S20 may be performed in one step, i.e., while being wetted with water, without being divided into the water application step S22 and the leveling step S24.

The surface treatment step S20 can be performed using a base material as shown in fig. 4.

Fig. 4 shows an example of a preferable mode for realizing the above surface treatment. Fig. 4 shows a cross section of the roll portion 10 cut along the line IV-IV in the disc roll 1 shown in fig. 1 and a cross section of the base material 40 used for surface treatment of the roll portion 10.

As shown in fig. 4, in this example, the surface treatment is performed by pressing the base material 40 against the rotating roll surface 12. That is, first, the roller portion 10 is rotated in the direction indicated by the arrow R shown in fig. 4 with the shaft portion 20 as the center.

Then, the base material 40 is pressed against the rotating roll surface 12, and this state is maintained. In this case, as shown in fig. 4, the base material 40 is preferably disposed along the roll surface 12. In fig. 4, the base material 40 is shown as being disposed along the circumferential direction of the roll surface 12, but the base material 40 may be disposed along the longitudinal direction of the roll surface 12. In this way, the roll surface 12 can be rotated while contacting the substrate 40.

As the substrate 40, for example, a sheet-like substrate 40 can be preferably used.

In the water application step S22, a method of bringing the base material 40 holding the liquid in advance into contact with the roll surface 12 may be used.

In the flattening process S24, the sheet-like base material 40 is pressed against the wetted roller surface 12 to arrange the base material 40 in the circumferential direction of the roller surface 12 and rotate the roller portion 10, thereby flattening the roller surface 12.

As the substrate 40, for example, a sheet-like substrate 40 in which irregularities for polishing are formed on the surface of the touch roll surface 12 such as sandpaper can be preferably used. By using the base material 40 having such a polishing function, movement and refilling of the microparticles constituting the roller surface 12 can be achieved.

As shown in fig. 4, a flexible substrate 40 that can be disposed along the roll surface 12 can be preferably used. Specifically, a sheet-like fibrous base material such as a woven fabric or a nonwoven fabric, or a sheet-like porous base material (e.g., a foamed molded article) made of a flexible synthetic polymer can be preferably used. For example, the sheet-like base material 40 (e.g., sandpaper) having the surface on which the irregularities for polishing are formed can be preferably used.

In the surface treatment step S20, the surface treatment may be performed by performing the above-described surface treatment on the roll surface 12 of the roll portion 10 rotating in one direction in the circumferential direction and further switching the rotation direction of the roll portion 10 to the opposite direction 1 or more times.

That is, in this case, first, the roll portion 10 is rotated in one direction of the circumferential direction (for example, the direction indicated by the arrow R shown in fig. 4) and the surface smoothing treatment is performed in a state where the roll surface 12 is wetted. The surface treatment may also be carried out in two stages, as described above, first wetting and then smoothing.

Next, the surface-treated roll surface 12 is not dried, and the rotation direction of the roll portion 10 is switched to the opposite direction, and the treatment is repeated. That is, in the repeated treatment, the roller portion 10 is rotated in the other direction in the circumferential direction (for example, the direction opposite to the direction indicated by the arrow R shown in fig. 4) and is subjected to a surface treatment for flattening the roller surface 12 in a state of being wetted.

Further, in the case of performing the 2 nd repetition, the second repetition is performed by switching the rotation direction of the roller section 10 to the opposite direction again without drying the roller surface 12 after the first repetition. That is, in the second repetition process, the roll surface 12 is subjected to the surface smoothing process in a wet state while the roll portion 10 is rotated again in one direction of the circumferential direction.

When the repeated process is performed 3 times or more, the rotation direction of the roller section 10 is similarly switched, and the surface treatment is performed on the roller surface 12 of the roller section 10 rotated in the switched direction. The surface treatment in the repeated treatment may be performed in two stages as described above.

In the surface treatment step S20, the pressure applied to the roll surface 12 in order to flatten the roll surface 12 is not particularly limited, and may be set arbitrarily within a range in which the above-described smoothing and densification of the roll surface 12 can be achieved.

That is, as described above, when the roll surface 12 is flattened by pressing the base material 40 (for example, the sheet-like base material 40 having a polishing function such as sandpaper) against the roll surface 12, a pressing force in a range of 100 to 2000N per unit length (1mm) in the width direction of the base material 40 (the longitudinal direction of the shaft portion 20) (that is, a pressing force in a range of 100 to 2000N/mm) may be applied to the roll surface 12.

In the surface treatment step S20, the speed at which the roll surface 12 is rotated when the roll surface 12 is flattened is not particularly limited, and may be set arbitrarily within a range in which the above-described smoothing and densification of the roll surface 12 can be achieved.

That is, the rotation speed of the roller 10 may be set to a range of, for example, 10 to 1500 rpm. The peripheral speed of the roller surface 12 may be set to, for example, 1 to 1000 m/min.

In addition, in the case of performing the surface treatment S20 in one stage, the roll surface 12 is flattened and surface-treated using a substrate wetted in advance.

When the substrate 40 contains water and is used, for example, a fibrous substrate or a porous substrate capable of holding a liquid such as water can be used. Specifically, for example, when the surface treatment is performed using water, a water-containing fibrous base material or a porous base material made of a hydrophilic material is preferably used.

In a state where the wetted substrate 40 is disposed along the roll surface 12, if the roll surface 12 is rotated, the wetted substrate 40 covers a part of the roll surface 12, and therefore, the liquid (moisture) is released slowly from the substrate 40 to wet the roll surface 12 efficiently, and the once wetted roll surface 12 can be effectively prevented from being dried again.

Next, in the clay coating step S30, clay water is applied to the roll surface 12 subjected to the surface treatment (clay water application step S32). Thereafter, the film is dried (drying step S34). The drying may be natural drying or may be performed using a dryer. This can form a coating film of the clay mineral and can also flatten irregularities that cannot be sufficiently flattened only in the surface treatment step S20. As a result, dust generation can be suppressed.

As the clay mineral, a mineral having a swelling power of 15ml/2g or more, preferably 20ml/2g or more, and more preferably 30ml/2g or more can be used. For example, a fire clay such as a knar clay or a frog clay, bentonite, or kaolin may be used.

The swelling power can be measured according to the Japanese Bentonite Geotechnology Standard test method (JBAS-104-77). Specifically, the measurement can be carried out as follows. 2g of the sample was accurately weighed and added to a 100ml stoppered measuring cylinder filled with 100ml of purified water, at which time, attention was paid to the fact that the added sample did not adhere to the inner wall. In addition, the sample is added in multiple portions in such a manner that the sample sufficiently absorbs water and disperses, and the latter sample is added after the former added sample substantially precipitates. The entire sample was added to the rear stopper, and after standing for 24 hours, the volume A (ml) accumulated in the lower part of the cylinder was read. The value read is the swelling force (ml/2 g).

The clay water used for coating may be, for example, one obtained by dissolving or dispersing 1 to 1000g of a clay mineral in 10L of water.

In the present embodiment, water is used, but the liquid is not particularly limited as long as it can appropriately dissolve or disperse the clay mineral, and any kind may be appropriately selected and used, and 1 kind may be used alone or 2 or more kinds may be used in combination. Water is preferred from the viewpoint of ease of handling and the like.

The coating amount is preferably about 0.01mm to 5mm in average film thickness, and may be increased. Or, on average, every 1m²The amount of the solid component having a surface area is about 0.1g to 1000g, preferably 0.1g to 100g, and more preferably 0.3 g to 50 g.

The coating may not cover the entire surface. Preferably 80% or more, more preferably 90% or more, and most preferably 100%.

The clay-based mineral liquid may be attached to the roll surface 12 by, for example, spraying, dipping, brushing, or dropping.

Fig. 5 shows the main steps included in embodiment 2 of the present invention. The right end shows a schematic view of the appearance of the surface.

In this embodiment, after the grinding step S10, the clay-containing water used in embodiment 1 is applied instead of the coating water (surface treatment step S40). The grinding step S10 is the same as that of embodiment 1, and therefore, description thereof is omitted.

In this embodiment, after clay-containing water is applied (clay water application step S42) and leveled and dried (leveling step S44 and drying step S46), a coating film of a clay mineral is formed in the same manner as in embodiment 1. In this step, as shown in the right column of the figure, a shearing force is applied to the wet roll surface 12 in a direction along the surface 12, and a part of the fine particles constituting the roll surface 12 is moved along the roll surface 12, thereby reducing the unevenness of the roll surface 12. At the same time, the clay minerals contained in the clay water also enter the recesses of the surface 12 to fill the recesses, and further, a clay coating is formed on the surface. Therefore, the unevenness that cannot be sufficiently flattened only by the water-only surface treatment step S20 as described in embodiment 1 can be flattened. As a result, dust generation can be suppressed.

In the thus obtained disc roll 1, the roll surface 12 is denser than the interior 13 of the roll 10. That is, in the roller portion 10, a surface portion having a predetermined thickness including the outer surface of the roller portion 10 and the vicinity thereof is locally densified.

In embodiment 2, the step of adhering clay water again and drying it (clay coating step S30) as in embodiment 1 is not required. However, as described in embodiment 1, a coating of a clay mineral may be further formed (clay coating step S30 is performed), and the thickness may be increased.

The surface 12 of the heat-resistant roll of the present invention is suppressed from dusting and is smoothed. In addition, the coating film having the clay mineral also has improved strength.

The arithmetic average roughness Ra of the roll surface 12 measured by the method defined in JIS B0601-1994 may be 5.0 μm or less, more preferably 3.0 μm or less, and particularly preferably 1.0 μm or less.

The maximum height Ry of the roll surface 12 measured by a method prescribed in JIS B0601-1994 may be 25.0 μm or less, more preferably 15.0 μm or less, and particularly preferably 10.0 μm or less.

The ten-point average roughness Rz of the roll surface 12 measured by the method defined in JIS B0601-1994 may be 25.0 μm or less, more preferably 15.0 μm or less, and particularly preferably 10.0 μm or less.

It is preferable that at least one of the arithmetic average roughness Ra, the maximum height Ry, and the ten-point average roughness Rz of the roll surface 12 is within the above range, and it is particularly preferable that all of the 3 are within the above range.

The roll portion 10 of the heat-resistant roll obtained in the present invention can maintain the same characteristics such as heat resistance in the vicinity of the surface finish state.

Examples

Example 1 and comparative example 1

A disk member having an outer diameter of 60mm and an inner diameter of 20mm was punched out of a disk roll base material, and a roll was constructed on a stainless steel shaft having a diameter of 20mm to a length of 100mm and a packing density of 1.35g/cm³A disc roll 1 shown in FIG. 1 was produced.

The disk member 11 includes: 10% by weight of a clay mineral, 10% by weight of bentonite, 40% by weight of an inorganic fiber, mullite fiber, and 32% by weight of a filler, respectively. In addition, the base material for the disc roll contains 6 wt% of pulp and 2 wt% of an organic binder as auxiliaries.

The assembled disc roll 1 is fired. The pulp and the organic binder contained in the disk member 11 are burned off by this firing.

Next, the roll surface 12 of the disc roll 1 is ground. The grinding is performed by setting the disc roller 1 to a predetermined driving device, rotating around the shaft portion 20, and bringing sandpaper into contact with the rotating roller surface 12.

Then, as in the grinding, dust-free paper (KimWipes, NIPPON PAPER CRECIA co., LTD.) previously wetted by water was pressed against the rotating roll surface 12 and kept for a predetermined time, thereby performing a surface treatment for flattening the roll surface 12 in a state of being wetted.

The surface-treated roll surface 12 is heated to be dried.

The roll surface 12 after the surface treatment is coated with an aqueous bentonite solution by a sprayer and brush. The bentonite aqueous solution was prepared by dissolving 50g of bentonite in 10L of water. Thereafter, the roll surface 12 is naturally dried to produce the disc roll 1.

As comparative example 1, a disc roll was prepared which was subjected to the surface treatment described above but not to the coating treatment described above.

The following characteristics were evaluated for each of the disc roll 1 and the disc roll not subjected to the coating treatment. The results are shown in table 1.

(1) Heat shrinkage percentage (Heat resistance)

After the disc roll was heated at 900 ℃ for 3 hours, the length of the roll in the longitudinal direction was measured, and the heat shrinkage rate was evaluated based on the following equation.

[ (measurement before heating-measurement after heating)/measurement before heating ]. times.100

(2) Resistance to spalling (Heat resistance)

The disk rolls were charged into an electric furnace maintained at 900 ℃ and after 15 hours, taken out and quenched to room temperature of 25 ℃. Then, the cycle of heating and quenching was repeated until cracking of the disc roll occurred or disc separation occurred, and the number of cycles of cracking or disc separation occurred was calculated.

(3) Flexibility (deflection under load)

Both ends of the disk roll supporting shaft were pressed against the roll surface made of the disk material by a pressing means at 8.82N/mm, and the load deflection at that time was measured.

(4) Durability (thermal wear test)

A disk member having an outer diameter of 80mm and an inner diameter of 30mm was punched out from a substrate for a disk roller containing ceramic fibers, and the roller was constructed on a shaft made of stainless steel having a diameter of 30mm to a length of 100mm and a packing density of 1.25g/cm³A disc roll was produced.

The surface of the disk roll was brought into contact with a 30 mm-diameter stainless steel shaft having 5 grooves 2mm wide and 2mm apart, and the shaft was rotated at 900 ℃ for 5 hours, then cooled to room temperature of 25 ℃ and the depth of the grooves formed on the surface of the disk roll was measured.

(5) Dusting property

The dustiness was evaluated by rubbing the roller surface on black graphic paper, measuring the weight of the powder attached to the graphic paper, and measuring the lightness of the graphic paper with a color difference meter.

The plate-like glass was actually produced using the above-described disc roll, and as a result, there was a significant difference in dusting property.

(6) Surface roughness

The arithmetic average roughness Ra, the maximum height Ry and the ten-point average roughness Rz were measured by the method specified in JISB0601-1994 using a stylus type surface roughness meter (JISB 0651).

[ Table 1]

Industrial applicability

The disk roll obtained by the production method of the present invention can be used for producing plate-like glass, particularly liquid crystal glass or plasma display glass.

Although several embodiments and/or examples of the present invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments and/or examples without materially departing from the novel teachings and advantages of this invention. Accordingly, such a large number of modifications are included in the scope of the present invention.

The contents of the documents cited in the present specification and the contents of the japanese application specification forming the paris priority base of the present application are incorporated herein in their entirety.