CN1378629A - 由纤维增强的塑料材料制成的薄壁圆筒 - Google Patents

由纤维增强的塑料材料制成的薄壁圆筒 Download PDF

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CN1378629A
CN1378629A CN00814115A CN00814115A CN1378629A CN 1378629 A CN1378629 A CN 1378629A CN 00814115 A CN00814115 A CN 00814115A CN 00814115 A CN00814115 A CN 00814115A CN 1378629 A CN1378629 A CN 1378629A
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cylinder
layer
fiber
longitudinal axis
fiber array
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CN1189684C (zh
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卡斯特·J·范韦普伦
诺伯图斯·F·J·埃尔曼斯
托马斯·M·琼克斯
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Stork Screens BV
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Abstract

本发明涉及一种由纤维增强的塑料制成的薄壁空心圆筒(12)。该圆筒的壁由至少一个层(20;32,34;32,44,46)组成,该层上具有排列在至少一个方向上的纤维,总的壁厚dtot在10至1000微米范围内,比值dtot/D≤0.0025。纤维的排列方向(一个或多个)根据希望的最终用途来选择。这种圆筒的例子特别包括:由碳/环氧树脂制成的多个层的层叠体。该层叠体可用来制造这种形式的圆筒,该层叠体具有至少一个层,该层上的纤维排列方向与圆筒的纵轴线平行或垂直。

Description

由纤维增强的塑料材料制成的薄壁圆筒
                        技术领域
本发明涉及由一种纤维增强的塑料制成的薄壁空心圆筒。
                        背景技术
例如，从DE-A-2911167中已知一种用作驱动轴的壁厚较大的空心圆筒。这个已知的圆筒是层状结构，它包括至少四个层。该层包含的玻璃纤维或碳纤维的排列方向与该轴的纵轴线形成一个确定的角度。根据这个专利公告，玻璃纤维排列方向角为±30°至±50°的最内层是吸收剪切负荷的主要支承。玻璃纤维排列方向角为0°至±15°的第一个中间层的功能是增加壁厚，以便抵抗使用过程中的扭转。另一个包含排列方向角为0°至15°的碳纤维的中间层用于增加该轴的刚度，以便抑制工作时轴产生的通常的声音/噪声。最后，该轴带有一个最外面的抗冲击保护层，该层上的玻璃纤维的排列方向角为±60°至90°，该层同样可抗扭转。根据示例，总壁厚大约为3.0mm。
另外，DE-A-2520623公开了一种由纤维增强的塑料材料制成的管子。该管子例如，可用在航空和航天领域，它包括多个具有排列方向任意的纤维的层。EP-A-0058783公开了一种管状体，例如柱，它包括多个塑料层并带有一个最外层的精加工层，在该精加工层中优选使用不同纤维的组合。
又例如，在NL-A-8802144中公开了一种薄壁空心圆筒，它用于制造所谓的“电镀”印刷印版，在该圆筒壁上利用激光作出许多格子点形式的孔。这种已知的圆筒由塑料材料制成，在塑料材料中可以加入固体颗粒和/或纤维，以增加机械稳定性和强度。这种性质的塑料材料制成的电镀印刷印版在商业上从未取得成功。
除了用于制造电镀印刷印版的上述用途以外，通常由金属(例如Ni)制成的薄壁空心圆筒还可用于其他印刷应用场合。例如，用于凸版印刷和照相凹版印刷，这时可在该圆筒的外表面上例如可以利用激光作出包括凹部的浮雕花纹，或者，还可用作曲面印刷的印刷平板的一个薄的金属支承，该支承可以安装在一个通气滚子(an air roller)上和从该滚子上取下。这种形式的薄壁空心圆筒的其他应用尤其包括：作为转移涂层和油墨的转移介质；如作为一种电成形模型的导电圆筒；也可用作任意方式驱动的滚子上的具有特殊摩擦/滑动性质的表面的一种涂层材料的转移装置。
在许多这些应用场合中，重要的是可以用激光来加工圆筒材料，因为这表示圆筒壁厚必需不超过确定的上限。另外，在某些印刷应用场合，该圆筒不是在整个圆周表面被支承，而只是支承在圆筒的末端(例如，支承在末端圆环上)。但在另一些应用场合中，如果圆筒的长度较大，则这种形式的薄壁圆筒必需要有足够的刚性(在纵向上)，以便容易搬运该圆筒，使圆筒不会损坏以及圆筒的弯曲在可以接受的范围内。
另外，例如在曲面印刷中，当利用空气使圆筒的直径增大时，很难使小直径的镍制圆筒在滚子上浮起。这种形式的小直径的镍制圆筒较难制造。另外，薄的镍制圆筒容易变皱。然而，壁厚较大、因而也是不容易变皱的圆筒价格昂贵，并且更难浮起。
薄壁金属圆筒经常是将圆筒推压在一起，成为卵形进行运输和储存的。然而，这只有在圆筒具有一定的直径才可能。
因此，持续需要有一种性质经过改善的、便于使用、运输和(暂时)储存的圆筒。
如上所述，根据NL-A-8802144，一般通过加入填充物和/或纤维，通常可以使塑料的机械性质更稳定。然而，该荷兰专利申请没有说明如何可以提高塑料的机械性质的稳定性。
美国专利US-A-3981237公开了一种用塑料材料例如聚酯制造的转动式印刷的筛网。塑料材料可以填充一种增强材料，例如玻璃纤维。这种转动式印刷筛网是由用传统的挤压方法制成的管子坯料制造的，然后经过在轴向双向上拉伸。这些填充物材料为(短的)割断的纤维，该纤维即使在轴向双向拉伸后，仍随机地分布在塑料材料中。因此，该纤维最大的体积密集度为40％。然而，这样制造的筛网的强度和刚性有许多需要改进的地方。该管子坯料可用激光发射穿孔，形成筛网孔。
另外，还应指出，日本专利JP-A-11278817公开了一种由碳纤维增强的材料制成的圆筒结构。考虑到在利用Czochralski方法生产单晶硅的装置中，作为一个绝缘圆筒使用的情况，该圆筒结构的壁厚较大。
上述其他专利公开物中公开的壁厚较厚的空心圆筒不适合上述的应用场合。
在先前的技术中，一般认为不可能用纤维增强的塑料材料来制造直径较大和壁厚较小(最多约1mm)，同时具有上述应用场合所要求的机械和化学性质的空心圆筒。
另外，已知由于塑性变形的影响，在负载作用下，塑料材料比金属(例如镍)更容易变形。
                        发明内容
本发明的目的是提供一种由纤维增强的塑料材料制成的薄壁空心圆筒，该圆筒的壁厚可允许用高能辐射处理成一个中间产品，同时其刚性对于许多其他应用场合是足够的，该圆筒可以与任意的支承一起使用和/或任意转动。
本发明的另一个目的是要提供一种由这种形式的纤维增强的塑料材料制成的薄壁空心圆筒，与在上述荷兰专利申请第8802144号中所述的，由(纤维增强的)塑料材料制成的印刷印版比较，该圆筒的机械性质得到改善。
本发明提供一种由纤维增强的塑料材料制成的薄壁空心圆筒，其包括至少一个层，该层上的纤维排列在至少一个方向上，其总的壁厚dtot在0.010至1mm(10至1000μm)范围内，并且比值dtot/D≤0.0025，式中D为圆筒的直径(mm)。根据本发明，已经证实可以制造一个非常薄的套筒，其最大壁厚为1mm，具有可以加工得很光滑的且尺寸公差很精确的一个连续外表面，对其所需材料很少。除此之外，应当指出，在许多情况下，不需要进一步加工。
优选的是，圆筒总的壁厚dtot在0.010至0.700mm范围内较好，更优选的是在0.020至0.300mm范围内。
例如，当壁厚为80μm时，圆筒的最小直径为32mm，当壁厚为1000μm时，圆筒的最小直径为400mm。圆筒的横截面优选是圆形的，其D/L比小于1，其中L为圆筒长度mm。
根据本发明的重量轻的圆筒非常适合于用作在诸如胶板印刷的快速回转的滚筒或滚子上的套筒，例如对于胶版印刷，这时，该套筒不会由于离心力而脱离滚子。通过适当地选择没有屈服点或屈服点高的塑料材料(一种或多种)和纤维类型(一类或多类)，可以制造不容易变皱的圆筒。与金属特别是镍比较，一般地，塑料更耐腐蚀，并能更好地抵抗化学品的作用。如果根据本发明的圆筒用在腐蚀性的介质中，例如在印刷时，则以上性质是有利的。当给定以上定义的壁厚与直径的比值时，可以不需将多个根据本发明的圆筒推压在一起，成为卵形，也容易运输和储存。该圆筒可很容易做成无缝的，因此，没有由焊缝造成的不均匀性。与金属圆筒比较，采用本发明的圆筒容易进行诸如切割和穿孔等加工。
加入有在一个方向排列的纤维(以下称为单向纤维)的单个塑料层具有各向异性的弹性性质，即：其性质依赖于负载作用的方向。
在该说明书中，纤维增强的塑料材料是指加入增强纤维的一个塑料基体层。根据本发明，这些纤维排列在一个方向上。
众所周知，加入纤维一般会改善塑料材料的刚性。可以加入所谓短纤维(也称为“切断纤维”)形式的纤维，也可加入在塑料中任意分布的长纤维和单向纤维。原则上说，使用单向纤维可以得到最大的刚性。另外，带有单向纤维的层的纤维含量最高，因而，就是这些纤维使得这些层的弹性模量可获得最大。
如上所述，具有单向纤维的单一一个塑料层具有各向异性的弹性性质。根据本发明，利用这种各向异性的现象来限制在各种应用场合出现的，在负载作用方向上的变形。对于每一种应用场合，负载作用方向，因而也是圆筒的纤维排列方向，与其他应用场合可能都不相同。
对于某些应用场合，可能同时有多个不同方向的负载作用在圆筒上；例如，如果由该圆筒制造转动式筛网印刷用的电镀印刷印版时，就有这种情况。根据本发明的一个实施例的圆筒，包括一个纤维增强的层，该层上的纤维排列在两个不同的方向上。这些纤维可以是机织或编织的纤维织物，纤维物或纤维布。
为了减少总的弯曲量，特别是在长圆筒的情况下，优选使纤维的排列方向与圆筒的纵轴线平行，即排列在轴向上。
对于例如在曲面印刷中，圆筒安装在一个通气滚子上的情况，纤维的排列方向优选与圆筒的纵轴线垂直。
根据本发明的另一个实施例的印刷印版，该圆筒包括纤维排列在第一个方向上的第一个层和纤维排列在第二个方向上的第二个层；该纤维排列的第一个方向和第二个方向不相同。如上所述，具有单向纤维的单独的层的纤维含量高(试比较：对于在环氧树脂中的单向碳纤维，纤维的含量按体积计为63％，而对于环氧树脂中的无纺物，纤维含量按体积计大约为35％)，这对弹性性质有利。根据本发明的圆筒的纤维含量，按体积计优选大于45％。根据本发明的这类圆筒至少由两个纤维增强的塑料层构成，一个层中的纤维排列在一个方向上，并且纤维排列的各个方向彼此不平行。
优选的是，第一个层的纤维排列方向与圆筒的纵轴线形成α角；而第二个层的纤维排列方向与印刷印版的纵轴线形成-α角。有利的是，该圆筒还可包括纤维排列在第三个方向上的另一个层，该另一个层上的纤维排列方向与圆筒的纵轴线平行或垂直。优选的是，该另一个层位于第一个和第二个层之间。
角度α的例子为：0°、30°、45°和大于60°。如果该圆筒为转动式筛网印刷的印刷印版的一个预型件(a preform)，则根据本发明的圆筒中使用的三个层的层叠体包括三个层，其层上的纤维的不同排列方向相对于圆筒的纵轴线的角度可为：0°和±60°，或0°和±45°，或0°和90°(×2)。用于根据本发明的圆筒中，作为曲面印刷的所谓“套筒”的三个层的层叠体包括三个层，层上纤维的不同排列方向相对于圆筒纵轴线的角度可为：90°和±30°，或90°和±45°，或0°(×2)和90°。
根据本发明的圆筒的另一个实施例，具有排列在第一个方向上的纤维的第一个层和具有排列在第二个方向上的第二个层可以互相交替放置。这种形式的实施例的一个例子是由一个四个层的层叠体制成的圆筒，其中，第一和第三个层上的纤维排列方向与第二和第四个层上的纤维排列方向相同。
根据一个特别优选的实施例，圆筒在厚度方向的结构是对称的，其最外的第一个层上的纤维排列方向与圆筒的纵轴线形成α角；而第二个层，即中间层上的纤维排列方向与圆筒的纵轴线形成-α角。在这个实施例中，该圆筒有利的是还包括纤维排列在第三个方向上的另一个层，该另一个层的纤维排列方向与印刷印版的纵轴线平行或垂直。如上述的包括三个层的圆筒一样，该另一个层优选位于第二个层，即中间层之间，即，位于在圆筒壁的厚度方向看的中心。
在上述用于制造根据本发明的圆筒，和包括纤维排列方向与圆筒的纵轴线平行或垂直的另一个层的多个层的层叠体中，该另一个层的厚度优选比其他层的厚度大。在这种情况下，一般，纤维排列方向相同的各层的厚度相同。
根据纤维的厚度(直径)和根据本发明圆筒的最终所希望的厚度的不同，该圆筒还可以包括多个纤维排列方向相同的相邻的层。
如果由根据本发明的圆筒来制造转动式筛网印刷印版，则圆筒的总壁厚优选在80～300μm范围内。壁厚小时，可根据要印刷的图样，用激光来制造印刷孔。如果将根据本发明的圆筒用作曲面印刷的套筒，则最小壁厚大约为0.08mm。对于标签印刷，总壁厚有利的是在0.02～0.15mm范围内。
根据本发明的薄壁圆筒容易用激光加工，例如，来制造筛网印刷用的印刷印版。应当注意，由这种进一步加工的圆筒容易制造平的印刷印版，为此，在纵向方向切开圆筒并将这样制成的平的筛网安装在合适的平面形框架上。
由根据本发明的圆筒制成的转动式筛网印刷的印刷印版的机械性质也很好。
如上所述和下面将要更详细地说明的那样，虽然有优选的纤维排列方向和材料，但根据最终用途的不同，纤维的排列方向、层的厚度和材料可以改变。
为了减小具有单向纤维的单个层的各向异性现象，如希望的话，在根据本发明的圆筒中，可以将各个材料层结合起来形成一个准各向同性的层叠体。
如上所述，可以随着所希望的性质的不同，选择纤维材料和粘合剂基体的塑料。适当的纤维材料的例子包括：碳纤维，诸如玻璃纤维和硼纤维的无机纤维，金属纤维和诸如拉伸纤维的有机塑料纤维，如芳族聚酰胺纤维和高强度拉伸的聚乙烯纤维，以及它们的组合。碳纤维和无机纤维是特别优选的，尤其是碳纤维最优选。所用的粘合剂材料不是关键性的，因为与纤维比较，它们对机械性质影响很小，因此可从已知的热塑塑料-例如聚酯，和热固塑料-例如环氧树脂中选择。考虑到价格与刚性的关系最佳，在通常的组合中，优选的是碳/环氧树脂组合。这种组合的刚性实际上为凯夫拉尔(kevlar)/环氧树脂组合的二倍大，为玻璃/环氧树脂组合的三倍大。其他刚性较大的组合包括：碳/聚酰亚胺，石墨/环氧树脂和碳化硅/陶瓷。然而，这些组合很昂贵。上述单个层的材料商业上有销售。
许多纤维/粘合剂基体单个层组合的弹性参数在1994年牛津大学出版社出版的I.M.Daniel等人著的“engineering Mechanics of CompositeMaterials(复合材料的工程力学)”一书中有说明。现将它们汇编在下面的表1中。
                                          表1
 纤维含量(体积％) 平行纤维的弹性模量(GPa) 垂直纤维的弹性模量(GPa)  滑动模量(GPa)  泊松比
  E-玻璃/环氧树脂     55     39     8.6     3.8   0.28
  S-玻璃/环氧树脂     50     43     8.9     4.5   0.27
  凯夫拉尔/环氧树脂     60     87     5.5     2.2   0.34
  碳/PEEK     58     131     8.7     5.0   0.28
  碳/环氧树脂     63     142     10.3     7.2   0.27
  碳/聚酰亚胺     45     216     5.0     4.5   0.25
  石墨/环氧树脂     57     294     6.4     4.9   0.23
  碳化硅/陶瓷     39     121     112     44   0.20
准各向同性的层叠体的弹性参数在表2中给出。
                                  表2
  弹性模量(GPa)   滑动模量(GPa)     泊松比
  E-玻璃/环氧树脂     18.9     7.3     0.29
  S-玻璃/环氧树脂     20.9     8.2     0.27
  凯夫拉尔/环氧树脂     32.6     12.3     0.33
  碳/PEEK     50.7     19.4     0.30
  碳/环氧树脂     56.7     22.1     0.29
  碳/聚酰亚胺     77.4     29.6     0.31
  石墨/环氧树脂     104     39.7     0.31
  碳化硅/陶瓷     113     46.4     0.22
除了上述的粘合剂和单向纤维以外，如果需要的话，制造各个层的材料还可包括其他传统的添加剂，如润滑剂、促粘剂、填料、颜料等。
另外，如果希望的话，在圆筒的内侧和/或外侧，根据本发明的印刷印版可带有一个或多个不含任何纤维而具有所希望的性质的另外的表面层，特别是塑料层。这种所希望的性质的例子特别包括：摩擦小(聚四氟乙烯)，耐磨损，耐刮伤，疏水性和强度高。
本发明还涉及利用根据本发明的圆筒作为生产转动式筛网印刷的印刷印版的预型件，作为曲面印刷和胶板印刷的安装在通气滚子上的套筒，作为照相凹版印刷的印刷印版，作为转移涂层和油墨的转移介质，作为电成形模型或作为一种转移涂层材料的装置。
                          附图说明
现在参照附图来说明本发明，其中：
图1表示由根据本发明的圆筒制成的转动式筛网印刷的印刷印版的示意性透视图；
图2表示具有排列在一个方向上的纤维的纤维增强塑料层的示意图；
图3表示一个对称的三个层的层叠体的示意性分解透视图；和
图4表示一个5个层的层叠体的示意性分解透视图。
                       具体实施方式
图1表示由根据本发明的薄壁空心圆筒12制成的一个转动式筛网印刷的印版10。根据要印刷的图样，利用高能辐射例如CO2激光在该圆筒上作出许多孔。在这种情况下，这些孔形成限定要印刷的图像16和18的许多印刷孔14。例如对于直径D为203.4mm，长度L为1850mm的圆筒，该圆筒的总的壁厚dtot为140μm。
图2表示一个平面形的纤维增强塑料层20上的纤维22(用较细的连续线示意性地表示)的排列方向与由该层制成的圆筒的纵轴线平行。纤维的这种轴向排列方向对减少印刷印版10的总的弯曲是有利的。
为了简单起见，在下面的附图中，相同的零件用相同的附图标记表示。
图3示意性表示一个三个层的层叠体30。在该层叠体中，中间层32的厚度为84微米，它由图2所示的纤维增强的塑料层构成，即：纤维22的排列方向与圆筒的纵轴线(图3中未示出)平行。在中间层32的两侧，各有一个厚度为28微米的最外层34，该最外层34上的纤维22的排列方向与圆筒的纵轴线垂直。带有这种形式的单向纤维的层叠体可用通常的方法制造，例如拉伸挤压、注模法、层叠法和卷绕法；如果需要，还可以利用磨削、抛光等进行机械加工。但在大多数情况下，这种形式的进一步机械加工是多余的。美国专利第US-A-5071506号中公开了一种制造根据本发明的圆筒的合适方法。在该方法中，将复合材料包覆在具有一个可膨胀内胆的心轴上。将心轴插入一个压力机模型中。当对该可膨胀内胆加压时，复合材料被压在该模型的壁上。接着，使复合材料固化。
可以利用中心层上的纤维排列方向与圆筒的纵轴线垂直，而外层上的纤维排列方向与圆筒纵轴线形成一个不为90°，优选为0°的α角的层叠体，作为制造根据本发明的圆筒的基础结构。在使用过程中，该圆筒被支承着(例如，曲面印刷的套筒)，因此，在这种情况下，圆筒弯曲较小，而切线方向的性质是重要的。
图4为表示根据本发明一个五个层的层叠体40的一个例子的平面形式层结构的示意图。该层叠体40为对称结构，它包括一个厚度为200微米的中间层32，其上的纤维22的排列方向与由该层叠体制成的圆筒的纵轴线方向平行。在中间层32的每一侧，各有一个中间层44。中间层44的厚度为20微米，其上的纤维排列方向与圆筒的纵轴线形成-70°的α角。同样，最外的第一个层46的厚度为10微米，其上的纤维22的排列方向与圆筒的纵轴线形成+70°的α角。利用这个五个层的层叠体制造了一个直径为120mm的圆筒。
应当指出，在实际中，纤维特定排列方向的选择部分地是由制造方法可再现性和总成本确定的。

Claims (20)

1.一种由纤维增强的塑料制成的薄壁空心圆筒(12)，它至少包括一个层(20；32，34；32，44，46)，该层上具有至少排列在一个方向上的纤维(22)，圆筒的总壁厚dtot在0.010至1mm范围内，比值dtot/D≤0.0025，式中的D为圆筒的直径，单位为mm。
2.如权利要求1所述的圆筒，其特征在于，其总壁厚在0.010至0.700mm范围内。
3.如权利要求2所述的圆筒，其特征在于，其总壁厚在0.020至0.300mm范围内。
4.如前述权利要求中任一项所述的圆筒，其特征在于，圆筒(12)包括纤维在两个方向上排列的一个纤维增强的层。
5.如前述权利要求中任一项所述的圆筒，其特征在于，纤维的排列方向与圆筒(12)的纵轴线平行或垂直。
6.如权利要求1～3中任一项所述的圆筒，其特征在于，该圆筒(12)包括纤维排列在第一个方向上的第一个层和纤维排列在第二个方向上的第二个层，该纤维的各排列方向不相同。
7.如权利要求6所述的圆筒，其特征在于，该第一个层的纤维排列方向与圆筒(12)的纵轴线形成α角，而第二个层的纤维排列方向与圆筒(12)的纵轴线形成-α角。
8.如权利要求6或7所述的圆筒，其特征在于，该圆筒(12)还包括纤维(22)排列在第三个方向上的另一个层(32)，该另一个层上的纤维排列方向与圆筒(12)的纵轴线平行或垂直。
9.如权利要求8所述的圆筒，其特征在于，所述另一个层(32)位于第一个层(34)和第二个层(34)之间。
10.如权利要求6或7所述的圆筒，其特征在于，纤维排列在第一个方向上的第一个层和纤维排列在第二个方向上的第二个层可以互相交替放置。
11.如权利要求1～3中任一项所述的圆筒，其特征在于，圆筒(12)在厚度方向为对称结构，其最外的第一个层(46)上的纤维排列方向与圆筒(12)的纵轴线形成α角，而其第二个中间层(44)上纤维的排列方向与圆筒(12)的纵轴线形成-α角。
12.如权利要求11所述的圆筒，其特征在于，该圆筒包括纤维(22)排列在第三个方向上的另一个层(32)，该纤维排列的第三个方向与圆筒(12)的纵轴线平行或垂直。
13.如权利要求12所述的圆筒，其特征在于，该另一个层(32)位于两个第二中间层(44)之间。
14.如权利要求8～9或11～13中任一项所述的圆筒，其特征在于，最外的两个第一层(46)的层厚度相同。
15.如权利要求8～9或12～13中任一项所述的圆筒，其特征在于，该另一个层(32)的厚度比其他层(34；44，46)的厚度大。
16.如前述权利要求中任一项所述的圆筒，其特征在于，该纤维增强的塑料材料由在环氧基体中的单向碳纤维构成。
17.如权利要求1～3中任一项所述的圆筒，其特征在于，该圆筒(12)由准各向同性的层叠体制成。
18.如前述权利要求中任一项所述的圆筒，其特征在于，在该圆筒(12)的内侧和/或外侧设有不含任何纤维的表面层。
19.如前述权利要求1～18中任一项所述的圆筒，其特征在于，圆筒(12)是无缝的。
20.利用根据前述权利要求1～19中任一项所述的圆筒(12)作为制造转动式筛网印刷的印刷印版的预型件，作为可交换地装在曲面印刷和胶版印刷的通气滚子上的套筒，作为照相凹版印刷的印刷印版，作为转移涂层和油墨的转移介质，作为电成形模型或作为转移涂层材料的装置。
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