CA1266815A - Mat covered roll construction - Google Patents
Mat covered roll constructionInfo
- Publication number
- CA1266815A CA1266815A CA000493888A CA493888A CA1266815A CA 1266815 A CA1266815 A CA 1266815A CA 000493888 A CA000493888 A CA 000493888A CA 493888 A CA493888 A CA 493888A CA 1266815 A CA1266815 A CA 1266815A
- Authority
- CA
- Canada
- Prior art keywords
- roll
- resin
- cover
- ribbon
- core
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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- Rolls And Other Rotary Bodies (AREA)
Abstract
ABSTRACT OF THE DISCLOSURE
A resin impregnated mat covered roll especially useful in the manufacture of coated and glossy grates of paper, capable of withstanding harsh operating conditions, high speeds, and high nip loads, has the cover formed from thin spirally wound layers of resin saturated non-woven fabric presenting a temperature resist-ing uniform, smooth, long lasting roll surface which will not wear unevenly or create high and low pressure nip areas or contain trapped air bubbles. The fabric of the cover is non-woven, non-needled, light in weight, preferably having a basis weight between one half to two ounces per square yard ant a thickness gauge of between .005 to .020 inches and is wound in ribbon or strip form around the core of the roll. The resin is preferably a thermosetting epoxite.
A resin impregnated mat covered roll especially useful in the manufacture of coated and glossy grates of paper, capable of withstanding harsh operating conditions, high speeds, and high nip loads, has the cover formed from thin spirally wound layers of resin saturated non-woven fabric presenting a temperature resist-ing uniform, smooth, long lasting roll surface which will not wear unevenly or create high and low pressure nip areas or contain trapped air bubbles. The fabric of the cover is non-woven, non-needled, light in weight, preferably having a basis weight between one half to two ounces per square yard ant a thickness gauge of between .005 to .020 inches and is wound in ribbon or strip form around the core of the roll. The resin is preferably a thermosetting epoxite.
Description
i2GG8~5 S P E C I F I ~ A T I O N
.
T I T L B
"MAT CWERBD ROLL CONSTRUCIION"
FI}~nl~ OF THE It~r~NTION
This invention relates to the art of covered rolls and roll covers and particularly deals with resin impregnated mat covered rolls for papermaking machinery capable of operat$ng at high speeds under heavy nip loads while maintaining a uniformly dense finished ~urface.
PRIOR ART
In the process of manufacturing paper, especially coated and glossy grades of paper, it has been found advantageous to use a reinforced resin composlte roll cover. These covers are subjected to extremely harsh treatment in high speed, high nip loads, 91088 coating and super calendering operations which often develop high temperatures. Heretofore such composite roll covers were formed from a thick needled, nonrwoven fibrous mat or blanket. The mat was coated with a thermosetting resin, wrapped around the core of the roll, heat treated to thermoset the resin, 20 and machined to present the finished roll surface. The needling of the thick ~at was required to provide penetration of the resin, but this operation al80 increased the density of the fibers around the needled holes. The resulting finished roll cover had alternating resin rich and mat rich zones which abrade and wear at Bifferent rates, developing alternating high and low i2~i6815 areas on the roll face and translating into high and low pressure areas in the nip. As as result the sheet of paper being treated soon became marked and when this condition arose, the roll had to be taken out of ~ervice and redreJsed to dcvelop a smooth uniform surface. This reconditioning of the roll was very costly and al~o required down time of the paper machine to accommodate roll replacements. Further, small air pockets were trapped ln the resin r~ch areas of the mat. These air pockets tended to get filled with foreign materials which also marked the paper. The 10 high den~ity a~eas of the needlea fabrlc were difficult to saturate with the resin often resulting ln voids contributing to the marking of the paper sheet.
It would then be an improvement in this art to provide reinforced resin covered rolls free from the heretofore encountered deficiencie6.
F;UMMARY OF THIS INVENTION
According to this invention there are now provided reinforced resin covered rolls having a rigid metal core spirally wrapped with a ribbon or strip of resln coated very thin, light welght non-woven fibrous material in such a manner as to eliminate air pockets, and roll surface zones of different propertie~. The rolls of this invention eliminate or at least minimize heretofore encountered alternating roll surface zones which abrade or wear at different rates resulting in alternating high and low areas on th- roll face and development of high and low pressure areas ln the nip when the roll is used ln pressure rolation with nother roll as in calendering operation~ on paper webs. The flbrous web mat providing the re$nforcement for the re-ln 1~ not needled, has a very uniform texture, and is ~ -2-.. ~ .. . . . . .. . . .
~Z66815 sufficiently thin and l~ght in weight B0 that the re6~n coatingboth faces of the web i~ not sufficiently separated to develop alternate web and resin bands on tbe circumference of the roll.
Preferred fabrics for the cover are non-woven, non-needled, mats of acrylic fibers, polye6ter fibers, ar~mid fibers, carbon fiber~, or blends of these fibers having a basis we~ght of between .5 oz/yd2 to 2.0 o~ yd2 and a gauge or thickness of between .005 lnches to .020 inche~.
~ he preferred resins are of the thermosetting type such 10 as polye-ter resin-, partlcularly epoxy resin~ applied in liquid form. Suitable oommercial grades of epoxy resins prefer~bly have an epoxide equivalent weight of 100 to 200. The epoxides are prepaired in many way~ such as by reacting phenol and acetone and polyamide~ or other curlng agents are reacted with the epoxy intermediate.
The fibrous mat 1- formed into a continuous ribbon of a de~ired width, uch as for exampl- 3 to 6 inches, is coated on both faces and penetrated with the resin and is spirally wound wlth lead angle of about 2 to 3 degrees under a tension load of 20 aboot 10 lb~. per inch width around the of the roll with the edges overlapped a desired amount, ruch as for exa~ple, 1-1/2 to
.
T I T L B
"MAT CWERBD ROLL CONSTRUCIION"
FI}~nl~ OF THE It~r~NTION
This invention relates to the art of covered rolls and roll covers and particularly deals with resin impregnated mat covered rolls for papermaking machinery capable of operat$ng at high speeds under heavy nip loads while maintaining a uniformly dense finished ~urface.
PRIOR ART
In the process of manufacturing paper, especially coated and glossy grades of paper, it has been found advantageous to use a reinforced resin composlte roll cover. These covers are subjected to extremely harsh treatment in high speed, high nip loads, 91088 coating and super calendering operations which often develop high temperatures. Heretofore such composite roll covers were formed from a thick needled, nonrwoven fibrous mat or blanket. The mat was coated with a thermosetting resin, wrapped around the core of the roll, heat treated to thermoset the resin, 20 and machined to present the finished roll surface. The needling of the thick ~at was required to provide penetration of the resin, but this operation al80 increased the density of the fibers around the needled holes. The resulting finished roll cover had alternating resin rich and mat rich zones which abrade and wear at Bifferent rates, developing alternating high and low i2~i6815 areas on the roll face and translating into high and low pressure areas in the nip. As as result the sheet of paper being treated soon became marked and when this condition arose, the roll had to be taken out of ~ervice and redreJsed to dcvelop a smooth uniform surface. This reconditioning of the roll was very costly and al~o required down time of the paper machine to accommodate roll replacements. Further, small air pockets were trapped ln the resin r~ch areas of the mat. These air pockets tended to get filled with foreign materials which also marked the paper. The 10 high den~ity a~eas of the needlea fabrlc were difficult to saturate with the resin often resulting ln voids contributing to the marking of the paper sheet.
It would then be an improvement in this art to provide reinforced resin covered rolls free from the heretofore encountered deficiencie6.
F;UMMARY OF THIS INVENTION
According to this invention there are now provided reinforced resin covered rolls having a rigid metal core spirally wrapped with a ribbon or strip of resln coated very thin, light welght non-woven fibrous material in such a manner as to eliminate air pockets, and roll surface zones of different propertie~. The rolls of this invention eliminate or at least minimize heretofore encountered alternating roll surface zones which abrade or wear at different rates resulting in alternating high and low areas on th- roll face and development of high and low pressure areas ln the nip when the roll is used ln pressure rolation with nother roll as in calendering operation~ on paper webs. The flbrous web mat providing the re$nforcement for the re-ln 1~ not needled, has a very uniform texture, and is ~ -2-.. ~ .. . . . . .. . . .
~Z66815 sufficiently thin and l~ght in weight B0 that the re6~n coatingboth faces of the web i~ not sufficiently separated to develop alternate web and resin bands on tbe circumference of the roll.
Preferred fabrics for the cover are non-woven, non-needled, mats of acrylic fibers, polye6ter fibers, ar~mid fibers, carbon fiber~, or blends of these fibers having a basis we~ght of between .5 oz/yd2 to 2.0 o~ yd2 and a gauge or thickness of between .005 lnches to .020 inche~.
~ he preferred resins are of the thermosetting type such 10 as polye-ter resin-, partlcularly epoxy resin~ applied in liquid form. Suitable oommercial grades of epoxy resins prefer~bly have an epoxide equivalent weight of 100 to 200. The epoxides are prepaired in many way~ such as by reacting phenol and acetone and polyamide~ or other curlng agents are reacted with the epoxy intermediate.
The fibrous mat 1- formed into a continuous ribbon of a de~ired width, uch as for exampl- 3 to 6 inches, is coated on both faces and penetrated with the resin and is spirally wound wlth lead angle of about 2 to 3 degrees under a tension load of 20 aboot 10 lb~. per inch width around the of the roll with the edges overlapped a desired amount, ruch as for exa~ple, 1-1/2 to
2- V2~inches. Successive layers of the spirally wrapped ribbon ~-re~-pplled in such a manner that the overlappings are axially ~ ~ di~pl;aced from the overlaps of the ad~acent layers. As the ;~ ~ rlbbon i- applied to the roll, a doctor bar or blade presses it tightly again-t the underlying surface, ~queezing out excess fluld r--ln from the coatlng and forming a cylindrical surface of ~; the ~ame diameter cro-~ the entire length of the roll. The ; overlap~ of the ucce~slve layers are preferably axially 60 30~ dl~pl-ced to lie ln lde-br ide rela~ion closlng up any zones
3-, . ~ .
. ~ ~
,, . . . . ~ .
~, ., ~ .
~66~5 which might otherwi~e produce air gaps or bubbles. Since the ribbon i9 80 thin it wlll readily conform to the underlylng surf~ce.
.. .. . .. .
After a ae~ired number of layers have been applied to produce t~icknesses of about 5/8 to 7/R lnch, the wound roll is heated to ther~oset the resin and the thermoset cover ls then machined and polished to proauce the deslred finished roll surface. About 1/8 to 1/4 lnch of thicknes6 i6 removed in the surface finish$ng operatlon.
Alternately the resin coated ribbon may be wound edgewise, preferably lncllned, ln a single ~piral wrapping around the roll eore with a lead of about 5/8~ per revolution. Since the ribbon i8 80 thin alternating resin rich and mat rich bands on the circumference will be eliminated because the coatings on both faces of the ribbon are so close together and the resin penetr~tes the thin mat. The thickness of the roll of the cover formed by the ~ingle path edgewise wrapping can be controlled by th- width of the ribbon and the angle at whieh the ribbon ~ pro~eets from the eore.
The roll eoré ean have a diameter of about 1~ to 40 inches and a length of about 100 to 400 inches.
:
~ It is then an ob~ect of thi6 invention to produce reinforced re~in eoated rolls substantlally free from mat rich and re~in rieh surface bands an~ espeeially suited for ;; ~ paper aklng maohinery.
Another ob~ect of this invention is to provide resin :
lmpregnat-d flber m~t eovers foF rolls whleh have a hard surface that wear~ at the ~ame rate along its entlre eircumference and aoeo-s ltB entire length and is eapable of withstanding heavy ~ 30 loads, hlgh ~peed-, and elevated temperatures.
':' ~ ~ ;;` , ;~Z668~5 A ~peclfic object of the invent~on 18 to provide sp~rally wound thin flbrous belt covered resin coated rolls for papermaking machinery free from ~ir pockets, altern~tlng re~in r~ch ~nd f~ber rlch b~nd areas which wear at different rate~
during operation of the roll and havlng a smooth, uniform s urface.
~ nother specific ob~ect of this lnventlon i8 to provide a belt covered roll for papermaking machinery formed from very thin belt materlal.
- Other and further ob~ects of thl~ lnventlon will become apparent to those skilled ln this art from tbe following detailed descriptlon of the annexed sheet of drawlng6, which ~how best mode examples of the invention.
ON THE DRAWINGS .
FIG. l is a schematlc perspectlve view of a pressure nlp forming palr of rolls having a flber web reinforced re~in cover on the upper roll ln accordance with thls lnventions FIG. 2 18 a schematlc side view illustrating the manner ln which the upper roll of FIG. l is wrapped;
:
FIG. 3 ls a schematic plon view illustratlng the spiral ~:
wrapplng of overiying layer6 on the rolls ~:;
FIG. ~ 18 a tran~versc cros~-sectlonal view along the llne IV-rV of FIG. 3~
FIG. 5 18 a fragmentary longitudlnal crQss-sectional view along the llne V'V of FIG. ~, but greatly enl~rged to ~how and exaggerate the overlap~s _5_ :
.. .. . . . ~. . . .
., ' ;.
;1 Z66815 FIG 6 iQ a schematlc pl~n view with part~ ln 6ection ~howing an alternative wrapping for the roll6 of th$s lnvention _ FIG.7 1~ a vlew s~mllar to FIG. 5, but ~howing a modifled covcred roll AS BHOWN ON THE DRAWING~
.
In FIG. 1 the reference numeral 10 designates in general a bottom ~etal roll 11 and a top belt or mat covered roll 12 forming nip N therebetween for receivlng sheet materlal, uch as paper therethrough, to exert a squeezlng action 10 thereon The roll 11 18 formed of a hard material, ~uch as steel, and i8 8upportea on shafts 13 which are rotatably mounted ln suitable bearings (not shown).
Tbe upper roll 12 has a cylindrical hard metal, such as ~teel, core 14 with pro~ecting axles 1~ rotatably 6upported in bearings (not shown) which are shlftably mounted to create a d-slr-d nip load at N. The ~teel roll cor~ 8 wrapped with the cover 16 of thi~ invention. The cover 16 presents a ~mooth uniform contlnuou~ cylindrical surface of the s~me diameter acros- thé entire length of the roll which can directly engage a 20 face of the paper web pas~ing through the nip N to finish treat thl- -urface proviaing a glossy or calendered finlsh thereto Th oover 16 for the roll 12 may be formed a8 ll~ustrated ~n F~G. 2 from a ribbon 17 of non-needled, non-woven flbrou- materlal as described abovc, whlch 1~ unwound from a feed roll 18 -nd fed around guldc rolla 19 through a bath 20 of liquia . . , :
re-ln materl~l al-o descrlbed above oontained in an open top tank 21. The re-in ooats both faces of the r~bbon 17 and the ooated ., ~
- . . ` . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. .
lZ6~815 ribbon is fed between squeeze rolls 22 as it emerges from the tank 21 to press the resin into the fiber. The squeeze coated ribbon is then spirally wound around the roll core 14 and a doctor blade or bar 23 presses the ribbon tightly against the underlying surface as it is being wound thereby squeezing out excess resin into a pan and forming a true cylindrical surface on the core free from undulations. The resin content of the applied ribbon may be controlled to form from 60 to 95 % of the weight of the finished cover.
As shown in FIGS. 3 to 5 the ribbon 17 is advanced along the length of the core 14 in inclined relation to the axis of the core to provide spiral wrappings in a plurality of layers, broken away, and illustrated at 24-27. Each layer has adjoining edges of the ribbon overlapped as illustrated at 28. The amount of overlap can vary as described above. Any number of successive layers can be applied to produce the desired thickness for the cover 16.
Instead of being wrapped flatwise around the core 14, the ribbon 17 can be wrapped edgewise around the core as :
20 illustrated in FIG. 6. As there shown, the ribbon is addressed - ~ ~ edgewise to the core at an angle from the axis of the core and is ^ wrapped in one path from one end to the other end of the core.
This, produces a cover 16a with a circumference composed of the outer end edges of the ribbon. Since, as explained above, the ribbon 17 is so thin, the coatings on the faces of this ribbon will be so close together and the resin will so penetrate the mat that the circumference of the roll cover is substantially a continuous resin surface. The wound roll of FIG. 6 is heat treated to thermoset the resin, and is then machined and polished 30 to form the continuous roll surface. The thickness of the cover . . , i26~31S
16a can be controlled by the width ~f the rlbbon, the degree of angulat~on in wh~ch lt i~ applled to the core and, of cour~e, the amount of cover material that i~ mach~ned off of the surface.
The cover ha~ ~ unifonm den~ity and can be provlded in various degree~ of hardness such as 90 to 95 durometer on the ~D~
scale. 8ecause the mat i8 iB 80 very thin it wlll conform readily to the underlying surface and ~ince the overlap areas will only produce very thin bands, the finished roll 6urface will have a constant diameter along lts entlre length. Further, the Ooverlapping p~ttern of ~ucce~sive layers in the embodiment lllustrated ln FIGæ. 2 to 5 18 such as to produce the overl~ps in slde-by-slde relatlon on succes~ive layers thus adding up to a uniform thickne6s in the flnished wrapping.
~ n high ~peed, high nip load operatlons, the temperature of the cover may often exceed 250 degrees F and the~e temperatures may vary across the face width of the roll. Even under such extreme temperature conditions the covers of thl~
lnvention will maintain their original 6mooth uniform 6urface.
8urface speeds may also exceed 6000 feet per minute at 20 nip loads which exceed 2500 pounds per linear inch of roll face lnch. The covers of this inventlon wear very well, even under such extreme conditions.
As lllustrated ln FIG. 7 the roll cover 16 may be used as a base for a pla~tic cover 30 such as polyurethane. Thi~
plastlc cover oan be grooved clrcumferentlally as illustrated at 31 for use ln a wet pre~s. The cover will have a thickness varylng from less than to more than the thlckne66 of the cover 16 and may be lntegrally anchored to the cover 16 during the thermosettlng tep which ~et~ the resln coating on the mat.
.
lZ66815 From the above descriptions lt will be therefore under~tood to those ~killed ln this art that this invention now provides fibrou~ belt or mat reinforced plastic covered paper machlne roll~ free fro~ defect~ heretofore encountered in belt wrapped roll~.
, ~
- ~ .
g_
. ~ ~
,, . . . . ~ .
~, ., ~ .
~66~5 which might otherwi~e produce air gaps or bubbles. Since the ribbon i9 80 thin it wlll readily conform to the underlylng surf~ce.
.. .. . .. .
After a ae~ired number of layers have been applied to produce t~icknesses of about 5/8 to 7/R lnch, the wound roll is heated to ther~oset the resin and the thermoset cover ls then machined and polished to proauce the deslred finished roll surface. About 1/8 to 1/4 lnch of thicknes6 i6 removed in the surface finish$ng operatlon.
Alternately the resin coated ribbon may be wound edgewise, preferably lncllned, ln a single ~piral wrapping around the roll eore with a lead of about 5/8~ per revolution. Since the ribbon i8 80 thin alternating resin rich and mat rich bands on the circumference will be eliminated because the coatings on both faces of the ribbon are so close together and the resin penetr~tes the thin mat. The thickness of the roll of the cover formed by the ~ingle path edgewise wrapping can be controlled by th- width of the ribbon and the angle at whieh the ribbon ~ pro~eets from the eore.
The roll eoré ean have a diameter of about 1~ to 40 inches and a length of about 100 to 400 inches.
:
~ It is then an ob~ect of thi6 invention to produce reinforced re~in eoated rolls substantlally free from mat rich and re~in rieh surface bands an~ espeeially suited for ;; ~ paper aklng maohinery.
Another ob~ect of this invention is to provide resin :
lmpregnat-d flber m~t eovers foF rolls whleh have a hard surface that wear~ at the ~ame rate along its entlre eircumference and aoeo-s ltB entire length and is eapable of withstanding heavy ~ 30 loads, hlgh ~peed-, and elevated temperatures.
':' ~ ~ ;;` , ;~Z668~5 A ~peclfic object of the invent~on 18 to provide sp~rally wound thin flbrous belt covered resin coated rolls for papermaking machinery free from ~ir pockets, altern~tlng re~in r~ch ~nd f~ber rlch b~nd areas which wear at different rate~
during operation of the roll and havlng a smooth, uniform s urface.
~ nother specific ob~ect of this lnventlon i8 to provide a belt covered roll for papermaking machinery formed from very thin belt materlal.
- Other and further ob~ects of thl~ lnventlon will become apparent to those skilled ln this art from tbe following detailed descriptlon of the annexed sheet of drawlng6, which ~how best mode examples of the invention.
ON THE DRAWINGS .
FIG. l is a schematlc perspectlve view of a pressure nlp forming palr of rolls having a flber web reinforced re~in cover on the upper roll ln accordance with thls lnventions FIG. 2 18 a schematlc side view illustrating the manner ln which the upper roll of FIG. l is wrapped;
:
FIG. 3 ls a schematic plon view illustratlng the spiral ~:
wrapplng of overiying layer6 on the rolls ~:;
FIG. ~ 18 a tran~versc cros~-sectlonal view along the llne IV-rV of FIG. 3~
FIG. 5 18 a fragmentary longitudlnal crQss-sectional view along the llne V'V of FIG. ~, but greatly enl~rged to ~how and exaggerate the overlap~s _5_ :
.. .. . . . ~. . . .
., ' ;.
;1 Z66815 FIG 6 iQ a schematlc pl~n view with part~ ln 6ection ~howing an alternative wrapping for the roll6 of th$s lnvention _ FIG.7 1~ a vlew s~mllar to FIG. 5, but ~howing a modifled covcred roll AS BHOWN ON THE DRAWING~
.
In FIG. 1 the reference numeral 10 designates in general a bottom ~etal roll 11 and a top belt or mat covered roll 12 forming nip N therebetween for receivlng sheet materlal, uch as paper therethrough, to exert a squeezlng action 10 thereon The roll 11 18 formed of a hard material, ~uch as steel, and i8 8upportea on shafts 13 which are rotatably mounted ln suitable bearings (not shown).
Tbe upper roll 12 has a cylindrical hard metal, such as ~teel, core 14 with pro~ecting axles 1~ rotatably 6upported in bearings (not shown) which are shlftably mounted to create a d-slr-d nip load at N. The ~teel roll cor~ 8 wrapped with the cover 16 of thi~ invention. The cover 16 presents a ~mooth uniform contlnuou~ cylindrical surface of the s~me diameter acros- thé entire length of the roll which can directly engage a 20 face of the paper web pas~ing through the nip N to finish treat thl- -urface proviaing a glossy or calendered finlsh thereto Th oover 16 for the roll 12 may be formed a8 ll~ustrated ~n F~G. 2 from a ribbon 17 of non-needled, non-woven flbrou- materlal as described abovc, whlch 1~ unwound from a feed roll 18 -nd fed around guldc rolla 19 through a bath 20 of liquia . . , :
re-ln materl~l al-o descrlbed above oontained in an open top tank 21. The re-in ooats both faces of the r~bbon 17 and the ooated ., ~
- . . ` . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. .
lZ6~815 ribbon is fed between squeeze rolls 22 as it emerges from the tank 21 to press the resin into the fiber. The squeeze coated ribbon is then spirally wound around the roll core 14 and a doctor blade or bar 23 presses the ribbon tightly against the underlying surface as it is being wound thereby squeezing out excess resin into a pan and forming a true cylindrical surface on the core free from undulations. The resin content of the applied ribbon may be controlled to form from 60 to 95 % of the weight of the finished cover.
As shown in FIGS. 3 to 5 the ribbon 17 is advanced along the length of the core 14 in inclined relation to the axis of the core to provide spiral wrappings in a plurality of layers, broken away, and illustrated at 24-27. Each layer has adjoining edges of the ribbon overlapped as illustrated at 28. The amount of overlap can vary as described above. Any number of successive layers can be applied to produce the desired thickness for the cover 16.
Instead of being wrapped flatwise around the core 14, the ribbon 17 can be wrapped edgewise around the core as :
20 illustrated in FIG. 6. As there shown, the ribbon is addressed - ~ ~ edgewise to the core at an angle from the axis of the core and is ^ wrapped in one path from one end to the other end of the core.
This, produces a cover 16a with a circumference composed of the outer end edges of the ribbon. Since, as explained above, the ribbon 17 is so thin, the coatings on the faces of this ribbon will be so close together and the resin will so penetrate the mat that the circumference of the roll cover is substantially a continuous resin surface. The wound roll of FIG. 6 is heat treated to thermoset the resin, and is then machined and polished 30 to form the continuous roll surface. The thickness of the cover . . , i26~31S
16a can be controlled by the width ~f the rlbbon, the degree of angulat~on in wh~ch lt i~ applled to the core and, of cour~e, the amount of cover material that i~ mach~ned off of the surface.
The cover ha~ ~ unifonm den~ity and can be provlded in various degree~ of hardness such as 90 to 95 durometer on the ~D~
scale. 8ecause the mat i8 iB 80 very thin it wlll conform readily to the underlying surface and ~ince the overlap areas will only produce very thin bands, the finished roll 6urface will have a constant diameter along lts entlre length. Further, the Ooverlapping p~ttern of ~ucce~sive layers in the embodiment lllustrated ln FIGæ. 2 to 5 18 such as to produce the overl~ps in slde-by-slde relatlon on succes~ive layers thus adding up to a uniform thickne6s in the flnished wrapping.
~ n high ~peed, high nip load operatlons, the temperature of the cover may often exceed 250 degrees F and the~e temperatures may vary across the face width of the roll. Even under such extreme temperature conditions the covers of thl~
lnvention will maintain their original 6mooth uniform 6urface.
8urface speeds may also exceed 6000 feet per minute at 20 nip loads which exceed 2500 pounds per linear inch of roll face lnch. The covers of this inventlon wear very well, even under such extreme conditions.
As lllustrated ln FIG. 7 the roll cover 16 may be used as a base for a pla~tic cover 30 such as polyurethane. Thi~
plastlc cover oan be grooved clrcumferentlally as illustrated at 31 for use ln a wet pre~s. The cover will have a thickness varylng from less than to more than the thlckne66 of the cover 16 and may be lntegrally anchored to the cover 16 during the thermosettlng tep which ~et~ the resln coating on the mat.
.
lZ66815 From the above descriptions lt will be therefore under~tood to those ~killed ln this art that this invention now provides fibrou~ belt or mat reinforced plastic covered paper machlne roll~ free fro~ defect~ heretofore encountered in belt wrapped roll~.
, ~
- ~ .
g_
Claims (10)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A mat covered roll for use in high speed, heavy nip load roll installations in papermaking machinery to maintain a uniform dense finished surface on the roll which comprises a rigid roll core, an outer cover on said core composed of multiple layers of spirally wound non-woven, non-needled fibrous material having a uniform texture with substantial consistency of fiber density, said material being coated on both faces and thoroughly impregnated between the faces with a thermosetting resin, said fibrous material having a thickness not exceeding .020 inches to position the resin coatings on the faces thereof so close together and the resin impregnation so thorough as to present a substantial continuous resin body, said resin being thermoset bonding the fibrous layers together and to the core and the peripheral surface of the cover being machined and polished forming a continuous uniform resin surface.
2. The roll of claim 1 wherein the cover has an initial thickness of about 5/8 to 7/8 inches and the machining operation is controlled to remove about 1/8 to 1/4 inch of said thickness.
3. The roll of claim 1 wherein the spirally wound layers are superimposed layers of flat fibrous ribbon with adjoining spirals overlapped edgewise at least about 1/3 the width of the ribbon.
4. The roll of claim 3 wherein the overlapped portions of adjoining layers are axially spaced in side-by-side relation.
5. The roll of claim 1 wherein the spirally wound layers are formed from a continuous ribbon of the resin coated and impregnated fibrous material applied edgewise to the core and radiating outwardly therefrom.
6. The roll of claim 1 wherein the fibrous material has a basis weight of about .5 to 2.0 ounces per square yard and the resin is an epoxy set to a hardness of about 90 to 95 durometer on the D scale.
7. The roll of claim 1 including a polyurethane cover surrounding and bonded to the fibrous material cover.
8. A nip defining roll assembly for papermaking machines including a rigid metal roll, a reinforced plastics material covered metal roll in pressure nip relation therewith, the cover on said covered roll being formed from multiple layers of a spirally wound wrapping of non-woven, non-needled synthetic fibrous tape coated on both faces thereof and impregnated therethrough with a thermosetting resin, said tape having a thickness not exceeding .020 inches and having a uniform texture and density of fibers to position the resin coatings on the faces thereof so close together and the resin impregnation therethrough so thorough as to form a substantial continuous resin body, said resin being thermoset to bond the cover around the metal roll and to integrate the layers together, and said cover having a machined and polished circumference presenting a continuous resin surface to the nip.
9. The roll assembly of claim 8 wherein the spirally wound wrapping is a single pass of the fibrous material in ribbon form applied edgewise to the roll and radiating therefrom at an angle to the roll axis.
10. The method of making mat covered rolls for papermaking machines which comprises forming a ribbon of non-woven, non-needled fibrous material having a thickness not exceeding .020 inches and having uniform texture and fiber density, coating both faces of the ribbon with a liquid thermosetting resin, squeezing the coated ribbon to impregnate the resin through the ribbon, spirally wrapping the coated and impregnated ribbon around a rigid roll core with adjoining spirals overlapped edgewise and cooperating to completely cover the core, repeating the spiral wrapping a plurality of times to form a plurality of layers of spiral wrappings on the core, positioning the overlapped portions of adjoining layers in axially spaced side-by-side relation to provide a cover of uniform thickness on the core, thermosetting the resin to bond the first layer to the core and adjacent layers to each other to integrate the layers for forming a substantially continuous resin body, and machining the circumferential periphery of the body to a uniform continuous resin surface of the same thickness along the entire length of the roll core.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US68005284A | 1984-12-10 | 1984-12-10 | |
| US680,052 | 1984-12-10 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1266815A true CA1266815A (en) | 1990-03-20 |
Family
ID=24729448
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000493888A Expired CA1266815A (en) | 1984-12-10 | 1985-10-25 | Mat covered roll construction |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JPS61144422A (en) |
| CA (1) | CA1266815A (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4877472A (en) * | 1988-10-31 | 1989-10-31 | Beloit Corporation | Method of making a bearing blanket |
| AU6845000A (en) * | 1999-08-27 | 2001-03-26 | Metso Paper Inc. | Shoe roll |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3588978A (en) * | 1968-12-18 | 1971-06-29 | Beloit Corp | Grooved roll for paper-making |
| US3707752A (en) * | 1970-10-28 | 1973-01-02 | Beloit Corp | Roll covering |
| JPS5153150A (en) * | 1974-11-05 | 1976-05-11 | Hiroyuki Kanai | Rooru oyobisono seizohoho |
| JPS5925886A (en) * | 1982-08-03 | 1984-02-09 | Chiyoda Chem Eng & Constr Co Ltd | Method for obtaining thermal cracked oil from heavy oil by two-stage thermal cracking |
-
1985
- 1985-10-25 CA CA000493888A patent/CA1266815A/en not_active Expired
- 1985-12-09 JP JP27522685A patent/JPS61144422A/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| JPS61144422A (en) | 1986-07-02 |
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| Date | Code | Title | Description |
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| MKEX | Expiry |