ROLLER AS WELL AS FLEECE LAYER AND CARDING MACHINE WITH SUCH A ROLLER

Description

[0001] The present invention relates to a roller as well as a nonwoven layer and a carding machine with such a roller.

[0002] Rollers are used in a wide variety of machines and systems for processing materials or guiding means of transport, such as conveyor belts, and are generally subject to high demands. Rollers used, for example, in nonwoven production in nonwoven laying machines or carding machines must be designed to be rigid, but should have low rotating masses. Such rollers, for example made of aluminum, are relatively light, but have a low modulus of elasticity. If the rollers are made of steel, they do have a high modulus of elasticity, but this is associated with a high mass. It is also known to make the roller body of the rollers from carbon fiber reinforced plastic; such rollers are relatively light and rigid, but entail very high acquisition costs compared to conventional solutions.

[0003] EP 0 736 369 A1 discloses a roller with a base body made of a fiber composite material and a coating that extends around the ends of the base body to the inside thereof.

[0004] EP 1 927 771 A2 discloses a bearing roller for moving heavy loads on a rail. The bearing roller comprises a sleeve-shaped base body, with a resin layer applied entirely to the outer side and partially to the inner side by insert molding.

[0005] It is an object of the present invention to provide a roller, as well as a nonwoven layer and a carding machine with such a roller, which overcome the aforementioned disadvantages of the prior art.

[0006] This object is achieved by the subject matter of claims 1, 9 and 10, respectively. Advantageous embodiments are the subject matter of the dependent claims.

[0007] A roller according to the invention, in particular for conveying and / or processing fiber webs, pre-piles, piles, nonwovens, or nonwoven fabrics, in particular for use in a nonwovens layering machine or a carding machine, comprises a substantially cylindrical roller base body and a cover layer made of a fiber composite material. The roller base body has an outer first circumferential surface, a first end portion, and a second end portion opposite the first end portion in the longitudinal direction of the roller base body, which corresponds to the axial direction of the roller base body. The cover layer completely surrounds the first circumferential surface of the roller base body in the circumferential direction of the roller base body. A first edge region of the cover layer extends beyond the first end portion of the roller base body, is folded inward, and is fixed with respect to the roller base body.

[0008] This creates a roller that, thanks to its fiber composite cover layer, exhibits high flexural rigidity and low mass. However, the roller base body allows the proportion of fiber composite to be reduced, allowing the roller to be manufactured relatively cost-effectively. The fiber composite cover layer exhibits a high modulus of elasticity while maintaining low mass. The roller base body can be made of a less expensive material, such as aluminum or steel, thus reducing costs compared to a roller whose roller body is made entirely of fiber composite.

[0009] Between the place of manufacture and the place of use, as well as during transport, the roller can be exposed to strong temperature fluctuations, for example of up to 30 Kelvin. Due to the significantly different temperature coefficients of the materials, there is a risk that such temperature fluctuations will lead to delamination of the cover layer from the roller base. This is prevented in this case by the first edge area of ​​the cover layer being folded inwards and fixed there with respect to the roller base. The cover layer made of fiber composite material has a lower temperature coefficient than the roller base and, due to its arrangement around the roller base and its end section, prevents the latter from expanding in both the radial and axial directions.

[0010] The cover layer covers the first lateral surface at least partially and preferably completely. In a particularly preferred embodiment, a second edge region of the cover layer extends beyond the second end section of the roller base body, is folded inward, and is fixed relative to the roller base body. The cover layer is thus symmetrically fixed to the roller base body and connected to it particularly reliably.

[0011] Preferably, the roller, in particular with regard to the roller base body and the cover layer, is designed both rotationally symmetrical to a longitudinal axis of the roller and symmetrical to a center plane of the roller or the roller base body, wherein the center plane is defined perpendicular to the longitudinal axis between the two opposite ends of the roller base body.

[0012] In the following, features of the roller are described with reference to the first end section of the roller base body and the first edge region of the cover layer. It is preferred that the second end section of the roller base body and the second edge region of the cover layer be configured analogously. In principle, however, the first and second end sections or the first and second edge regions could also be configured differently.

[0013] The roller base preferably forms a winding core around which the cover layer is wrapped. The cover layer can comprise a non-crimp or woven fabric of fibers, for example, carbon fibers. The cover layer can be single-layer or multi-layer.

[0014] Preferably, a first portion of fibers of the fiber composite material of the cover layer runs essentially in the circumferential direction of the roller base body, and a second portion of fibers of the fiber composite material of the cover layer runs essentially in the longitudinal direction of the roller base body. As a result, the cover layer can counteract expansion of the roller base body both in the radial direction and in the longitudinal direction. It is understood that the first portion of fibers and the second portion of fibers can also run obliquely with respect to the circumferential direction and the longitudinal direction, respectively, wherein the first portion of fibers preferably extends completely around the circumference of the roller base body, and the second portion of fibers extends completely from the first edge region to the second edge region of the cover layer.

[0015] In the first end section of the roller base body, the cover layer rests against the first lateral surface of the roller base body. The first edge region of the cover layer extends beyond the first lateral surface or the first end section and then runs inward toward the longitudinal axis of the roller base body.

[0016] Preferably, the roller base body is tubular, at least in the first end section of the roller base body, and the first edge region of the cover layer is folded around the first end section to such an extent that it is arranged inside the first end section. Analogously, the second end section of the roller base body can be tubular, and the second edge region of the cover layer is folded around the first end section to such an extent that it is arranged inside the second end section. Tubular means that a substantially rotationally symmetrical recess extends longitudinally into the roller base body from the respective end face of the roller base body.

[0017] In a particularly preferred embodiment, the roller base is designed as a hollow shaft, which allows the mass of the roller base to be further reduced. To keep costs low, the first and second edge regions are still arranged and fixed in the first and second end sections of the roller base, respectively. The first and second edge regions are defined by a first and second circumferential edge of the cover layer, respectively. This means that the cover layer ends at these edges and does not extend internally through the roller base, or the fibers are not also wound longitudinally around the roller base.

[0018] To establish a secure connection to the roller base body, the first edge region is preferably secured with an adhesive and frictional fit. The second edge region is also preferably secured with an adhesive and frictional fit. According to the invention, a frictional connection is created by means of a clamping element, which is described in detail below.

[0019] An adhesive bond can be achieved using an adhesive or a resin used to laminate the fiber composite material of the cover layer. Adhesion to the roller base body can be increased by roughening or structuring the first lateral surface of the roller base body, at least in sections and preferably completely, for example by sandblasting.

[0020] According to the invention, the first edge region and preferably also the second edge region can be folded around the roller base body itself and fixed thereto according to a first alternative or can be folded around a further component of the roller and fixed thereto according to a second alternative, as described below.

[0021] In the first alternative, the roller base body has a curvature on the front side in the first end section, and preferably also in the second end section, around which the first edge region or the second edge region of the cover layer is folded inward. The curvature defines a bending radius of the cover layer around which the cover layer is folded, thereby avoiding high shear stresses in the cover layer and protecting the fibers of the fiber composite material. At the same time, the roller has the simplest possible structure with few components.

[0022] The curvature initially extends inward from the first lateral surface in the direction of the longitudinal axis of the roller base body. Preferably, the curvature extends to a fastening section of the roller base body for the respective edge region of the cover layer. The fastening section is preferably straight in axial cross-section and inclined relative to the longitudinal axis of the roller base body, preferably at an angle between 2.5° and 60°, more preferably between 5° and 30°.

[0023] In this embodiment, the cover layer is completely supported by the roller base body. In other words, the roller base body extends longitudinally along the entire cover layer, with the exception of the first and second edge regions of the cover layer, which are folded around the first and second end sections of the roller base body.

[0024] In the second alternative, the roller further comprises a first end ring and preferably a second end ring, which are arranged coaxially to the roller base body and adjoin the roller base body at the first and second end sections, respectively. The first and second end rings are flush with the first shell surface and have a curvature on a side facing away from the roller base body, around which the first and second edge regions of the cover layer are folded inwards. The curvature defines a bending radius of the cover layer, around which the cover layer is folded, thereby avoiding high shear stresses in the cover layer and protecting the fibers of the fiber composite material. As a result, the curvature and thus the bending radius of the cover layer can be designed independently of the wall thickness of the roller base body, which in turn enables the wall thickness of the roller base body to be minimized. The first and second end rings adjoin directly to the free end face of the first and second end rings.second end section. In the area where the first and second end rings are flush with the roller base body, they have an outer diameter that corresponds to the outer diameter of the roller base body or the first lateral surface.

[0025] The curvature initially extends inward from the outer side of the end ring adjacent to the first lateral surface in the direction of the longitudinal axis of the roller base body. Preferably, the curvature extends to a fastening section of the respective end ring for the corresponding edge region. The fastening section is preferably straight in an axial cross-section and inclined relative to the longitudinal axis of the roller base body, preferably at an angle between 2.5° and 60°, more preferably between 5° and 30°.

[0026] In this embodiment, the cover layer is supported by the roller base body and the first and second end rings. In other words, the roller base body, the first end ring, and the second end ring extend longitudinally along the entire cover layer, with the exception of the first and second edge regions of the cover layer, which are folded around the first and second end rings.

[0027] The first and second end rings may be formed of aluminum and, independently thereof, may have a surface that is roughened or textured, particularly in the attachment portion, to improve the adhesion of the cover layer.

[0028] Preferably, the first and second end sections of the roller base body are tubular and have an inner diameter. The first and second end rings can each have a first section which is inserted into the first and second end sections, respectively, and whose outer diameter substantially corresponds to the inner diameter of the end sections. On the end face of the roller base body, the first and second end rings extend radially outward from the first section to a jacket section which is arranged flush with the first jacket surface of the roller base body and forms the outer side of the end ring. The curvature extends from the jacket section to the fastening section of the respective end ring, which is preferably arranged at least partially or completely inside the roller base body.

[0029] In order to frictionally secure the first edge region, the roller according to the invention comprises at least one first clamping element. The roller preferably further comprises a second clamping element. The first and second clamping elements preferably press the first and second edge regions of the cover layer, respectively, against the fastening section of the roller base body or the first and second end rings, respectively, thereby securing the cover layer.

[0030] In the first alternative described above, the first clamping element and the first end section of the roller base body have corresponding conical contact surfaces, between which the first edge region is received. Similarly, the second clamping element and the second end section of the roller base body can have corresponding conical contact surfaces, between which the second edge region is received. The conical contact surfaces of the roller base body in the first and second end sections, respectively, are preferably formed by the fastening sections of the roller base body.

[0031] In the second alternative described above, the first clamping element and the first end ring have corresponding conical contact surfaces, between which the first edge region is received. Similarly, the second clamping element and the second end ring can have corresponding conical contact surfaces, between which the second edge region is received. The conical contact surfaces of the first and second end rings, respectively, are preferably formed by the fastening portion of the respective end ring.

[0032] The first and second edge regions can be positioned directly against the respective contact surfaces to enable direct force transmission. The conical shape allows high normal forces to be transmitted to the first and second edge regions without significant shear stresses acting on the fibers of the fiber composite.

[0033] In a preferred embodiment, the first clamping element is adjustable in the longitudinal direction of the roller such that the contact pressure acting on the first edge region of the cover layer by means of the first clamping element can be adjusted. This preferably also applies to the second clamping element. For example, the first and second clamping elements can be screwed to another component of the roller, such as a roller base, so that the contact pressure can be varied by means of the screw connection.

[0034] The first and second clamping elements are, for example, ring-shaped or disc-shaped and arranged coaxially with the roller base body, in particular at its first and second end sections. If the first and second end sections are tubular and / or if the first and second end rings are used, the first and second clamping elements are preferably arranged radially within the roller base body or the first and second end rings.

[0035] In general, the roller may have a first roller base and a second roller base. The roller bases are substantially ring- or disc-shaped and may be formed integrally with the roller base body or as separate elements.

[0036] The roller may further comprise a first and a second shaft journal configured to rotatably support the roller. For this purpose, the first and second shaft journals are arranged coaxially with the roller base. The first and second shaft journals may be formed integrally with the first and second roller bases, respectively, or as separate elements.

[0037] When the first and second shaft journals are formed integrally with the first and second roller bases, respectively, the first and second roller bases are preferably formed separately from the roller base body and centered relative to it. For example, the roller base body is formed as a hollow shaft and is conical in the first and second end sections, with the first and second roller bases having a corresponding conical shape.

[0038] If the first and second shaft journals are designed as separate elements, the first and second roller bases each have a through-opening in the longitudinal direction of the roller base body, in which the first and second shaft journals are mounted. In order to center the first and second shaft journals relative to the roller base body, the through-opening in the first and second roller bases is preferably conically shaped, and the first and second shaft journals each have a conically shaped end that is received in the through-opening of the respective roller base. In this embodiment, the first and second roller bases are preferably substantially cylindrical and are received in the first and second end sections of the roller base body, for example, pressed into them.

[0039] It is conceivable that the first and second roller bases simultaneously form the first and second clamping elements, respectively, and secure the cover layer relative to the roller base. Preferably, however, the first and second clamping elements are formed separately and screwed to the first and second roller bases, respectively, with the screws distributed over the circumference of the first and second clamping elements to ensure uniform contact pressure on the first and second edge regions of the cover layer. The first and second clamping elements can each have a central through-opening through which the first and second shaft journals extend, respectively.

[0040] In principle, it is preferred that the first roller base be accommodated in the first end section of the roller base body, the second roller base be accommodated in the second end section of the roller base body, and the first and second roller base be clamped together in the longitudinal direction of the roller base body by means of a clamping device. The axial clamping advantageously contributes to minimizing the thermal expansion of the roller base body and thus reduces the risk of delamination of the cover layer from the roller base body.

[0041] The tensioning device can, for example, comprise a rod arranged coaxially with the roller base body and extending from one end of the roller to the other end through the shaft journals, the roller bases, and the roller base body. At least one end of the rod, preferably both ends, has a threaded portion with a nut, by means of which the tension can be adjusted when the other end of the rod is locked. The rod can, for example, be made of steel.

[0042] In an alternative embodiment, the tensioning device comprises carbon fiber filaments, which are preferably attached to the roller bottoms or shaft journals by means of loop suspension.

[0043] In order to reliably secure the first and second edge regions of the cover layer and prevent them from being damaged, they should be folded inwards without creases and overlaps and preferably clamped. For this purpose, it is advantageous if the first edge region and the second edge region each have a plurality of incisions distributed in the circumferential direction. Each incision of the plurality of incisions is formed, starting from a circumferential edge of the cover layer, in such a way that the first or second edge region is formed without creases and two partial sections of the first or second edge region, which are separated from one another by an incision in the plurality of incisions, do not overlap. This can be achieved, for example, in that each incision in the plurality of incisions is shaped to taper from the respective edge, for example essentially triangular.

[0044] The roller has an outer second surface, which is at least partially formed by the cover layer. The second surface can be understood as the roller's usable surface. For example, if the roller forms a deflection roller in a nonwoven layering machine, the second surface forms the contact surface with the deflected conveyor belt. If the roller is used in a carding machine, a set of teeth can be provided on the second surface.

[0045] The cover layer preferably extends in the longitudinal direction of the roller over at least 50%, more preferably over at least 70%, even more preferably over at least 80% of the second circumferential surface. The cover layer can also form the entire second circumferential surface, i.e. extend in the longitudinal direction over 100% of the second circumferential surface. The latter is conceivable, for example, with deflection rollers. In the case of rollers of a carding machine, an area is preferably provided at both axial ends of the second circumferential surface which is not formed by the cover layer and serves to attach a wire which forms the clothing. These end areas of the second circumferential surface can be formed by the first and second clamping elements or the first and second roller bases.

[0046] The roller base body is preferably made of metal, particularly aluminum or steel, or of a plastic, particularly GRP (glass fiber reinforced plastic) or polyamide. Compared to rollers made entirely of fiber composite material, this results in a cost reduction while still maintaining sufficient flexural rigidity.

[0047] The roller base body preferably has a wall thickness of between 1 mm and 50 mm, more preferably between 1 mm and 30 mm, and even more preferably between 1 mm and 10 mm. By designing the roller base body as a hollow shaft with a thin wall thickness, the roller has a low mass.

[0048] Preferably, the cover layer comprises carbon fibers, glass fibers or mineral fibers, such as ceramic fibers or silicate fibers, and a matrix of plastic, in particular of resins made of epoxy, polyester, polyurethane or melamine.

[0049] The cover layer preferably has a layer thickness of between 0.1 mm and 10 mm, more preferably between 0.5 mm and 8 mm, even more preferably between 1 mm and 5 mm.

[0050] The ratio of the wall thickness of the roller base body to the layer thickness of the cover layer can be easily varied to adjust the properties of the roller.

[0051] The roller can have a longitudinal length of between 1.0 m and 18.0 m, preferably between 2.0 m and 18.0 m, more preferably between 4.0 m and 18.0 m. The outer diameter of the roller can be between 50 mm and 800 mm, preferably between 80 mm and 400 mm, even more preferably between 100 mm and 350 mm. With these dimensions, the advantages of the invention already described with regard to cost reduction with sufficient flexural rigidity while avoiding delamination of the cover layer from the roller base body become particularly apparent.

[0052] The advantages of a relatively low mass are particularly advantageous at high rotational speeds and / or accelerations of the roller. Therefore, the roller can preferably be operated at a peripheral speed of between 30 m / min and 6,000 m / min, more preferably between 100 m / min and 5,500 m / min, and even more preferably between 400 m / min and 5,000 m / min. Particularly high peripheral speeds of up to 3,500 m / min or 5,000 m / min are achieved, for example, with random rollers at the carding exit or with knock-off rollers in aerodynamic web formation.

[0053] A nonwoven layering machine comprises at least one conveyor belt for conveying a fibrous web and a plurality of deflection rollers around which the at least one conveyor belt is guided, wherein at least one deflection roller of the plurality of deflection rollers is formed by a roller according to the invention. As described above, it is particularly important in nonwoven layering machines that the deflection rollers are dimensionally stable despite high loads and have a low mass due to the high accelerations to which they can be exposed. This can be achieved relatively cost-effectively using the roller according to the invention. All features described herein with regard to the roller according to the invention can apply analogously to use in a nonwoven layering machine.

[0054] In the nonwoven layer, the roller is rotatably mounted and subjected to high speeds and accelerations. For example, the at least one conveyor belt is moved over the roller at a speed of between 100 m / min and 1,000 m / min, preferably between 200 m / min and 900 m / min, and even more preferably between 400 m / min and 700 m / min.

[0055] In a preferred embodiment, the web layer comprises a feed belt, at least a first conveyor belt and a second conveyor belt, an upper carriage and a laying carriage, and a take-off belt. The feed belt is designed to feed a fibrous web coming from a card to the web layer and to transfer it to the first conveyor belt. The first conveyor belt conveys the fibrous web to the upper carriage, in which the fibrous web is deflected. From the upper carriage, the fibrous web is transferred to the second conveyor belt. The second conveyor belt conveys the fibrous web to the laying carriage, wherein the fibrous web between the upper carriage and the laying carriage can be covered by the first conveyor belt. The laying carriage is designed to travel back and forth perpendicular to the conveying direction of the take-off belt and, in the process, deposit the fibrous web onto the take-off belt. The at least one conveyor belt can comprise at least one or more of the first conveyor belt, the second conveyor belt, if applicable.additional conveyor belts, the feed belt and the discharge belt.

[0056] A carding machine for producing a fibrous web comprises a reel (also called a main roll) and a plurality of engaging rolls, wherein each engaging roll of the plurality of engaging rolls is configured to engage with fiber material and is assigned to, arranged upstream of, or arranged downstream of the reel, wherein at least one engaging roll of the plurality of engaging rolls is formed by a roll according to the invention. For this purpose, the engaging roll has a set of teeth provided on the second lateral surface of the roll. Advantageously, the set can be formed by a wire having a plurality of teeth, wound around the second lateral surface of the roll, and connected to the second lateral surface in at least one end region, preferably in two end regions of the second lateral surface, for example, soldered thereto.

[0057] For example, if the roller is designed as a random roller at an exit of the carding machine, it can be designed for peripheral speeds of up to 3,500 m / min.

[0058] The present invention further relates to a needling machine for consolidating a fibrous web, comprising a needling zone with at least one needle bar with a plurality of needles, which is configured to consolidate the fibrous web. Furthermore, the needling machine comprises a plurality of rollers for guiding the nonwoven web to be consolidated or consolidated, such as feed or take-off rollers, wherein at least one of the plurality of rollers is formed by a roller according to the invention.

[0059] The majority of the needle-punching machine's rollers are typically operated at low speeds. Due to the large span that must be bridged in the needle-punching machine, rollers often have to be temporarily supported to minimize or eliminate roller deflection, thereby increasing the complexity of the machine and its costs. By using rollers according to the invention in the needle-punching machine, which can exhibit greater flexural rigidity than conventional rollers with the same dimensions, intermediate support is no longer necessary.

[0060] The present invention further relates to an aerodynamic nonwoven forming system, wherein at least one roller, in particular the knock-off roller, can be formed by a roller according to the invention.

[0061] The present invention further relates to a drafting system comprising a plurality of rollers for drawing the fibrous web or nonwoven web, wherein at least one of the plurality of rollers is formed by a roller according to the invention. The drafting system can be provided before and / or after a nonwoven layer, or also after a bonding device such as a needling machine.

[0062] In addition to the areas of application already mentioned, there are many other applications for the roller according to the invention. Most of these generally relate to machines that convey and / or process material webs or pieces of material. Its use is particularly preferred in machines that transport and / or process web-shaped goods with high thickness precision.

[0063] The use of the roller according to the invention is also particularly advantageous where long, slender rollers are used and high demands are placed on high rigidity (low deflection) under high line loads, i.e., precise gap dimensions must be maintained. This particularly applies to rollers that run at high speeds or rotational speeds. The relatively low weight of the roller according to the invention is a particular advantage here.

[0064] Concrete further examples for the use of the roller according to the invention are other textile machines (e.g. calenders) for calibrating, laminating, pressing, embossing, patterning, ironing; plastics machines for films, for example for laminating and embossing; printing machines and coating machines; machines for leather production and leather finishing; machines for wood processing and veneer production; rolling mills for metals and paper pressing plants, etc.

[0065] Further features and advantages of the present invention will become apparent from the following description with reference to the accompanying drawings. Fig. 1 shows an embodiment of a roller according to the invention in a cross-sectional view. Figs. 2a, b show two alternatives of a first embodiment of a roller according to the invention in a detailed view. Figs. 3a, b show two alternatives of a second embodiment of the roller according to Fig. 1 in a detailed view. Fig. 4 schematically shows an edge region of a cover layer of a roller according to the invention in a perspective view. Fig. 5 schematically shows a nonwoven layering machine with a roller according to the invention in a side view. Fig. 6 schematically shows a carding machine with a roller according to the invention in a side view.

[0066] In Fig. 1 an embodiment of a roller 2 according to the invention is shown in a cross-sectional view along the longitudinal axis 4 of the roller 2. The roller 2 comprises a substantially cylindrical roller base body 6, which is preferably designed as a hollow shaft. This does not necessarily have to be the case, but it is advantageous if the roller base body 6 is tubular at least at its ends. The roller base body 6 has an outer first circumferential surface 8, a first end section 10 and a second end section 12. The first and second end sections 10, 12 are each arranged at one end of the roller base body 6 and lie opposite one another in the longitudinal direction. The roller base body 6 has a wall thickness W and is preferably made of a metal, such as steel or aluminum, or a plastic.

[0067] The roller 2 further comprises a cover layer 14 made of a fiber composite material, which preferably comprises carbon fibers and a polyester resin as a matrix and, regardless of the materials used, has a layer thickness S. Due to this structure, the roller 2 has high flexural rigidity with low mass. The cover layer 14 completely surrounds the first lateral surface 8 in the circumferential direction of the roller base body 6 and also extends in the longitudinal direction of the roller base body 6, preferably completely along the first lateral surface 8. As a result, the first lateral surface 8 of the roller base body 6 is completely covered by the cover layer 14. An outer diameter of the roller 2 is identified by the reference symbol DA.

[0068] A first edge region 16 of the cover layer 14 extends beyond the first end section 10 of the roller base body 6, is folded inward, and fixed relative to the roller base body 6. In the illustrated embodiment, the roller 2 is constructed symmetrically and is therefore designed analogously at both ends. However, this does not necessarily have to be the case, and the two ends of the roller 2 can also be designed differently, but preferably both according to an embodiment of the invention.

[0069] A second edge region 18 of the cover layer 14 extends here beyond the second end section 12 of the roller base body 6, is folded inwards and fixed with respect to the roller base body 6.

[0070] Generally within the scope of the invention, the fiber composite material of the cover layer 14 comprises fibers which are wound in the form of a woven fabric, a scrim or in the form of prepregs in one layer or in multiple layers around the roller base body 6 and then folded or turned over inwards in the first and second end sections 10, 12, i.e. in the direction of the longitudinal axis 4.

[0071] A first part of fibers of the fiber composite material runs essentially in the circumferential direction of the roller base body 6 and a second part of fibers of the fiber composite material runs essentially in the longitudinal direction of the roller base body 6. Because the cover layer 14 is folded over in the first and second end sections 10, 12 and fixed with respect to the roller base body 6, the cover layer 14 counteracts thermal expansion of the roller base body 6 both in the radial direction and in the longitudinal direction and delamination of the cover layer 14 from the roller base body 6 can be avoided.

[0072] To avoid shear stresses in the cover layer 14, the first and second edge regions 16, 18 are folded inward by a curvature. In a first embodiment, the roller base body 6 has a corresponding curvature on the front side in the first and second end sections 10, 12, as described with reference to Fig. 2a und 2b described in more detail. In a second embodiment, the roller 2 comprises at least a first end ring 20 and preferably also a second end ring 22, as in Fig. 1 presented and with reference to Fig. 3a und 3b described in more detail. Then, the first and second end rings 20, 22 each have the curvature around which the edge regions 16, 18 are folded. The following statements apply to both the first and second embodiments, unless otherwise described.

[0073] The cover layer 14 can be adhesively secured both in the first and second edge regions 16, 18, as well as in the region of the first lateral surface 8 of the roller base body 6. For this purpose, the resin of the fiber composite material of the cover layer 14 and / or a separate adhesive can be used. Additionally or alternatively, the cover layer 14 can be frictionally secured in the first edge region 16 and preferably also in the second edge region 18.

[0074] In the illustrated embodiment, the roller 2 comprises a first clamping element 24 and preferably a second clamping element 26. The first clamping element 24 frictionally secures the first edge region 16 of the cover layer 14, and the second clamping element 26 frictionally secures the second edge region 18. The first and second clamping elements 24, 26 press the first and second edge regions 16, 18, respectively, against a fastening section 28 of the roller base body 6 (see Fig. 2a, b ) or, as here, the first or second end ring 20, 22 (see Fig. 3a, b ). Preferably, the first and second clamping elements 24, 26 are ring-shaped or disc-shaped and arranged coaxially to the longitudinal axis 4 of the roller base body 6, preferably in each case at one end of the roller 2. If the first and second end sections 10, 12 are tubular or if the roller base body 6 is designed as a hollow shaft, as shown, the first and second clamping elements 24, 26 are preferably at least partially received in the first and second end sections 10, 12 of the roller base body 6, respectively.

[0075] The contact pressure on the first and second edge regions 16, 18 can be adjusted by adjusting the first and second clamping elements 24, 26 in the longitudinal direction of the roller base body 6. This can be achieved by screwing the first and second clamping elements 24, 26 to another component of the roller 2, so that the contact pressure can be changed by means of the screw connection. The longitudinal axes of the screws 30a-d are preferably aligned parallel to the longitudinal axis 4 of the roller base body 6, and the screws 30a-d of each clamping element 24, 26 are distributed over the circumference.

[0076] In general, the roller 2 may further comprise a first roller base 32 and a second roller base 34. The first and second roller bases 32, 34 each form a base of the substantially cylindrical roller base body 6, with the first roller base 32 being arranged in the first end section 10 and the second roller base 34 being arranged in the second end section 12. The first and second clamping elements 24, 26 may then be screwed to the respective roller base 32, 34, as already described.

[0077] The first and second roller bases 32, 34 can be formed integrally with the roller base 6 or, as shown, provided as separate elements. In this case, the first and second roller bases 32, 34 are substantially ring- or disc-shaped, i.e., have a cylindrical shape, and are arranged coaxially with the roller base 6. An outer diameter of the first and second roller bases 32, 34 substantially corresponds to the inner diameter of the roller base 6 in the first and second end sections 10, 12. The roller base 6 can each have a seat 36a, b in both end sections 10, 12 for receiving the respective roller base 32, 34. Each seat 36a, b comprises an inner circumferential surface of the roller base body 6 in the first and second end sections 10, 12, respectively, and a stop surface which positions the first and second roller bottoms 32, 34 in the longitudinal direction of the roller base body 6.The stop surface is formed, for example, by a step on the inside of the roller base body 6, wherein the roller base body 6 has a larger inner diameter on the side of the step facing the respective end than on the other side of the step.

[0078] The roller 2 may further comprise a first shaft journal 38 and a second shaft journal 40, which are configured to rotatably support the roller 2. For this purpose, the first and second shaft journals 38, 40 are arranged coaxially with the roller base body 6.

[0079] The first and second shaft journals 38, 40 can in turn be formed integrally with the first and second roller bases 32, 34, respectively, or as separate elements.

[0080] Shaft journals 38, 40, designed as separate elements, must be centered with respect to the roller base 6 to ensure the concentricity of the roller 2. In the illustrated embodiment, the first and second roller bases 32, 34 each have a through-opening 42, 44 in the longitudinal direction of the roller base 6, in which the first and second shaft journals 38, 40 are mounted. The through-openings 42, 44 are conically shaped, and the first and second shaft journals 38, 40 each have a corresponding, conically shaped end 38a, 40a, which is received in the respective through-opening 42, 44. The first and second clamping elements 24, 26 also have a through-opening through which the respective shaft journal 38, 40 passes.

[0081] A (temperature-related) expansion of the roller 2 or the roller base body 6 can be further counteracted by clamping the first and second roller bases 32, 34 together in the longitudinal direction of the roller base body 6 by means of a clamping device 46. As shown, the clamping device 46 can comprise a rod 48, for example made of steel, and can be arranged coaxially to the roller base body 6. For clamping, the rod 48 is counter-tightened in the longitudinal direction outside the roller bases 32, 34. Here, the rod 48 extends through the first shaft journal 38, the first roller base 32, the roller base body 6, the second roller base 34 and the second shaft journal 40 coaxially to the longitudinal axis 4 and has a threaded section at each of its two ends. A nut is screwed onto each of these threaded sections and rests against the respective shaft journal 38, 40.

[0082] As in Fig. 1 As can be seen, the roller 2 has an outer circumferential surface 50, which is also referred to as the second circumferential surface 50 to better distinguish it from the first circumferential surface 8 of the roller base body 6. The second circumferential surface 50 is formed largely, and in some embodiments completely, by the cover layer 14. For example, the cover layer 14 extends in the longitudinal direction of the roller 2 over at least 80% or at least 90% of the length L 1 of the second circumferential surface 50. The length of the entire roller 2 is designated as L 2 and depends on the length of the shaft journals 38, 40 and thus on the bearing of the roller 2 in the respective machine. For the present consideration, the length L 1 of the second circumferential surface 50 is therefore of greater importance.

[0083] The second lateral surface 50 forms the actual usable surface of the roller 2. If the roller 2 is used, for example, as a deflection roller for a conveyor belt, for example in a nonwoven layer, the second lateral surface 50 forms the contact surface with the conveyor belt. If the roller 2 is used in a carding machine, a set of teeth can be provided on the second lateral surface 50. The set of teeth is usually formed by winding a wire around the roller 2, which is to be fastened to the roller ends. In this case, it is therefore advantageous if a first and a second end region 50a, 50b of the second lateral surface 50 are not formed by the cover layer 14. Rather, the first and the second end region 50a, 50b can be formed by the first and second clamping elements 24, 26, respectively, or the first and second roller bases 32, 34, respectively.

[0084] In Fig. 2a, 2b, 3a, 3b A detailed view of the first end section 10 of different embodiments of the roller 2 is shown. All statements apply analogously to the second end section 12.

[0085] Fig. 2a und 2b relate to the first embodiment, in which the cover layer 14 is folded around the first end section 10 of the roller base body 6 itself, which has the curvature 52. The curvature 52 runs from the first lateral surface 8 initially inwards in the direction of the longitudinal axis 4 of the roller base body 6 and up to the fastening section 28 of the roller base body 6 for the first edge region 16. In the cross-sectional view, the fastening section 28 is preferably straight and inclined with respect to the longitudinal axis 4, so that it provides a substantially conical contact surface for the first edge region 16 of the cover layer 14 and is preferably arranged in the interior of the roller base body 6.

[0086] In the embodiment according to Fig. 2a The first end region 50a of the second lateral surface 50 is formed by the first clamping element 24 or the first roller base 34, which are arranged flush with the cover layer 14, so that a second lateral surface 50 that is as free from interference as possible is formed. The first clamping element 24 or the first roller base 34 can have a groove corresponding to the curvature 52, which rests against the unwrapped part of the cover layer 14.

[0087] In the embodiment according to Fig. 2b no end region 50a, b of the second lateral surface 50 is provided next to the cover layer 14. The second lateral surface 50 is formed entirely by the cover layer 14. The first clamping element 24 or the first roller base 32 are at least partially and preferably completely received in the roller base body 6.

[0088] Fig. 3a und 3b relate to the second embodiment, in which the cover layer 14 is wrapped around the first end ring 20, which has the curvature 52. The first end ring 20 is arranged coaxially to the roller base body 6 and, at the first end section 10, directly adjoins the roller base body 6. The first end ring 20 is flush with the first lateral surface 8, thus having an outer diameter that corresponds to the outer diameter of the roller base body 6 or the first lateral surface 8.

[0089] In the illustrated embodiment, the first end ring 20 has a first section 54 that is inserted into the first end section 10 of the roller base body 6, wherein an outer diameter of the first section 54 substantially corresponds to the inner diameter of the roller base body 6 in the first end section 10. On the end face of the roller base body 6, the first end ring 20 extends radially outward to a jacket section 56 of the first end ring 20, which is arranged flush with the first jacket surface 8 of the roller base body 6, i.e., has the same outer diameter as the latter. The curvature 52 extends from the jacket section 56 to the fastening section 28, which is preferably straight in cross-sectional view and inclined with respect to the longitudinal axis 4 of the roller base body 6, such that it provides a substantially conical contact surface for the first edge region 16 of the cover layer 14.

[0090] In the embodiment according to Fig. 3a is analogous to the embodiment according to Fig. 2a the first end region 50a of the second lateral surface 50 is provided. In the embodiment according to Fig. 3b is analogous to the embodiment according to Fig. 2b no end region 50a, b of the second lateral surface 50 is provided, so that the second lateral surface 50 is completely formed by the cover layer 14.

[0091] Fig. 4 shows a schematic perspective view of the folded-over first edge region 16. By folding over the first edge region 16, a substantially circumferential first edge 16a of the cover layer 14 is arranged radially within the first lateral surface 8. As a result, the first edge 16a has a smaller diameter and a smaller circumference than the part of the cover layer 14 arranged on the first lateral surface 8. This applies analogously to a second edge of the cover layer 14 in the second edge region 18. In order to reliably clamp the first and possibly also the second edge region 16, 18, the respective edge region 16, 18 should, however, be designed to be wrinkle-free and have no overlaps of the cover layer material.

[0092] The first edge region 16 and preferably also the second edge region 18 can therefore have a plurality of incisions 57 distributed in the circumferential direction. Each incision 57 of the plurality of incisions 57 is formed, starting from the first edge 16a or the second edge of the cover layer 14, such that the respective edge region 16, 18 is folded inward without creases and without overlaps. Two partial sections 16b, 16c separated from one another by an incision 57 therefore do not overlap. For this purpose, the incisions 57 can be tapered starting from the respective edge 16a, for example, essentially triangular.

[0093] In Fig. 5 A nonwoven layer 58 is shown schematically in a side view. The nonwoven layer 58 comprises at least one conveyor belt for conveying a fibrous web (not shown), here a feed belt 60, a first conveyor belt 62, a second conveyor belt 64, and a take-off belt 66. Furthermore, the nonwoven layer 58 preferably comprises an upper carriage 68 and a laying carriage 70. The feed belt 60 is configured to feed a fibrous web coming from a card to the nonwoven layer 58 and transfer it to the first conveyor belt 62. The first conveyor belt 62 conveys the fibrous web to the upper carriage 68, where the fibrous web is deflected. The fibrous web is then transferred from the first conveyor belt 62 to the second conveyor belt 64. The second conveyor belt 64 conveys the fibrous web to the laying carriage 70.The laying carriage 70 is designed to move back and forth perpendicular to the conveying direction of the take-off belt 66, which is aligned perpendicular to the plane of the drawing, and in doing so to lay the fibrous web onto the take-off belt 66.

[0094] The nonwoven layer 58 comprises a plurality of deflection rollers 72a-t around which the at least one conveyor belt 60, 62, 64 is guided, wherein at least one deflection roller 72a-t of the plurality of deflection rollers 72a-t is formed by the roller 2, as described herein.

[0095] All conveyor belts 60, 62, 64 are designed to rotate and are each driven by at least one of the deflection rollers.

[0096] More specifically, in the illustrated embodiment, the feed belt 60 is guided around a first and a second deflection roller 72a, 72b. Adjacent to the feed belt 60, the first conveyor belt 62 preferably runs around a third deflection roller 72c and from there continues to the superstructure 68, where the first conveyor belt 62 is deflected around a fourth and a fifth deflection roller 72d and 72e. Preferably, both the first and the second conveyor belt 62, 64 lead from the superstructure 68 to the laying carriage 70. A third conveyor belt 74 can be provided, which also leads from the other side to the laying carriage 70. In the laying carriage 70, the second and, if present, the third conveyor belt 64, 74 or alternatively the first and second conveyor belts 62, 64 are wrapped around a sixth deflection roller 72f or a seventh deflection roller 72g, respectively, between which a laying gap is formed for delivering the fibrous web onto the take-off belt 66.From the laying carriage 70, the third conveyor belt 74 leads over several deflection rollers 72h-l, first over the discharge belt 66, and back to the laying carriage 70, with an eighth deflection roller 72j being rotatably mounted in a first auxiliary carriage 76. The first auxiliary carriage 76 is provided for length compensation of the second and third conveyor belts 64, 74 and can be moved opposite to the laying carriage 70. The second conveyor belt 64 leads from the laying carriage 70, first over the discharge belt 66 and over several deflection rollers 72m-r back to the laying carriage 70, with the ninth deflection roller 72o also being rotatably mounted in the first auxiliary carriage 76. The first conveyor belt 62 runs from the superstructure 68 to a tenth and an eleventh deflection roller 72s, 72t back to the feed belt 60, with the eleventh deflection roller 72t being rotatably mounted in a second auxiliary carriage 78. The second auxiliary carriage 78 is provided for length compensation of the first conveyor belt 62.The roller according to the invention can also be used in all other known designs of nonwoven layers.

[0097] In Fig. 6 A carding machine 80 for producing a card web or a pre-pile is shown schematically in a side view. The carding machine 80 is configured in particular for producing a fibrous card web from a fiber flock mat. For this purpose, the carding machine 80 comprises a drum 82, also called the main roller, and a plurality of engaging rollers 84a-v, 86, 88, 90, 92 which are configured for engaging with fiber material, are assigned to the drum 82, are arranged upstream or downstream, and of which at least one engaging roller is formed by a roller 2 according to the invention.

[0098] The plurality of engagement rollers 84a-v, 86, 88, 90, 92 of the carding machine 80 can, for example, comprise a licker-in 86 and a transfer roller 88 upstream of the reel 82, as well as a feed roller 90 and a pre-roller 92. The plurality of engagement rollers 84a-j can comprise a plurality of turner and worker rollers 84a-j, each arranged in pairs along the circumference of the reel 82 and / or the licker-in 86. The plurality of engagement rollers 84k-n can also comprise upper or lower random rollers 84k,m and / or doffer rollers 84l,n provided downstream of the reel 82, or upper and lower take-off rollers 84o-r arranged downstream thereof. Finally, the plurality of engagement rollers may comprise at least one upper and / or lower compression roller 84s-v. For example, a first and a second upper compression roller 84s, t are provided between the upper doffer roller 84l and the upper take-off roller 84o.A first and a second lower compression roller 84u, v can also be provided between the lower doffer roller 84n and the lower take-off roller 84q.

[0099] Further advantageous areas of application of the roller 2 according to the invention will be apparent to the person skilled in the art based on the disclosure of the present invention.

Claims

1. A roller (2), comprising: a substantially cylindrical roller main body (6) having an outer first lateral surface (8), a first end section (10) and a second end section (12), which lies opposite the first end section (10) in a longitudinal direction of the roller main body (6); and a covering layer (14) made of a fibre composite material; wherein the covering layer (14) completely surrounds the first lateral surface (8) of the roller main body (6) in a circumferential direction of the roller main body (6); wherein a first edge region (16) of the covering layer (14) extends beyond the first end section (10) of the roller main body (6), is folded over inwards and is fixed in relation to the roller main body (6), and wherein the roller (2) comprises at least one first clamping element (24), which fixes the first edge region (16), wherein the first clamping element (24) is annular or disc-shaped and is arranged coaxially with respect to the roller main body (6), characterized in that the first end section (10) of the roller main body (6) has, at an end, a curvature (52) which starts from the first lateral surface (8) and around which the first edge region (16) of the covering layer (14) is folded over inwards, and the first clamping element (24) and the first end section (10) of the roller main body (6) have corresponding conical contact surfaces, between which the first edge region (16) is accommodated, or in that the roller (2) further comprises a first end ring (20), which is arranged coaxially with respect to the roller main body (6) and adjoins the roller main body (6) at the first end section (10), wherein the first end ring (20) is flush with the first lateral surface (8) and has, on a side facing away from the roller main body (6), a curvature (52) around which the first edge region (16) of the covering layer (14) is folded over inwards.

2. The roller (2) according to claim 1, characterized in that the first edge region (16) is fixed adhesively and frictionally.

3. The roller (2) according to claim 1 or 2, characterized in that the first clamping element (24) is adjustable in the longitudinal direction of the roller (2) to adjust a contact pressure acting on the first edge region (16) of the covering layer (14) by means of the first clamping element (24).

4. The roller (2) according to any of the preceding claims, characterized in that the roller main body (6) is of tubular shape at least in the first end section (10), and the first edge region (16) is arranged in an interior of the first end section (10).

5. The roller (2) according to claim 4, characterized in that the roller (2) comprises a first roller base (32) and a second roller base (34), wherein the first roller base (32) is accommodated in the first end section (10) of the roller main body (6), and the second roller base (34) is accommodated in the second end section (12) of the roller main body (6), wherein the first and the second roller bases (32, 34) are clamped together in the longitudinal direction of the roller main body (6) by means of a clamping device (46).

6. The roller (2) according to any of the preceding claims, characterized in that the first edge region (16) of the covering layer (14) has a plurality of notches (57) distributed in the circumferential direction, wherein each notch (57) of the plurality of notches (57) is formed in such a way, starting from an edge (16a) of the covering layer (14) which extends in the circumferential direction, that the first edge region (16) is formed without folds and two subsections (16b, 16c) of the first edge region (16), which are separated from one another by a notch (57) of the plurality of notches (57), do not overlap.

7. The roller (2) according to any of the preceding claims, characterized in that the roller (2) has an outer second lateral surface (50) which is formed at least partially by the covering layer (14), wherein the covering layer (14) extends in the longitudinal direction of the roller (2) over at least 50%, more preferably over at least 70%, even more preferably over at least 80%, of the second lateral surface (50).

8. The roller (2) according to any of the preceding claims, characterized in that the roller main body (6) is formed from metal, in particular aluminium or steel, or from a plastic, in particular GRP (glass-reinforced plastic) or polyamide, and the covering layer (14) comprises carbon fibres, glass fibres or mineral fibres, such as ceramic fibres or silicate fibres, and a matrix of plastic, in particular a matrix of resins of epoxy, polyester, polyurethane or melamine.

9. A crosslapper (58) having at least one conveyor belt (60, 62, 64, 66, 74) for conveying a fibrous web and a plurality of deflection rollers (72a-t), around which the at least one conveyor belt (60, 62, 64, 66, 74) is guided, wherein at least one deflection roller (72a-t) of the plurality of deflection rollers (72a-t) is configured as a roller (2) according to any of claims 1 to 8.

10. A carding machine (80) for producing a fibrous web, comprising a main cylinder (82) and a plurality of engagement rollers (84a-v), wherein each engagement roller (84a-v) of the plurality of engagement rollers (84a-v) is configured for engagement with fibre material and is associated with the main cylinder (82), adjacent thereto or upstream or downstream thereof, wherein at least one engagement roller (84a-v) of the plurality of engagement rollers (84a-v) is configured as a roller (2) according to any of claims 1 to 8.