Method for manufacturing multi-piece pressing roller

Abstract

The present invention belongs to the technical field of pressure roller manufacturing and discloses a method for manufacturing a multi-piece pressure roller. The method comprises: step S1, providing a long strip of extruded profile having a preset external profile and internal longitudinal airway holes and longitudinal communication holes through an integrated extrusion process; step S2, cutting the profile as needed to obtain a pressure roller core; step S3, processing a piston hole connected to the communication hole; step S4, providing an air barrier within the communication hole to separate air-controlled partitions; step S5, processing a channel to connect the airway hole to the corresponding air-controlled partition; and step S6, completing the assembly of the piston and pressure roller sheet. The present invention significantly reduces manufacturing costs and cycle times through the "extrusion molding + modular configuration" approach, and achieves flexible and adjustable air-controlled partitions, thus having significant economic and technical advantages.

Description

Technical Field

[0001] The present invention relates to the technical field of pressure roller manufacturing, and in particular to a method for manufacturing a multi-zone air-controlled multi-piece pressure roller for industrial composite processing. Background Art

[0002] Laminating multiple layers of sheet materials, such as films, fabrics, and rubber sheets, is a common process in modern industrial production. To ensure lamination quality, rollers are often used to press the materials together, ensuring a tight fit between the layers and effectively removing bubbles caused by trapped air.

[0003] Multi-piece pressing rollers, particularly those with zoned pneumatic control, are among the most advanced laminating devices currently available. These rollers consist of a core, also known as a core, and a large number of independently movable radially movable roller segments. Complex air paths within the core divide the roller axially into multiple, independently controlled zones. By applying varying air pressures to each zone, the roller segments within that zone can generate varying pressing forces, precisely adapting to sheet materials of varying width or thickness, achieving optimal contoured lamination.

[0004] However, the manufacturing process of such high-performance multi-piece pressure rollers in the existing technology has significant defects. Its core component, the pressure roller core, needs to integrate complex internal air paths including the main air inlet, partitioned air paths and piston cylinders, so there are usually two manufacturing methods. The first is fully customized production: based on the specific requirements of each order regarding the total length, installation method, number and position of air control partitions, a new set of drawings is designed, and then a whole piece of metal bar such as an aluminum bar is used to manufacture it through a large amount of subtractive processing methods such as milling and drilling. The second method is to assemble multiple independently processed functional parts into a complete core through welding, screwing, etc.

[0005] The above existing manufacturing method has the following problems:

[0006] 1) High manufacturing cost: A large number of finishing processes and complex assembly processes consume a lot of machine time and manpower, resulting in high manufacturing costs for a single core.

[0007] 2) Long production cycle: The fully customized production model cannot prepare materials and standardize production. The cycle from drawing design to final product delivery is very long and cannot meet the market demand for rapid response.

[0008] 3) Design rigidity and lack of flexibility: Once the core is processed, the internal gas control partition layout is permanently fixed and cannot be modified or adjusted according to subsequent process changes or new application requirements, resulting in extremely poor flexibility.

[0009] Therefore, there is an urgent need for a new method for manufacturing multi-piece pressing rollers to overcome the problems of high cost, long cycle, and poor flexibility in the existing technology. Summary of the Invention

[0010] The purpose of the present invention is to provide a method for manufacturing a multi-piece pressure roller, aiming to solve the technical problems in the prior art of multi-zone air-controlled multi-piece pressure roller core, such as high manufacturing cost, long production cycle and inflexible air-controlled zoning due to reliance on customized processing.

[0011] To achieve the above object, the present invention provides the following technical solutions:

[0012] A method for manufacturing a multi-piece pressing roller comprises the following steps:

[0013] Step S1: providing a long extruded profile, wherein the extruded profile is formed by integral extrusion, and its cross section has a predetermined external profile and at least one longitudinal airway hole and at least one longitudinal communication hole integrally formed and extending along its length;

[0014] Step S2: cutting the extruded profile according to a preset roller length to obtain a roller core having a predetermined length;

[0015] Step S3: machining a plurality of piston holes in the roller core, so that each of the piston holes is connected to the longitudinal communication hole;

[0016] Step S4: disposing at least one air barrier in the longitudinal communication hole to separate the longitudinal communication hole into at least two mutually isolated air control zones along its length direction;

[0017] Step S5: selecting a corresponding longitudinal airway hole for each air control zone, and processing a connecting channel to connect the longitudinal airway hole with the air control zone;

[0018] Step S6: Assemble the piston and the pressing roller sheet onto the pressing roller core to complete the manufacture of the multi-piece pressing roller.

[0019] Preferably, in step S4, an air control zone is defined by placing two air blocking sheets in the longitudinal communication hole at intervals along the axial direction thereof.

[0020] Preferably, in step S5, the connecting channel is realized by machining an external process hole on the pressure roller core body, and the external process hole connects the selected longitudinal airway hole and the corresponding air control partition; the method also includes using a seal to seal the external opening of the external process hole after the connection.

[0021] Preferably, the method further comprises the following steps: processing an air inlet connected to the longitudinal air duct hole at at least one end of the pressure roller core body for connecting to an external air source.

[0022] Preferably, the method further comprises the following steps: using a seal to seal the openings of the longitudinal airway holes and the longitudinal communication holes at both ends of the pressure roller core.

[0023] Preferably, in step S1, the extruded profile is extruded from an aluminum alloy material.

[0024] Preferably, the method also includes a step of modifying the air control partition, including: changing the position of the air barrier plate in the longitudinal communication hole to re-divide the air control partition; and processing new connecting channels according to the re-divided air control partition to establish a connecting relationship between the new longitudinal airway hole and the new air control partition.

[0025] A multi-piece pressure roller core manufactured by the above-mentioned manufacturing method, wherein the core is composed of an integrally extruded profile, and the interior of the profile has an integrally formed longitudinal airway hole and a longitudinal communication hole running through its length direction; the longitudinal communication hole is provided with an air barrier plate that divides it into multiple air-controlled partitions; the core is also processed with a piston hole connected to the air-controlled partition, and a channel for connecting the longitudinal airway hole with the corresponding air-controlled partition.

[0026] Compared with the prior art, the present invention has the following beneficial effects:

[0027] 1. This invention utilizes the core concept of "extrusion molding followed by simplified subsequent processing," replacing the traditional "complex, integrated processing." Through aluminum alloy extrusion, the complex internal airway structure is integrally formed during the profile production stage. Subsequent processing, such as cutting and drilling, requires only minimal processing to complete the core. This allows long, extruded profiles to be mass-produced and readily available as standard parts. Upon order placement, only cutting is required, significantly shortening lead times and reducing manufacturing costs.

[0028] 2. This invention breaks down the roller core manufacturing process into two stages: standard profile manufacturing and personalized configuration. Roller blades, pistons, extruded profiles, and other components can all be mass-produced as standard parts, achieving a high degree of modularity and transforming the previous model of completely relying on customized production.

[0029] 3. The air-controlled zones in this invention are created by placing removable air-blocking plates within the communication holes. This means that even after the roller is manufactured, if the customer's application scenario changes and the length or position of the air-controlled zones need to be adjusted, this can be achieved through a simple process of repositioning the air-blocking plates and re-machining the communication holes, providing unprecedented flexibility and adaptability throughout the product's life cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for use in the description of the embodiments. Obviously, the drawings described below are only some illustrative embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0031] Figure 1 Schematic diagram of the cross-section of a multi-piece pressing roller manufactured according to an embodiment of the present invention.

[0032] In the figure: 1-extruded profile / roller core; 2-longitudinal airway hole; 3-longitudinal communication hole; 4-piston hole; 5-positioning rod; 6-air barrier; 7-external process hole; 8.1-process hole sealing screw; 8.2.1-communication hole sealing screw; 8.2.2-airway hole sealing screw; 9-connecting hole; 10-air inlet; 11-mounting hole; 12-piston; 13-roller plate; P-air control partition. DETAILED DESCRIPTION

[0033] To make the objectives, technical solutions, and advantages of the present invention more apparent, embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It is apparent that the described embodiments are only some of the embodiments of the present invention, and not all of them. All other embodiments derived by persons of ordinary skill in the art based on the embodiments of the present invention without inventive effort are also within the scope of protection of the present invention.

[0034] The embodiment of the present invention provides a new method for manufacturing a multi-piece pressure roller, the core idea of ​​which is to manufacture the pressure roller core structure, which was originally achieved through complex cutting processing, through an integrated extrusion molding method.

[0035] See also Figure 1 As shown, the manufacturing method of the present invention specifically comprises the following steps:

[0036] Step S1: Providing an extruded profile 1

[0037] First, a mold with a specific cross-sectional shape is designed. Then, through an aluminum alloy extrusion process, a long extruded profile 1 is mass-produced. This profile is formed in one piece, and its cross-section contains most of the structural features required to manufacture the roller core. Specifically, the cross-section has the following characteristics:

[0038] Used to assemble the outer contour of the pressure roller sheet 13.

[0039] At least one, preferably multiple longitudinal airway holes 2 are provided along the length of the profile, and these holes serve as the main air supply pipes for each air control zone.

[0040] A longitudinal communication hole 3 located in the middle of the profile serves as a "distribution chamber" connecting the main air channel and the piston below.

[0041] Through a single extrusion process, these complex internal channels are precisely manufactured with smooth inner walls, resulting in superior airflow performance compared to channels formed by traditional drilling. This extruded profile can be stocked in large quantities as standard raw material.

[0042] Step S2: Cut to a fixed length to obtain the roller core

[0043] Based on the total roller length required by the customer's order, a cutting device is used to precisely cut the long extruded profile 1 into a roller core of a predetermined length. This step quickly transforms standardized raw materials into semi-finished products of customized length.

[0044] Step S3: Processing piston hole 4 and other holes

[0045] Perform necessary machining on the cut roller core. Mainly includes:

[0046] A plurality of piston holes 4 are machined at the bottom of the core body for accommodating the pistons 12 .

[0047] The connecting holes 9 are processed so that each piston hole 4 is fluidically connected with the longitudinal communication hole 3 above.

[0048] As needed, a mounting hole 11 and an air inlet 10 communicating with the longitudinal airway hole 2 are processed on the end face or side of the core. The air inlet 10 is used for subsequent installation of an air pipe joint to connect to an external air source.

[0049] Step S4: Constructing the gas control partition P

[0050] This is a key and innovative step in achieving zoned gas control.

[0051] Based on design requirements, air barrier sheets 6 are placed at specific locations within the longitudinal communication hole 3. Air barrier sheets 6 serve as sealed partitions that effectively separate the communication hole 3 along its length. For example, two air barrier sheets 6 are spaced apart within the communication hole 3, and the space between them forms an independent air control zone P. Air barrier sheets 6 can be secured in place using mechanical clips or positioning rods 5.

[0052] For each formed air control zone P, one of the multiple longitudinal air passage holes 2 is selected as its air supply source. Then, an external process hole 7 is machined on the side of the core body. This hole needs to be precisely drilled through the wall of the selected longitudinal air passage hole 2 and continue to extend until it communicates with the corresponding air control zone P.

[0053] After establishing connectivity, use a sealing screw 8.1 with a sealing ring to tighten and seal the external opening of the external process hole 7. This completes a complete, independent air path from the specific air inlet 10 -> specific longitudinal airway hole 2 -> specific process hole 7 -> specific air control zone P -> corresponding piston hole 4.

[0054] Step S5: Sealing and assembly

[0055] After all machining and gas line construction are completed, the final sealing and assembly work is carried out.

[0056] Use sealing screws 8.2.1 and 8.2.2 to seal the longitudinal communication holes 3 at both ends of the roller core and the open ends of the longitudinal airway holes 2 not used as air inlets.

[0057] The standard piston 12 is installed into the piston hole 4, and then the standard pressure roller sheet 13 is sequentially sleeved onto the outside of the pressure roller core.

[0058] Install the air pipe joint at the air inlet 10.

[0059] At this point, a complete multi-zone air-controlled multi-piece pressing roller has been manufactured.

[0060] Furthermore, the method of the present invention offers excellent post-process modifiability. If the length or position of the air-controlled partition P needs to be changed during use, all that's required is: unscrewing and moving the air-blocking plate 6 to the new position; sealing the existing external process hole 7 with sealant or screws; and re-drilling a new external process hole 7 to establish a new air connection based on the new partition position, which is then sealed with sealing screws 8.1. This low-cost modifiability is unmatched by existing technologies.

[0061] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for manufacturing a multi-piece pressing roller, characterized in that: The following steps are involved: Step S1: providing a long extruded profile (1), wherein the extruded profile (1) is formed by integral extrusion, and its cross section has a preset external profile and at least one longitudinal airway hole (2) and at least one longitudinal communication hole (3) integrally formed and extending along its length; Step S2: cutting the extruded profile (1) according to a preset roller length to obtain a roller core having a predetermined length; Step S3: machining a plurality of piston holes (4) in the roller core, and connecting each of the piston holes (4) to the longitudinal communication hole (3) via a connecting hole (9); Step S4: arranging at least one air blocking plate (6) in the longitudinal communication hole (3) to separate the longitudinal communication hole (3) into at least two mutually isolated air control partitions (P) along its length direction; Step S5: selecting a corresponding longitudinal airway hole (2) for each air control partition (P), and processing a connecting channel so that the longitudinal airway hole (2) is connected to the air control partition (P); Step S6: Assembling the piston (12) and the pressure roller sheet (13) onto the pressure roller core to complete the manufacture of the multi-piece pressure roller; The method further comprises the step of modifying the gas control partition (P), comprising: changing the position of the gas blocking plate (6) in the longitudinal communication hole (3) to re-divide the gas control partition (P); And according to the re-divided air control partition (P), a new connecting channel is processed to establish a connecting relationship between the new longitudinal air channel hole (2) and the new air control partition (P).

2. The method for manufacturing a multi-piece pressing roller according to claim 1, characterized in that: In step S4, an air control zone (P) is defined by placing two air blocking sheets (6) in the longitudinal communication hole (3) at intervals along its axial direction.

3. The method for manufacturing a multi-piece pressing roller according to claim 1, characterized in that: In step S5, the connecting channel is realized by machining an external process hole (7) on the roller core body, wherein the external process hole (7) connects the selected longitudinal airway hole (2) and the corresponding air control partition (P); the method further includes sealing the external opening of the external process hole (7) with a seal after the connection.

4. The method for manufacturing a multi-piece pressing roller according to claim 1, wherein: The method further comprises the following steps: machining an air inlet (10) connected to the longitudinal airway hole (2) at at least one end of the roller core body for connecting to an external air source.

5. The method for manufacturing a multi-piece pressing roller according to claim 1, characterized in that: The method further comprises the following steps: using a sealing member to seal the openings of the longitudinal airway hole (2) and the longitudinal communication hole (3) at both ends of the pressure roller core.

6. The method for manufacturing a multi-piece pressing roller according to claim 1, characterized in that: In step S1, the extruded profile (1) is extruded from an aluminum alloy material.

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