WO2004013399A1 - Process for forming rollers to use in plants for continuous surface lapping of fabrics by abrasive steel laminar elements - Google Patents

Abstract

Process for the formation of an abrasive coating on operative rollers (110) in plants for continuous lapping of fabrics by application to said rollers of metal laminar elements (85) having an abrasive surface, and by means to assist formation and application of said laminar elements.

Description

⁵ . Process for forming rollers to use in plants for continuous surface lapping of fabrics by abrasive steel laminar elements

The invention concerns a process for the formation of rollers for continuous surface lapping of fabrics.

Presently known plants and process for changing the appearance of ° fabrics by mechanical means comprise lapping rollers around which a fabric is 'stretched, said fabric unwinding from one roller and, after lapping, winding onto another roller for collection.

Before passing between the lapping rollers, the fabric is immersed in a bath containing water or some other liquid but also including 5 substances that combine with the abrasive action to produce certain special effects on the treated materials.

The operative surfaces of the lapping rollers can be separated into areas of different shapes and sizes with spaces or channels in between. 0 The most difficult part of the process obtainable with these plants ■ naturally concerns preparation of the rollers.

Added to the difficulties of forming abrasive areas of the desired type and size, there is also that of forming channels or spaces between the abrasive areas having not only operative edges but also shaped to assist the flow of liquid and the discharge of material removed by abrasion.

These problems are aggravated by the frequent need to change ^' rollers as their working surfaces wear down. Purpose of the present invention is to define a process able to provide the required abrasive surfaces simply and less expensively as will now be explained.

Subject of the invention is a process for easy formation and application of the abrasive coating to the rollers in plants for the continuous lapping of fabrics. Metal laminar elements, preferably of stainless steel, are prepared and given an abrasive coating; the elements can take the form of lengths of a self-adhesive abrasive band.

The abrasive coating can be applied to the metal laminar elements by electrodeposition. The laminar elements can be square, rectangular, rhombic or may ^' take the form of a cylindrical sleeve.

Electrodeposition on the cylindrical laminar elements is carried out by electrodeposition rollers.

Electrodeposition of the abrasive coating on the laminar elements can be done to a certain pattern by previously placing a perforated sheet over said laminar elements so that deposition is only applied at the position of the perforations.

In other types of execution electrodeposition to produce a certain pattern is done with a coating consisting of a layer, made by silk- screening or photo-engraving, where the perforated areas form the pattern. In one type of execution the length of abrasive self-adesive band is wound spirally round the operative roller. The two ends of the band can be held firm at each end by a clamp.

The turns of the band can be either close together or else separated so that a helical groove is formed.

In one type of execution the lengths of self-adhesive abrasive band are applied longitudinally to the operative roller. These lengths are about as long as the roller itself, or can be shorter and be applied in a variety of lines separated by longitudinal and circumferential channels.

The rhombic laminar elements are mounted on the operative roller in

^' aligned or unaligned rows to create this particular shape, with two helical channels facing the opposite way so that one channel assists diffusion of the liquid in the wet lapping process, and the other assists discharge of the abraded particles.

The square or rectangular laminar elements and the lengths of self- adhesive band are mounted on the operative rollers so as to leave beween them longitudinal aligned or unaligned channels connected by circumferential channels. In one type of execution the rollers for electrodeposition of the abrasive coating and those for lapping the fabric are made of rubber to facilitate application of the cylindrical sleeve. In another type of execution said rollers for electrodeposition of the abrasive coating and the rollers for lapping the fabric are slightly tapered to facilitate application of the cylindrical sleeve.

In one advantageous type of execution said rollers for electrodeposition of the abrasive coating and the rollers for lapping the fabric present an internal sealed chamber communicating with the cylindrical surface of the rollers through a series of holes, with a valve at one end for admission and discharge of compressed air as required. When the cylindrical sleeve is being put on or taken off, the presence of compressed air makes possible creation of an air cushion between the surface of the rollers and of the sleeve making it easier to. slide trie sleeve on and off. Once the sleeve is in position the compressed air can be discharged so that the sleeve adheres securely to the roller. The invention offers evident advantages.

Application of lengths of abrasive self-adhesive band or of laminar elements with an outer abrasive surface not only eliminates the most costly and difficult part of preparing the surfaces of operative rollers but also assists their replacement: The abrasive elements can be varied as desired, and therefore:

- the size of the abrasive surface;

- the space between the various areas; - the type of abrasive;

- the degree of fineness of the abrasive, etc.

The electrodeposition rollers and the operative rollers with chamber for compressed air, not only assist formation of a cylindrical laminar sleeve but also its application as well as facilitating replacement of the operative roller.

Formation of patterned abrasive areas by simply mounting a perforated sheet prior to electrodeposition makes possible the creation of abrasive areas -of any shape and size. The present invention as here described not only drastically lowers lapping costs but also offers the possibility of an unlimited variety. Characteristics and purposes of the invention will be made still clearer by the following examples of its execution illustrated by diagrammatical ly designed figures. Fig. 1 Application of an abrasive self-adhesive band spirally on an operative roller, perspective.

Fig. 2 As above,showing patterned abrasive areas on the self- adhesive band, perspective. Fig. 3 Roller with abrasive self-adhesive band wound spirally, held at each end by clamps, perspective.

Fig. 4 Roller with a wide abrasive self-adhesive band wound spirally, perspective. Fig. 5 Roller with lengths of abrasive self-adhesive band, as long as the roller itself, mounted longitudinally, perspective.

Fig. 6 Roller with short lengths of abrasive self-adhesive band mounted in longitudinal lines, pespective.

Fig. 7 Rectangular oblong metal lamina with one face protected by a self-adhesive strip and the other partly covered by a perforated sheet, perspective.

Fig. 8 The lamina in Figure 7 after electrodeposition of abrasive, perspective.

Fig. 9 Square metal lamina with one face protected by a self- adhesive sheet to permit electrodeposition of abrasive on the free face, perspective.

Fig. 10 Rhombic metal lamina with one face protected by a self- adhesive sheet to permit electrodeposition of abrasive on the free face, perspective. Fig. 11 Oblong abrasive laminae as in Figure 8, mounted on an operative roller and held stable by clamps at each end, perspective.

Fig. 12 Square laminae coated with abrasive, glued onto an operative roller, perspective.

Fig. 13 Rhombic laminae coated with abrasive, glued onto an operative roller, perspective.

Fig. 14 Roller for electrodeposition on metal sleeves, with an inner sealed chamber for compressed air, circumferential through perforations and valve at one end, perspective.

Fig. 15 The roller in Figure 14 after application of a metal cylindrical sleeve for electrodeposition of abrasive, perspective.

Fig. 16 The roller in Figure 15 after electrodeposition of abrasive on the sleeve, perspective. Fig. 17 Operative roller with inner sealed chamber for compressed air, circumferential through perforations and valve, when the sleeve taken from the electrodeposition roller in Figure 16 is being fitted on, perspective. Fig. 18 Electrodeposition process, when the sleeve is being covered by a perforated sheet to produce patterned areas, perspective. Fig. 19 Operative roller as in Figure 17 with a sleeve obtained by the process in seen in Figure 18, perspective. Figure 1 shows the operative roller 10 of a machine for treating fabrics, whose surface is rendered abrasive by means of an abrasive self-adhesive band 15 unwound from a reel 16 and spirally wound on, by separated turns, little by little detaching the protective strip 17. The band is firmly fixed on, both by the adhesive 16 and by the two clamps 18, one at each end, as shown in Figure 3. The abrasive surface is formed of .diamond particles 20.

Figure 2 shows a process similar to that described in Figure 1 , with he band 30 from a reel 31 , except that this band has small circular abrasive areas 35. Figure 4 shows the coating on an operative roller 40, made by the turns of a wide abrasive self-adhesive band 41. The channel 45 left between turns is narrower. Figure 5 shows an operative roller 50 with longitudinal channels 51 separating longitudinal areas on which lengths 55 of abrasive self- adhesive band have been laid. Figure 6 shows an operative roller 60 the abrasive surface of which is formed by application of lengths 61 of abrasive self-adhesive band leaving free channels, longitudinal 65 and circumferential 66. Figure 7 shows a rectangular oblong metal lamina 70 protected on one face by a self-adhesive strip 71 to be placed in a bath for electro- deposition. to obtain the diamond-coated surface 75 seen in Figure 8. The adhesive sheet 76 with perforations 77 is seen on the right. After electrodeposition there will be diamond-coated areas 78, at the positions of the holes 77 in sheet 76.

Figures 9 and 10 show square and rhombic laminae, respectively 80 and 85, whose surfaces 81 have been made abrasive by electrodeposition.

Figure 11 illustrates application of rectangular oblong laminae 70 to an operative roller 90, their surface 75 having been made abrasive as seen in Figure 8.

The laminae 70 are held in place by clamps 18 at each end, also by glueing if required.

Figure 12 shows application by glueing of the square laminae 80 seen in Figure 9 to an operative roller 100.

As Figure 12 shows, the laminae 80 are deposited so as to leave circumferential grooves 101 connected by longitudinal unaligned grooves 102.

Figure 13 shows application by glueing of the rhombi 85, seen in

Figure 10, to an operative roller 110.

These rhombi 85 are so placed as to create among them two helical channels, respectively 115 and 116, that cross over each other. This pattern is of special interest as rotation of the roller produces a screwing effect of the channels in opposite directions. One channel can assist flow of liquid during the wet treatment and the other assist discharge of abraded particles.

Figure 14 shows an electrodeposition roller of plastic material 120, with pins 121 , that comprises a sealed chamber 125 connected to the outer cylindrical surface by perforations 126 passing through, and by the valve 127 at the end 122.

Through the valve 127, compressed air is admitted to the sealed chamber 125 forming an air cushion that permits a metal sleeve 130 (Figure 15) to slide on more easily. Once the sleeve 130 is fully in position, the compressed air is let out through the valve 127 so that the sleeve settles down on the electrodeposition roller and adheres closely to it, as seen in Figure T5. The abrasive coating 135, obtained by electrodeposition, is seen in Figure 16 where said electrodeposition roller 120 is shown at the end of the treatment. ^■ Figure 17 illustrates an operative roller 140, with pins 141 , this one too having a sealed air chamber 145 connected to the outer cylindrical surface through perforations 146 and the valve 147. In said Figure 17 the sleeve 130, coated with abrasive 135 on the electrodeposition roller 120, (Figure 16), is here drawn to show it during application to the operative roller 140. Compressed air emerging through the perforations 146 creates the air cushion that assists application. Once the sleeve is on, compressed air is released through the valve 147 allowing the sleeve to adhere firmly to the operative roller. Figure 18 shows the electrodeposition roller 120 carrying a sleeve 150 to be given the electrodeposition treatment, the sheet 155 with perforations 157 being already placed on it. ^' The figure shows these areas as circular but the shape can of course be any other preferred.

Figure 19 illustrates the operative roller 140 to which the sleeve 150 has been applied after electrodeposition by means of the roller 120. This sleeve is covered with small circular diamond-coated areas 160.

Claims

1. Process for forming abrasive coatings on operative rollers (10, 40, 50, 60, 90, 100, 110, 140) in plants for the continuous lapping of fabrics, characterized in that the abrasive surface is obtained by application to said rollers (10, 40, 50 60, 90, 100, 110, 140) of metal laminar elements (15, 70, 80, 85, 130, 150) with abrasive surfaces and by means to assist formation and application of said laminar elements. 2. Process as in claim 1 , ^' characterized in that the metal laminar elements (15, 70, 80, 85, 130, 150) are of stainless steel. 3. Process as in claim 1 , characterized in that the metal laminar elements consist of lengths (55, 61 ) of an abrasive self-adhesive metal band (15). 4. Process as in claim 3, characteized in that the length of abrasive self-adhesive metal band (15) is spirally wound round an operative roller (10).

5. Process as in claim 4, characterized in that the two ends of the abrasive self-adhesive metal band (15) are made even more stable by applying clamps (58).

6. Process as in claim 4,

^• characterized in that the ^'turns of the abrasive self-adhesive metal band (15) are in contact one with another.

7. Process as in claim 4, characterized in that the turns of the abrasive self-adhesive metal band (15) are separated so forming a helical channel.

8. Process as in claim 3, characterized in that the lengths (55) of abrasive self-adhesive metal band (15) are laid longitudinally on the operative roller (50). 9. Process as in claims 3 and 8, characterized in that the lengths (55) of abrasive self-adhesive metal band (15) are about as long as the operative roller (50) itself.

10. Process as in claim 3, characterized in that the lengths (61 ) of abrasive self-adhesive metal band (15) are shorter than the operative roller (60) and are laid in lines divided by channels, longitudinal (65) and circumferential (.66). 1 ^'1. Process as in claim 1 , characterized in that the abrasive coating on the metal laminar elements (70, 80, 85, 130, 150) is applied by electrodeposition. 12. Process as in claims 1 and 11 , characterized in that the metal laminar elements (80) are square. 13. Process as in claims 1 and 11 , characterized in that the metal laminar elements (70) are rectangular.

14. Process as in claims 1 and 11, characterized in that the metal laminar elements (85) are rhombic.

15. Process as in claim 14 characterized in that the rhombic laminar elements (85) are laid on an operative roller (110) in rows aligned and unaligned so as to create between said elements (85) two helical channels (115, . 116) facing in opposite ways to assist the spread of liquid in the wet lapping process through one channel and to assist discharge of abraded particles through the other channel.

16. Process as in claim 1 , characterized in that the metal laminar elements are formed of cylindrical sleeves (130, 150).

17. Process as in claims 1 and 16, characterized in that electrodeposition is applied to the sleeves (130, 150) by rollers (120) for electrodeposition.

18. Process as in claims 1 , 16, 17, characterized in that the rollers (120) for electrodeposition of the abrasive coating and the rollers (140) for lapping the fabrics, each present an inner sealed chamber (125, 145), communicating with the cylindrical surface of said rollers through a series of perforations (126, 146), and a valve (127, 147) at one end for admission and discharge, as required, of compressed air which, during application ^• and removal of the cylindrical sleeves (130, 150), creates an air cushion between the surface of the rollers (120, 140) and said sleeves, that therefore slide on more easily while, when application is completed, discharge of the compressed air promotes stable adherence between sleeve (130, 150) and roller (120, 140).

19. Process as in claims 1 , 16, 17, characterized in that the rollers (120) for electrodeposition of the abrasive coating, and rollers (140) for lapping the fabrics are made of rubber to assist application and removal of the sleeves (130, 150).

20. Process as in claims 1 , 16, 17, characterized in that the rollers (120) for electrodeposition of the abrasive coating and rollers (140) for lapping the fabrics are slightly tapered to assist application and removal of the sleeves (130, 150). 21. Process as in claims 1 and 11 , characterized in that, prior to electrodeposition, the laminar elements (70, 80, 85, 130, 150) are clad, by silk-screening, with a layer comprising patterned perforated areas so that electrodeposition is limited to those areas whose position corresponds to that of. said perforated areas.

22. Process as in claims 1 and 11 , charactrized in that, prior to electrodeposition, the laminar elements (70, 80, 85, 130, 150) are clad, by photo-engraving, with a layer in which there are pattern-forming perforated areas, electrodeposition being there confined to said areas.

23. Process as in claims 1.and 11 , characterized in that, prior to electrodeposition, the laminar elements (70, 80, 85, 130, 135) are clad with a sheet (76, 155) containing pattern-forming perforated areas (77, 157), electrodeposition being confined to the areas (78, 160) of said laminar elements the position of which corresponds to that of said perforated areas.