Method for manufacturing the construction of a fiber web machine roller, shell construction of a fiber web machine roller and roller of a fiber web machine

Abstract

A method for producing the structure of a fiber web machine roller (10), in which fiber reinforcement tape (121, 122) is wound onto a substrate (20) serving as the core (103) of the structure as a structural part of the roller (10) and matrix material is simultaneously introduced into the structure (12) thus formed, characterized in that in the method one or more layers of fiber reinforcement tape are formed on the substrate (20) and the thickness reduction at the edge of the tape (121, 122) is selected such that one or more layers of fiber reinforcement tape in the area of ​​the working surface (103) of the roller (10) form a substantially uniformly thick fiber reinforcement layer.

Description

The invention relates to a method intended for producing the construction of a roll of a fiber web machine according to the preamble of claim 1. Furthermore, the invention relates to a roll shell construction intended for a fiber web machine according to claim 14 and to a fiber web machine roll according to the preamble of claim 15.For treating and directing the travel of the fibrous web in fibrous web machines, various types of rolls are generally used. Typically, the roll body and roll shell are made of metal, and often the roll shell has a coating / finish. Recently, polymer coatings / coatings have been increasingly used because of their positive properties, and polymers are also suitable for the production of roll parts or the entire roll.It is known that the durability and strength properties of polymeric structures have been improved by embedding suitable reinforcing materials such as glass fibers, carbon fibers and the like in the matrix material. Fillers can also be used. In particular, the surface of nip-contacted polymer rolls and / or polymer-coated rolls is subject to considerable dynamic loading. This has considerable effects on the service life of the coating, and there has been a need to improve the durability of the polymer coating, especially under dynamic loading.The formation of a fiber reinforced surface or even a fiber reinforced structure on the roll has typically been accomplished by winding fibers, fiber mats or other fiber structures around the roll or core. A typical aim is to create a uniform structure at least in the longitudinal and circumferential direction of the roll for at least each possible separate layer.EP 0 363 887 A2 describes a roll formed from carbon fiber composite, in which the carbon fiber is introduced into the composite by winding it onto the roll to be produced. In the roller described in EP 0 363 887 A2, the winding angles are selected such that at least two layers of the roller have different winding angles. DE 35 27 912 A1 also describes a carbon fiber-reinforced roll shell in which the carbon fiber layer is produced by winding the roll core with carbon fiber.EP 1 001 081 A2 describes a coated roller which is intended for nip contact with another roller in connection with paper treatment. The covering of the roller consists of fibers inserted into matrix material. The fibers are oriented relative to the roller in such a way that a certain effect is achieved.EP 1 041 197 A1 describes the coating of a hard metal roller with an elastic surface layer. The surface layer comprises a lower bonding layer and an outer functional layer. To form said connecting layer, fibers are wound around the roller at an angle to the longitudinal axis of the roller such that the adjacent fiber strips form a uniform, coherent surface in which the fiber strips all run at the same angle in contact with one another, and only then is a second layer formed in a corresponding manner, but now with a winding angle opposite to the first-mentioned angle.US 2002 / 0 189 749 A1 discloses a method for producing the construction of a fiber web machine roll, in which fiber reinforcing tape is wound as a structural part of the roll onto a base serving as core of the construction and matrix material is simultaneously introduced into the construction thus formed, wherein one or more fiber reinforcing tape layers are formed on the base and the overlap of the tape windings is selected such that one or more fiber reinforcing tape layers form a substantially uniformly thick fiber reinforcing layer in the region of the useful coating of the roll.Another method for manufacturing the construction of a fiber web machine roll is shown in JP S61-144 422A.In the casings of fiber web machine rolls produced by winding, namely in conjunction with the surface layers or coverings, there is in particular the risk of differences in thickness arising if adjacent fiber strips are partially superimposed. In the manufacture of the roll, this results in a need for intermediate grinding, which increases the number of manufacturing process operations and makes the manufacture more complicated and time consuming.It is the object of the invention to improve the state of the art in industry by providing a method intended for manufacturing the construction of a fiber web machine roll in which the problems of the state of the art are minimized.This object is achieved in the manner set forth in claims 1, 14 and 15.In the method according to the invention intended for producing the construction of a fiber web machine roll, fiber reinforcing tape is / are wound onto the backing serving as core of the construction and matrix material is simultaneously introduced into the construction thus formed and one or more fiber reinforcing tape layers are formed on the backing and the thinning, i.e. reduction in thickness, of the tape at its edge is chosen such that one or more fiber reinforcing layers form a substantially uniformly thick fiber reinforcing layer in the region of the wear backing of the roll.According to one embodiment of the invention, in the method at least the first layer is formed by guiding the fiber reinforcement band in a first winding direction and with a first pitch which is smaller than the band width and leads to an overlapping of the band windings, wherein in the method the band is reduced, i.e. thinned, in the thickness direction in the overlapping region.According to a preferred embodiment, the method comprises forming the entire coating thickness from a (single) fiber reinforcement tape layer.In the method for manufacturing the construction of a fiber web machine roll according to another preferred embodiment of the invention, fiber reinforcing tape is wound as a roll construction component onto the backing serving as the core of the construction and matrix material is simultaneously introduced into the construction thus produced. Further, in the method, a first layer is formed by guiding fiber reinforcement tape in a first winding direction and thereafter at least one subsequent layer is formed by guiding fiber reinforcement tape in said first winding direction.A construction formed in this way has a very uniform thickness, so that intermediate grinding between the application of the individual layers is superfluous during production.In the method according to a preferred embodiment, the formation of said first layer is effected by winding the fibre reinforcement tape with a first pitch and the formation of at least one subsequent layer is effected by winding the fibre reinforcement tape with said first pitch. In this way, even more effective abrupt thickness variations can be avoided and an even more uniform surface is obtained.According to one embodiment, the method comprises rotating said substrate in a first direction and simultaneously guiding the first layer of fiber reinforcement material onto the substrate.According to another embodiment, the method comprises guiding the following layer of fibrous reinforcement as a ribbon, starting at the same end as when applying the first layer, onto the support again by rotating said support in the first direction.According to a further embodiment, in the method, the following layer of fiber reinforcement material is guided, starting at the opposite end as that when applying the first layer, by rotating said support in the opposite direction as when applying the first layer to the support.Preferably, the winding of the fiber reinforcement tape is performed at a pitch equal to or less than the width of the tape. In this case, successive turns come to lie partly one above the other.According to a preferred embodiment, the fibre reinforcement tape is wound onto the backing with a pitch of P=W / (N+ 5); in this case W denotes the bandwidth and N denotes an integer ≥1.According to a further embodiment of the invention, the first and at least one subsequent strip of the same pitch are wound with their starting points offset with respect to one another such that the angular spacing is 1 / (2Y)×360 °, wherein Y denotes the number of layers located directly one above the other.In the method, the amount of layers to be wound and / or the covering of the band windings are preferably selected such that one or more fiber reinforcement band layers form a substantially uniformly thick fiber reinforcement layer in the region of the wear lining of the roll.The invention also relates to a shell construction of a fiber web machine roll produced by any of the above-described processes.The invention further relates to a fiber web machine roll which has at least one roll shell and a journal at each of both ends, wherein the roll shell consists of a construction produced by winding matrix material and fiber reinforcing tape. It is characteristic of the invention that the thickness reduction at the band edge is such that the fiber reinforcing layer formed from one or more fiber reinforcing band layers has a substantially uniform thickness in the region of the wear lining of the coating.According to one embodiment of the invention, the roll shell construction comprises at least two layers placed one above the other made of fibre reinforcement tape into the construction, the fibre reinforcement tapes of the layers being wound substantially in the same direction.Preferably, the fibre reinforcement tapes of the layers are wound substantially at the same pitch.In this way, a fiber reinforcement structure of very uniform thickness and thus also of uniformly strong structure is obtained.According to a preferred embodiment, the construction forms the wear lining of the roll, wherein the roll comprises a roll shell, preferably a roll shell made of metal, and the wear lining consists of fibre reinforcement and the polymer matrix.According to another embodiment, said construction forms the roll shell.Preferably, the overlap of the fiber band windings and / or layers is such that the fiber reinforcement layer formed from one or more fiber reinforcement band layers has a substantially uniform thickness in the region of the wear surface of the roll.The additional features characteristic of the invention will become apparent from the claims and the following description of the embodiments shown in the drawings.In the following, the invention and its operation will be described with reference to the attached schematic drawings. The following are shown: FIG. 1 schematically shows an embodiment of the method according to the invention; FIG. 2 schematically shows an embodiment of the method according to the invention, which is used for producing the shell construction of a fiber web machine roll; FIG. 3 is a schematic view showing a configuration of the roller according to the present invention; FIG. 4 is a schematic view showing another form of construction of the roller according to the present invention; FIG. 5 schematically shows an embodiment of the cross section according to the invention of the wear lining of a fiber web machine roll; FIG. 6 schematically shows another embodiment of the cross section according to the invention of the wear lining of a fiber web machine roll.Figure 1 schematically shows a preferred embodiment of the method according to the invention, which is used for forming the shell construction 12 of a fiber web machine roll. The construction preferably comprises fiber reinforcement tape 14 and matrix material associated therewith. The tape is preferably 5-25 cm wide, typically about 15 cm wide. The belt may be of woven or mat-like nonwoven fabric or combinations thereof, and the fiber may be of a per se known fiber material such as glass or carbon fiber or the like. The matrix material can consist of a matrix known per se in fiber-reinforced constructions, such as epoxy resin, polyester resin or the like.The roll construction 12 typically comprises at least two, but typically an even greater number of, fiber reinforcement layers. In FIG. 1 the formation of two successive fibre reinforcement layers can be seen. The formation takes place on the base 20, which base may, as the case may be, consist for example of a mould when the roll body is produced, or of a roll body already produced previously when, for example, the wear lining of the roll is produced. In FIG. 1, the support is shown very schematically as a body with a cylindrical outer surface. In Figure 1, the formation of the fiber reinforcement structure 12 is shown by illustrating the edge 121 of the first fiber reinforcement tape and the edge 122 of the second fiber reinforcement tape and winding them around the backing. In the following, these edge reference numerals are also used for the tapes.In the method for manufacturing the construction of the fiber web machine roll, according to a preferred embodiment, fiber reinforcing tape 121 is wound onto the backing 20 serving as core of the construction 12 to be formed, which contains matrix material and onto which matrix material is simultaneously applied. Winding is understood to mean that either the strip is wound onto the stationary support or else the support rotates and the strip is simultaneously guided onto the surface of the support 20. Typically, the structure 12 to be manufactured comprises a plurality of layers to be formed one above the other. The formation of the first layer is performed by guiding fiber reinforcement tape 121 to wind in a first direction indicated by arrow D in FIG. 1. The exemplary initial location of the first layer forming belt 121 is denoted by the reference numeral 16. At the starting point 16, the fibre reinforcement band 121 is in a certain position, both in the direction of the longitudinal axis C and on the circumference of the construction to be formed in a certain angular position a 0. The first layer is applied to the base with the first winding direction and with a specific pitch P. In other words, the tape advances longitudinally of the substrate 20 each turn by the distance P. At least one following fiber reinforcement tape / matrix layer is applied to the first layer. To form the following layer, the second fiber reinforcement band 122 is routed onto the first fiber reinforcement band so as to wind in the same said first direction D as the first fiber reinforcement band 121. The layers are formed in such a way that the amount of the crossing fibre reinforcement bands is minimized. In addition to the fact that the two layers located one above the other have the same winding direction D, it is advantageous that the pitch P of the fiber reinforcement bands 121, 122 forming these layers is also the same.The starting point of the fiber reinforcement band of the second layer is denoted by reference numeral 18. In the special case shown in FIG. 1, in which two layers are formed one above the other, the angular distance between the first 16 and the second 18 starting point is α=90°.More generally, according to a preferred embodiment, the advantageous angular distance can be defined such that the first and at least one subsequent band are offset with respect to one another with their starting point such that the angular distance is α=1 / (2Y)×360 °, wherein Y is the number of layers located directly one above the other.FIG. 2 schematically shows an embodiment of the method according to the invention which is used to form the shell structure 12 of a fiber web machine roll 10. The roller core 103 serves as the backing 20 in the embodiment of FIG. 2. In the drawing, one end of the fiber web machine roll 10 is shown. The roller comprises the cylindrical core part 103, which here serves as a support 20 for the structure 12 to be formed on its surface. At the end of the roll core, a journal 101 including accessories is arranged in a manner known per se. The band here has the width W and the pitch P is here substantially smaller than the band width. The pitch to be chosen is preferably less than or in certain cases equal to the width W of the band. Generally, the appropriate slope P can be determined according to the formula P = W / (N+ 5), where W is the bandwidth and N is an integer ≥1. In FIG. 2, the construction 12 formed on the roller surface thus serves as a wear lining for the roller 10.In particular, the mutual position of the edges of the belts 121, 122,..., 12N with respect to one another can influence the uniformity of the construction 12 to be formed. The position of the edges is determined both by the band width and by the selected pitch P. If the selected pitch is at most equal to the band width, this leads to a certain overlap of the band edges, by which is meant here the position of the band edge relative to the width of the preceding band. For example, at 1 / 3 coverage, the edge is 1 / 3 bandwidth from the edge of the preceding band on top of it, at 1⁄2 coverage, in the middle of the preceding band.FIG. 3 shows a schematic form of a roll construction according to the invention on the basis of two strip layers 31, 32 located one above the other. The width and pitch of the belts were selected here such that a 1 / 3 overlapped construction results. The total thickness of the individual layer 31, 32 varies in this case such that the covering 35 forms a double strip layer and the region between the covering forms a single strip layer.The starting location (reference numeral 16 in FIG. 1 ) of the ribbon 121 of the first layer 31 is known such that the starting location (reference numeral 18 in FIG. 1 ) of the ribbon of the second layer 32 has been arranged relative to the first starting location such that the ribbon 122 of the second layer 32 covers the first ribbon with 2 / 3 overlap. In this case, the total thickness of the layers over the strip connecting points 33 of the strips of layers located one above the other remains substantially unchanged and there are no differences in thickness even though the edges of the strips are located side by side in a butt-seam manner (?). In an overlap of this type, it is preferred to use tape having substantially the same thickness over its entire width W.In FIG. 4, the winding of a band 121 is shown which has an overlap 35 such that the edge of the second 42 and the third 43 band winding still comes to lie on the first winding 41, the edge of the third 43 and the fourth 44 band winding comes to lie on the second winding 42 and so on. In this case, regions 45 with three belts located one above the other and regions 46 with two belts located one above the other are produced in the belt layer. In such an arrangement, it is advantageous that the strip is reduced in thickness at its edges 122, in this case by 50% of the thickness over the length of the region 45. full-thickness strip is located in the middle of the region 45 and thickness-reduced strips are located above and below it by 50%. In this way, a reference is obtained in a winding cycle in which the fibre reinforcement bands are overlapped and at the same time a substantially uniformly thick fibre reinforcement layer is formed. Depending on the method to be implemented, the thickness reduction is selected such that a substantially uniform fiber reinforcement layer is formed in the region of the wear lining of the roll, taking into account the selected overlap and the layers located one above the other. Preferably, the width of the thickness-reduced region at both edges of the tape is W / [2x(N+V2)], wherein W denotes the tape width and N denotes an integer ≥1. = =FIG. 6 schematically shows yet another embodiment of the cross section according to the invention of the wear lining of a fiber web machine roll with an example of winding up a (single) band 121. In the embodiment of FIG. 6, the overlap 35 is selected such that only the edge of the second band winding rests on the first band winding 41, the edge of the third winding 43 rests on the second band winding 42 and so on. In this case, there is only a tape layer (?) located on it in the central region of the tape, and the overlap of the tape extends from its edges into the central region. In such an arrangement, it is advantageous that the strip narrows from the central region toward the edges 122 in the thickness direction.According to one embodiment, particularly when more than two layers located one above the other are wound, the individual winding layers can be designed with different pitches. It is advantageous to choose each slope to be the multiple of another slope, preferably a multiple of the smallest slope used, such that the slope is P=W / (N+ 5), where W is the bandwidth and N is an integer ≥1. In this case, the starting point of the larger equidirectional slopes is preferably placed between the smaller slopes; for example, with a 150 mm band, the 3 x 20 mm slope would begin in the positions 0°, +90°, +180° and the 2 x 60 mm slope would begin in the positions +45°, +1354.FIG. 5 shows a section through the wear lining 102 applied to the surface of the jacket 103 of a fiber web machine roll 10. To form this wear lining, at the very first a first layer of fibre reinforcement tape was wound in a first direction and then at least one subsequent layer of fibre reinforcement tape was also wound in said first direction. These form the basic construction 102.1 of the wear lining. To this base construction, likewise made of fiber reinforcement material and matrix material, the intermediate construction 102.2 was applied. This intermediate layer is made of a suitably implemented fiber reinforcement construction. A preferred method is to wind fiber reinforcement ribbons with very small pitch and large overlap so that multiple ribbons are overlapped over relatively long distances. In this way, a relatively thick intermediate layer is obtained. The covering construction 102.3 is applied to the intermediate layer, the production of which is effected by winding fiber reinforcement tape in the first direction and then at least one subsequent layer of fiber reinforcement tape in the first direction. In this way, the covering construction 102.3 of the wear lining is produced.Here, the first layer of both the deck and base structures comprises tape wound at a first pitch and the following layer also comprises tape wound at said first pitch. The deck and base construction preferably correspond to the construction shown in Fig. 3.It should be noted that only some of the most advantageous embodiments of the invention have been presented above. It is thus understood that the invention is not limited to the embodiments described above, but can be implemented in many ways within the scope set forth in the claims. Features described in connection with the various embodiments may also be used in connection with other embodiments within the scope of the basic idea of the invention and / or various entities may be composed of the described features if this is desired and the technical requirements are met for this

Claims

A method for manufacturing the construction of a fibre web machine roll (10), in which fibre reinforcement tape (121, 122) as a structural part of the roll (10) is wound onto a base (20) serving as core (103) of the construction and matrix material is simultaneously introduced into the construction (12) thus formed, characterised in that in the method one or more fibre reinforcement tape layers are formed on the base (20) and the thickness reduction at the edge of the tape (121, 122) is selected such that one or more fibre reinforcement tape layers form a substantially uniformly thick fibre reinforcement layer in the region of the wear lining (103) of the roll (10).Method according to claim 1, characterised in that in the method at least one first layer is formed by guiding fibre reinforcement tape (121, 122) winding in a first direction, wherein the fibre reinforcement tape (121, 122) is guided onto the base (20) with a first pitch which is smaller than the tape width and leads to a tape overlap, and that the fibre reinforcement tape (121, 122) is reduced in thickness in the overlap region.Method according to claim 1 or 2, characterized in that in the method the whole coating thickness is formed with a single fibre reinforcement tape layer.Method according to claim 2, characterised in that in the method the width of the region to be reduced in thickness at both edges of the band (121, 122) is W / [2×(N+1 1⁄2)], wherein W denotes the band width and N denotes an integer ≥ 1.A method according to claim 1, characterized in that in the method a first layer is formed by guiding reinforcing fibre tape (121, 122) winding in a first direction and thereafter at least one subsequent layer is formed by guiding reinforcing fibre tape (121, 122) with said first winding direction.Method according to claim 5, characterised in that at least one subsequent layer is applied to the base (20) by winding fibre reinforcement tape (121, 122) with the same, first pitch.A method according to claim 1, characterized in that said method comprises rotating said backing (20) in a first direction and simultaneously directing said first layer of fibrous reinforcement onto said backing (20).Method according to claim 7, characterized in that in the method said support (20) rotates in the first direction and simultaneously the following layer of fiber reinforcement is directed onto the support (20) starting at the same end as the first layer.Method according to claim 7, characterised in that in the method said support (20) rotates in the other direction and at the same time the following layer of fibre reinforcement is directed onto the support (20) starting at the opposite end as in the first layer.The method according to claim 8, characterized in that the fiber reinforcement tape (121, 122) is guided onto the substrate (20) with a pitch equal to or less than the tape width.Method according to claim 8, characterised in that fibre reinforcement band (121, 122) is led onto the base (20) with a pitch of P = W / (N+ 5), wherein W denotes the band width and N denotes an integer ≥ 1.Method according to Claim 5, characterized in that the first and at least one subsequent strip (121, 122) of the same pitch are offset with respect to one another with their starting points in such a way that the offset is 1 / (2Y)×360 °, wherein Y denotes the number of layers located directly one above the other.Method according to one of the above claims 1 to 12, wherein in the method the amount of layers to be wound and / or the covering of the band windings are selected such that one or more fiber reinforcement band layers form a substantially uniformly thick fiber reinforcement layer in the region of the wear lining (103) of the roll (10).A shell construction of a fibre web machine roll (10), characterized in that the construction is manufactured according to the method of any of the above claims 1 to 13.A fibre web machine roll (10) comprising at least one roll shell and journals (101) at both ends of the roll (10), the roll shell of which consists of a construction (12) formed by winding matrix material and fibre reinforcement tape (121, 122), characterised in that the thickness reduction at the edge of the tape (121, 122) is such that the fibre reinforcement layer formed from one or more fibre reinforcement tape layers has a substantially uniform thickness in the region of the wear lining (103) of the roll (10).The fiber web machine roll (10) according to claim 15, characterized in that the structure (12) comprises at least two layers located one above the other, which are introduced into the structure (12) by winding fiber reinforcement tape (121, 122), and that the fiber reinforcement tapes (121, 122) of the layers are wound substantially in the same direction.The fiber web machine roll (10) according to claim 16, characterized in that the fiber reinforcement bands (121, 122) of the layers are wound substantially with the same pitch.Roller (10) according to claim 15, characterised in that said structure (12) is the wear pad (103) of a metal covered roller (10).Roll (10) according to claim 15, characterized in that said structure (12) forms the roll shell.Roll (10) according to one of the above claims 15 to 19, characterized in that the overlap of the fiber band windings and / or layers is such that the fiber reinforcement layer formed from one or more fiber reinforcement band layers has a substantially uniform thickness in the region of the wear lining (103) of the roll (10).

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