roll

Abstract

To provide a roll using a material in stead of carbon fiber reinforced plastic (CFRP), being a roll which has reduced environmental effects compared with the CFRP.SOLUTION: In this roll, a material including cellulose is formed into a roll shape, Nano-cellulose, more concretely, a cellulose nano-fiber, cellulose nano-crystal, and bacteria nano-cellulose can be used for the cellulose. A hard pipe 4, a plated layer 6 or a DLC film 5 can be arranged outside a cellulose roll 1 in which a material including the nano-cellulose is formed into a roll shape. In this case, the DLC film 5 can be formed outside the hard pipe 4 or the plated layer 6. Also, a mixing layer can be formed between the hard pipe 4 and the DLC film 5, between the plated layer 6 and the DLC film 5, or between the hard pipe 4 and the plated layer 6.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a roll intended to reduce the environmental load. [Background technology]

[0002] Films and glass plates with various functions (hereinafter referred to as "functional materials") are used in mobile devices such as smartphones and tablets, as well as wearable devices. The equipment used to manufacture these functional materials uses various rolls, such as conveyor rolls, gravure rolls, and nip rolls. These rolls are made of metals such as aluminum, SUS304, and STKM13a, and carbon fiber reinforced plastics (CFRP) are also used to increase the rigidity (strength) of the rolls.

[0003] A carbon roll (Patent Document 1) made of carbon fiber reinforced plastic (CFRP) has been known as one type of roll. Carbon rolls have properties such as light weight, high strength, high rigidity, and low thermal expansion, and are used in various situations. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2013-28861 A Summary of the Invention [Problem to be solved by the invention]

[0005] While carbon rolls have the excellent properties mentioned above, they have the drawback of being difficult to recycle, both technically and cost-wise. For this reason, CFRP, the material from which carbon rolls are made, is sometimes disposed of in landfills, but as CFRP itself does not decompose naturally, there are concerns about its impact on the environment.

[0006] The present invention has been made in view of the above problems, and an object of the present invention is to provide a roll using a material that can replace CFRP and that has a smaller environmental impact than CFRP. [Means for solving the problem]

[0007] The roll of the present invention is a roll of a material containing cellulose. Nanocellulose, such as cellulose nanofiber (CNF), cellulose nanocrystal (CNC), bacterial nanocellulose, etc., can be used as the cellulose. Effect of the Invention

[0008] Since the roll of the present invention is made of a material containing naturally decomposable cellulose, it has a small impact on the environment and contributes to environmental conservation and improvement. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a front view showing an example of a roll of the present invention. [Diagram 2] FIG. 2A is a front view showing another example of a roll of the present invention, and FIG. 2B is an enlarged view of part IIb of FIG. [Diagram 3] FIG. 3A is a front view showing another example of the roll of the present invention, and FIG. [Figure 4] FIG. 4A is a front view showing another example of a roll of the present invention, and FIG. [Diagram 5] 1(a) and 1(b) show an example in which the roll of the present invention is mounted on another shaft member. [Figure 6] 4 is a flowchart showing an example of a roll manufacturing process. [Figure 7] FIG. 1 is a schematic diagram showing an example of an apparatus used for forming a DLC film. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] (Embodiment) An example of an embodiment of the roll of the present invention will be described with reference to the drawings. The roll of the present invention can be used as various industrial rolls such as a conveying roll, a gravure roll, and a nip roll, which are parts of a manufacturing device for functional materials, etc., but here, the case where the roll is a gravure roll will be described as an example.

[0011] As an example, the roll shown in FIG. 1 is a roll (hereinafter referred to as "cellulose roll") 1 made of a material containing cellulose. Here, cellulose also includes so-called nanocellulose. Nanocellulose also includes cellulose nanofibers (CNF) and cellulose nanocrystals (CNC) made from wood and other raw materials, as well as bacterial nanocellulose produced by microscopic bacteria such as acetic acid bacteria. CNC is also called cellulose nanowhiskers (CNW). The nanocellulose also includes that produced from cellulose dissolved by electrospinning. The nanocellulose may be in the form of a gel or pellets.

[0012] Here, an example will be described in which CNF is used as cellulose.

[0013] The cellulose roll 1 of this embodiment is made by winding a material (in a fibrous or sheet-like form) in which CNF and a thermosetting resin (binder) are mixed together into a roll and hardening it. The cellulose roll 1 can also be molded by extrusion molding (injection molding).

[0014] The CNFs used to make the cellulose rolls can be about 150 nm long and 3 nm wide, although they can be larger or smaller.

[0015] The resin to be kneaded with the CNF can be, for example, a thermosetting resin, more specifically, an epoxy resin or a polypropylene resin. It is desirable that the CNF is contained in the resin at 1 wt% or more. However, this content is an example, and other contents are also possible. The resin material can be polycarbonate (PC), polyamide (PA), polystyrene terephthalate (PBT), polyacetal (POM), polyphenylene ether (PPE), etc., and there is no particular restriction on the material.

[0016] As shown in FIG. 1, the cellulose roll 1 of this embodiment has a roll body in the shape of a pipe made of cellulose, which is attached to the outside of a shaft material 3 via a bearing 2 when in use. In this case, the bearings 2 are preferably provided via metallic flanges 12 embedded on both ends of the cellulose roll 1. The cellulose roll 1 may be made of solid wood. The outer diameter, inner diameter, length, etc. of the cellulose roll 1 can be designed as appropriate depending on the application. The structure of the roll can be changed depending on the roll diameter and purpose.

[0017] The cellulose roll 1 can be used as a roll by itself, but can also be used as a roll base material for a roll as shown in Figs. 2(a) and (b) for the purpose of improving abrasion resistance.

[0018] 2(a) and (b) show an example of a roll using a cellulose roll 1 as a roll base material. A hard tube 4 having a higher hardness than the cellulose roll 1 is provided on the outside of the cellulose roll 1. For example, a sleeve made of SUS or aluminum can be used for the hard tube 4. In this embodiment, a SUS tube (SUS304) is used as the hard tube 4. In addition to a metal sleeve, a resin such as polyvinyl chloride (PVC) or polypropylene (PP) can also be used. There is no particular restriction on the thickness of the metal sleeve and the resin sleeve, and it is preferable that the thickness is 0.1 mm or more, and a thickness of 5 mm or more is also acceptable.

[0019] In this embodiment, the cellulose roll 1 and the rigid tube 4 are bonded with an adhesive (not shown) to increase the degree of adhesion between them. The rigid tube 4 can also be attached to the outside of the cellulose roll 1 by shrink fitting. Specifically, the rigid tube 4 is thermally expanded and placed over the outside of the cellulose roll 1, and then the rigid tube 4 is cooled and contracted, thereby making the rigid tube 4 adhere closely to the cellulose roll 1. In addition to shrink fitting, it is also possible to fasten them together using an adhesive such as an epoxy adhesive, pins, or the like.

[0020] Although not shown in the drawings, it is also possible to form irregularities such as cells or engravings on the surface of the hard tube 4. By providing irregularities on the surface of the hard tube 4, it can be used as a gravure roll.

[0021] In a roll equipped with a hard tube 4 as shown in Fig. 2(a)(b), a DLC film 5 as shown in Fig. 3(a)(b) can be provided on the outer periphery of the hard tube 4. The DLC film 5 of the roll shown in Fig. 3(a)(b) has a thickness of about 0.5 to 50 µm and a hardness of about 800 to 6000 HV. The thickness of the DLC film 5 is 1 µm or more, preferably 6 µm or more.

[0022] A hydrocarbon gas such as CH4 (methane), C7H8 (toluene), C2H2 (acetylene), or C6H6 (benzene) can be used as the source gas to form the DLC film 5. There is no particular designation for the structure of the DLC film 5, but it may contain a third element such as Si (silicon), O2 (oxygen), B (boron), N2 (nitrogen), Cr (chromium), or Ti (titanium) to relieve internal stress.

[0023] The rolls shown in Figures 3(a) and (b) form a DLC film 5 directly on the surface of a rigid tube 4, but in order to improve the adhesion between the two, an intermediate layer other than the HCr plating layer (hereinafter referred to as a "mixing layer") can also be provided between the rigid tube 4 and the DLC film 5.

[0024] The mixing layer may be mainly composed of Si, Cr, Ti, or may be a compound with nitrogen, or may contain C (carbon) or H (hydrogen), etc. The mixing layer may be provided as needed, and may be omitted if not required.

[0025] In a roll having a hard tube 4 as shown in Fig. 2(a)(b), instead of the DLC film 5, a plating layer 6 as shown in Fig. 4(a)(b) can be provided on the outer periphery of the hard tube 4. Specifically, an HCr plating layer or a Ni plating layer can be provided on the outside of the hard tube 4. The plating layer 6 can be formed by a conventional method. When the hard tube 4 is made of aluminum, it is preferable to perform Ni plating and then HCr plating.

[0026] (Other embodiments) 2 shows an example in which a rigid tube 4 is provided on the outer periphery of the cellulose roll 1, but a plating layer 6 can be provided instead of the rigid tube 4. In this case, a DLC film 5 can be provided on the outside of the plating layer 6. Also, instead of providing a rigid tube 4 or a plating layer 6 on the outer periphery of the cellulose roll 1, a DLC film 5 can be provided.

[0027] A sponge (sponge layer) for cleaning or dehydrating can be provided on the outermost periphery (outside) of each roll shown in the above embodiment. The sponge layer can be provided over the entire length of the roll in the longitudinal direction, or can be provided partially. There is no particular restriction on the material of the sponge layer, and various materials such as urethane-based sponges such as polyvinyl chloride (PVC) and polyvinyl alcohol (PVA) can be used.

[0028] The cellulose roll 1 of each roll shown in the above embodiment is mounted on a shaft material via a bearing 2 attached to a flange 12 as an example, but the cellulose roll 1 of each roll can also be mounted on the outside of a shaft member 13 embedded at each of both ends in the longitudinal direction, as shown in Figures 5(a) and (b).

[0029] A rubber material (rubber layer) for conveying, nipping, and tension cutting can be provided on the outermost periphery (outside) of each roll shown in the above embodiment. The rubber layer can be provided over the entire length of the roll in the longitudinal direction or partially. There is no particular limitation on the material of the rubber layer, and various materials such as EPDM (EPT), urethane, Viton, silicone, and fluorine-based rubber can be used.

[0030] Next, an example of a method for manufacturing the roll will be described. In this example, a roll is manufactured in which a hard tube 4 is provided on the outside of a cellulose roll 1 and a DLC film 5 is formed on the surface of the hard tube 4.

[0031] 6, the roll can be manufactured through a base material manufacturing process S1, a hard tube mounting process S2, a cleaning process S3, a mixing layer forming process S4, and a film forming process S5. The cleaning process S3 and the mixing layer forming process S4 need to be performed only when necessary, and can be omitted when not necessary.

[0032] Of the above steps, the cleaning step S3, the mixing layer forming step S4, and the film forming step S5 can be performed using an apparatus shown in Fig. 7. In Fig. 7, 7 is a vacuum chamber, 8 is an RF high-frequency power supply, 9 is an RF electrode, 10 is a high-voltage pulse power supply, and 11 is a gas inlet. An ICP (Inductively Coupled Plasma) power supply can also be used instead of the RF high-frequency power supply 8. By using an ICP power supply, the plasma density becomes higher than that of the RF high-frequency power supply 8, and the DLC film 5 can be thickened in a shorter time than when the RF high-frequency power supply 8 is used.

[0033] In the base material production step S1, a material in which CNF and a thermosetting resin are mixed is wound into a roll shape and hardened to produce the cellulose roll 1. The cellulose roll 1 can also be formed by extrusion molding (injection molding).

[0034] In the rigid tube fitting step S2, the rigid tube 4 is fitted around the outer periphery of the manufactured cellulose roll 1. Specifically, the rigid tube 4, whose inner diameter is smaller than the outer diameter of the cellulose roll 1, is heated and expanded to fit around the outside of the cellulose roll 1. The fitted rigid tube 4 is then cooled naturally or forcibly to be tightly attached to the outer periphery of the cellulose roll 1. An adhesive (not shown) can be interposed between the cellulose roll 1 and the rigid tube 4.

[0035] In addition, when providing the surface of the rigid tube 4 with irregularities, the irregularities can be formed before the rigid tube 4 is placed over the outer periphery of the cellulose roll 1, or after the rigid tube 4 is placed over the outer periphery of the cellulose roll 1.

[0036] In the cleaning step S3, the cellulose roll 1 covered with the rigid tube 4 is set in the RF electrode 9 of the vacuum chamber 7, and the vacuum chamber 7 is evacuated. In this state, the surface of the rigid tube 4 is etched and cleaned with argon and hydrogen ions in order to clean the surface of the rigid tube 4 and improve adhesion. The etching process can be performed in the same manner as in the past. The cleaning can be performed, for example, under the following conditions. Gas used: Ar, H2 Negative pulse voltage: -1~-15kV RF output: 50~1500W

[0037] In the mixing layer forming step S4, a mixing layer (not shown) that is not intended for HCr plating is formed on the surface of the hard tube 4 that covers the outside of the cellulose roll 1. Specifically, the cellulose roll 1 covered with the hard tube 4 is set inside the RF electrode 9 of the vacuum chamber 7, and the inside of the vacuum chamber 7 is made into a vacuum state. A raw material gas (e.g., C, Si) is injected into the vacuum chamber 7 from the gas inlet 11, and C radicals are generated to form a mixing layer on the surface of the hard tube 4, thereby increasing the adhesive force (adhesion) of DLC.

[0038] If Si ions are injected as the source gas, Si can act as a primer. In addition, a mixed gas of N2, Ar (argon), CH4, C2H2, CF4 (carbon tetrafluoride), C, H, B, etc. can also be injected as the source gas. The mixing layer can be formed, for example, under the following conditions. Gases used: HMDSO, HMDS, TMS (Si-based gas), CH4, C2H2 Negative pulse voltage: -1~-15kV RF output: 50~1500W

[0039] In the film-forming step S5, a DLC film 5 is formed on the surface of the hard tube 4 (if a mixing layer is formed, the surface of the mixing layer; the same applies below) on the outside of the cellulose roll 1. Specifically, the inside of a vacuum chamber 7 in which the cellulose roll 1 covered with the hard tube 4 is set is kept at room temperature (preferably about 20°C to 50°C) and in a vacuum state.

[0040] In this state, a high-frequency voltage is applied by the RF high-frequency power supply 8 to generate plasma around the rigid tube 4 (specifically, around the RF electrode 9 in the vacuum chamber 7), and a negative high-voltage pulse is applied to the cellulose roll 1 by the high-voltage pulse power supply 10.

[0041] Thereafter, a source gas (e.g., C, O2) is injected into the vacuum chamber 7 from the gas inlet 11, and the source gas is reacted in the vacuum chamber 7 to deposit DLC on the surface of the rigid tube 4, thereby forming a DLC film 5 on the surface of the rigid tube 4. The DLC film 5 has a thickness of 1 μm or more, and preferably 6 μm or more. In this manufacturing method, the DLC film 5 is formed in a room temperature environment, so that the rigid tube 4 is less likely to thermally expand, and the cellulose roll 1 and the rigid tube 4 are less likely to deform even if the film is formed over a long period of time. Therefore, a DLC film 5 having a thickness of 6 μm or more can be formed over a long period of time.

[0042] There is no particular designation for the DLC film 5, and in addition to the main constituent elements carbon and hydrogen, it may contain a third element such as silicon or nitrogen. The DLC film 5 may also be a hydrophilic DLC film containing oxygen. The DLC film 5 may be formed, for example, under the following conditions. Gas used: CH4, C2H2 Negative pulse voltage: -1~-15kV RF output: 50~1500W

[0043] The DLC film 5 can also be formed in two or more separate steps. In this case, after the first film formation is performed under the above conditions, the second film formation can be performed under the following conditions, for example. Gas used: C7H8, C2H2 Negative pulse voltage: -1~-15kV RF output: 50~1500W

[0044] After the DLC film 5 is formed, the product is produced without any particular steps such as polishing.

[0045] In the roll of the present invention, even after the formation of the DLC film 5, the uneven shape of the surface of the hard tube 4 hardly changes from that before the film formation, and the area ratio is 10% or less.

[0046] The manufacturing process shown in Fig. 6 is just one example, and the roll of the present invention can also be manufactured by other methods. For example, when the cellulose roll 1 itself is used as the roll, the steps after the hard tube attachment step S2 in the manufacturing process shown in Fig. 6 can be omitted.

[0047] Similarly, when neither the DLC film 5 nor the plating layer 6 is provided on the outside of the rigid tube 4, the cleaning step S3 and subsequent steps in the manufacturing process shown in Fig. 6 can be omitted. When the plating layer 6 is provided on the outside of the rigid tube 4 instead of the DLC film 5, a plating step (not shown) is performed instead of the film formation step S5. [Industrial Applicability]

[0048] The roll of the present invention can be used for producing functional materials such as films and glass plates. [Explanation of symbols]

[0049] 1 cellulose roll 2. Bearings 3 Shaft material 4 Hard tube 5 DLC film 6 Plating layer 7. Vacuum Chamber 8 RF high frequency power supply 9 RF electrode 10 High voltage pulse power supply 11 Gas inlet 12 Flange 13 Shaft member

Claims

1. In the role, A roll base material is provided in which a material containing cellulose is formed into a roll shape, A hard tube having a hardness higher than that of the roll base material is provided on the outside of the roll base material, A cellulose-free sponge is provided on the outermost periphery outside the rigid tube. A roll characterized by:

2. 2. The roll of claim 1, The sponge is a cleaning sponge or a dewatering sponge. A roll characterized by:

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