CN112248638B - 一种碳纤维套筒网纹辊的加工方法 - Google Patents

一种碳纤维套筒网纹辊的加工方法 Download PDF

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CN112248638B
CN112248638B CN202011186001.1A CN202011186001A CN112248638B CN 112248638 B CN112248638 B CN 112248638B CN 202011186001 A CN202011186001 A CN 202011186001A CN 112248638 B CN112248638 B CN 112248638B
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carbon fiber
curing
winding
anilox roller
ceramic
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CN112248638A (zh
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蒋佗贤
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Shaoxing Wanyin New Material Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
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    • B41F31/00—Inking arrangements or devices
    • B41F31/26—Construction of inking rollers
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
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    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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    • B32B37/24—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer not being coherent before laminating, e.g. made up from granular material sprinkled onto a substrate
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Abstract

本申请提供一种碳纤维套筒网纹辊的加工方法，属于曲面印版技术领域。玻璃纤维、陶瓷纤维纸和复合碳纤分别浸泡树脂，备用，按照步骤：钢模具上缠绕玻璃纤维→缠绕陶瓷纤维纸→缠绕玻璃纤维→送入固化炉，一次固化→冷却至室温，表面处理去掉表层树脂→复合碳纤过树脂，缠绕复合碳纤→送入固化炉，二次固化→冷却至室温，表面处理去掉表层树脂→喷底基防腐层→喷陶瓷，冷却，打磨→雕刻，精磨，抛光，退模，形成套筒网纹辊。将本申请应用于印花或印刷，具有耐高温、可清洗、供墨稳定等优点。

Description

一种碳纤维套筒网纹辊的加工方法
技术领域
本申请涉及一种碳纤维套筒网纹辊的加工方法，属于曲面印版技术领域。
背景技术
套筒网纹辊在在柔印和印花中较为普遍，常规的套筒网纹辊多采用平直标准形状的套筒，一般由内而外依次为玻纤层1a、发泡层2a和铝合金层3a，而后在铝合金层3a表面喷涂陶瓷，再雕刻网纹。这种结构的套筒网纹辊主要重量来自于较厚的铝合金层，对于常规使用而言并不成问题，然而，当进行宽幅印花(比如1.5m以上)时，在转移和安装过程中容易出现重心不稳、磕坏的现象；作为花纹控制部分的陶瓷以喷涂方式与铝合金层的粘结牢度不佳，当网纹辊转速提升、温度较高时容易出现烧蚀现象，陶瓷鼓包，图案精准度降低；中间的发泡层虽然可以降低一定的重量，但不耐高温，出现变形、套接契合度变差。
发明内容
有鉴于此，本申请提供一种碳纤维套筒网纹辊的加工方法，不仅可以实现减重，且不变形、耐高温、网纹层温差小，供墨稳定。
具体地，本申请是通过以下方案实现：
一种碳纤维套筒网纹辊的加工方法，包括以下过程：玻璃纤维浸泡树脂，备用→钢模具上缠绕玻璃纤维，为玻纤层一→缠绕陶瓷纤维纸，为内陶瓷层→缠绕玻璃纤维，为玻纤层二→送入固化炉，一次固化→冷却至室温，表面处理去掉表层树脂→复合碳纤过树脂，缠绕复合碳纤，为复合碳纤层，复合碳纤构成为：碳纤维30～40份、酚醛环氧树脂或甲基丙烯酸缩水甘油脂10～30份、乙烯-四氟乙烯共聚物10～15份、固化剂5～10份、促进剂2～4份、抗氧剂0.5～1.5份、防老化剂0.5～0.8份→送入固化炉，二次固化→冷却至室温，表面处理去掉表层树脂→喷底基防腐层→喷陶瓷，为外陶瓷层，冷却，打磨→雕刻，精磨，抛光，退模。
本申请在网纹辊加工过程中，在钢模具上依次形成玻纤层一、内陶瓷层、玻纤层二、复合碳纤层、外陶瓷层，内陶瓷层、复合玻纤层、外陶瓷层实现分层三级隔热，网纹层的温差小，且不受转速影响，供墨稳定，可实现1000℃以上的高温(玻纤层一与空心处的套辊摩擦生热)，即便转速达到400r/min也不会出现变形现象，成型分为两次固化，先缠绕玻璃纤维、陶瓷纤维纸和玻璃纤维，完成一次固化形成玻纤层一、内陶瓷层和玻纤层二，再缠绕复合碳纤完成二次固化形成复合碳纤层，最后喷陶瓷形成外陶瓷层，外陶瓷层既是印花作用层，也是雕刻层。耐湿，即便进行清洗，也不会被腐蚀。
所述钢模具的外径为70-207mm，负公差0.05-0.2mm。作为精密仪器，本案加工形成的套筒网纹辊的中空内壁内径尺寸的控制，是完成抱合紧密度的基础。缠绕过程为基础尺寸的控制，在后续固化过程中，缠绕的玻璃纤维、复合碳纤维等会出现再塑过程，将其负公差控制在0.05-0.2mm，即留出了基本形变空间，又有利于最终定型尺寸的控制。
所述玻纤层一的缠绕过程中，玻璃纤维缠绕8圈，缠绕厚度为0.2-1.5mm。玻纤层一是中空套筒网纹辊的最内层，在印花过程中，网纹辊套装于印花转轴上，玻纤层一是摩擦与抱合的最近一层，既是基础尺寸的控制部位，也是接触高温、发生形变的部位，将其尺寸控制在较小范围内，既降低了操作难度，借助于圈数来控制厚度，也提高了操作精准度。
所述内陶瓷层的缠绕厚度0.2-5mm。内陶瓷层以陶瓷纤维纸的缠绕形成，纤维纸本身在缠绕过程中就会形成一定的层叠结构，将其设置在距离中空内层相对较近的位置，即刻起到很好的隔热效果，又有利于提高尺寸稳定性。
所述玻纤层二的缠绕厚度0.2-2mm。玻纤层二作为中间层，也是整个结构的支撑部位，对尺寸进行强化和巩固，因此相对玻纤层一的厚度更大。
所述复合碳纤层的缠绕厚度0.8-5cm。在印花过程中，一个会影响套筒网纹辊的参数就是转速，当转速高于300r/min时，高速运转会因摩擦受热造成热形变，复合碳纤层相对发泡层结构，不仅不会出现污染问题，且刚性好、耐高温、耐摩擦、导热、耐腐蚀，比重小，比强度高，与铝合金、聚氨酯发泡材料相比，制造相同规格的辊子，性能更佳。
所述防腐层厚1-4丝。
所述外陶瓷层厚度1-50丝。
所述一次固化温度为130-180℃，固化时间1-3h。
所述二次固化温度为130-180℃，固化时间1-3h。
所述雕刻的深度为7-8μm。
附图说明
图1为常规套筒网纹辊的结构示意图；
图2为本申请碳纤维套筒网纹辊的结构示意图。
图中标号：1a.玻纤层；2a.发泡层；3a.铝合金层；1.玻纤层一；2.内陶瓷层；3.玻纤层二；4.复合碳纤层；5.外陶瓷层。
具体实施方式
本实施例中所用的原料主要包括玻璃纤维、陶瓷纤维纸、复合碳纤，玻璃纤维、陶瓷纤维纸和复合碳纤在网纹辊加工前预先以树脂胶水浸泡，方便缠绕和定位。
复合碳纤构成为：碳纤维30～40份、酚醛环氧树脂或甲基丙烯酸缩水甘油脂10～30份、乙烯-四氟乙烯共聚物10～15份、固化剂5～10份、促进剂2～4份、抗氧剂0.5～1.5份、防老化剂0.5～0.8份，均为质量份。
钢模具的外径为70-207mm，负公差0.05-0.2mm。作为精密仪器，本案加工形成的套筒网纹辊的中空内壁内径尺寸的控制，是完成抱合紧密度的基础。缠绕过程为基础尺寸的控制，在后续固化过程中，缠绕的玻璃纤维、复合碳纤维等会出现再塑过程，将其负公差控制在0.05-0.2mm，即留出了基本形变空间，又有利于最终定型尺寸的控制。
采用上述原料进行碳纤维套筒网纹辊的加工方法包括以下步骤：
(1)钢模具上缠绕玻璃纤维，玻璃纤维缠绕8圈，缠绕厚度为0.2-1.5mm。该处是中空套筒网纹辊的最内层，在印花过程中，网纹辊套装于印花转轴上，该处是摩擦与抱合的最近一层，既是基础尺寸的控制部位，也是接触高温、发生形变的部位，将其尺寸控制在较小范围内，既降低了操作难度，借助于圈数来控制厚度，也提高了操作精准度；
(3)缠绕陶瓷纤维纸，缠绕厚度0.2-5mm。该层以陶瓷纤维纸的缠绕形成，纤维纸本身在缠绕过程中就会形成一定的层叠结构，将其设置在距离中空内层相对较近的位置，即刻起到很好的隔热效果，又有利于提高尺寸稳定性；
(4)缠绕玻璃纤维，缠绕厚度0.2-2mm。该处作为中间层，也是整个结构的支撑部位，对尺寸进行强化和巩固，因此相对步骤(1)的厚度更大；
(5)送入固化炉，一次固化，一次固化温度为130-180℃，固化时间1-3h；
(6)冷却至室温，以打磨等表面处理方式，磨掉表层树脂；
(7)复合碳纤过树脂，缠绕复合碳纤，缠绕厚度0.8-5cm。在印花过程中，一个会影响套筒网纹辊的参数就是转速，当转速高于300r/min时，高速运转会因摩擦受热造成热形变，复合碳纤层相对发泡层结构，不仅不会出现污染问题，且刚性好、耐高温、耐摩擦、导热、耐腐蚀，比重小，比强度高，与铝合金、聚氨酯发泡材料相比，制造相同规格的辊子，性能更佳；
(8)送入固化炉，二次固化，二次固化温度为130-180℃，固化时间1-3h；
(9)冷却至室温，表面处理去掉表层树脂；
(10)喷底基防腐层，防腐层厚1-4丝；
(11)喷陶瓷，厚度1-50丝，冷却，打磨；
(12)雕刻，雕刻深度为7-8μm，精磨，抛光，退模。
本申请在网纹辊加工过程中，在钢模具上依次缠绕玻璃纤维、陶瓷纤维纸、玻璃纤维、复合碳纤、喷防腐层、喷陶瓷，经过两次固化，分别形成玻纤层一1、内陶瓷层2、玻纤层二3、复合碳纤层4、防腐层(厚度较小，图中未标出)和外陶瓷层5，内陶瓷层2、复合玻纤层4、外陶瓷层5实现分层三级隔热，网纹层的温差小，且不受转速影响，供墨稳定，可实现1000℃甚至1260℃以上的高温(该高温的其中一个来源是玻纤层一1与空心处的套辊的摩擦生热)，即便转速达到400r/min也不会出现变形现象。
成型分为两次固化：先缠绕玻璃纤维、陶瓷纤维纸和玻璃纤维，完成一次固化后，上述三部分材料分别形成玻纤层一1、内陶瓷层2和玻纤层二3；再缠绕复合碳纤，完成二次固化形成复合碳纤层4，最后喷底基防腐层，喷陶瓷形成外陶瓷层5，外陶瓷层5既是印花作用层，也是雕刻层。耐湿，即便进行清洗，也不会被腐蚀。
表1为容积对照表
Figure BDA0002751449160000051
表2常规网纹辊与本实施例网纹辊的使用对照表
常规套筒网纹辊 本申请
适用温度范围 -30℃-150℃ -30℃-1260℃
适用幅宽范围 10cm-250cm 10cm-500cm
适用转速范围 0m/min-400m/min 0m/min-2000m/min
使用周期/寿命 1年 3年
重量/根 80kg/1.8m 35kg/1.8m
成本/根 1元/c㎡ 1.15元/c㎡
印花效果 良 优
供墨稳定状态 均匀 均匀且稳定
环保性 环保 环保
对比表1和表2可以看出：本申请所提供的套筒网纹辊不仅使用寿命长、刚性好，转速400r/min以上也很少存在变形的情况，质量轻，使用过程中无异味、不污染，可清洁，不会被腐蚀，可耐1260℃的高温，成本远低于进口，供墨均匀且稳定。

Claims (7)

1.一种碳纤维套筒网纹辊的加工方法，其特征在于：原料包括玻璃纤维、陶瓷纤维纸、复合碳纤，玻璃纤维、陶瓷纤维纸和复合碳纤在网纹辊加工前预先以树脂胶水浸泡，
复合碳纤构成为：碳纤维30～40份、酚醛环氧树脂或甲基丙烯酸缩水甘油脂10～30份、乙烯-四氟乙烯共聚物10～15份、固化剂5～10份、促进剂2～4份、抗氧剂0.5～1.5份、防老化剂0.5～0.8份，均为质量份，
钢模具的外径为70-207mm，负公差0.05-0.2mm，
原料按照以下步骤进行加工：
（1）钢模具上缠绕玻璃纤维，玻璃纤维缠绕厚度为0.2-1.5mm；
（2）缠绕陶瓷纤维纸，陶瓷纤维纸缠绕厚度0.2-5mm；
（3）缠绕玻璃纤维，玻璃纤维缠绕厚度0.2-2mm；
（4）送入固化炉，一次固化，冷却至室温，表面处理去掉表层树脂；
（5）缠绕复合碳纤；
（6）送入固化炉，二次固化，冷却至室温，表面处理去掉表层树脂；
（7）喷底基防腐层；
（8）喷陶瓷，冷却，打磨；
（9）雕刻，精磨，抛光，退模。
2.根据权利要求1所述的一种碳纤维套筒网纹辊的加工方法，其特征在于：步骤（4）中，一次固化温度为130-180℃，固化时间1-3h。
3.根据权利要求1所述的一种碳纤维套筒网纹辊的加工方法，其特征在于：步骤（5）中，复合碳纤缠绕厚度0.8-5cm。
4.根据权利要求1所述的一种碳纤维套筒网纹辊的加工方法，其特征在于：步骤（6）中，二次固化温度为130-180℃，固化时间1-3h。
5.根据权利要求1所述的一种碳纤维套筒网纹辊的加工方法，其特征在于：步骤（7）中，防腐层厚1-4丝。
6.根据权利要求1所述的一种碳纤维套筒网纹辊的加工方法，其特征在于：步骤（8）中，喷陶瓷厚度1-50丝。
7.根据权利要求1所述的一种碳纤维套筒网纹辊的加工方法，其特征在于：步骤（9）中，雕刻深度为7-8μm。
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