JPH05319641A - Film taking-up press roll - Google Patents

Abstract

PURPOSE:To provide a film taking-up press roll conformable to a broader and thinner film and the speed-up of manufacturing line by use of a lightweight and highly rigid CFRP by constituting the press roll from a roll shell and two shafts inserted from both the ends, and making the deflective deformation of the shell outer form correctable. CONSTITUTION:A film taking-up press roll is formed of a roll shell 1 and two shafts 5 inserted from both the ends of the roll shell 1, and the end parts of the roll shell 1 are supported by the respective shafts 5 over a desired length so that the deflecting form of the shell outer form can be corrected. For example, the roll shell 1 has bearing parts 2, 3, 6 for the shafts 5 at least in four positions in total in the inner part and end parts. Axially roll shells divided into three are connected to form the one roll shell 1, and the materials of the roll shell 1 and the shafts 5 are carbon fiber composite materials. Further, a rubber coat 4 is applied to the outside of the roll shell 1.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roll mainly used in a winding process of a wide film ultra-thin film and the like, and particularly to a contact pressure roll at the final winding.

[0002]

2. Description of the Related Art Conventionally, most of the rolls used in the manufacturing process of film paper, foil, etc. are steel rolls. However, since a steel roll has a large weight and a large moment of inertia, an aluminum roll for the purpose of reducing the weight and the moment of inertia is also used only partly. Also, in order to prevent air from being caught and to improve the quality and shape of the work at the time of the final winding, it is common to press the roll onto the outer surface of the work and wind it. The pressure roller used is also steel or aluminum, and its outer surface is generally covered with rubber.

The pressure contact roll for such an application influences the performance of the wound film depending on its nature and also affects the winding speed, so that it is regarded as the most important roll in the process and has various shapes. Things are being considered.

The simplest form is one in which journals are provided on both end faces of the roll shell and the journals are pressed against the work being wound up. In another form, the journal is applied to the inside of the roll shell via a rotary joint. Through pressure oil,
There is a structure in which the roll shell is deformed in a specific direction to control the contact pressure, and further, the bending of the roll is prevented. As the rubber shape coated on the outside of the roll shell, there are a straight shape and a crowned shape.

[0005]

Although there have been remarkable advances in film manufacturing technology in recent years, the following points are listed as the fundamental problems to be further overcome. (1) Correspondence to wide film width (2) Correspondence to thin film thickness (3) Correspondence to high production line speed The present inventors diligently respond to such technical problems As a result of conducting research and development, it has been impossible to achieve these objectives with the metal materials that have been conventionally used, and it is possible to achieve extremely high performance by using carbon fiber composite materials (hereinafter referred to as CFRP). It has also been found that it is possible to manufacture various contact pressure rolls.

The details of the conventional metal roll and the CFRP roll are as follows.

First of all, as for the first problem, that is, the width of the film is widened, it is first important that the contact pressure roll uniformly applies a contact pressure to the work to be wound. If the contact pressure is not evenly applied, curling occurs and the rolled-up film becomes a so-called drum shape and entraps air inside, resulting in devitrification and a defective product. In addition, if this is extreme, it may cause collapse of the roll. As a matter of course, this tendency is abruptly promoted as the width of the film becomes wider, that is, as the length of the contact pressure roll becomes longer.

In order to solve such a problem, it is important to suppress the deflection of the roll due to its own weight by using CFRP having a significantly higher specific rigidity than the conventional metal roll.

In order to cope with the second problem of film thinning, it is most important to reduce the tension of the winding film and to suppress the fluctuation of the tension as much as possible. If a conventional metal roll is used to achieve this purpose, the moment of inertia is extremely large, and minute tension control is impossible. Furthermore, since the roll weight is large, the mechanical loss in the bearing portion is large, and there is a limit to reducing the tension and controlling the minute tension in combination with the above reason. Therefore, in the production of ultra-thin films, the CFR is lightweight and highly rigid.
This is where the use of P rolls is desired.

The third problem, namely, the tendency of speeding up the film production line, is particularly important for reducing the manufacturing cost, but the machine base is frequently started and stopped due to the speedup, and the moment of inertia is large. In the case of the conventional metal roll, the transitional state becomes long, and the film during this period does not become a product, which causes a problem in product yield. Further, since the operation in the steady state is shortened, it becomes a big problem to measure high productivity.

From this point of view, it has been proved that the use of CFRP makes it possible to manufacture a contact pressure roll having a performance which cannot be reached by the conventional metal contact pressure roll, but also in terms of shape. We have found a method to provide high performance rolls by adopting a completely new structure different from conventional ones.

That is, as an example of a conventional contact pressure roll, in a structure in which journals are simply attached to both ends of a roll shell, no matter how CFRP has a large specific rigidity, the initial purpose is to increase the film width. It cannot be fully achieved. This is because, in the mere two-end journal pressing method, only both ends of the roll shell are pressed against the work and the central part is bent, so that a sufficient contact pressure cannot be obtained.
Since this tendency is proportional to the cube of the roll length, it has a very large effect.

In order to avoid such problems, there is also a method in which pressurized oil is passed through the inside of the roll shell through a rotary joint to bend the roll shell toward the winding film side to offset the bending caused by contact pressure. This method is very disliked because it requires a very large-scale apparatus and further uses oil, which may stain the winding film. Also, a method of utilizing air pressure instead of the above-mentioned oil pressure can be considered, but it is not generally used because of danger. On the other hand, it is also very common to apply a crown to the rubber shape covering the outer peripheral surface of the roll shell in accordance with the bending expected after the contact pressure.

However, although crowning has a considerable effect, it does not always exhibit sufficient performance because it is subtly changed depending on the hardness, surface shape, line speed, etc. of rubber and crowning is performed empirically. Absent.

For these reasons, the development of a truly high-performance pressure contact roll is desired. Therefore, the problem to be solved by the present invention is to widen, thin and manufacture a film as described above by using CFRP that is lightweight and has high rigidity, which is impossible with the conventional metal contact rolls. It is to provide a new contact pressure roll that can respond to speedup of the line.

[0016]

Although the basic structure of the present invention is to use CFRP as a constituent material of a roll shell, the feature of the present invention is that the structure of the roll is as shown in FIG. Specifically, the roll shell 1 has four bearing portions, and two shafts (shafts) 5 are inserted from the left and right ends of the roll shell 1, and the roll shell 1 is inserted by the shafts through the bearing portions. The support is provided at a plurality of locations from the inside so that the bending deformation of the roll shell 1 caused by the contact pressure of the contact pressure roll to the winding film is corrected.

In FIG. 1, reference numeral 2 denotes a pair of inner bearing housings which are arranged inside the roll shell 1 at a predetermined interval, and end bearing housings 3 are fixed to both ends of the roll shell 1, respectively. .. A pair of shafts 5 are inserted into the bearing housings 2 and 3 from both ends of the roll shell 1, and the shafts 5 rotatably support the roll shell 1 via bearings 6. Further, the end portions of the shaft 5 protruding from both ends of the roll shell 1 are also fulcrum bearings 7.
And the load bearing 8.

By adopting such a structure,
We have made it possible to manufacture long contact rolls that can sufficiently cope with wider film widths. Moreover, the amount of bending or the load of the roll shell 1 does not necessarily have to be initially determined, and can be set arbitrarily while checking the winding state of the film, so that the most convenient winding state can be obtained. Therefore, the above-mentioned inconvenience of the crown roll does not occur. Further, the shafts 5 inserted from the left and right can not only serve to suppress the bending force of the roll shell 1 but also serve as a rotating torque or a brake, and for this reason, the tension of the film can be delicately controlled. Became possible.

That is, one of the pair of left and right roll shafts 5 is rotated to serve as a so-called tendency.
By stopping the other and playing the role of a brake, it becomes possible to theoretically reduce the film tension to zero.
It has become possible to manufacture contact pressure rolls for thin film. As a matter of course, it is possible to double the effect of tendency by rotating both shafts 5, and it is also possible to stop both shafts 5 before use.

Next, the method for producing the contact pressure roll of the present invention will be described in detail.

The roll shell 1 is formed of carbon fiber by filament winding or a sheet wrapping method. The important point here is that fiber orientation must be performed so as to increase the elastic modulus in the axial direction as much as possible. Since rotational balance and uniformity of elastic modulus of the roll shell 1 are extremely important, it is necessary to perform rotational curing or vertical curing for curing. Element tube 1 molded in this way
Remove a from the mandrel and cut it to the required length. In this case, there is a method in which the roll shell 1 is divided into three parts in the axial direction and the inner bearing 6 is attached to the joint part of each roll shell, although it depends on the manufacturing method.

In the case of such a system, the central shell 1a
The bearing 6 is joined to and the bearing inner diameter is finished to the required accuracy.
Next, to join the tube 1a at both ends to the tube 1a at the center,
Adhesion, fixing with bolts or pin 9 as shown in FIG.
A fixing means such as joining is adopted, but in order to have sufficient reliability against repeated bending fatigue, the above means are combined and used. Furthermore, it is necessary to process the bonding surface of the joint portion of the raw pipe 1a into a step shape as shown in FIG. 2 to suppress the shear stress of the joint portion to a low level.

The bearing portions arranged at both ends of the central raw pipe 1a may be joined to the end raw pipe 1a in advance, or may be joined after the three raw pipes 1a are joined. Good. After this, the bearings at both ends are finished to the required accuracy. The roll shell core thus produced is wrapped with rubber and vulcanized, and the outer peripheral surface of the rubber is polished to complete the roll shell body.

The above is the manufacturing method in the case of the method of joining the roll shells 1, but there is also a method of manufacturing with one roll shell 1 as shown in FIG. In this case, the bearing portion inside the roll shell is cold-fitted or press-fitted to form a hole for injecting an adhesive from the outer surface of the roll shell 1, and the adhesive is injected from the outside. Further, if necessary, bolting or pinning is carried out to prevent displacement within the bearing portion.

In this case, as a matter of course, it is necessary to machine and finish the inner surface of the inner bearing portion to a predetermined size in advance. Although such a manufacturing method is excellent in terms of reliability at the joint portion of the roll shell 1, when manufacturing a very long roll shell 1, there are limits in terms of equipment and devices, and there are restrictions. is there.

Next, since the shaft 5 rotates at a high speed like the roll shell, low inertia is desired.
It is preferable to manufacture in.

[0027]

EXAMPLES The present invention will be specifically described below with reference to examples.

(Example 1) Inner diameter 220 of roll shell core
mm, outer diameter 265 mm, rubber outer diameter 300 mm, length 7150 mm
The contact pressure roll for film winding of the three-joint type was manufactured. The distance between the bearing cores at both ends and the inside and between the insides was 1620 mm and 3850 mm, respectively. Since it is a triple splice, the roll shells were stacked stepwise for the purpose of improving the reliability of the adhesive strength between the roll shells, and pinning was performed from the outer surface of the roll shell to the internal bearing portion.

A carbon fiber Pyrofil HR40 manufactured by Mitsubishi Rayon was used as the material of the roll shell tube, and an epoxy resin was used as the matrix resin, which was molded by the filament winding method. The carbon fiber is a high elastic carbon fiber, and the Young's modulus in the axial direction of the finished composite is 1
At 6000 kg / mm ² , the specific gravity was 1.56 gr / cm ³ . The roll shell core thus produced was coated and vulcanized with neoprene rubber, and the polishing shell was balanced to complete the roll shell.

On the other hand, for the shaft, the same carbon fiber as above was used, and only the bearing portion was made of steel. CF of shaft
The outer diameter of the RP part is 170 mm, the inner diameter is 111 mm, and the total length is 2
It was 032 mm. When the roll shell and shaft manufactured in this way are combined and used as the contact pressure roll in the final winding process of the 5 mm thick polyester film production line, there is very little air entrapment and the line speed can be increased. Became. The amount of air entrapped in the rolled-up film was 10% or less, which was less than half of the conventional value. The line speed was 300 m / min, which was 1.7 times that of the conventional one, and it was confirmed that the contact pressure roll according to the present invention is extremely effective.

(Example 2) Inner diameter of roll shell core 200
mm, outer diameter 250 mm, rubber outer diameter 280 mm, length 5700 mm
The contact pressure roll for film winding of the one roll shell method was manufactured. Since both ends of the roll shell were made of steel of 50 mm each, the length of the CFRP portion was 5580 mm. As for the method of manufacturing the raw tube, it was manufactured by filament winding as in Example 1. The same carbon fibers and matrix resin as those used in Example 1 were used.

The bearing portion inside the roll shell was finished to a predetermined accuracy and then cooled with liquid nitrogen and then fitted to the inside diameter of the roll shell. The diameter of the roll shell inner diameter surface and the bearing outer diameter surface was 0.15 mm. After cooling and fitting in this way, a hole was punched from the outside of the CFRP and an adhesive was injected. By doing so, it was possible to have both the effect of press fitting and the effect of adhesion. The bearing core distance between both ends and inside of this contact pressure roll is 1225 mm and 3200 mm, respectively.
And The roll shell core thus manufactured was coated and vulcanized with neoprene rubber in the same manner as in Example 1, and polishing balance was taken to manufacture a roll shell.

As for the shaft, CF is used as in the first embodiment.
Made of RP. The inner diameter is 93, the outer diameter is 160 mm, and the total length is 1.
It was 5888 mm. Similar to Example 1, only the bearing portion was made of steel. When the roll shell and shaft produced in this way were combined and used as a contact pressure roll in the final winding step of the polyester film production line of thickness 5,
Very little air entrapment and a line speed of 3
It has become possible to increase the pressure to more than 00 m / min, and it has been found that the contact roll according to the present invention is very effective.

[0034]

As described above in detail, the film winding contact pressure roll according to the present invention has a plurality of bearings in the roll shell and has a special structure in which the bending is corrected by the shafts inserted from both ends. Therefore, the amount of bending is small, and therefore, the wound film does not entrap air and a high quality film can be manufactured.

When CFRP is used as the material of the roll shell and the shaft, the start-up / shutdown time of the apparatus is shortened because of its light weight, low inertia and high rigidity, and the product yield is improved. In addition, since it has low inertia and enables delicate tension control by changing the rotation mode of the shaft, it becomes possible to manufacture a thin film, especially when used as a contact pressure roll when manufacturing a film such as polyester. Suitable.

[Brief description of drawings]

FIG. 1 is a longitudinal sectional view showing an internal structure of a film winding contact pressure roll according to the present invention.

FIG. 2 is a cross-sectional view showing the joint structure of a roll shell core tube joined together.

[Explanation of symbols]

 1 CFRP roll shell 2 Inner bearing housing 3 Both end bearing housing 4 Outer coated rubber 5 CFRP shaft 6 Bearing 7 Support point bearing 8 (Load bearing) bearing 9 pin

[Explanation of symbols]

Claims (4)

[Claims] 1. A roll shell and two shafts inserted from both ends of the roll shell, wherein the end portion of the roll shell is supported by each of the shafts for a desired length, and the bending shape of the shell outer shape is corrected. A film winding contact pressure roll characterized by being made possible. 2. The contact pressure roll for winding a film according to claim 1, wherein bearings for a shaft are provided at least at four locations inside and at the end of the roll shell. 3. The film winding contact pressure roll according to claim 1, wherein a roll shell divided into three parts in the axial direction is joined to form one roll shell. 4. The film winding contact pressure roll according to claim 1, wherein the material is a carbon fiber composite material.