Method of manufacturing roll, and roll

Abstract

To provide a novel roll that has characteristics of both carbon fiber-reinforced plastic and metal.SOLUTION: A roll 10 has: a cylinder part 16 which contains carbon fiber-reinforced plastic; and a coil part 18 which consists of wire material 18a of metal wound around a surface of the cylinder part. The wire material 18a of metal may be sectioned in a square shape. The roll 10 may further have a flange part 14 which holds the cylinder part 16 and an end of the coil part 18. The flange part 14 may have a first step part 14a restricting an axial position of the coil part 18 and a second step part 14b restricting an axial position of the cylinder part.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a roll, for example, a roll used for transporting a film. [Background technology]

[0002] In recent years, the film manufacturing industry has seen ever-increasing demands for higher film performance and film thickness accuracy, leading to fierce competition among companies in the development of new technologies and manufacturing methods. This has led to ever more demanding requirements for manufacturing equipment and peripheral components. Rolls, in particular, are in direct contact with film and are considered a crucial component that determines the performance of film products, so even greater technological innovation is being called for for rolls.

[0003] Conventionally, metal rolls have generally been used for applications such as conveyance guides, nip stretching, and winding. However, with the trend toward wider films and faster line speeds, metal rolls have a large moment of inertia and a large deflection due to their own weight, and there has been a limit to how much improvement can be made to them for use in production lines with strict requirements.

[0004] Therefore, rolls made of carbon fiber reinforced plastics (CFRP) have been devised. Rolls made of CFRP are lightweight and strong, with a specific gravity of about 1 / 4 that of steel and strength about 1.5 times that of steel. However, the abrasion resistance of CFRP can be significantly inferior to that of steel.

[0005] In view of this situation, a roll has been devised in which a metal sleeve is attached to the outer peripheral surface of a cylinder containing carbon fiber reinforced plastic, and the outer peripheral surface of the metal sleeve is chrome plated (see Patent Document 1). [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 7047169 Summary of the Invention [Problem to be solved by the invention]

[0007] However, the aforementioned roll is a CFRP roll with an extremely low coefficient of thermal expansion, and the metal sleeve expands in a high-temperature environment, potentially cracking the plating film on the metal surface. Furthermore, even if the metal sleeve and CFRP roll are not secured at their ends to allow for deformation of the expanding metal sleeve, this type of roll is not suitable for applications that require softening and processing films, such as submerged rolls in a tank. This is because liquid seeping in from the roll ends can soften the epoxy resin or other materials used in the CFRP.

[0008] The present invention has been made in view of the above circumstances, and one of its exemplary objects is to provide a new roll having both the properties of carbon fiber reinforced plastic and metal. [Means for solving the problem]

[0009] In order to solve the above problems, a roll according to one embodiment of the present invention has a cylindrical portion containing carbon fiber reinforced plastic and a winding portion made of a metal wire wound around the surface of the cylindrical portion.

[0010] According to this embodiment, the cylindrical portion containing carbon fiber reinforced plastic suppresses the deflection of the entire roll, and the wear resistance of the roll can be improved by covering the surface of the cylindrical portion with metal wires.

[0011] The metal wire may have a rectangular cross section, which can reduce gaps between the wires wound around the surface of the cylindrical portion and between the wire and the cylindrical portion.

[0012] The roll may further have a plating layer formed on the surface of the winding portion, which can smooth out irregularities on the roll surface and improve wear resistance.

[0013] The roll may further include a flange portion that holds the end of the tubular portion and the winding portion. The flange portion may have a first step portion that regulates the axial position of the winding portion and a second step portion that regulates the axial position of the tubular portion. The first step portion may be formed axially outward of the second step portion. This allows the winding portion to cover the entire tubular portion. Furthermore, even when the roll is used in a tank, liquid in the tank is less likely to reach the tubular portion.

[0014] Another aspect of the present invention is a method for manufacturing a roll, which includes the steps of preparing a cylindrical portion containing carbon fiber reinforced plastic and winding a metal wire around the surface of the cylindrical portion to form a wound portion.

[0015] According to this embodiment, the winding portion can be formed using the same metal wire regardless of the diameter or length of the cylindrical portion.

[0016] The method may further include a step of polishing the outer circumferential surface of the winding portion, which makes it possible to easily smooth the outer circumferential surface of the winding portion.

[0017] A plating layer may be formed on the polished outer peripheral surface of the winding portion, thereby improving the wear resistance of the outer peripheral surface of the roll and making it smoother.

[0018] The metal wire may have a rectangular cross section with a width of 1 to 10 mm and a thickness of 0.5 to 2 mm.

[0019] Any combination of the above components and conversion of the present invention into a method, device, system, etc. are also valid aspects of the present invention. [Effects of the Invention]

[0020] According to the present invention, a new roll having the properties of both carbon fiber reinforced plastic and metal can be provided. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a side view showing the entire roller according to the present embodiment. [Figure 2] 2 is a cross-sectional view taken along the line AA of the roll shown in FIG. 1. [Figure 3] 5A to 5C are schematic diagrams for explaining a method for manufacturing a roll. [Figure 4] FIG. 2 is a diagram schematically illustrating a cross section of adjacent wires in a winding portion. DETAILED DESCRIPTION OF THE INVENTION

[0022] The present invention will be described below based on embodiments with reference to the drawings. The same or equivalent components, parts, and processes shown in each drawing will be given the same reference numerals, and redundant explanations will be omitted as appropriate. Furthermore, the embodiments are illustrative rather than limiting the invention, and all features and their combinations described in the embodiments are not necessarily essential to the invention.

[0023] (roll) Fig. 1 is a side view showing the entire roller according to this embodiment. The roll 10 shown in Fig. 1 is used to transport and wind up thin, sheet-like materials such as films and foils. The roll 10 includes a cylindrical large-diameter portion 12 that comes into direct contact with the film or the like, and flange portions 14 that are provided to fit onto both axial ends of the large-diameter portion 12. The flange portions 14 serve as a rotation axis when the roll 10 is installed in a transport device.

[0024] The large diameter portion 12 according to this embodiment has a length L selected appropriately within the range of 3000 to 8000 mm, a diameter D selected within the range of 150 to 300 mm, and a thickness T selected appropriately within the range of 10 to 30 mm, but is not limited to these ranges. The material of the flange portion 14 is, for example, stainless steel such as SUS or carbon steel for mechanical construction such as S45C.

[0025] Fig. 2 is a cross-sectional view taken along the line AA of the roll 10 shown in Fig. 1. As shown in Fig. 2, the roll 10 includes a cylindrical portion 16 containing CFRP, a winding portion 18 made of metal wire rods 18a wound around the surface of the cylindrical portion 16, and flange portions 14 that hold the ends of the cylindrical portion 16 and the winding portion 18. As a result, the cylindrical portion 16 containing CFRP suppresses deflection of the entire roll 10, while covering the surface of the cylindrical portion 16 with the metal wire rods 18a improves the wear resistance of the roll 10.

[0026] The metal wire 18a according to this embodiment has a rectangular cross section, as shown in FIG. 2. This reduces gaps between the wires 18a wound around the surface of the cylindrical portion 16 and between the wire 18a and the cylindrical portion 16. The wire 18a according to this embodiment has a rectangular cross section with a width W of 0.8 to 2.5 mm and a thickness t1 appropriately selected within a range of 0.4 to 2 mm, but the cross section is not limited thereto. For example, the wire 18a may have a rectangular cross section with a width W of 1 to 10 mm and a thickness of 0.5 to 2 mm. The cross section width W may be 1 to 2 mm. The wire 18a is preferably made of an invar material with a small coefficient of expansion. For rolls in a production line using corrosive gases, wires such as SUS316 and titanium may be used.

[0027] The flange portion 14 has a first step 14a that regulates the position of the winding portion 18 in the axial direction Ax, and a second step 14b that regulates the position of the tubular portion 16 in the axial direction Ax. The first step 14a is formed further outward in the axial direction Ax (to the left in FIG. 2) than the second step 14b. This allows the winding portion 18 to cover the entire tubular portion 16. Furthermore, even when the roll 10 is used in a tank, liquid in the tank is less likely to reach the tubular portion 16.

[0028] Furthermore, in the roll 10 according to this embodiment, a plating layer 20 is formed on the surface of the winding portion 18. This makes it possible to smooth out irregularities on the surface of the roll 10 while improving wear resistance. The plating layer 20 is, for example, a thin film of hard chrome plating. Alternatively, instead of the plating layer 20, a thin film formed by thermal spraying a cermet material such as tungsten or chromium oxide, or a thin film formed by thermal spraying a ceramic material such as alumina, may be used. The thickness of the plating layer 20 is 20 to 200 μm, preferably 30 to 100 μm.

[0029] (Roll manufacturing method) Next, a method for manufacturing a roll according to this embodiment will be described. Fig. 3 is a schematic diagram for explaining the method for manufacturing a roll. In the method for manufacturing a roll according to this embodiment, first, a cylindrical portion 16 containing CFRP and having a predetermined shape is prepared. The predetermined shape refers to the length, diameter, thickness, etc.

[0030] The flange portion 14 is press-fitted into the prepared tubular portion 16 and installed in the manufacturing equipment. Next, one end of the wire 18a is hooked into a hole 14c formed near the first step 14a of the flange portion 14, and brass is driven in from above to secure the wire 18a by caulking. The method of fastening is not particularly limited, and may be press-fitting or welding. As the tubular portion 16 rotates in the direction of arrow R1 while gradually moving in the direction of arrow B, the wire 18a supplied from the wire supply device 22 is spirally wound around the surface of the tubular portion 16, forming the winding portion 18. At this time, the other end of the wire 18a is fixed to the flange portion 14 by spot welding. In order to stabilize the initial position of the wire 18a, a wall 14d (abutment portion) corresponding to the width W of the wire 18a is formed on the first step 14a.

[0031] According to the roll manufacturing method of this embodiment, the winding portion 18 can be formed using the same metal wire regardless of the diameter or length of the cylindrical portion 16. In other words, when attaching a metal tube to a cylindrical portion of CFRP, it is necessary to prepare a metal tube according to the diameter and length of the cylindrical portion, but according to the roll manufacturing method of this embodiment, it is not necessary to prepare such a variety of metal tubes.

[0032] Next, the outer circumferential surface of the winding portion 18 wound around the tubular portion 16 is polished. The polishing amount is smaller than the thickness t1 of the wire rod 18a, for example, approximately 0.1 to 1.0 mm. The final thickness t2 of the winding portion 18 after polishing is approximately 0.3 to 1.2 mm. This allows the outer circumferential surface of the winding portion 18 to be easily smoothed. FIG. 4 is a schematic diagram showing the cross section of adjacent wire rods in the winding portion. If the cross section of the wire rod 18a is not a perfect rectangle, specifically if the corners of the rectangle are rounded to some extent during the wire rod manufacturing process, recesses 19 will be formed between adjacent wire rods 18a. Therefore, the recesses 19 can be eliminated by polishing the surface of the wire rod 18a wound around the tubular portion 16 by the polishing amount S. Then, a plating layer is formed on the polished outer circumferential surface of the winding portion 18. This improves the wear resistance of the outer circumferential surface of the roll while further smoothing it.

[0033] Although the present invention has been described above with reference to the above-mentioned embodiments, the present invention is not limited to the above-mentioned embodiments, and suitable combinations and substitutions of the configurations of the embodiments are also included in the present invention. Furthermore, it is possible to suitably rearrange the combinations and processing orders in the embodiments based on the knowledge of those skilled in the art, and to make modifications to the embodiments such as various design changes, and such modified embodiments are also included in the scope of the present invention. [Explanation of symbols]

[0034] 10 roll, 12 large diameter portion, 14 flange portion, 14a first step portion, 14b second step portion, 14c hole, 14d wall, 16 cylindrical portion, 18 winding portion, 18a wire rod, 19 recess, 20 plating layer

Claims

1. a cylindrical portion containing carbon fiber reinforced plastic; a winding portion made of a metal wire wound on the surface of the cylindrical portion; A roll having:

2. 2. The roll according to claim 1, wherein the metal wire has a rectangular cross section.

3. 3. The roll according to claim 1, further comprising a plating layer formed on the surface of the winding portion.

4. a flange portion for holding the cylindrical portion and an end portion of the winding portion; The flange portion is a first step portion that restricts the axial position of the winding portion; a second step portion that restricts the axial position of the cylindrical portion, The first step portion is formed axially outward of the second step portion.

3. The roll according to claim 1 or 2.

5. providing a tubular portion containing carbon fiber reinforced plastic; a step of winding a metal wire on the surface of the cylindrical portion to form a winding portion; A method for manufacturing a roll having the above structure.

6. The method for manufacturing a roll according to claim 5, further comprising a step of polishing the outer peripheral surface of the winding portion.

7. 7. The method for manufacturing a roll according to claim 6, wherein a plating layer is formed on the outer peripheral surface of the ground winding portion.

8. The method for manufacturing a roll according to any one of claims 5 to 7, wherein the metal wire has a rectangular cross section having a width of 1 to 10 mm and a thickness of 0.5 to 2 mm.

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