CN101304863A - Circumferentially variable surface temperature roller - Google Patents

Abstract

A casting roller having a variable temperature surfaces comprises a rotatable cylindrical shell (12). Axially aligned heating electric elements (14) are equally spaced and internal to an outer surface of the rotatable cylindrical shell. A brush assembly (16) is in electrical contact with the heating elements during a portion of the rotatable cylindrical shell rotation about an axis. A stationary core (26) is internal to the rotatable cylindrical shell. An annular space is between the stationary core and the rotatable cylindrical shell. A cooling fluid fills (22) at least a portion of the annular space.

Description

The roller of circumferentially variable surface temperature

Invention field

Roller (casting roller), the casting roller that is specifically related to have the radially variable surface temperature are cast in relating to that the present invention is general.

Background of invention

Extrude with embossing operation in, the surface temperature of the roller of contact melted material or coiled material is an important technical parameters.Typical roller design type provides unique roller body temperature of being determined by the inner loop temperature of fluid media (medium).Maximum temperature is limited in the temperature value that material can be easy to divest from roller surfaces usually.

In expired prior art U.S. Patent No. 2526318, can find the trial that addresses this problem, in this patent ambiguous description have the form of two variable warm areas, but detailed design standard or operating characteristics is not provided.Prior art U.S. Patent No. 5945042,6260887 and 6568931 has afterwards similarly been described the method that a more than warm area is provided at the roller circumference, but detailed design standard or operating characteristics is not provided.Prior art U.S. Patent No. 6554755 has been described a kind of design that the different roller of temperatures at localized regions is provided, but unique embodiment of this method but is a device of making the deflection of compensation housing.

On the contact point of melted material or coiled material (web), need the high-temperature region to improve the contact between material and the roller surfaces and improve the print effect of roller surfaces, still, material can not be peeled off from roller surfaces when this temperature is too high usually.Therefore, require low surface temperature from the angle of peeling off, film forming and pattern that this point has limited roller surfaces duplicate.

Thereby the objective of the invention is provides at least two zones with enough temperature difference that the film forming and the print effect of improvement are provided on a zone in the roller periphery, and material evenly can be peeled off from second area.

Summary of the invention

In brief, according to an aspect of the present invention, the casting roller with variable temperature surface comprises rotatable cylindrical housings.The electrical heating elements homogeneous phase of axially-aligned is every the inside that is arranged in rotatable circular cylindrical shell external surface.The brush accessory when the part of rotatable cylindrical housings is pivoted and heating element heater electrically contact.Static inner core is in rotatable cylindrical housings inside.Between static inner core and rotatable cylindrical housings, be annular space.Cooling fluid is filled to the annular space of small part.

The present invention is based on finite element analysis and investigated the influence of roller diameter, thickness of shell and building material, the detailed design standard and the operating characteristics of hope are provided.

The present invention and purpose thereof and advantage significantly are embodied in the detailed description of preferred embodiments that hereinafter provides.

Accompanying drawing is briefly described

Fig. 1 casts the viewgraph of cross-section of roller for the present invention.

Fig. 2 casts the perspective view on the partial cross section of another embodiment of roller for the present invention.

Fig. 3 A casts the viewgraph of cross-section of the another embodiment of roller for the present invention.

Fig. 3 B is the perspective view on the partial cross section of embodiment shown in Fig. 3 A.

Fig. 3 C is the enlarged cross-sectional view of embodiment middle shell shown in Fig. 3 A and leg.

Fig. 4 is shown with the cooling effectiveness chart of calculating in the various roller designs of the present invention.

Fig. 5 is shown with the chart of the thermal efficiency again of calculating in the various roller designs of the present invention.

Fig. 6 is the viewgraph of cross-section of roller surfaces pattern.

Fig. 7 is the chart of temperature to the pressure that demonstrates the pattern print effect.

Fig. 8 is the chart that is shown with the housing distortion of calculating under the maximum temperature.

Fig. 9 be shown with stand clamp pressure and support by the internal pressure gradient under the housing distortion chart of calculating.

Figure 10 is the viewgraph of cross-section that forms axial elasticity pressure (compliant pressure) roller of clamping with second roller.

Detailed description of the invention

The present invention be more particularly directed to the element of molded component, the synergistic element of device perhaps more direct and of the present invention.Obviously easy to know, element can not take well known to a person skilled in the art various forms when having special instruction or description.

The electrical heating housing of embodiment 1-fluid media (medium) cooling

Roll 12 is processed into and is equipped with a series of electrical heating elements 14 near the housing outer surface close arrangement.Brush accessory 16 is installed on the roller, and it is used to only provide electric energy to the heater on the desirable thermal treatment zone 18.The inner surface 20 of shell 12 is placed in the fluid media (medium) 22 removing the heat that is brought by heating element heater, and removes the heat from rapidoprint continuously.Fluid media (medium) inlet 32 is connected on the roller by commercially available rotary connector.Diameter of the housing is based on required heating residence time, final chilling temperature, linear velocity and building material.The heat that remove from shell 12 and cast-molding material 86 cooling zone 24 is as Fig. 1 and shown in Figure 10.Circulate in the annular region of fluid media (medium) 22 below inner surface 20.

Embodiment 2-has the roller of two surperficial warm areas that the hot fluid medium by different temperatures forms

With reference to Fig. 2, shell 46 is around inner casing (stator) 40 rotations that are fixed on the graphite bearing (carbon bearing) 54.Graphite seal 52 is installed in case fluid stopping body seepage near bearing.Stator is processed to have at least two runners that separate 42.Between fluid stream, form the border at the close-fitting deflector 44 between stator 40 and the shell 46.Higher temperature fluid 47 passes through the part of stators 40 and circulates.When its this zone of process, reach required technological temperature with the heated shell that contacts of shell 46.Second area maintains lower temperature by the circulation of lower temperature fluid 49.Stator 40 is designed to the contact point minimum between high-temperature region and low-temperature space.

Embodiment 3-has the shell roller of inner support and two different warm areas

This embodiment is similar to above-mentioned embodiment, that is, inner casing is fixed, and shell is around the inner casing rotation, by two warm areas of thermal medium circulation formation.This embodiment has been used the inner thin outer crust 70 that is supported by a series of pivot carrying legs 72.Carrying leg 72 is adjustable independently, changes the application of force to shell 70, thereby compensation is owing to the casing deformation that is heated and the mechanics load causes.Thermal medium has the intra-zone circulation of leg, and diversed by the first axial diversion plate 74 and the second axial diversion plate 76 on 2 o'clock, thereby forms high-temperature region and cooling zone.This heat transmission medium also can provide hydrodynamic lubrication between leg and shell inner surface.

Thin outer crust 70 has advantage in application, because of it can provide heating, cooling thermal response system more rapidly in addition.When having littler diameter under the same linear velocity, also can realize this point.The power that minor diameter will convert to still less forms patterned surfaces, and higher contact stress in the clamping under the specified load.

With reference to Fig. 3 A, 3B and 10, roller is made up of at least three main region.In this embodiment, shell 70 is done corresponding to these zones and is rotated counterclockwise.Cooling zone 41 forms a series of runners 42 that are revealed in housing 25 inner surfaces.The supply system 60 of high temperature fluid 2 closely contacts to remove heat with shell inner surface.High temperature fluid 2 retrieval systems are collected from the fluid of runner 42, and direct fluid flows out roller.Close-fitting deflector 44 is arranged on the inlet of cooling zone 41 so that the fluid partitioning between cooling zone and the carrying leg district 45 to be provided.The first axial diversion plate 74 in the outlet of cooling zone 41 to separate cooling zone 41 and the fluid between the hot-zone 43 again.Be similar to cooling section 41, hot arc 43 is the fluid dispensing section again, and high temperature fluid 1 supply system 56 makes fluid-tight touch on the shell inner surface by the fluid of removing the system of backflowing 58 of passing through high temperature fluid 1 therein.The outlet that the second axial diversion plate 76 is installed in this district separated should distinguish from carrying leg district 45.The purpose of this section is to be increased in to enter bite 35 case temperature before.

Carrying leg district 45 is formed with the axial member that cooperates each carrying leg 72 by being processed into grooving 29 in the longitudinal direction.The power that is applied on each carrying leg is adjustable independently by leg load carrier 78.What illustrate is Artificial Control worm spiral governor motion, but is not restricted to this embodiment.High temperature fluid 3 supply systems 48 be positioned at maintained since near the porch of the carrying leg 72 the shell interface this place continuously supply be used for the fluid of hydrodynamic lubrication.High temperature fluid 3 retrieval systems 50 are collected the unnecessary fluid of removing from roller.Each of these zones all be arranged on fixing inner casing 40 around, and be limited in centre so that different thermal expansions to be provided.Fixedly inner casing 40 connects the machine structure rigidly by support 80 on each end.What the bearing 28 of shell 70 by being installed in every end was limited rotates around fixing inner casing 40.Seal 30 is connected on the bearing 28 to stop liquid from fluid inner chamber seepage.The rotation that drive sprocket 82 can be used to housing overcomes chucking power and internal friction power.

Among these embodiment each all can be according to describing based on the physical-property parameter of cast-molding material to be processed, required process conditions, the physical parameter of roller and the dimensionless parameter of required speed of production.The hot transmission described the transient heat transmission of using similarity method in the handbook, still do not instruct direct method synthesis to consider that cast-molding material and the roller design standard that stands a more than heat transfer process design.

Nondimensional temperature ratio θ can obtain based on following parameter: T _Infinite, be described as the body temperature of heat transmission medium.T _Beginning, be defined as the roller housing that depends on concrete technology function or the initial temperature of cast-molding material, and T _{The end}, the temperature when being defined as given technological operation and finishing.This ratio is more for a short time to show that the efficient that realizes required process goal is high more.

Can obtain another dimensionless parameter, i.e. non dimensional time, it is normally defined τ in the disclosed document.This parameter by using material thermal diffusion coefficient and thickness with the temporal dimension standardization.

It is that ordinate, non dimensional time are the chart of abscissa that Fig. 4 is expressed as dimensionless temperature ratio θ.This family's curve has the exponential form of following equation.

${\mathrm{\&theta;}}_t(x,k,h,t):={\mathrm{<figure-callout\; id="1"\; label="Pls"\; filenames="A20068003374300201.png,A20068003374300251.png"\; state="\{\{state\}\}">Pls</figure-callout>}1}_0\&CenterDot;e^{\frac{-(x-K_{\mathrm{mat}}\&CenterDot;\frac{k}{h\&CenterDot;t})}{1-K_{\mathrm{mat}}\&CenterDot;\frac{k}{h\&CenterDot;t}}}$

Coefficient in the equation is fit to the finite element result of relevant physical properties, roller geometry and the roller physical property of various processing simulations and cast-molding material.The subscript of matched curve has alphabetical c1.Curve subscript al, steel, ag and cu represent that the casing structure material is respectively aluminium, steel, silver and copper.In addition, subscript value 0625 and 125 is represented the thickness of shell value of ten sixth inches (0.00158m) and 1/8th inches (0.0031m) respectively.Based on heat transfer coefficient h is 350Btu/ (hr*ft ²* °F) (1990 watts/(m ²* ℃) and thermal diffusion coefficient be 0.005ft ²/ hr (0.00000013m ²/ s) the commercially available plastic material of cooling calculates.

The roller design can be determined by satisfying concrete these equatioies that require of a cover.Temperature based on temperature, heat transmission medium temperature and the melted material in each district defines dimensionless temperature ratio, chart can be used to measure the process efficiency of given operating condition and roller form or be used to select process efficiency among Fig. 4, under this process efficiency, service speed can be determined by given roller diameter, thickness of shell and building material.Fig. 5 represents to make the chart of curve from the hot again dimensionless temperature ratio θ of the housing of FEM calculation with respect to non dimensional time Θ.Subscript adopts convention as shown in Figure 4.Calculated value is based on 350Btu/ (hr*ft ²* °F) (1990 watts/(m ²* ℃) internal heat transfer coefficient h and 3Btu/ (hr*ft ²* °F) (17.03 watts/(m ²* ℃ external heat transfer coefficient).

Referring now to Figure 10, the axial elasticity pressure roll is generally with numeral 10 representatives.Axial elasticity pressure roll 10 generally comprises in static inner core 26, and a plurality of carrying legs 72 pivotally are installed on the static inner core 26.A series of non magnetic distributor (divider) forms a plurality of annular compartments, and each carrying leg 72 takies an annular compartment.

With reference to Fig. 3 A, 3B and 3C, carrying leg 72 eccentric installations that illustrate.Pivoting point 15 and leg are regulated pin 17 and are connected on the carrying leg 72.Nonmagnetic material is used for making carrying leg 72, but is not limited to this embodiment among the present invention.The curved surface 33 of carrying leg 72 has the curvature that is slightly smaller than thin-wall shell 70 interior surface curvatures.This has formed between these assemblies the cross section of convergence at the interface.

Among Figure 10, axial elasticity pressure (compliant pressure) roller 10 comprises non-rotary static inner core 26, and it is the main support structure of axial elasticity pressure roll 10.Nonmagnetic material is used for the manufacturing of static inner core 26, but is not limited to this embodiment among the present invention.The cylindrical shape that axial hole 27 is arranged on static inner core 26 has.Have one in these holes at least and be used to hold magnetic field generator 37.In a preferred embodiment, magnetic field generator 37 with a plurality of carrying legs 72 each all link to each other.Can realize being suitable for the local modulation of thin-wall shell 70 like this.In another embodiment, magnetic field generator 37 can be arranged in each of a plurality of carrying legs 72, shown in Fig. 3 C.

Axial hole 27 is used for the circulation of heat transmission medium at inner core.A series of groove 29 forms diametrically, and the support to carrying leg 72 is provided.Seat on the static inner core 26 can be installed bearing 28 and fluid seal 30.

In operation, be subjected in the region of convergence of viscous fluid 11, deriving pressure distribution by the fluid dynamic influence of thin-wall case with respect to the viscous fluid of the shear stress that relative velocity forms of carrying leg.This pressure acts on the thin-wall case crooked inner surface of housing 25 and the curved surface of leg 33.This pressure that acts on leg causes producing perpendicular to the power of Center of Pressure curvature.This power is obstructed because of the spring preloading power that acts on the carrying leg 72.This acts on the internal stress on the pressure formation housing that rotates on the thin-wall shell 70.Act on the power on the housing and the clean poor local deformation that causes thin-wall case on this zone of outside chucking power from internal flow is power actuated.

Can thin-wall case among this embodiment, because the structural design of housing is not to push crooked standard by beam bending standard and housing to arrange with small shell diameter.The wall thickness of housing can be as thin as a wafer, and the surface of shell of outside chucking power is inner directly to be supported by magnetic-Pheological fluid (not shown) and the pressure that the interaction of carrying leg 72 forms because stand.

Thin-wall shell 70 is subject to bearing 28 and rotates around static inner core 26.The housing rotation can provide by the frictional force on the bite 35, and as shown in figure 10, perhaps by external drive mechanism, drive sprocket 82 as shown.Under given convergence interface, relative velocity and fluid viscosity, form uniform pressure along the crooked inner surface of housing 25.Annular compartment links to each other with carrying leg 72, and magnetic-Pheological fluid and axially variable magnetic field generator 37 can be subjected to convertible fluids power pressure by changing fluid viscosity.Apply axially variable pressure along thin-wall case and can produce a spot of local deformation variation and the frequency more a lot of than height in existing other technology.

Fig. 8 shows the result of FEM calculation, and it is used to simulate the influence of the variable interior pressure-volume amount of this device for bite upper roller radial surface profile.The size of housing can be represented according to following parameter value: the flexible rigidity of about 1800 ft lbf-inches (203 newton * m) and 0.025 thickness of shell and diameter ratio.The product value that flexible rigidity is defined as the elastic modelling quantity of material and thickness of shell cube deducts the product value of the difference of Poisson's ratio square (Poisson ' s ratio squared) divided by constant 12 and 1.Average clamp pressure along the 250psi (1.724MPa) of the regional area that is parallel to rotating shaft on thin-wall shell 24 is used for calculating.Variable (UX) is radial displacement on the x-direction, and it is also vertical with the clamp pressure that applies.This value shows then that towards the housing center bigger distortion is arranged during for bigger positive number.

The bending that is labeled as diamond shape is illustrated under the clamping load and does not have desirable housing distortion under the inner support.Be labeled as triangular shaped curve and represent that the local pressure that applies is for have average pressure 50psi (0.344MPa) the effect influence on the equal area with supporting leg 72 curved surfaces down at the housing center.Curve with rectangle marked is represented to distribute for the just influence of the radial deformation that obtains to the barometric gradient of 20psi (0.103MPa is to 0.137MPa) scope by apply 15psi along shell inner surface.At shell with have to give between the leg curved surface of average shear rate of 2501/s and conclude a contract or treaty and use basic hydrodynamics principle to calculate the pressure of about 30psi (0.206MPa) in the fluid viscosity zone that 10Pa-s shears.

Figure 10 shows the viewgraph of cross-section of extruding the typical two roller clampings of using in the distortion of casting coiled material.The 10 upwards loads of footpath of axial elasticity pressure roll, the interface of the formation melt resin 86 and second roller 84.Use noncontact distortion detector 88,, can measure the surface of shell distortion of generation as laser triangulation device or vortex device.By sending the microprocessor 92 of deformation signal 90, this measurement data is used to control along the upwards inner loading environment of roller axle to the intensity that changes one or more magnetic field generators 37.

Except aforesaid magnetic-Pheological fluid, this device goes for there is not magnetic-other fluid of Pheological fluid shape, but it will demonstrate non-Newtonianism (viscosity of fluid is independent of the shear rate that applies).Local pressure changes and can adjust by the spacing of regulating shell and leg curved surface.The average shear rate ratio of this spacing is in the surface velocity divided by the housing of spacing height.Has logarithmic relationship between the viscosity of non-newtonian fluid and the shear rate.For external control, provide the another kind of means that form the local pressure difference in each chamber interior with the spacing of fluid with required shearing sensibility.

Key advantage of the present invention is owing to increased surface temperature on the contact point on melted material and pattern roller surface, clamp pressure copying pattern that can be lower.One of them example can be simulated with the software Polyflow of computational fluid dynamics, and in this example, resin material, Merlon are subjected to terminal pressure and have studied the meticulous geometrical pattern of the mobile formation of material.Fig. 6 represents two kinds of example of size of resin material and geometrical pattern.Fig. 7 expresses the improvement of pattern print effect when mold surface temperature raises.When extremely hanging down, can obtain duplicating of same degree to applied pressure under the fixed temperature.For identical print effect, patterned surfaces temperature rising 10% can bring 67.5% the reduction of exerting pressure.

In an example, building material is aluminium, has 0.125 inch wall thickness, 20 that " surface of shell of surperficial six inch diameters carries out finite element analysis, has measured along the influence of the variable heat of circumference for mechanical stress and thermal deformation.Fig. 9 represents the housing distortion curve that calculates.Even distribution pressure was for the result that influences of case surface when following curve table was shown in maximum temperature point.Top curve applies the result that influences of internal pressure compensation when representing to be adjusted to the minimal surface distortion.Bigger has bigger distortion on the occasion of showing apart from the shell center.

List of parts

10 axial elasticity pressure rolls

11 viscous fluids convergences (converging) district

12 shells

14 heating element heaters

15 pivots

16 brush accessories

17 adjustment pins

18 thermals treatment zone

20 inner surfaces

22 fluid media (medium)s

The district of 24 coolings

25 shell inner surface

26 static inner cores

27 axial holes

28 bearings

29 grooves

30 seals

32 fluid media (medium)s inlet

The curved surface of 33 legs

35 bites

37 magnetic field generators

40 fixing inner casings (stator)

41 cooling zones

42 runners

43 hot-zones again

44 tight fit deflectors

45 carrying leg districts

46 shells

47 high temperature fluids

48 high temperature fluids, 3 supply systems

49 cryogens

50 high temperature fluids, 3 retrieval systems

52 graphite seals

54 graphite bearings

56 high temperature fluids, 1 supply system

58 high temperature fluids, 1 retrieval system

60 high temperature fluid bodies, 2 supply systems

62 high temperature fluids, 2 retrieval systems

70 shells

72 carrying legs

74 first axial diversion plates

76 second axial diversion plates

78 leg load carriers

80 supports

82 drive sprockets

84 second rollers

86 materials enter clamping

88 distortion detectors

90 deformation signals

92 microprocessors

Claims (24)

1. casting roller with variable temperatures surface comprises:

Rotatable cylindrical housings;

Homogeneous phase is every the heating element heater of the axially-aligned of the inside that is arranged in described rotatable circular cylindrical shell external surface;

When the described rotatable cylindrical housings of part is pivoted and the brush accessory that electrically contacts of described heating element heater;

Static inner core in described rotatable cylindrical housings inside;

Annular space between described static inner core and described rotatable cylindrical housings; And

Be filled to the cooling fluid of the described annular space of small part.

2. casting roller as claimed in claim 1, wherein, deflector limits described cooling fluid and flows to the described annular space of part.

3. casting roller as claimed in claim 1, wherein, described cooling fluid is selected from the organic synthesis medium of operating temperature range in 60C arrives 350C (140F-662F) scope.

4. casting roller as claimed in claim 3, wherein, fluid viscosity changes in 0.26 centipoise scope at 8.2 centipoises.

5. casting roller as claimed in claim 3 wherein, changes in the 2.82kJ/kg*K scope of the 1.62kJ/kg*K of the specific heat of described medium when 60C during to 360C.

6. casting roller as claimed in claim 3 wherein, changes in the 0.086kW/m*K scope of the 0.125W/m*K of thermal conductivity when 60C during to 360C.

7. casting roller as claimed in claim 3 wherein, changes in the 801kg/m3 scope of the 1016kg/m3 of described density of medium when 60C during to 360C.

8. casting roller as claimed in claim 1, wherein, described heating element heater is telescopic heater.

9. casting roller as claimed in claim 8, wherein, described heater diameter is 0.25 inch, has the hot-fluid output of about 60W/in2.

10. casting roller with variable surface temperature comprises:

Rotatable cylindrical housings;

Static inner core in described rotatable cylindrical shell inside;

Annular space between described static inner core and described rotatable cylindrical housings;

In described annular space, form the deflector in first and second zones;

Under first temperature around the first fluid of described first annular space; With

Under second temperature around second fluid of described second annular space.

11. casting roller as claimed in claim 10, wherein, described first fluid is a cooling fluid, and it is selected from the organic synthesis fluid of operating temperature range in 60C arrives 350C (140F-662F) scope.

12. casting roller as claimed in claim 11, wherein, fluid viscosity changes in 0.26 centipoise scope at 8.2 centipoises.

13. casting roller as claimed in claim 11 wherein, changes in the 2.82kJ/kg*K scope of the 1.62kJ/kg*K of the specific heat of described fluid when 60C during to 360C.

14. casting roller as claimed in claim 11 wherein, changes in the 0.086kW/m*K scope of the 0.125kW/m*K of described fluid thermal conductance when 60C during to 360C.

15. casting roller as claimed in claim 11, wherein, the 1016kg/m of the density of described fluid when 60C ³801kg/m during to 360C ³Change in the scope.

16. casting roller as claimed in claim 10, wherein, 1/3rd of the each covering shell girth of described first annular space.

17. casting roller as claimed in claim 10, wherein, each 2/3rds of the described cylindrical housings that covers of described second annular space.

18. casting roller as claimed in claim 10, wherein,

Described rotatable cylindrical housings is thin, and,

Leg supports described rotatable cylindrical housings by clamping.

19. the method with material casting coiled material comprises:

Make described coiled material be positioned at the thermal treatment zone of described roller;

Heat described coiled material to the casting temperature;

On described coiled material, form impression;

Keeping described coiled material contacts with described roller through at least a portion cooling zone on the described roller; And

Described coiled material is removed from roller in described film cooling back.

20. method as claimed in claim 19, wherein, the surface temperature of described roller increases greater than 30 degrees centigrade to 60 degrees centigrade of coiled material glass transition temperatures.

21. method as claimed in claim 19, wherein, the surface temperature of described roller is reduced to 3 degrees centigrade to 5 degrees centigrade that are lower than the coiled material glass transition temperature.

22. the casting roller with variable surface temperature comprises:

Rotatable cylindrical housings;

Static inner core in described rotatable cylindrical shell inside;

Annular space between described static inner core and described rotatable cylindrical housings;

In described annular space, form the deflector in first and second zones;

Under first temperature around the first fluid of described first annular space;

Under second temperature around second fluid of described second annular space;

Wherein, described rotatable cylindrical housings is thin, and, have the leg that supports described rotatable cylindrical housings by clamping.

23. casting roller as claimed in claim 22, wherein,

The 3rd zone is formed around described leg by described deflector; And

The 3rd fluid under the 3rd temperature is in described the 3rd zone.

24. casting roller as claimed in claim 23, wherein, the described leg of described the 3rd fluid lubrication.

Images