JP2006029452A - Paper manufacturing machine having thermal splay coating, roller made of carbon fiber reinforced resin for printing machine, and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a paper manufacturing machine having thermal spray coating of high adhesion, abrasion resistance and impact resistance, and a method of manufacturing a roller made of carbon fiber reinforced resin for a printing machine. <P>SOLUTION: A polyurethane resin is applied to a surface of a roller base material as a base layer, the roughening treatment is performed by lathe, and further a thermal splay coating layer of metal or metallic alloy is formed as an intermediate layer. Oxide ceramics or cermet is thermally sprayed to form a top layer of high abrasion resistance. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to improving the surface performance of lightweight carbon fiber reinforced resin (hereinafter CFRP) rolls used in papermaking and printing machines.

  In recent years, in the papermaking and printing industries, the weight of rolls has been reduced for the purpose of improving low energy and operability. Improvements have been made from conventional iron or steel to aluminum, and to lighter CFRP-based rolls. This CFRP roll is used as a roll or a guide roller that plays a role of pressing the paper particularly in papermaking and printing processes.

  CFRP rolls are lighter than conventional roll bases, but are inferior in roll surface properties, particularly wear resistance. Therefore, it has been proposed to apply Cr plating to the surface. Furthermore, proposals for applying various ceramics and cermet sprayed coatings have also been made public (for example, JP-A-9-175703, JP-A-10-157323, JP-A-11-165930, US Pat. Nos. 6,240,639, and 6,339,883).

However, rolls for paper machines and printing machines are required to have not only wear resistance during high-speed rotation but also impact resistance during starting and stopping. That is, a film having excellent toughness and high adhesion to CFRP as a base material is required. For this reason, various improvements in the adhesion between the CFRP substrate and the thermal spray coating have been proposed. For example, in Japanese Patent Application Laid-Open No. 5-32472, a plurality of depressions are provided on the surface of the CFRP base material to improve the adhesion of the thermal spray coating to the CFRP base material. In addition, US Pat. 6, 240, 639, and 6,339,883 proposes a method of roughening the surface by blasting. JP-A-11-165930 and JP-A-2001-270015 also propose a method of forming a surface roughness by spraying a mixture of resin and ceramic particles on the surface of a base material and firing it at a temperature of about 100 ° C.
Japanese Patent Laid-Open No. 9-175703 JP-A-10-157323 Japanese Patent Laid-Open No. 11-165930 US patent no. No. 6,240,639 US patent no. No. 6,339,883 JP-A-5-32472 JP 2001-270015 A Fujio Oishi, “The Story of Plastics”, Nippon Business Publishing, 1997

  However, the depth of the recess formed on the CFRP substrate in the above-mentioned Japanese Patent Laid-Open No. 5-32472 is as large as 1.00 mm. In this case, although the adhesion between the base material and the thermal spray coating is improved, since the deep groove is filled with thermal spraying, there are problems such as thermal influence on the CFRP base material during thermal spraying and extension of the thermal spraying process. Also, US Pat. 6, 240, 639, no. In the blasting process proposed in US Pat. No. 6,339,883, since the blast particles directly collide with the CFRP substrate, there are disadvantages such as exposure to the surface of the fiber or destruction of the fiber. In order to avoid this problem, it is effective to reduce the blast pressure and increase the distance between the base material and the like, but in this case, in general, there remains a problem that sufficient surface roughness cannot be obtained. In JP-A-11-165930 and JP-A-2001-270015, a mixture of a resin and ceramic particles is sprayed on the surface of a base material, and then unevenness is formed on the surface by firing. Although this method does not cause mechanical and thermal damage to the base material and forms the necessary surface roughness on the surface of the base material, it is difficult to apply to a large structure roll that requires a baking step after coating. There is.

  In the present invention, on the surface of the CFRP roll, a base layer made of a resin that improves adhesion with CFRP, a metal or metal alloy intermediate layer that improves the impact resistance of the roll, a ceramic or cermet top layer that is excellent in wear resistance To form. The present invention provides a roll for a CFRP paper machine and printing machine, which improves the shortcomings of the prior art and is excellent in wear resistance and impact resistance, which enables long-term operation in an actual machine, and a method for producing the roll.

  In the present invention, a polyurethane resin that can be roughened without damaging the substrate is formed on the surface of the CFRP roll, and a metal or a metal alloy, a ceramic, or a cermet film is sequentially formed by a thermal spraying method. The film for rolls devised in the present invention can achieve a very high adhesion of 55 kgf / cm 2 between the CFRP and the thermal sprayed film. In addition, the invented multilayer coating makes it possible to commercialize CFRP rolls with excellent wear resistance and impact resistance, thereby realizing a longer life of the roll and improved safety.

  CFRP is used for the roll base material of the present invention. Generally, a thermosetting or thermoplastic resin is used for a matrix phase for fixing CFRP fibers, and a thermoplastic epoxy resin is used in the present invention.

  In order to increase the adhesion between the CFRP roll surface and the thermal spray coating, it is necessary to sufficiently roughen the roll surface. Sufficient roughening treatment can provide a sufficient anchor effect between the surface of the CFRP roll and the coating during the formation of the coating during thermal spraying.

  However, roughening by blasting will damage the CFRP roll surface. Accordingly, the roughening treatment of the CFRP roll surface is performed by spraying a resin that can be cured even at room temperature onto the CFRP surface and machining the surface of the cured resin. In the present invention, this roughened resin layer is used as a base layer. The base layer made of this resin can prevent the CFRP from being damaged and can provide a sufficient anchoring effect for the sprayed coating to be sprayed thereafter. In addition, the resin used as the base layer can be cured at room temperature and does not have a thermal influence on the CFRP substrate.

  A polyurethane-based resin is used for this base layer. The polyurethane resin is excellent in adhesiveness with the epoxy resin of the CFRP base material. Moreover, its heat resistance is better than that of the epoxy resin of the base material, and plays a role of softening, thermal damage and suppressing the CFRP base material from heat generated during subsequent thermal spraying of ceramics or cermet.

  In spraying the base layer, it is desirable to wash the surface of the CFRP base material with an organic solvent and apply a primer as a pretreatment. After that, a polyurethane resin is applied to a thickness of 2.0 mm by a liquid spraying device and cured at room temperature for 6 to 12 hours, and then the surface roughness is Ra to 10 to 20 μm and the thickness to 150 to 300 μm by lathe processing. adjust.

  On the base layer roughened by the above method, a coating of an intermediate layer made of metal or metal alloy is formed by a thermal spraying method. Al, Ni—Cr, Cu, Zn, or the like is selected as the metal or metal alloy. In particular, the ideal selection material for the intermediate layer is low melting point Zn or Zn alloy that has a small thermal effect on CFRP. The thermal spray coating used as the intermediate layer is formed by arc spraying, and the thickness of this coating is 100 to 150 μm.

  The effect expected of this intermediate layer prevents the high temperature ceramic or cermet molten particles sprayed on the upper layer from adhering directly to the base layer. This is to prevent overheating of the base layer and maintain high adhesion between the CFRP and the base layer. In addition, the intermediate layer formed of the metal or metal alloy has the effect of improving the impact resistance of the ceramic or cermet sprayed coating having a low toughness.

  In the ceramics or thermist sprayed on the intermediate layer so as to be the top, a part of the heat during the spraying is transferred to the base layer through the intermediate layer made of metal or metal alloy. This heat softens the polyurethane resin of the base layer. The softening of the base layer and the collision of the ceramic or cermet particles cause a part of the metal or metal alloy film of the intermediate layer to bite into the base layer. Thereby, the adhesion between the base layer and the intermediate layer is further strengthened.

  The top layer formed by spraying ceramics or cermet improves the wear resistance of the CFRP roll. The ceramic sprayed as the top layer is made of an oxide of Al, Ti, Cr, Zr, or a mixture thereof, and is mainly formed by plasma spraying. Similarly, cermet is a mixture of WC, CrC, TiC, etc. and Co, Ni, Cr, and the thermal spraying is performed by flame spraying or high-speed flame spraying depending on the denseness and surface roughness of the coating.

  The thermal spray material for the top layer, which requires wear resistance, is preferably WC-Co. The thermal spraying method is flame spraying or high-speed flame spraying. The thickness of the film is designed to be 50 to 300 μm depending on the use environment. The surface roughness can also be adjusted by the thermal spray material and the thermal spraying method according to the application, but the range of Ra 5.0 to 18 μm is preferable.

  As described above, the present invention improves the adhesion and impact resistance between the CFRP roll substrate and the wear-resistant film as the top layer by forming a base layer and an intermediate layer.

  FIG. 1 shows the structure of the film with improved adhesion to the CFRP substrate, and FIG. 2 shows the test piece for measuring the adhesion used to measure the adhesion. The test piece for measuring the adhesion shown in FIG. 2 was obtained by forming a multilayer coating (1) on a CFRP substrate (5) having a diameter of 35 mm and a thickness of 5 mm, and then forming a tensile jig (6 ) Was adhered and used for the test. In FIG. 2, the multilayer coating (1) is constructed as shown in FIG. 1. As shown in FIG. 1, the CFRP surface of FIG. 1 (5) is washed ascending, a primer is applied, and a polyurethane resin base layer is formed thereon. Was applied to a thickness of 2.0 mm. Further, after hardening at room temperature of 20 ° C. for 8 hours, the lathe was processed to have a thickness of 200 μm. At this time, the surface roughness of the base layer in FIG. 1 (4) was Ra 10 to 20 μm. The intermediate layer (3) shown in FIG. 1 was formed by arc spraying of Zn to a film thickness of 100 μm. Top layer having wear resistance In FIG. 1 (2), a WC-20% Co powder was deposited to a film thickness of 200 μm by flame spraying.

  Table 1 shows the results of measurement of adhesion. For the multilayer coating and CFRP substrate of the present invention, in the case of this example, the adhesion is about 55 kgf / cm <2>, which is the highest base layer made of polyurethane resin. On the other hand, the adhesion strength of the test pieces on which other base layers were constructed shows a low value.

  As Example 2, a film having wear resistance and impact resistance according to the present invention was formed on the surface of a CFRP roll used as a rider roll for suppressing paper wound around a winder in a winder part of a papermaking machine. . The structure of the film is shown in FIG. The roll was cylindrical with an outer diameter of 125 mm, a surface length of 3100 mm, and a thickness of 5.5 mm. The peripheral surface of the CFRP roll was washed with acetone and coated with a primer, and a polyurethane resin base layer was applied to a thickness of 2.0 mm thereon. This base layer FIG. 3 (4) was cured at room temperature of 20 ° C. for 8 hours and then turned to a thickness of 200 μm. The surface roughness at this time was Ra 10 to 20 μm. A Zn intermediate layer 3 (3) was formed thereon by arc spraying to a film thickness of 100 μm. The top layer was sprayed with WC-20% Co powder using a flame spraying method. The thickness of the top layer shown in FIG. 3 (2) was 200 μm.

  The manufactured roll was used as a paper machine rider roll, and an actual machine operation test was conducted. As a result, peeling of the film was not observed even after 1 year, and the film thickness reduction was extremely small. This test roll continues to operate normally thereafter.

It is a figure which shows the structure of the multilayer sprayed coating of the test piece for adhesive force measurement. It is a figure which shows the test piece for adhesive force measurement. It is a figure which shows the structure of the rider roll membrane | film | coat of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Coating | coated layer 2 Top thermite layer 3 Zn spraying intermediate | middle layer 4 Roughened base layer 5 CFRP base material 6 Pulling jig 7 CFRP base material of a lighter roll

Claims (7)

  A base layer formed by a liquid spraying method on the surface of a carbon fiber reinforced resin roll, a metal or metal alloy intermediate layer formed by a thermal spraying method thereon, and a wear resistance composed of a ceramic or cermet top layer, Roll for paper machines and printing machines with excellent impact resistance.   The paper machine and printing machine roll according to claim 1, wherein the base layer is made of polyurethane resin to improve adhesion to the carbon fiber reinforced resin.   The roll for a paper machine and a printing machine according to claim 1, wherein the intermediate layer is made of Al, Ni-Cr, Cu, Zn or the like.   The top layer is a cermet sprayed layer composed of ceramics composed of oxides of Al, Ti, Cr, Zr, or a mixture thereof, or a mixture of WC, CrC, TiC, etc. and Co, Ni, Cr, etc. The roll for a paper machine and a printing machine according to claim 1.   A polyurethane-based resin is formed as a base layer on the surface of the carbon fiber reinforced resin roll by a liquid spraying method, and a metal or metal alloy is sprayed on the base layer to form an intermediate layer. Furthermore, a method for manufacturing a roll for a paper machine and a printing machine, in which a ceramic or cermet layer is thermally sprayed on the intermediate layer to form a top layer.   The surface roughness of a base layer is a manufacturing method of the roll for paper machines and a printing machine of Claim 5 which is Ra10-20micrometer by lathe processing.   6. The method for manufacturing a roll for a paper machine and a printing machine according to claim 5, wherein an arc spraying method is used for forming the intermediate layer, and a plasma or flame spraying method is used for forming the top layer.

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