CN109049912A - 蜂窝结构复合辊及其加工方法 - Google Patents
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Abstract
本发明涉及一种蜂窝结构复合辊及其加工方法,复合辊包括辊芯和复合套筒,复合套筒自内向外依次为玻璃钢内粘结层、蜂窝板填充结构层、玻璃钢粘结固定层和套筒外面层,复合套筒通过玻璃钢内粘结层与辊芯的表面复合。加工方法包括:对辊芯进行加工;在辊芯上绕制玻璃纤维纱带固化得到玻璃钢内粘结层;将蜂窝板片包绕在玻璃钢内粘结层的外表面得到蜂窝板填充结构层;在蜂窝板填充结构层上绕制玻璃纤维纱带固化得到玻璃钢粘结固定层;选择辊面材料,在玻璃钢粘结固定层的外表面复合套筒外面层;对复合套筒的外表面进行磨削、抛光处理。本发明能够降低复合辊的质量,提高辊筒转速,降低使用能耗,增强复合辊结构强度和稳定性,延长使用寿命。
Description
技术领域
本发明属于辊筒的技术领域,特别是涉及一种蜂窝结构复合辊及其加工方法。
背景技术
现有的辊筒一般不存在中间填充层,直接根据用途的不同在金属辊芯上复合不同材料(包括聚氨酯、合成橡胶、合成树脂、塑料或金属合金等),由于金属辊芯外径较大,造成辊筒总体质量大,使用时能耗高,不利于辊筒的高速运行。
发明内容
本发明所要解决的技术问题是提供一种蜂窝结构复合辊及其加工方法,降低质量,提高结构强度和稳定性,延长使用寿命。
本发明解决其技术问题所采用的技术方案是提供一种蜂窝结构复合辊,包括辊芯和复合套筒,所述复合套筒自内向外依次为玻璃钢内粘结层、蜂窝板填充结构层、玻璃钢粘结固定层和套筒外面层,所述复合套筒通过玻璃钢内粘结层与辊芯的表面复合。
所述辊芯包括中间的空心辊筒和两端的辊撑。
所述蜂窝板填充结构层采用芳纶蜂窝板。
所述套筒外面层采用聚氨酯、合成橡胶、合成树脂、金属合金或者陶瓷制成。
所述辊芯为金属辊芯、碳纤维辊芯、玻璃钢辊芯或者碳纤维玻璃钢复合辊芯。
本发明解决其技术问题所采用的技术方案是提供一种上述的蜂窝结构复合辊的加工方法,包括以下步骤:
(1)加工辊芯:根据设计图纸对辊芯进行加工;
(2)包绕玻璃钢内粘结层:在辊芯上绕制含有树脂的玻璃纤维纱带或者玻璃纤维布,固化后得到玻璃钢内粘结层;
(3)包绕蜂窝板填充结构层:根据复合辊的外径尺寸确定蜂窝板填充结构层的厚度,将经过裁切的蜂窝板片包绕在玻璃钢内粘结层的外表面得到蜂窝板填充结构层;
(4)包绕玻璃钢粘结固定层:在蜂窝板填充结构层上绕制含有树脂的玻璃纤维纱带或者玻璃纤维布,固化后得到玻璃钢粘结固定层;
(5)复合套筒外面层:选择辊面材料,在玻璃钢粘结固定层的外表面复合套筒外面层;
(6)对复合套筒的外表面进行磨削、抛光处理至到达设计外径尺寸。
有益效果
在本发明中,蜂窝板填充结构层作为复合套筒的主体结构层,通过其厚度设计可以对复合辊的外径尺寸进行控制,可以降低辊芯的径向尺寸,蜂窝板填充结构层的蜂窝状空心结构,能够大大降低贴版复合套筒的质量,使装备轻量化,提高辊筒转速,有利于降低复合辊的使用能耗;蜂窝板填充结构层的蜂窝状组织架构,稳定性强,能够提高复合辊的结构强度和韧性,提高复合辊的抗疲劳性和耐冲击性,有利于延长版辊筒的使用寿命;蜂窝板填充结构层作为主体结构层具有非常小的热膨胀性能,能够在受热时保持结构的稳定性,保持了符合辊受热时整体尺寸的稳定性。
附图说明
图1为本发明的结构示意图。
图2为本发明的局部剖面结构示意图。
具体实施方式
下面结合具体实施例,进一步阐述本发明。应理解,这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解,在阅读了本发明讲授的内容之后,本领域技术人员可以对本发明作各种改动或修改,这些等价形式同样落于本申请所附权利要求书所限定的范围。
如图1和图2所示的一种蜂窝结构复合辊,包括辊芯1和复合套筒。
辊芯1包括中间的空心辊筒和两端对称设置的辊撑,采用金属辊芯、碳纤维辊芯、玻璃钢辊芯或者碳纤维玻璃钢复合辊芯。复合套筒自内向外依次为玻璃钢内粘结层2、蜂窝板填充结构层3、玻璃钢粘结固定层4和套筒外面层5,蜂窝板填充结构层3采用芳纶蜂窝板,套筒外面层5采用聚氨酯、合成橡胶、合成树脂、金属合金或者陶瓷制成。复合套筒通过玻璃钢内粘结层2与辊芯1的表面复合。
下面提供一种上述的蜂窝结构复合辊的加工方法,包括以下步骤:
(1)加工辊芯1:根据设计图纸对辊芯1进行加工;
(2)包绕玻璃钢内粘结层2:在辊芯1上绕制含有树脂的玻璃纤维纱带或者玻璃纤维布,固化后得到玻璃钢内粘结层2;
(3)包绕蜂窝板填充结构层3:根据复合辊的外径尺寸确定蜂窝板填充结构层3的厚度,将经过裁切的蜂窝板片包绕在玻璃钢内粘结层(2)的外表面得到蜂窝板填充结构层3;
(4)包绕玻璃钢粘结固定层4:在蜂窝板填充结构层3上绕制含有树脂的玻璃纤维纱带或者玻璃纤维布,固化后得到玻璃钢粘结固定层4;
(5)复合套筒外面层5:选择辊面材料,在玻璃钢粘结固定层4的外表面复合套筒外面层5;
(6)对复合套筒的外表面进行磨削、抛光处理至到达设计外径尺寸。
下面提供5种蜂窝结构复合辊的具体加工方法的实施例:
实施例1
(1)加工辊芯1:根据设计图纸对辊芯1进行加工;
(2)包绕玻璃钢内粘结层2:在辊芯1上绕制含有树脂的玻璃纤维纱带,单边厚度1mm,固化后得到玻璃钢内粘结层2;
(3)包绕蜂窝板填充结构层3:根据复合辊的外径尺寸确定蜂窝板填充结构层3的厚度为20mm,在包绕蜂窝板之前,先在玻璃钢内粘结层2上涂刷一层树脂作为粘结剂,然后将经过裁切的蜂窝板片包绕在玻璃钢内粘结层2的外表面得到蜂窝板填充结构层3,蜂窝板片采用芳纶蜂窝版片;
(4)包绕玻璃钢粘结固定层4:在蜂窝板填充结构层3上绕制含有树脂的玻璃纤维纱带,单边厚度4mm,固化后得到玻璃钢粘结固定层4;
(5)复合套筒外面层5:选择辊面材料合成树脂,采用旋转浇筑法在玻璃钢粘结固定层4的外表面浇淋合成树脂,单边厚度1.5mm,并固化得到合成树脂层;
(6)对复合辊的外表面进行磨削、抛光处理至到达设计外径尺寸。
实施例2
(1)加工辊芯1:根据设计图纸对辊芯1进行加工;
(2)包绕玻璃钢内粘结层2:在辊芯1上绕制含有树脂的玻璃纤维纱带,单边厚度2mm,固化后得到玻璃钢内粘结层2;
(3)包绕蜂窝板填充结构层3:根据复合辊的外径尺寸确定蜂窝板填充结构层3的厚度为70mm,在包绕蜂窝板之前,先在玻璃钢内粘结层2上涂刷一层树脂作为粘结剂,然后将经过裁切的蜂窝板片包绕在玻璃钢内粘结层2的外表面得到蜂窝板填充结构层3,蜂窝板片采用芳纶蜂窝版片;
(4)包绕玻璃钢粘结固定层4:在蜂窝板填充结构层3上绕制含有树脂的玻璃纤维纱丝,单边厚度5mm,固化后得到玻璃钢粘结固定层4;
(5)复合套筒外面层5:选择辊面材料为金属合金,采用热喷涂法在玻璃钢粘结固定层4的外表面喷涂金属涂层,单边厚度2mm,得到金属合金涂层5;
(6)对复合辊的外表面进行磨削、抛光处理至到达设计外径尺寸。
实施例3
(1)加工辊芯1:根据设计图纸对辊芯1进行加工;
(2)包绕玻璃钢内粘结层2:在辊芯1上绕制含有树脂的玻璃纤维纱带,单边厚度1.5mm,固化后得到玻璃钢内粘结层2;
(3)包绕蜂窝板填充结构层3:根据复合辊的外径尺寸确定蜂窝板填充结构层3的厚度为30mm,在包绕蜂窝板之前,先在玻璃钢内粘结层2上涂刷一层树脂作为粘结剂,然后将经过裁切的蜂窝板片包绕在玻璃钢内粘结层2的外表面得到蜂窝板填充结构层3,蜂窝板片采用芳纶蜂窝版片;
(4)包绕玻璃钢粘结固定层4:在蜂窝板填充结构层3上绕制含有树脂的玻璃纤维纱带单边厚度4mm,固化后得到玻璃钢粘结固定层4;
(5)复合套筒外面层5:选择辊面材料为聚氨酯,采用旋转浇筑法在玻璃钢粘结固定层4的外表面浇淋聚氨酯,单边厚度4mm,并固化得到聚氨酯层;
(6)对复合辊的外表面进行磨削、抛光处理至到达设计外径尺寸。
实施例4
(1)加工辊芯1:根据设计图纸对辊芯1进行加工;
(2)包绕玻璃钢内粘结层2:在辊芯1上绕制含有树脂的玻璃纤维纱带单边厚度3mm,固化后得到玻璃钢内粘结层2;
(3)包绕蜂窝板填充结构层3:根据复合辊的外径尺寸确定蜂窝板填充结构层3的厚度为100mm,在包绕蜂窝板之前,先在玻璃钢内粘结层2上涂刷一层树脂作为粘结剂,然后将经过裁切的蜂窝板片包绕在玻璃钢内粘结层2的外表面得到蜂窝板填充结构层3,蜂窝板片采用芳纶蜂窝版片;
(4)包绕玻璃钢粘结固定层4:在蜂窝板填充结构层3上绕制含有树脂的玻璃纤维纱带丝,单边厚度4mm,固化后得到玻璃钢粘结固定层4;
(5)复合套筒外面层5:选择辊面材料为陶瓷,采用热喷涂法在玻璃钢粘结固定层4的外表面喷涂金属过渡涂层单边厚度1.5mm,再通过热喷涂法在金属过渡涂层上喷涂陶瓷涂层单边厚度0.3mm,得到陶瓷层5;
(6)对复合辊的外表面进行磨削、抛光处理至到达设计外径尺寸。
实施例5
(1)加工辊芯1:根据设计图纸对辊芯1进行加工;
(2)包绕玻璃钢内粘结层2:在辊芯1上绕制含有树脂的玻璃纤维纱带,单边厚度5mm,固化后得到玻璃钢内粘结层2;
(3)包绕蜂窝板填充结构层3:根据复合辊的外径尺寸确定蜂窝板填充结构层3的厚度为150mm,在包绕蜂窝板之前,先在玻璃钢内粘结层2上涂刷一层树脂作为粘结剂,然后将经过裁切的蜂窝板片包绕在玻璃钢内粘结层2的外表面得到蜂窝板填充结构层3,蜂窝板片采用芳纶蜂窝版片;
(4)包绕玻璃钢粘结固定层4:在蜂窝板填充结构层3上绕制含有树脂的玻璃纤维纱带单边厚度6mm,固化后得到玻璃钢粘结固定层4;
(5)复合套筒外面层5:选择辊面材料为合成橡胶,先在玻璃钢粘结固定层4的外表面毛化处理后包胶,包胶单边厚度20mm,再对辊筒进行硫化成型固化后得到合成橡胶层5;
(6)对复合辊的外表面进行磨削、抛光处理至到达设计外径尺寸。
本发明的复合辊具有质量轻、强度高、抗疲劳性和耐冲击性好、尺寸稳定性好等特点,有利于延长复合辊的使用寿命,使装备轻量化,提高辊筒转速,有利于降低使用能耗,应用前景好。
Claims (6)
1.一种蜂窝结构复合辊,包括辊芯(1)和复合套筒,其特征在于:所述复合套筒自内向外依次为玻璃钢内粘结层(2)、蜂窝板填充结构层(3)、玻璃钢粘结固定层(4)和套筒外面层(5),所述复合套筒通过玻璃钢内粘结层(2)与辊芯(1)的表面复合。
2.根据权利要求1所述的一种蜂窝结构复合辊,其特征在于:所述辊芯(1)包括中间的空心辊筒和两端的辊撑。
3.根据权利要求1所述的一种蜂窝结构复合辊,其特征在于:所述蜂窝板填充结构层(3)采用芳纶蜂窝板。
4.根据权利要求1所述的一种蜂窝结构复合辊,其特征在于:所述套筒外面层(5)采用聚氨酯、合成橡胶、合成树脂、金属合金或者陶瓷制成。
5.根据权利要求1所述的一种蜂窝结构复合辊,其特征在于:所述辊芯(1)为金属辊芯、碳纤维辊芯、玻璃钢辊芯或者碳纤维玻璃钢复合辊芯。
6.一种权利要求1所述的蜂窝结构复合辊的加工方法,包括以下步骤:
(1)加工辊芯(1):根据设计图纸对辊芯(1)进行加工;
(2)包绕玻璃钢内粘结层(2):在辊芯(1)上绕制含有树脂的玻璃纤维纱带或者玻璃纤维布,固化后得到玻璃钢内粘结层(2);
(3)包绕蜂窝板填充结构层(3):根据复合辊的外径尺寸确定蜂窝板填充结构层(3)的厚度,将经过裁切的蜂窝板片包绕在玻璃钢内粘结层(2)的外表面得到蜂窝板填充结构层(3);
(4)包绕玻璃钢粘结固定层(4):在蜂窝板填充结构层(3)上绕制含有树脂的玻璃纤维纱带或者玻璃纤维布,固化后得到玻璃钢粘结固定层(4);
(5)复合套筒外面层(5):选择辊面材料,在玻璃钢粘结固定层(4)的外表面复合套筒外面层(5);
(6)对复合套筒的外表面进行磨削、抛光处理至到达设计外径尺寸。
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