CN101440494B - 用于涂覆开松辊针布环的方法及用于开松辊的针布环 - Google Patents
用于涂覆开松辊针布环的方法及用于开松辊的针布环 Download PDFInfo
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Abstract
本发明涉及用于对开松化纤材料的开松辊(1)的针布环(17,30)进行涂覆的方法,通过化学涂覆在所述针布环(17,30)上施加至少两层,该方法的特征在于包括下述方法步骤:在所述针布环(17,30)上施加由有色金属制成的第一层作为基础涂层;在所述基础涂层上施加至少一个基于镍磷合金的无硬质材料体的另一层;以及随后对所述被涂覆的针布环(17,30)进行热处理,其中,在低于所述针布环(17,30)的基础材料的回火温度的温度范围内执行所述热处理。
Description
技术领域
本发明涉及一种用于涂覆开松辊针布环的方法以及一种用于开松辊的针布环。
背景技术
已知自由端纺纱装置开松辊的各种实施方式。这种开松辊被用于,在将纺纱筒提供的纤维条喂入自由端纺纱装置的纺纱设备(其以高转速回转)之前,将纤维条开松为单纤维。为此,这种开松辊在其周边具有撕裂结构(tearing structure),该撕裂结构对供应来的纤维条进行梳理,并且在此过程中将纤维条开松为单纤维。另外,开松辊在其撕裂工具(即所谓的针布环)的构造方式上有所不同。
DE 3515153C2公开了一种构造为所谓一体(solid)环的针布环,换句话说,该针布环由一体的、经过硬化处理的钢环制成。在该示例中,在针布环周面内开设至少一个沿着周向延伸的槽和多个大致垂直于该槽延伸的切口(incision),以形成撕裂工具。这种一体环的特征在于高的功能性。
另外,DE 19813991A1公开了一种针布环,其中,针布丝(clothingwire)以螺旋方式施加在筒形基体的侧面上。在这里,由比较软的金属材料(例如铝)制成的基体在其侧面上设有螺旋形槽。针布丝嵌入该槽内并且被机械地固定在该处。这两种类型的针布环的共同点在于,施加有含硬质材料体的多层涂层(尤其是镍金刚石涂层),以防护磨损。
然而,在加工化纤时,镍金刚石涂层被证实是有缺点的。在加工化纤时,尤其是制造纱线支数低于Nm 14的粗支纱线时,在保持被纺纱线的所有质量特征情况下难以实现稳定的纺纱过程。设有镍金刚石涂层的针布环具有较高的表面粗糙度,这损坏了被开松为单纤维的化纤材料,从而在接下来的纺纱过程中纱线断裂会有显著增加。同样,由于对化纤的损伤,从而强度值和拉伸值显著降低。
发明内容
本发明的任务在于,提供一种用于涂覆开松辊针布环的方法,该开松辊用于加工化学纤维,通过该方法,针布环的表面具有了较高耐磨性,从而尺寸稳定。此外,本发明的任务在于提供用于开松辊的针布环,该针布环的特征在于,在加工化学纤维时,针布环在保证达到目标纱线质量情况下具有较高耐磨性。
根据本发明,该任务通过根据第一方面的方法以及根据第二方面的针布环来解决。根据本发明的该第一方面,在针布环上施加由有色金属制成的第一层作为基础涂层;在基础涂层上施加至少一个基于镍磷合金的无硬质材料体的另一层;以及随后对所述被涂覆的针布环进行热处理,其中,在低于所述针布环的基础材料的回火温度的温度范围内执行所述热处理。根据本发明的第二方面,所述针布环具有由有色金属制成的基础层和至少一个基于镍磷合金的无硬质材料体的另一层。
根据本发明的该第一方面,提出一种用于涂覆开松辊的针布环的方法,该针布环至少设有两层,其中,在针布环上施加由有色金属制成的基础涂层,针布环被涂覆至少一个另一无硬质材料体的层,该层基于镍磷合金,随后对被涂覆的针布环进行热处理,其中,在低于所述针布环(17,30)的基础材料的回火温度的温度范围内执行所述热处理。首先施加的基础涂层用作将要在随后的方法步骤中施加的由镍磷合金制成的磨损和腐蚀防护层的承载层。镍磷涂层的主要优点在于其具有恒定的尺寸稳定性,即,针布环表面上的均匀层分布,这是由于没有采用硬质材料体而获得的。与现有技术涂层相比,可以实现非常均匀的表面形状,均匀的表面形状使得要开松的化纤材料仅遇到很小的阻力。除了有耐腐蚀性,镍磷涂层在摩擦和抗磨损方面还具有优异的摩擦学特性。因而,与具有常规镍硬化物质涂层的现有技术相比,在该情况下由该针布环表面对待开松的化纤材料造成的损伤更小。根据本发明的方法使得可以在涂层中不使用硬质材料体(根据现有技术通过硬质材料体实现了针布环的磨损防护),这是通过在低于针布环基础材料的回火温度下执行随后的热处理而实现的,由此获得较高的表面硬度。在此,可以使镍磷层硬度增高直至1200HV。
在这里,热处理应该在低于摄氏320度的温度下执行。以这种方式可以避免形成针布环尖端区域的撕裂件硬度的降低。此外可以减少在涂层中出现微小裂缝,这些微小裂缝是由于针布环基础材料和涂层的不同膨胀系数而引起的,在温度超过320℃时会增加。
有利的是,应该以3小时以上至6小时的时长来执行热处理,以获得针布环表面的目标硬度。
根据第三方面,提出在无氧条件下执行对针布环的最后热处理。在执行热处理时排除氧可以使得针布环不变色。在无氧条件下的热处理例如可以在保护性气体环境情况下或者真空炉内进行。
有利的是,涂层可以具有10μm至40μm的总厚度,优选为15μm至30μm。要施加的层厚取决于针布环的应力和应用领域,尤其是取决于要开松的化纤材料的特性。
在本发明的一个改进中,可在作为第二层施加的第一镍磷层上施加第二镍磷层,该第二镍磷层的施加是在具有与施加第一镍磷层相同的参数的涂覆浴(bath)中实现的。
为了施加第二镍磷层,可以在施加第一镍磷层之后遮盖针布环内侧面,此后再次把针布环施加到涂覆浴中,以施加第二镍磷层。以这种方式避免针布环涂层内侧出现另一个层,从而在将针布环布置在用作驱动装置的辊体上时,借助滑动配合或者间隙配合保证了为此所必须的配合尺寸,同时针布环外表面形成有目标层厚的抗磨层。通过覆盖针布环的内侧,使得第二镍磷层仅施加在针布环的直接与要开松的化纤材料接触的外侧上。
在此,第一镍磷层施加的厚度可以在5μm至10μm范围内。这主要用于被挤压到辊体上的针布环内侧的腐蚀防护。
根据第四方面,第二镍磷层施加的厚度可以在10μm至25μm范围内。通过施加该第三层,从而与第二层一起实现了针布环抗磨损层的所需厚度。根据本发明的该第二方面,提出一种用于开松辊的针布环,其表面设有包含至少两层的涂层,其中,针布环具有由有色金属制成的基础层以及至少一个基于镍磷合金的无硬质材料体的另一层。在通过根据本发明涂布了的针布环加工化学纤维时,在纱线支数低于Nm 14的粗支纱线情况下也可以获得稳定的纺纱过程,同时保持被纺纱线的所有质量特征。在加工化学纤维时,与应用具有镍金刚石涂层的针布环相比,可以明显降低纱线断裂数量。
附图说明
以下根据在附图中示出的实施方式进一步描述本发明。
图中:
图1示出具有可回转安装的筒形辊体的开松辊;
图2示出针布环的截面图。
具体实施方式
以下根据在附图中示出的实施方式进一步描述本发明。图1示出开松辊,其具有可回转安装的筒形辊体和锯齿针布。基本上公知与自由端纺纱装置相关的开松辊,在图1中以附图标记1表示,其在未示出的开松辊壳体中旋转。开松辊1的任务是将通过喂给罗拉输送到其上的纤维条分解为单纤维。单纤维随后借助于纤维引导通道喂入纺纱机构(例如纺纱转子)。
在纺纱进程中,这种开松辊1通常以6000至12000转每分钟的转速运行。
开松辊1具有支承轴2,在该支承轴的端部固定有所谓的驱动锭盘3。在纺纱运行期间,未示出的切向带作用在该驱动锭盘3上。支承轴通过滚动轴承4可旋转地支承在轴承壳体5的内部。轴承壳体5自身固定在开松辊壳体未示出的支承架内,并且通过锁止元件锁定在那里,该锁止元件切向接合穿过塑性材料环6。
辊体7布置在支承轴2的前侧。在此,辊体7通过压配合以不旋转的方式与支承轴2连接。辊体7呈筒形且在背侧具有凸缘8。在这里,辊体7的表面优选是光滑的。开松辊1在前侧具有另一凸缘11,该凸缘11例如通过螺栓12和压簧13与支承轴2连接。
构造为一体环30的针布环可按照图2直接固定在筒形辊体7的表面上,或者将锯齿针布10安装在承载件14上,该锯齿针布10和承载件14是针布环17的部件。图1示出由锯齿针布10和承载件14构成的针布环17的实施方式。在此,前端凸缘11在组装状态下将锯齿针布10固定在辊体7上。锯齿针布10具有以螺旋弹簧方式形成的基体15,该基体15的截面可以有不同实施方式。
图1所示的锯齿针布10借助其基体15的卷绕而安装到承载件14的螺旋形延展槽9内。在此,基体15具有大致长方形截面形状。基体15以力配合或者形状配合的方式固定在槽9内。承载件14借助滑动配合或者间隙配合布置在辊体7上,由此实现了针布环17的可更换性。锯齿针布10具有多个撕裂元件16,各个撕裂元件16从基体15径向伸出。
图2的示图示出被构造为一体环的针布环30,针布环30例如由钢制成,其大致包括管状基体31,该管状基体31在其内径范围内具有环形定心肩部32。可以看出,针布环30在其外周构造为撕裂装置。在针布环30的外周区域内布置有多个齿33,这些齿33是通过铣削加工周向方向上的螺旋形槽34及基本平行于转动轴35延展的切口36而形成。
以下将借助于根据图1所示的开松辊1的承载件14来描述根据本发明的方法。该方法也可以按照同样方式应用于图2所示的被实施为一体环的针布环30。承载件14设有多层以化学方式施加的镍磷涂层,其用于防护腐蚀和磨损。在此,依据本发明的方法,在承载件14上至少施加两层,其中,被施加的第一层作为基础涂层,而随后的至少一层构成为腐蚀和磨损防护层。
在涂覆处理开始之前,用酸洗液处理承载件14以去除氧化层并且激活惰性表面。由此,通过去除承载件14表面上的非活性物质或者对其的化学转化提高了表面活性。承载件14的表面活性是随后涂层处理的前提条件,用以确保涂层足够的湿润或者粘附。
在以下方法步骤中施加基础涂层,基础涂层使用如镍的有色金属,其完全包覆承载件14。基础涂层的厚度为0.5μm至3μm。在这里,所施加的基础涂层可以看做是用于后续涂层的纯粹承载层。
接着,在化学浴中施加至少一用来防磨损的第二层(镍磷层),该第二层完全包覆承载件14。因为承载件14将被挤压到开松辊1的辊体7上,所以在开松辊1的内周上不应该施加太厚的涂层,以保证在辊体7上进行滑动配合所需要的配合尺寸。因而在第一镍磷层层厚达到大约5μm至10μm时中断涂层过程,并且向承载件14施加完全覆盖内表面的覆盖物。跟着,再次将承载件14施加到化学浴中,以获得与耐磨性要求相匹配的磨损防护层层厚,这是通过施加另一第二镍磷层而实现的。在化学浴中保持为施加第一镍磷层而设定的化学浴参数,在这种条件下在第一镍磷层上施加第二镍磷层。第三层的厚度可以根据应力的程度和应用情况在10μm至25μm之间变化。在镍浴中为此而选择的磷的浓度取决于表面的目标硬度。伴随着磷含量的增加,就可以获得较大的表面硬度。
涂覆过程结束之后,接着进行热处理,以硬化此时还比较软的镍磷层。该过程在无氧环境中进行,例如在真空炉内或者保护性气体环境中。在这里,在要硬化的承载件的回火温度范围内(即,低于320摄氏度的范围内)选择温度,以避免在承载件尖端区域内硬度降低。为了在低于320℃的温度下获得针布环17、30表面的目标硬度,热处理要进行3小时以上至6小时的时长。
此外,与超过回火温度范围的通常情况相比,在低于该温度的情况下,由于镍层和钢基质的膨胀系数不同而出现的微小裂缝较少。通过根据本发明的方法可以使针布环17、30表面的硬度增高至1200HV。此外,由于压应力的升高而提高了粘附强度。
Claims (11)
1.用于对开松化纤材料的开松辊(1)的针布环(17,30)进行涂覆的方法,通过化学涂覆在所述针布环(17,30)上施加至少两层,该方法的特征在于包括下述方法步骤:
在所述针布环(17,30)上施加由有色金属制成的第一层作为基础涂层;
在所述基础涂层上施加至少一个基于镍磷合金的无硬质材料体的另一层;以及
随后对所述被涂覆的针布环(17,30)进行热处理,其中,在低于所述针布环(17,30)的基础材料的回火温度的温度范围内执行所述热处理。
2.根据权利要求1所述的方法,其特征在于,所述热处理在低于320摄氏度的温度下执行。
3.根据权利要求1或2所述的方法,其特征在于,在3小时以上至6小时的时长内执行所述热处理。
4.根据权利要求1所述的方法,其特征在于,在无氧条件下执行所述热处理。
5.根据权利要求1所述的方法,其特征在于,所述在所述基础涂层上施加至少一个基于镍磷合金的无硬质材料体的另一层包括在涂覆浴中执行第一镍磷层以及在第一镍磷层上施加第二镍磷层,该第二镍磷层的施加是在具有与施加第一镍磷层相同的参数的所述涂覆浴中进行的。
6.根据权利要求5所述的方法,其特征在于,在施加所述第一镍磷层之后遮盖所述针布环(17,30)内侧面,之后将所述针布环(17,30)再次施加到所述涂覆浴中。
7.根据权利要求5或6所述的方法,其特征在于,以5μm至10μm的厚度来施加第一镍磷层。
8.根据权利要求5或6所述的方法,其特征在于,以10μm至25μm的厚度来施加第二镍磷层。
9.用于开松化纤材料的开松辊(1)的针布环(17,30),所述针布环的表面设有包括根据权利要求1至8之一所述方法的至少两层的涂层,该针布环的特征在于,所述针布环(17,30)具有由有色金属制成的基础层和至少一个基于镍磷合金的无硬质材料体的另一层。
10.根据权利要求9所述的针布环,其特征在于,所述针布环是一体环(30)。
11.根据权利要求9所述的针布环,其特征在于,所述针布环(17)具有承载件(14),该承载件(14)在其表面上设有槽(9)以接纳锯齿针布(10)。
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