A system and method of manufacturing wire guide rollers

Abstract

A SYSTEM AND METHOD OF MANUFACTURING WIRE GUIDE ROLLERS The present invention discloses a method of manufacturing a wire guide roller, comprising the steps of preparing a polymer coating (300a) for adhesion onto an outer surface of a roller body (300), coating an adhesive layer (300b) on the outer surface of the roller body (300) for adhesion of the polymer coating (300a), casting the polymer coating (300a) in a roller mould assembly comprising the roller body (300) for adhering the polymer coating (300a) onto the outer surface of the roller body (300) and grooving the polymer coating (300a) adhered to the outer surface of the roller body (300) by a cutting tool to form a plurality of grooves on a surface of the polymer coating (300a). The surface of the polymer coating (300a) is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by a vision inspection module (606) for assessing dimensions of the grooves.

Description

[0001] A SYSTEM AND METHOD OF MANUFACTURING WIRE GUIDE ROLLERS

[0002] FIELD OF INVENTION

[0003] The present invention relates to the technical field of industrial cutting and precision operations. More specifically, a method for manufacturing wire guide rollers with polyurethane coating.

[0004] BACKGROUND OF THE INVENTION

[0005] Wire guide rollers are indispensable components widely utilized across diverse industries, such as semiconductor manufacturing, sapphires, quartz, and metalworking. The critical nature of these rollers stems from their integral role in ensuring reliable performance in various industrial processes. Particularly in high-abrasion multi-line cutting machines, the dependability and precision of wire guide rollers become paramount for the seamless operation of manufacturing processes. To address the challenges posed by such demanding applications, the incorporation of polymer coatings on wire guide rollers has become a common practice. Polymer coatings offer a versatile solution, enhancing the performance and longevity of wire guide rollers in several ways.

[0006] A Japanese patent application with publication no. JP 2016087764 A discloses a guide roller comprising an inner roller supported by a shaft and an outer roller made of iron with minute holes. An epoxy resin adhesion assisting layer and a polyurethane outer covering layer is applied to the outer surface of the outer roller. The manufacturing process involves applying a moulding adhesive to the roller body, creating an adhesion assisting layer with heat-resistant resin, and forming the outer covering layer using a mould. Additionally, the method includes steps for removing, washing, reapplying the adhesive, and remoulding the outer covering layer if necessary, ensuring strong adhesion and quality in the final product.

[0007] Another Japanese patent application with publication no. JP 2012179693 A discloses a wire saw roller design featuring a core material, a urethane resin outer layer, and a specialized adhesive layer. Notably, the adhesive layer establishes a connection with the urethane outer layer using a reactive adhesive containing polyol and isocyanate components. The method of manufacturing involves creating the urethane outer layer and applying the adhesive layer on either the core material's outer surface or the urethane outer layer's inner surface, ensuring a stronger adhesion with the urethane layer. In the recycling process, the urethane outer layer is detached, and a new urethane layer is affixed after applying the adhesive layer to the core material's outer surface. This adhesive ensures a superior bond with the new urethane outer layer compared to the core material, facilitating efficient recycling of the wire saw roller.

[0008] Another Japanese patent application with publication no. JP 2009190140 A discloses a wire saw guide roller, featuring an inner roller and an outer roller made of divided pieces affixed around the inner roller's outer surface. The outer roller incorporates a resin layer with a wire guide groove, with the resin securely bonded to the divided pieces through an applied adhesive. Crucially, the design includes restricting portions near both ends of the roller, preventing any displacement of the resin layer concerning the divided pieces. These restricting portions are crafted as concave grooves on the outer surface of the divided pieces, allowing the resin layer to conform tightly. The method of manufacturing involves pre-shaping concave or convex portions on the divided pieces, applying an adhesive, curing the resin layer along these contours, and forming the guide groove. The method ensures a stable and precisely aligned wire saw guide roller, enhancing wire guidance accuracy and reliability. However, polymer coatings on the wire guide rollers are prone to wear, thus affecting the durability and longevity of the coatings. Furthermore, proper adherence of the polymer coating contributes to the durability of the coatings thus affecting the lifespan of the wire guide roller. Therefore, it is vital to have a method of manufacturing wire guide rollers that allows proper inspection of the polymer coating for increasing the durability and ensuring optimal functionality of the wire guide rollers over extended periods of operation.

[0009] SUMMARY OF INVENTION

[0010] The object of the present invention is to provide a method of manufacturing wire guide rollers with polyurethane coatings. One key aspect of this invention is the development of a grooving tool engineered to precisely cut through the polyurethane coating. The grooving tool not only ensures accuracy in the grooving process but also contributes to the longevity and reliable performance of the coated rollers.

[0011] Advantageously, the method introduces an inspection method for assessing and confirming the wear resistance of the coated rollers. By scrutinizing and evaluating the condition of the grooves, this method provides a practical means to gauge the wear and tear on wire guide rollers for maintaining and extending the operational life of wire guide rollers in various industrial settings.

[0012] In one aspect of the present invention, there is provided a method of manufacturing a wire guide roller, comprising the steps of preparing a polymer coating for adhesion onto an outer surface of a roller body, coating an adhesive layer on the outer surface of the roller body for adhesion of the polymer coating, casting the polymer coating in a roller mould assembly comprising the roller body for adhering the polymer coating onto the outer surface of the roller body and grooving the polymer coating adhered to the outer surface of the roller body by a cutting tool to form a plurality of grooves on a surface of the polymer coating. The surface of the polymer coating is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by a vision inspection module for assessing dimensions of the grooves.

[0013] Preferably, the polymer coating is a polyurethane blend including one or more polyol and isocyanate derivatives.

[0014] Preferably, the method further comprises the step of mixing the polyurethane blend with one or more additives and crosslinking agents.

[0015] Preferably, the method further comprises the step of coating a release agent on an inner surface of a roller mould for preventing adhesion of a polyurethane surface of the roller body to the inner surface of the roller mould of the roller mould assembly.

[0016] Preferably, the method further comprises the step of treating the outer surface of the roller body by sandblasting such that a textured surface is imparted for efficient casting of the polymer coating.

[0017] Preferably, the method further comprises the steps of preheating the roller mould assembly with the polymer coating and curing the polymer coating for adhesion of the polymer coating on the outer surface of the roller body.

[0018] Preferably, the method further comprises the step of removing worn-out polymer coating on the roller body by a cleaning agent to recoat the adhesive layer for recasting the polymer coating.

[0019] Preferably, the method further comprises the step of inclining the cutting tool on a lathe at varying angles. In another aspect of the present invention, there is provided a system for manufacturing wire guide rollers, comprising a polymer coating module configured to prepare a polymer coating for adhesion onto an outer surface of a roller body, an adhesive coating module configured to coat an adhesive layer on the outer surface of the roller body for adhesion of the polymer coating, a roller mould assembly comprising the roller body for casting the polymer coating onto the outer surface of the roller body to adhere the polymer coating, a grooving module configured to groove the polymer coating adhered to the outer surface of the roller body using a cutting tool, forming a plurality of grooves on a surface of the polymer coating, and a vision inspection module for assessing dimensions of the grooves. The surface of the polymer coating is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by the vision inspection module.

[0020] Preferably, the roller mould assembly further comprises a roller mould such that an inner surface of the roller mould is coated with a release agent to facilitate removal of the roller body during casting.

[0021] BRIEF DESCRIPTION OF THE DRAWINGS

[0022] FIG. 1 illustrates a roller mould for casting polymer coating on the surface of a roller body.

[0023] FIG. 2 illustrates a roller body with adhesive layer and polymer coating on the surface of the roller body.

[0024] FIG. 3 illustrates a flowchart of the method for manufacturing a wire guide roller. DETAILED DESCRIPTION OF THE INVENTION

[0025] Hereinafter, the invention shall be described according to the preferred embodiments of the present invention and by referring to the accompanying description and drawings. However, it is to be understood that limiting the description to the preferred embodiments of the invention is merely to facilitate discussion of the present invention and it is envisioned that those skilled in the art may devise various modifications without departing from the scope of the appended claim.

[0026] From here on, spatially relative terms, such as “top”, “bottom”, “left”, “right”, “inner”, “outer” and the like, may be used herein for ease of description to describe one technical element or feature's relationship to another technical element or feature as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the technical features in use or operation in addition to the orientation depicted in the figures.

[0027] For example, if a technical feature within the figures is turned over, its elements described as “top” of other elements or features would then be oriented “bottom” of the other elements or features. Thus, the exemplary term “top” can encompass both an orientation of above and below. The device may be otherwise oriented and the spatially relative descriptors used herein are interpreted accordingly.

[0028] For example, if a technical feature within the figures is flipped horizontally, its elements described as “left” of other elements or features would then be oriented “right” of the other elements or features. Thus, the exemplary term “left” can encompass both an orientation of left and right. The device may be otherwise oriented and the spatially relative descriptors used herein are interpreted accordingly.

[0029] FIG.3 illustrates the flowchart of the method for manufacturing wire guide rollers. The method begins with the step 501 of preparing a polymer coating 300a for adhesion onto an outer surface of a roller body 300. The polymer coating 300a is typically applied to enhance the durability, wear resistance, and other desirable properties of the roller. To ensure effective bonding and optimal performance, the polymer coating 300a is formulated to exhibit strong resistance to abrasion ideal for various applications of the roller. The formulation of the polymer coating 300a takes into account factors such as the operating environment, desired properties (e.g., hardness, flexibility, chemical resistance), and the compatibility with the roller body 300 material. A polymer coating module 602 is configured to prepare the polymer coating 300a for adhesion onto an outer surface of a roller body 300. The polymer coating module 602 comprises at least one mixing tanks, one or more stirrers, temperature sensor, in communication with an electronic platform for configuring the settings or parameters during preparation. The parameters include but are not limited to, viscosity, chemical composition, and mixing ratios.

[0030] Preferably, the polymer coating 300a is a polyurethane blend including one or more polyol and isocyanate derivatives. The polyol derivatives include but are not limited to, polyethylene glycol, polypropylene glycol, polytetrahydrofuran, polycarbonate diols, hydroxyethyl acrylate, and hydroxypropyl acrylate. The isocyanate derivatives include but are not limited to, methylene diphenyl diisocyanate, toluene diisocyanate, hexamethylene diisocyanate, and isophorone diisocyanate. In one example embodiment of the preparation of the polymer coating 300a, polytetrahydrofuran glycol is mixed with toluene diisocyanate to form a polyurethane blend. The polyurethane blend is mixed with one or more additives and crosslinking agents. The modified polyurethane blend forms covalent bonds with the silicon-based polymers and crosslinking agents resulting in the production of robust three-dimensional network within the polyurethane.

[0031] The method continues with step 502, coating an adhesive layer 300b on the outer surface of the roller body 300 for adhesion of the polymer coating 300a. Coating an adhesive layer 300b on the outer surface of the roller body 300 is a critical step in the process of preparing the surface for the subsequent application of the polymer coating 300a. The purpose of the adhesive layer 300b is to act as a primer and to promote strong and durable adhesion between the roller body 300 and the polymer coating 300a. The outer surface of the roller body 300 may be prepared by firstly sandblasting said outer surface of the roller body 300 such that a textured surface is imparted for efficient casting of the polymer coating 300a. The adhesive layer 300b, acting as the primer, may then be applied to enhance the bonding of the outer surface of the roller body 300.

[0032] The adhesive layer 300b is applied directly onto a clean outer surface or sandblasted outer surface of the roller body 300. The adhesive layer 300b may be coated on the outer surface of the roller body 300 through airgun spray coating, brush coating or any other techniques suitable for coating the adhesive layer 300b onto the outer surface of the roller body 300. Preferably, manual spraying utilizing an airgun spray system can be sprayed either linearly or rotatably along the periphery of the roller body 300 in a controlled movement to provide an even and smooth coating of the adhesive layer 300b. By way of example, the adhesive layer 300b is either one or a combination of epoxy adhesives, polyurethane adhesives, or any other specialized adhesives capable of bonding to the surface of the roller body 300 and to the polymer coating 300a.

[0033] The method continues with step 503, casting the polymer coating 300a in a roller mould assembly comprising the roller body 300 for adhering the polymer coating 300a onto the outer surface of the roller body 300. Upon coating the roller body 300 with the adhesive layer 300b, the roller body 300 is ready for the application of the polymer coating 300a. The adhesive layer 300b not only serves as a primer but also serves as a bonding agent, promoting strong adhesion between the roller body 300 and the polymer coating 300a. The roller mould assembly comprises the roller body 300 and roller mould 100 for casting the polymer coating 300a onto the outer surface of the roller body 300 by adhering the polymer coating 300a to the adhesive layer 300b. The roller mould 100 as shown in FIG. 1 comprises an upper concave portion 100a in connection with a bottom concave portion 100b forming a slot for allowing placement of the roller body 300 in the roller mould 100. Prior to placing the roller body 300 into the roller mould 100, a release agent 104 is coated on the inner surface of the roller mould 100 for preventing adhesion of the outer surface of the polymer coating 300a to the inner surface of the roller mould 100 of the roller mould assembly. Preferably, the release agent 104 is a water-based nano silicon-based compound. Advantageously, the compound contains silicon oxygen (Si-O) bonds diluted with evaporating solvent creating a barrier that has non-stick properties such that when the inner surface of the roller mould 100 is coated with the release agent 104, the non-stick properties of the release agent 104 facilitates the removal of the roller body 300 during casting.

[0034] Once the inner surface of the roller mould is coated with the release agent 104, the roller body 300 that has been coated with the adhesive layer 300b is then placed into the roller mould 100 for the casting step. The casting step begins by preheating the roller mould assembly with the polymer coating 300a, thereafter curing the polymer coating 300a for adhesion of the polymer coating 300a on the outer surface of the roller body 300. At least one end plate 200 is positioned at distal ends of both the upper concave portion 100a and bottom concave portions 100b of the roller mould 100 to prevent leaking of polymer coating 300a during casting. Additionally, the concave portions 100a, 100b include recesses 102 formed along the length of the concave portions 100a, 100b and are workably configured with the end plates 200 having slotting edges 200a to facilitate insertion of the upper concave portion 100a and bottom concave portion 100b into one another for rapid detachability of the concave portions 100a, 100b during casting of the polymer coating 300a.

[0035] Subsequently, after the casting step, is step 504, grooving the polymer coating 300a adhered to the outer surface of the roller body 300 by a cutting tool to form a plurality of grooves on the surface of the polymer coating 300a. A grooving module 604 is configured with cutting tools to groove the polymer coating 300a adhered to the outer surface of the roller body 300. Preferably, the cutting tools comprise one or more arcshaped blades or linear blades for forming the plurality of grooves on the surface of the polymer coating 300a. The grooving step further comprises the step of inclining the cutting tool on a lathe at varying angles.

[0036] The linear or arc-shaped blades are characterized by precise radius measurements, an inclined leading angle, and a major flank that tilts toward the insert holder. Preferably, the blades are inclined on the lathe at a leading angle. The inclined orientation enhances the grooving action by facilitating an effective engagement with the polymer coating 300a on the surface of the roller body 300. The leading angle ensures a controlled entry into the polymer coating 300a, reducing the force required for cutting and minimizing heat generation. The major flank of the blade is strategically positioned to tilt towards the insert holder which enhances stability during cutting operations, providing robust support for the cutting tool. The tilt also contributes to the overall rigidity of the cutting tool, promoting accuracy and reducing the likelihood of vibration or deflection.

[0037] The combined effect of the linear or arc-shaped blades, precise radius measurements, inclined leading angle, and major flank orientation is the creation of a primary clearance. The clearance is pivotal for ensuring unobstructed grooving paths and preventing material buildup during the grooving process. Advantageously, the design of the blade extends the service life of the cutting tool, allowing for longer working hours, and thereby enhancing the durability of the blades. Furthermore, the durability of the blade reduces the need for frequent blade replacement and easy maintenance, ensuring uniformity in the dimensions of the processed roller body 300.

[0038] After the grooving step is completed, the method continues to step 505, inspecting the grooves formed on the surface of the polymer coating 300a to determine the integrity of the wire guide roller. The surface of the polymer coating 300a is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by a vision inspection module 606 for assessing the dimensions of the grooves. Preferably, the gum mixture is a blend of a base and catalyst of specialized material gum with adhesive properties.

[0039] The gum mixture is applied onto the surface of the polymer coating 300a and due to the chemical reaction between the base and catalyst, the gum mixture is cured and adhered onto the grooved surface of the polymer coating 300a to replicate the grooving patterns formed on the surface of the polymer coating 300a. Subsequently, the solidified gum mixture is subjected to examination under a precision vision measuring machine to capture images of the grooves and assess the groove pattern in terms of but not limited to, depth, width, and angle between consecutive grooves. In one example embodiment, the vision inspection module 606 may incorporate machine learning for evaluating the dimensions of the grooves. The machine learning model can be trained by inputting data obtained from previous inspections and comparing with reference data to determine the optimal dimensions of the grooves.

[0040] The method further comprises step 506, removing worn-out polymer coating 300a on the roller body 300 by a cleaning agent to recoat the adhesive layer 300b for recasting the polymer coating 300a. Once the polymer coating 300a on the roller body 300 has deteriorated beyond its serviceable life, the polymer coating 300a will undergo removal using a grooving machine. Subsequently, the remaining adhesive layer 300b or primers will be thoroughly cleaned utilizing a specialized cleaner designed to eliminate both the polymer coating 300a and any adherent primer from the surface of the roller body 300. By way of example yet not limiting, the cleaning solution incorporates methylbenzene, toluene, and xylene. In one example embodiment, the roller body 300 is immersed in the cleaning solution to remove the coatings on the surface of the roller body 300. In another example embodiment, a mechanical agitator may be rotatably incorporated to provide agitation to the cleaning solution for removal of the coatings as the cleaning solution flows around the roller body 300. After the roller body 300 is cleaned, the roller mould assembly is sandblasted for reuse in the recoating process.

[0041] It is also an aspect of the invention to provide a system to carry out the method as described above for manufacturing wire guide rollers. The system comprises a polymer coating module 602 configured to prepare a polymer coating for adhesion onto the outer surface of a roller body 300; manual spraying of an adhesive layer 300b on the outer surface of the roller body 300 for adhesion of the polymer coating 300a; a roller mould assembly comprising the roller body 300 for casting the polymer coating 300a onto the outer surface of the roller body 300 to adhere the polymer coating 300a; a grooving module 604 configured to groove the polymer coating 300a adhered to the outer surface of the roller body 300 using a cutting tool, forming the plurality of grooves on the surface of the polymer coating 300a. The roller mould assembly further comprises a roller mould 100 such that the inner surface of the roller mould 100 is coated with the release agent 104 to facilitate removal of the roller body 300 during casting.

[0042] A vision inspection module 606 is provided by the system to assess dimensions of the grooves. The surface of the polymer coating 300a is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by the vision inspection module 606.

[0043] The polymer coating module 602, , and grooving module 604 is preferably operably configured by an electronic platform. In one example embodiment, it is preferred that a specialized system for manual spraying is integrated to facilitate the uniform and precise application of the adhesive layer 300b onto the outer surface of the roller body 300 as shown in FIG. 2. The system may include spray guns, nozzles, brushes, or rollers to ensure an even distribution of the adhesive layer 300b. Parameters such as but not limited to, coating thickness and application speed may be monitored and adjusted in real-time to ensure that the adhesive layer 300b is applied with accuracy and adheres properly to the outer surface of the roller body 300.

[0044] The grooving module 604 is preferably a lathe configured with cutting tools embedded with linear or arc shape blades. The grooving module 604 may include a control system to govern the grooving process. By way of example, the control system may be configured to adjust grooving parameters such as but not limited to, groove depth, width and pattern.

[0045] The vision inspection module 606 comprises an imaging device in communication with a processing unit for obtaining images of the groove patterns form on the gum mixture and analysing the images to evaluate the dimensions of the groove patterns. The imaging device include at least one camera unit configured with one or more lenses of varying focal length, and at least one light source. In one example embodiment, the camera unit and focusing lens are arranged vertically above the gum mixture along the y-axis to capture images of the grooves form on the gum mixture illuminated by the light source. The captured images are sent to the processing unit and the images are analysed to evaluate the dimensions of the grooves form.

[0046] The present disclosure includes as contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a degree of particularly, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangements of parts may be resorted to without departing from the scope of the invention.

Claims

CLAIMS1. A method of manufacturing a wire guide roller, comprising the steps of preparing a polymer coating (300a) for adhesion onto an outer surface of a roller body (300); coating an adhesive layer (300b) on the outer surface of the roller body (300) for adhesion of the polymer coating (300a); casting the polymer coating (300a) in a roller mould assembly comprising the roller body (300) for adhering the polymer coating (300a) onto the outer surface of the roller body (300); and grooving the polymer coating (300a) adhered to the outer surface of the roller body (300) by a cutting tool to form a plurality of grooves on a surface of the polymer coating (300a); wherein the surface of the polymer coating (300a) is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by a vision inspection module (606) for assessing dimensions of the grooves.

2. The method according to claim 1, wherein the polymer coating (300a) is a polyurethane blend including one or more polyol and isocyanate derivatives.

3. The method according to claim 2, further comprising the step of mixing the polyurethane blend with one or more additives and crosslinking agents.

4. The method according to the preceding claims, further comprising the step of coating a release agent (104) on an inner surface of a roller mould (100) for preventing adhesion of the outer surface of the polymer coating (300a) to the inner surface of the roller mould (100) of the roller mould assembly.

5. The method according to any one of the preceding claims, further comprising the step of treating the outer surface of the roller body (300) such that a textured surface is imparted for efficient casting of the polymer coating (300a).

6. The method according to any one of the preceding claims, further comprising the steps of preheating the roller mould assembly with the polymer coating (300a); and curing the polymer coating (300a) for adhesion of the polymer coating (300a) on the outer surface of the roller body (300).

7. The method according to any one of the preceding claims, further comprising the step of removing worn-out polymer coating (300a) on the roller body (300) by a cleaning agent to recoat the adhesive layer (300b) for recasting the polymer coating (300a);8. The method according to the preceding claims, further comprising the step of inclining the cutting tool on a lathe at varying angles.

9. A system for manufacturing wire guide rollers, comprising a polymer coating module (602) configured to prepare a polymer coating for adhesion onto an outer surface of a roller body (300); manual spraying of an adhesive layer (300b) on the outer surface of the roller body (300) for adhesion of the polymer coating (300a); a roller mould assembly comprising the roller body (300) for casting the polymer coating (300a) onto the outer surface of the roller body (300) to adhere the polymer coating (300a);a grooving module (604) configured to groove the polymer coating (300a) adhered to the outer surface of the roller body (300) using a cutting tool, forming a plurality of grooves on a surface of the polymer coating (300a); and a vision inspection module (606) for assessing dimensions of the grooves; wherein the surface of the polymer coating (300a) is applied with a gum mixture to replicate the groove patterns and upon solidification of the gum mixture, subject to inspection by the vision inspection module (606).

10. The system according to claim 9, wherein the roller mould assembly further comprises a roller mould (100) such that an inner surface of the roller mould (100) is coated with a release agent (104) to facilitate removal of the roller body (300) during casting.

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