Base material for disk process for producing the same, and disk roll

Patent metadata

Field	Value
Publication number	US-9604865-B2
Application number	US-201414306262-A
Country	US
Kind code	B2
Filing date	Jun 17, 2014
Priority date	Nov 6, 2008
Publication date	Mar 28, 2017
Grant date	Mar 28, 2017

Abstract

A process for producing a base material for disks including forming a raw slurry material into a platy shape and drying the plate, the raw slurry material containing inorganic fibers which have a wet volume of about 300 mL/5 g or larger and which are amorphous or have a degree of crystallinity of about 50% or lower.

First claim

What is claimed is:

1. A process for producing a base material for obtaining therefrom ring-shaped disks for use in forming a disk roll, the process comprising the steps of:
(1) forming a raw slurry material consisting essentially of more than 30% by mass to about 70% by mass of mullite fibers comprising Al 2 O 3 and SiO 2 in a ratio that Al 2 O 3 :SiO 2 is from about 60:about 40 to about 99:about 1, about 2% by mass to about 30% by mass of Kibushi clay, 2% by mass to 20% by mass of bentonite, more than 25% by mass to about 40% by mass of mica, and one or more members selected from an organic binder, organic fibers and a flocculant,
(2) forming the raw slurry material of step (1) into a platy shape, and
drying the plate formed in step (2) thereby producing a base material.

2. The process for producing a base material according to claim 1 , wherein the mullite fibers have a wet volume of about 300 mL/5 g or larger.

3. The process for producing a base material according to claim 1 , wherein the mullite fibers are amorphous or have a degree of crystallinity of about 70% or lower.

4. The process for producing a base material according to claim 1 , wherein the mullite fibers have an average fiber diameter of about 2 μm-about 7 μm.

5. A method for producing a glass, the method comprising
conveying glass on a disk roll, the disk roll comprising a rotating shaft and a plurality of ring-shaped disks fitted thereon by insertion, wherein a peripheral surface of the ring-shaped disks is a conveying surface of the disk roll,
the disks consisting essentially of
more than 30% by mass to about 70% by mass of mullite fibers comprising Al 2 O 3 and SiO 2 in a ratio that Al 2 O 3 :SiO 2 is from about 60:about 40 to about 99:about 1,
about 2% by mass to about 30% by mass of Kibushi clay,
2% by mass to 20% by mass of bentonite,
more than 25% by mass to about 40% by mass of mica, and
one or more members selected from an organic binder, organic fibers and a flocculant.

6. A process for producing a base material for obtaining therefrom ring-shaped disks for use in forming a disk roll, the process comprising the steps of:
(1) forming a raw slurry material consisting essentially of more than 30% by mass to about 70% by mass of mullite fibers comprising Al 2 O 3 and SiO 2 in a ratio that Al 2 O 3 :SiO 2 is from about 60:about 40 to about 99:about 1, about 2% by mass to about 30% by mass of Kibushi clay, 2% by mass to 20% by mass of bentonite, and more than 25% by mass to about 40% by mass of mica,
(2) forming the raw slurry material of step (1) into a platy shape, and
drying the plate formed in step (2) thereby producing a base material.

7. The process for producing a base material according to claim 6 , wherein the mullite fibers have a wet volume of about 300 mL/5 g or larger.

8. The process for producing a base material according to claim 6 , wherein the mullite fibers are amorphous or have a degree of crystallinity of about 70% or lower.

9. The process for producing a base material according to claim 6 , wherein the mullite fibers have an average fiber diameter of about 2 μm-about 7 μm.

10. A method for producing a glass, the method comprising
conveying glass on a disk roll, the disk roll comprising a rotating shaft and a plurality of ring-shaped disks fitted thereon by insertion, wherein a peripheral surface of the ring-shaped disks is a conveying surface of the disk roll,
the disks consisting essentially of
more than 30% by mass to about 70% by mass of mullite fibers comprising Al 2 O 3 and SiO 2 in a ratio that Al 2 O 3 :SiO 2 is from about 60:about 40 to about 99:about 1,
about 2% by mass to about 30% by mass of Kibushi clay,
2% by mass to 20% by mass of bentonite, and
more than 25% by mass to about 40% by mass of mica.

Assignees

• Nichias Corp

Inventors

• Horiuchi Osamu
• Watanabe Kazuhisa
• Nakayama Masaaki

Classifications

• C04B2235/9607

  Thermal properties, e.g. thermal expansion coefficient · CPC title

• Y10T428/21

  Circular sheet or circular blank · CPC title

• C04B2235/3472

  Alkali metal alumino-silicates other than clay, e.g. spodumene, alkali feldspars such as albite or orthoclase, micas such as muscovite, zeolites such as natrolite · CPC title

• C04B33/36

  Reinforced clay-wares · CPC title

• C03B13/16 Primary

  Construction of the glass rollers · CPC title