JP2002060105A - Metal coated roller - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a low-cost metal coated roller adopting a sheet winding method using prepreg as void formation preventive measures in an FRP roller and using matrix resin of large rupture elongation and laminated constitution restraining crack initiation as crack initiation preventive measures. SOLUTION: In this metal coated roller with metal plating applied to the outer surface of a roller core body formed by laminating fiber reinforced plastic comprising reinforcing fiber and matrix resin, at two or more kinds of winding angles, (A) at least the outermost layer of the roller core body is formed of a prepreg layer, and (B) the thickness of the prepreg layer is in a range of 0.1-1.2 mm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal-coated roll made of fiber-reinforced plastic having an outer surface metal-plated.

[0002]

2. Description of the Related Art Conventionally, rolls and cores used in the production of films and papers and printing presses are often made of metal such as iron or aluminum alloy. However, recently, rolls made of fiber reinforced plastic (hereinafter referred to as FRP), which are lightweight and have a high specific modulus, have been used. This is because the characteristics of the FRP are effective not only in reducing maintenance work but also in improving production speed and product quality.

[0003] Further, among such FRP rolls, there is an FRP roll in which the outer surface is plated with a metal (for example, chromium or nickel) to improve the surface characteristics. Such a metal coat roll is usually manufactured by the following procedure.

A roll core is formed by laminating a plurality of prepregs using a so-called sheet winding method or a filament winding method in which a reinforcing fiber yarn is laminated while impregnating the resin with a resin, and the matrix resin is heated and cured to form an FRP roll core. To manufacture. Next, the outer surface of the obtained roll core is polished and smoothed. Thereafter, a metal plating process is performed, and the surface is smoothed by grinder polishing or buff polishing. However, when the roll core is polished as a pre-treatment for plating, a concave portion such as a void may appear on the surface due to cracks during molding or impregnation of the resin. These recesses often cause pinholes and peeling during plating.
On the other hand, Japanese Patent Application Laid-Open No. 4-28233 proposes to fill a concave portion with a repair agent to obtain a smooth surface. Further, in JP-A-63-12588, in a roll core body, a winding angle of a reinforcing fiber is set with respect to an axial direction.
The outer layer is in the range of ± 5 to ± 15 °, and the inner layer is ± 60 to 90
It has been proposed to prevent the occurrence of cracks during molding by forming a two-layer structure having the range of ゜.

[0005]

However, the above method has the following problems. That is, FRP
By adding a process of repairing recesses such as voids and cracks generated in the rolls with resin etc.,
The cost increases and the work efficiency deteriorates. This is because it must be performed manually while visually confirming the concave portion.

The present invention solves the drawbacks of the prior art, and adopts a sheet winding method using a prepreg as a measure for preventing the occurrence of voids. It is an object to provide an inexpensive metal coat roll by using a matrix resin having a large diameter.

[0007]

In order to solve the above-mentioned problems, a metal coat roll of the present invention has the following constitution. That is, (1) In a metal coat roll in which metal plating is applied to the outer surface of a roll core formed by laminating fiber reinforced plastics composed of reinforced fibers and a matrix resin at two or more winding angles, (A) At least the outermost layer of the roll core comprises a prepreg layer, and
(B) The metal coat roll, wherein the thickness of the outermost layer is in the range of 0.1 to 1.2 mm.

(2) A metal-coated roll in which metal plating is applied to the outer surface of a roll core formed by laminating fiber-reinforced plastics comprising a reinforcing fiber and a matrix resin at two or more winding angles, wherein (A) ) At least the outermost layer of the roll core comprises a prepreg layer, and
(B) A metal coat roll, wherein the elongation at break of the outermost layer matrix resin is 8% or more.

(3) The metal-coated roll according to (1) or (2), wherein the winding angle of the outermost layer of the prepreg of the roll core is within a range of ± 1 to ± 15 °. .

(4) The metal-coated roll according to any one of (1) to (3), wherein in the fiber-reinforced plastic, carbon fiber having a tensile modulus of 390 GPa or more is used as the reinforcing fiber.

(5) The prepreg layer used as at least the outermost layer of the roll core has a matrix resin having an elongation at break of 8% or more.
The metal coat roll according to (3) or (4).

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below.

[0013] The metal coat roll of the present invention is a metal coat in which metal plating is applied to the outer surface of a roll core obtained by laminating reinforced fiber plastics composed of reinforced fibers and a matrix resin at two or more winding angles. In the roll, (A) at least the outermost layer of the roll core comprises a prepreg layer, and (B) the outermost layer has a thickness of 0.1%.
１．２1.2 mm. Further, the metal coat roll of the present invention comprises a reinforcing fiber plastic comprising a reinforcing fiber and a matrix resin.
(A) In a metal coat roll in which metal plating is applied to an outer surface of a roll core body laminated at a winding angle of more than one kind, (A) at least the outermost layer of the roll core body is formed of a prepreg layer, and (B) ) The elongation at break of the matrix resin in the outermost layer is 8% or more.

As the reinforcing fibers of the FRP roll of the present invention, it is preferable to use mainly carbon fibers from the viewpoint of obtaining a lightweight and high-rigidity roll, but other reinforcing fibers may be used. The above reinforcing fibers may be used in combination. Further, when using carbon fiber, it is preferable to use a carbon fiber having a tensile modulus of 390 GPa or more from the viewpoint of using as a substitute for a steel roll. A carbon fiber having a tensile modulus of 390 GPa and a fiber volume content of 50
When CFRP is used as the roll material at 〜60%, the flexural modulus is about 140 to 150 GPa. This value is lower than the bending elastic modulus of steel of 200 GPa, but it is possible to express the same rigidity as a steel roll by increasing the wall thickness. If a carbon fiber having a tensile modulus of elasticity lower than 390 GPa is used, the increase in wall thickness becomes too large, and the carbon fiber is lightweight and has a small deflection due to its own weight.
FRP material has almost no merit.

As the matrix resin, an epoxy resin is preferable from the viewpoint of obtaining high rigidity.
From the viewpoint of cost and corrosion resistance, a phenol resin, a vinyl ester resin, an unsaturated polyester resin, or the like may be used.

The lamination method is preferably a sheet winding method. This is because, in the case of a roll core laminated by the filament winding method, since the reinforcing fibers cannot be sufficiently impregnated with the resin, a void-like void appears on the outer surface after curing, and the void adversely affects the plating process. In the case of forming by a filament winding method, it is necessary to laminate a prepreg by a sheet winding method at least on the outer surface layer from the viewpoint of preventing generation of voids on the surface layer.

Further, the prepreg used for the roll material is not limited to a unidirectional one, and a cloth (woven fabric) prepreg may be used, but the outermost layer is preferably a unidirectional one. Further, the fiber direction can be appropriately selected, but there is a preferable mode for the outermost layer.

Regarding the lamination structure, the axial force (tensile, compressive, bending, etc.) and the circumferential force (internal pressure, external pressure,
Since it is required to withstand crushing, it is important to orient the wrapping angle of the reinforcing fibers in the axial direction and the circumferential direction. When it is necessary to emphasize the strength and elastic modulus in the axial direction such as a roll or a long core, the winding angle with respect to the axial
It is preferable to contain a layer of up to ± 20 ° at 80% or more. When the torque is large, such as in a drive shaft, it is preferable to increase the number of ± 45 ° layers. Here, the winding angle means an intersection angle between the fiber and the roll axis when the reinforcing fiber is orthogonally projected using a plane including the roll axis as a projection plane. The layer referred to here is a single layer of a plurality of prepregs having the same winding angle, such as a 0 ° layer and a 90 ° layer. ± 4
In the case of a 5 ° layer or the like, one layer is formed by setting the positive and negative angles as one set.

In the practice of the present invention, when the thickness of the FRP roll core is in the range of 4 to 20 mm, it is important that the thickness of the outermost layer be in the range of 0.1 to 1.2 mm. .
From the viewpoint of preventing the generation of cracks, preferably 0.1
~ 1.0mm, more preferably 0.1 ~ 0.8m
m. The following can be considered as a reason for this.

When the temperature of the roll core is lowered after heating and curing, the roll that has been thermally expanded contracts. The roll core made of FRP often has a plurality of layers laminated, and the degree of thermal shrinkage varies depending on the winding angle of the carbon fiber in each layer.
As the winding angle approaches 0 °, the heat shrinkage in the roll circumferential direction increases. Therefore, when a layer having a winding angle of about 0 ° is laminated on the outermost layer, the outermost layer has a greater thermal shrinkage than the innermost thermal shrinkage. Is likely to occur.
In this phenomenon, as the thickness of the outermost layer increases, the tension generated in the circumferential direction on the outer surface increases, and the occurrence of cracks increases.

The outermost prepreg layer has a thickness of 0.1 mm.
If it is thinner, the outermost prepreg layer may be partially ground due to problems in the accuracy of forming and machining in the outer surface grinding process after forming the roll core. It is important that the thickness of the outermost prepreg layer is 0.1 mm or more.

The winding angle of the outermost layer is most preferably 0 ° in order to minimize bending during use by increasing the bending elastic modulus in the axial direction as much as possible. From the viewpoint of preventing cracks, the outermost layer is preferably a helical winding, but the bending elastic modulus is not sacrificed so much until the winding angle is in the range of 0 to ± 15 °. This 2
Due to the balance between the two conditions, the winding angle of the outermost carbon fiber is preferably in the range of ± 1 to ± 15 °, and more preferably ± 1 from the viewpoint of improving the bending elastic modulus in the axial direction.
±± 5 °.

It is important that the elongation at break of the matrix resin is 8% or more from the viewpoint of preventing the occurrence of cracks. For the metal plating, any commonly used plating method may be used.

[0024]

EXAMPLES The present invention will be described below more specifically based on examples.

(Examples 1 to 16) FIG. 1 is a sectional view showing an example of a metal coat roll according to the present invention, in which an FRP roll core is formed by a sheet winding method. In FIG. 1, reference numeral 2 denotes a plating layer, and reference numeral 3 denotes a plating layer.
Is a prepreg layer which is the outermost layer of the roll core. 4a
.. 4n are each constituent layer of the roll core.

A prepreg having a thickness of 0.135 mm made of carbon fiber having a tensile modulus of 430 GPa and an epoxy resin is placed on a core bar having a diameter of 85 mm and a length of 2,000 mm so that the direction of the reinforcing fibers is 0 ° and ± 45 ° with respect to the axial direction. , At an angle of 90 ° in the order shown in Table 1 (Example 4). FR
The wall thickness of the roll core made of P was 7.83 mm, and the thickness of the outermost layer was 0.81 mm as a result of measuring the thickness by enlarging the cross section after curing. After laminating, rotate 130
C. for 3 hours to cure the epoxy resin. After hardening, the core is pulled out, the outer surface is ground and the outer diameter is 100m
m, an inner diameter of 85 mm and a length of 1700 mm were obtained from an FRP roll. The number of cracks and the number of voids in the axial direction on the outer surface of the roll core body made of FRP thus manufactured were visually confirmed. As a result, no cracks or voids were observed.

Next, the outer surface of the obtained FRP roll core was etched with a mixed solution of sulfuric acid and chromic acid, and then subjected to copper plating by electroless plating and electroplating. Thereafter, the surface of the copper plating was ground and trimmed, and then subjected to chrome plating to obtain the metal coat roll shown in FIG.

Examples 1 to 3 and Examples 5 to 8 were manufactured in the same manner as in the conditions of curing and the like, only by changing the laminated structure of the surface layer of the roll core. For comparison with the prior art, in Example 9, a roll core was manufactured by a filament winding method with the same lamination structure as in Example 4. FIG. 2 shows that the thickness of the outermost layer of the prepreg is 1.2 m.
FIG. 2 is a side view of a conventional FRP roll having a length of m or more. In FIG. 2, reference numeral 6 denotes a crack generated during molding.

Table 2 shows the results of observation of the number of cracks and voids in Examples 1 to 9. As an overall evaluation, a case where no crack was observed and no problem occurred during the plating treatment was rated as ○, and a case where a crack was observed but no problem occurred in the plating treatment was rated as △. In addition, those which caused a problem in the plating treatment and required repair were marked as x.

Comparing Examples 1 to 6, it was found that the number of generated cracks was reduced by reducing the thickness of the outermost layer. However, in Example 1 in which the thickness of the outermost layer was 0.1 mm or less, generation of cracks after molding was not observed, but all the outermost prepreg layers were ground in the grinding step after molding. A part has occurred partially. An attempt was made to apply a plating treatment to the roll cores of Examples 7 and 8 in which many cracks occurred. However, the etching solution bleed linearly on the cracks, and partially linear non-plating was observed. occured.

In Example 9, which was formed by the conventional filament winding method, no crack was observed on the surface of the roll core, but a number of voids due to insufficient resin impregnation of the fiber were observed. When electroless plating, copper plating and chromium plating were performed in this state, many pinholes were formed.

Examples 5 and 10 shown in Table 3
12 is a case where the winding angle of the outermost layer is increased while the thickness of the outermost layer is kept constant. It was found that increasing the winding angle of the outermost layer reduced the number of cracks.

Examples 10, 13 and 14 shown in Table 4
Is an example in which the winding angle of the outermost prepreg is fixed to 0 ° and the breaking elongation of the matrix resin used for the prepreg layer is changed. Examples 14 to 16 are examples in which the resin of the outermost layer having a breaking elongation of 10% was used and the winding angle of the outermost layer was increased. From these results, it was found that the number of cracks was reduced by using a prepreg having a high elongation at break of the matrix resin of the outermost layer. It was also found that cracks were reduced by increasing the winding angle.

[0034]

[Table 1]

[0035]

[Table 2]

[0036]

[Table 3]

[0037]

[Table 4]

[0038]

According to the metal coat roll of the present invention, at least the outermost layer of the roll core comprises a prepreg layer,
The thickness of the roll core is in the range of 0.1 to 1.2 mm, or at least the outermost layer of the roll core is made of a prepreg layer, and the elongation at break of the matrix resin of the prepreg layer is 8% or more. By doing so, the following effects can be obtained. (A) It is possible to prevent the occurrence of cracks during the production of FRP rolls. (B) Due to the above-described effect (1), it is possible to omit a crack filling operation using a resin manually before plating. (C) If the process proceeds to the next plating process without noticing cracks due to cracks that cannot be found visually or overlooked visually, abnormalities are first noticed at the electroless plating stage, and the electroless plating layer is scraped. An extra step of dropping occurs. In the worst case, it is assumed that an abnormality is found in the buff polishing of the chromium plating layer in the final step, and the entire step must be repeated. According to the present invention, the instability of the manufacturing process as described above can be significantly reduced.

[Brief description of the drawings]

FIG. 1 is a sectional view of an embodiment of a metal coat roll according to the present invention.

FIG. 2 is a side view of a conventional FRP roll.

[Explanation of symbols]

 1: Metal coat roll 2: Plating layer 3: Outermost prepreg layer 4: Each constituent layer 5: Roll core 6: Crack during molding

 ──────────────────────────────────────────────────続 き Continued on the front page F-term (reference)

Claims (5)

[Claims] 1. A metal-coated roll in which metal plating is applied to the outer surface of a roll core obtained by laminating fiber-reinforced plastics comprising a reinforcing fiber and a matrix resin at two or more winding angles, wherein (A) At least the outermost layer of the roll core comprises a prepreg layer, and (B) the thickness of the outermost layer is in the range of 0.1 to 1.2 mm. 2. A metal-coated roll in which metal plating is applied to the outer surface of a roll core formed by laminating fiber-reinforced plastics comprising a reinforcing fiber and a matrix resin at two or more winding angles, wherein (A) At least the outermost layer of the roll core is made of a prepreg layer, and (B) the matrix resin of the outermost layer has a breaking elongation of 8% or more. 3. The metal-coated roll according to claim 1, wherein a winding angle of a prepreg as an outermost layer of the roll core is within a range of ± 1 to ± 15 °. 4. The metal-coated roll according to claim 1, wherein in the fiber-reinforced plastic, a carbon fiber having a tensile modulus of 390 GPa or more is used as the reinforcing fiber. 5. The matrix resin of a prepreg layer used as at least the outermost layer of the roll core has an elongation at break of 8%.
% Or more.