AT507316A2 - ROLLER ROLLER, DISC ELEMENT FOR SHAPING THE ROLL LAYER ON A ROLLER ROLLER, AND METHOD FOR PRODUCING A ROLLER ROLLER - Google Patents

Description

• · · · t "·" • · ····· * • · · · · · · 1

The invention relates to a grooved roller for use in a web forming machine for generating a vacuum, wherein the grooved roller has a frame and a groove layer. The invention also relates to a corresponding disc element and a grooved roller.

Patent Publication Fl 20031461 proposes a roller in which an open surface structure is connected to the roll neck in a closed manner. A roll having such a construction may be used in a web forming machine at a plurality of positions to create a vacuum associated with the roll. The construction of an open surface of the roll consists of separate grooves having crests between them. Some mentioned ways of carrying out the formation of rolling grooves include milling and turning. Further, it has been proposed in this application to perform the grooves by welding, gluing or mechanically locking separate leaf discs to the surface of the frame roller. Leaf discs can be made of metal, polymer or a combination of several materials.

Making a grooved roll using the prior art methods is expensive. The material of the crests between the grooves is metal in the prior art to achieve sufficiently resistant rolls. Actual embodiments are found only for metal. Manufacturing the prior art designs is typically difficult and expensive. In addition, when a grooved roller is made of metal, it is exceptionally heavy.

The object of the invention is to provide a novel roller for use in a web forming machine for generating a vacuum. A grooved roll according to the invention can be made dimensionally accurate regardless of the casting process or the molding process of the grooved layer. The characteristic features of this invention are that a filler component layer is included between the frame and the groove layer, and the groove layer has separately formed disk elements having a bottom part and a disk part. Another object of the invention is to provide a novel disc member for forming a groove layer of a grooved roller used in a web forming machine for generating a vacuum. Disc elements according to the invention may be stacked one over the other for the duration of a molding. The characteristic features of this invention are that the disc element is a separately formed 67182

Disc element is that has a bottom part and a disc part. Another object of the invention is a novel method of manufacturing a grooved roll used in a web forming machine to create a vacuum. The method according to the invention enables a cost-efficient method of forming a grooved roll. Attaching a groove layer to the frame simultaneously compensates for inaccuracies of the disc elements. The characteristic features of this invention are that a groove layer is attached to a frame using a filler component layer, and the groove layer is formed of separately formed disk elements having a bottom part and a disk part.

The invention relates to a grooved roller for use in a web forming machine for generating a vacuum. A vacuum is created in conjunction with the web supported by the grooved roll. In other words, the grooved roll is used to create a vacuum between the grooved roll and the web. The web refers to cardboard or paper webs. Conversely, the web forming machine, that is, a fiber web forming machine, refers to machines used to produce paper or paperboard. The grooved roller has a frame and a groove layer. In the groove layer, adjacent grooves may be separate grooves having a circumference, or may be formed by a spiral groove. In addition, a filler component layer is included between the frame and the groove layer. The filler component layer thus functions simultaneously as a fastening component layer. In other words, the groove layer is attached to the frame with the filler component layer. The filler component layer enables simplification of the production of the grooved roll since it is not necessary to weld individual disc elements to the frame surface. In addition, the filler component layer can be used to attach materials of many different types to the frame. The frame material can be selected relatively freely with regard to the attachment. In other words, the material of both the frame and the groove layer can be selected exactly as desired when their attachment to each other is solved by the use of a filler component layer. The production of a grooved roll according to the invention can be carried out in its entirety in a considerably cheaper manner compared with the prior art, at the same time providing a grooved roll which is equipped with better properties than before. φ · · ······ · t t ···········································································································································································

In addition to the filler component layer included between the frame and the groove layer, the groove layer has separately formed disk elements having a bottom part and a disk part. Separately formed disc elements can be manufactured in a simple way, for example by casting. When a disk member has a bottom part and a disk part, assembling a groove layer using disk elements is easily performed. The bottom part holds the disc parts of the disc elements at a desired distance from each other. Separately formed disc elements can be made of a hard material, for example of a thermosetting plastic. The material for the grooved roll must be hard to maintain its shape. In particular, deformations of high grooved ridges in the grooved roll are possible if the material is too soft.

In one embodiment, the grooved roller has a frame and a groove layer consisting of a plurality of ridges and grooves in a comb layer. In addition, the groove layer between the ridges and the grooves of the comb layer has a continuous bottom portion of the comb layer attached to the frame with a continuous filler component layer. That is, the groove layer using the filler component layer is attached over a longer distance than a comb width. By attaching the groove layer with the same filler component layer over a longer distance than a comb width, a continuous construction is achieved. In addition, this construction is easy to manufacture.

In another embodiment, a composite layer is cast between the frame and the groove layer centered with the grooved roll in the vertical position and the groove layer substantially relative to the frame. Using this method, it is possible to eliminate manufacturing defects occurring in the frame or groove layer, typically casting defects in the disk elements forming the groove layer, in a simple manner already in the mounting stage of the frame and the groove layer. This simplifies the manufacture and subsequently required corrections are very low.

In a third embodiment, the filler component is cured by heating. This allows a rapid formation of a resilient filler component having a thickness of several millimeters. In other words, the thickness of the filler component is a significant part of eliminating dimensional errors occurring in the

Frame and the groove layer occur, sufficient. On the other hand, this filler component layer can be formed and cured at a sufficient rate for efficient production.

The invention will now be described in detail by making reference to the attached drawings which illustrate some of the embodiments of the invention in which:

Figure 1 shows a grooved roll according to the invention seen from the end of the grooved roll,

Figure 2 shows a grooved roller according to the invention seen from the side of the grooved roller,

Figure 3a shows a portion of a grooved roll from the side of the grooved roll during grooving production;

Figure 3b shows a portion of a grooved roll from the side of the grooved roll in a fully formed grooved roll,

Figure 4 shows a partial section of a grooved roll according to the invention from the side of the grooved roll in a fully manufactured grooved roll,

Figure 5a shows a separately formed disc element according to the invention,

Figure 5b shows separately formed disc elements according to the invention connected together,

Figure 6a shows a portion of a grooved roll according to the invention from the side of the grooved roll during manufacture,

Figure 6b shows a portion of a grooved roll according to the invention from the side of the grooved roll for a fully formed grooved roll, and

Figure 7 shows an application of a grooved roll according to the invention.

Figure 1 shows a grooved roller 10 according to the invention seen from the end of the grooved roller 10. The grooved roller is for use in a web forming machine

Creating a vacuum constructed. The grooved roll creates a vacuum on the part of the web for which the web covers the grooved roll. A web forming machine has a plurality of positions where a grooved roll according to the invention can be used. A grooved roll according to the invention can be used, for example, in the drying section (the drying section) as a reverse roll, a backup roll or a paper roll. In addition, a grooved roll according to the invention may be used as a

Dewatering roll in the press section (the press section) or in the forming section (the sheet forming zone) are used. The roll can be made within a very wide range of diameters. Further, the groove depth as well as the comb width for optimizing the operation of the grooved roller can be widely adjusted. The groove layer of the grooved roller, that is, the disc elements, must be made of a hard plastic, so that they can be provided with desired profiles.

When the material of the disc member is hard, the disc member maintains its shape. Disc elements made of a hard material keep their shape upright. Accurate dimensional stability is required because then the manufacture between the frame and the disc element is simplified because casting can be performed without pressure. A pouring between the frame and the

Disc member without pressure is significantly easier compared to die casting, which requires soft materials to ensure sufficient roundness.

The grooved roll 10 according to the invention, shown in FIG. 1, has a frame 12 and a groove layer 14. At the center of the frame 12 there is a shaft 22 from which the grooved roller can be secured to the frame of the web forming machine. The groove layer 14 has a comb layer 16 and a bottom layer 18. The comb layer 16 and the bottom layer 18 are visible as a groove layer 14 from the end of the grooved roll 10. A broken line 19 illustrates that the groove layer in the longitudinal direction of the grooved roller has combs made of a comb layer and comb bottoms consisting of a bottom layer. The term " longitudinal direction of the grooved roll " is here used to denote the width direction of the web forming machine. In addition, a filler component layer 20 is interposed between the frame 12 and the groove layer 14. The filler component layer allows attachment of many types of groove layers to the frame. Material selections that are freer than before allow production of grooved rolls that are lighter than before. In addition, at the same time a construction is achieved which resists corrosion and wear better than before. • · # # ···································· 6

Figure 2 shows a side view of a grooved roll 10 according to the invention. A portion in the middle of the grooved roller is not shown. The frame 12 consists of a continuous frame component, but the frame may also consist of more than one frame component in the longitudinal direction of the frame. Metal frame components may be connected, for example, by laser welding. Advantageously, the frame is made of a composite material, such as carbon fiber. A filler component layer allows the groove layer 14 to be made of a different material than the frame 12. In the case where the prior art grooves 24 are formed directly on the surface of the frame 12 for creating a groove layer 14, the groove layer 14 and the frame 12 are made of the same material. Nevertheless, very different properties are required for these. Disc members made of plastic, for example, are connected to the frame 12 for producing the groove layer 14. Combs 26 are provided in the groove layer between the grooves 24.

In the grooved roll shown in Fig. 2, the frame is made of a composite material, preferably carbon fiber. The density of the composite material chosen for the frame should be below 2100 kg / m3, preferably below 1800 kg / m3. Using a properly selected composite material, preferably carbon fiber, a grooved roll having desired properties can be made. For example, a key feature is vibration, which becomes significant especially at machine speeds exceeding 2000 m / min. The wall thickness of the composite frame is 5 to 30 mm, preferably 5 to 25 mm. In general, a small mass, a higher specific frequency, and a lower level of vibration due to good damping characteristics can be considered advantages of the composite construction. The density of the composite material selected for the groove layer should be below 2000 kg / m 3, preferably below 1700 kg / m 3. Due to their lightness, the composite construction also enables non-powered solutions. The mass of non-driven grooved rolls has an effect on machine operation since undriven rolls take the energy required for rotation from the fabric. Heavy non-driven rollers would stress the screen especially during acceleration. In general, it can be said that lightweight grooved rolls according to the invention allow faster adjustment of the grooved roll speed to the operating condition than before and with lower stresses. In addition, composites have good resistance under the conditions prevailing in the web forming machine where the temperature can exceed 100 eC and the moisture level can be appreciably high. Further, process chemicals occur in the web forming machine, such as chlorides and alkalis, to which the grooved roll must be resistant. The invention enables a composite frame, because the combs are not fixed by welding, for example, as in the prior art. In addition to plastic composites, light metals are good materials due to their lightness. The roll diameter is 400 to 1000 mm, typically 600 to 900 mm. In a reverse roll application, it may exceed 1500 mm. The width of the web forming machine, d. H. the roll length can be for example 11m.

Figure 3a shows a portion of a grooved roll 10 seen from the side of the grooved roll 10 during manufacture of the grooved roll. The grooved roll 10 has a frame 12 and a groove layer 14. A filler component layer 20 is included between the frame 12 and the groove layer 14. Using the filler component layer, a rectangular belt produced by extrusion has been attached to the grooved roller, and inequalities between the angular belt and the grooved roller have been filled.

FIG. 3b shows a partial section of a grooved roll 10 from the side of the grooved roll 10, wherein the grooved roll 10 is completely manufactured. The groove layer 14 of the grooved roll 10 consists of an open rectangular band. In other words, the grooves 24 and the ridges 26 are made of an opened square profile formed by extrusion. Thus, the filler component layer 20 included between the frame 12 and the groove layer 14 allows the frame and the groove layer to be made of different material.

Figure 4 shows a portion of a grooved roll according to the invention from the side of the grooved roll 10, wherein the grooved roll is completely made. The grooved roller has disc elements. In other words, the groove layer of the grooved roller consists of disc elements. Preferably, each disk element 28 has a bottom part 30 and a disk part 32. When the disc member 28 has a bottom portion 30 and a disc portion 32, attaching the disc member 28 is very easy because attaching the bottom portion 30 of the disc member 28 to the frame 12 with a filler component also secures the disc portion 32 to the frame 12. At the same time grooves 24 are generated between the combs 26. Attaching such a disk member with a filler component is very advantageous because then the grooves need not be supported during manufacture using a separate support means to correct for a width. In the prior art, when disc elements are fixed by, for example, welding, they may deform, in which case it is difficult to fix them. In the prior art, support disk elements during manufacture cause additional work compared to the method according to the invention.

Figure 4 shows a portion of a grooved roll 10 according to the invention from the side of the grooved roll 10, the grooved roll 10 being completely made. The groove layer 14 of the grooved roll 10 consists of separately formed disk elements 28. Separately formed disk elements are preferably separately cast disk elements which are made by separate casting with, for example, die casting and joined together when fully manufactured. The disk elements 28 are connected to the frame 12 with a filler component layer 20 made by casting. Casting allows the filler component layer to be made to a desired thickness. The thickness of the filler component layer is 2 to 8 mm, preferably 3 to 5 mm. Although the average thickness is over 2 mm, the thickness may be smaller at some points. In this case, the filler component layer can be used to significantly compensate for inaccuracies in the constituents forming the groove layer and the frame. In other words, the filler component layer enables removal of inaccuracies generated in the production of the frame and the groove layer when the frame and the groove layer are bonded together. More specifically, the filler component layer can be used to reduce casting defects that occur in the

Disc elements occur to uniform.

FIG. 4 shows details of the groove roller dimensions. The height of the comb layer 16 of the grooved roll, d. H. the groove depth a, is 15 to 112 mm, preferably 20 to 80 mm. The width b of the combs is 1.5 to 5 mm, preferably 2 to 3 mm. The groove width c is 3 to 8 mm, preferably 4 to 6 mm. The thickness i of the bottom layer 18 is less than half the height h of the groove layer 14, preferably the thickness i of the bottom layer 18 is less than 1/3 of the height h of the groove layer 14. The thickness i of the bottom layer 18 is 3 to 15 mm, preferably 4 to 8 mm. For example, when the thickness i of the bottom layer 18 is 5 mm, the dimensions d, e, f and g are as follows. The distance d between the wedge structure 42 and the groove bottom 24 is 0.5 to 2 mm, preferably about 1 mm. The distance e between the wedge structure 42 and the inner periphery 50 of the disk element

9 is 0.5 to 2 mm, preferably about 1 mm. The thickness of the wedge structure 42 is 2 to 4 mm, preferably about 3 mm. The wedge or alignment structure may also have a uniform thickness, although it preferably has a slightly wedge-like shape. The opening degree of the groove surface is 30 to 90%, preferably 45 to 75%. In other words, the grooves cover 30 to 90% of the groove surface, preferably 45 to 75%, and the combs cover the remainder. Plastic and composite used as the surface material of the grooved roll should be hard so that the grooves and crests in a desired type can be processed in the grooved roller. In addition, the combs should be stiff and they should not bend, even during use. For this reason, the material of the groove layer should be hard; therefore, a deep groove groove layer may not be made of rubber, for example.

The hardness of the groove layer, d. H. Shore A is 80 to 100, preferably 88 to 98. It is thus possible to use vinyl ester, polyester and epoxy. The above materials can also be used with reinforced fibers; Thus, the disc elements may consist of, for example, vinyl ester / glass fiber composite.

The groove layer 14 in the grooved roll according to the invention, shown in Figure 4, is preferably made of a composite material, since a composite material precisely allows the desired properties for the groove layer. A composite material is a generic name for combinations of two or more materials in which the materials interact, but do not dissolve or unite.

In the grooved roll 10 according to the invention shown in FIG. 4, a separately formed disk element 28 has a bottom part and a disk part 32. The bottom portion 30 further includes an axial wedge structure 42 for aligning the disc elements 28 with each other. The wedge construction is required for fabrication because it allows assembly and alignment of the separately manufactured disk elements relative to one another. Alignment takes place in a simple way, but still exactly. Thus, the disc elements can be stacked on each other so that their wedge parts coincide with each other. Holes at the center of the disc elements coincide with each other and the disc elements form a long opening in which the frame is placed.

10

The wedge construction also seals the disc elements together so that the casting material can be highly fluid. When the disk elements are around the frame, a filler component layer is formed between the frame and the disk elements. The filler component layer is of plastic material, i. H. of polymeric material, which is preferably epoxy. Epoxy is extremely good as the material of the filler component layer, i. H. as the casting material, since epoxy is liquid and easily fills even small holes.

Figure 5a shows a disc member 28 for forming the groove layer of a grooved roller used in a web forming machine for generating a vacuum. Such a disk element 28 is a separately formed disk element 28. The separately formed disk element is continuous in the axial direction. The separately formed disc element does not consist of disc elements which are spirally connected to each other. The separately formed disc element 28 advantageously has a bottom part 30 and a disk part 32. The bottom part 30 further comprises a wedge structure 42 for aligning the separately formed disc elements 28 to each other.

When a grooved roll is used which is used to create a vacuum in a web forming machine, the grooved layer is secured to the frame with a filler component layer. In terms of roll operation and cost efficiency, the disk element must be made such that the comb is as narrow as possible and the groove is as wide as possible.

Figure 5b illustrates separately formed disc elements which are interconnected. Each separately formed disc member has a bottom part 30 and a disc part 32, so that when the disc elements 28 are connected, the groove layer 14 of the grooved roller is directly formed. The disk parts have a desired distance from each other in a fully manufactured grooved roller when the distance of the disk elements from the bottom parts is determined.

The bottom portion 30 of the separately formed disc member 28, shown in Figure 5b, has an axial wedge structure 42 for aligning the disc members 28 to each other. The wedge construction further seals the disk elements to each other so that a continuous bottom part 31 of the comb layer for the disk elements is produced. A continuous bottom part does not allow liquid cast material in one

11 significant way. When the bottom portion of the comb layer is continuously formed by means of a wedge structure, manufacturing becomes easier. More specifically, clamping the end flanges of the construction is not required in the manufacture during casting.

As described above, disc elements made of a hard material, preferably thermosetting plastic, are very dimensionally stable. Due to the good dimensional stability, die casting is not required. Conversely, a wedge design allows for sealing of the bottom portion of the comb structure which prevents casting material from passing through the bottom portion. If sufficient tightness is achieved with the wedge design, clamping of the end flanges is not required. Producing grooved rolls made of disc elements having a wedge construction is advantageous because there is no need to use the aforementioned methods.

The inner periphery 50 of the separately formed disc member shown in FIG. 5a has an alignment protrusion 52. When the separately formed disc elements 28 are connected, the alignment projections 52 are placed at radially different locations (Figure 5b). Thereafter, when the frame is placed in the center of the connected disk elements, the frame is automatically centered with respect to the disk elements. The disc elements may also be placed on the frame. The disk elements may be individually placed on the frame, but preferably the disk elements are placed on the frame as groups that have been joined together. An alignment protrusion per disc element is sufficient, but there may also be more than one alignment protrusion. Preferably, each disc element has an equal number of alignment projections that allow the disc elements of the same shape to be cast. The alignment projection is, for example, a hemisphere having a diameter of about 5 mm. The slotted surface allows the frame to be pressed into easily connected disc elements or to assemble the disc elements around the frame. The contact area between the spherical surface and the frame is small so that the filler component layer does not lack significantly at the position of the aligning component. The alignment projection may also have another shape, such as a rectangular shape.

Separately formed disc elements may also be used to form a spiral groove in the groove layer. In this case, the disc elements also cover a uniform circle from the frame, but the disc part is turned. Thus, the radial adjustment of the disk parts relative to each other must be performed accurately. In a preferred embodiment, the disc parts are perpendicular to the frame shaft, in which case no need to worry about this aspect.

FIG. 6 a shows a groove roller blank 11 whose groove layer is formed from separately formed disc elements 28. The disk elements have a bottom part 30, a disk part 32 and an alignment part 54. The alignment member ensures that the disk elements are absolutely parallel during casting. An alignment part on the outer periphery allows a very high accuracy.

Figure 6b shows a grooved roll 10 made from a grooved roll blank 11 shown in Figure 6a. Alignment parts 54, d. H. an alignment sublayer, have been machined out of the surface of the groove roller blank 11. The alignment sublayer may be very thin. When the alignment piece is removed, the material loss is very moderate. However, reworking as a separate step causes an extra operation, but compared to milling, material loss is very reduced. The comb layer formed by separately cast disk elements may then be processed.

Preferably, a separately formed disc element consists of a disc part and a groove part. If the disk part has no other structures, the groove layer is formed directly and requires no subsequent processing.

The disc elements can be produced particularly well by printing processes. Disc elements made of a fiber reinforced material can be made by, for example, transfer molding (transfer molding) or compression molding (injection compression molding). In a transfer molding, the raw material is heated and metered into a separate cylinder, from which it is pressed to a mold cavity. Conversely, in compression molding, the raw material is metered to an open mold and the mold is closed, whereby the piece takes the shape of the mold cavity with compressive forces ranging between 5 and 25 MPa. During pressing, the raw material is in a liquid state that is a homogeneous whole. Thus, for example, no air bubbles are generated in the disk elements.

In hot forming (hot pressing), a reinforcement and a resin are molded into the final shape in a heated mold by using a hydraulic press 13. Preferably, the disk element is produced by hot molding of SMC or BMC material. Then, reduced demand for subsequent finishing, high strength, and low creep of the disk member are achieved as compared with other plastic products as well as good mechanical strength and heat resistance. In addition to the above, a key feature of molded articles is dimensional stability, since the molding shrinkage during curing is only 0.05 to 0.3%. In addition, a design that provides alignment and sealing properties may be created with the technique used.

Figure 7 shows the use of a grooved roll 10 according to the invention in an impingement dryer section 40. The grooved roll 10 creates a vacuum in conjunction with a web 36 supported by a wire 34 over part of the course of the grooved roll passing through the wire 34 and the web 36 is covered. Vacuum generation in conjunction with a grooved roll 10 according to the invention is enhanced with a flow control device 38. In this embodiment, the reversing roller 44, whose diameter may be even more than 1500 mm as described above, may be a grooved roller. The reversing roll 44 is driven since its significant large size increases the mass of a grooved roll used as a reverse roll to a level at which application of a non-driven grooved roll would require significantly more energy from the wire for its rotation.

Innsbruck, November 5, 2009

Claims (14)

Claims 1. A rip roll for use in a web forming machine for creating a vacuum, said grooved roll (10) having a frame (12) and a groove layer (14), characterized in that a filler component layer (20) is interposed between said frame (12). and the groove layer (14) is inserted and the groove layer (14) has separately formed disk elements (28) having a bottom part (30) and a disk part (32). 2. grooved roller according to claim 1, characterized in that the bottom part (30) has an axial wedge construction (42) for aligning the disc elements (28) to each other. 3. grooved roller according to claim 1 or 2, characterized in that the groove layer (14) consists of a composite material. 4. grooved roller according to one of claims 1 to 3, characterized in that the frame (12) consists of a composite material. 5. grooved roller according to one of claims 1 to 4, characterized in that the frame (12) consists of carbon fiber. A disk member for forming a groove layer of a grooved roller used in a web forming machine for generating a vacuum, characterized in that the disk member (28) is a separately formed disk member (28) having a bottom part (30) and a disk part (32) ) having. 7. Disc element according to claim 6, characterized in that the Bodenteii (30) has a construction with axial wedges (42) for aligning the disc elements (28) to each other. 8. Disc element according to claim 6 or 7, characterized in that the disc element (28) has an inner circumference (50) having an alignment projection (52). 2 9. Disc element according to claim 9, characterized in that the disc element (28) is a composite material. A method of manufacturing a grooved roller for use in a web forming machine for creating a vacuum, wherein the grooved roller (10) comprises a frame (12) and a groove layer (14), characterized in that the groove layer (14) is attached to the frame (12 ) is attached to a filler component layer (20) and the groove layer (14) is formed of separately formed disc elements (28) having a bottom portion (30) and a disc portion (32). A method according to claim 10, characterized in that separately formed disc elements are aligned with each other with a construction with axial wedges (42) included in a bottom part (30). 12. The method according to claim 11, characterized in that a filler component layer (20) between the frame (12) and the groove layer (14) with the groove roller (10) in the vertical position and the groove layer (14) substantially with respect to the Frame (12) is poured centered. The disc member according to claim 12, characterized in that the groove layer (14) is centered with respect to the frame (12) using an alignment projection (52) included on the inner periphery (50) of each disc member (28) , 14. The method according to claim 11 or 12, characterized in that the filler component (20) is cured by heating. Innsbruck, November 5, 2009