A rubber roll and a method for manufacturing the same

Abstract

The application relates to a rubber roller and a preparation method thereof, the preparation method comprising the following steps: pretreating a roller core; providing a coating rubber material, the coating rubber material being a liquid composite material; coating the surface of the roller core with the coating rubber material; heating and gelling the rubber roller formed by coating; rough machining the rubber roller after gelling, so that the shape and size of the rubber roller are close to process requirements; high-temperature curing the rubber roller after rough machining; and finishing the rubber roller after high-temperature curing. The preparation method can not only reduce the difficulty of rubber roller machining, but also completely avoid the problems of rubber material falling off and end face cracking of the rubber roller in the machining process, improves the first-time product yield, avoids the repairing process after cracking, improves the overall quality of the product, and improves the production efficiency.

Description

Technical Field

[0001] This application relates to the field of rubber roller technology, and in particular to a rubber roller and its preparation method. Background Technology

[0002] Composite material rollers, often called resin rollers, are rollers formed by coating a metal roller core with a composite material and then processing it through a series of processes.

[0003] Currently, the manufacturing methods for composite material rollers mainly include several processes such as coating, curing, and machining. In the machining process, due to the high hardness and strength of the composite material surface, turning and grinding require significant turning forces to achieve a smooth surface, making the process difficult. Furthermore, machining can easily lead to cracking or even delamination of the roller end face, resulting in a low first-pass yield and poor product quality. Summary of the Invention

[0004] To address the problems existing in the prior art, the present invention provides a method for preparing a rubber roller, which can avoid the problems of rubber material falling off and end face cracking during the machining process.

[0005] On one hand, the present invention provides a method for preparing a rubber roller, comprising:

[0006] Pre-treat the roller core;

[0007] A coating compound is provided, wherein the coating compound is a liquid composite material;

[0008] The surface of the roller core is coated with the coating material;

[0009] The rubber roller formed by the coating is heated to gel.

[0010] The gelled rubber roller is rough-processed to make its shape and size close to the process requirements;

[0011] The rough-processed rubber roller is then cured at high temperature.

[0012] The rubber roller after high-temperature curing is then precision-machined.

[0013] In one embodiment, the pretreatment of the roller core includes adding extension ends at both ends of the roller core, the extension ends having a length of 100-250mm.

[0014] In one embodiment, the pretreatment of the roller core includes:

[0015] The surface of the roller core is sandblasted; and / or

[0016] The surface of the roller core is cleaned and removed using a cleaning agent; and / or

[0017] The surface of the roller core is machined to remove oxide layers, rust, etc.; and / or

[0018] An adhesive is applied to the surface of the roller core to form an adhesive layer on the surface of the roller core.

[0019] In one embodiment, the method for preparing the composite material roller further includes preheating the roller core before coating the surface of the roller core with the coating material.

[0020] In one embodiment, when the rubber roller is heated and gelled, the heating temperature is 45-85°C and the heating time is 14-16 hours. After gelling, the hardness of the roller surface is 78 Shore D-85 Shore D.

[0021] In one embodiment, the roughing of the gelled roller includes turning the roller surface to make the shape and size of the roller surface close to the process requirements.

[0022] In one embodiment, the rough processing of the gelled roller includes cutting the roller along its total length, with the roller retaining a shrinkage allowance after cutting.

[0023] In one embodiment, the shrinkage allowance is 0-200 mm.

[0024] In one embodiment, in the step of subjecting the rough-processed rubber roller to high-temperature curing, the curing temperature is 100-140°C and the curing time is 48-60 hours or more.

[0025] On the other hand, the present invention also provides a rubber roller, which is prepared by the rubber roller preparation method of any of the above embodiments.

[0026] Beneficial Effects: In the preparation method of this rubber roller, after the coating material is heated and gelled but before high-temperature curing, the coating material on the roller surface is machined. Since gelation occurs at a low temperature during this stage, the shrinkage of the coating material is small, and there is no significant force between it and the roller core. Therefore, the internal stress in the gelled coating material is relatively low. Furthermore, the coating material at this stage is not fully reacted, the intermolecular cohesive force is small, and the coating material itself has a certain elastic variable space, resulting in relatively low shear strength and requiring less machining force. Therefore, machining the coating material at this stage not only reduces the difficulty of machining but also avoids significant internal stress and the large reaction force generated by large machining forces. This prevents the coating material from being subjected to excessive forces during rough machining, thus avoiding cracking of the rubber surface.

[0027] Compared with the existing technology of machining the rubber roller after the coating material has fully reacted and cured, this method can not only reduce the difficulty of machining the rubber roller, but also completely avoid the problems of rubber material falling off and end face cracking that are prone to occur when the rubber roller is stressed during machining. This improves the first-pass yield, avoids the repair process after cracking, improves the overall quality of the product, and increases production efficiency. Attached Figure Description

[0028] Figure 1 This is a flowchart of a method for preparing a composite material rubber roller in one embodiment. Detailed Implementation

[0029] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0030] Currently, in the machining process, due to the high hardness and strength of the composite material surface of the rubber roller, a large turning force is required to turn and grind the composite material surface of the rubber roller to make it smooth. The machining is difficult, and the end face of the rubber roller is prone to cracking or even delamination during machining.

[0031] The applicant found that the main reason for the above problems is that, due to the different coefficients of thermal expansion between the composite material and the metal roller core, the shrinkage capacity of the composite material is much greater than that of the metal roller core. This causes the composite material to generate large internal stress during the curing process, which cannot be effectively released, ultimately forming residual stress inside the rubber roller. Furthermore, because the composite material is fully reacted after curing, the intermolecular cohesive force is very large, and the shear strength is particularly high. Therefore, during machining and grinding, greater force is required to smooth the surface of the composite material, resulting in high processing difficulty. When the composite material is subjected to a large external force, a reaction force is formed between the composite material and the roller core. This reaction force, together with the residual stress inside the rubber roller, acts on the composite material, making the end face of the rubber roller prone to cracking and delamination during machining.

[0032] Based on this, the present application provides a method for preparing a rubber roller, which performs machining on the rubber roller before the composite material is cured, reducing the difficulty of machining and avoiding the problem of the rubber roller cracking or delaminating under stress during machining.

[0033] Specifically, at least one embodiment of this application provides a method for preparing a rubber roller, comprising:

[0034] Pre-treat the roller core;

[0035] A coating compound is provided, wherein the coating compound is a liquid composite material;

[0036] The surface of the roller core is coated with the coating material;

[0037] The rubber roller formed by the coating is heated to gel.

[0038] The gelled rubber roller is rough-processed to make its shape and size close to the process requirements;

[0039] The rough-processed rubber roller is then cured at high temperature.

[0040] The rubber roller after high-temperature curing is then precision-machined.

[0041] The method for preparing the rubber roller provided in the above embodiments of this application involves machining the rubber coating on the roller surface after the coating material has been heated and gelled but before high-temperature curing. Since gelation occurs at a low temperature during this stage, the shrinkage of the coating material is small, and there is no significant force between it and the roller core. Therefore, the internal stress in the gelled coating material is relatively low. Furthermore, the coating material at this stage has not fully reacted, the intermolecular cohesive force is small, and the coating material itself has a certain elastic variable space, resulting in relatively low shear strength and requiring less machining force. Therefore, machining the coating material at this stage not only reduces the difficulty of machining but also avoids significant internal stress and the large reaction force generated by large machining forces. This prevents the coating material from being subjected to large forces during rough machining, thus avoiding cracking of the rubber surface.

[0042] Compared with the prior art where the rubber roller is machined after the coating material has fully reacted and cured, the method for preparing composite material rubber rollers provided in the above embodiments of this application can not only reduce the difficulty of machining the rubber rollers, but also completely avoid the problem of rubber material falling off and end face cracking when the rubber rollers are subjected to stress during machining. This improves the first-pass yield, avoids the repair process after cracking, improves the overall quality of the product, and increases production efficiency.

[0043] The following is a detailed description of a method for preparing a rubber roller according to an embodiment of the present disclosure, with reference to the accompanying drawings.

[0044] Figure 1 This is a flowchart of a method for preparing a rubber roller according to an embodiment of this application.

[0045] like Figure 1 As shown, the method includes the following steps.

[0046] Step S1: Roll core pretreatment.

[0047] In this embodiment, the roller core can be a roller body made of metal materials, such as an iron core or a steel core.

[0048] Pretreatment of the roll core may include pretreating the surface of the roll core and creating extensions at both ends of the roll core.

[0049] For example, in this embodiment, creating extension ends at both ends of the roller core may include welding a roller body structure of the same material as the roller core to both ends of the roller core to form extension ends at both ends of the roller core, with the length of the extension ends being 100-250mm. In this way, by creating extension ends at both ends of the roller core, the length shrinkage of the roller core during processing can be absorbed, avoiding the situation where the length of the roller core after processing does not meet the process requirements.

[0050] In this embodiment, the pretreatment of the roller core made of metal material may include cleaning, grinding, etc., to make the surface of the roller core clean and flat.

[0051] In some embodiments, the surface pretreatment may include sandblasting the surface of the roller core to increase the surface roughness of the roller core, thereby improving the adhesion between the coated rubber and the roller core after coating, enhancing the bonding strength between the coated rubber and the roller core, and ensuring the quality of the rubber roller.

[0052] In some embodiments, surface pretreatment may further include using a cleaning agent to wash away dirt such as dust and oil from the roller core surface, ensuring the cleanliness of the roller core surface and facilitating the subsequent coating process.

[0053] In some embodiments, surface pretreatment may further include machining the surface of the roller core to remove oxide layers, rust, etc., ensuring the flatness of the roller core surface and preventing the rubber compound from delaminating after being coated onto the roller core, thus ensuring the quality of the rubber roller.

[0054] In some embodiments, surface pretreatment may further include applying an adhesive to the surface of the roller core to form an adhesive layer on the surface of the roller core, which facilitates the coating of the coating material in subsequent processes.

[0055] Step S2: Provide the coating compound.

[0056] The coating compound is a liquid composite material. In this embodiment, the coating compound can be prepared by mixing synthetic resin and functional additives. For example, the synthetic resin can be epoxy resin, phenolic resin, polyamide resin, etc., and the functional additives can include defoamers, coupling agents, etc.

[0057] The coating compound can be pre-formulated or purchased according to production requirements. In this embodiment, the coating compound can be prepared by adding resin and functional additives to a mixing device in a certain weight ratio according to production requirements, and then mixing them evenly for later use.

[0058] Step S3: Apply a coating compound to the surface of the roller core.

[0059] Specifically, in this embodiment, a casting machine can be used for the coating operation. For example, the coating material obtained in step S2 is mixed evenly with other additives such as curing agent in the casting machine, and then poured onto the surface of a rotating roller core. At the same time, the casting machine moves along the axial direction of the roller core while pouring until the coating operation of the roller core is completed.

[0060] In some embodiments, step S3 further includes preheating the roller core before coating its surface with the coating compound. During coating, to reduce the viscosity of the coating compound and improve its fluidity, it needs to be heated to a specified temperature before coating. In this embodiment, to reduce the temperature difference between the roller core and the coating compound, the roller core needs to be preheated to a specified temperature based on the temperature of the coating compound. This ensures that the coating compound maintains its original temperature for a certain period after being poured onto the roller core, maintaining good fluidity and allowing the coating compound to evenly coat the roller core, thus improving the coating effect. Preheating the roller core to a specified temperature means heating it to a temperature close to that of the coating compound. For example, if the coating compound temperature is around 50°C, the roller core can be preheated to 45-55°C, such as 45°C, 50°C, or 55°C.

[0061] Step S4: Heat and gel the coated roller.

[0062] In some embodiments, the rubber roller after the coating in step S3 can be directly heated with a heating lamp to gel and solidify the coating material on the surface of the roller. Of course, in some other embodiments, other equipment such as a warm air furnace can also be used for heating.

[0063] In this embodiment, when heating and gelling the rubber roller, the heating temperature is 45-85℃, the heating time is 14-16 hours, and the hardness of the roller surface after gelling is ensured to be 78 Shore D-85 Shore D.

[0064] For example, in one instance, the heating temperature is 45°C and the heating time is 16 hours.

[0065] For example, in one instance, the heating temperature is 60°C and the heating time is 15.5 hours.

[0066] For example, in one instance, the heating temperature was 75°C and the heating time was 14.5 hours.

[0067] For example, in one instance, the heating temperature is 85°C and the heating time is 14 hours.

[0068] In this embodiment, after the heating and gelation in step S4, the coating material on the roller surface has solidified but has not yet fully reacted. At this time, the internal stress between the coating materials is small, the cohesive force between molecules is small, the coating material itself has a certain elastic variable space, and the shear strength of the coating material is also relatively low, which is then utilized for subsequent machining.

[0069] Specifically, in this embodiment, by controlling the heating temperature and heating time, the hardness of the rubber roller surface after gelation is made to be 78 Shore D-85 Shore D. A roller surface with this hardness avoids excessive machining forces during machining and also prevents the coating material from being fully formed. For example, when the hardness of the gelled rubber roller surface is greater than 85 Shore D, such as 90 Shore D, its surface hardness is basically the same as that of the finished rubber roller. However, machining under these conditions still carries a certain probability of end-face cracking, and cannot completely prevent the rubber roller from cracking and delaminating under stress during machining. Conversely, when the hardness of the gelled rubber roller surface is less than 78 Shore D, such as 70 Shore D, although end-face cracking can be completely avoided during machining, the rubber material in this state is not fully formed, causing significant deformation of the roller surface during subsequent high-temperature curing. This necessitates further machining, which can then lead to end-face cracking again.

[0070] Step S5: Roughly process the rubber roller.

[0071] In this embodiment, after the rubber roller provided in step S4 has cooled naturally to room temperature, it can be rough-processed using machining equipment.

[0072] In this embodiment, rough machining of the rubber roller may include rough turning the roller surface using a lathe to make the shape and size of the roller surface close to the process requirements. For example, in some embodiments, after rough turning, the diameter of the rubber roller is slightly larger than the diameter of the finished rubber roller, leaving a small amount of fine grinding allowance.

[0073] In this embodiment, the rough processing of the rubber roller may also include cutting the roller along its total length to bring its length close to the process requirements. Additionally, in this embodiment, a shrinkage allowance is retained after cutting. Since the total length cutting of the rubber roller in this embodiment is performed after low-temperature gelation and before high-temperature curing, the roller is not yet fully shaped at this point. During the subsequent high-temperature curing process, the roller core will shrink by a certain amount. Therefore, in this embodiment, by leaving a shrinkage allowance during the total length cutting of the rubber roller, the situation where the length shrinkage of the rubber roller after high-temperature curing does not meet the process requirements can be avoided.

[0074] Specifically, in this embodiment, the shrinkage allowance is 0-200mm, meaning the length of the cut rubber roller is 0-200mm longer than the length of the finished rubber roller. It should be noted that in this embodiment, the specific value of the shrinkage allowance can be determined based on the material of the roller core. If the roller core shrinkage is small, a smaller shrinkage allowance can be retained, such as 3mm, 5mm, or 10mm; if the roller core shrinkage is large, a larger shrinkage allowance can be retained, such as 20mm, 30mm, or 50mm.

[0075] Step S6: High-temperature curing.

[0076] In this embodiment, the rubber roller processed in step S5 can be placed in a curing device for high-temperature curing, so that the coating material can react completely and be cured into shape.

[0077] In one embodiment, the high-temperature curing temperature of the rubber roller is 100-140°C, and the curing time is 48-60 hours.

[0078] In this embodiment, after the rubber roller is cured at high temperature, the hardness of its roller surface is between 88 Shore D and 93 Shore D, and the rubber roller has been completely cured and formed.

[0079] Step S7: Perform finishing on the rubber roller.

[0080] In this embodiment, the finishing process includes fine grinding of the roller surface to ensure that the surface roughness and flatness meet the process requirements. It should be noted that in this embodiment, after the rubber roller is cured at high temperature, only fine grinding is performed. The roller surface is not repeatedly subjected to large turning or cutting forces, thus avoiding the problem of end-face cracking of the rubber roller.

[0081] This application also provides a composite material roller, which is prepared by the composite material roller preparation method of any of the above embodiments.

[0082] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0083] The embodiments described above are merely illustrative of several implementation methods of this application, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this application, and these all fall within the protection scope of this application. Therefore, the protection scope of this patent application should be determined by the appended claims.

Claims

1. A method for preparing a rubber roller, characterized in that, include: Pre-treat the roller core; A coating compound is provided, wherein the coating compound is a liquid composite material; The surface of the roller core is coated with the coating material; The rubber roller formed by coating is heated and gelled at a temperature of 45-85℃ for 14-16 hours. The hardness of the roller surface after gelling is 78 Shore D-85 Shore D. The gelled rubber roller is rough-machined to make its shape and size close to the process requirements, while retaining a fine grinding allowance; The rough-processed rubber roller is then cured at high temperature. The rubber roller after high-temperature curing is precision-machined, and the precision-machined part includes fine grinding of the roller surface.

2. The preparation method according to claim 1, characterized in that, The pretreatment of the roller core includes adding extension ends at both ends of the roller core, the length of which is 100-250mm.

3. The preparation method according to claim 1, characterized in that, The pretreatment of the roller core includes: The surface of the roller core is sandblasted; and / or The surface of the roller core is cleaned and removed using a cleaning agent; and / or The surface of the roller core is machined to remove the oxide layer and rust; and / or An adhesive is applied to the surface of the roller core to form an adhesive layer on the surface of the roller core.

4. The preparation method according to claim 1, characterized in that, The preparation method further includes preheating the roller core before coating the surface of the roller core with the coating material.

5. The preparation method according to claim 1, characterized in that, The rough processing of the gelled rubber roller includes turning the roller surface to make the shape and size of the roller surface close to the process requirements.

6. The preparation method according to claim 1, characterized in that, The rough processing of the gelled roller includes cutting the roller along its total length, with the roller retaining a shrinkage allowance after cutting.

7. The preparation method according to claim 6, characterized in that, The shrinkage allowance is 0-200mm.

8. The preparation method according to claim 1, characterized in that, In the step of high-temperature curing the rough-processed rubber roller, the curing temperature is 100-140℃ and the curing time is 48-60 hours.

9. A rubber roller, characterized in that, The rubber roller is prepared by the method of any one of claims 1-8.

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