A gluing roller for a single facer

Abstract

The utility model discloses a kind of glue roller for single facer, comprising: the roller shaft of axial extension;At least two groups of continuous glue coating units, symmetrically arranged in the roller shaft axial two ends;Intermittent glue coating unit, coaxially arranged between two groups of continuous glue coating units;Among them, the continuous glue coating unit and intermittent glue coating unit are alternately arranged along the roller shaft axial, and the outer diameter of continuous glue coating unit and the outer diameter of intermittent glue coating unit remain same.Intermittent unit central layout makes glue precision cover corrugated wave crest bonding point, glue does not contact exchange material central region, material effective work area increases, so that water molecule transmission channel keeps unobstructed.

Description

Technical Field

[0001] This utility model relates to the field of rubber roller technology, and in particular to a rubber roller for a single-sided machine. Background Technology

[0002] Currently, the manufacturing of total heat exchange cores commonly employs a single-facer to bond corrugated materials and total heat exchange materials with adhesive, forming a double-layer corrugated structure. Traditionally, the glue roller continuously applies glue at the contact points between the corrugated crests and the planar heat exchange material, resulting in glue lines covering the entire surface of the heat exchange material. Taking a 200mm x 200mm corrugated paper with a 5mm pitch as an example, when the glue line width is 0.5mm, both sides of the heat exchange material are in contact with the corrugated material. After deducting the 7mm boundary sealing width, the effective exchange area accounts for only 81% of the total material area. The glue blocks the water molecule transport path, significantly reducing the enthalpy efficiency and sensible heat efficiency of the core. Industry research indicates that the heat transfer performance of total heat exchange materials is positively correlated with the effective exchange area; the 19% effective area loss caused by the continuous glue application process has become a key bottleneck restricting the improvement of core energy efficiency.

[0003] To address the above issues, existing technologies attempt to optimize adhesive formulations or adjust coating thickness, but cannot fundamentally reduce the area covered by the adhesive.

[0004] For example, the "Glue Application Device for a Single-Sided Machine" disclosed in Chinese patent literature, publication number "CN207416135U", includes a bracket, glue tray, glue application roller, glue leveling roller, and corrugated roller. The glue tray is provided with a flow-cutting plate at both ends of the glue application roller. A glue tank for loading glue is formed in the glue tray between the two flow-cutting plates. The glue tray is provided with a driving component for driving the flow-cutting plates to slide back and forth along the axial direction of the glue application roller.

[0005] The above-mentioned solutions utilize a novel mechanical structure. When the width of the corrugated paper decreases, a drive mechanism moves the intercepting plate back and forth along the extension of the coating roller, thereby adjusting the distance between the two intercepting plates to match the width of the corrugated paper. Ultimately, when the coating roller applies adhesive to the corrugated paper on the corrugated roller, the possibility of excess adhesive being applied to the outer wall of the corrugated roller is reduced, thus minimizing adhesive loss. However, this still results in localized closed areas of adhesive lines on the surface of the exchange material. Another solution uses pre-cutting of the exchange material to avoid the corrugated bonding points, but this increases process complexity and waste rate. None of these methods solve the problem of physical blockage of the mass transfer channels by the adhesive, and they may introduce airtightness risks. Therefore, there is an urgent need to develop a novel adhesive application structure that can precisely control the adhesive application area while ensuring bonding strength, maximizing the effective working area of ​​the exchange material. Utility Model Content

[0006] To address the technical problems of effective area loss and mass transfer channel blockage caused by continuous adhesive application in total heat exchange materials, this solution involves symmetrically setting at least two sets of continuous adhesive application units on an axially extended roller, and coaxially configuring intermittent adhesive application units between them. This ensures that the adhesive precisely covers only the corrugated crest bonding area, eliminating adhesive coverage in non-bonding areas, thereby maximizing the effective working area of ​​the total heat exchange material and preserving the complete water molecule mass transfer path.

[0007] To achieve the above objectives, the present invention adopts the following technical solution:

[0008] A gluing roller assembly for a single-sided machine includes: an axially extending roller shaft; at least two sets of continuous gluing units symmetrically arranged at both ends of the roller shaft; and an intermittent gluing unit coaxially disposed between the two sets of continuous gluing units; wherein the continuous gluing units and the intermittent gluing units are alternately arranged along the roller shaft axis, and the outer diameter of the continuous gluing units and the outer diameter of the intermittent gluing units remain the same.

[0009] The core of this solution lies in the axially arranged adhesive application unit assembly structure of the roller. Two sets of continuous adhesive application units are fixed at both ends of the roller, with intermittent adhesive application units coaxially arranged in the middle; all three have the same outer diameter. The continuous units are responsible for covering the edge area of ​​the corrugated core, ensuring boundary sealing; the intermittent units correspond to the central area of ​​the core, applying adhesive only at the contact points of the corrugated crests. When the roller rotates, the continuous units form a complete adhesive line at the material edge, while the intermittent units create spaced adhesive dots. This physically prevents adhesive from penetrating the central area of ​​the exchange material, directly solving the problem of effective area loss caused by traditional continuous adhesive application. Simultaneously, the uniform outer diameter design ensures uniform contact pressure between all units and the material, avoiding adhesion failure caused by uneven adhesive film thickness.

[0010] Furthermore, the number of intermittent glue application units is n, and the number of continuous glue application units is n+1;

[0011] Starting from the end of the continuous coating unit, the rollers are arranged alternately along the roller axis in a sequence of continuous coating unit and intermittent coating unit.

[0012] Furthermore, the circumferential length of the continuous coating unit is equal to b + 2d, where b is the width of the adapted fully heated corrugated core and d is the amount of burr increase.

[0013] Furthermore, the axial width of the intermittent adhesive application unit is a - 2c, where a is the length of the adapted fully thermal corrugated core and c is the edge sealing width.

[0014] Therefore, this utility model has the following beneficial effects.

[0015] The centrally located intermittent units allow the adhesive to precisely cover the corrugated crest bonding points, preventing the adhesive from contacting the central area of ​​the exchange material. This increases the effective working area of ​​the material and keeps the water molecule transfer channels unobstructed.

[0016] The circumferential dimensions of the continuous and intermittent glue application units are directly related to the core dimensions through a formula, ensuring that the glue precisely covers the sealing and bonding areas, thus preventing seal failure caused by insufficient glue or overflow.

[0017] The alternating arrangement of n discontinuous units and n+1 continuous units allows a single roller to process multiple cores, reducing downtime for roller changes and improving production line switching efficiency.

[0018] The fan-shaped adhesive area is circumferentially distributed to form discrete adhesive dots instead of continuous adhesive lines, further reducing the adhesive coverage area by 15%-20%, and enhancing the thermal conductivity of the exchange material. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the roller shaft in Example 1.

[0020] Figure 2 This is the front view of the roller in Example 1.

[0021] Figure 3 yes Figure 2 Sectional view at point AA.

[0022] Figure 4 This is a schematic diagram of the roller shaft in Example 2.

[0023] Figure 5 This is the front view of the roller in Example 2.

[0024] Figure 6 yes Figure 5 Sectional view at point BB.

[0025] In the diagram: 1. Roller, 2. Continuous coating unit, 3. Intermittent coating unit, 4. Fan-shaped coating area, 5. Fan-shaped coating area. Detailed Implementation

[0026] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0027] Example 1

[0028] like Figure 1 , 2As shown in Figure 3, in this embodiment, the gluing roller assembly uses an axially extending roller shaft 1 as its core support. Two functional units are coaxially formed on its surface: two sets of continuous gluing units 2 are formed at both ends of the roller shaft, and a set of intermittent gluing units is centrally located between the two continuous units. The continuous gluing units have a solid annular structure, made of a metal substrate covered with a hydrophilic coating. The intermittent gluing units 3 also have an annular structure, but their circumferential surfaces are distributed with effective working arc surfaces at specific angles. The axial end faces of the three units are integrally formed, creating a seamless composite roller surface. The roller shaft is radially positioned at both ends through interference-fit bearing seats, ensuring that the rotation center is parallel to the single-facer conveyor track.

[0029] The continuous coating unit's annular structure has a complete circumferential working surface, its axial width determined by boundary sealing requirements, covering the corrugated core's sealing and rough edge areas. The intermittent coating unit's annular structure, through its circumferential arc surface design, forms an effective coating surface only within specific angular intervals. Both types of units have strictly identical outer diameters, ensuring uniform linear pressure applied to the material in all areas during roller rotation. Units are connected using end-face flanges, with axial locking achieved through high-strength bolts, eliminating the risk of micro-displacement during high-speed rotation.

[0030] When the roller contacts the corrugated material, the continuous coating unit forms a full-circumferential adhesive film at the material's edge area, ensuring boundary airtightness; the intermittent coating unit periodically contacts the center of the material, depositing adhesive only at the corrugated crest bonding points. This physical isolation mechanism strictly confines the adhesive to the functional area: the continuous unit covers the required width for sealing, while the intermittent unit precisely matches the crest spacing. The adhesive transfer process relies on the hydrophilic properties of the roller surface to reduce surface tension, causing the water-based adhesive to form a uniform liquid film rather than discrete droplets.

[0031] In this embodiment, the continuous gluing unit is 25 mm wide, including a 10 mm permanent sealing area and a 15 mm cutting buffer strip. Its circumference of 230 mm corresponds to the corrugated paper width of 200 mm plus 15 mm rough edges on both sides. The intermittent gluing unit is 180 mm wide, determined by subtracting the 10 mm sealing area on each side from the paper length of 200 mm. The 78.26-degree central angle on the surface of the intermittent unit is the effective working area (calculated by the formula: 180 / 230 multiplied by 360 degrees), and the remaining areas do not come into contact with the glue.

[0032] The roller diameter of 36.61 mm is calculated from a circumference of 230 mm. During operation, the rotation speed is controlled between 300 and 500 revolutions per minute, matching the paper travel speed of 2 to 5 meters per minute. The unit's inner hole and roller shaft use an interference fit; during assembly, they are heated to 200 degrees Celsius before fitting, and after cooling, a tight connection is formed. The surface hydrophilic treatment uses an electrochemical anodizing process, generating a porous oxide layer that reduces the contact angle of the water-based adhesive to below 15 degrees. This ensures uniform adhesive spread on the roller surface, with a measured adhesive film thickness error not exceeding 0.05 mm. The uniform diameter design ensures uniform pressure as the paper passes through, and the adhesive line width remains stable at 0.5 mm.

[0033] Specifically, the left and right continuous units cover a 25mm area along the paper edge, forming a continuous sealing adhesive line. The middle 180mm area is handled by intermittent units; with each rotation of the roller, a 78.26-degree working arc surface leaves adhesive dots at the corrugated crests. The spacing of these adhesive dots precisely matches the 5mm corrugated pitch, preventing adhesive contamination of the paper's central area. In practical application testing, the effective working area of ​​the 200×200mm full heat exchange material is increased by approximately 20% compared to traditional processes.

[0034] In this embodiment, the left and right ends of the gluing roller assembly are continuous gluing units, while the middle is an intermittent gluing unit. All three units have the same outer diameter, and their surfaces are treated with a hydrophilic process to form a microporous oxide layer. The continuous gluing unit has a complete annular structure with an axial width of 25 mm, covering the edge area of ​​the corrugated paper; the intermittent gluing unit has an axial width of 180 mm, and its effective working area is a 78.26-degree central angle. The units are press-fitted with the roller shaft using a heat-shrink process.

[0035] In this embodiment, the roller's structural design enables precise control of the glue application area: continuous units block air leakage paths at the boundaries, while intermittent units prevent glue from penetrating the center of the paper. Actual measurements show that the effective working area of ​​the 200×200 mm total heat exchange material is increased by approximately 20% compared to traditional processes, and the water vapor transmission rate is restored to over 90%.

[0036] In this embodiment, when put into use again, the glue roller assembly is installed above the glue tank of the single-sided machine, and both ends of the roller shaft are connected to the frame via tapered bearings. After starting the equipment, water-based adhesive is injected into the glue tank via a metering pump, and the liquid level is maintained at 1 / 3 of the roller diameter. The roller shaft is driven by a variable frequency motor, and the speed is increased in steps from 200 rpm to the working speed of 450 rpm. During this stage, the adhesive forms a continuous liquid film on the hydrophilic surface.

[0037] As the corrugated base paper passes through the roll surface at a linear speed of 3 m / min, the continuous coating units on both sides first contact the paper edge. The 25 mm wide continuous units continuously transfer the adhesive during rotation, forming a 10 mm sealing tape and a 15 mm rough edge adhesive zone on each side of the paper. The middle 180 mm wide area is handled by intermittent coating units: with each rotation of the roll, its 78.26-degree effective working arc surface (corresponding to a circumference of 45 mm) briefly contacts the corrugated crest, depositing a 1.2 mm diameter adhesive dot at the crest apex with a 5 mm pitch. During non-working arc surface periods, the unit surface detaches from the paper and is re-wetted with adhesive.

[0038] In this embodiment, the roller assembly is adapted to a standard 200×200 mm full heat exchange core production line, which can process 4,000-5,000 pieces per shift (8 hours). When switching to different core specifications, only the corresponding size of the gluing unit needs to be replaced, and the equipment adjustment time is reduced to within 30 minutes.

[0039] Example 2

[0040] In this embodiment, the glue-applying roller assembly is manufactured as a single roller body using an integral molding process, forming six continuous functional zones axially. From the starting end to the ending end, the roller body sequentially includes: a first continuous glue-applying zone smoothly transitioning to a first discontinuous glue-applying zone, a reusable continuous glue-applying zone extending in the middle, followed by a second discontinuous glue-applying zone, and finally converging at the second continuous glue-applying zone. The outer surfaces of all functional zones maintain a complete and continuous cylindrical working surface without any assembly seams.

[0041] The continuous coating zone has a smooth, circumferential surface. The end areas maintain standard dimensions, while the axial dimension of the central reuse zone is significantly increased, continuously covering the boundaries of the front and rear working areas. The intermittent coating zone has multiple sets of radially arranged fan-shaped bosses forming fan-shaped coating areas 5. These bosses are evenly distributed radially from the center of the roller. Annular isolation grooves are provided between adjacent bosses, with stepped depths and smooth transitions between the groove bottom and the boss root. The top surface of the bosses is precisely coplanar with the surface of the continuous coating unit, and the sidewall inclination angle is controlled within a specific range to ensure smooth glue flow.

[0042] It is also worth noting that the transition zone between adjacent functional units in this embodiment adopts a gradual design, with a gentle slope transition at the junction of the continuous and intermittent glue application units. This structure avoids the dead zones of glue retention that occur with traditional stepped connections. The internal stiffness of the roller is adjusted through optimized material distribution: the cross-sectional dimensions of the central reuse area are moderately increased, the end areas maintain a standard wall thickness, and the roots of the bosses in the intermittent glue application units are locally reinforced. This structure enables the roller to maintain uniform deformation characteristics under multiple loads.

[0043] The surface treatment employs a zoned functionalization strategy. The continuous coating zone utilizes a combination of mirror polishing and hydrophilic coating to ensure uniform adhesive film formation. The top surfaces of the bosses in the intermittent coating units undergo ultra-slip treatment to reduce adhesive adhesion; the grooved areas are treated with hydrophobic modification to prevent adhesive migration to non-working areas. The entire roller body undergoes multi-stage heat treatment to eliminate internal stress and ensure dimensional stability during long-term operation.

[0044] Compared to the axially segmented structure of Example 1, this solution achieves a fundamental improvement through integral molding: eliminating all connection interfaces and completely avoiding the risk of seal failure; improving the positional accuracy of functional areas by orders of magnitude; replacing the axially discontinuous units with a radial fan-shaped structure, transforming the adhesive dot distribution from a linear arrangement to a planar matrix. The reused continuous adhesive application area serves as the core load-bearing unit, and its extended design effectively resists bending deformation under multi-station loads, while providing seamless transition support for the working areas on both sides.

[0045] As the number of workstations expands further, the overall roller body exhibits unique advantages: the radial fan shape can proportionally increase the number of groups, and dynamic balance is maintained through phase difference design; the reuse area evolves into a multi-segment load-bearing structure, with the cross-sectional dimensions changing with the load gradient; and the continuous transition surface avoids wave-like deformation caused by the increase of units in the split structure.

[0046] This embodiment maintains the core advantage of precise adhesive positioning in Embodiment 1, while achieving efficient multi-station collaboration through integral molding and a radial fan-shaped design. Seamless transitions between functional units ensure consistent adhesive line width, optimized material stiffness distribution suppresses high-speed rotational vibration, and zoned surface treatment extends the maintenance-free cycle.

[0047] In practical applications, the adhesive roller assembly is installed in a full heat exchange core production line. The roller has a diameter of 73.21 mm and a surface circumference of 460 mm. Both ends of the roller shaft are supported by tapered roller bearings, and the bearing housings are equipped with bidirectional adjusting screws. During the initial startup of the equipment, the roller rotates at a low speed. The water-based adhesive forms a uniform liquid film on the surface of the continuous adhesive application section, while the adhesive on the surface of the intermittent adhesive application section is discretely distributed due to the constraint of the annular grooves.

[0048] When the production line is running at full speed, the roller's operating speed remains stable at the set value. Four sets of 200×200 mm corrugated cores synchronously pass through their corresponding stations, with the conveyor belt speed precisely matched to the roller speed. The continuous adhesive application section contacts the core edge with a 25 mm axial width, forming a 10 mm wide sealing tape along the core's length, while extending outwards into a 15 mm rough edge adhesive zone. During adhesive film transfer, the hydrophilic surface properties allow the adhesive to spread evenly along the core edge, and the rough edge area absorbs boundary fluctuations caused by assembly errors.

[0049] The intermittent adhesive application section covers the central area of ​​the core with an axial width of 180 mm. As the roller rotates, the 39.13-degree arc working area periodically contacts the core surface: when the working arc surface reaches its lowest point, the adhesive film on its surface completes the transfer within a 0.1-second contact time, forming an array of adhesive dots with a diameter of 1.5 mm at the corrugated crest; when the non-working area detaches from the core, the depth difference of the annular groove blocks adhesive migration, ensuring absolute cleanliness of the non-bonding area. After each contact, the working arc surface is re-immersed in the adhesive tank, and the adhesive rapidly fills the surface micropores under capillary action.

[0050] When operating synchronously at four stations, the consistent diameter of the continuous and intermittent gluing sections ensures uniform pressure throughout the line. The 25mm wide continuous gluing section forms a continuous sealing band on both sides of the core, while the 180mm wide intermittent gluing section generates a matrix of glue dots spaced 5mm apart in the center of the core. The rough edge design allows for a ±1.5mm tolerance in the actual effective sealing width, preventing film breakage due to positioning deviations in traditional structures. Zoned glue tank control allows for independent start and stop of each station; when a station's core is low on material, the liquid level in the corresponding chamber automatically drops, disengaging from contact.

[0051] The adhesive dot forming process exhibits dynamic self-adjusting characteristics: the 39.13-degree included angle of the working arc surface corresponds to a circumference of 50 mm, ensuring sufficient contact time for each corrugated peak; the liquid resistance effect formed by the groove depth inhibits adhesive overflow; hydrophilic / hydrophobic partitioning ensures the stability of adhesive film transfer. During online cleaning, high-pressure water flows axially, and the groove structure guides the rapid discharge of contaminants, leaving no dead corners.

[0052] Example 3

[0053] like Figure 4 , 5 As shown in Figure 6, in this embodiment, the gluing roller assembly has six independent units mounted on the roller shaft surface, forming two sets of parallel working areas. Starting from the end, the roller body consists of: a first continuous gluing unit connected to a first intermittent gluing unit, followed by a reused continuous gluing unit; the other side of the reused unit is connected to a second intermittent gluing unit, and the end is fitted with a second continuous gluing unit. The reused continuous gluing unit serves as a core transition body, with different connection structures on its left and right end faces: an annular tenon groove is provided on the left side, and a stepped tenon is machined on the right side, achieving seamless engagement with adjacent units.

[0054] In this embodiment, the axial width of the reused continuous coating unit is twice that of the first continuous coating unit, forming the main coating area in the middle of the glue roller assembly.

[0055] The surface of the intermittent adhesive application unit has two sets of radial fan-shaped adhesive application areas 4. Each set of areas extends from the center to the outer periphery, forming raised working surfaces at equal angles. Adjacent fan-shaped areas are separated by recessed grooves, with the bottom of the grooves lower than the raised surfaces, forming a physical isolation zone. The edges of the raised areas have smooth transition curves to prevent adhesive residue. The fan-shaped areas of the two sets of intermittent units are staggered along the circumferential direction, forming a specific phase difference.

[0056] During assembly, the right tenon of the first interrupted unit is inserted into the left tenon of the reuse unit, and the left tenon of the second interrupted unit is fitted into the right tenon of the reuse unit. The tenon and mortise mating surfaces are precision ground, and the height difference at the connection is close to zero. The pre-tightening bolts apply axial pressure to uniformly compress the sealing element, ensuring no glue leakage during high-speed rotation. The left and right functional surfaces of the reuse unit are on the same cylindrical reference plane, forming a continuous roller surface with the working areas of the front and rear groups.

[0057] Compared to the single-station axial layout of Embodiment 1, this embodiment achieves dual-station expansion through reused units:

[0058] The reusable unit simultaneously bears the load of two working areas, and its axial length is greater than that of the end unit, enhancing the bending resistance in the middle. The mortise and tenon design reduces the number of interfaces, lowers accumulated assembly errors, and ensures seamless, detachable connections between units. This prevents rolling marks from forming at the boundaries during use and allows for quick disassembly and adjustment when the glue application unit needs to be repositioned. Furthermore, radial fan-shaped areas replace axially discontinuous units, and the glue dot distribution changes from a linear array to a planar matrix.

[0059] In addition, regarding the roller material, this embodiment continues to use the 304 stainless steel base of Embodiment 1, but adds a hard alloy plating layer to the surface of the tenon of the reused unit. The fan-shaped protrusion area of ​​the discontinuous unit is specially polished, and the surface roughness is reduced by two levels compared with the groove area. While maintaining the advantage of precise glue positioning in Embodiment 1, this embodiment achieves double the efficiency through dual-station parallel operation, and the radial fan-shaped distribution makes the glue dots cover more evenly.

Claims

1. A gluing roller for a single-sided machine, characterized in that, include: Axially extending roller; At least two sets of continuous adhesive application units are symmetrically arranged at both ends of the roller shaft; An intermittent glue application unit is coaxially arranged between two sets of continuous glue application units; The continuous coating unit and the intermittent coating unit are arranged alternately along the roller axis, and the outer diameter of the continuous coating unit and the outer diameter of the intermittent coating unit are the same.

2. The gluing roller for a single-sided machine according to claim 1, characterized in that: The surfaces of the continuous coating unit and the intermittent coating unit are provided with a hydrophilic coating layer.

3. The gluing roller for a single-sided machine according to claim 1, characterized in that: The continuous coating unit and the intermittent coating unit are integrally formed and are made of stainless steel.

4. The gluing roller for a single-sided machine according to any one of claims 1-3, characterized in that: The circumference length of the continuous coating unit is equal to b + 2d, where b is the width of the adapted fully heated corrugated core and d is the amount of burr increase.

5. The gluing roller for a single-sided machine according to claim 4, characterized in that: The axial width of the intermittent adhesive application unit is a - 2c, where a is the length of the adapted fully thermal corrugated core and c is the edge sealing width.

6. The gluing roller for a single-sided machine according to claim 1, characterized in that: The number of intermittent glue application units is n, and the number of continuous glue application units is n+1; Starting from the end of the continuous coating unit, the rollers are arranged alternately along the roller axis in a sequence of continuous coating unit and intermittent coating unit.

7. The gluing roller for a single-sided machine according to claim 6, characterized in that: The number of intermittent glue application units is two, and the number of continuous glue application units is three. The axial width of the continuous glue application unit in the middle of the three continuous glue application units is greater than the axial width of the continuous glue application units at both ends.

8. The gluing roller for a single-sided machine according to claim 7, characterized in that: The intermittent coating unit includes at least two fan-shaped coating areas along the circumference of the roller shaft, and each fan-shaped coating area is evenly distributed along the circumference of the roller shaft.

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