JP2011179580A - Guide roller and manufacturing method of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a guide roller which realizes weight reduction, and its manufacturing method. <P>SOLUTION: The cylindrical guide roller includes a first fiber reinforced resin layer 3, a second fiber reinforced resin layer 4 provided on the first fiber reinforced resin layer, and a diamond-like carbon film 5 provided on the second fiber reinforced resin layer 4, wherein an orientation direction of a reinforced fiber in the first fiber reinforced resin layer is not aligned in an axial direction of the guide roller and an orientational direction of a reinforced fiber in the second fiber reinforced resin layer is aligned in an axial direction of the guide roller. After heating and curing a wound body formed by laminating and winding a second pre-preg sheet taken as a second fiber reinforced resin layer on a first pre-preg sheet taken as a first fiber reinforced resin layer and then adjusting surface roughness and out-of-roundness by grinding the second fiber reinforced resin layer, a diamond-like carbon film is formed. Since a roller body which is smooth and excellent in out-of-roundness can be formed through the grinding, the diamond-like carbon film can be made thinner. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to, for example, a guide roller used when a belt-shaped plastic film, a paper sheet, a ceramic green sheet, or the like is conveyed, and a method for manufacturing the guide roller.

  Guide rollers used when transporting belt-shaped plastic films, paper sheets, etc., require weight reduction, mechanical strength, wear resistance of the roller surface due to friction with carrier film or sheet, etc. Therefore, in recent years, a roller body made of carbon fiber reinforced resin having a metal film having excellent wear resistance, metal plating, or the like is used on the outer surface.

For example, in Japanese Patent No. 3793652 (Patent Document 1), there is a first carbon fiber layer in which each carbon fiber has a first predetermined angle with respect to the axial direction of the roller, and each carbon fiber of the first carbon fiber layer. On the other hand, the surface of the carbon fiber layer composed of the second carbon fiber layer where each carbon fiber intersects at a second predetermined angle is integrated with a resin cured layer in order to smooth the unevenness caused by each carbon fiber. In order to improve the wear resistance of the surface of the cured resin layer after grinding or polishing the surface of the cured resin layer, a roller having a plated layer has been proposed.
Here, it is described that the rigidity can be increased without impeding weight reduction by intersecting carbon fibers at a predetermined angle (paragraph numbers 0028, 0029, etc.).

It is known that chromium plating is generally effective as a metal plating excellent in wear resistance. However, it is difficult to reduce the weight of the roller because chromium plating is generally heavy because it requires base plating and the number of work steps increases. For this reason, Japanese Unexamined Patent Application Publication No. 2002-60922 (Patent Document 2) discloses a guide roller that employs metal spraying instead of metal plating. Specifically, it is manufactured as follows.
A carbon fiber sheet impregnated with a thermosetting resin into a prepreg (semi-cured state) is wound around the mold so as to form a number of layers, heat-cured, and the surface is further fixed with an epoxy adhesive. Then, the surface of the roller body formed to ensure flatness is polished (paragraph number 0044), and then a low melting point metal is sprayed onto the polished surface by flame spraying to form a metal sprayed layer having a thickness of 300 μm. After this, polishing is performed so that the thickness of the metal sprayed layer becomes 200 μm (paragraph 0045).
Here, it is described that by setting the thickness of the metal sprayed layer within a predetermined range, the base treatment is not required, and productivity can be improved (paragraph 0010).

In addition, as a guide roller that eliminates the need for ground treatment during chrome plating, Japanese Patent Laid-Open No. 2006-90525 (Patent Document 3) discloses an inner layer made of fiber-reinforced plastic having a resin content of less than 50% by weight and a resin content of A roller having an outer layer made of 50 to 95% by weight of a fiber reinforced plastic and having a metal plating layer on the surface is disclosed.
Here, for the inner layer, the prepregs A and B in which the carbon fibers are aligned in one direction and impregnated with an epoxy resin are laminated so that the alignment directions of the carbon fibers are orthogonal (paragraph number 0053, Table 1), As the outer layer, a resin cured product of a prepreg sheet in which a polyester fiber nonwoven fabric is impregnated with a resin so that the resin content is 50% by weight is used (Table 2).
As the metal plating layer, a metal plating layer formed by electroless plating having a thickness of 10 to 100 μm or a chromium plating having a thickness of 55 to 150 μm has been proposed.
By making the fiber reinforced plastic tube into a fiber reinforced plastic having a resin content of less than 50% by weight, mechanical properties such as strength and rigidity are secured, while the outer layer is a fiber reinforced plastic having a resin content of 50 to 95% by weight. By doing so, the surface accuracy is improved. Further, the predetermined surface smoothness is ensured by grinding and polishing the outer layer, and there is no influence of the waviness of the inner layer, and in order to obtain a uniform surface, the outer layer thickness is 0.2 to 1.5 mm. It has been proposed to do.
Furthermore, since the accuracy (cylindricity, roundness) of cylindrical polishing performed before plating is reduced and cylindrical polishing may be necessary again, the thickness of the electroless plating layer is most preferably 30 to 60 μm. Preferred is described.

Japanese Patent No. 3793652 JP 2002-60922 A JP 2006-90525 A

Regardless of whether metal plating or metal spraying is used, in order to reduce weight, it is necessary to omit the base plating and to reduce the thickness of the plating layer and metal spraying layer. In order to realize this, there is a limit to making these thin films.
In addition, in order to obtain a metal plating layer and a metal sprayed layer that are thin and excellent in smoothness, it is necessary to mirror the fiber reinforced resin layer as a base. However, in the conventional method, the epoxy resin is further fixed to the polished surface of the fiber reinforced resin layer to smooth the unevenness of the polished surface, or the fiber reinforced with high resin content (low fiber content). A resin layer is formed and the fiber reinforced resin layer is polished.
In these methods, the thickness of the resin layer is increased as a precondition for thinning the metal plating layer and the metal sprayed layer, and it is difficult to further reduce the weight.

  This invention is made | formed in view of such a situation, The place made into the objective is to provide the guide roller which can aim at the further weight reduction conventionally, and its manufacturing method.

  The present inventor tried to adopt a diamond-like carbon film instead of metal plating or metal spraying in order to further reduce the weight while ensuring mechanical strength such as wear resistance. However, when diamond-like carbon thin film is adopted, it has been found that it is necessary to solve a new problem that the surface roughness of the underlying fiber reinforced resin layer is more easily reflected than metal plating or metal spraying. . The inventor completed the present invention as a result of various further studies.

  That is, the guide roller of the present invention includes a first fiber reinforced resin layer; a second fiber reinforced resin layer provided on the first fiber reinforced resin layer; and a diamond shape provided on the second fiber reinforced resin layer. A cylindrical guide roller provided with a carbon film, wherein the orientation direction of the reinforcing fibers in the first fiber reinforced resin layer is not aligned in the axial direction of the guide roller, and in the second fiber reinforced resin layer The orientation direction of the reinforcing fibers is the axial direction of the guide roller.

  The second fiber reinforced resin layer is formed by winding a prepreg sheet in which reinforcing fibers are aligned in one direction so that the orientation direction of the reinforcing fibers is the axial direction, and then thermosetting. Preferably, the first fiber reinforced resin layer is wound so as to include at least one winding step in which the orientation direction of the reinforcing fibers of the prepreg sheet is not the axial direction. It is preferably formed by thermosetting.

  Moreover, it is preferable that the prepreg sheet used for formation of the said 2nd fiber reinforced resin layer is what impregnated the epoxy resin to the carbon fiber sheet with which the carbon fiber was aligned in one direction. Moreover, it is preferable that the surface roughness of the said 2nd fiber reinforced resin layer is 1.0 micrometer or less as an average roughness (Ra), and the thickness of the said diamond-like resin film is 1-10 micrometers.

  In the guide roller manufacturing method of the present invention, the second reinforcing fibers are aligned in one direction on the wound body of the first prepreg sheet in which the orientation direction of the first reinforcing fibers is not aligned with the longitudinal direction of the cylindrical body. A wound body obtained by winding 2 prepreg sheets so that the orientation direction of the second reinforcing fibers is the longitudinal direction of the cylindrical body was heat-cured, and the reinforcing fibers were oriented in the longitudinal direction of the cylindrical body. A step of forming a fiber-reinforced resin cylindrical body having a fiber-reinforced resin layer as a surface layer; a step of polishing the surface of the fiber-reinforced resin cylindrical body; and a diamond-like carbon on the polishing surface obtained by the polishing step Forming a film.

  The polishing step is preferably performed by advancing an abrasive along the longitudinal direction of the fiber reinforced resin cylindrical body while rotating the fiber reinforced resin cylindrical body, and the diamond-like carbon film forming step Is preferably performed by an ion implantation method.

  In the guide roller of the present invention, since the fiber reinforced resin is oriented in one direction in the fiber reinforced resin layer that becomes the lower ground of the diamond-like carbon film that is the sliding surface, the fiber reinforced resin layer is polished at the time of polishing. , The reinforcing fiber does not flicker with the resin. Accordingly, a smooth base surface can be secured even after polishing, and as a result, a sliding surface made of a thin and smooth diamond-like carbon film can be provided.

It is a figure which shows the structure of the guide roller of one Embodiment of this invention. It is a figure for demonstrating the manufacturing method of this invention. It is an electron micrograph of the guide roller surface obtained in the present Example. It is an electron micrograph of the guide roller surface obtained in the comparative example. It is a chart which shows the measurement result of the surface roughness of the part image | photographed with the electron microscope of the guide roller obtained by the comparative example.

  Although embodiments of the present invention will be described below, it should be considered that the embodiments disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is defined by the terms of the claims, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.

[Guide roller]
First, a guide roller according to an embodiment of the present invention will be described with reference to FIG.
Fig.1 (a) is a longitudinal direction (axial direction) sectional drawing of the guide roller of this invention, (b) is a side view.

  The roller body 1 of the guide roller is a cylindrical body composed of a first fiber reinforced resin layer 3 and a second fiber reinforced resin layer 4 provided on the outer surface thereof. In the guide roller of the present invention, the outer surface of the roller body 1 (the outer surface of the second fiber reinforced resin layer 4) may be abbreviated as a diamond-like carbon film (hereinafter referred to as “DLC film”). ) 5 covered.

As the first fiber reinforced resin layer 3, specifically, a thermoset of a prepreg sheet in which a fiber sheet made of reinforcing fibers is impregnated with a thermosetting resin to be in a semi-cured state is preferably used.
Although it does not specifically limit as said reinforced fiber, Carbon fiber, glass fiber, an alumina fiber, polyester fiber, nylon fiber etc. are mentioned, Among these, carbon fiber excellent in specific strength and specific rigidity is used preferably. As the reinforcing fiber, one having a diameter of 5 to 13 μm is usually used.
As the fiber sheet, a nonwoven fabric of reinforcing fibers; a woven fabric such as plain weave, twill weave and satin weave; a fiber sheet arranged in parallel in one direction can be used.
Moreover, as said thermosetting resin, an epoxy resin, unsaturated polyester resin, a phenol resin etc. are used, Of these, an epoxy resin is preferably used from the point that the thermal contraction rate at the time of thermosetting is small.

  Although the thickness per sheet of the prepreg sheet having the above configuration is not particularly limited, it is usually preferable to use a thickness of about 0.1 to 0.3 mm, more preferably 0.1 to 0.2 mm. Use things.

  The first fiber reinforced resin layer 3 is formed by winding the prepreg sheet as described above around a columnar or cylindrical core and then thermosetting it.

  The winding (cylindrical winding operation) is preferably performed so that the orientation direction of the reinforcing fibers included in the prepreg sheet does not coincide with the longitudinal direction of the core material, that is, the axial direction of the guide roller to be manufactured. . This is because the guide roller in which the orientation direction of the reinforcing fibers coincides with the longitudinal direction of the cylindrical body is likely to be twisted as a cylindrical shape. When a plurality of prepreg sheets are laminated, it is preferable to include at least one layer in which the orientation direction of the reinforcing fibers of the prepreg sheet does not coincide with the axial direction of the guide roller. Therefore, when using a fiber sheet or woven fabric in which the reinforcing fibers are aligned in one direction, it is preferable to laminate the layers so that the orientation direction is changed for each layer. For example, as the prepreg sheets constituting the first layer, the second layer, the third layer, etc., the alignment direction of the reinforcing fibers is the longitudinal direction of the roller (axial direction), the circumferential direction, and a direction oblique to the axis, It is preferable to change for each layer. More preferably, the orientation direction of the reinforcing fiber is intersecting with the axial direction of the core material (corresponding to the axial direction of the roller body to be formed). In order to prevent this, the predetermined angle is shifted. In the case of using a prepreg sheet in which reinforcing fibers are aligned in one direction, it is most preferable to stack them while shifting by 90 ° (that is, orthogonal).

  Although the thickness of the 1st fiber reinforced resin layer 3 is not specifically limited, Since it rolls so that the prepreg sheet of the said thickness may be laminated | stacked, it is 0.4-2 mm normally, Preferably it is 0.5-1.5 mm. . Therefore, when the prepreg sheet having the above thickness is used, it is preferably wound and used so that about 2 to 15 layers, preferably about 5 to 10 layers are laminated.

  From the viewpoint of close integration of the first fiber reinforced resin layer 3 and the second fiber reinforced resin layer 4, the thermosetting treatment of the prepreg sheet constituting the first fiber reinforced resin layer 3 is performed using the second fiber reinforced resin layer 4. It is preferable to perform simultaneously with the heat treatment performed after winding the prepreg sheet to be formed.

The second fiber reinforced resin layer 4 is a cured product of a prepreg sheet obtained by impregnating a thermosetting resin into a fiber sheet in which reinforcing fibers are aligned in the longitudinal direction (axial direction) of the roller body 1.
In the prepreg sheet used for the configuration of the second fiber reinforced resin layer 4, the same reinforcing fibers and thermosetting resin as those used for the first fiber reinforced resin layer 3 can be used. That is, a carbon fiber having a diameter of 5 to 13 μm is preferably used as the reinforcing fiber, and an epoxy resin is preferably used as the thermosetting resin.

  However, the prepreg sheet used for the second fiber reinforced resin layer 4 is different from the prepreg sheet used for the first fiber reinforced resin layer 3 in the following points. That is, the second fiber reinforced resin layer 4 is limited to a fiber sheet type prepreg sheet in which the reinforcing fibers are aligned in one direction (hereinafter referred to as “one-way type prepreg sheet”), and this The unidirectional type prepreg sheet is that the orientation direction of the reinforcing fibers of the prepreg sheet is provided so as to be the axial direction of the roller body (longitudinal direction of the cylindrical body).

  It is preferable that the thickness of the second fiber reinforced resin layer 4 is equal to the thickness of the first fiber reinforced resin layer 3 or the prepreg sheet having the above thickness is laminated and wound so as to be thinner than the first fiber reinforced resin layer 3. . Specifically, the thickness is preferably about 0.4 to 1.5 mm, more preferably 0.5 to 1 mm. Therefore, when using the prepreg sheet having the above-described normal thickness, the prepreg sheet is wound so as to be laminated in about 2 to 10 layers, preferably about 5 to 8 layers.

  Although the fiber content rate in the 2nd fiber reinforced resin layer 4 is based on the fabric weight in a prepreg sheet, it is 40-95 mass% normally, Preferably it is 50-95 mass%.

  The second fiber reinforced resin layer 4 is formed by winding a prepreg sheet for the first fiber reinforced resin, and then converting the unidirectional type prepreg sheet into the reinforcing fiber direction of the prepreg sheet and the longitudinal direction of the core (corresponding to the axial direction of the roller). ) And then, by heating and thermosetting the thermosetting resin of these prepreg sheets, it is formed together with the first fiber reinforced resin layer.

  The surface roughness of the second fiber reinforced resin layer is preferably 1.0 μm or less, more preferably 0.8 μm or less, and even more preferably about 0.7 μm, as average roughness (Ra). Such smoothness is achieved by polishing the surface after curing. In particular, in the guide roller of the present invention, since the carbon fibers of the fiber sheet used in the second fiber reinforced resin layer are aligned in the longitudinal direction of the roller, a plurality of prepreg sheets are laminated. However, the polishing direction and the alignment direction for adjusting the roundness can be made constant. Accordingly, it is possible to minimize the unevenness of the surface of the second fiber reinforced resin layer caused by polishing, removal, dropout, breakage of the reinforcing fiber due to polishing, and to obtain a mirror surface.

  In the guide roller of the present invention, a diamond-like carbon film (DLC film) is laminated on the second fiber reinforced resin layer 4 having the above-described configuration.

A diamond-like carbon film (DLC film) is a carbon thin film with high hardness, electrical insulation, infrared transmission, etc. similar to diamond. It contains some hydrogen, has an amorphous structure, diamond bond, graphite bond, etc. Have
Such a DLC film can be formed by a CVD method, a plasma CVD method, a PVD method, an ion implantation method, or the like, but is preferably formed by an ion implantation method.

The thickness of the DLC film 5 is not particularly limited, but is about 1 to 10 μm, preferably about 3 to 5 μm.
Even with this thickness, wear resistance and slidability can be secured. Since the outer surface of the second fiber reinforced resin layer 4 has achieved high smoothness (preferably, an average roughness (Ra) of 1.0 μ or less) over the entire length in the longitudinal direction of the roller, the thickness described above. However, the DLC film can be uniformly formed on the entire outer surface of the guide roller.

  On the other hand, since the DLC film 5 is a thin film, a film reflecting the surface state of the base surface is formed. Moreover, since the DLC film 5 is a thin film, it is difficult to adjust the smoothness and roundness by polishing the DLC film 5 itself. For these reasons, there is a significance that the roundness is sufficiently increased and the smoothness of the substrate surface is increased before the DLC film 5 is formed.

In the guide roller having the above-described configuration, the DLC film 5 constituting the outer surface of the guide roller is formed of a thin film having a thickness of about 1 to 10 μm or less, and therefore satisfies the requirements for weight reduction and wear resistance. Can do.
In this regard, the conventional metal sprayed film requires a thickness of about 200 μm, and even in the case of a metal plating layer, it is necessary to form a plating layer of 50 μm or more in order to form a stable plating layer. . However, with a DLC film, a film having a high hardness and excellent wear resistance can be formed with a thickness of about 1 to 10 μm.

  The guide roller as described above may be used by inserting a bearing or the like at both ends of the roller body 1 and inserting the shaft. Although the manufacturing method of the guide roller of this invention is not specifically limited, It can manufacture suitably with the manufacturing method of this invention demonstrated below.

[Guide roller manufacturing method]
In the guide roller manufacturing method of the present invention, the second reinforcing fibers are aligned in one direction on the wound body of the first prepreg sheet in which the orientation direction of the first reinforcing fibers is not aligned with the longitudinal direction of the cylindrical body. A wound body obtained by winding 2 prepreg sheets so that the orientation direction of the second reinforcing fibers is the longitudinal direction of the cylindrical body was heat-cured, and the reinforcing fibers were oriented in the longitudinal direction of the cylindrical body. Forming a fiber reinforced resin cylindrical body having a fiber reinforced resin layer as a surface layer;
A step of polishing the surface of the fiber reinforced resin cylindrical body; and a step of forming a diamond-like carbon film on the polished surface obtained by the polishing step.

  In the step of winding a prepreg sheet to produce a fiber-reinforced resin cylindrical body, a metal column such as an iron core or a cylindrical core material is used, and the prepreg sheet is wound around the core material. By using a core material whose cross-sectional shape is close to a perfect circle in advance, a fiber-reinforced resin cylindrical body produced by winding can be made close to a perfect circle. First, a wound body of the first prepreg sheet is formed by winding the first prepreg sheet constituting the first fiber reinforced resin layer on the core, and then the prepreg constituting the second fiber reinforced resin layer What is necessary is just to wind a sheet | seat.

  In order to produce a fiber reinforced resin cylindrical body whose surface is a fiber reinforced resin layer in which the orientation direction of the reinforced fibers is the axial direction of the guide roller, the second prepreg sheet may be wound at least twice or more. Preferably, it is preferably about 5 to 10 turns from the viewpoint of sufficiently corresponding to the adjustment of roundness.

  As the first and second prepreg sheets, those mentioned in the guide roller of the present invention can be used. That is, carbon fibers, glass fibers, alumina fibers, polyester fibers, nylon fibers and the like having a diameter of about 5 to 13 μm are usually used as reinforcing fibers, and epoxy resins, unsaturated polyester resins, phenol resins are used as thermosetting resins. Etc. are used.

  However, the first prepreg sheet is not particularly limited, but a unidirectional type prepreg sheet is used as the second prepreg sheet. This unidirectional type prepreg sheet is wound so that the orientation direction of the reinforcing fibers is the longitudinal direction of the cylindrical body (the axial direction of the roller body).

  After winding, the resin of the first and second prepreg sheets is cured by heating. As a result, a wound body is formed in which the first fiber reinforced resin layer, which is the cured body of the first prepreg sheet, is laminated and integrated with the second fiber reinforced resin layer, which is the cured body of the second prepreg sheet. When the core is extracted after curing, a fiber-reinforced resin cylindrical body is obtained.

  Next, the surface of the obtained fiber reinforced resin cylindrical body, that is, the second fiber reinforced resin layer is polished. In producing the cylindrical roller body, since the thickness with respect to the axis may vary, it is required to be close to a perfect circle by polishing. Furthermore, in the guide roller of the present invention, the DLC film formed on the second fiber reinforced layer is a thin film, and the surface roughness of the second fiber reinforced resin layer as a base is easily reflected, so that the smooth surface has few irregularities. It is necessary to keep.

  Although it does not specifically limit as a grinding | polishing method, as shown in FIG. 2, a bearing is internally fitted in the both ends of the fiber reinforced resin cylindrical body 10, and the axis | shaft 12 is penetrated. Next, by rotating the shaft 12, the reinforcing fiber is oriented in the axial direction while rotating the fiber reinforced resin cylindrical body 10 of the first fiber reinforced resin layer and the second fiber reinforced resin layer. The second fiber reinforced resin layer is preferably moved by being moved along the longitudinal direction (axial direction) of the fiber reinforced resin cylindrical body 10 as an outer layer.

  Although detailed reason is unknown by such grinding | polishing, the surface layer part of the hardening body of the 2nd prepreg sheet laminated body which comprises the 2nd fiber reinforced resin layer is grind | polished, and the layer under it is exposed. Even in such a case, there is almost no loss of fibers and no flaking, and an excellent smooth surface can be maintained. Specifically, the average surface roughness (Ra) is preferably 1.0 μm or less, more preferably 0.8 μm or less, and even more preferably about 0.7 μm. In this respect, when a prepreg sheet using a woven fabric type fiber sheet is used as the outermost layer or a unidirectional prepreg sheet is provided so as to intersect the axial direction of the roller, polishing is performed in the same manner. This is in contrast to the unevenness of the surface after polishing due to the fibers becoming fluffy, falling off, or falling off due to polishing. Further, in the conventional method, after polishing the fiber reinforced resin layer, a step of smoothing the uneven surface by further fixing an epoxy resin or the like is necessary, but in the manufacturing method of the present invention, these operations are performed. There is an advantage that the process can be omitted.

Next, a DLC film is formed.
As a method for forming the DLC film, a plasma CVD method, a sputtering method, an ion plating method, and the like can be used as a method for forming the film in the temperature range so as not to cause thermal damage to the roller body 10. Of these, the ion implantation method is particularly preferable.
The ion implantation method is a method in which a plasma is generated by applying a high-frequency voltage around a substrate, and a high voltage pulse is further applied to implant and form a film of ions around the substrate. Specifically, plasma is formed around the base roller (roller on which the second fiber reinforced resin layer is formed), and a negative pulse voltage is applied to the roller to extract ions from the plasma and accelerate it. Then, ion implantation is performed on the second fiber reinforced resin layer. When plasma is formed using a gas containing carbon, a DLC film is formed.

  A carbon compound is used as a plasma raw material to be used. As the carbon compound, saturated hydrocarbons such as methane, ethane, propane and butane, unsaturated hydrocarbons such as ethylene, propylene and butadiene, and aromatic hydrocarbons such as benzene and toluene can be used. By using such a hydrocarbon as a raw material, hydrogen is contained in the DLC film. The hydrogen content in the DLC film depends on the manufacturing method and film forming conditions. The plasma forming method is not particularly limited, and examples thereof include a high frequency discharge method, a microwave discharge method, and a hot filament discharge method.

  The film formation using ion implantation is characterized in that a film having excellent adhesion can be formed because a mixing layer is formed at the interface between the second fiber reinforced resin layer and the thin film. Further, the ion implantation method can form a film at a lower temperature than the CVD method, the plasma CVD method, and the like, and can form a dense film similar to the CVD method with high adhesion to the substrate. There is a feature.

  Prior to the DLC film formation, as a pretreatment, the second fiber reinforced resin layer may be exposed to a pretreatment gas such as a plasma containing a fluorine-containing gas, a hydrogen-containing gas, or an oxygen-containing gas. The pretreatment may be performed a plurality of times.

The DLC film is formed to have a thickness of about 1 to 10 μm, preferably 3 to 5 μm. Even with this thickness, the conditions required for the guide roller can be satisfied from the inherent wear resistance and sliding properties of the DLC film.
Furthermore, as described above, the polished surface of the second fiber reinforced resin layer serving as the base achieves an average surface roughness (Ra) of 1.0 μm or less, preferably 0.8 μm or less, and more preferably about 0.7 μm. Therefore, even with a DLC film having such a thickness, the reinforcing fibers in the underlying second fiber reinforced resin layer are not broken and exposed together with the resin.

  Furthermore, in the method of the present invention, after polishing the second fiber reinforced resin layer to ensure roundness, it is not necessary to fix the resin for smoothing the uneven surface. Since there is no need for treatment or polishing after the formation of a wear-resistant film like a metal sprayed film, the number of work steps can be reduced as compared with the conventional method, and productivity can be improved.

(1) Example As a prepreg sheet as a constituent material of the first fiber reinforced resin layer and the second fiber reinforced resin layer, an epoxy resin is impregnated into a fiber sheet in which carbon fibers (diameter 5 to 7 μm) are aligned in one direction. Used. The thickness per sheet of this prepreg sheet is 0.1 to 0.17 mm.

  The prepreg sheet was wound around an iron pipe having an outer diameter of 57 mm so as to be inclined with respect to the axial direction of the iron pipe, and was wound so as to have eight layers in a reciprocating manner. Next, the resin was heat-cured at 120 ° C. after winding 6 times (six layers) so that the orientation direction of the carbon fibers was the axial direction of the iron pipe. After curing, the pipe was pulled out to obtain a fiber reinforced resin cylindrical body.

As shown in FIG. 2, bearings are attached to both ends of the fiber reinforced resin cylindrical body 10 and the shaft 12 is inserted. The surface of the second fiber reinforced resin layer was polished by moving the polishing member 11 along the axial direction while rotating the shaft 12 in the arrow direction.
When the surface roughness after polishing was measured using a surface roughness measuring instrument E35A manufactured by Tokyo Seimitsu Co., Ltd., the average roughness (Ra) was 0.7.

A DLC film was formed on this polished surface by ion implantation. The thickness of the formed DLC film was 3 to 5 μm. Thus, the DLC film (thickness average 4 μm) was formed on the outer surface of the cylindrical body composed of the first fiber reinforced resin layer (about 0.85 mm) and the second fiber reinforced resin layer (thickness 0.65 mm). A guide roller was produced.
The surface after the DLC film was formed was observed with an electron microscope. An electron micrograph is shown in FIG. In FIG. 3, it can be seen that the white lines that serve as the reinforcing fibers are oriented in one direction.

(2) Comparative Example The same type of prepreg sheet as that used in the examples was used.
On a steel pipe, the prepreg sheet is wound as 8 layers as the first fiber reinforced resin layer, and then the orientation directions of the reinforced fibers are orthogonal in the first and second layers as the second fiber reinforced resin layer. In order, 6 layers were laminated and wound.
After the resin was heat-cured, the second fiber reinforced resin layer was polished under the same conditions as in the example. A DLC film was formed on this polished surface by ion implantation in the same manner as in the example. Thus, the DLC film (thickness average 4 μm) was formed on the outer surface of the cylindrical body composed of the first fiber reinforced resin layer (about 0.85 mm) and the second fiber reinforced resin layer (thickness 0.65 mm). A guide roller was produced.

  The surface after the DLC film was formed was observed with an electron microscope. An electron micrograph is shown in FIG. In FIG. 4, it is presumed that the white line that becomes the reinforcing fiber intersects, but a protrusion of the DLC film was recognized due to the occurrence of scarring.

The result of having measured the surface roughness of the DLC film of the part image | photographed with the microscope picture using the Tokyo Seimitsu Co., Ltd. surface roughness measuring device E35A is shown in FIG. It was confirmed that the portion observed as the protrusion was a convex portion having a height of 213.7 μm. This is presumably because a part of the reinforcing fibers of the second fiber reinforced resin layer was cut off together with the resin.
Therefore, in order to achieve a DLC film with high smoothness in a guide roller using a fiber reinforced resin layer in which the orientation of carbon fibers is not specified, further processing of the DLC film surface is required after the DLC film is formed. Become.

Since the guide roller of the present invention is lightweight and has excellent wear resistance and sliding properties, it can be used as various conveying rollers such as plastic sheets, paper sheets, and ceramic green sheets.
In addition, according to the guide roller manufacturing method of the present invention, it is not necessary to perform a base treatment for plating or smooth the uneven surface after polishing, so that the number of work steps can be reduced as compared with the conventional method. The guide roller is highly productive.

1 Roller Body 3 First Fiber Reinforced Resin Layer 4 Second Fiber Reinforced Resin Layer 5 DLC Film 10 Fiber Reinforced Resin Cylindrical Body 11 Polishing Member

Claims (8)

A cylindrical guide provided with a first fiber reinforced resin layer; a second fiber reinforced resin layer provided on the first fiber reinforced resin layer; and a diamond-like carbon film provided on the second fiber reinforced resin layer Laura,
The orientation direction of the reinforcing fibers in the first fiber reinforced resin layer is not aligned with the axial direction of the guide roller, and the orientation direction of the reinforcing fibers in the second fiber reinforced resin layer is the axial direction of the guide roller. Guide roller that has become. The second fiber reinforced resin layer is formed by winding a prepreg sheet in which reinforcing fibers are aligned in one direction so that the orientation direction of the reinforcing fibers is the axial direction, and then thermosetting. The guide roller according to claim 1, wherein The first fiber reinforced resin layer is wound by heat so as to include at least one winding step in which the orientation direction of the reinforcing fibers of the prepreg sheet is not the axial direction of the guide roller. The guide roller according to claim 1, wherein the guide roller is formed. The guide roller according to claim 2 or 3, wherein the prepreg sheet used for forming the second fiber reinforced resin layer is obtained by impregnating an epoxy resin into a carbon fiber sheet in which carbon fibers are aligned in one direction. 5. The surface roughness of the second fiber reinforced resin layer is 1.0 μm or less as an average roughness (Ra), and the thickness of the diamond-like resin film is 1 to 10 μm. Guide roller. On the wound body of the first prepreg sheet in which the orientation direction of the first reinforcing fibers is not aligned in the longitudinal direction of the cylindrical body, the second prepreg sheet in which the second reinforcing fibers are arranged in one direction is used. The wound body formed by winding so that the orientation direction is the longitudinal direction of the cylindrical body is heat-cured, and the fiber reinforced resin layer in which the reinforcing fibers are oriented in the longitudinal direction of the cylindrical body is the surface layer. Forming a fiber reinforced resin cylindrical body;
A method for producing a guide roller, comprising: a step of polishing a surface of the fiber reinforced resin cylindrical body; and a step of forming a diamond-like carbon film on a polished surface obtained by the polishing step. The method of manufacturing a guide roller according to claim 6, wherein the polishing step is performed by advancing the abrasive along the longitudinal direction of the fiber reinforced resin cylindrical body while rotating the fiber reinforced resin cylindrical body. . The guide roller manufacturing method according to claim 6 or 7, wherein the diamond-like carbon film forming step is performed by an ion implantation method.