WO2019184092A1 - 一种起皱刀及其制备方法 - Google Patents

一种起皱刀及其制备方法 Download PDF

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Publication number
WO2019184092A1
WO2019184092A1 PCT/CN2018/090759 CN2018090759W WO2019184092A1 WO 2019184092 A1 WO2019184092 A1 WO 2019184092A1 CN 2018090759 W CN2018090759 W CN 2018090759W WO 2019184092 A1 WO2019184092 A1 WO 2019184092A1
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WIPO (PCT)
Prior art keywords
protective layer
creping blade
creping
resistant coating
substrate
Prior art date
Application number
PCT/CN2018/090759
Other languages
English (en)
French (fr)
Inventor
周静
周子超
Original Assignee
赣州恩创科技有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 赣州恩创科技有限公司 filed Critical 赣州恩创科技有限公司
Priority to EP18911993.6A priority Critical patent/EP3779037A4/en
Publication of WO2019184092A1 publication Critical patent/WO2019184092A1/zh
Priority to US17/031,835 priority patent/US11951708B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F—MECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00—Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/12—Crêping
    • B31F1/14—Crêping by doctor blades arranged crosswise to the web
    • B31F1/145—Blade constructions
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21G—CALENDERS; ACCESSORIES FOR PAPER-MAKING MACHINES
    • D21G3/00—Doctors
    • D21G3/04—Doctors for drying cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0207—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section of particular shape or construction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0284—Laminating honeycomb cores; applying cover sheets to core edges; working core edges
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/322—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer only coatings of metal elements only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/341—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with at least one carbide layer
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/34—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates
    • C23C28/347—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one inorganic non-metallic material layer, e.g. metal carbide, nitride, boride, silicide layer and their mixtures, enamels, phosphates and sulphates with layers adapted for cutting tools or wear applications
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/129—Flame spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment

Definitions

  • the invention relates to a creping knife and a preparation method thereof, in particular to a creping knife applied to prepare household paper and a preparation method thereof.
  • the creping knife is an important part in the process of producing a household paper, and the role in the production process is to peel the paper from the surface of the dryer while applying the necessary pressure to the contact paper surface to form a wrinkle-like structure on the surface of the paper.
  • the creping knife In order to meet the requirements of the wrinkle process, the creping knife should have the following main properties: good wear resistance, suitable sharpness of the creping blade edge, contour geometry conforming to the performance requirements of paper strength, bulk, etc., creping knife base Suitable for rigidity and elasticity.
  • creping knives are basically divided into two categories: steel creping knives and coated creping knives.
  • the steel creping knife is the earliest creping knife used in the production of household paper and is still widely used.
  • a schematic view of a steel creping knife is shown in Figure 1.
  • the wear resistant coating is generally a ceramic material or a composite material containing carbides, and such creping knives are collectively referred to as ceramic creping knives.
  • the ceramic creping knives currently available in the market have substantially the same structure, as shown in Fig. 3.
  • the shaded portion is a ceramic coating, and the ceramic coating is only present on the working surface portion, and there is no apical surface at the creping blade. coating.
  • the contact between the coating of the ceramic creping knives and the dryer is usually pre-ground with a small transition angle.
  • the top of the transition angle of the ceramic coating is used instead of the steel substrate to contact the dryer. . Since the wear resistance of the coating is much higher than that of the steel, the purpose of improving the wear resistance of the creping blade and prolonging the life of the creping blade can be achieved.
  • the second drawback of the ceramic creping knife is that the working edge is prone to a small irregular irregularity as shown in Fig. 4 (Fig. 4 is only for illustration, the specific size is subject to the actual situation), resulting in the appearance of paper. Vertical stripes.
  • ceramic materials are brittle, which is easy to cause cracking of the cutting edge during processing and use.
  • Stripe which affects the quality of paper products, can lead to direct failure of the creping knife and shorten the life of the creping cutter.
  • creping knives with new forms/materials are required to be supplied to related tissue paper manufacturers to improve product quality and reduce production costs.
  • an object of the present invention is to provide a creping knife which is provided with a protective layer to improve the self-sharpness of the creping blade and reduce the probability of the creping knife, which has a longer use. Lifespan, and the paper thus produced has a better quality.
  • the present invention provides a creping blade comprising a base body having a wear-resistant coating at the top end thereof, and a wear-resistant coating layer at a contact point of the creping blade with the drying cylinder A protective layer is provided and the hardness of the protective layer is lower than the hardness of the surface of the paper machine dryer.
  • the working surface of the substrate refers to the side surface of the dryer which is close to the paper machine during the working process; the top portion refers to the portion of the paper which is detached from the surface of the dryer during the working process.
  • the surface contacting the paper is referred to as the top surface; the contact point is the portion where the creping blade contacts the surface of the dryer during operation;
  • the thickness of the substrate refers to the thickness of the top surface perpendicular to the surface of the dryer before the substrate is processed;
  • the width refers to the size of the top end of the creping blade to the unprocessed inclination, the uncoated front, and the length of the creping blade refers to the dimension along the axial direction of the dryer.
  • one side of the wear-resistant coating at the contact point of the creping knife and the surface of the dryer will contact the surface of the dryer to peel the paper from the surface of the dryer, and the peeled paper will be worn with the wear-resistant coating.
  • the abrasion resistant coating exerts a certain amount of pressure on the paper surface to form a wrinkle-like structure on the surface of the paper.
  • the wear-resistant coating can strengthen the strength of the impact surface of the paper during use, effectively preventing the damage of the creping knife caused by the impact, and The paper faces the scratch damage caused by the continuous rubbing of the top of the creping blade.
  • the present invention can protect the dryer by providing a protective layer under the wear-resistant coating at the contact point of the creping blade and the dryer.
  • the hardness and wear resistance of the protective layer are lower than that of the drying cylinder, and when the working part of the creping blade (ie, the side of the wear-resistant coating contacting the surface of the dryer) is passivated or subjected to a large impact force, the creping blade The mouth (protective layer) collapses, causing the creping knife to come out of contact with the dryer, thereby reducing the chance of the creping knife damaging the dryer.
  • the protective layer may be located between the wear-resistant coating and the top surface of the substrate (as shown in FIG. 5), or may be disposed along the working surface of the substrate, or may be distributed between the wear-resistant coating and the top surface of the substrate, Set along the working surface of the base.
  • the protective layer when the protective layer is disposed along the working surface of the substrate, the protective layer is located at a location on the working surface of the substrate adjacent the wear resistant coating, as shown in FIG. Also, in this case, the side of the protective layer close to the top end face of the substrate should also be covered with a wear resistant coating.
  • the protective layer does not need to cover the entire working surface, and has an appropriate width along the working surface, as shown by w' in FIG.
  • the manner of setting may include the following: the first mode: the protective layer protrudes from the working surface of the base body (as shown in FIG. 6); or, the second mode: the top end of the base body There is a notch, the protective layer is located in the notch, and the outer surface of the protective layer is in the same plane as the working surface of the base body (as shown in FIG. 7-10); or, the third mode: the top end of the base body is provided There is a gap, and the protective layer comprises two parts, one part is located in the notch and the other part protrudes from the working surface of the base body (as shown in Fig. 11 and Fig. 12).
  • the cross section of the protective layer may be any suitable shape such as a triangle, a diamond, a trapezoid, another regular shape or an irregular shape, as shown in FIGS. 7-12.
  • the hardness of the protective layer can be controlled to ⁇ HV 0.3 300, preferably HV 0.3 100-300, more preferably HV 0.3 130-250, more preferably HV 0.3 150-220, depending on the circumstances You can choose 140, 160, 180, 200, 220, 240, 260, 280, and so on.
  • the protective layer may be made of any material capable of satisfying the above hardness requirements, preferably a softer metal or alloy material including one of copper, aluminum, zinc, tin, nickel, cobalt and magnesium; the above alloy includes An alloy composed of at least two of copper, aluminum, zinc, tin, nickel, cobalt, and magnesium.
  • the wear resistance and strength of the protective layer are generally relatively lower than those of the wear resistant coating.
  • the creping knives are generally long (up to about 4 meters in length), similar to a long steel strip, the protective layer is similar to a strip embedded at the top of the steel strip, and, in the preferred case, the protective layer can be with the steel strip The same thickness.
  • the thickness of the protective layer can be controlled to be from 0.1 to 2.0 mm, preferably from 0.3 to 1.0 mm.
  • the thickness refers to the size of the outer surface of the protective layer to the surface of the substrate, as shown by h' in FIGS. 6-10, when the thickness of each part of the protective layer is inconsistent, the thickness means that it is close to the wear-resistant coating portion.
  • the thickness of this portion of the protective layer should have a suitable thickness to ensure that it does not wear to the base portion during wear, as shown in Figures 7 and 10.
  • the wear resistant coating has a thickness of from 0.03 to 0.25 mm, preferably from 0.05 to 0.12 mm, further preferably from 0.03 to 0.1 mm.
  • the wear-resistant coatings are relatively thick. Due to their high hardness, the tip portion will wear out over time, and an arc (or rounded corner) appears along with the arc. Increasingly large, the paper grain will become thicker and the quality will decrease.
  • the creping blade of the invention is provided with a protective layer having a hardness lower than that of the drying cylinder.
  • the wear-resistant coating is in contact with the surface of the drying cylinder on the side of the working surface and the side of the protective layer on the working surface, and wrinkles
  • the base of the knife is not in contact with the drying cylinder, the area of the contact portion between the wear-resistant coating and the drying cylinder remains unchanged, and the contact area between the protective layer and the drying cylinder is slightly changed, because the hardness and wear resistance of the protective layer are far less than the drying.
  • the contact portion between the protective layer and the surface of the drying cylinder will wear synchronously with the wear of the wear-resistant coating, so the contact surface between the working surface and the drying cylinder is not limited, and the contact angle of the creping knife with the drying cylinder during the working process Can be kept constant without rounding.
  • the working edge portion can be always sharp, and the paper grain of the paper can be kept relatively thin and does not follow the use time.
  • the elongation is thickened and the quality is maintained at a high level. That is to say, the present invention can improve the self-sharpness of the creping blade by providing a protective layer.
  • the material of the wear resistant coating may be a combination of one or more of a metal, a metal oxide, a ceramic material, a silicate, a carbide, a boride, and a nitride; preferably, the material of the wear resistant coating includes a metal a combination of one or more of alumina, chromia, zirconia, tungsten carbide, chromium carbide, zirconium carbide, tantalum carbide, and titanium carbide; in the present invention, any material that meets the requirements for use can be used.
  • wear resistant coatings for example, tungsten carbide-cobalt-chromium alloy (weight content 86%, 10%, 4%, respectively) or tungsten carbide-chromium-nickel alloy (weight content 73%, 20%, 7 respectively) %), it is also possible to use a mixture of the two in proportion, as can be referred to the existing ceramic creping knife with a wear-resistant coating.
  • the working layer and the trench may be formed in the protective layer, by providing the trench, It can reduce the width of the contact surface and increase the self-sharpness.
  • the working raft has a width of 0.15 mm-0.4 mm
  • the groove has a depth of 0.2 mm-0.5 mm
  • the width is 1.5 mm-2.5 mm
  • the working raft is disposed between the groove and the top end surface of the base body.
  • the shape and size of the groove meets the following requirements: During use of the creping blade, when the working ram is completely worn, the connection point of the groove and the working surface at the end remote from the working ram does not come into contact with the dryer of the paper machine.
  • the angle between the top surface of the working weir and the working surface is between 0 and 15 degrees, preferably below 8 degrees.
  • the groove may be triangular, rectangular or trapezoidal or the like, but is not limited thereto.
  • the specific values of the length, width and height of the substrate can be selected as desired.
  • the substrate has a thickness of from 0.6 to 1.5 mm, a width of from 100 to 150 mm, and a length equal to the length of the dryer.
  • the base body may be selected from a suitable strip steel material, that is, the above base body may be a steel base body.
  • the invention also provides a preparation method of the above creping knife, which comprises forming a protective layer on the top surface and/or the working surface of the substrate, and then forming an abrasion-resistant coating on the top surface of the substrate, which is obtained after grinding. Wrinkle knife.
  • the preparation methods can be:
  • the creping blade with the protective layer on the top surface of the base body a protective layer is formed on the top end surface of the base body, and the top end surface of the base body is ground to form an appropriate angle (inclination angle ⁇ , the angle is generally between 0°-20°, in particular, the angle can be It is a negative value, which is rarely seen in practical applications. Then, a wear-resistant coating is formed on the protective layer and is ground to form a transition angle ⁇ (the angle is generally between 0°-15°, width w Generally, it is between 0.5-2.5mm. The specific value is selected according to the equipment. When the creping knife is shipped from the factory, the transition angle can be formed without grinding. It can be ground before the paper machine is used. The same is true for the knives), and the preparation process is as shown in Fig. 14, and a creping blade is obtained.
  • inclination angle ⁇ the angle is generally between 0°-20°, in particular, the angle can be It is a negative value, which is rarely seen in practical applications.
  • the creping blade with the protective layer on the working surface of the base body a protective layer is formed on the working surface of the base body, and the top end surface of the base body is ground to form an appropriate angle (inclination angle ⁇ , the angle is generally between 0°-20°, in particular, the angle can be It is a negative value, which is rarely seen in practical applications. Then, a wear-resistant coating is formed on the top surface of the substrate, and a transition angle ⁇ is formed by grinding (the angle is generally between 0° and 15°, and the width is generally Between 0.5-2.5 mm, the specific value is specifically selected according to the equipment condition), and the preparation process is as shown in Fig. 15, and a creping knife is obtained.
  • inclination angle ⁇ the angle is generally between 0°-20°, in particular, the angle can be It is a negative value, which is rarely seen in practical applications.
  • a wear-resistant coating is formed on the top surface of the substrate, and a transition angle ⁇ is formed by grinding (the angle is generally between 0
  • the creping blade with the protective layer on the top end surface and the working surface of the substrate a protective layer is formed on the top end surface of the base body and the working surface, and the top end surface of the base body is ground to form an appropriate angle (inclination angle ⁇ , the angle is generally between 0°-20°) In special cases, the angle can be a negative value, which is rarely seen in practical applications. Then, a wear-resistant coating is formed on the protective layer on the top surface of the substrate to form a transitional tilt angle ⁇ (angle is generally Between 0°-15°, the width w is generally between 0.5 and 2.5 mm, and the specific value is specifically selected according to the equipment.
  • the preparation process is as shown in Fig. 16, and a creping knife is obtained.
  • a creping blade in which all or part of the protective layer is located in the notch of the top end of the substrate: a notch is formed at the top end of the substrate, a protective layer is formed in the notch, and the top surface of the substrate is ground to form an appropriate angle (inclination angle ⁇ , the angle is generally 0°) Between -20 °, in particular, the angle can be negative, which is rarely seen in practical applications.) Then, a wear-resistant coating is formed on the top surface of the substrate, and a transition angle ⁇ is formed by grinding (the angle is generally Between 0°-15°, the width w is generally between 0.5 and 2.5 mm, and the specific value is specifically selected according to the equipment. The preparation process is as shown in Fig. 17, and a creping knife is obtained.
  • the creping blade of the present invention can be selected from a material of a steel creping blade which is currently widely used as a substrate to facilitate switching with a steel creping blade which is now commonly used.
  • the protective layer and the wear-resistant coating can be made by surface engineering techniques such as thermal spraying, electroplating, and laser cladding.
  • the protective layer has an appropriate hardness and can function to protect the drying cylinder, and at the same time, the working edge of the wear-resistant coating in contact with the surface of the drying cylinder can be kept sharp and sharp. Improve the self-sharpening effect of the creping knife.
  • the wear-resistant coating has high wear resistance, low thermal conductivity, and high bonding strength with the substrate, which ensures that the two will not be detached in subsequent processing or/and use.
  • the wear-resistant coating of the creping blade of the invention has a constant working area and a stable shape, and is generally a strip-shaped structure of 0.03 mm-0.25 mm wide, and the contact area with the drying cylinder is small, so that the paper of the prepared paper can be made.
  • the surface wrinkle structure is basically unchanged.
  • the creping blade of the invention has the unrestricted area of the friction surface of the working surface and has high wear-resisting coating, high abrasion resistance and high impact resistance of the paper impact portion, so that the creping blade has a long service life. It can reach several times or more than dozens of times the service life of ordinary steel creping knives.
  • Figure 1 is a schematic view of a steel creping knife.
  • Figure 2 is a schematic illustration of a steel creping knife in a failed state.
  • Figure 3 is a schematic view of a ceramic creping knife.
  • Figure 4 is a schematic illustration of a ceramic creping knife with a breach.
  • Figures 5-13 are schematic illustrations of creping knives having different forms of protective layers, respectively.
  • the protective layer is distributed along the working surface.
  • the material is made of metal copper with a thickness (h') of 0.5 mm and a width (w) of 4 mm.
  • the hardness of the protective layer is HV 0.3 150;
  • the coating material is a tungsten carbon (WC) series alloy powder, and the coating is ground, and finally the thickness of the wear resistant coating is 0.03 mm;
  • the contact point of one side of the wear resistant coating with the surface of the dryer cylinder (during use) was machined to form a structural angle of the creping blade at an angle of 76° to obtain a creping knife.
  • Test paper machine a paper machine No. 2 paper machine
  • Test purpose comparison of creping knife life and paper output quality
  • the paper machine is produced using steel creping knives for many years, and the life of the creping cutter is about 1.5 hours. After the creping knife is replaced, the worn creping blade edge is re-grinded, and the creped knives after grinding can be recycled. In general, a new creping knife can be ground 5-6 times, and the width of the creping knife will be narrow to nearly 110mm and will not be repaired and completely scrapped.
  • Pulp raw material cane pulp, wood pulp mixed pulp
  • Dryer specifications diameter 2.4m, length 4.0m, cast iron dryer, surface sprayed with stainless steel coating
  • Paper quality analysis The quality of the paper produced by the creping knife of this embodiment completely meets the quality standards required by the manufacturer, and the main indexes are superior to the steel creping cutter. Compared with the steel creping knife, the surface brightness of the paper product is improved, the visual effect is good, the wrinkles are uniform, and the color remains basically unchanged for a long time, which is particularly suitable for producing fine-grain paper. When the wrinkles change beyond the standard, the creping knife does not necessarily fail, and the paper with a slightly rough wrinkle can be reused until the smear of the paper surface is excessive or the quality of the wrinkles exceeds the standard. The paper has a good feel and a good bulk. The life statistics of the creping knife are shown in Table 1.
  • the service life of the creping blade of this embodiment is slightly different, and is expected to be consistent with the hardness and wear resistance of the design.
  • the ultra-long service life greatly reduces the labor intensity of the worker, reduces the yield loss caused by the tool change, and the wrinkle of the embodiment.
  • the machine can produce 2.5 tons of products, and at the same time reduce the waste of paper produced by the tool change.
  • This embodiment provides a creping blade, as shown in Fig. 6, which has a specification of 4300 mm ⁇ 120 mm ⁇ 1.2 mm, which is prepared by the following steps (as shown in Fig. 15):
  • the protective layer is distributed along the working surface and is made of metallic nickel with a thickness (h') of 0.5 mm and a width (w) of 4 mm.
  • the hardness of the protective layer is HV 0.3 150;
  • the coating material is a tungsten carbon (WC) series alloy powder, and the coating is ground, and the thickness of the final wear resistant coating is 0.05 mm;
  • the contact point of one side of the wear-resistant coating with the surface of the dryer cylinder (during use) is processed to form a structural angle of the creping blade at an angle of 80° to obtain a creping blade.
  • Test purpose comparison of creping knife life and paper output quality
  • the paper machine is produced using steel creping knives for many years, and the life of the creping cutter is about 0.8 hours. After the creping knife is replaced, the worn creping blade edge is re-grinded, and the creped knives after grinding can be recycled. In general, a new creping knife can be ground 5-6 times, and the width of the creping knife will be narrow to nearly 90mm and will not be repaired and completely scrapped.
  • Pulp raw material wood pulp board
  • Dryer specifications 3.5m in diameter, 4300m in length, steel drying cylinder, stainless steel coating on the surface
  • Wrinkle knife tip angle 80°
  • Adhesive conventional adhesive, such as related products produced by Shanghai Derunbao Special Lubricant Co., Ltd.
  • Paper quality analysis The quality of the paper produced by the creping knife of this embodiment completely meets the quality standards required by the manufacturer, and the main indexes are superior to the steel creping cutter. Compared with the steel creping knife, the surface brightness of the paper product is improved, the visual effect is good, the wrinkles are uniform, and the color remains basically unchanged for a long time, which is particularly suitable for producing fine-grain paper. When the wrinkles change beyond the standard, the creping knife does not necessarily fail, and the paper with a slightly rough wrinkle can be reused until the smear of the paper surface is excessive or the quality of the wrinkles exceeds the standard. The paper has a good feel and a good bulk. The life statistics of the creping knife are shown in Table 2.
  • the service life of the creping blade of this embodiment is slightly different, and is expected to be consistent with the hardness and wear resistance of the design.
  • the ultra-long service life greatly reduces the labor intensity of the worker, reduces the yield loss caused by the tool change, and the wrinkle of the embodiment.
  • the machine can produce more products, and at the same time reduce the waste of paper produced by the tool change.
  • This embodiment provides a creping blade, as shown in FIG. 5, having a specification of 4000 mm ⁇ 120 mm ⁇ 1.2 mm, which is prepared by the following steps (as shown in FIG. 14):
  • a protective layer is formed on the top surface of the substrate by laser cladding, and the protective layer is distributed along the working surface, and the material thereof is metallic magnesium, the thickness (h') is 0.7 mm, and the hardness of the protective layer is HV 0.3200 ;
  • the coating material is chromium carbide, and the coating is ground, and finally the thickness of the wear resistant coating is 0.05 mm;
  • Test paper machine a paper machine No. 2 paper machine
  • Test purpose comparison of creping knife life and paper output quality
  • the paper machine is produced using steel creping knives for many years, and the creping knife has a life of about 1-2 hours. After the creping knife is replaced, the worn creping blade edge is re-grinded, and the creped knives after grinding can be recycled. Generally, a new creping knife can be ground 6-7 times, and the width of the creping knife will be narrow to nearly 110mm and will not be repaired and completely scrapped.
  • Pulp raw material bamboo pulp and wood pulp mixed pulp
  • Dryer specifications diameter 2.3m, length 4.5m, cast iron dryer, surface sprayed with stainless steel coating
  • Wrinkle knife tip angle 80°
  • Adhesive a conventional adhesive, such as related products produced by Ashland (Changzhou) Chemical Co., Ltd.
  • Paper quality analysis The quality of the paper produced by the creping knife of this embodiment completely meets the quality standards required by the manufacturer, and the main indexes are superior to the steel creping cutter. Compared with the steel creping knife, the surface brightness of the paper product is improved, the visual effect is good, the wrinkles are uniform, and the color remains basically unchanged for a long time, which is particularly suitable for producing fine-grain paper. When the wrinkles change beyond the standard, the creping knife does not necessarily fail, and the paper with a slightly rough wrinkle can be reused until the smear of the paper surface is excessive or the quality of the wrinkles exceeds the standard. The paper has a good feel and a good bulk. The life statistics of the creping knife are shown in Table 3.
  • the service life of the creping blade of this embodiment is slightly different, and is expected to be consistent with the hardness and wear resistance of the design.
  • the ultra-long service life greatly reduces the labor intensity of the worker, reduces the yield loss caused by the tool change, and the wrinkle of the embodiment.
  • the machine can produce 2.3 tons of products, and at the same time reduce the waste of paper produced by the tool change.
  • This embodiment provides a creping blade, as shown in FIG. 5, having a specification of 3150 mm ⁇ 120 mm ⁇ 1.2 mm, which is prepared by the following steps (as shown in FIG. 14):
  • a supersonic spraying method is formed on the top surface of the substrate to form a protective layer, the protective layer is distributed along the working surface, the material is metal copper, the thickness (h') is 0.6 mm, and the hardness of the protective layer is HV 0.3 150;
  • the coating material is chromium carbide, and the coating is ground, and finally the thickness of the wear resistant coating is 0.08 mm;
  • the contact point of one side of the wear-resistant coating with the surface of the dryer cylinder (during use) was processed to form a structural angle of the creping blade at an angle of 83° to obtain a creping knife.
  • Test paper machine a paper machine No. 2 paper machine
  • Test purpose comparison of creping knife life and paper output quality
  • Contrast target cermet creping knife
  • the paper machine has been produced for many years using cermet creping knives, which have a life of about 30 hours.
  • Pulp raw material mixed pulp of wood pulp and bamboo pulp
  • Dryer specifications diameter 3400m, length 3200m, cast iron dryer, surface sprayed with stainless steel coating
  • Adhesive conventional adhesive, such as related products produced by Shanghai Derunbao Special Lubricant Co., Ltd.
  • the service life of the creping blade of this embodiment is slightly different, and is expected to be consistent with the hardness and wear resistance of the design.
  • This embodiment provides a creping blade, as shown in Fig. 7, having a specification of 3150 mm ⁇ 120 mm ⁇ 1.2 mm, which is prepared by the following steps (as shown in Fig. 17):
  • the lengths of the two sides are 1.0 mm and 15 mm, respectively, the short side is located at the top end surface, and the long side is located at the working surface;
  • the long side of the protective layer is flush with the working surface of the base body, the short side is flush with the top end surface of the base body, the material of the protective layer is metallic nickel, and the hardness of the protective layer is HV 0.3 230;
  • the wear-resistant coating material is tungsten carbide, and the wear-resistant coating is ground, and finally the thickness of the wear-resistant coating is 0.06 mm;
  • the contact point of one side of the wear-resistant coating with the surface of the dryer (during use) was machined to form a structural angle of the creping blade at an angle of 85° to obtain a creping blade.
  • Test paper machine a paper machine No. 1 paper machine
  • Contrast target cermet creping knife
  • the paper machine has been produced for many years using cermet creping knives, which have a life of about 25 hours.
  • Pulp raw material bamboo pulp
  • Dryer specifications diameter 3400m, length 3200m, cast iron dryer, surface sprayed with stainless steel coating
  • Adhesive conventional adhesive, such as related products produced by Shanghai Derunbao Special Lubricant Co., Ltd.
  • Paper quality analysis The quality of the paper produced by the creping knife of this embodiment completely meets the quality standards required by the manufacturer, and the main indexes are superior to the cermet creping knives. Compared with the use of cermet creping knives, the surface brightness of the paper products is improved, the visual effect is good, the wrinkles are uniform, and the swatches are kept substantially unchanged for a long time, and are particularly suitable for producing fine embossed paper. When the wrinkles change beyond the standard, the creping knife does not necessarily fail, and the paper with a slightly rough wrinkle can be reused until the smear of the paper surface is excessive or the quality of the wrinkles exceeds the standard. The paper has a good feel and a good bulk. The life statistics of the creping knife are shown in Table 5.
  • the service life of the creping blade of this embodiment is slightly different, and is expected to be consistent with the hardness and wear resistance of the design.
  • the lengths of the two sides are 1.0 mm and 15 mm, respectively, the short side is located at the top end surface, and the long side is located at the working surface;
  • the long side of the protective layer is flush with the working surface of the base body, the short side is flush with the top end surface of the base body, the material of the protective layer is metal copper, and the hardness of the protective layer is HV 0.3 140;
  • the wear-resistant coating material is tungsten carbide, and the wear-resistant coating is ground, and finally the thickness of the wear-resistant coating is 0.06 mm;
  • the contact point of one side of the wear resistant coating with the surface of the dryer cylinder (during use) was machined to form a structural angle of the creping blade at an angle of 76° to obtain a creping knife.
  • Test paper machine a paper machine No. 2 paper machine
  • Test purpose comparison of creping knife life and paper output quality
  • the paper machine is produced using steel creping knives for many years, and the life of the creping cutter is about 1.5 hours. After the creping knife is replaced, the worn creping blade edge is re-grinded, and the creped knives after grinding can be recycled. Generally, a new creping knife can be ground 6-7 times, and the width of the creping knife will be narrow to nearly 110mm and will not be repaired and completely scrapped.
  • Pulp raw material pure wood pulp
  • Dryer specifications diameter 2.5m, length 4.0m, cast iron dryer, surface sprayed with stainless steel coating
  • Adhesive conventional adhesive, such as related products produced by Shanghai Derunbao Special Lubricant Co., Ltd.
  • Paper quality analysis The quality of the paper produced by the creping knife of this embodiment completely meets the quality standards required by the manufacturer, and the main indexes are superior to the steel creping cutter. Compared with the steel creping knife, the surface brightness of the paper product is improved, the visual effect is good, the wrinkles are uniform, and the color remains basically unchanged for a long time, which is particularly suitable for producing fine-grain paper. When the wrinkles change beyond the standard, the creping knife does not necessarily fail, and the paper with a slightly rough wrinkle can be reused until the smear of the paper surface is excessive or the quality of the wrinkles exceeds the standard. The paper has a good feel and a good bulk. The life statistics of the creping knife are shown in Table 6.
  • the service life of the creping blade of this embodiment is slightly different, and is expected to be consistent with the hardness and wear resistance of the design.
  • the ultra-long service life greatly reduces the labor intensity of the worker, reduces the yield loss caused by the tool change, and the wrinkle of the embodiment.
  • the machine can produce 2.5 tons of products, and at the same time reduce the waste of paper produced by the tool change.
  • the creping blade of the present invention can make the paper wrinkle structure of the prepared paper substantially unchanged, and has a long service life.

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Abstract

本发明提供了一种起皱刀及其制备方法。该起皱刀包括一个基体，该基体的顶端设有耐磨涂层，并且，该起皱刀与烘缸的接触点处的耐磨涂层下方设有保护层，并且，所述保护层的硬度低于造纸机烘缸表面的硬度。本发明的起皱刀同时具有工作面摩擦部位面积不受限制且有高耐磨涂层、纸面冲击部位具有高耐磨性与高抗冲击性，使起皱刀具有较长的使用寿命，能够达到普通钢制起皱刀使用寿命的数倍以上，甚至几十倍以上。

Description

一种起皱刀及其制备方法 技术领域
本发明涉及一种起皱刀及其制备方法，尤其涉及一种应用于制备生活用纸的起皱刀及其制备方法。
背景技术
起皱刀是生产生活用纸工艺中的重要部件，在生产工艺中的作用是将纸张从烘缸表面剥离，同时对接触的纸面施加必要的压力以使纸张表面形成皱纹状结构。
为满足起皱工艺要求，起皱刀应该具有如下主要性质：耐磨性好，起皱刀刃口具有适宜的锐度，轮廓几何形状符合对纸张强度、松厚度等的性能要求，起皱刀基体有适宜的刚性和弹性。
目前被广泛使用的起皱刀，基本上分为两类：钢制起皱刀和带有涂层的起皱刀。
钢制起皱刀是生活用纸生产中最早使用的起皱刀，目前仍在广泛使用。钢制起皱刀的示意图见图1。
钢制起皱刀一般由淬火钢材制成，有较好的耐磨性和柔韧性。工作时由贴近烘缸面与顶端面的交线作为工作刃口，一方面起到把粘贴在烘缸表面的纸剥离的作用，另一方面，起皱刀顶端靠近刃口处起到在纸的表面压迫起皱作用。皱纹的粗细可以通过预设起皱刀顶端与侧面夹角的大小进行一定范围的调节。
钢制起皱刀在实际使用中存在明显的不足，主要表现在使用寿命短、皱纹不稳定两个方面，这些不足会严重影响生产效率的提高和产品质量的提升。
钢制起皱刀寿命短的原因是耐磨性不强，其失效过程通过图1和图2的对比就可以说明。钢制起皱刀刚开始工作时，纸张质量较好，但是，随着时间的推移，起皱刀的工作刃口会产生变化，与烘缸贴近的起皱刀工作部位由接近线性状态而很快被磨损成带状形态，刃口变成圆角，顶端因纸张冲击与刮擦而开始出现沿起皱刀长度方向的冲击纹和垂直方向的非均匀磨损痕，出现沟槽。上述现象会随着时间的延长逐步积累，纸张的起皱情况和物理性能也会随之发生渐变，起皱刀工作一定时间后，刃口钝化，由此开始，制备得到的纸的皱纹结构超出质量标准要求，起皱刀失效下机。
钢制起皱刀存在着上述的明显缺陷。目前逐步取代钢制起皱刀的是利用热喷涂等表面技术在钢制基材上形成局部致密耐磨涂层的起皱刀。耐磨涂层一般为陶瓷材料或含有碳化物的复合材料，这类起皱刀被统称为陶瓷起皱刀。
目前市场中可以见到的陶瓷起皱刀，其结构大致相同，如图3所示，阴影部分为陶瓷涂层，该陶瓷涂层仅存在于工作面部分，在起皱刀的顶端面并没有涂层。与钢刀显著不同的是，陶瓷起皱刀的涂层与烘缸接触部分在制作时通常预先研磨有一个小的过渡角，工作时陶瓷涂层过渡角的顶端替代钢制基体与烘缸接触。由于涂层的耐磨性远高于钢材，因此能够达到提 高起皱刀耐磨性、延长起皱刀寿命的目的。
但是，陶瓷起皱刀仍旧存在一些缺陷：其一是与钢制起皱刀一样，与烘缸接触的工作面会随着时间的推移而刃口钝化，导致纸面皱纹结构发生变化。这种变化积累到一定程度而超出质量标准时，就会导致起皱刀失效。虽然这种陶瓷起皱刀的失效过程会远远长于普通钢刀，但是，在使用过程中导致的纸面皱纹结构变化问题仍然存在，同样不能保持纸面皱纹的均匀一致。
陶瓷起皱刀的第二个缺陷是工作刃口容易出现如图4所示的微小的非规则状的崩口(图4仅为示意，具体尺寸以实际情况为准)，从而导致纸面出现纵向条纹。一般陶瓷材料都具有脆性，在加工制作和使用过程中容易造成刃口崩裂，在刮擦缸面剥离纸张的起皱过程中，如果崩口较大，纸面与崩口接触的地方会形成线状条纹，影响纸品质量，严重的会导致起皱刀直接失效，缩短起皱刀寿命。
陶瓷起皱刀的第三个缺陷是由于涂层材料的硬度远高于烘缸表面的硬度，当振动较为严重时，容易发生冲击，这容易导致烘缸表面受伤。
鉴于目前使用的起皱刀存在的不足，需要有新的形式/材料的起皱刀提供给相关生活用纸生产企业，以提高产品质量、降低生产成本。
发明内容
为解决上述技术问题，本发明的目的在于提供一种起皱刀，通过设置保护层来提高起皱刀的自锐性、降低起皱刀伤缸的机率，该起皱刀具有更长的使用寿命，并且，由此生产的纸张具有更好的质量。
本发明的目的还在于提供上述起皱刀的制备方法。
为达到上述目的，本发明提供了一种起皱刀，其包括一个基体，该基体的顶端设有耐磨涂层，并且，该起皱刀与烘缸的接触点处的耐磨涂层下方设有保护层，并且，所述保护层的硬度低于造纸机烘缸表面的硬度。
在本发明中，基体的工作面是指在工作过程中起皱刀靠近造纸机的烘缸的一侧表面；顶端是指在工作过程中起皱刀接触从烘缸表面脱离的纸张的部分，接触纸张的面称为顶端面；接触点是指起皱刀在工作过程中与烘缸表面相接触的部位；基体的厚度是指基体被加工之前其顶端垂直于烘缸表面的厚度尺寸；基体的宽度是指起皱刀被夹持部分的底端到未加工倾角、未喷涂涂层之前的顶端的尺寸；起皱刀的长度是指沿着烘缸轴向方向的尺寸。
在工作过程中，起皱刀与烘缸表面的接触点处的耐磨涂层的一侧会与烘缸表面接触，将纸张从烘缸的表面剥离，剥离的纸张会与耐磨涂层的正面接触，耐磨涂层会对纸面施加一定的压力以使纸张表面形成皱纹状结构。
纸张脱离烘缸瞬间会对起皱刀顶端靠近工作刃口处持续进行冲击，耐磨涂层能够强化使用过程中纸面冲击部位的强度，有效防止上述冲击所造成的起皱刀的损坏，以及纸面对起皱刀顶端持续摩擦造成的刮擦损伤。
本发明通过在起皱刀与烘缸的接触点处的耐磨涂层下方设置保护层，能够起到保护烘缸的作用。该保护层的硬度、耐磨性等低于烘缸，当起皱刀的工作部位(即与烘缸表面接触的耐磨涂层的侧面)钝化或受到较大冲击力时，起皱刀刃口(保护层)会塌陷，使起皱刀与烘缸脱离接触，从而降低起皱刀损伤烘缸的几率。保护层可以位于耐磨涂层与基体的顶端面之间(如图5所示)，也可以沿基体的工作面设置，也可以既分布在耐磨涂层与基体的顶端面之间，又沿基体的工作面设置。
根据本发明的具体实施方案，优选地，当保护层沿基体的工作面设置时，保护层位于基体的工作面上靠近耐磨涂层的位置处，如图6所示。并且，在这种情况下，保护层靠近基体的顶端面的侧面也应覆盖有耐磨涂层。但是，保护层并不需要覆盖整个工作面，沿着工作面有适当的宽度即可，如图6中的w'所示。
当保护层沿基体的工作面设置时，设置的方式可以包括以下几种：第一方式：保护层凸出于基体的工作面(如图6所示)；或者，第二方式：基体的顶端处设有一个缺口，保护层位于缺口内，并且，保护层的外表面与基体的工作面位于同一平面内(如图7-图10所示)；或者，第三方式：基体的顶端处设有一个缺口，保护层包括两部分，一部分位于缺口内，另一部分凸出于基体的工作面(如图11、图12所示)。在第二方式中，保护层的截面可以为任意适合的形状，例如三角形、菱形、梯形、其他规则形状或者不规则形状，如图7-图12所示。
根据本发明的具体实施方案，保护层的硬度可以控制为≤HV 0.3 300，优选为HV 0.3 100-300，更优选为HV 0.3 130-250，更优选为HV 0.3 150-220，根据情况的不同可以选择140、160、180、200、220、240、260、280等等。保护层可以采用任何能够满足上述硬度要求的材料制成，优选为较软的金属或合金材料，上述金属包括铜、铝、锌、锡、镍、钴和镁等中的一种；上述合金包括铜、铝、锌、锡、镍、钴和镁中的至少两种所组成的合金。与耐磨涂层相比，保护层的耐磨性能和强度一般相对要低一些。
起皱刀一般都比较长(长度可以达到4米左右)，类似一条长钢带，保护层类似一条镶嵌在钢带顶端的条带，并且，在优选的情况下，保护层可以与钢带是同等厚度的。根据本发明的具体实施方案，保护层的厚度可以控制为0.1-2.0mm，优选为0.3-1.0mm。该厚度是指保护层的外表面到基体表面的尺寸，如图6-图10中的h’所示，当保护层各部分的厚度不一致时，该厚度是指其靠近耐磨涂层部分的厚度，这部分的保护层应具有适当的厚度，以保证在磨耗过程中不会磨至基体部分，例如图7和图10所示。
根据本发明的具体实施方案，耐磨涂层的厚度为0.03-0.25mm，优选为0.05-0.12mm，进一步优选为0.03-0.1mm。现有的陶瓷起皱刀中，耐磨涂层均比较厚，由于其硬度较高，随着时间的推移，刃尖部分会出现磨损，出现圆弧(或称圆角)，随着圆弧越来越大，纸张纸纹也会越来越粗，质量下降。本发明的起皱刀设有硬度低于烘缸的保护层，在使用过程中，只有耐磨涂层靠工作面一侧及保护层靠工作面一侧与烘缸的表面相互接触，起皱刀的基体并不 与烘缸接触，耐磨涂层与烘缸的接触部分的面积保持不变，保护层与烘缸的接触面积有微小变化，由于保护层的硬度和耐磨性远不如烘缸，保护层与烘缸表面的接触部分会随着耐磨涂层的磨损而同步磨损，所以工作面与烘缸的接触面不受限制，起皱刀在工作过程中与烘缸的接触角能够保持恒定，不会出现圆角。当耐磨涂层的厚度控制在0.03-0.07mm这一很薄的范围时，可以使工作刃口部分一直是尖锐的，纸张的纸纹能够一直保持比较细的状态，不会随着使用时间的延长而变粗，一直保持较高的质量，也就是说，本发明通过设置保护层能够提高起皱刀的自锐性。
耐磨涂层的材料可以为金属、金属氧化物、陶瓷材料、硅酸盐、碳化物、硼化物和氮化物中的一种或几种的组合；优选地，耐磨涂层的材料包括金属、氧化铝、氧化铬、氧化锆、碳化钨、碳化铬、碳化锆、碳化钽和碳化钛等中的一种或几种的组合；在本发明中，任何满足使用要求的材料均可以用于制作耐磨涂层，例如，碳化钨-钴-铬合金(重量含量分别为86％、10％、4％)或碳化钨-碳化铬-镍合金(重量含量分别为73％、20％、7％)，也可以采用二者按比例制成的混合物，具体可以参照现有的带有耐磨涂层的陶瓷起皱刀进行。
根据本发明的具体实施方案，当保护层沿基体的工作面设置时，在第二方式中，保护层内还可以形成有工作垛和沟槽(如图13所示)，通过设置沟槽，可以减少接触面的宽度，增加自锐性。其中，工作垛的宽度为0.15mm-0.4mm，沟槽的深度为0.2mm-0.5mm、宽度为1.5mm-2.5mm，工作垛设于沟槽与基体的顶端面之间。沟槽的形状和尺寸满足以下要求：在起皱刀的使用过程中，当工作垛全部磨损时，沟槽与工作面在远离工作垛的一端的连接点不与造纸机的烘缸接触。
根据本发明的具体实施方案，优选地，工作垛的顶面与工作面的夹角为0-15°，优选8°以下。
根据本发明的具体实施方案，沟槽可以为三角形、矩形或梯形等，但不限于此。
根据本发明的具体实施方案，基体的长度、宽度、高度的具体数值可以根据需要进行选择，优选地，基体的厚度为0.6-1.5mm，宽度为100-150mm，长度与烘缸的长度相同。基体可以选择适宜的带状钢材料，即上述基体可以为钢制基体。
根据本发明的具体实施方案，优选地，基体的顶端面与工作面之间的夹角(即起皱刀的结构角)为70°-150°，优选为70°-90°。
本发明还提供了上述起皱刀的制备方法，其是在基体上的顶端面和/或工作面形成保护层，然后再在基体的顶端面处形成耐磨涂层，经研磨加工后得到起皱刀。
对于不同结构的起皱刀，其制备方法分别可以为：
保护层位于基体顶端面的起皱刀：在基体的顶端面形成保护层，将基体的顶端面研磨形成适当的角度(倾角β，角度一般在0°-20°之间，特别情况下角度可以是负值，实际应用中此种情况很少出现)，然后再在保护层之上形成耐磨涂层，经研磨加工形成一个过渡倾角α(角度一般在0°-15°之间，宽度w一般在0.5-2.5mm之间，具体数值根据设备情况进行具体 的选择；在起皱刀出厂时，可以不研磨形成这一过渡倾角，在上纸机使用前再研磨即可，以下结构的起皱刀也是如此)，其制备过程如图14所示，得到起皱刀。
保护层位于基体工作面的起皱刀：在基体的工作面形成保护层，将基体的顶端面研磨形成适当的角度(倾角β，角度一般在0°-20°之间，特别情况下角度可以是负值，实际应用中此种情况很少出现)，然后在基体的顶端面形成耐磨涂层，经研磨加工形成一个过渡倾角α(角度一般在0°-15°之间，宽度w一般在0.5-2.5mm之间，具体数值根据设备情况进行具体的选择)，其制备过程如图15所示，得到起皱刀。
保护层位于基体顶端面和工作面的起皱刀：在基体的顶端面和工作面形成保护层，将基体的顶端面研磨形成适当的角度(倾角β，角度一般在0°-20°之间，特别情况下角度可以是负值，实际应用中此种情况很少出现)，然后再在基体顶端面上的保护层之上形成耐磨涂层，经研磨加工形成一个过渡倾角α(角度一般在0°-15°之间，宽度w一般在0.5-2.5mm之间，具体数值根据设备情况进行具体的选择)，其制备过程如图16所示，得到起皱刀。
保护层全部或部分位于基体顶端缺口内的起皱刀：在基体的顶端处形成一个缺口，在缺口内形成保护层，将基体的顶端面研磨形成适当的角度(倾角β，角度一般在0°-20°之间，特别情况下角度可以是负值，实际应用中此种情况很少出现)，然后在基体的顶端面形成耐磨涂层，经研磨加工形成一个过渡倾角α(角度一般在0°-15°之间，宽度w一般在0.5-2.5mm之间，具体数值根据设备情况进行具体的选择)，其制备过程如图17所示，得到起皱刀。
在制备时，可以先对基体进行加工，使其具备起皱刀的初步形状。
本发明的起皱刀可以选用目前被广泛使用的钢制起皱刀的材料作为基体，以利于和现在普遍使用的钢制起皱刀进行切换。保护层、耐磨涂层可以利用热喷涂、电镀、激光熔覆等表面工程技术制成。
在本发明的起皱刀中，保护层具有适当的硬度，能够起到保护烘缸的作用，同时，还可以使耐磨涂层与烘缸表面接触的工作刃口一直保持尖锐的状态，大幅提高起皱刀的自锐作用。耐磨涂层具有高耐磨性、低导热性，与基体间有很高的结合强度，能够保证在后续的加工或/和使用中两者不会脱离。
本发明的起皱刀的耐磨涂层工作部位面积恒定，形状稳定，一般为0.03mm-0.25mm宽的带状结构，其与烘缸接触面积很小，从而能够使制备得到的纸张的纸面皱纹结构基本没有变化。
本发明的起皱刀的刃口的线压力一般在2.5-3N/mm，能够有效减小起皱刀与烘缸的摩擦力，从而使烘缸转动过程中的阻力变小，达到节约能源的目的。
本发明的起皱刀同时具有工作面摩擦部位面积不受限制且有高耐磨涂层、纸面冲击部位具有高耐磨性与高抗冲击性，使起皱刀具有较长的使用寿命，能够达到普通钢制起皱刀使用寿命的数倍以上，甚至几十倍以上。
附图说明
图1为钢制起皱刀的示意图。
图2为处于失效状态的钢制起皱刀的示意图。
图3为陶瓷起皱刀的示意图。
图4为带有崩口的陶瓷起皱刀的示意图。
图5-图13分别为具有不同形式的保护层的起皱刀的示意图。
图14-图17分别为不同起皱刀的制备过程示意图。
具体实施方式
为了对本发明的技术特征、目的和有益效果有更加清楚的理解，现对本发明的技术方案进行以下详细说明，但不能理解为对本发明的可实施范围的限定。
实施例1
本实施例提供了一种起皱刀，如图6所示，其规格为4000mm×120mm×1.2mm，其是通过以下步骤制备的(如图15所示)：
根据起皱刀的规格选择相应规格的钢制基体；
采用超音速火焰喷涂在基体的工作面靠近顶端处喷涂一层保护层，该保护层沿着工作面分布，其材质为金属铜，厚度(h')为0.5mm，宽度(w)为4mm，保护层的硬度为HV 0.3 150；
将基体的顶端面研磨出一个过渡倾角，角度为5°，预磨部分的宽度为2mm；
采用超音速火焰喷涂在基体的顶端面形成涂层，涂层材料为钨碳(WC)系列合金粉末，对涂层进行研磨，最终耐磨涂层的厚度为0.03mm；
对耐磨涂层的一侧与烘缸表面(使用过程中)的接触点出进行加工，形成起皱刀的结构角，角度为76°，得到起皱刀。
对本实施例制备的起皱刀进行实际实验，具体按照以下方式进行：
试验纸机：某卫生纸厂2号纸机
试验目的：起皱刀寿命和出纸质量比较
对比标的：钢制起皱刀(其工作状态的示意图如图1所示)
该纸机长年使用钢制起皱刀进行生产，起皱刀寿命大约1.5个小时。起皱刀换下后，对磨损的起皱刀刃口进行重新修磨，修磨后的起皱刀可以循环使用。一般地，一把新起皱刀可以修磨5-6次，起皱刀宽度会窄至接近110mm时不再修磨而彻底报废。
采用本实施例的起皱刀进行实用对比试验。
试验时的具体工艺条件如下：
产品：抽取式面纸巾
纸浆原料：蔗浆、木浆混合浆
纸幅宽度：3550mm
纸品克重：12.5g/m 2，(无湿强度剂)
烘缸规格：直径2.4m、长度4.0m，铸铁烘缸，表面喷涂不锈钢涂层
烘缸线速度：600-750m/min
卷纸速度：500-650m/min
纸幅含水率：5.5％
起皱刀顶端倾角：76°
起皱刀载荷：4-5N/mm
起皱刀伸出长度：25mm
粘合剂：常规粘合剂即可，例如凯美科瑞亚(苏州)化工有限公司生产的相关产品
试验结果分析：
纸品质量分析：采用本实施例的起皱刀生产出来的纸品质量完全满足厂家要求的质量标准，主要指标均优于钢制起皱刀。与使用钢制起皱刀相比，纸品表面亮度提高，目视效果很好，皱纹均匀一致，长时间保持基本不变，特别适合生产细纹纸。皱纹变化至超过标准时，起皱刀不必然失效，生产稍粗皱纹的纸品时可以重复使用，直到纸面出现条纹或皱纹质量超标时，起皱刀失效。纸品手感好，松厚度好。起皱刀的寿命统计结果如表1所示。
表1 起皱刀寿命统计
Figure PCTCN2018090759-appb-000001
本实施例的起皱刀的使用寿命略有区别，与设计的硬度、耐磨性预计是一致的。
使用本实施例的起皱刀，除了提升纸品质量外，其超长的使用寿命，大大减轻了工人的劳动强度，减少了因换刀而产生的产量损失，一把本实施例的起皱刀的寿命周期内，机台可多生产2.5吨产品，同时还减少了换刀产生的纸品浪费。
实施例2
本实施例提供了一种起皱刀，如图6所示，其规格为4300mm×120mm×1.2mm，其是通过以下步骤制备的(如图15所示)：
根据起皱刀的规格选择相应规格的钢制基体；
采用超音速火焰喷涂在基体的工作面靠近顶端处喷涂一层保护层，该保护层沿着工作面分布，其材质为金属镍，厚度(h')为0.5mm，宽度(w)为4mm，保护层的硬度为HV 0.3 150；
将基体的顶端面研磨出一个过渡倾角，角度为5°，预磨部分的宽度为2mm；
采用超音速火焰喷涂在基体的顶端面形成涂层，涂层材料为钨碳(WC)系列合金粉末，对涂层进行研磨，最终耐磨涂层的厚度为0.05mm；
对耐磨涂层的一侧与烘缸表面(使用过程中)的接触点出进行加工，形成起皱刀的结构角，角度为80°，得到起皱刀。
对本实施例制备的起皱刀进行实际实验，具体按照以下方式进行：
试验纸机：某卫生纸厂4号纸机
试验目的：起皱刀寿命和出纸质量比较
对比标的：钢制起皱刀
该纸机长年使用钢制起皱刀进行生产，起皱刀寿命大约0.8个小时。起皱刀换下后，对磨损的起皱刀刃口进行重新修磨，修磨后的起皱刀可以循环使用。一般地，一把新起皱刀可以修磨5-6次，起皱刀宽度会窄至接近90mm时不再修磨而彻底报废。
采用本实施例的起皱刀进行实用对比试验。
试验时的具体工艺条件如下：
产品：抽式面纸巾
纸浆原料：木浆板
纸幅宽度：4100mm
纸品克重：14.5g/m 2，(无湿强度剂)
烘缸规格：直径3.5m、长度4300m，钢制烘缸，表面喷涂不锈钢涂层
烘缸线速度：830m/min
卷纸速度：590m/min
纸幅含水率：25％
起皱刀顶端倾角：80°
起皱刀载荷：30N/mm
起皱刀伸出长度：15mm
粘合剂：常规粘合剂即可，例如上海德润宝特种润滑剂有限公司生产的相关产品
试验结果分析：
纸品质量分析：采用本实施例的起皱刀生产出来的纸品质量完全满足厂家要求的质量标准，主要指标均优于钢制起皱刀。与使用钢制起皱刀相比，纸品表面亮度提高，目视效果很好，皱纹均匀一致，长时间保持基本不变，特别适合生产细纹纸。皱纹变化至超过标准时，起皱刀不必然失效，生产稍粗皱纹的纸品时可以重复使用，直到纸面出现条纹或皱纹质量超标时，起皱刀失效。纸品手感好，松厚度好。起皱刀的寿命统计结果如表2所示。
表2 起皱刀寿命统计
Figure PCTCN2018090759-appb-000002
本实施例的起皱刀的使用寿命略有区别，与设计的硬度、耐磨性预计是一致的。
使用本实施例的起皱刀，除了提升纸品质量外，其超长的使用寿命，大大减轻了工人的劳动强度，减少了因换刀而产生的产量损失，一把本实施例的起皱刀的寿命周期内，机台可 生产更多的产品，同时还减少了换刀产生的纸品浪费。
实施例3
本实施例提供了一种起皱刀，如图5所示，其规格为4000mm×120mm×1.2mm，其是通过以下步骤制备的(如图14所示)：
根据起皱刀的规格选择相应规格的钢制基体；
将基体的顶端面研磨出一个过渡倾角，角度为7°，预磨部分的宽度为2.0mm；
采用激光熔覆的方式在基体的顶端面形成一层保护层，该保护层沿着工作面分布，其材质为金属镁，厚度(h')为0.7mm，保护层的硬度为HV 0.3 200；
采用超音速火焰喷涂在保护层的表面形成涂层，涂层材料为碳化铬，对涂层进行研磨，最终耐磨涂层的厚度为0.05mm；
对耐磨涂层的一侧与烘缸表面(使用过程中)的接触点出进行加工，形成起皱刀的结构角，角度为80°，得到起皱刀。
对本实施例制备的起皱刀进行实际实验，具体按照以下方式进行：
试验纸机：某卫生纸厂2号纸机
试验目的：起皱刀寿命和出纸质量比较
对比标的：钢制起皱刀
该纸机长年使用钢制起皱刀进行生产，起皱刀寿命大约1-2个小时。起皱刀换下后，对磨损的起皱刀刃口进行重新修磨，修磨后的起皱刀可以循环使用。一般地，一把新起皱刀可以修磨6-7次，起皱刀宽度会窄至接近110mm时不再修磨而彻底报废。
采用本实施例的起皱刀进行实用对比试验。
试验时的具体工艺条件如下：
产品：卷面纸巾
纸浆原料：竹浆和木浆混合浆
纸幅宽度：4000mm
纸品克重：13.5g/m 2，(无湿强度剂)
烘缸规格：直径2.3m、长度4.5m，铸铁烘缸，表面喷涂不锈钢涂层
烘缸线速度：700-950m/min
卷纸速度：600-850m/min
纸幅含水率：6.5％
起皱刀顶端倾角：80°
起皱刀载荷：4-5N/mm
起皱刀伸出长度：20mm
粘合剂：常规粘合剂即可，例如亚士兰(常州)化学有限公司生产的相关产品
试验结果分析：
纸品质量分析：采用本实施例的起皱刀生产出来的纸品质量完全满足厂家要求的质量标准，主要指标均优于钢制起皱刀。与使用钢制起皱刀相比，纸品表面亮度提高，目视效果很好，皱纹均匀一致，长时间保持基本不变，特别适合生产细纹纸。皱纹变化至超过标准时，起皱刀不必然失效，生产稍粗皱纹的纸品时可以重复使用，直到纸面出现条纹或皱纹质量超标时，起皱刀失效。纸品手感好，松厚度好。起皱刀的寿命统计结果如表3所示。
表3 起皱刀寿命统计
Figure PCTCN2018090759-appb-000003
本实施例的起皱刀的使用寿命略有区别，与设计的硬度、耐磨性预计是一致的。
使用本实施例的起皱刀，除了提升纸品质量外，其超长的使用寿命，大大减轻了工人的劳动强度，减少了因换刀而产生的产量损失，一把本实施例的起皱刀的寿命周期内，机台可多生产2.3吨产品，同时还减少了换刀产生的纸品浪费。
实施例4
本实施例提供了一种起皱刀，如图5所示，其规格为3150mm×120mm×1.2mm，其是通过以下步骤制备的(如图14所示)：
根据起皱刀的规格选择相应规格的钢制基体；
将基体的顶端面研磨出一个过渡倾角，角度为5°，预磨部分的宽度为2.0mm；
采用超音速喷涂的方式在基体的顶端面形成一层保护层，该保护层沿着工作面分布，其材质为金属铜，厚度(h')为0.6mm，保护层的硬度为HV 0.3 150；
采用超音速火焰喷涂在保护层的表面形成涂层，涂层材料为碳化铬，对涂层进行研磨，最终耐磨涂层的厚度为0.08mm；
对耐磨涂层的一侧与烘缸表面(使用过程中)的接触点出进行加工，形成起皱刀的结构角，角度为83°，得到起皱刀。
对本实施例制备的起皱刀进行实际实验，具体按照以下方式进行：
试验纸机：某卫生纸厂2号纸机
试验目的：起皱刀寿命和出纸质量比较
对比标的：金属陶瓷起皱刀
该纸机长年使用金属陶瓷起皱刀进行生产，起皱刀寿命大约30个小时。
采用本实施例的起皱刀进行实用对比试验。
试验时的具体工艺条件如下：
产品：卷式面纸巾
纸浆原料：木浆和竹浆混和浆
纸幅宽度：3000mm
纸品克重：13.5g/m 2，(无湿强度剂)
烘缸规格：直径3400m、长度3200m，铸铁烘缸，表面喷涂不锈钢涂层
烘缸线速度：900m/min
卷纸速度：600m/min
纸幅含水率：22％
起皱刀顶端倾角：83°
起皱刀载荷：27N/mm
起皱刀伸出长度：15mm
粘合剂：常规粘合剂即可，例如上海德润宝特种润滑剂有限公司生产的相关产品
试验结果分析：
纸品质量分析：采用本实施例的起皱刀生产出来的纸品质量完全满足厂家要求的质量标准，主要指标均优于金属陶瓷起皱刀。与使用金属陶瓷起皱刀相比，纸品表面亮度提高，目视效果很好，皱纹均匀一致，长时间保持基本不变，特别适合生产细纹纸。皱纹变化至超过标准时，起皱刀不必然失效，生产稍粗皱纹的纸品时可以重复使用，直到纸面出现条纹或皱纹质量超标时，起皱刀失效。纸品手感好，松厚度好。起皱刀的寿命统计结果如表4所示。
表4 起皱刀寿命统计
Figure PCTCN2018090759-appb-000004
本实施例的起皱刀的使用寿命略有区别，与设计的硬度、耐磨性预计是一致的。
使用本实施例的起皱刀，除了提升纸品质量外，其超长的使用寿命，大大减轻了工人的劳动强度，减少了因换刀而产生的产量损失，一把本实施例的起皱刀的寿命周期内，机台可生产更多的产品，同时还减少了换刀产生的纸品浪费。
实施例5
本实施例提供了一种起皱刀，如图7所示，其规格为3150mm×120mm×1.2mm，其是通过以下步骤制备的(如图17所示)：
根据起皱刀的规格选择相应规格的钢制基体；
在基体的顶端处形成一个直角三角形缺口，两条边的长度分别为1.0mm、15mm，短边位于顶端面，长边位于工作面；
在缺口内形成保护层，保护层的长边与基体的工作面平齐，短边与基体的顶端面平齐，保护层的材质为金属镍，保护层的硬度为HV 0.3 230；
将基体的顶端面研磨出一个过渡倾角，角度为5°，预磨部分的宽度为1.8mm；
采用超音速火焰喷涂在基体的顶端面形成耐磨涂层，耐磨涂层材料为碳化钨，对耐磨涂层进行研磨，最终耐磨涂层的厚度为0.06mm；
对耐磨涂层的一侧与烘缸表面(使用过程中)的接触点出进行加工，形成起皱刀的结构角，角度为85°，得到起皱刀。
对本实施例制备的起皱刀进行实际实验，具体按照以下方式进行：
试验纸机：某卫生纸厂1号纸机
试验目的：起皱刀寿命和出纸质量比较
对比标的：金属陶瓷起皱刀
该纸机长年使用金属陶瓷起皱刀进行生产，起皱刀寿命大约25个小时。
采用本实施例的起皱刀进行实用对比试验。
试验时的具体工艺条件如下：
产品：抽式面纸巾
纸浆原料：竹浆
纸幅宽度：3000mm
纸品克重：13.5g/m 2，(无湿强度剂)
烘缸规格：直径3400m、长度3200m，铸铁烘缸，表面喷涂不锈钢涂层
烘缸线速度：850m/min
卷纸速度：580m/min
纸幅含水率：20％
起皱刀顶端倾角：85°
起皱刀载荷：34N/mm
起皱刀伸出长度：15mm
粘合剂：常规粘合剂即可，例如上海德润宝特种润滑剂有限公司生产的相关产品
试验结果分析：
纸品质量分析：采用本实施例的起皱刀生产出来的纸品质量完全满足厂家要求的质量标准，主要指标均优于金属陶瓷起皱刀。与使用金属陶瓷起皱刀相比，纸品表面亮度提高，目视效果很好，皱纹均匀一致，长时间保持基本不变，特别适合生产细纹纸。皱纹变化至超过标准时，起皱刀不必然失效，生产稍粗皱纹的纸品时可以重复使用，直到纸面出现条纹或皱纹质量超标时，起皱刀失效。纸品手感好，松厚度好。起皱刀的寿命统计结果如表5所示。
表5 起皱刀寿命统计
Figure PCTCN2018090759-appb-000005
本实施例的起皱刀的使用寿命略有区别，与设计的硬度、耐磨性预计是一致的。
使用本实施例的起皱刀，除了提升纸品质量外，其超长的使用寿命，大大减轻了工人的劳动强度，减少了因换刀而产生的产量损失，一把本实施例的起皱刀寿命周期内，机台可生产更多的产品，同时还减少了换刀产生的纸品浪费。
实施例6
本实施例提供了一种起皱刀，如图7所示，其规格为4000mm×120mm×1.2mm，其是通过以下步骤制备的(如图17所示)：
根据起皱刀的规格选择相应规格的钢制基体；
在基体的顶端处形成一个直角三角形缺口，两条边的长度分别为1.0mm、15mm，短边位于顶端面，长边位于工作面；
在缺口内形成保护层，保护层的长边与基体的工作面平齐，短边与基体的顶端面平齐，保护层的材质为金属铜，保护层的硬度为HV 0.3 140；
将基体的顶端面研磨出一个过渡倾角，角度为5°，预磨部分的宽度为1.8mm；
采用超音速火焰喷涂在基体的顶端面形成耐磨涂层，耐磨涂层材料为碳化钨，对耐磨涂层进行研磨，最终耐磨涂层的厚度为0.06mm；
对耐磨涂层的一侧与烘缸表面(使用过程中)的接触点出进行加工，形成起皱刀的结构角，角度为76°，得到起皱刀。
对本实施例制备的起皱刀进行实际实验，具体按照以下方式进行：
试验纸机：某卫生纸厂2号纸机
试验目的：起皱刀寿命和出纸质量比较
对比标的：钢制起皱刀
该纸机长年使用钢制起皱刀进行生产，起皱刀寿命大约1.5个小时。起皱刀换下后，对磨损的起皱刀刃口进行重新修磨，修磨后的起皱刀可以循环使用。一般地，一把新起皱刀可以修磨6-7次，起皱刀宽度会窄至接近110mm时不再修磨而彻底报废。
采用本实施例的起皱刀进行实用对比试验。
试验时的具体工艺条件如下：
产品：抽取式面纸巾
纸浆原料：纯木浆
纸幅宽度：3600mm
纸品克重：13.5g/m 2，(无湿强度剂)
烘缸规格：直径2.5m、长度4.0m，铸铁烘缸，表面喷涂不锈钢涂层
烘缸线速度：750-900m/min
卷纸速度：600-800m/min
纸幅含水率：7.5％
起皱刀顶端倾角：76°
起皱刀载荷：4-5N/mm
起皱刀伸出长度：18mm
粘合剂：常规粘合剂即可，例如上海德润宝特种润滑剂有限公司生产的相关产品
试验结果分析：
纸品质量分析：采用本实施例的起皱刀生产出来的纸品质量完全满足厂家要求的质量标准，主要指标均优于钢制起皱刀。与使用钢制起皱刀相比，纸品表面亮度提高，目视效果很好，皱纹均匀一致，长时间保持基本不变，特别适合生产细纹纸。皱纹变化至超过标准时，起皱刀不必然失效，生产稍粗皱纹的纸品时可以重复使用，直到纸面出现条纹或皱纹质量超标时，起皱刀失效。纸品手感好，松厚度好。起皱刀的寿命统计结果如表6所示。
表6 起皱刀寿命统计
Figure PCTCN2018090759-appb-000006
本实施例的起皱刀的使用寿命略有区别，与设计的硬度、耐磨性预计是一致的。
使用本实施例的起皱刀，除了提升纸品质量外，其超长的使用寿命，大大减轻了工人的劳动强度，减少了因换刀而产生的产量损失，一把本实施例的起皱刀寿命周期内，机台可多生产2.5吨产品，同时还减少了换刀产生的纸品浪费。
由实施例1-6可以看出：本发明的起皱刀能够使制备得到的纸张的纸面皱纹结构基本没有变化，具有较长的使用寿命。

Claims (20)

  1. 一种起皱刀，其包括一个基体，该基体的顶端设有耐磨涂层，并且，该起皱刀与烘缸的接触点处的耐磨涂层下方设有保护层，并且，所述保护层的硬度低于造纸机烘缸表面的硬度。
  2. 根据权利要求1所述的起皱刀，其中，所述保护层位于所述耐磨涂层与所述基体的顶端面之间，和/或，所述保护层沿所述基体的工作面设置。
  3. 根据权利要求2所述的起皱刀，其中，当所述保护层沿所述基体的工作面设置时，所述保护层位于所述基体的工作面上靠近所述耐磨涂层的位置处。
  4. 根据权利要求2所述的起皱刀，其中，所述设置的方式包括以下几种：
    第一方式：所述保护层凸出于所述基体的工作面；或者，
    第二方式：所述基体的顶端处设有一个缺口，所述保护层位于所述缺口内，并且，所述保护层的外表面与所述基体的工作面位于同一平面内；或者，
    第三方式：所述基体的顶端处设有一个缺口，所述保护层包括两部分，一部分位于所述缺口内，另一部分凸出于所述基体的工作面。
  5. 根据权利要求4所述的起皱刀，其中，在第二方式和第三方式中，所述保护层的截面为三角形、菱形、梯形、其他规则形状或者不规则形状。
  6. 根据权利要求5所述的起皱刀，其中，在第二方式中，所述保护层内形成有工作垛和沟槽。
  7. 根据权利要求1-6任一项所述的起皱刀，其中，所述保护层的耐磨性能和硬度低于所述耐磨涂层。
  8. 根据权利要求1-7任一项所述的起皱刀，其中，所述保护层的硬度≤HV 0.3300。
  9. 根据权利要求8所述的起皱刀，其中，所述保护层的硬度为HV 0.3100-300。
  10. 根据权利要求9所述的起皱刀，其中，所述保护层的硬度为HV 0.3130-250。
  11. 根据权利要求10所述的起皱刀，其中，所述保护层的厚度为HV 0.3150-220。
  12. 根据权利要求1-11任一项所述的起皱刀，其中，所述保护层的材料为金属或合金。
  13. 根据权利要求12所述的起皱刀，其中，所述金属包括铜、铝、锌、锡、镍、钴和镁中的一种；所述合金包括铜、铝、锌、锡、镍、钴和镁中的至少两种所组成的合金。
  14. 根据权利要求1-13任一项所述的起皱刀，其中，所述保护层的厚度为0.1-2.0mm。
  15. 根据权利要求14所述的起皱刀，其中，所述保护层的厚度为0.3-1.0mm。
  16. 根据权利要求1-15任一项所述的起皱刀，其中，所述耐磨涂层的厚度为0.03-0.25mm，优选为0.05-0.12mm。
  17. 根据权利要求1-16任一项所述的起皱刀，其中，所述耐磨涂层的材料为金属、金属氧化物、陶瓷材料、硅酸盐、碳化物、硼化物和氮化物中的一种或几种的组合；优选地，所述耐磨涂层的材料包括金属、氧化铝、氧化铬、氧化锆、碳化钨、碳化铬、碳化锆、碳化钽和碳化钛中的一种或几种的组合；更优选地，所述耐磨涂层的材料为碳化钨-钴-铬合金或碳化钨-碳化铬-镍合金。
  18. 根据权利要求6所述的起皱刀，其中，所述工作垛的宽度为0.15mm-0.4mm，所述沟槽的深度为0.2mm-0.5mm、宽度为1.5mm-2.5mm，所述工作垛设于所述沟槽与所述基体的顶端面之间；
    优选地，所述沟槽为三角形、矩形或梯形。
  19. 根据权利要求1-18任一项所述的起皱刀，其中，所述基体的厚度为0.6-1.5mm，宽度为100-150mm；
    优选地，所述基体为钢制基体；
    优选地，所述基体的顶端面与工作面之间的夹角为70°-150°，优选为70°-90°。
  20. 权利要求1-19任一项所述的起皱刀的制备方法，其是在基体上的顶端面和/或工作面形成保护层，然后再在基体的顶端面处形成耐磨涂层，经研磨加工后得到所述起皱刀；
    优选地，所述制备方法包括：
    在基体的顶端面形成保护层，将基体的顶端面研磨形成适当的角度，然后在保护层之上形成耐磨涂层，经研磨加工后得到所述起皱刀；或者，
    在基体的工作面形成保护层，将基体的顶端面研磨形成适当的角度，然后在基体的顶端面形成耐磨涂层，经研磨加工后得到所述起皱刀；或者，
    在基体的顶端面和工作面形成保护层，将基体的顶端面研磨形成适当的角度，然后在基体顶端面上的保护层之上形成耐磨涂层，经研磨加工后得到所述起皱刀；或者，
    在基体的顶端处形成一个缺口，在所述缺口内形成保护层，将基体的顶端面研磨形成适当的角度，然后在基体的顶端面形成耐磨涂层，经研磨加工后得到所述起皱刀；
    优选地，所述保护层和所述耐磨涂层通过热喷涂、电镀或激光熔覆制成。
PCT/CN2018/090759 2018-03-26 2018-06-12 一种起皱刀及其制备方法 WO2019184092A1 (zh)

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