CN103708196A - Composite roller and preparation method for same - Google Patents
Composite roller and preparation method for same Download PDFInfo
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- CN103708196A CN103708196A CN201310688390.1A CN201310688390A CN103708196A CN 103708196 A CN103708196 A CN 103708196A CN 201310688390 A CN201310688390 A CN 201310688390A CN 103708196 A CN103708196 A CN 103708196A
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Abstract
The invention discloses a composite roller and a preparation method for the same. The composite roller comprises a fibre-reinforced inner layer and a non-metal outer layer, wherein the fibre-reinforced inner layer and the non-metal outer layer are closely compounded to form an integer by a convex-concave inlaid structure; the fibre-reinforced inner layer is composed of the following raw materials according respective proportions in parts by weight: 20-50 parts of glass fibres, 50-80 parts of synthetic resin and 4-10 parts of plasticizer; the non-metal outer layer is selected from at least one of modified polyurethane, modified nitrile rubber, modified butadiene styrene rubber and modified butadiene rubber. The roller provided by the invention is prepared from polymer-matrix composite materials, and the weight of the prepared roller is reduced by more than twice compared with a steel roller, thus transport, installation and maintenance for the roller are more convenient, and running is more energy-saving.
Description
Technical field
The present invention relates to Idler Technology field, particularly relate to a kind of compound roller and preparation method thereof.
Background technology
Belt transportation is the major way of loose unpacked material transportation, is widely used in the Bulk material of the industries such as mine, metallurgy, power plant, coal, cement, grain depot, harbour and saltern.Carrying roller is the core component of belt conveyer, and can the quality of its performance directly affect belt conveyer and normally move.At present, on market, existing carrier roller of belt conveyer mainly comprises the several types such as steel carrying roller, plastic conveyer roller, carrier roller.In use, more or less all there are some fatal shortcomings in these carrying rollers.Traditional steel carrying roller, wears no resistance, and particularly rear its surface of wearing and tearing easily produces burr for a long time, causes scratching, scratching belt, causes great economic loss; Easily get rusty, while using under high corrosive environment, the life-span is extremely short; Quality weight, is not easy to transportation, installs and safeguards, cost of manufacture and use cost are significantly improved.The advantages such as plastic conveyer roller has that quality is light, shock resistance, withstanding corrosion, noise are low, but the performances such as it is wear-resisting, heat-resisting, weather-proof, mechanical strength obviously can not be met the need of market.Although the advantage such as wear-resisting, anti-oxidant and acid and alkali-resistance that carrier roller has, but exist, fragility is large, quality heavy, inconvenience is installed, the shortcomings such as concentricity is poor, there is obvious difference with the thermal expansion coefficient of pottery, metal in the plastic seal device of simultaneously installing because of carrying roller two ends, thereby causes its practical life greatly to shorten.
Summary of the invention
In view of this, the object of the invention is to propose a kind of compound roller and preparation method thereof, to reduce the weight of internal lining pipe, improve bending strength, the processing characteristics of internal lining pipe.
Based on above-mentioned purpose, compound roller provided by the invention comprises fiber reinforcement internal layer and non-metal skin, between described fiber reinforcement internal layer and non-metal skin, by convex-concave mosaic texture, is closely combined into integral body;
Wherein, described fiber reinforcement internal layer is comprised of according to weight portion proportioning separately following raw material: 20～50 parts of glass fibres, 50～80 parts of synthetic resin and 4～10 parts of plasticizer; Described non-metal skin is selected from least one in modified polyurethane, modification nitrile rubber, modified styrene butadiene rubber and modification butadiene rubber material.
Alternatively, described fiber is selected from glass fibre, at least one in aramid fiber and carbon fiber.
Alternatively, described synthetic resin is selected from epoxy resin, phenol resin, vinylite, unsaturated polyester resin, at least one in polyvinylchloride and nylon resin.
Alternatively, described plasticizer is selected from dibutyl phthalate, dioctyl phthalate, at least one in epoxidized soybean oil.
The present invention also provides a kind of method of preparing above-mentioned compound roller, comprises the following steps:
By weight ratio 50～80 parts of synthetic resin and 4～10 parts of plasticizer are mixed and obtain thermosetting resin adhesive on puddle mixer, again 20～50 parts of glass fiber yarns are flooded to described thermosetting resin adhesive, then by extruder, the glass fibre that has flooded thermosetting resin adhesive is processed into outside face with the fiber reinforcement internal layer of groove structure;
Outer at the outside face machining of non-metallic with groove structure fiber reinforcement internal layer, between described fiber reinforcement internal layer and non-metal skin, by convex-concave mosaic texture, be closely combined into integral body, obtain compound roller; Wherein said non-metal skin is selected from least one in modified polyurethane, modification nitrile rubber, modified styrene butadiene rubber and modification butadiene rubber material.
Alternatively, take described modified polyurethane comprises as the outer field preparation process of non-metal:
According to weight portion proportioning, 5～20 parts of base polyurethane prepolymer for use as through silane coupler modified ceramic powder, 20～40 parts of epoxy resin and 50～80 parts of meltings are mixed, be evacuated to negative 0.05～0.2 MPa 2～8 minutes; Then under the environment of 90 ℃～140 ℃, in mixed liquor, add 1～4 part of dibutyltin dilaurate and 5～20 parts of diamido dichloro diphenyl methanes to react; After reaction finishes, mixed liquor is injected and is placed with in the mould space of described fiber reinforcement internal layer, at 70 ℃～150 ℃, solidify;
Wherein, described ceramic powder is selected from least one in silicon dioxide, silicon nitride, carborundum and french talc.
Preferably, the modifying process of described ceramic powder is: adopt atomizing cone silane coupling agent to be evenly dispersed in to the surface of ceramic powder, then ceramic powder is placed under the environment of 110～130 ℃ and reacts 3～5 hours, obtain modified ceramic powder.
Alternatively, take described modification nitrile rubber, modified styrene butadiene rubber or modification butadiene rubber comprises as the outer field preparation process of non-metal:
According to weight portion proportioning, 40～60 parts of nitrile rubbers or buna-S or butadiene rubber, 10～30 parts of carbon blacks, 10～300 parts of rubber powders, 2～15 parts of epoxidized soybean oils are joined in Banbury mixer and under the environment of 90～150 ℃, stir and within 0.5～2 hour, become dough shape sizing material with 2～15 parts of zinc oxide; Then described dough shape micelle, 0.5～3 part of Masterbatch and 2～10 parts of vulcanizators are placed in the mill of 60～90 ℃ and continue 10～60 minutes slabbing sizing materials of refining glue, then with mould cutting machine, described sheet sizing material is cut into glue embryo.
Preferably, take described modification nitrile rubber, modified styrene butadiene rubber or modification butadiene rubber also comprises as the outer field preparation process of non-metal: the outside face that described glue embryo is wrapped in to fiber reinforcement internal layer, then put into together mould inner pressure real, then be placed in interior the sulfuration 5～30 minutes of mould of 90 ℃～150 ℃, obtain described compound roller.
As can be seen from above, roller provided by the invention adopts polymer matrix composite preparation, and the carrying roller weight ratio steel carrying roller making has reduced more than one times, makes the transportation of carrying roller, installation and maintenance more convenient, turns round more energy-conservation.That the skin of this roller (wearing layer) adopts is wear-resisting, prepared by one or more composite materials of heat resist modification polyurethane, nitrile rubber, buna-S, butadiene rubber, greatly improved the wear-resisting of carrying roller, withstanding corrosion, shock resistance, noise-reducing, heat-resisting, the performance such as weather-proof, and extend service life of carrying roller.The skin of this roller adopts fibre reinforced materials to prepare, and the carrying roller that makes to make has the intensity of steel carrying roller, has solved the bad problem of general polymer carrying roller bending strength.And the internal layer of carrying roller and the outer convex-concave mosaic texture that adopts are closely combined into a roller integral body, have solved the problem that rubber idler easily comes unstuck.Composite roller provided by the invention has that high comprehensive performance, price are suitable, long service life and the advantage such as installation is convenient.
Accompanying drawing explanation:
Fig. 1 is the structural representation of embodiment of the present invention carrying roller;
Fig. 2 is the structural representation of the compound roller of the embodiment of the present invention.
The specific embodiment
For making the object, technical solutions and advantages of the present invention clearer, below in conjunction with specific embodiment, the present invention is described in more detail.
Referring to Fig. 1 and 2, be respectively the structural representation of embodiment of the present invention carrying roller and compound roller, described carrying roller comprises compound roller 1, bearing seat 2, sealing arrangement 3, bearing 4, rotating shaft 5 and snap ring 6, described compound roller 1 comprises inner fiber reinforcement internal layer 7 and outside non-metal skin 8, between described fiber reinforcement internal layer 7 and non-metal skin 8, by convex-concave mosaic texture 9, is closely combined into integral body.Particularly, can groove be set at the outside face of fiber reinforcement internal layer 7, at the inside face of non-metal skin 8, projection be set, projection is snapped in groove and makes described fiber reinforcement internal layer 7 and non-metal skin 8 closely be combined into integral body.
Wherein, described fiber reinforcement internal layer is comprised of according to weight portion proportioning separately following raw material: 20～50 parts of glass fibres, 50～80 parts of synthetic resin and 4～10 parts of plasticizer; Described non-metal skin is selected from least one in modified polyurethane, modification nitrile rubber, modified styrene butadiene rubber and modification butadiene rubber material.
Alternatively, described fiber is selected from glass fibre, at least one in aramid fiber and carbon fiber.
Alternatively, described synthetic resin is selected from epoxy resin, phenol resin, vinylite, unsaturated polyester resin, at least one in polyvinylchloride and nylon resin.
Preferably, described plasticizer is selected from dibutyl phthalate, dioctyl phthalate, at least one in epoxidized soybean oil.
Preferably, described fiber reinforcement internal layer is 1:3～5:6 with the ratio of the outer field thickness of non-metal.
Preferably, described fiber reinforcement internal layer is 2:3 with the ratio of the outer field thickness of non-metal.
The present invention also provides a kind of method of preparing described compound roller, and as one embodiment of the present of invention, the concrete preparation method of described compound roller is as follows:
Step 1, by weight ratio 60～75 parts of synthetic resin and 5～8 parts of plasticizer are mixed and obtain thermosetting resin adhesive on paddle agitator, again 25～40 parts of glass fiber yarns are flooded to described thermosetting resin adhesive, then by extruder, the glass fibre that has flooded thermosetting resin adhesive is processed into outside face with the fiber reinforcement internal layer of groove structure.Fiber reinforcement internal layer is put into circular die, between described groove structure and circular die, leave space, to pour into a mould in subsequent step.
Step 2, adopt atomizing cone silane coupling agent to be evenly dispersed in to the surface of ceramic powder, then ceramic powder is placed under the environment of 120 ℃ and reacts 4 hours, obtain modified ceramic powder.Alternatively, described ceramic powder can be silicon dioxide, silicon nitride, carborundum, at least one in french talc.
Step 3, by weight ratio 15～20 parts of base polyurethane prepolymer for use as through silane coupler modified ceramic powder, 20～30 parts of epoxy resin and 60～75 parts of meltings are mixed, be evacuated to negative 0.1 MPa 5～7 minutes, drain the bubble in mixed liquor; Then under the environment of 100 ℃～120 ℃, in described mixed liquor, add 2～4 parts of dibutyltin dilaurates and 8～18 parts of diamido dichloro diphenyl methanes to react; Reaction is carried out exhaust by mixed liquor after finishing, and then mixed liquor is poured in the circular die described in step 1, mixed liquor is entered in the space between groove structure and circular die, then solidify at 90 ℃～140 ℃, obtains compound roller after cooling and demolding.Base polyurethane prepolymer for use as and epoxy resin is polymerization reaction take place all, and two quasi-molecule interchains intert to form inierpeneirating network structure mutually, is solidified into modified polyurethane (non-metal is outer) in mould.Preferably, described fiber reinforcement internal layer is 2:3 with the ratio of the outer field thickness of non-metal.
It should be noted that, the groove structure of described fiber reinforcement inner layer outer surface is processed by mould structure sizing, the protruding formula structure of the outer inside face of non-metal is before cladding material processing sizing, automatically to fill up (before cladding material sizing, the having certain flowing power) of the groove structure formation of fiber reinforcement internal layer, by the concave inlaid of groove structure and bulge-structure, the outer mortise of fiber reinforcement internal layer and non-metal.
As another embodiment of the present invention, the concrete preparation method of described compound roller is as follows:
Step 1, by weight ratio 50～68 parts of synthetic resin and 4～8 parts of plasticizer are mixed and obtain thermosetting resin adhesive on paddle agitator, again 20～35 parts of glass fiber yarns are flooded to described thermosetting resin adhesive, then by extruder, the glass fibre that has flooded thermosetting resin adhesive is processed into outside face with the fiber reinforcement internal layer of groove structure.Fiber reinforcement internal layer is put into circular die, between described groove structure and circular die, leave space, to pour into a mould in subsequent step.
Step 2, adopt atomizing cone silane coupling agent to be evenly dispersed in to the surface of ceramic powder, then ceramic powder is placed under the environment of 118 ℃ and reacts 4.5 hours, obtain modified ceramic powder.Alternatively, described ceramic powder can be silicon dioxide, silicon nitride, carborundum, at least one in french talc.
Step 3, by weight ratio 15～20 parts of base polyurethane prepolymer for use as through silane coupler modified ceramic powder, 28～36 parts of epoxy resin and 50～70 parts of meltings are mixed, be evacuated to negative 0.2 MPa 2～5 minutes, drain the bubble in mixed liquor; Then under the environment of 90 ℃～125 ℃, in described mixed liquor, add 1.5～2 parts of dibutyltin dilaurates and 5～12 parts of diamido dichloro diphenyl methanes to react; Reaction is carried out exhaust by mixed liquor after finishing, and then mixed liquor is poured in the circular die described in step 1, mixed liquor is entered in the space between groove structure and circular die, then solidify at 80 ℃～150 ℃, obtains compound roller after cooling and demolding.Base polyurethane prepolymer for use as and epoxy resin is polymerization reaction take place all, and two quasi-molecule interchains intert to form inierpeneirating network structure mutually, is solidified into modified polyurethane (non-metal is outer) in the mould of specific standard.Preferably, described fiber reinforcement internal layer is 2.5:3 with the ratio of the outer field thickness of non-metal.
As another embodiment of the present invention, the concrete preparation method of described compound roller is as follows:
Step 1, by weight ratio 60～75 parts of synthetic resin and 5～8 parts of plasticizer are mixed and obtain thermosetting resin adhesive on paddle agitator, again 25～40 parts of glass fiber yarns are flooded to described thermosetting resin adhesive, then by extruder, the glass fibre that has flooded thermosetting resin adhesive is processed into outside face with the fiber reinforcement internal layer of groove structure.
Step 2, according to weight portion proportioning, 45～56 parts of nitrile rubbers, 12～30 parts of carbon blacks, 50～280 parts of rubber powders, 5～15 parts of epoxidized soybean oils, 8～15 parts of zinc oxide are joined in Banbury mixer and under the environment of 100～140 ℃, stir and within 1.5～2 hours, become dough shape sizing material; Then described dough shape micelle, 1.5～3 parts of Masterbatchs and 5～8 parts of sulphur are placed in the mill of 70～88 ℃ and continue 10～50 minutes slabbing sizing materials of refining glue, then with mould cutting machine, described sheet sizing material is cut into glue embryo.
Step 3, described glue embryo is wrapped in to the outside face of fiber reinforcement internal layer, then put into together mould inner pressure real (glue embryo fiberfill fibers strengthens the groove structure of inner layer outer surface), then be placed in the mould of 90 ℃～130 ℃ baking 20～30 minutes, unvulcanized sheet rubber glue embryo one heating will have certain flowing power, the groove structure that fills up liner forms concaveconvex structure, thereby obtains compound roller.
Therefore, between described fiber reinforcement internal layer and non-metal skin, by convex-concave mosaic texture, be closely combined into integral body, described fiber reinforcement internal layer is 2.2:3 with the ratio of the outer field thickness of non-metal.
As another embodiment of the present invention, the concrete preparation method of described compound roller is as follows:
Step 1, by weight ratio 50～68 parts of synthetic resin and 4～8 parts of plasticizer are mixed and obtain thermosetting resin adhesive on paddle agitator, again 22～48 parts of glass fiber yarns are flooded to described thermosetting resin adhesive, then by extruder, the glass fibre that has flooded thermosetting resin adhesive is processed into outside face with the fiber reinforcement internal layer of groove structure.
Step 2, according to weight portion proportioning, 40～58 parts of buna-S or butadiene rubber, 12～25 parts of carbon blacks, 20～300 parts of rubber powders, 2～13 parts of epoxidized soybean oils are joined in Banbury mixer and under the environment of 110～150 ℃, stir and within 0.8～2 hour, become dough shape sizing material with 4～14 parts of zinc oxide; Then described dough shape micelle, 1～2.5 part of Masterbatch and 3～8 parts of sulphur are placed in the mill of 65～85 ℃ and continue 18～60 minutes slabbing sizing materials of refining glue, then with mould cutting machine, described sheet sizing material is cut into glue embryo.
Step 3, described glue embryo is wrapped in to the outside face of fiber reinforcement internal layer, then put into together mould inner pressure real (glue embryo fiberfill fibers strengthens the groove structure of inner layer outer surface), then be placed in the mould of 98 ℃～145 ℃ baking 10～25 minutes, unvulcanized sheet rubber glue embryo one heating will have certain flowing power, the groove structure that fills up liner forms concaveconvex structure, thereby obtains compound roller.
Therefore, between described fiber reinforcement internal layer and non-metal skin, by convex-concave mosaic texture, be closely combined into integral body, described fiber reinforcement internal layer is 2:3 with the ratio of the outer field thickness of non-metal.
Compound roller provided by the invention is made to carrying roller, and as shown in Figure 1, fiber reinforcement internal layer mainly plays a supportive role, and non-metal skin is softer rubber or elastic body, has fine resistance to abrasion.The weight of this carrying roller be same specification steel carrying roller (roller be steel carrying roller) 50%, the wear resisting property of this carrying roller is 3 times of same specification steel carrying roller, 3 times of the plastic conveyer roller that the bending strength of this carrying roller is same specification (roller is plastic carrying roller).
As mentioned above, roller provided by the invention adopts polymer matrix composite preparation, and the carrying roller weight ratio steel carrying roller making has reduced more than one times, makes the transportation of carrying roller, installation and maintenance more convenient, turns round more energy-conservation.That the skin of this roller (wearing layer) adopts is wear-resisting, prepared by one or more composite materials of heat resist modification polyurethane, nitrile rubber, buna-S, butadiene rubber, greatly improved the wear-resisting of carrying roller, withstanding corrosion, shock resistance, noise-reducing, heat-resisting, the performance such as weather-proof, and extend service life of carrying roller.The skin of this roller adopts fibre reinforced materials to prepare, and the carrying roller that makes to make has the intensity of steel carrying roller, has solved the bad problem of general polymer carrying roller bending strength.And the internal layer of carrying roller and the outer convex-concave mosaic texture that adopts are closely combined into a roller integral body, have solved the problem that rubber idler easily comes unstuck.Composite roller provided by the invention has that high comprehensive performance, price are suitable, long service life and the advantage such as installation is convenient.
Those of ordinary skill in the field are to be understood that: the foregoing is only specific embodiments of the invention; be not limited to the present invention; within the spirit and principles in the present invention all, any modification of making, be equal to replacement, improvement etc., within all should being included in protection scope of the present invention.
Claims (9)
1. a compound roller, is characterized in that, comprises that fiber reinforcement internal layer and non-metal are outer, between described fiber reinforcement internal layer and non-metal skin, by convex-concave mosaic texture, is closely combined into integral body;
Wherein, described fiber reinforcement internal layer is comprised of according to weight portion proportioning separately following raw material: 20～50 parts of glass fibres, 50～80 parts of synthetic resin and 4～10 parts of plasticizer; Described non-metal skin is selected from least one in modified polyurethane, modification nitrile rubber, modified styrene butadiene rubber and modification butadiene rubber material.
2. compound roller according to claim 1, is characterized in that, described fiber is selected from glass fibre, at least one in aramid fiber and carbon fiber.
3. compound roller according to claim 1, is characterized in that, described synthetic resin is selected from epoxy resin, phenol resin, vinylite, unsaturated polyester resin, at least one in polyvinylchloride and nylon resin.
4. compound roller according to claim 1, is characterized in that, described plasticizer is selected from dibutyl phthalate, dioctyl phthalate, at least one in epoxidized soybean oil.
5. prepare according to a method for the compound roller described in any one in claim 1～4, it is characterized in that, comprise the following steps:
By weight ratio 50～80 parts of synthetic resin and 4～10 parts of plasticizer are mixed and obtain thermosetting resin adhesive on puddle mixer, again 20～50 parts of glass fiber yarns are flooded to described thermosetting resin adhesive, then by extruder, the glass fibre that has flooded thermosetting resin adhesive is processed into outside face with the fiber reinforcement internal layer of groove structure;
Outer at the outside face machining of non-metallic with groove structure fiber reinforcement internal layer, between described fiber reinforcement internal layer and non-metal skin, by convex-concave mosaic texture, be closely combined into integral body, obtain compound roller; Wherein said non-metal skin is selected from least one in modified polyurethane, modification nitrile rubber, modified styrene butadiene rubber and modification butadiene rubber material.
6. the preparation method of compound roller according to claim 5, is characterized in that, the described modified polyurethane of take comprises as the outer field preparation process of non-metal:
According to weight portion proportioning, 5～20 parts of base polyurethane prepolymer for use as through silane coupler modified ceramic powder, 20～40 parts of epoxy resin and 50～80 parts of meltings are mixed, be evacuated to negative 0.05～0.2 MPa 2～8 minutes; Then under the environment of 90 ℃～140 ℃, in mixed liquor, add 1～4 part of dibutyltin dilaurate and 5～20 parts of diamido dichloro diphenyl methanes to react; After reaction finishes, mixed liquor is injected and is placed with in the mould space of described fiber reinforcement internal layer, at 70 ℃～150 ℃, solidify;
Wherein, described ceramic powder is selected from least one in silicon dioxide, silicon nitride, carborundum and french talc.
7. the preparation method of compound roller according to claim 6, it is characterized in that, the modifying process of described ceramic powder is: adopt atomizing cone silane coupling agent to be evenly dispersed in to the surface of ceramic powder, then ceramic powder is placed under the environment of 110～130 ℃ and reacts 3～5 hours, obtain modified ceramic powder.
8. the preparation method of compound roller according to claim 5, is characterized in that, take described modification nitrile rubber, modified styrene butadiene rubber or modification butadiene rubber to comprise as the outer field preparation process of non-metal:
According to weight portion proportioning, 40～60 parts of nitrile rubbers or buna-S or butadiene rubber, 10～30 parts of carbon blacks, 10～300 parts of rubber powders, 2～15 parts of epoxidized soybean oils are joined in Banbury mixer and under the environment of 90～150 ℃, stir and within 0.5～2 hour, become dough shape sizing material with 2～15 parts of zinc oxide; Then described dough shape micelle, 0.5～3 part of Masterbatch and 2～10 parts of vulcanizators are placed in the mill of 60～90 ℃ and continue 10～60 minutes slabbing sizing materials of refining glue, then with mould cutting machine, described sheet sizing material is cut into glue embryo.
9. the preparation method of compound roller according to claim 8, it is characterized in that, take described modification nitrile rubber, modified styrene butadiene rubber or modification butadiene rubber also comprises as the outer field preparation process of non-metal: the outside face that described glue embryo is wrapped in to fiber reinforcement internal layer, then put into together mould inner pressure real, then be placed in interior the sulfuration 5～30 minutes of mould of 90 ℃～150 ℃, obtain described compound roller.
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