EP1612329B1 - Roll cover made of fibre reinforced composite material - Google Patents

Abstract

The cover(8) material is based on fibers(5) in a matrix(6) and the compound composition continuously varies depending on the area of the roll surface(14) to which the compound is applied. Fillers(9) of different types may also be included in the composition and the latter and/or the fiber(5) content and/or matrix(6) type and/or filler may continuously vary. Composition may vary in the axial and/or radial(7) direction of the roll body(4) onto which the compound is applied. Fiber type, content and/or diameter and/or length distribution and/or orientation may be varied. At least one fiber type may comprise loose fibers of specific length distribution and/or contains fibers which are randomly embedded in the matrix. Fibers have a length distribution of 1-10mm, preferably 1-3mm and/or more preferably 3-10mm. The matrix can comprise one or more different resin types. Matrix composition can be altered by varying the mixing ratio of at least one resin and/or hardener. Fillers can be used to influence wear resistance and/or viscosity and/or surface tension and/or conductivity. Filler particle size can also be varied. An independent claim is included for a process for manufacturing the claimed roll cover. A compound comprising fibers and a matrix is applied onto specific positions on the roll and the composition of matrix and fibers is varied according to the axial and/or radial position on the roll.. The same step is repeated at different positions on the roll.

Description

The invention relates to a roll cover made of a fiber composite material.

Roll coverings made of fiber composite materials are used in web-processing machines in a variety of ways. The most demanding requirements are placed on elastic calendar covers with regard to compressive stress and dynamic stress on paper machines. These covers are usually constructed of fiber composite material.

Essentially, two methods for applying a fiber reinforcement are known from the prior art.

From the WO 94/09208 The so-called laminating process is known in which fiber and / or fabric tapes are applied to a roll body and then connected to one another by means of resins, for example epoxide resins, to form a fiber composite material. In order to meet different requirements, such a roll cover is composed of several differently laminated layers.

From the US 6,319,185 . DE 199 25 421 A1 and US2002 / 0045523 Roll covers are known with varying fiber content in the matrix component. The BP 0 487 447 A1 further discloses a roll cover with wear reducing filler in the matrix material.

As a further application method, the so-called filament winding method is known, in which fiber bundles are wound onto a roll body and then joined together by means of resins to form a fiber composite material.

In the case of the first-mentioned application method, the disadvantage is that the finished roll cover is made up of different layers. The interface between different layers is often here, due to the sudden change in material properties, the starting point for Delaminationserscheinungen in roll cover.

The second application method is not suitable, for example, for the production of wear layers to be brought into contact with the paper web in straighteners, since such roll shells lead to an uneven smoothing of the paper web, since the wound fibers are substantially rectified.

However, a satisfactory smoothing effect can be achieved with applied fibers in the form of random fibers. Thus, it is necessary that the roll covers produced by the filament winding method are additionally provided with one or more laminated layers, which takes over the function of the wear layer. Thus, roller covers are created here, which are composed of several unterschildlichten layers.

Starting from the roll covers known from the prior art, it is the object of the present invention to propose a roll cover in which the o. G. Disadvantages are prevented.

The object is achieved by a roll cover with the features of claim 1.

Advantageous embodiments and further developments of the invention are specified in the subclaims.

Accordingly, the present invention provides a fiber composite roll cover made of a material having a fibrous component and having a matrix component comprising the fibrous component material composition and a matrix component The matrix component changes quantitatively and qualitatively at least in sections continuously and in which a wear-reducing type of filler is used, which is formed by a carbide or oxide and has a particle size in the nanometer range.

In this context, a matrix component is to be understood as meaning the material or the material composition in which other dissolved or undissolved materials are embedded. In the case of the roll cover according to the invention thus the fiber component is embedded in the matrix component.

The invention thus provides, at least in sections, a roll cover without boundary layers, since the material composition of the roll cover changes continuously in sections.

Thus, a roll cover is provided, which has a continuous course of characteristic properties such as, for example, Young's modulus, fracture toughness, abrasion resistance or hardness.

Further advantageous embodiments and modifications of the invention will become apparent from the sub-claims.

According to a preferred embodiment of the invention, the Materialzusarnrrmensetzung of fiber component and matrix component and filler component changes at least in sections continuously.

At a roll cover a variety of requirements are made. For example, it is often necessary that a roll cover is dimensionally stable and at the same time has a high wear resistance. The dimensional stability is realized here by the radially inward areas. The wear resistance, however, is realized by the radially outward areas.

Furthermore, there are applications in which it makes sense if the roll cover has properties that change in the axial direction of the roll body.

A preferred embodiment of the invention therefore provides that the material composition in the axial direction and / or in the radial direction of the roll cover changes continuously at least in sections.

There are different ways conceivable how the material composition of the roll cover material can change continuously. On the one hand, it is possible that the proportion of the material composition of at least one of the components changes, namely the fiber component and / or the matrix component and / or the filler component.

Thus, for example, it is possible for the proportion of the fiber component in the radial direction to be reduced from 30% to 5% to the outside, whereas the proportion of the matrix component increases correspondingly while the proportion of the filler component remains the same.

Furthermore, it is conceivable that the composition of one or more of the components changes.

Thus, the fiber component is preferably formed by one or more fiber types.

Here, for example, a change in the composition of the fiber component should be understood to mean that the proportion and / or the diameter and / or the length distribution and / or the orientation of the fibers of at least one fiber type change.

By changing the different proportions of the individual fiber types on the fiber component, a desired property profile of the roll cover can be adjusted depending on the location.

Also, by changing the fiber diameter, the length distribution and the orientation of the fibers, the stability can be influenced location-dependent. For example, the tensile strength is strongly dependent on the orientation of the fibers.

Furthermore, the matrix component preferably comprises one or more resin types and one or more types of curing agents.

Here, for example, a change in the composition of the matrix component should be understood to mean that the mixing ratio of at least one type of resin and / or at least one hardener component in the matrix component changes.

Thus, for example, it is conceivable that the mixing ratio of at least one type of resin changes while maintaining the hardness in the radial direction of the roll cover in which the proportion of epoxy resin from the inside of the roll cover towards the outside (paper side) of the roll cover from 100% to 0% continuously decreases whereas the proportion of polyurethane resin inversely increases from 0% to 100% in the direction of the outside of the roll cover from the inside of the roll cover. Thus, a roll cover is produced, which has a paper-side wear layer of polyurethane resin and a base layer of epoxy resin, wherein the two layers merge continuously in the radial direction.

In addition, the filler component is preferably formed by one or more types of fillers.

In this case, for example, a change in the composition of the filler component should be understood to mean that the proportion and / or the grain size of at least one filler type changes.

Preferred fiber types include inorganic fibers of glass, metal, ceramic fibers, boron or organic fibers, for example carbon and / or aramid and / or polypropylene or polyester or high-performance thermoplastics such as, for example, PPS or PEEK or PTFE fibers. For example, it is conceivable on the basis of the above statements that, if the fiber component consists of only one type of fiber, the proportion of one fiber type, for example glass fibers, and thus the proportion of the fiber component in the material composition can be changed continuously in the radial direction. Furthermore, it is also possible to increase the proportion of one fiber type in the fiber component and to correspondingly reduce the proportion of another type of fiber in the fiber component while maintaining the proportion of the fiber component in the material composition of fiber component and matrix component.

In order to be able to exert targeted influence on the properties of the roll cover, a preferred embodiment of the invention provides that at least one fiber type is formed by fiber pieces with a defined length distribution, which are not connected to one another before being embedded in the matrix component.

Fiber pieces should be understood in this context that the fibers are not formed as fiber bundles (in contrast to filament winding process) or as fiber mats (in contrast to the lamination process). Rather, pieces of fiber having a defined length distribution prior to embedding in the matrix component are discrete, i.e., loose. unconnected fiber pieces.

In particular, for the paper-side surface of the roll cover it is necessary to avoid marking effects that this surface is formed by tangled fibers. Accordingly, a preferred embodiment of the invention provides that at least one type of fiber comprises a portion of fiber pieces embedded in an undirected orientation in the matrix component.

A preferred embodiment of the invention provides that at least one fiber type from the range of inorganic and / or organic fibers (elastomer, thermoplastics or thermosets) fiber pieces with a length distribution of 0.1 to 100 mm, preferably from 1 to 30mm, more preferably from 1 up to 3 mm and / or from 3 to 10 mm, preferably fibers of aramid and / or glass and / or carbon.

The types of resins used are preferably elastomeric or thermosetting resins. Accordingly, one embodiment of the invention provides that at least one type of resin is an elastomeric or thermosetting resin (epoxies, cyanate esters, phenolic resins), but also thermoplastic materials (PE, PP, PPS, PEEK, ...) and / or mixtures thereof.

Here, as a duroplastic resin, for example, epoxy resin or cyanate ester resins also phenolic resins may be mentioned. In particular, bisphenol A epoxy resins with amine hardener, wherein the proportions hardener per 100 parts of resin in the range 0 to 300 parts (eg Ancamine 2390 [Air Products] 107 parts), but especially 5 to 40 parts, particularly preferably 5 to 25 parts. However, the crosslinking can also be prepared by catalysts that crosslink the epoxy resin three-dimensionally without curing agents. Further, as the elastomeric resins, polyurethane resin or rubber is used.

For example, in order to be able to influence the properties of the paper-side wearing layer in a targeted manner, preferred embodiments of the invention provide that fillers which are also used are fillers influencing the viscosity and / or fillers influencing the surface tension and / or fillers influencing the conductivity.

The wear-reducing types of fillers are preferably found in a range of 0 to 100 wt.%, In particular in a range of 10 to 60 wt. %, more preferably in a range of 20 to 50 wt.% Use.

Thermoplastics or ionic fillers are preferably used as fillers influencing the surface tension, in a range from 0 to 60% by weight, in particular 5 to 20% by weight, to achieve a surface tension of 20 to 70mN / m, preferably 25 to 56mN / m. more preferably from 25 to 48mN / m.

Ausführungsbeispiel 1

eine Walze mit Walzenkörper und erfindungsgamäßem Walzenbezug,

Ausführungsbeispiel 2

eine Vorrichtung zur Durchführung des erfindungsgemäßen Herstellungsverfahrens,

Ausführungsbesipiel 3

eine Vorrichtung zur Durchführung des erfindungsgemäßen Herstellungsverfahrens mit mehreren Auftragsvorrichtungen.

Furthermore, the filler types can have a particle size in the nanometer and / or micrometer and / or millimeter range, ie both types of filler are conceivable which have only particle sizes in the nanometer range as well as filler types which have a particle size distribution from the nanometer range to the millimeter range.

Embodiment 1

a roller with roller body and erfindungsgamäßem roller cover,

Embodiment 2

an apparatus for carrying out the production method according to the invention,

Embodiment 3

an apparatus for carrying out the manufacturing method according to the invention with a plurality of application devices.

The embodiment 1 relates to a roll with a roll cover according to the invention. The roll cover of the invention was applied to a roll body by a suitable method.

The roll cover has a roll side and a paper or wear side. The roll cover is applied with the roll side on the lateral surface of the roll body and ally with this. The roll cover comprises a fiber component, a matrix component and a filler component, wherein the fiber component and the filler component are embedded in the matrix component.

According to the invention, the material composition of the roll cover, consisting of fiber component, matrix component and filler component, changes continuously in the radial direction of the roll.

In the present exemplary embodiment, the fiber component is formed by a single type of fiber, for example in the form of carbon fibers. According to the invention, the composition of the fiber component changes continuously in the radial direction of the roll cover, in which the proportion of carbon fibers in the material composition of fiber component, matrix component and filler component in the radial direction of the roll cover from the roll side to the paper or wear side decreases continuously and by the length distribution the carbon fibers in the radial direction of the roll cover from the roll side to the paper or wear side decreases continuously.

Furthermore, in the present embodiment, the matrix component is formed by a first matrix type and a second matrix type.

The first matrix type in the present exemplary embodiment comprises an epoxy resin fraction. The second matrix type comprises in the present exemplary embodiment a polyurethane proportion,

The proportion of the first matrix type in the axial direction decreases continuously from the roll side to the paper or wear side. Conversely, the proportion of the second matrix type increases continuously in the radial direction from the roll side to the paper or wear side. Thus, a roll cover is provided which is dimensionally stable and has an abrasion-resistant paper or wear side.

The filler component is in the present embodiment by a wear-reducing filler eg. In the form of nanoparticles of alumina or the like. Formed

Furthermore, the proportion of nanoparticles increases continuously in the radial direction from the roll side to the paper or wear side.

Embodiment 2 describes an arrangement for carrying out a suitable method.

The arrangement is essentially formed by the roll body to be coated with a roll shell and by an application device, which is spaced in the radial direction of the roll body to this.

Furthermore, a part of a roll cover already formed on the roll body can be seen. The roller body of the present embodiment is made of a metallic material. It would also be conceivable that the roller body is at least partially made of a composite material.

During the application process, the roller body rotates in the direction of rotation about its axial axis of rotation while the applicator moves parallel to the axis of rotation along the direction of movement and optionally additionally can move perpendicular to the axis of rotation along the direction of movement.

The application device has an ejection opening for the exit of loose fiber pieces of the fiber component and an outlet opening for the exit of a mixture of the matrix component, the filler component and further components, such as, for example, a color component and the like. The ejection opening and the outlet opening are adjusted in such a way that the mixture and the loose fiber pieces impinge substantially on the same point of the lateral surface of the roller body and thereby form a Faserverbund material. The mixture and the loose fiber pieces are thus applied in an injection process in which the loose fiber pieces are embedded in the mixture of matrix component, filler component and color component. An application of individual components by sprinkling is also possible according to the invention.

Furthermore, the application device has a Einspelsvorrichtung for feeding the fiber component. In the present embodiment, the Einspelsvorrichtung is designed as a feed opening, in which the fiber component is introduced. In the present embodiment, the supplied fiber component is in the form of long fiber strands. A comminuting device is provided between the feed opening and the ejection opening. In the comminuting device, the introduced fiber component is comminuted to loose pieces of fiber having a defined length distribution.

In addition, the applicator has supply openings for feeding the matrix component, the filler component (also pre-bleached with another component, for example, resin) and the color component. The matrix component typically comprises one or more resin types and one or more types of curing agents. In the present embodiment, the resin type (s) are supplied to the application device via the feed opening. Furthermore, the hardener or types of the applicator are supplied via the feed opening. The filler component and the color component are supplied to the application device via the supply openings.

In the application device itself, the supplied matrix component, the filler component and the color component are mixed to form the mixture, which is injected via the outlet opening onto the roll body to produce a roll cover according to the invention.

In the manufacture of the fiber composite roll cover on the roll body, the loose fiber pieces of the fiber component and the mixture of matrix component and filler component are applied to the roll body by rotating the roll body and moving the applicator along the direction of travel at different locations, the composition being of loose fiber pieces and mixture and the composition of the loose fibers and / or the mixture itself is adjusted depending on the axial and / or radial position of the location on the roll body to achieve that the material composition of fiber component, matrix components and filler component according to the invention, according to the respective requirements to the roll cover, at least in sections continuously changes.

Thus, it is possible that the fiber component is formed by one or more types of fibers, such as glass or carbon or aramid or boron or polypropylene or polyester or PPS or PEEK fibers, and / or that the composition of the Fiber component changes in which the proportion and / or the diameter and / or the length distribution and / or the orientation of the fiber pieces of at least one fiber type changes. Preferably, the loose fiber pieces have a length distribution of 1 to 10 mm, preferably from 1 to 3 mm and / or from 3 to 10 mm, the length distribution according to the invention depending on the axial and radial position of the location on which these vary on the roll body can or varies.

As already mentioned, the matrix component is formed by one or more resin types and by one or more types of hardeners. As resin types, for example, elastomeric and / or thermoplastic and / or thermosetting resins are conceivable. The composition of the matrix component changes, for example, in that the mixing ratio and the components of at least one type of resin and / or at least one hardener component changes, for example the change from a bisphenol A epoxy resin type to a bisphenol F epoxy resin type and / or a variation of aromatic and / or aliphatic amine hardeners.

Furthermore, the filler component is formed by one or more types of filler, wherein as fillers, for example, wear-reducing fillers and / or fillers influencing the viscosity and / or fillers influencing the surface tension and / or fillers influencing the conductivity can be used. As wear-reducing filler types are carbides or metals or oxides such as metal oxides such as Cr oxide, Fe oxide or Al oxide or fiber pulp of carbon and / or aramid and / or glass in the size range of 1 to 1000 .mu.m, preferably 5 to 100 .mu.m conceivable , Thermoplastics or ionic fillers are conceivable as fillers influencing the surface tension. The composition of the Fühlstoftkomponente changes here, for example, in which changes the proportion and / or the grain size of at least one Füllstofftyps. In this case, at least one type of filler may have a particle size in the nanometer and / or in the micrometer and / or in the millimeter range.

Of course, with the method, independently of one another, a plurality of layers with mutually corresponding outside and inside diameters can be produced, which are subsequently connected to one another by adhesives or adhesion promoters.

Furthermore, a typical rubber cover can be applied to the fiber composite roll cover according to the invention, which is crosslinked by vulcanization.

Example 3 describes a further arrangement for carrying out a suitable method.

In this arrangement, several, as described in Example 2, application devices are provided, which are arranged one behind the other in the circumferential direction of the roller body to be coated with a roll body.

Claims (19)

1. Bonded fibre roll cover for use in sheet-processing machines wherein the material of the roll cover includes a fibre component and a matrix component and the composition of the material composed of fibre component and matrix component changes continuously sectionwise at least and wherein the material of the roll cover includes a filler component formed by one or more types of filler, characterized in that a wear-reducing type of filler which is formed by a carbide or oxide and has a particle size in the nanometre range is used.
2. Bonded fibre roll cover according to Claim 1, characterized in that the composition of the material composed of fibre component and matrix component and filler component changes continuously sectionwise at least.
3. Bonded fibre roll cover according to either of Claims 1 and 2, characterized in that the composition and/or the fraction of fibre component and matrix component and filler component changes continuously.
4. Bonded fibre roll cover according to any one of Claims 1 to 3, characterized in that the composition changes continuously sectionwise at least in the axial direction and/or in the radial direction of the roll cover.
5. Bonded fibre roll cover according to any one of Claims 1 to 4, characterized in that the fibre component is formed by one or more types of fibre.
6. Bonded fibre roll cover according to Claim 5, characterized in that one type of fibre is formed by inorganic fibres for example glass, metal, ceramic fibres, boron or organic fibres such as for example carbon and/or aramid and/or polypropylene or polyester or high-performance thermoplastics such as for example PPS or PEEK or PTFE fibres.
7. Bonded fibre roll cover according to Claim 5 or 6, characterized in that the composition of the fibre component changes by the proportion and/or diameter and/or length distribution and/or orientation of the fibres of at least one type of fibre changing.
8. Bonded fibre roll cover according to Claim 5, 6 or 7, characterized in that at least one type of fibre is formed by loose pieces of fibre which have a defined length distribution and which are not bonded together before being embedded in the matrix component.
9. Bonded fibre roll cover according to any one of Claims 5 to 8, characterized in that at least one type of fibre includes a proportion of pieces of fibre which are embedded in the matrix component without being aligned.
10. Bonded fibre roll cover according to any one of Claims 5 to 9, characterized in that at least one type of fibre includes pieces of fibre which have a length distribution of 1 to 10 mm, preferably from 1 to 3 mm and/or of 3 to 10 mm.
11. Bonded fibre roll cover according to any one of Claims 1 to 10, characterized in that the matrix component comprises one or more types of resin and one or more types of hardener.
12. Bonded fibre roll cover according to Claim 11, characterized in that one type of resin is an elastomeric or a thermoset resin (epoxides, cyanate esters, phenolic resins) and/or a thermoplastic material of construction (PE, PP, PPS, PEEK, ...) and/or a mixture thereof.
13. Bonded fibre roll cover according to Claim 12, characterized in that the thermoset resin is an epoxy resin.
14. Bonded fibre roll cover according to Claim 12, characterized in that the elastomeric resin is polyurethane resin or rubber.
15. Bonded fibre roll cover according to any one of Claims 11 to 14, characterized in that the composition of the matrix component changes by the mixing ratio of at least one type of resin and/or at least one hardener component changing.
16. Bonded fibre roll cover according to any one of the preceding claims, characterized in that fillers which influence the viscosity and/or fillers which influence the surface tension and/or fillers which influence the conductivity are further used as types of filler.
17. Bonded fibre roll cover according to Claim 16, characterized in that thermoplastics or ionic fillers are types of filler which influence the surface tension.
18. Bonded fibre roll cover according to any one of the preceding claims, characterized in that the composition of the filler component changes by the proportion and/or the particle size of at least one type of filler changing.
19. Bonded fibre roll cover according to any one of the preceding claims, characterized in that at least one further type of filler has a particle size in the nanometre and/or micrometre and/or millimetre range.