Water core structure of super-long calender roll and calender roll

Abstract

The application discloses a water core structure suitable for an ultra-long calender roller and the calender roller. The water core structure suitable for the ultra-long calender roller comprises a first pipe body made of a corrosion-resistant material with strength and rigidity, a second pipe body made of a non-metal material, a connecting unit and a partition strip. A plurality of second pipe bodies are sleeved on the first pipe body and are arranged in sections along the axial direction of the first pipe body, and the adjacent second pipe bodies are fixed by the connecting unit. At least two sink grooves extending along the axial direction are formed on the second pipe body, and the partition strip is embedded in the sink grooves aligned along the axial direction of the second pipe body and protrudes from the second pipe body. The water core structure suitable for the ultra-long calender roller has the beneficial effects that the manufacturing, assembly, cost and performance of the water core structure suitable for the ultra-long calender roller are revolutionarily changed.

Description

Technical Field

[0001] This invention relates to the field of pattern shaping technology, and more particularly to a water core structure and calendering roll adapted to ultra-long calendering rolls. Background Technology

[0002] The calender rolls need to be circulated with cooling water during operation to control the temperature of the roll surface. The roll surface is engraved with patterns. When the molten glass passes through the upper and lower rolls, it is instantly cooled to set the patterns.

[0003] Traditional water cores are manufactured using a single material. The mainstream solution is integral extrusion molding of 6061 aluminum alloy, but aluminum alloy has poor corrosion resistance in circulating cooling water environments and is heavy and costly. Other solutions use stainless steel tubing as the water core body, which improves corrosion resistance, but its higher density exacerbates the weight problem. For ultra-large calendering rolls with a length approaching 7 meters, a diameter of 560 mm, and a net weight exceeding 8 tons, using water cores made of any single metal material presents a common technical drawback: the high density of the metal material results in an extremely heavy water core (approximately 1.2 tons for the aluminum alloy solution), requiring large lifting equipment for assembly and disassembly, making the operation dangerous and extremely inconvenient.

[0004] Furthermore, existing water cores, in order to achieve compartmentalized cooling, typically rely on extrusion molding or deep-hole machining of thick-walled tubes for their flow channel structure. This results in high mold costs, significant manufacturing difficulties, and once the flow channels are formed, their distribution is fixed, lacking design flexibility. In ultra-long dimensions, if segmented manufacturing followed by assembly is used, the alignment accuracy of the flow channels between segments is difficult to guarantee, directly affecting the smoothness and uniformity of the cooling water's axial flow.

[0005] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] The technical problem to be solved by this invention is: to solve the problem of the difficulty in processing the water core structure of the ultra-large calender roll to adapt to the ultra-long calender roll.

[0007] The present invention solves the above-mentioned technical problems through the following technical means: This invention claims to protect a water core structure adapted to ultra-long calendering rolls, including a first tube made of corrosion-resistant, strong, and rigid material, a second tube made of non-metallic material, a connecting unit, and a separator. Several second tubes are sleeved on the first tube, and the several second tubes are arranged in segments along the axial direction of the first tube. Adjacent second tubes are fixed by the connecting unit. At least two grooves extending axially are opened on the second tubes, and separators are embedded in the grooves aligned along the axial direction of the second tubes. The separators protrude from the second tubes.

[0008] Preferably, it also includes an elastic sealing unit, and the mounting groove is lined with an elastic sealing unit.

[0009] Preferably, the second tube is made of nylon.

[0010] Preferably, the connecting unit includes a connecting plate and a first screw. A first mounting groove is radially formed on the surface of an adjacent second tube. The connecting plate is arranged in the first mounting groove and is pressed and fitted into the first mounting groove by the first screw.

[0011] Preferably, it also includes a support flange, a flow guide, and a transition flange. The support flange and the transition flange are respectively inserted into both ends of the first pipe body and connected to the second pipe body; the flow guide is provided on the end face of the support flange away from the first pipe body.

[0012] Preferably, the support flange located outside the first pipe body has a first mounting portion protruding radially, and the end of the spacer bar of the first mounting portion abuts against it.

[0013] Preferably, the separator is made of wood or aluminum.

[0014] Preferably, a sealing ring is provided between the support flange, the transition flange and the first pipe body.

[0015] The present invention claims to protect a calendering roll, including a water core structure adapted to an ultra-long calendering roll, a roll body, a rotary joint, an end face flange and a water outlet pipe. The roll body has a roll cavity, and the water core structure adapted to the ultra-long calendering roll is coaxially arranged in the roll cavity. A protruding partition strip separates the gap between the roll body and the second pipe body to form multiple cooling channels. A rotary joint is provided at one end of the roller body, and a water inlet is provided on the rotary joint. An end face flange is provided at the other end of the roller body, and the end face flange is connected to multiple water outlet pipes, which are connected to the corresponding cooling channels.

[0016] Preferably, a gap is provided between the end face of the water core structure adapted to the ultra-long calender roll and the end face flange to form a second flow channel, and a third mounting groove is provided on the end face flange facing the first tube body. The separator extends radially along the second tube body to be inserted and matched with the corresponding third mounting groove. The water inlet, cooling flow channel, second flow channel and water outlet are interconnected.

[0017] The advantages of this invention are: 1. Firstly, this invention is specifically designed for the water core structure of an ultra-long calendering roll measuring 7 meters and weighing 1.2 tons. It abandons the conventional thinking of using integrated metal or non-metal materials, instead employing a first tube made of corrosion-resistant, high-strength, and rigid material as a supporting skeleton to bear all bending moments and ensure the rigidity of the water core structure for the ultra-long and heavy calendering roll. This is complemented by a second tube made of non-metallic material as a flexible covering. The use of a non-metallic second tube offers at least three advantages: firstly, it significantly reduces the weight of the water core structure for the ultra-long calendering roll; secondly, it facilitates processing and is beneficial for the formation of subsequent cooling channels; and thirdly, it significantly reduces costs. This is not a simple material replacement, but rather a synergistic effect achieved through a combination of rigidity and flexibility. The steel core compensates for the lack of rigidity in nylon, while the nylon compensates for the weight and corrosion limitations of the steel core. Both are indispensable, working together to achieve a synergistic effect that leverages the strengths of both materials. Secondly, a groove is set on the second tube. Firstly, the second tube is made of a non-metallic material, making it easier to process. Secondly, the partition strip inside the groove serves two purposes: First, the partition strip / groove acts as a guide, facilitating alignment when the first tube is installed on the second. Second, the partition strip itself protrudes from the second tube, creating a flow channel using the groove, partition strip, and the inner wall of the subsequent calendering roll. Compared to the existing water-core structure of the integrated metal-fitted ultra-long calendering roll, which requires drilling deep holes or designing complex flow channels within the metal tube, this approach offers at least two clear advantages. Firstly, the cooling water does not flow inside the tube or the roll, but rather in the gap between the groove wall of the second tube's outer wall, the inner wall of the subsequently installed roll, and the side of the partition strip. This ensures good cooling while reducing processing difficulty and cost. Benefit 2: The separation strips can greatly ensure the uniformity of cooling and the efficiency of heat exchange by diverting the cooling water. It can be said that this achieves two benefits at once. The combined effect of these factors has brought about a revolutionary change in the manufacturing, assembly, cost, and performance of the water core structure for ultra-large, ultra-heavy, and ultra-long calendering rolls.

[0018] 2. The elastic sealing unit is an O-ring, which allows the separator strip to fit against the inner wall of the calender roll, preventing cooling water from flowing between different channels.

[0019] 3. Nylon material has at least four advantages: first, it is lightweight; second, it is low-cost; third, it is easy to process; and fourth, nylon has good self-lubricating properties and heat resistance, which can be said to perfectly meet the material requirements of the second tube in this invention.

[0020] 4. The flow guide shroud diverts the cooling water, allowing it to enter the cooling channel evenly. The flow guide shroud and the partition strips work together to evenly divide the cooling channel, achieving good cooling uniformity and high heat exchange efficiency. Attached Figure Description

[0021] Figure 1This is a radially cut-out schematic diagram of the water core structure adapted to the ultra-long calendering roll in Embodiment 1 of the present invention; Figure 2 This is a cross-sectional diagram from an AA perspective; Figure 3 This is a schematic diagram of the supporting flange structure in Embodiment 1 of the present invention; Figure 4 This is a schematic diagram of the calendering roll cut along the radial direction in Embodiment 2 of the present invention; Figure 5 This is a cross-sectional diagram from a BB perspective; Figure 6 This is a schematic diagram of the end face flange in Embodiment 2 of the present invention; Figure 7 This is a cross-sectional diagram from a CC perspective; 1. Roller body; 1a. First flow channel; 1b. Cooling flow channel; 1c. Second flow channel; 2. Rotary joint; 20. Water inlet; 3. End face flange; 30. Third mounting groove; 31. Threaded hole; 32. Recessed hole; 4. Water outlet pipe; 5. Ball valve; 6. Water core structure; 60. First tube body; 61. Second tube body; 610. Settling tank; 62. Connecting unit; 620. Connecting plate; 621. First screw; 63. O-ring; 64. Separator strip; 65. Support flange; 650. First mounting part; 66. Shield; 67. Transition flange; 68. Sealing ring. Detailed Implementation

[0022] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1 See Figure 1 and Figure 2 and Figure 3 This embodiment requires the protection of a water core structure adapted to ultra-long calendering rolls, specifically designed for calendering rolls with excessive length, diameter, and net weight. This structure includes a first tube 60, a second tube 61, a connecting unit 62, an O-ring 63, a separator 64, a support flange 65, a flow guide 66, and a transition flange 67.

[0024] The first tube 60 is a metal tube, serving as the load-bearing skeleton of the water core structure 6. It is preferably a stainless steel tube with strong corrosion resistance and sufficient strength and rigidity. The axis of the first tube 60 is parallel to the axis of the calendering roll. A second tube 61 is coaxially sleeved outside the first tube 60. The second tube 61 and the first tube 60 have a transition fit. This transition fit is preferably based on a hole-basis system, with a hole tolerance of H8 and an axis tolerance of js7.

[0025] The second tube 61 has multiple segments, which extend axially along the first tube 60. The second tube 61 is made of non-metallic material, preferably nylon, which is not only lightweight, but also has high heat resistance and chemical stability, making it suitable for high-temperature glass environments, and is easy to process.

[0026] The adjacent second tubes 61 are fixed to the surface of the first tube 60 by a connecting unit 62. Specifically, the connecting unit 62 includes a connecting plate 620 and a first screw 621. The surface of the adjacent second tubes 61 is provided with a first mounting groove along the radial direction. The connecting plate 620 is arranged in the first mounting groove. The connecting plate 620 is pressed and fitted into the first mounting groove by the first screw 621, so that the second tubes 61 are spliced ​​together to form a sealed whole covering the first tube 60.

[0027] The outer wall of the second tube 61 has six grooves 610 radially formed. The six grooves 610 are arranged in a ring array along the axis of the second tube 61. The corresponding grooves 610 on each second tube 61 are aligned with each other and connected along the axis.

[0028] Furthermore, the settling tank 610 is lined with an O-ring 63, and a partition strip 64 is embedded in the settling tank 610, which is aligned axially with the second tube 61. The partition strip 64 protrudes from the surface of the second tube 61. The partition strip 64 is made of wood or aluminum.

[0029] It should be noted that the O-ring 63 allows the separator strip to fit against the inner wall of the calender roll, preventing the cooling water from flowing between the different channels. It is not limited to the O-ring 63; it can also be a sealing strip or other elastic sealing unit.

[0030] A first stepped hole is coaxially formed at one end of the first tube body 60. One end of the support flange 65 is coaxially inserted into the first stepped hole. The support flange 65 located outside the first stepped hole has a first mounting part 650 protruding radially. There are six first mounting parts 650, which are arranged in a circular array along the axis of the support flange 65. The first mounting parts 650 abut against the end of the separator strip 64. A second screw passes through the support flange 65 and connects to the second tube body 61. A flow guide 66 is coaxially connected to the end of the support flange 65 away from the first tube body 60.

[0031] The first pipe body 60 has a second stepped hole coaxially opened at the other end of the pipe opening. The transition flange 67 has a three-section stepped shaft structure. The middle section has the largest diameter and is the large diameter section. One end of the transition flange 67 is inserted into the second stepped hole. The large diameter section is connected to the second pipe body 61 by a third screw. The other end of the transition flange 67 is defined as the smallest diameter section.

[0032] It should be noted that the number of settling tanks 610 is not limited to six, but there must be at least two. The number and position of the first mounting parts 650 correspond to the number and position of the partition bars 64, so similarly, the number is not limited. In addition, O-rings 68 are provided between the support flange 65, the transition flange 67 and the first pipe body 60. The sealing rings 68 serve a sealing function and are not limited to O-rings.

[0033] Example 2 See Figure 4 and Figure 5 and Figure 6 and Figure 7 Based on Embodiment 1, this embodiment requires protection of the calendering roll, including roll body 1, water core structure 6, rotary joint 2, end face flange 3, water outlet pipe 4 and ball valve 5. The roll body 1 has a roll cavity, and the water core structure 6 is coaxially arranged in the roll cavity. The partition strip 64 evenly divides the gap between the roll cavity and the second tube body 61 to form six cooling channels 1b.

[0034] A rotary joint 2 is mounted on one end of the roller body 1 via a fourth screw. The rotary joint 2 has a water inlet 20. The flow guide 66 is directly opposite the water outlet of the rotary joint 2, which divides the water flow to form a first flow channel 1a. The other end of the roller body 1 is connected to an end face flange 3 via a fifth screw. The end face flange 3 has a coaxial recess 32. The smallest diameter section is inserted into the recess 32, and a gap is reserved between the larger diameter section and the end face flange 3 to form a second flow channel 1c.

[0035] Six third mounting slots 30 are provided on the end face of the end flange 3 facing the first pipe body 60. The six third mounting slots 30 are arranged in a circular array along the axis of the end flange 3. The partition strip 64 extends radially along the second pipe body 61 to be inserted and matched with the corresponding third mounting slot 30.

[0036] The end flange 3 has six threaded holes 31 arranged in a ring array along the axis of the end flange 3. The threaded holes 31 are connected to the second flow channel 1c. Each threaded hole 31 is connected to a water outlet pipe 4, and each water outlet pipe 4 is equipped with a ball valve 5.

[0037] The process of manufacturing and assembling the cooling water core for this calendering roll is as follows: S1. Process several sections of the second tube body 61 to the required outer diameter and length; S2. Machining the countersunk groove 610 on the second tube body 61. The inner diameter of the second tube body 61 and the outer diameter of the first tube body 60 adopt the basic hole system. The hole tolerance is H8 and the shaft tolerance is js7. Drilling and tapping the end face of the second tube body 61. S3. Machining the outer diameter of the first tube body 60mm and the first and second stepped holes at both ends; S4. Place the processed second tube 61 onto the first tube 60, and use a wooden or aluminum strip with the same width as the countersink 610 as a separator 64 to ensure the straightness of the countersink 610 of each second tube 61. Mill the countersink 610 at the connection point, and connect the connecting plate 620 to the connecting plate 620 with the first screw 621. S5. The processed support flange 65, transition flange 67 and end face flange 3 are connected with corresponding screws, and the end face is connected to ball valve 5 and water outlet pipe 4.

[0038] S6 Place the O-ring 63 into the settling tank 610, and place wooden or aluminum strips into the settling tank 610, which is aligned axially with the second tube body 61. S7. Use a crane or other lifting tools to insert the water core into the inner cavity of the calender roll and fix the water outlet flange to the end face of the calender roll.

[0039] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A water-core structure adapted to ultra-long calendering rolls, characterized in that, The first tube (60) is made of a corrosion-resistant, strong and rigid material, the second tube (61) is made of a non-metallic material, the connecting unit (62) and the partition strip (64). The first tube (60) is fitted with several second tubes (61), which are arranged in segments along the axial direction of the first tube (60). Adjacent second tubes (61) are fixed by the connecting unit (62). At least two axially extending grooves (610) are opened on the second tubes (61). The partition strip (64) is embedded in the grooves (610) aligned along the axial direction of the second tubes (61). The partition strip (64) protrudes from the second tubes (61).

2. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, It also includes a resilient sealing unit, which is lined with the mounting groove.

3. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, The second tube (61) is made of nylon.

4. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, The connecting unit (62) includes a connecting plate (620) and a first screw (621). The surface of the adjacent second tube (61) is provided with a first mounting groove along the radial direction. The connecting plate (620) is arranged in the first mounting groove. The connecting plate (620) is pressed and fitted into the first mounting groove by the first screw (621).

5. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, It also includes a support flange (65), a flow guide (66) and a transition flange (67). The support flange (65) and the transition flange (67) are respectively inserted into the two ends of the first pipe body (60) and connected to the second pipe body (61); the flow guide (66) is provided on the end face of the support flange (65) away from the first pipe body (60).

6. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, The support flange (65) located outside the first pipe body (60) has a first mounting part (650) protruding radially, and the first mounting part (650) abuts against the end of the separator (64).

7. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, The separator (64) is made of wood or aluminum.

8. The water core structure for adapting ultra-long calendering rolls according to claim 1, characterized in that, A sealing ring (68) is provided between the support flange (65), the transition flange (67) and the first pipe body (60).

9. A calendering roll, characterized in that, The device includes a water core structure for adapting ultra-long calendering rolls as described in any one of claims 1 to 8, a roll body (1), a rotary joint (2), an end face flange (3), and a water outlet pipe (4). The roll body (1) has a roll cavity, and a water core structure (6) is coaxially arranged in the roll cavity. A protruding partition strip (64) separates the gap between the roll body (1) and the second pipe body (61) to form multiple cooling channels (1b). A rotary joint (2) is provided at one end of the roller body (1), and a water inlet (20) is provided on the rotary joint (2). An end face flange (3) is provided at the other end of the roller body (1). The end face flange (3) is connected to multiple water outlet pipes (4), and the water outlet pipes (4) are connected to the corresponding cooling channels (1b).

10. The calendering roll according to claim 9, characterized in that, A gap is provided between the end face of the water core structure adapted to the ultra-long calender roll and the end face flange (3) to form a second flow channel (1c). The end face flange (3) facing the first tube body (60) is provided with a third mounting groove (30). The partition strip (64) extends radially along the second tube body (61) to be inserted and matched with the corresponding third mounting groove (30). The water inlet (20), cooling flow channel (1b), second flow channel (1c) and water outlet (4) are connected to each other.

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