Sponge contact compression roller and manufacturing method thereof
By using a sponge contact pressure roller with a multi-layer structure in the contact pressure roller, the problem of the film without anti-adhesion is difficult to achieve flat winding during the winding process, and a more uniform air rolling amount control and film winding effect are achieved.
Patent Information
- Application Number
- CN202510248170.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-03-04
- Publication Date
- 2025-04-15
AI Technical Summary
In the process of plastic film manufacturing, films that lack anti-adhesion properties are difficult to achieve flat winding when the mother is winding, and conventional rubber contact rollers cannot effectively control the amount of air injected, resulting in problems of bubbles, curling edges and film deformation.
A sponge contact pressing roller is adopted, and a multi-layer structure is arranged on the outside of the shaft core, including a first adhesive layer, a sponge layer, a second adhesive layer and a rubber layer. The sponge layer is made of non-water absorbent material, the rubber layer is made of ethylene-Class rubber, and the first and second adhesive layers are made of polyurethane hot melt adhesive.
The sponge layer of the sponge contact pressure roller is lower and more uniform after being pressed, and the amount of air is more uniform and controllable, which solves the problem of difficulty in film winding and avoids the problem of easy damage and pollution of the sponge roller.
Smart Images
Figure CN119822133A_ABST
Abstract
Description
Technical Field
[0001] The invention relates to the technical field of contact pressure rollers, in particular to a sponge contact pressure roller and a manufacturing method thereof. Background Art
[0002] During the plastic film manufacturing process (such as cast film, blown film, biaxial stretching, etc.), a contact roller needs to be installed to press against the mother roll when the mother roll is rolled up. The contact roller will move as the diameter of the mother roll increases, following the contour of the mother roll. The air (air roll amount) drawn in between the film roll layers during winding is controlled to avoid the mother roll being wound too tightly, causing deformation of the film after unfolding, or to avoid the mother roll being wound too loosely, causing shrinkage inside the roll to produce vertical stripes.
[0003] For some optical films that require high transparency, anti-sticking and lubricating masterbatch cannot be added; or for some functional films, such as aluminum-plastic film CPP, considering the electrolyte resistance, not enough anti-sticking and lubricating masterbatch can be added; or some functional films are particularly soft, and the addition of anti-sticking and lubricating masterbatch has no effect. For such films, due to their lack of anti-adhesion properties, during the mother roll winding process, the general rubber contact roller cannot achieve smooth winding, and its contact pressure cannot roll a uniform air layer between the mother roll layers, resulting in bubbling and warping. The film is severely deformed after unfolding and cannot be used normally.
[0004] Sponge rollers are generally used for cleaning functions of equipment such as cleaning, painting, grinding, and gluing.
[0005] Therefore, an extremely soft contact roller is urgently needed to improve the film that lacks anti-adhesion properties. Too much air involvement in gap winding can easily produce longitudinal stripes, while the use of conventional rubber contact rollers for contact winding can easily produce bulging and warping.
[0006] Among the common rollers, sponge rollers have the lowest hardness and are generally used for cleaning, coating, grinding, gluing and other equipment. However, sponge rollers are not easy to process and their surface roughness is difficult to control. Second, they are prone to wear and tear when used directly as contact rollers, resulting in the risk of chipping and contaminating the film surface. Summary of the invention
[0007] In view of the deficiencies in the prior art, the present invention provides a B that solves the problems mentioned in the above background.
[0008] The present invention provides the following technical solution: a sponge contact pressure roller, comprising: an axis core, a first adhesive layer is arranged on the outer side of the axis core, a sponge layer is connected to the first adhesive layer, a second adhesive layer is arranged on the outer side of the sponge layer, a rubber layer is connected to the second adhesive layer, and axis heads are arranged on both sides of the axis core.
[0009] Preferably, the sponge layer is made of non-water-absorbent material, the rubber layer is made of EPDM rubber, and the first adhesive layer and the second adhesive layer are both made of polyurethane hot-melt adhesive.
[0010] Preferably, the non-absorbent material is polypropylene, polyvinyl chloride or polyurethane, and the pore size of the sponge layer after foaming is between 900um and 2000um; the obtained sponge has a Shore hardness of 25 to 35;
[0011] The EPDM rubber is EPDM rubber, and the Shore hardness is controlled at 40-50;
[0012] The thickness of the sponge layer is in the range of 1.5 to 2.5 cm, the thickness of the rubber layer is 30% to 45% of the thickness of the sponge layer, and the roughness Ra of the surface of the rubber layer 5 after grinding is in the range of 0.5 mm to 1.2 mm;
[0013] The first adhesive layer is made of thermoplastic polyurethane hot melt adhesive, and the second adhesive layer is made of reactive polyurethane hot melt adhesive;
[0014] The thickness of the first adhesive layer and the second adhesive layer is set to 0.5-1.2 mm.
[0015] Preferably, the shaft core is made of metal material.
[0016] Preferably, the metal material is carbon steel, alloy steel, high speed steel or cemented carbide.
[0017] Preferably, the shaft core is made of non-metallic material.
[0018] Preferably, the non-metal material is ultra-high molecular weight polyethylene or carbon fiber.
[0019] Preferably, the straightness of the shaft core is 0.1 mm / m, the roundness is plus or minus 0.05, and the dynamic balance test meets the G1 standard.
[0020] A method for manufacturing a sponge contact roller, characterized in that it comprises the following steps:
[0021] Step S1, shaft core cleaning preparation: clean the shaft core surface with 95% purity industrial alcohol, and after it is clean and dry, apply a first adhesive layer on the surface;
[0022] Step S2, processing the sponge layer: placing the shaft core vertically in a columnar container, adding a foaming resin, a foaming agent, a coupling agent, and antioxidant and anti-aging additives to uniformly foam to form a sponge layer;
[0023] Step S3, rubber layer coating preparation: after the sponge layer is completed, the sponge roller is placed in a glue pool of PVA high-temperature hydrosol and soaked, the PVA high-temperature hydrosol is injected into the holes formed in the sponge layer, and the PVA high-temperature hydrosol in the sponge layer is hardened, and the second adhesive layer is coated on the surface of the sponge layer;
[0024] Step S4, coating the rubber layer, coating the rubber layer on the second adhesive layer, and after the rubber layer is vulcanized, grinding it with an external cylindrical grinder to ensure that the roundness is within plus or minus 0.01;
[0025] Step S5, cleaning the sponge contact pressure roller, placing the entire sponge contact pressure roller in 100° C. water and soaking it until all the PVA high-temperature hydrosol is washed away and all the pores in the sponge layer are exposed again;
[0026] Step S6, installing the shaft head: after the sponge contact pressure roller is dried, the shaft heads are installed on both ends of the shaft core, and the sponge contact pressure roller is manufactured.
[0027] Preferably, in step S3, after the PVA high temperature hydrosol is solidified and hardened, the sponge layer is polished with an external cylindrical grinder to ensure that the roundness is within plus or minus 0.025.
[0028] Compared with the prior art, the present invention has the following beneficial effects:
[0029] 1. The present invention uses a sponge roller as a basis and adheres a soft rubber layer to the outside. The sponge layer of the sponge contact roller has a lower and more uniform pressure after being pressed, and the air entrainment is more uniform and controllable. This solves the problem that the air entrainment in the film roll is difficult to control even if the roller pressure is adjusted to a lower level in time due to the high hardness of the rubber in the winding process of the general rubber contact roller. This solves the problem that the film without anti-sticking masterbatch is difficult to wind.
[0030] 2. The present invention is prepared by coating with a rubber layer. After the sponge layer is completed, the sponge roller is placed in a glue pool of PVA high-temperature hydrosol for immersion, and the PVA high-temperature hydrosol is injected into the holes formed in the sponge layer. After the PVA high-temperature hydrosol in the sponge layer is hardened, a second adhesive layer is coated on the surface of the sponge layer to facilitate the polishing of the sponge layer, and then the rubber layer is coated, thereby avoiding the problem of directly using the sponge roller as a contact pressure roller, which is difficult to process, easy to be damaged during use, and easy to age and pollute the film. BRIEF DESCRIPTION OF THE DRAWINGS
[0031] Figure 1 It is a schematic diagram of the front cross-section structure of the present invention;
[0032] Figure 2 It is a schematic diagram of the side section structure of the present invention;
[0033] Figure 3 It is a flow chart of the present invention.
[0034] In the figure: 1, shaft core; 2, first adhesive layer; 3, sponge layer; 4, second adhesive layer; 5, rubber layer; 6, shaft head. DETAILED DESCRIPTION
[0035] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
[0036] See also Figure 1-2 A sponge contact roller comprises: an axis core 1, a first adhesive layer 2 is arranged on the outer side of the axis core 1, a sponge layer 3 is connected to the first adhesive layer 2, a second adhesive layer 4 is arranged on the outer side of the sponge layer 3, a rubber layer 5 is connected to the second adhesive layer 4, and axis heads 6 are arranged on both sides of the axis core 1.
[0037] The sponge layer 3 is made of non-water-absorbent material, the rubber layer 5 is made of EPDM rubber, and the first adhesive layer 2 and the second adhesive layer 4 are both made of polyurethane hot-melt adhesive;
[0038] In a specific embodiment, the non-absorbent material is polypropylene, polyvinyl chloride or polyurethane, and the pore size of the sponge layer 3 after foaming is between 900um and 2000um; the obtained sponge has a Shore hardness of 25 to 35;
[0039] In a specific embodiment, the EPDM rubber used to make the rubber layer 5 is EPDM rubber, and the Shore hardness is controlled at 40 to 50;
[0040] In a specific embodiment, the first adhesive layer 2 is made of thermoplastic polyurethane hot melt adhesive, and the second adhesive layer 4 is made of reactive polyurethane hot melt adhesive;
[0041] The thickness of the sponge layer 3 ranges from 1.5 to 2.5 cm, the thickness of the rubber layer 5 is 30% to 45% of the thickness of the sponge layer 3, the roughness Ra of the rubber layer 5 after surface grinding ranges from 0.5 mm to 1.2 mm, and the thickness of the first adhesive layer 2 and the second adhesive layer 4 is set at 0.5 to 1.2 mm.
[0042] The shaft core 1 is made of metal material;
[0043] In a specific embodiment, the metal material is carbon steel, alloy steel, high speed steel or cemented carbide.
[0044] The shaft core 1 is made of non-metallic material.
[0045] In a specific embodiment, the non-metallic material is ultra-high molecular weight polyethylene or carbon fiber. Considering that the contact pressure of the sponge contact roller during use is less than that of a conventional contact roller, and the contact pressure is adjustable, a shaft core made of carbon fiber material is preferably used to reduce the influence of the shaft core weight and its inertia on the contact pressure control.
[0046] The straightness of shaft core 1 is 0.1mm / m, the roundness is plus or minus 0.05, and the dynamic balance test meets the G1 standard.
[0047] See also Figure 3 A method for manufacturing a sponge contact roller, characterized in that it comprises the following steps:
[0048] Step S1, cleaning and preparing the shaft core 1: cleaning the surface of the shaft core 1 with industrial alcohol with a purity of 95%, and coating the first adhesive layer 2 on the surface after the shaft core 1 is clean and dried;
[0049] Step S2, processing the sponge layer 3: vertically placing the shaft core 1 in a columnar container, adding a foaming resin, a foaming agent, a coupling agent, and antioxidant and anti-aging additives to uniformly foam to form the sponge layer 3;
[0050] Step S3, preparation for coating with rubber layer 5: after the sponge layer 3 is completed, the sponge roller is placed in a glue pool of PVA high-temperature hydrosol and soaked, and PVA high-temperature hydrosol, i.e., polyvinyl alcohol high-temperature hydrosol, is injected into the holes formed in the sponge layer 3, and after the PVA high-temperature hydrosol in the sponge layer 3 is hardened, a second adhesive layer 4 is coated on the surface of the sponge layer 3;
[0051] Step S4, coating the rubber layer 5, coating the rubber layer 5 on the second adhesive layer 4, and after the rubber layer 5 is vulcanized, grinding it with an external cylindrical grinder to ensure that the roundness is within plus or minus 0.01;
[0052] Step S5, cleaning the sponge contact pressure roller, placing the entire sponge contact pressure roller in 100° C. water and soaking it until all the PVA high-temperature hydrosol is washed away and all the holes in the sponge layer 3 are exposed again;
[0053] Step S6, installing the shaft head 6: after the sponge contact pressure roller is dried, the shaft heads 6 are installed on both ends of the shaft core 1, and the sponge contact pressure roller is manufactured.
[0054] Furthermore, in step S3, after the PVA high temperature hydrosol is solidified and hardened, the sponge layer 3 is polished with an external cylindrical grinder to ensure that the roundness is within plus or minus 0.025.
[0055] Based on the sponge roller, a layer of soft rubber layer 5 is bonded to the outside. The sponge layer 3 of the sponge contact roller has lower and more uniform pressure after being pressed, and the amount of air entrained is also more uniform and controllable, which solves the problem that in the winding process of the general rubber contact roller, due to the high hardness of the rubber, even if the roller pressure is adjusted to a lower level in time, it is difficult to control the amount of air entrained in the film roll, and solves the problem of difficulty in winding the film without adding anti-sticking masterbatch. Before the sponge layer 3 is coated with the rubber layer 5, the sponge roller is placed in a glue pool of PVA high-temperature hydrosol for immersion, and the PVA high-temperature hydrosol is injected into the holes formed in the sponge layer 3. After the PVA high-temperature hydrosol in the sponge layer 3 is hardened, the sponge layer 3 is polished, coated with the second adhesive layer 4 and coated with the rubber layer 5, so that the hardened sponge layer 3 is convenient for polishing, gluing and coating, which solves the problem of difficult processing of the sponge layer 3.
[0056] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include", "comprises" or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article or apparatus that includes a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or apparatus.
[0057] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.
Claims
1. A sponge contact roller, characterized in that: include: An axis core (1), wherein a first adhesive layer (2) is arranged on the outer side of the axis core (1), a sponge layer (3) is connected to the first adhesive layer (2), a second adhesive layer (4) is arranged on the outer side of the sponge layer (3), a rubber layer (5) is connected to the second adhesive layer (4), and axis heads (6) are arranged on both sides of the axis core (1).
2. A sponge contact roller according to claim 1, characterized in that: The sponge layer (3) is made of non-water-absorbent material, the rubber layer (5) is made of EPDM rubber, and the first adhesive layer (2) and the second adhesive layer (4) are both made of polyurethane hot-melt adhesive.
3. A sponge contact pressure roller according to claim 2, characterized in that: The non-water-absorbent material is polypropylene, polyvinyl chloride or polyurethane, and the pore size of the sponge layer (3) after foaming is between 900um and 2000um; the obtained sponge has a Shore hardness of 25 to 35; The EPDM rubber is EPDM rubber, and the Shore hardness is controlled at 40-50; The thickness of the sponge layer (3) is in the range of 1.5 to 2.5 cm, the thickness of the rubber layer (5) is 30% to 45% of the thickness of the sponge layer (3), and the roughness Ra of the surface of the rubber layer (5) after grinding is in the range of 0.5 mm to 1.2 mm; The first adhesive layer (2) is made of thermoplastic polyurethane hot melt adhesive, and the second adhesive layer (4) is made of reactive polyurethane hot melt adhesive; The thickness of the first adhesive layer (2) and the second adhesive layer (4) is set at 0.5 to 1.2 mm.
4. A sponge contact pressure roller according to claim 3, characterized in that: The shaft core (1) is made of metal material.
5. A sponge contact pressure roller according to claim 4, characterized in that: The metal material is carbon steel, alloy steel, high speed steel or hard alloy.
6. The sponge contact roller according to claim 3, characterized in that: The shaft core (1) is made of non-metallic material.
7. A sponge contact pressure roller according to claim 6, characterized in that: The non-metal material is ultra-high molecular weight polyethylene or carbon fiber.
8. The sponge contact roller according to claim 1, characterized in that: The straightness of the shaft core (1) is 0.1 mm / m, the roundness is plus or minus 0.05, and the dynamic balance test reaches the G1 standard.
9. A method for manufacturing a sponge contact roller, characterized in that: The following steps are involved: Step S1, cleaning and preparing the shaft core (1): cleaning the surface of the shaft core (1) with industrial alcohol having a purity of 95%, and after cleaning and drying, coating the surface with a first adhesive layer (2); Step S2, processing the sponge layer (3): vertically placing the shaft core (1) in a columnar container, adding a foaming resin, a foaming agent, a coupling agent, and an anti-oxidation and anti-aging agent to uniformly foam the sponge layer (3); Step S3, preparation for coating with the rubber layer (5): after the sponge layer (3) is completed, the sponge roller is placed in a glue pool of PVA high-temperature hydrosol for immersion, the PVA high-temperature hydrosol is injected into the holes formed in the sponge layer (3), and after the PVA high-temperature hydrosol in the sponge layer (3) is hardened, a second adhesive layer (4) is coated on the surface of the sponge layer (3); Step S4, coating the rubber layer (5), coating the rubber layer (5) on the second adhesive layer (4), and after the rubber layer (5) is vulcanized, grinding it with an external cylindrical grinder to ensure that the roundness is within plus or minus 0.01; Step S5, cleaning the sponge contact roller, placing the entire sponge contact roller in 100° C. water and soaking it until all the PVA high-temperature hydrosol is washed away and all the pores in the sponge layer (3) are exposed again; Step S6, installing the shaft head (6): after the sponge contact pressure roller is dried, the shaft heads (6) are installed at both ends of the shaft core (1), and the sponge contact pressure roller is manufactured.
10. The method for manufacturing a sponge contact roller according to claim 9, characterized in that: In the step S3, after the PVA high temperature hydrosol is solidified and hardened, the sponge layer (3) is polished with an external cylindrical grinder to ensure that the roundness is within plus or minus 0.025.