Optical grade non-stick roll and method of manufacture

Abstract

The application discloses an optical-grade non-stick roller and a manufacturing method thereof. The optical-grade non-stick roller comprises a roller body, a metal base layer formed on the surface of the roller body, an insulating micro-point layer, a metal filling layer and a non-stick layer. The insulating micro-point layer comprises micro-points distributed on the surface of the metal base layer, and gaps are formed between adjacent micro-points. The metal filling layer covers the micro-points and fills the gaps between the micro-points to form micro-holes distributed on the surface of the insulating micro-point layer. The non-stick layer is formed in the micro-holes. The surface roughness RA of the metal filling layer and the non-stick layer is less than 0.01. The optical-grade non-stick roller has the non-stick property of the non-stick layer and the flatness of the metal filling layer after polishing. In addition, the network structure formed between the metal base layer and the insulating micro-point layer can guarantee the hardness and strength of the optical-grade non-stick roller.

Description

Technical Field

[0001] This invention belongs to the field of roller technology, and particularly relates to optical-grade non-stick rollers and their manufacturing methods. Background Technology

[0002] Rollers are cylindrical, rotating parts on machines. They have a wide range of applications, mainly in the production and processing of continuous or discontinuous sheet materials.

[0003] The performance requirements for rollers vary depending on the application.

[0004] In the prior art, Chinese patent application No. 202211158128.1 discloses a method for preparing a non-stick roller composite coating and the non-stick roller composite coating itself. The method for preparing the non-stick roller composite coating improves the adhesion of the non-stick layer material by pre-treating the surface of the metal substrate and spraying a transition layer. PFA (fusible polytetrafluoroethylene) is used in the sprayed non-stick layer to improve its wettability and compatibility, and AT40 (Al2O3-40wt.%TiO2) is added to improve the wear resistance of the non-stick layer.

[0005] For example, the existing technology disclosed in Chinese patent application No. 201210232872.1, a room-temperature curing epoxy non-stick coating for papermaking rollers, is composed of the following components by mass percentage: epoxy resin: 45%-49%, acetone: 11%-13%, molybdenum disulfide: 4%-6%, coupling agent: 0.8%-1.0%, dispersant: 1.3%-1.5%, curing agent: 19%-23%, graphite: 4%-6%, chromium trioxide: 4%-6%, polytetrafluoroethylene: 3%-5%, and defoamer: 0.6%-0.8%, with the sum of the mass percentages of all the above components being 100%. By coating the surface of papermaking rollers with this non-stick coating, the adhesion of pulp, additives, or coatings to the roller surface can be reduced or prevented, thereby greatly reducing the possibility of paper breakage and ensuring normal production. In addition, this coating also has the function of preventing roller corrosion.

[0006] Polytetrafluoroethylene (PTFE), as a widely used material with non-stick properties, can be used as a functional material on the surface of rollers to improve their non-stickiness. However, in some special fields, such as optical instruments and equipment, rollers are required not only to be non-stick but also to meet certain requirements for hardness and roughness. Spraying PTFE onto the surface of rollers cannot meet these requirements. Summary of the Invention

[0007] This invention addresses the problem that existing technologies using rollers simply coated with polytetrafluoroethylene (PTFE) cannot simultaneously meet the requirements for non-stickiness, hardness, and roughness, and proposes the following technical solution:

[0008] This invention provides an optical-grade non-stick roller, comprising:

[0009] Roller body;

[0010] Metal base layer, formed on the surface of the roller;

[0011] An insulating micro-dot layer, wherein the insulating micro-dots include micro-dots distributed on the surface of a metal substrate, with gaps formed between adjacent micro-dots;

[0012] A metal filler layer, wherein the metal filler layer covers the microdots and fills the gaps between the microdots to form micropores distributed on the surface of the insulating microdot layer;

[0013] The non-stick layer is formed within the micropores;

[0014] The surface roughness RA formed by the metal filler layer and the non-stick layer together does not exceed 0.01.

[0015] In some specific embodiments, the metal base layer is a chromium-plated layer with a thickness of 0.05 mm.

[0016] In some specific embodiments, the insulating micro-dot layer is formed by high-pressure spraying of insulating particles with a diameter not exceeding 0.1 mm, wherein the diameter of the insulating particles is larger than the particle diameter of the metal substrate.

[0017] In some specific embodiments, the metal filler layer is an HRC62 hard chrome plating layer.

[0018] In some specific embodiments, the non-stick layer is a polytetrafluoroethylene layer.

[0019] The present invention also provides a method for manufacturing an optical-grade non-stick roller, the method being used to manufacture the optical-grade non-stick roller according to any one of claims 1 to 5, the method comprising:

[0020] A metal base layer is formed on the surface of the roller;

[0021] Insulating particles are high-pressure sprayed onto the surface of a metal substrate to form an insulating micro-dot layer;

[0022] Electroplating forms a metal filler layer, which fills the gaps between microdots and covers the microdots, while simultaneously forming micropores on the surface of the insulating microdot layer.

[0023] Spray a non-stick material, making the thickness of the non-stick material greater than the thickness of the insulating micro-dot layer;

[0024] Polish the non-stick material after grinding it down to expose the metal filler layer.

[0025] In some specific embodiments, the metal substrate is a chromium-plated layer, and the thickness of the metal substrate is 0.05 mm.

[0026] In some specific embodiments, the diameter of the insulating particles does not exceed 0.1 mm.

[0027] In some specific embodiments, the non-stick material is polytetrafluoroethylene.

[0028] The beneficial effects of the present invention are as follows: the optical grade non-stick roller of the present invention, through the metal filling layer and the non-stick layer forming the roller surface, not only has the non-stick properties exhibited by the non-stick layer, but also the flatness exhibited by the metal filling layer after polishing; in addition, the network structure formed by the metal filling layer between the metal base layer and the insulating micro-dot layer can ensure the hardness and strength requirements of the optical grade non-stick roller. Attached Figure Description

[0029] Figure 1 The diagram shown is a structural schematic of the non-stick roller in the embodiment. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments.

[0031] Example

[0032] Figure 1 A schematic diagram of the structure of an optical grade non-stick roller according to this embodiment is shown. The optical grade non-stick roller includes a roller body 1, and a metal base layer 2, an insulating micro-dot layer 3, a metal filler layer 4 and a non-stick layer 5 formed on the surface of the roller body 1.

[0033] The metal base layer 2 is set on the surface of the roller body 1 to serve as a basic reinforcement and connection. The insulating micro-dot layer 3 is sprayed onto the surface of the metal base layer 2 to form micro-dots. Due to the relatively large particle size of the sprayed particles, certain gaps are formed between the micro-dots. During the formation of the metal filler layer 4, the metal material enters into the gaps between the micro-dots to fill them and simultaneously coat the micro-dots. Since the gaps at the top of the micro-dots are even larger, the metal filler layer 4 can be controlled in a way that prevents it from completely filling the gaps at the top, thus forming trumpet-shaped micropores at the top. When the non-stick layer 5 is subsequently formed, it does not... The adhesive layer 5 fills the micropores. After the surface of the roller is smoothed, a densely distributed dotted non-stick layer 5 is formed on the surface. This non-stick layer 5 gives the roller body 1 a non-stick property. At the same time, the non-stick layer 5 is filled in the funnel-shaped micropores formed by the metal filler layer 4. The metal filler layer 4 forms an important foundation between itself and the roller body 1 through the metal base layer 2, ensuring that the surface of the roller body 1 has the required strength and hardness. The insulating micro-dot layer 3 inside the metal filler layer 4 forms funnel-shaped micropores by controlling the particle size to accommodate the metal filler layer 4 for filling.

[0034] In this embodiment, the surface roughness RA formed by the metal filler layer and the non-stick layer together does not exceed 0.01.

[0035] The metal base layer 2 is an electroplated layer. A base layer is electroplated on the surface of the roller 1 through an electroplating process. The material of the electroplated layer can be chromium, copper, nickel, etc., among which chromium is the preferred electroplating material.

[0036] The insulating micro-dot layer 3 is the sum of the microparticles formed on the surface of the metal substrate 2 by high-pressure spraying of insulating material particles. The particle size is relatively large, which will form an insulating micro-dot layer 3 with gaps on the surface of the metal substrate 2. The insulating material can be resin powder, ceramic powder, etc., but is not limited to the above materials. The particle size of the particles is limited to facilitate the formation of an insulating micro-dot layer 3 with gaps, so as to facilitate the subsequent formation of the metal filling layer 4 and the formation of trumpet-shaped micropores.

[0037] The metal filler layer 4 is also an electroplated layer. Through electroplating, a network structure covering the insulating micro-dot layer 3 and connected to the metal base layer 2 is formed on the surface of the metal base layer 2 and the insulating micro-dot layer 3. This metal structure layer provides the roller surface with the required hardness and, through grinding, the required roughness. The material for the electroplated metal filler layer 4 can be chromium, copper, nickel, etc., with HRC62 hard chromium being a preferred electroplating material.

[0038] The non-stick layer 5 is formed by spraying. During the spraying process, the material of the non-stick layer 5 fills the micropores and simultaneously covers the surface of the metal filler layer 4. By grinding the non-stick layer 5 to remove excess material above the micropores and further polishing the surface, the overall smoothness exhibited by the metal filler layer 4 and the non-stickiness exhibited by the non-stick layer 5 filled in the micropores can be obtained. The material of the non-stick layer 5 is usually formed by spraying polytetrafluoroethylene, or the non-stickiness can be obtained by spraying nanomaterials and utilizing the nano-properties of the materials.

[0039] In addition, this embodiment also provides a method for manufacturing an optical-grade non-stick roller, which is as follows:

[0040] A metal base layer 2 is formed by electroplating on the surface of the roller body 1;

[0041] Insulating particles are high-pressure sprayed onto the surface of the metal substrate 2 to form an insulating micro-dot layer 3;

[0042] Electroplating forms a metal filler layer 4, which fills the gaps between microdots and covers the microdots, while micropores are formed on the surface of the insulating microdot layer 3.

[0043] A non-stick layer 5 is formed by spraying a non-stick material, making the thickness of the non-stick material greater than the thickness of the insulating micro-dot layer;

[0044] Polish the non-stick material after grinding it down to expose the metal filler layer.

[0045] In the above process, the electroplating to form the metal base layer 2, the high-pressure spraying to form the insulating micro-dot layer 3, the electroplating to form the metal filler layer 4, and the spraying to form the non-stick layer 5 can all be obtained by using existing processing technology and conventional processing parameters. Moreover, the above processing technology and conventional processing parameters can be adaptively adjusted according to different sizes of rollers 1 and different performance parameter requirements for rollers 1.

[0046] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it.

Claims

1. An optical-grade non-stick roller, characterized in that, include: Roller body; Metal base layer, formed on the surface of the roller; An insulating micro-dot layer, wherein the insulating micro-dots include micro-dots distributed on the surface of a metal substrate, with gaps formed between adjacent micro-dots, the insulating micro-dot layer is formed by high-pressure spraying of insulating particles with a diameter not exceeding 0.1 mm, the diameter of the insulating particles being larger than the particle diameter of the metal substrate; A metal filling layer, wherein the metal filling layer covers the microdots and fills the gaps between the microdots to form micropores distributed on the surface of the insulating microdot layer, and the insulating microdot layer inside the metal filling layer forms a micropore that can accommodate the metal filling layer and further form a funnel-shaped micropore by controlling the particle size of the particles. The non-stick layer is formed within the micropores; The surface roughness RA formed by the metal filler layer and the non-stick layer together does not exceed 0.

01.

2. The optical-grade non-stick roller according to claim 1, characterized in that, The metal base layer is a chromium-plated layer with a thickness of 0.05 mm.

3. The optical-grade non-stick roller according to claim 1, characterized in that, The metal filler layer is an HRC62 hard chrome plating layer.

4. The optical-grade non-stick roller according to claim 1, characterized in that, The non-stick layer is a polytetrafluoroethylene layer.

5. A method for manufacturing an optical-grade non-stick roller, characterized in that, The manufacturing method is used to manufacture the optical-grade non-stick roller according to any one of claims 1 to 4, and the manufacturing method is as follows: A metal base layer is formed on the surface of the roller; Insulating particles are high-pressure sprayed onto the surface of a metal substrate to form an insulating micro-dot layer; Electroplating forms a metal filler layer, which fills the gaps between microdots and covers the microdots, while simultaneously forming micropores on the surface of the insulating microdot layer. Spray a non-stick material, making the thickness of the non-stick material greater than the thickness of the insulating micro-dot layer; Polish the non-stick material after grinding it down to expose the metal filler layer.

6. The method for manufacturing an optical-grade non-stick roller according to claim 5, characterized in that, The metal base layer is a chromium-plated layer, and the thickness of the metal base layer is 0.05 mm.

7. The method for manufacturing an optical-grade non-stick roller according to claim 5, characterized in that, The diameter of the insulating particles does not exceed 0.1 mm.

8. The method for manufacturing an optical-grade non-stick roller according to claim 5, characterized in that, The non-stick material is polytetrafluoroethylene.

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