JP6253957B2 - Manufacturing method of ceramic coating roller - Google Patents

Description

  The present invention generally has good surface smoothness with a ceramic coating layer formed on the surface of a hollow or solid roller base material such as a fiber reinforced composite material such as carbon fiber reinforced plastic or a metal such as aluminum, In addition, the present invention relates to a method for producing a ceramic coating roller excellent in wear resistance, heat resistance, acid resistance, and solvent resistance.

  Conventionally, as a surface treatment of a steel roller used as a film conveying roller, a guide roller or the like, copper, HCr plating, thermal spraying, or the like is used to improve wear resistance.

  On the other hand, with the increase in size and length of the roller, it is attempted to produce the roller with a fiber reinforced composite material such as a light weight and low deflection carbon fiber reinforced plastic instead of the heavy steel roller. In addition, in order to improve the wear resistance and heat resistance of the surface of rollers made of these fiber reinforced composite materials, it is proposed that the surface be plated or ceramics, cermet, metal, etc. are sprayed Has been.

  Patent Document 1 discloses a wear resistance and surface smoothness in which an undercoat layer made of an organic polymer material and an inorganic material is provided on the surface of a roller of plastic or fiber reinforced plastic, and a ceramic film is formed by spraying ceramics thereon. Describes an excellent roller.

  Further, Patent Document 2 has a structure in which a mixture of a resin of the same type as the base resin and ceramic particles is provided as an intermediate layer on the surface of the fiber reinforced plastic base material, and a thermal spray coating layer made of carbide cermet is provided as a top coat. A plastic matrix composite having excellent surface properties such as wear resistance is described.

  However, it is extremely difficult to plate the roller-shaped substrate made of fiber reinforced composite material or to perform spraying as described in the above-mentioned patent document, resulting in high processing costs. It was.

  Therefore, conventionally, it has been considered to coat the surface of the base material with a fluororesin instead of plating, but the conventional fluororesin coating needs to be fired at about 260 ° C. or higher. For this reason, binders and adhesives cannot withstand such high temperatures in fiber reinforced composite substrates, and in reality it is not possible to apply fluororesin coatings to fiber reinforced composite substrates. It is.

  Patent Document 3 proposes spray coating a fluorine / silica-containing polymer coating material containing spherical fine particle alumina on the surface of a carbon fiber reinforced plastic roller. In Patent Document 3, the coated material is cured even at room temperature, and the roller thus manufactured can obtain a hardness of 5H or more in a pencil test, and has a sufficient height to be used as a paper transport roller. It is described that.

No. 4-7378 Japanese Patent No. 4436957 Japanese Unexamined Patent Publication No. 2000-25959

  However, according to the results of the research experiment conducted by the present inventors, when a fluorine / silica-containing polymer coating material containing spherical fine particle alumina is spray-coated on the surface of a roller made of carbon fiber reinforced plastic as described in Patent Document 3, It was found that it is necessary to heat cure (fire) the coated material after coating at a temperature of 80 ° C. or higher in order to fully exhibit the coating film performance and surface peeling performance of the coating film. . Further, even if heat curing is performed, the roller surface hardness is actually about 3H at the maximum, and the roller surface roughness (Rmax) after coating is about 6 μm (Ra about 1.5 μm). is there. The hardness and roughness of such a roller are still insufficient for a guide roller used in a film drying process, for example, and further improvement is desired.

  Therefore, the present inventors pay attention to a ceramic coating layer having a sufficient hardness (pencil hardness 9H) that is currently used in frying pans, rice cookers, etc., and an inorganic ceramic coating agent (ie, ceramic paint). It was decided to paint on the roller surface using. However, in order to obtain a predetermined surface smoothness on the roller surface after coating, it has been found that it is not sufficient to finish the surface only with a normal polishing finish.

  As a result of many research experiments, the present inventors have adopted polishing using a grindstone or abrasive paper containing a polishing agent on the roller surface after coating, and finishing with a material such as cotton that does not contain the polishing agent. By doing so, it has been found that a ceramic coating roller having sufficient precision that can be used in a film drying process and the like, and having surface smoothness (roughness) and hardness can be produced.

  The present invention has been made based on such novel findings of the present inventors.

  The object of the present invention is to form a ceramic coating layer on the surface of a hollow or solid roller base material which is made of a fiber reinforced composite material such as carbon fiber reinforced plastic or a metal such as aluminum without requiring baking after painting. Another object of the present invention is to provide a method for producing a ceramic coating roller having good surface smoothness and excellent wear resistance, heat resistance, acid resistance and solvent resistance.

The above object is achieved by the method for manufacturing a ceramic coating roller according to the present invention. In summary, according to a first aspect of the present invention, there is provided a method for manufacturing a ceramic coated roller comprising:
(A) a step of spraying a ceramic coating on the surface of a roller base made of fiber reinforced plastic or metal to form a ceramic coating layer and curing the coating;
(B) a step of polishing the surface of the cured ceramic coating layer with a polishing member containing an abrasive and then finishing with a finishing member not containing the abrasive;
A method for producing a ceramic coating roller is provided.

According to a second aspect of the present invention, there is provided a method for producing a ceramic coating roller comprising:
(A) a step of winding a predetermined reinforcing fiber around a mandrel with a predetermined resin to form a reinforcing fiber layer;
(B) curing the resin of the reinforcing fiber layer to produce a roller base material to be a fiber reinforced plastic;
(C) a step of spraying a ceramic coating on the surface of the fiber reinforced plastic roller substrate to form a ceramic coating layer and curing the coating;
(D) a step of polishing the surface of the cured ceramic coating layer with a polishing member containing an abrasive and then finishing with a finishing member not containing the abrasive;
A method for producing a ceramic coating roller is provided.

According to a third aspect of the present invention, there is provided a method for producing a ceramic coating roller comprising:
(A) A step of winding a prepreg produced using a predetermined reinforcing fiber and a predetermined resin around a mandrel to cure the resin, and manufacturing a roller base material to be a fiber reinforced plastic,
(B) a step of spraying a ceramic coating on the surface of the fiber reinforced plastic roller base material to form a ceramic coating layer and curing the coating;
(C) after polishing the surface of the cured ceramic coating layer with a polishing member containing an abrasive, and finishing with a finishing member that does not contain an abrasive;
A method for producing a ceramic coating roller is provided.

  In the present invention, according to the first embodiment, the roller base made of fiber reinforced plastic is formed of a plurality of reinforcing fiber layers, and the outermost fiber layer of the reinforcing fiber layer includes Wrap around the mandrel in the same angular direction.

In the present invention, according to another embodiment, the reinforcing fiber of the fiber reinforced plastic is an inorganic fiber such as carbon fiber, glass fiber or basalt fiber; metal fiber such as boron fiber, titanium fiber or steel fiber; , Organic fibers such as PBO (polyparaphenylene benzbisoxazole), polyamide, polyarylate, and polyester; are used alone or in a hybrid mixed with multiple types,
The resin of the fiber reinforced plastic is a room temperature curing type or thermosetting type epoxy resin, vinyl ester resin, MMA resin, acrylic resin, unsaturated polyester resin, phenol resin, nylon or vinylon.

  According to another embodiment of the present invention, the finished ceramic coating roller has a surface roughness (Ra) of 0.2 μm or more and 1.6 μm or less, and a surface hardness (pencil hardness H). Is 7H or more and 9H or less.

  In the present invention, according to another embodiment, the accuracy of the finished ceramic coating roller is roundness, cylindricity, and runout within 0.02 mm.

  In the present invention, according to another embodiment, the polishing member has a coarseness of # 800 to # 2000, and is polished while relatively moving the ceramic coating roller and the polishing member. Do.

  In the above-mentioned present invention, according to another embodiment, the finishing member is a cloth-like member woven or knitted with cotton, wool, or hemp singly or mixed with a plurality of types.

  In the present invention, according to another embodiment, the ceramic coating layer has a plurality of layers. According to another embodiment, the ceramic coating layer has two layers, and the surface ceramic coating layer contains mica.

  According to the present invention, the surface smoothness in which the ceramic coating layer is formed on the surface of the roller base material which is made of fiber reinforced plastic (fiber reinforced composite material) or metal without requiring baking after coating, and A ceramic coating roller excellent in wear resistance, heat resistance, acid resistance and solvent resistance can be obtained.

FIG. 1A is a schematic perspective view for explaining an embodiment of a ceramic coating roller manufactured according to the present invention, and FIGS. 1B and 1C are respectively a ceramic coating according to the present invention. It is the perspective view and front view explaining the surface grinding | polishing and finishing process of a roller. It is a perspective view explaining the manufacturing method of a hollow tubular fiber reinforced plastic roller base material. FIG. 3A is a cross-sectional view showing an embodiment of a ceramic coating roller having one ceramic coating layer, and FIG. 3B is a diagram of a ceramic coating roller having two ceramic coating layers. It is sectional drawing which shows another Example.

  Hereinafter, a method for manufacturing a ceramic coating roller according to the present invention will be described in more detail with reference to the drawings.

Example 1
FIG. 1A shows an embodiment of a ceramic coating roller 1 manufactured by the manufacturing method according to the present invention. Although the ceramic coating roller 1 can be a solid roller, in this embodiment, it has a roller base 2 that is a hollow roller, and a ceramic coating layer 3 formed on the outer surface of the roller base 2. ing. The ceramic coating roller 1 manufactured according to the present invention having such a configuration, as will be described in detail later, has excellent surface smoothness and excellent properties such as wear resistance, heat resistance, acid resistance, and solvent resistance. ing. Further, according to the present invention, the ceramic coating roller 1 having various dimensions can be produced. For example, a large roller having an outer diameter (D) of 500 mm or more and a length (L) of 2000 mm or more can be easily obtained. In addition, it can be manufactured with high accuracy. More specifically, for example, a diameter (D) × length (L) = 500 mm × 9000 mm, or a diameter (D) × length (L) = 1200 mm, used as a conveyance roller or a guide roller for a film or the like. A large roller such as × 2500 mm can be manufactured at low cost and with high accuracy.

Referring also to FIGS. 1 (b) and (c), the method for producing a ceramic coated roller of the present invention is as follows.
(A) a step of spraying a ceramic coating on the surface of the roller base 2 made of fiber reinforced plastic or metal to form a ceramic coating layer 3 and curing it;
(B) a step of polishing the surface of the cured ceramic coating layer 3 with a polishing member 12 containing an abrasive and then finishing with a finishing member 12A containing no abrasive;
Have

  1 (a) to 1 (c), the roller base material 2 is a fiber reinforced composite material (fiber reinforced plastic) obtained by impregnating a reinforced fiber with a matrix resin and cured, or aluminum or steel. It can produce with metals, such as. When carbon fiber reinforced plastic (CFRP) using carbon fiber as the reinforcing fiber is used for the roller base material 2, it is lightweight and can also be used as a heat-resistant roller for use in a furnace that requires heat resistance. Become.

  As the reinforcing fiber of the fiber reinforced plastic, carbon fiber is most preferable, but various other fibers can be used. For example, as the reinforcing fiber, in addition to carbon fiber, inorganic fiber such as glass fiber and basalt fiber; metal fiber such as boron fiber, titanium fiber, and steel fiber; and further, aramid, PBO (polyparaphenylene benzbisoxazole) Organic fibers such as polyamide, polyarylate, and polyester can be used alone or in a mixture of plural kinds.

  In addition, a thermosetting resin or a thermoplastic resin can be used as the matrix resin impregnated in the reinforcing fiber with the fiber reinforced plastic, and the room temperature curing type or thermosetting type epoxy can be used as the thermosetting resin. Resin, vinyl ester resin, MMA resin, acrylic resin, unsaturated polyester resin, phenol resin, or the like is preferably used, and nylon, vinylon, or the like can be suitably used as the thermoplastic resin.

  In the case of the roller base material 2 that is a hollow tube made of the above-mentioned fiber reinforced plastic or metal such as aluminum, the thickness (T) of the roller base material 2 is appropriately selected according to the application. In addition, the size is, for example, diameter (D0≈D) × length (L0 = L) = 500 mm × 9000 mm, or diameter (D0≈D) × length, depending on the desired dimensions of the product roller 1. A large roller having a length (L0 = L) = 1200 mm × 2500 mm can also be produced.

  As will be described in detail later, the ceramic coating layer 3 is formed by coating (coating formation) an inorganic ceramic coating agent, that is, a ceramic paint on the roller base material surface by spray coating. The film thickness (t) is 50 μm at the maximum, and is usually 20 μm or more (that is, 20 μm ≦ t ≦ 50 μm). When the film thickness (t) is less than 20 μm, there is a problem that the polishing margin is small and sufficient surface smoothness cannot be obtained, and when it exceeds 50 μm, there is a problem that spray coating becomes difficult. In addition, the cost increases.

Ceramic paints are blended by weight%
Silicon compound: 30-40%,
Colloidal silica: 40-50%
Organic pigments: 0-25%
-Water: 2-10%
IPA (isopropyl alcohol): 0 to 15%
Is included. However, it is not limited to this.

  Next, with reference to FIGS. 1-3, one Example of the ceramic coating roller manufacturing method of this invention is described.

(Molding of fiber base material made of fiber reinforced plastic)
In this embodiment, when a fiber reinforced plastic is used as the roller base material 2, in particular, a hollow roller (hereinafter referred to as “CFRP roller”) using a carbon fiber reinforced plastic using carbon fiber as the reinforcing fiber. explain.

  The CFRP roller as the roller base material 2 of the present embodiment can be suitably manufactured by using a filament winding method or a sheet winding method well known to those skilled in the art, but the molding method is limited to these methods. Is not to be done.

(Filament winding method)
A case where the CFRP roller 2 is manufactured by the filament winding method will be described with reference to FIG. In this embodiment, first, the carbon fiber f is wound around the mandrel 100 using a predetermined resin, and the reinforcing fiber layer 20 to be the CFRP roller 2, that is, in this embodiment, the carbon fiber layer 20 for the CFRP roller 2 is formed. Form. The carbon fiber layer 20 can be composed of a plurality of layers, for example, first to n-th carbon fiber layers 20a, 20b,... 20n, and each carbon fiber layer 20a, 20b,. Can vary the winding angle (α) of the fiber f with respect to the roller axis.

  In general, a molded product molded by the filament winding method usually has more voids than a molded product molded by the sheet winding method. Therefore, when plus or minus helical winding is performed by the filament winding method as described above, the fiber f is not crossed in the outermost layer 20n of the carbon fiber layer 2 in order to avoid formation of voids. It is desirable to use a so-called crossless winding that winds around the same angle direction only in the plus direction or only in the minus direction. Thereby, the roller base material 2 can be produced with very few voids by the filament winding method. As described above, by producing the CFRP roller 2 by a method having very few voids, it is not necessary to perform a sealing process before coating. Thus, cost reduction can be realized by omitting the steps.

  Next, taping is performed from above the carbon fiber layer 20, and the carbon fiber layer 20 is wound up, and then the mandrel 100 is placed in a curing furnace to cure the resin of the carbon fiber layer 20. Thereby, the roller base material, that is, the CFRP roller (element tube) 2 is formed.

  The CFRP roller 2 obtained as described above after removing the tape is polished to adjust the roller diameter to a predetermined dimension. The roughness Ra of the roller surface after the polishing treatment is 0.8 to 15 μm, preferably 2 to 8 μm. Thereafter, although the roller surface is cleaned, the surface blasting process as a roughening process before coating, which is normally performed, is not performed. This is because if such a surface blasting process is performed, a void may be generated on the surface of the CFRP roller.

  However, when a metal such as aluminum is used as the roller base material 2, it is preferable to perform a blasting process so that the surface has the above-mentioned surface roughness for the purpose of improving the adhesion of the subsequent coating film.

  Next, a ceramic coating layer (film layer) 3 is formed on the surface of the roller base 2 by uniformly applying a predetermined ceramic paint on the surface of the CFRP roller 2 by spray coating.

(Sheet winding method)
The sheet winding method is performed in the same manner as the filament winding method except that a sheet-like carbon fiber prepreg is used.

  In other words, when the CFRP roller 2 is manufactured by the sheet winding method, it will be described with reference to FIG. 2. First, the carbon fiber prepreg 20 is obtained so as to obtain a predetermined thickness with a predetermined laminated structure on the mandrel 100. (20a, 20b,... 20n) are wound with a predetermined fiber orientation.

  Next, after taping and winding the carbon fiber prepreg 20, the mandrel is charged into a curing furnace, the resin of the carbon fiber prepreg 20 is cured, and a roller substrate made of carbon fiber reinforced plastic, that is, a CFRP roller ( (Tube) 2 is produced.

  The CFRP roller 2 obtained as described above after removing the tape is polished so as to adjust the roller diameter to a predetermined dimension in the same manner as the filament winding method. The roughness Ra of the roller surface after the polishing treatment is 0.8 to 15 μm, preferably 2 to 8 μm. Thereafter, although the roller surface is cleaned, surface treatment such as surface blasting before coating is not performed.

  Next, a ceramic coating layer (film layer) 3 is formed on the surface of the roller base 2 by uniformly applying a predetermined ceramic paint on the surface of the CFRP roller 2 by spray coating.

(Formation of ceramic coating layer)
As described above, the surface of the CFRP roller 2 having the predetermined surface roughness is coated with a ceramic paint so that the thickness (t) is 30 μm to 50 μm by spray coating, and a ceramic coating layer (coating layer) 3 is formed (coated). Usually, the maximum film thickness (t) by one spray coating is about 50 μm.

  According to the present invention, the coated material after spray coating, that is, the ceramic coating roller 1 is allowed to stand at room temperature for about 10 to 72 hours without heating, and the coating film is cured. It is preferable to heat at about 100 ° C. in order to dry moisture more quickly and thereby prevent foreign matter from adhering to the ceramic coating roller 2.

  In this state, the surface coating of the ceramic coating roller 2, that is, the hardness of the ceramic coating layer 3 is 7H or more in pencil hardness, and the maximum is 9H.

  As shown in FIG. 3A, the spray coating of the ceramic paint on the surface of the CFRP roller 2 can be made as one ceramic coating layer 3 so that the thickness (t) is about 50 μm. As shown in FIG. 3 (b), a two-layer or more, for example, two-layer structure of a first ceramic coating layer 3a and a second ceramic coating layer 3b as a surface layer may be employed. In this case, the thickness (t1) of the first ceramic coating layer 3a is 10 to 40 μm (usually about 30 μm), and the thickness (t2) of the second ceramic coating layer 3b is 10 to 30 μm (usually about 20 μm). The total thickness of the coating layer is not limited to this, but is about 50 μm as in the case of one-time coating.

  As described above, when the ceramic coating layer 3 has a two-layer structure, the second ceramic coating layer 3b as the surface layer is polished. However, the first ceramic coating layer 3a and the second ceramic coating layer are polished. The composition of the ceramic paint can be different from that of the layer 3b. For example, although mentioned later in detail, the ceramic coating for the second layer (surface layer) 3b can contain a small amount of mica (mica). In this case, when the polishing amount reaches the first layer 3a when polishing the roller surface, that is, the surface of the second ceramic coating layer 3b, the apparent surface state changes. (That is, since the ceramic coating layer of the second layer (surface layer) 3b contains mica, the mica is exposed and polished on the surface, and a "glitter" feeling is visually observed), and before such a surface state disappears. There is an advantage that the polishing operation can be performed while visually confirming the limit of the polishing amount (polishing allowance) such as completing the polishing operation.

  According to the present invention, the ceramic coating layer 3 is formed by spray coating and does not require firing at a high temperature, so that no large-scale equipment is required. Can be easily handled at low cost.

(Surface finishing of ceramic coating layer)
The ceramic coating layer 3 spray-coated as described above is then subjected to surface polishing and finishing according to the method that characterizes the present invention. The surface polishing / finishing process will be described with reference to FIGS.

  According to the present invention, the surface of the spray-coated and cured ceramic coating layer 3 is first polished by the polishing means 10.

  The polishing means 10 includes a rotating member 11 composed of a rigid rotating body 11a made of metal or the like and an elastic body 11b attached integrally to the rotating body 11a. The rotating member 11 is rotated in a predetermined direction by driving a rotating shaft 13 integrally attached to the rotating body 11a by driving means (not shown) such as an electric motor. The polishing member 12 is installed on the opposite side of the elastic body 11b from the rotating body 11a. In the present invention, a grindstone or abrasive paper containing an abrasive is used as the polishing member 12. The “abrasive paper” is produced by using paper or cloth as a base material and adhering abrasive grains (abrasive) to the base material. As abrasive grains (abrasives), for example, garnet, aluminum oxide, silicon carbide and the like are used.

  The abrasive paper 12 that is preferably used as an abrasive member in the present embodiment is attached as a so-called wheel paper to the elastic body 11b of the rotating member 11 having a diameter of 5 to 25 cm. In this example, the roughness of the “eyes” of the wheel paper 12 was able to obtain good results using the hole paper # 1200. According to the results of our research experiments, the roughness of the “eyes” of usable wheel paper (abrasive paper) is # 60 to # 2000, preferably # 800 to # 2000. It is said.

  The rotating member 11 is arranged so that the polishing surface of the wheel paper 12 is parallel to the axis O1 of the ceramic coating roller 1, and the radius from the rotation center of the wheel paper 12 (that is, the rotation axis of the rotating shaft 13) O2. The contact area S shifted by a predetermined distance E in the direction is pressed and installed so as to contact the surface of the ceramic coating roller 2 with a predetermined pressure P.

  In this state, the ceramic coating roller 1 is changed according to the size of the roller 1, but is rotated around the roller axis O1 at 3 to 400 rpm and linearly at 0.2 to 10 cm / sec in the axial direction. Moved. The rotating member 11, that is, the wheel paper 12 is rotated at 100 to 2000 rpm, preferably 400 to 1500 rpm. The direction of rotation is reversed as necessary. Note that the polishing means 10 may be moved along the axis O1 of the roller 1 instead of moving the ceramic coating roller 1 in the direction of the axis O1. If necessary, in the polishing operation, cutting water or cutting oil can be applied as a lubricant to the contact area S between the ceramic coating roller 1 and the wheel paper 12 in order to improve slipperiness.

  Thus, in the present invention, the surface of the cured ceramic coating layer 3 of the ceramic coating roller 1 is moved relative to the roller 1 by the polishing means 10 including the polishing member containing the abrasive, for example, the polishing paper 12. Then, the finishing process is performed with the finishing member 12A that does not contain an abrasive. That is, the finishing process can be similarly performed in the polishing means 10 by using a finishing member 12A not containing an abrasive instead of the polishing member 12 containing an abrasive. The finishing member 12A is preferably a cloth-like member that is woven or knitted with natural fibers that are not chemical fibers, such as cotton, wool, or hemp, alone, or mixed. Chemical fibers are undesirable because they can dissolve during use.

  By such surface polishing / finishing process, the surface roughness (Ra) of the ceramic coating roller 1 having a surface hardness (pencil hardness H) of 7H or more and 9H or less becomes 0.2 μm or more and 1.6 μm or less. Can be finished as follows. Moreover, the precision (roundness, cylindricity, runout, etc.) of the finished ceramic coating roller 1 can be processed to 0.02 mm or less.

  Regarding the surface roughness, if the surface roughness (Ra) is less than 0.2 μm, there is a problem that it takes time and costs are increased. On the other hand, when the thickness exceeds 1.6 μm, the surface irregularities are too large to obtain sufficient surface smoothness, and when used for a film transport roller, the film is scratched and cannot be used in actual use. There is a case.

  With respect to the surface hardness (H), if it is less than 5H, there is a problem that sufficient wear resistance cannot be obtained. 9H is the maximum value in pencil hardness.

  Next, an experimental example performed to verify the performance of the ceramic coating roller 1 manufactured according to the present invention will be described.

Experimental example 1
First, as a roller base material 2 of the ceramic coating roller 1, a hollow tube made of carbon fiber reinforced plastic was produced by a filament winding method.

  In this experimental example, (1) outer diameter (D0) × length (L0) × thickness (T) = 120 mm × 1200 mm × 5 mm (sample 1) and (2) outer diameter (D0) × length (L0) Two types of hollow tubular carbon fiber reinforced plastic roller base materials 2 having x thickness (T) = 50 mm × 300 mm × 5 mm (sample 2) were produced.

  As carbon fiber f which is a reinforced fiber of carbon fiber reinforced plastic, monofilament average diameter 7 μm, converged number 12,000 fiber bundle, that is, PAN-based carbon fiber strand (“TR50” (trade name) manufactured by Mitsubishi Rayon Co., Ltd.) An epoxy resin (“HP100” manufactured by Nippon Steel & Sumikin Materials Co., Ltd.) was used as the resin.

  Further, in order to produce Sample 1 and Sample 2, carbon fibers that become the roller base material 2 at an angle of 90 ° (circumferential direction) and ± 5 ° on a mandrel having an outer diameter of 110 mm and 40 mm and a length of 2 m, respectively. It wound so that layer 20 (20a, 20b, ... 20n) might be about 5 mm thickness (fiber volume content Vf = 57%). Note that the fiber f of the outermost layer 20n of the carbon fiber layer 2A was wound at an angle (α) of 45 ° in the same direction.

  Thereafter, taping was performed using a PET tape having a width of 25 mm and a thickness of 0.1 mm, and then the mandrel 100 around which the carbon fiber layer 20 impregnated with the resin serving as the roller base material 2 was wound was placed in a heat curing furnace. The resin was cured. Thereafter, the cured carbon fiber reinforced plastic molded product (element tube) 2 was removed from the mandrel 100.

  The CFRP roller 2 demolded from the mandrel 100 is subjected to a polishing process, and (1) outer diameter (D0) = 120 mm (sample 1) and (2) outer diameter (D0) 50 mm (sample 2). A hollow tubular CFRP roller base material 2 was obtained. The roughness Ra of the roller surface after the polishing treatment was 6 μm.

  The ceramic coating layer (coating layer) 3 was formed (coated) by spraying a ceramic paint on the surface of the CFRP roller 2 thus obtained.

  In this experimental example, the ceramic coating layer 3 has a two-layer structure of a first ceramic coating layer 3a and a second ceramic coating layer 3b, as shown in FIG. Further, as shown in Table 1, the first ceramic coating layer 3a and the second ceramic coating layer 3b were differently mixed in the ceramic paint component.

  Further, the second ceramic paint (top) contained a small amount of mica (mica).

  That is, the first ceramic coating layer 3a was formed by spray coating the surface of the CFRP roller 2 using the first ceramic paint (primer). Next, after the first ceramic coating layer 3a is applied, the surface of the first ceramic coating layer 3a of the CFRP roller 2 is spray-coated using the second ceramic paint (top) to form the second ceramic coating layer 3b. Was formed and dried. The ceramic coating layers 3a and 3b were dried by inserting the CFRP roller 2 into a heating furnace after each spray coating and heating to 100 ° C.

  The thickness (t1) of the first ceramic coating layer 3a was 30 μm, and the thickness (t2) of the second ceramic coating layer 3b was 20 μm.

  In this state, the surface coating of the ceramic coating roller 1, that is, the hardness of the ceramic coating layer 3, was 9H in pencil hardness.

  The surface of the ceramic coating layer 3 that was spray-coated and hardened was polished by the polishing means 10 having the configuration shown in FIGS. 1B and 1C and finished. As the polishing member 12 attached to the rotating member 11 of the polishing means 10, that is, the elastic body 11 b, foil paper # 1200 having a diameter of 12 cm was used and pressed against the surface of the ceramic coating roller 1.

  That is, the rotating member 11 is arranged so that the polished surface of the wheel paper 12 is parallel to the axis O1 of the ceramic coating roller 1, and from the rotation center of the wheel paper 12 (that is, the rotation axis of the rotating shaft 13) O2. The contact area S shifted by a distance E = 4 cm in the radial direction was pressed and placed so as to contact the surface of the ceramic coating roller 1.

  The ceramic coating roller 1 was rotated around the roller axis O1 at 80 rpm and was linearly moved at 2 cm / sec in the axial direction. On the other hand, the rotating member 11, that is, the wheel paper 12 was rotated at 1000 rpm.

  In such a polishing operation, polishing was performed while supplying cutting water as a lubricant to the contact region S between the ceramic coating roller 1 and the wheel paper 12. Thereafter, a finishing member 12A, which is a cloth-like member using a material such as cotton that does not contain an abrasive, is attached by the polishing means 10 to finish the roller surface.

  In this experimental example, the ceramic coating layer 3 has a two-layer structure, and the ceramic coating (top) for the second layer (surface layer) 3b contains a small amount of mica (mica). When the second layer (surface layer) ceramic coating layer 3b is polished, if the first layer 3a is reached, the presence of mica cannot be visually confirmed. Decided to stop.

  In both the sample 1 and the sample 2 produced in this experimental example, the surface hardness (pencil hardness H) of the surface-finished ceramic coating roller 1 is 9H, and the surface roughness (Ra) of the ceramic coating roller 1 is The thickness was 0.2 μm. Further, the accuracy (roundness, cylindricity, runout) of the finished ceramic coating roller 1 was 0.02 mm or less.

  Also, in this experimental example, according to the present invention, the ceramic coating is performed by spray coating and does not require firing at a high temperature, so that no large-scale equipment is required, and for large product rollers. It was also found that it can be easily handled.

Experimental example 2
A ceramic coating roller 1 was obtained by spray-coating a ceramic paint using the same materials and production conditions as in the above Experimental Example 1.

  After changing the count of the wheel paper 12 in various ways and polishing, finishing was performed using a finishing member 12A that was a cloth-like member using a material such as cotton that did not contain an abrasive. It turned out that the count of the wheel paper 12 is preferably # 800 to # 2000.

  Further, although the grinding work was performed using a grindstone instead of the wheel paper as the grinding member 12, it has been found that a grindstone having the same “eyes” roughness as the wheel paper can also be used. However, also in this case, after the polishing operation, it is necessary to perform finishing using the finishing member 12A which is a cloth-like member using a material such as cotton that does not contain an abrasive.

  As can be understood by referring to the above experimental examples and the like, according to the present invention, the roller base material 2 is made of carbon fiber reinforced plastic, and such a carbon fiber reinforced plastic roller base material (CFRP base tube). The ceramic coating roller 1 using the CFRP base tube manufactured according to the present invention is heated at a high temperature because the heat-resistant ceramic paint can be applied by spray coating and cured by heating at room temperature or about 100 ° C. It can be used as an in-furnace roller in an atmosphere. For example, the roller used in the film drying process is installed in a furnace at 150 ° C., and in particular, a metal roller such as aluminum changes in accuracy as the temperature changes. The ceramic coating roller using the CFRP raw tube using the epoxy resin for use can be used without being deformed even in an environment exceeding 150 ° C. Therefore, the line speed can be improved and the film manufacturing cost can be reduced.

  Furthermore, since the ceramic coating layer 3 of the ceramic coating roller 1 manufactured according to the present invention can be removed by polishing, it can be reworked when it is aged over a long period of use. In this case, when the ceramic coating layer 3 is formed of a plurality of layers, it is possible to visually determine the deterioration over time and the state change of the roller surface, and the convenience is extremely improved.

DESCRIPTION OF SYMBOLS 1 Ceramic coating roller 2 Roller base material 3 Ceramic coating layer 3a 1st ceramic coating layer 3b 2nd ceramic coating layer 10 Polishing means 11 Rotating member 11a Rotating body 11b Elastic body 12 (12A) Polishing and finishing member 13 Rotating shaft 20 (20a, 20b, ... 20n) Carbon fiber layer (reinforced fiber layer)
100 mandrels

Claims (10)

A method of manufacturing a ceramic coating roller,
(A) a step of winding a predetermined reinforcing fiber around a mandrel with a predetermined resin to form a reinforcing fiber layer;
(B) curing the resin of the reinforcing fiber layer to produce a roller base material to be a fiber reinforced plastic;
(C) a step of spraying a ceramic coating on the surface of the fiber reinforced plastic roller substrate to form a ceramic coating layer and curing the coating;
(D) a step of polishing the surface of the cured ceramic coating layer with a polishing member containing an abrasive and then finishing with a finishing member not containing the abrasive;
A method for producing a ceramic coating roller, comprising: A method of manufacturing a ceramic coating roller,
(A) A step of winding a prepreg produced using a predetermined reinforcing fiber and a predetermined resin around a mandrel to cure the resin, and manufacturing a roller base material to be a fiber reinforced plastic,
(B) a step of spraying a ceramic coating on the surface of the fiber reinforced plastic roller base material to form a ceramic coating layer and curing the coating;
(C) after polishing the surface of the cured ceramic coating layer with a polishing member containing an abrasive, and finishing with a finishing member that does not contain an abrasive;
A method for producing a ceramic coating roller, comprising: The roller base material made of fiber reinforced plastic is formed of a plurality of reinforcing fiber layers, and the outermost fiber layer of the reinforcing fiber layer is wound around the mandrel in the same angular direction. A method for producing a ceramic coating roller according to 1 or 2 . Reinforcing fibers of the fiber reinforced plastic include: carbon fibers, glass fibers, basalt fibers, and other inorganic fibers; boron fibers, titanium fibers, steel fibers, and other metal fibers; aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, poly Organic fibers such as arylate and polyester are used singly or mixed in plural types and used in a hybrid.
The resin of the fiber reinforced plastic is a room temperature curing type or thermosetting type epoxy resin, vinyl ester resin, MMA resin, acrylic resin, unsaturated polyester resin, phenol resin, nylon or vinylon. The method for producing a ceramic coating roller according to any one of claims 1 to 3 . The finished ceramic coating roller has a surface roughness (Ra) of 0.2 μm or more and 1.6 μm or less, and a surface hardness (pencil hardness H) of 7H or more and 9H or less. The manufacturing method of the ceramic coating roller in any one of Claims 1-4 . The ceramic coating roller according to any one of claims 1 to 5 , wherein the accuracy of the finished ceramic coating roller is 0.02 mm or less in terms of cylindricity, roundness, runout, and the like. Roller manufacturing method. The abrasive member, mesh size is # 800 # 2000, claim 1-6, characterized in that performing polishing while relatively moving said polishing member and the ceramic coating roller A method for producing a ceramic coating roller as described in the above section. The said finishing member is a cloth-like member woven or knitted by mixing cotton, wool, or hemp alone or in combination of a plurality of types thereof, according to any one of claims 1 to 7 . Manufacturing method of ceramic coating roller. The method for manufacturing a ceramic coating roller according to any one of claims 1 to 8 , wherein the ceramic coating layer includes a plurality of layers. 10. The method of manufacturing a ceramic coating roller according to claim 9 , wherein the ceramic coating layer has two layers, and the surface ceramic coating layer contains mica. 10.

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