Low deflection calendering rolls working at high temperature

Abstract

Provided is a calendaring device including two rolls. The two rolls have a shaft made of a material being steel or a nickel-iron alloy; at least one intermediate cylinder made of a material being a cemented carbide or a nickel-iron alloy; and an outer shell made of a material being cemented carbide. The calendaring device has at least one aperture, so that ends of the outer shell have homogeneous displacement when subjected to a force and thickness of a pressed web is uniform. An expansion coefficient of the shaft is between 10 x 10-6 / K and 20 x 10-6 / K. An expansion coefficient of the at least one intermediate cylinder is between 6 x 10-6 / K and 12 x 10- 6 / K. An expansion coefficient of the outer shell is between 5 x 10-6 / K and 8 x 10-6 / K. Provided is also a method of calendering a web material.

Description

LOW DEFLECTION CALENDERING ROLLS WORKING AT HIGH TEMPERATUREFIELD OF THE DISCLOSURE

[0001] The present disclosure relates to a calendering device having at least two rolls. The rolls are made of an outer shell and at least one intermediate cylinder, and a shaft to compress a web by passing the web through the rolls. The rolls of the calendering device are mechanically stable, and can withstand high thermal stresses with a low level of deflection. Provided is also a method of calendering a material.BACKGROUND

[0002] Calendering rolls are oftentimes made of hardened steel, tool steel, or coated steel. In order to maintain a uniform thickness over the entire width and surface area of a pressed web, calendering rolls have a large diameter, or they work in cooperation with other counter-rolls. Large diameter rolls have a correspondingly large contact area with the web, that significantly increases the calendering forces that are conferred back onto the calendering rolls.

[0003] Small steel rolls cannot be used alone, as they would potentially bend down dramatically, thereby generating an uneven calendared web material. This is the sole reason that they are used with large counter-rolls that prevent them from bending down. These counter-rolls come with an inherent drawback, and a necessity, of making the calendering device greater in size. This generally leads to increased tool costs during the manufacturing process of calendering devices.

[0004] Cemented carbides, or other materials, that are stiffer than steel, have attracted the attention of great research interest, as their inherently higher Young’s modulus limits a roll deflection. In this case, the rolls can be made of a solid cemented carbide as described in application publication CN102101170, or made of a sprayed layer of a cemented carbide on a steel shaft as disclosed in application publications CN219357388 and CN219058819, or may include a ring that is mounted on a shaft made of steel.

[0005] The shaft ends of a solid roll made of a cemented carbide are fragile as described in application publication CN102101170, and exhibit a poor tensile strength, and may therefore break apart by the high calendering forces.

[0006] The spraying process of the cemented carbide, described in application publications CN219357388 and CN219058819, allows no time for metallurgical processes to occur. This means that sprayed cemented carbide is oftentimes considerably porous, unless the metallic binder content is very high, in which case, the wear resistance is conversely decreased.

[0007] Rolls made of a cemented carbide ring, which is mounted on a shaft can be used at room temperatures or at temperatures below 100°C, but they do not allow for a homogeneous thickness to occur on the calendared web.

[0008] Of note, the thickness of a compressed web is generally dictated by the distance between the two calendering rolls. The generative lines of the rolls, that are in contact with the web, receive the highest contact pressure during the calendering process. This contact pressure creates a displacement of surfaces of the calendering rolls that is dictated by two components. A first component is due to the bending down of the calendering rolls, and a second component is due to local surface deformations formed on the calendering rolls. The displacement of these surfaces leaves a print on the calendared web, and the variations in surface displacement of the calendering rolls along the roll axis, translate into variations in the web thickness once calendering is done.

[0009] When, for example, the temperature is increased above 100°C, the steel expansion increases the stress amount that is imparted back onto the inner diameter of the cemented carbide ring, as the steel shaft has a much higher expansion coefficient than cemented carbides. This will then lead to cracking and fracturing of the calendering rolls.

[0010] While alternative materials to cemented carbides do exist, which may encompass ceramic-metal composites based on certain particular carbides, nitrides, oxides, borides, these materials also demonstrate a low expansion coefficient compared to steel, and therefore also cannot withstand high calendering temperatures.

[0011] In view of the foregoing, there is a need for an improved calendering device, where the outer shell of the calendering device is physically stable, and does not break apart when used at high thermal stresses.SUMMARY

[0012] Provided is a calendering device having at least two rolls configured to rotate around each of their longitudinal axis. The at least two rolls, each including, a shaft made of a material being any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy (having a nickel amount in the nickel-iron alloy between about 42 wt.% and 54 wt.%). The shaft has at least one bearing mounted in a longitudinal axial end of the shaft configured to rotate the shaft. The shaft has an expansion coefficient between about 10 x 10’6 / K and about 20 x 10’6 / K. The at least two rolls further have at least one intermediate cylinder made of a material including any one of a cemented carbide, a nickel-iron alloy (having a nickel amount in the nickel-iron alloy between about 42 wt.% and 54 wt.%), tool steel, or cast iron. The at least one intermediate cylinder has an expansion coefficient between about 6 x 10’6 / K and about 12 x 10’6 / K. The at least two rolls further have an outer shell made of a material including a cemented carbide. The outer shell has an expansion coefficient between about 5 x 10’6 / K and about 8 x 10’6 / K.

[0013] Optionally, the cemented carbide of the outer shell and the least one intermediate cylinder has a ceramic hard phase including at least one of tungsten carbide, niobium carbide, tantalum carbide, titanium carbide, silicon carbide, molybdenum carbide.

[0014] Optionally, the cemented carbide of the outer shell and the least one intermediate cylinder has a ceramic hard phase further including at least one of tungsten nitride, niobium nitride, tantalum nitride, titanium nitride, silicon nitride, molybdenum nitride, tungsten carbonitride, niobium carbonitride, tantalum carbonitride, titanium carbonitride, silicon carbonitride, molybdenum carbonitride, tungsten boride, niobium boride, tantalum boride, titanium boride, silicon boride, molybdenum boride, or any alloys or combinations thereof.

[0015] Optionally, close to an inner diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 12 wt.% to about 32 wt.% based on a total amount of the cemented carbide, the binder phase including at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 6 x 10’6 / K to about 12 x 10’6 / K.

[0016] Optionally, close to an outer diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 6 wt.% to about 20 wt.% based on a total amount of the cemented carbide, the binder phase including at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 5 x 10’6 / K to about 8 x 10’6 / K.

[0017] Optionally, the calendering device has an aperture located between the shaft and the outer shell, such that ends of the shell have a homogeneous displacement when subjected to a calendering force and a thickness of the pressed web by the at least two rolls is uniform.

[0018] Optionally, the calendering device has at least another intermediate cylinder located between the shaft and the outer shell made of a material including a cemented carbide.

[0019] Optionally, the shaft, the at least one intermediate cylinder, the at least another intermediate cylinder, and the outer shell are assembled by shrink-fitting.

[0020] Optionally, the aperture is located between the at least one intermediate cylinder and the shaft.

[0021] Optionally, the expansion coefficient of the shaft is greater than the expansion coefficient of the at least one intermediate cylinder.

[0022] Optionally, the expansion of the at least one intermediate cylinder is greater than the expansion coefficient of the at least another intermediate cylinder.

[0023] Optionally, the expansion coefficient of the at least another intermediate cylinder is greater than the expansion coefficient of the outer shell.

[0024] Optionally, the aperture is located between the at least one intermediate cylinder and the outer shell.

[0025] Optionally, the aperture is located between the at least another intermediate cylinder and the outer shell.

[0026] Optionally, the calendering device has a plurality of apertures located between the shaft and the outer shell.

[0027] Optionally, the calendering device has a plurality of apertures located between the at least one intermediate cylinder and the shaft.

[0028] Optionally, the calendering device has a plurality of apertures located between the at least one intermediate cylinder and the outer shell.

[0029] Optionally, the calendering device has a plurality of apertures located between the at least another intermediate cylinder and the outer shell.

[0030] Optionally, the outer shell of the calendering device is stable and does not break apart at thermal stresses above 100°C.

[0031] Optionally, close to the outer diameter of the outer shell, the outer shell has a Young’s modulus in a range of from about 450 GPa to about 650 GPa with a lower binder content.

[0032] Also provided is a method of calendering a material e.g. a web, comprising passing the material through a calendering device to flatten and thereby compress the material. The calendering device has at least two rolls configured to rotate around each of their longitudinal axis. The at least two rolls, each including, a shaft made of a material being any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy (having a nickel amount in the nickel-iron alloy between about 42 wt.% and 54 wt.%). The shaft has at least one bearing mounted in a longitudinal axial end of the shaft configured to rotate the shaft. The shaft has an expansion coefficient between about 10 x 10’6 / K and about 20 x 10’6 / K. The at least two rolls further have at least one intermediate cylinder made of a material including any one of a cemented carbide, a nickel-iron alloy (having a nickel amount in the nickel-iron alloy between about 42 wt.% and 54 wt.%), tool steel, or cast iron. The atleast one intermediate cylinder has an expansion coefficient between about 6 x 10’6 / K and about 12 x 10’6 / K. The at least two rolls further have an outer shell made of a material including a cemented carbide. The outer shell has an expansion coefficient between about 5 x 10’6 / K and about 8 x 10’6 / K.

[0033] Other systems, methods, features and advantages will be, or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the present disclosure, and be protected by the following claims. Nothing in this section should be taken as a limitation on those claims. Further aspects and advantages are discussed below in conjunction with the examples of the disclosure. It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are examples and explanatory and are intended to provide further explanation of the disclosure as claimed.BRIEF DESCRIPTION OF THE DRAWINGS

[0034] The accompanying drawings, which are included to provide a further understanding of the subject matter and are incorporated in and constitute a part of this specification, illustrate implementations of the subject matter and together with the description serve to explain the principles of the disclosure.

[0035] FIG. 1 shows a top perspective view of a calendering device in accordance with the present subject matter.

[0036] FIG. 2A shows a cross-sectional view of a roll of the calendering device in accordance with the present subject matter.

[0037] FIG. 2B shows a cross-sectional view of a roll of the calendering device, and further shows an aperture located between the outer shell and the shaft on one end of the roll in accordance with the present subject matter.

[0038] FIG. 3A shows a cross-sectional view of a roll of the calendering device in accordance with the present subject matter.

[0039] FIG. 3B shows a cross-sectional view of a roll of the calendering device, and further shows an aperture located between the at least one intermediate cylinder and the shaft on one end of the roll in accordance with the present subject matter.

[0040] FIG. 4A shows a cross-sectional view of a roll of the calendering device in accordance with the present subject matter.

[0041] FIG. 4B shows a cross-sectional view of a roll of the calendering device, and further shows an aperture located between the at least another intermediate cylinder and the outer shell on one end of the roll in accordance with the present subject matter.

[0042] FIG. 5A shows a cross-sectional view of a roll of the calendering device, and further shows a plurality of apertures superimposed between the at least one intermediate cylinder and the shaft, and between the at least one intermediate cylinder and the outer shell on one end of the roll in accordance with the present subject matter.

[0043] FIG. 5B shows a cross-sectional view of a roll of the calendering device, and further shows a plurality of apertures superimposed between the at least one intermediate cylinder and the shaft, between the at least another intermediate cylinder and the at least one intermediate cylinder, and between the at least another intermediate cylinder and the outer shell on one end of the roll in accordance with the present subject matter.DETAILED DESCRIPTION

[0044] Unless defined otherwise all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the presently described subject matter pertains.

[0045] Where a range of values is provided, for example, concentration ranges, percentage ranges, or ratio ranges, it is understood that each intervening value, to the tenth of the unit of the lower limit, unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the described subject matter. The upper and lower limits of these smaller ranges may independently be included in thesmaller ranges, and such examples are also encompassed within the described subject matter, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either or both of those included limits are also included in the described subject matter.

[0046] The following definitions set forth the parameters of the described subject matter.

[0047] As used herein, the terms “about”, “approximately”, and “close” are used interchangeably. They are meant plus or minus 5% of the numerical value of the number with which it is being used in the claims and herein this disclosure. Thus, “about” may be used to provide flexibility to a numerical range endpoint, in which, a given value may be “above” or “below” the given value. As such, for example a value of 50% may be intended to encompass a range, which may be defined by for example ranges like 47.5%-52.25%, 47.5%-52.5%, 47.75%-50%, 50%-52.5%, 48%-48.5%, 48%-48.75%, 48%-49%, 48%-49.5%, 48%-49.75%, 48%-50%, 48%-50.25%, 48%- 50.5%, 48%-50.75%, 48%-51 %, 48%-51.5%, 48%-51.75%, 48%-52%, 48%-52.25%, 48%-52.5%, 48.25%-48.5%, 48.25%-48.75%, 48.25%-49%, 48.25%-49.5%, 48.25%- 49.75%, 48.25%-50%, 48.25%-50.25%, 48.25%-50.5%, 48.25%-50.75%, 48.25%- 51 %, 48.25%-51 .25%, 48.25%-51 .5%, 48.25%-51 .75%, 48.25%-52%, 48.25%- 52.25%, 48.25%-52.5%, 48.5%-48.75%, 48.5%-49%, 48.5%-49.5%, 48.5%-49.75%, 48.5%-50%, 48.5%-50.25%, 48.5%-50.5%, 48.5%-50.75%, 48.5%-51 %, 48.5%- 51.25%, 48.5%-51.5%, 48.5%-51 .75%, 48.5%-52%, 48.5%-52.25%, 48.5%-52.5%, 49%-49.25%, 49%-49.5%, 49%-49.75%, 49%-50%, 49%-50.25%, 49%-50.5%, 49%- 50.75%, 49%-51 %, 49%-51 .25%, 49%-51 .5%, 49%-51 .75%, 49%-52%, 49%-52.25%, 49%-52.5% 49.5%-49.75%, 49.5%-50%, 49.5%-50.25%, 49.5%-50.5%, 49.5%- 50.75%, 49.5%-51 %, 49.5%-51.5%, 49.5%-51 .75%, 49.5%-52%, 49.5%-52.25%, 49.5%-52.5%, 49.75%-50%, 49.75%-50.25%, 49.75%-50.5%, 49.75%-50.75%, 49.75%-51 %, 49.75%-51 .25%, 49.75%-51 .5%, 49.75%-51 .75%, 49.75%-52%, 49.75%-52.25%, 49.75%-52.5%, 50%-50.25%, 50%-50.5%, 50%-50.75%, 50%-51 %, 50%-51.25%, 50%-51.5%, 50%-52%, 50%-52.25%, 50%-52.5%.

[0048] As used herein, the term “aperture” refers to an opening, a gap, a hole, a space, a slit, or a slot.

[0049] As used herein, the term “bearing” refers to a physical element that constrains a relative motion to only a desired motion-type and characteristics, and further that reduces any potential friction created between the individual moving parts. The unique design of the particular bearing determines the specific type of movement that is conveyed to a moving part. The specific design of the bearing may, for instance, facilitate a free linear movement of the moving part, or may equally impart a free rotation around a fixed axis. Alternatively, it may prevent, suppress, or otherwise inhibit a motion by specifically controlling the vectors of normal loads and forces that physically act on the moving parts. Bearings may facilitate the desired motion by minimizing the effect of friction. Thus, bearings are classified exclusively according to the particular type of operation, the specific motion types that are allowed, or to the particular directions of the loads and forces that are applied to the moving parts.

[0050] As used herein, the term “between” explicitly includes both the upper and the lower numerical values of a parameter that is located between the upper and the lower numerical values. Thus, in one example, an expansion coefficient between about 10 x 10’6 / K and about 20 x 10’6 / K is meant to include either about 10 x 10’6 / K, about 11 x 10’6 / K, about 12 x 10’6 / K, about 13 x 10’6 / K, about 14 x 10’6 / K, about 15 x 10’6 / K, about 16 x 10’6 / K, about 17 x 10’6 / K, about 18 x 10’6 / K, about 19 x 10’6 / K, or about 20 x 10’6 / K. In another example, an expansion coefficient between about 6 x 10-6 / K and about 12 x 10’6 / K is meant to include either about 6 x 10’6 / K, about 7 x 10’6 / K, about 8 x 10’6 / K, 9 x 10’6 / K, about 10 x 10’6 / K, about 11 x 10’6 / K, or about 12 x 10’6 / K. In still another example, an expansion coefficient between 5 x 10’6 / K and about 8 x 10-6 / K is meant to either include about 5 x 10’6 / K, about 6 x 10’6 / K , about 7 x 10-6 / K, or about 8 x 10’6 / K. In yet another example, a Ni amount in the nickel-iron alloy between about 42 wt.% and about 54 wt.% is meant to include either about 42 wt.% Ni, about 43 wt.% Ni, about 44 wt.% Ni, about 45 wt.% Ni, about 46 wt.% Ni, about 47 wt.% Ni, about 48 wt.% Ni, about 49 wt.% Ni, about 50 wt.% Ni, about 51 wt.% Ni, about 52 wt.% Ni, about 53 wt.% Ni, or about 54 wt.% Ni.

[0051] As used herein, the term “calendering” is a type of physical levelling and segmenting process for webs to produce a special effect, namely flattening by shear forces, through passing the web of material between at least two adjacent rolls of the calendering device as disclosed herein. As used herein in the specification as well asin the claims, the term “device” is used interchangeably with the term “calendering device” unless specifically indicated otherwise.

[0052] As used herein, the term “cemented carbide” generally refers to a composite material constituted of a ceramic hard phase generally including a carbide typically used in a weight of from about 80 wt.% to about 94 wt.%, or from about 68 wt.% to about 88 wt.% based on the total weight of the cemented carbide, anchored and cemented by a metallic binder matrix such as e.g., cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any alloys or combinations thereof (i.e. thus creating the metallic binder phase). By forming a gradient, close to an outer diameter of the outer shell 6, the cemented carbide of the outer shell 6 may have a binder phase generally in an amount of from about 6 wt.% to about 20 wt.% based on the total weight of the cemented carbide. Conversely, by forming a gradient, close to an inner diameter of the outer shell 6, the cemented carbide of the outer shell 6 may have a binder phase usually from about 12 wt.% to about 32 wt.% based on the total weight of the cemented carbide. Thus, close to an outer diameter of the outer shell 6, the metallic binder may for example further be in an amount of from about 8 wt.% to about 20 wt.%, from about 10 wt.% to about 20 wt.%, from about 12 wt.% to about 20 wt.%, from about 14 wt.% to about 20 wt.%, from about 16 wt.% to about 20 wt.%, from about 18 wt.% to about 20 wt.%, from about 8 wt.% to about 10 wt.%, from about 10 wt.% to about 12 wt.%, from about 12 wt.% to about 14 wt.%, from about 8 wt.% to about 12 wt.%, from about 8 wt.% to about 9 wt.%, from about 11 wt.% to about 12 wt.%, from about 8 wt.% to about 14 wt.%, from about 11 wt.% to about 14 wt.%, from about 13 wt.% to about 14 wt.%, from about 8 wt.% to about 16 wt.%, from about 8 wt.% to about 18 wt.%, from about 11 wt.% to about 16 wt.%, from about 13 wt.% to about 16 wt.%, from about 15 wt.% to about 16 wt.%, from about 14 wt.% to about 16 wt.%, from about 16 wt.% to about 18 wt.%, from about 18 wt.% to about 20 wt.%, from about 14 wt.% to about 18 wt.%, from about 15 wt.% to about 18 wt.%, from about 15 wt.% to about 19 wt.%, from about 15 wt.% to about 20 wt.%, from about 17 wt.% to about 19 wt.%, from about 17 wt.% to about 20 wt.%, from about 18 wt.% to about 19 wt.%, or from about 19 wt.% to about 20 wt.%, based on the total weight of the cemented carbide. Alternatively, close to an inner diameter of the outer shell 6, the metallic binder may further be present in an amount of from about 14 wt.% to about 32 wt.%, from about 16 wt.% to about 32 wt.%,from about 18 wt.% to about 32 wt.%, from about 20 wt.% to about 32 wt.%, from about22 wt.% to about 32 wt.%, from about 24 wt.% to about 32 wt.%, from about 26 wt.% to about 32 wt.%, from about 28 wt.% to about 32 wt.%, from about 30 wt.% to about 32 wt.%, from about 20 wt.% to about 22 wt.%, from about 22 wt.% to about 24 wt.%, from about 24 wt.% to about 26 wt.%, from about 22 wt.% to about 28 wt.%, from about23 wt.% to about 28 wt.%, from about 24 wt.% to about 28 wt.%, from about 25 wt.% to about 28 wt.%, from about 26 wt.% to about 28 wt.%, from about 27 wt.% to about 28 wt.%, from about 26 wt.% to about 30 wt.%, from about 27 wt.% to about 30 wt.%, from about 29 wt.% to about 30 wt.%, from about 21 wt.% to about 32 wt.%, from about 23 wt.% to about 32 wt.%, from about 25 wt.% to about 32 wt.%, from about 27 wt.% to about 32 wt.%, from about 29 wt.% to about 32 wt.%, or from about 31 wt.% to about 32 wt.%, based on the total weight of the cemented carbide. The ceramic hard phase powder and the metallic based metallic binder phase powder can be processed into a wide variety of microstructures that achieve different mechanical and physical properties. Moreover, additional components can be added to the composition to help control, and further to refine the properties achieved by the cemented carbide compositions. By controlling various parameters including grain size, metallic binder content, dotation (i.e., alloy carbides), and carbon content, a cemented carbide manufacturer can favorably tailor, and direct the performance of cemented carbides to specific and unique applications. A cemented carbide is ideally designed to provide the physical optimal properties of both a ceramic, such as, a high temperatureresistance, corrosion-resistance, a great hardness and wear resistance, and those of a soft ductile metal, such as the capability to undergo plastic deformation, and provide a good fracture toughness. The naturally ductile soft metal binder serves to offset the characteristic brittle behavior of the ceramic hard phase, and thus raises its associated fracture toughness and its durability. The ceramic hard phase of the cemented carbide is most typically constituted of refractory carbides, however alternatively of borides, nitrides, or carbonitrides of metals, such as, but not limited to most typically tungsten, however alternatively niobium, tantalum, titanium, silicon, molybdenum, or any combinations or alloys thereof. The ceramic hard phase can be present in the cemented carbide powder in any possible combination having the mentioned metals, and in a weight that is not inconsistent and incompatible with the objectives of the present subject matter. To qualify as a cemented carbide herein, a cemented carbidegenerally may have a ceramic hard phase of from about 70 vol.% to about 90 vol.% based on a total volume of the cemented carbide, e.g., ranging from about 72 vol.% to about 90 vol.%, from about 74 vol.% to about 90 vol.%, from about 76 vol.% to about 90 vol.%, from about 78 vol.% to about 90 vol.%, from about 80 vol.% to about 90 vol.%, from about 82 vol.% to about 90 vol.%, from about 84 vol.% to about 90 vol.%, from about 86 vol.% to about 90 vol.%, from about 88 vol.% to about 90 vol.%, from about 70 vol.% to about 72 vol.%, from about 72 vol.% to about 74 vol.%, from about 74 vol.% to about 76 vol.%, from about 72 vol.% to about 76 vol.%, from about 76 vol.% to about 78 vol.%, from about 78 vol.% to about 80 vol.%, from about 70 vol.% to about82 vol.%, from about 71 vol.% to about 82 vol.%, from about 72 vol.% to about 82 vol.%, from about 73 vol.% to about 82 vol.%, from about 74 vol.% to about 82 vol.%, from about 75 vol.% to about 82 vol.%, from about 76 vol.% to about 82 vol.%, from about 77 vol.% to about 82 vol.%, from about 78 vol.% to about 82 vol.%, from about79 vol.% to about 82 vol.%, from about 80 vol.% to about 82 vol.%, from about 81 vol.% to about 82 vol.%, from about 70 vol.% to about 83 vol.%, from about 71 vol.% to about83 vol.%, from about 72 vol.% to about 83 vol.%, from about 73 vol.% to about 83 vol.%, from about 74 vol.% to about 83 vol.%, from about 75 vol.% to about 83 vol.%, from about 76 vol.% to about 83 vol.%, from about 77 vol.% to about 83 vol.%, from about 78 vol.% to about 83 vol.%, from about 79 vol.% to about 83 vol.%, from about80 vol.% to about 83 vol.%, from about 81 vol.% to about 83 vol.%, from about 82 vol.% to about 83 vol.%, from about 70 vol.% to about 84 vol.%, from about 71 vol.% to about84 vol.%, from about 72 vol.% to about 84 vol.%, from about 73 vol.% to about 84 vol.%, from about 74 vol.% to about 84 vol.%, from about 75 vol.% to about 84 vol.%, from about 76 vol.% to about 84 vol.%, from about 77 vol.% to about 84 vol.%, from about 78 vol.% to about 84 vol.%, from about 79 vol.% to about 84 vol.%, from about 80 vol.% to about 84 vol.%, from about 81 vol.% to about 84 vol.%, from about 82 vol.% to about 84 vol.%, from about 83 vol.% to about 84 vol.%, from about 70 vol.% to about85 vol.%, from about 71 vol.% to about 85 vol.%, from about 72 vol.% to about 85 vol.%, from about 73 vol.% to about 85 vol.%, from about 74 vol.% to about 85 vol.%, from about 75 vol.% to about 85 vol.%, from about 76 vol.% to about 85 vol.%, from about 77 vol.% to about 85 vol.%, from about 78 vol.% to about 85 vol.%, from about 79 vol.% to about 85 vol.%, from about 80 vol.% to about 85 vol.%, from about 81 vol.% to about 85 vol.%, from about 82 vol.% to about 85 vol.%, from about 83 vol.% to about85 vol.%, from about 84 vol.% to about 85 vol.%, based on the total volume of the cemented carbide.

[0053] As used herein, the term “expansion coefficient” is the equivalent of the coefficient of thermal expansion, which is an expansive response of a material to a temperature increase.

[0054] Wherever used throughout the disclosure, the term “generally” has the meaning of “approximately”, “typically” or “closely” or “within the vicinity or range of”.

[0055] As used herein, the term “homogeneous” refers to the thickness of the web being more equivalent, similar, uniform, identical, and consistent throughout the entire volume and the surface area of the web after calendering is done performed by the calendering device disclosed herein.

[0056] As used herein, the term, “shaft” refers to a rotating apparatus-part, which is usually circular in a cross-section, and which is used to transmit power from one part of the calendering device to another.

[0057] As used herein, the term “steel” is an alloy of at least iron and carbon with improved strength, hardness, abrasion-, wear- and fractureresistance compared to many other forms of iron. High speed steel, for example, is a subset of tool steels, which are commonly used as cutting tool material. It is superior to high-carbon tool steels, in that, it can withstand much higher temperatures without losing its temper and hardness. This property allows high speed steel to cut much faster than high carbon steel, hence its derived name high-speed steel.

[0058] As used herein, the term “substantial” or “substantially” refers to the complete or nearly complete extent or degree of an action, characteristic, property, state, structure, item, or result.

[0059] As used herein, the term “vol.%” refers to the volume of a ceramic hard phase of a cemented carbide based on a total volume of a cemented carbide.

[0060] As used herein, the term “Young’s modulus” also referred to as the modulus of elasticity refers to a mechanical property of solid materials that measures the tensile stiffness or the compressive stiffness, when a net force is appliedlongitudinally and lengthwise. Young's modulus is a measure of the ability of a material to withstand changes in length when subjected to lengthwise tension or compression. It is the modulus of elasticity for tension or compression. Young's modulus is defined as the ratio of the stress (force per unit area) applied to the object and the resulting axial strain (displacement or deformation) in the linear elastic region of the material. The stiffer a given material is, the higher is the given material’s Young’s modulus.

[0061] As used herein, the terms “web” or “web material” are used interchangeably, and they refer to a nonwoven fibered or powdered material that can be pressed directly between at least two rolls of the calendering device disclosed herein. Calendering rolls are used to press powdered or fibered materials to confer cohesion that make them usable in the shape of a film, a sheet, or of a web. The material can be pressed directly between at least two rolls of the calendering device disclosed herein, or it can be pressed against one or both sides of another film or web. For instance, the manufacturing of electrodes for batteries used in electrical vehicles includes pressing active substances against a metallic foil typically made of aluminum or copper. The active substances can be wet or dry. In the case of a wet process, a drying process is needed following the calendering operation. In the case of a dry process, heat and higher pressure are needed to get a cohesive and usable material. The calendering roll is thus heated in its mass to compress the web. In both cases, wet or dry process, it is important to get an even thickness within few micrometers after calendering is complete.

[0062] As used herein, the term “wt.%” refers to the amount of a ceramic hard phase or a binder phase of a cemented carbide based on a total weight of a cemented carbide.

[0063] With reference to FIG.1 , FIG. 2A, FIG. 3A, and FIG. 4A, provided is a calendering device 1A including at least two rolls 2 configured to rotate around each of their longitudinal axis 3. A web 1 to be pressed by the two rolls 2 is passed through the two rotating rolls 2 to flatten and thereby compress the web 1 by the calendering device 1 A. The two rolls 2 of the calendering device 1 A, each has a shaft 4 made of a material being any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy (having a nickel amount in the nickel-iron alloy between about 42wt.% and 54 wt.%). The shaft 4 has at least one bearing 9 mounted in a longitudinal axial end of the shaft 4 configured to rotate the shaft 4. The shaft 4 may have an expansion coefficient between about 10 x 10’6 / K and about 20 x 10’6 / K, i.e. , about 10 x 10'6 / K, about 11 x 106 / K, about 12 x 106 / K, about 13 x 106 / K, about 14 x 106 / K, about 15 x 10’6 / K, about 16 x 10’6 / K, about 17 x 10’6 / K, about 18 x 10’6 / K, about 19 x 10'6 / K, or about 20 x 10’6 / K.

[0064] The two rolls 2, further have at least one intermediate cylinder 7 as shown in FIG. 3A, FIG. 3B, FIG. 4A, FIG. 4B, FIG. 5A, and FIG. 5B made of a material including any one of a cemented carbide, a nickel-iron alloy (having a nickel amount in the nickel-iron alloy between about 42 wt.% and 54 wt.%), tool steel, or cast iron. The intermediate cylinder 7 may have an expansion coefficient between about 6 x 10’6 / K and about 12 x 10’6 / K, i.e., about 6 x 10’6 / K, about 7 x 10’6 / K, about 8 x 10’6 / K, 9 x 10’6 / K, about 10 x 10’6 / K, about 11 x 10’6 / K, or about 12 x 10’6 / K.

[0065] Moreover, the two rolls 2 each further has an outer shell 6 as shown in FIG. 2A, Fig. 2B, FIG. 3A, FIG. 3B, FIG. 4A, FIG. 4B, FIG. 5A, and FIG. 5B made of a material including a cemented carbide. The outer shell 6 may have an expansion coefficient between about 5 x 10’6 / K and about 8 x 10’6 / K, i.e., about 5 x 10’6 / K, about6 x 10’6 / K , about 7 x 10’6 / K, or about 8 x 10’6 / K.

[0066] With further reference to FIG.1 , provided is also a method of calendering a material for example a web 1 , comprising passing the web 1 between the set of closely spaced rotating rolls 2 of the calendering device 1A to thereby flatten and compress the web 1 . As the web 1 passes through the closely spaced rotating rolls 2, a pressure is applied at the nip point, where the rotating rolls 2 meet, thus effectively squeezing and compressing the web 1 imparted by shear forces as the web 1 moves through the rolls 2. The rolls 2 shown in FIG. 1 can be rotated by being an integral component of an electronic calendering machine.

[0067] The cemented carbide of the outer shell 6 and the least one intermediate7 cylinder typically has a ceramic hard phase, which may include or consist of at least one of tungsten carbide, niobium carbide, tantalum carbide, titanium carbide, silicon carbide, molybdenum carbide, or any alloys or combinations thereof. Alternatively, the cemented carbide of the outer shell 6 and the least one intermediate 7 cylindermay have a ceramic hard phase further including at least one of tungsten nitride, niobium nitride, tantalum nitride, titanium nitride, silicon nitride, molybdenum nitride, tungsten carbonitride, niobium carbonitride, tantalum carbonitride, titanium carbonitride, silicon carbonitride, molybdenum carbonitride, tungsten boride, niobium boride, tantalum boride, titanium boride, silicon boride, molybdenum boride, or any alloys or combinations thereof.

[0068] With further reference to FIG. 2A, in some examples, the outer shell 6 has a gradient material extending radially, such that the outer shell 6 has a higher binder content on its inner diameter compared to its outer diameter. The binder material amount may vary in a continuous manner from an inside diameter to an outer diameter of the outer shell 6, thus further resulting in continuous variations of the expansion coefficient.

[0069] Close to an outer diameter of the outer shell 6, the cemented carbide of the outer shell 6 may have a binder phase generally in an amount of from about 6 wt.% to about 20 wt.% based on a total amount of the cemented carbide, which may include or consist of at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any alloys or combinations thereof. This may, for example, further include the metallic binder ranging in an amount of from about 8 wt.% to about 20 wt.%, from about 10 wt.% to about 20 wt.%, from about 12 wt.% to about 20 wt.%, from about 14 wt.% to about 20 wt.%, from about 16 wt.% to about 20 wt.%, from about 18 wt.% to about 20 wt.%, from about 8 wt.% to about 10 wt.%, from about 10 wt.% to about 12 wt.%, from about 12 wt.% to about 14 wt.%, from about 8 wt.% to about 12 wt.%, from about 8 wt.% to about 9 wt.%, from about 11 wt.% to about 12 wt.%, from about 8 wt.% to about 14 wt.%, from about 11 wt.% to about 14 wt.%, from about 13 wt.% to about 14 wt.%, from about 8 wt.% to about 16 wt.%, from about 8 wt.% to about 18 wt.%, from about 11 wt.% to about 16 wt.%, from about 13 wt.% to about 16 wt.%, from about 15 wt.% to about 16 wt.%, from about 14 wt.% to about 16 wt.%, from about 16 wt.% to about 18 wt.%, from about 18 wt.% to about 20 wt.%, from about 14 wt.% to about 18 wt.%, from about 15 wt.% to about 18 wt.%, from about 15 wt.% to about 19 wt.%, from about 15 wt.% to about 20 wt.%, from about 17 wt.% to about 19 wt.%, from about 17 wt.% to about 20 wt.%, from about 18 wt.% to about 19 wt.%, or from about 19 wt.% to about 20 wt.%, based on a total weight of thecemented carbide. Thus, in this case, the expansion coefficient may vary in a range of from about 5 x 10’6 / K to about 8 x 10’6 / K, such as e.g., from about 6 x 10’6 / K to about 8 x 10’6 / K, from 7 x 10’6 / K to about 8 x 10’6 / K, from about 5 x 10’6 / K to about 6 x 10’6 / K, from about 6 x 10’6 / K to about 7 x 10’6 / K, or from about 7 x 10’6 / K to about 8 x 10’6 / K. Further, in this case, the Young’s modulus may span a range of from about 450 GPa to about 650 GPa, from about 475 GPa to about 650 GPa, from about 500 GPa to about 650 GPa, from about 525 GPa to about 650 GPa, from about 550 GPa to about 650 GPa, from about 575 GPa to about 650 GPa, from about 600 GPa to about 650 GPa, from about 625 GPa to about 650 GPa, from about 450 GPa to about 475 GPa, from about 475 GPa to about 500 GPa, from about 500 GPa to about 525 GPa, from about 450 GPa to about 525 GPa, from about 475 GPa to about 525 GPa, from about 525 GPa to about 550 GPa, from about 525 GPa to about 575 GPa, from about 550 GPa to about 575 GPa, from about 575 GPa to about 600 GPa, from about 525 GPa to about 600 GPa, from about 550 GPa to about 600 GPa, from about 575 GPa to about 600 GPa, from about 600 GPa to about 625 GPa, from about 625 GPa to about 650 GPa, or from about 600 GPa to about 650 GPa.

[0070] Close to an inner diameter of the outer shell 6, the cemented carbide of the outer shell 6 may have a binder phase usually in an amount of from about 12 wt.% to about 32 wt.% based on a total amount of the cemented carbide, which may include or consist of at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any alloys or combinations thereof. This may, for example, further include the metallic binder ranging in an amount of from 14 wt.% to about 32 wt.%, from about 16 wt.% to about 32 wt.%, from about 18 wt.% to about 32 wt.%, from about 20 wt.% to about 32 wt.%, from about 22 wt.% to about 32 wt.%, from about 24 wt.% to about 32 wt.%, from about 26 wt.% to about 32 wt.%, from about 28 wt.% to about 32 wt.%, from about 30 wt.% to about 32 wt.%, from about 20 wt.% to about 22 wt.%, from about 22 wt.% to about 24 wt.%, from about 24 wt.% to about 26 wt.%, from about 22 wt.% to about 28 wt.%, from about 23 wt.% to about 28 wt.%, from about 24 wt.% to about 28 wt.%, from about 25 wt.% to about 28 wt.%, from about 26 wt.% to about 28 wt.%, from about 27 wt.% to about 28 wt.%, from about 26 wt.% to about 30 wt.%, from about 27 wt.% to about 30 wt.%, from about 29 wt.% to about 30 wt.%, from about 21 wt.% to about 32 wt.%, from about 23 wt.% to about 32 wt.%, from about 25 wt.% to about 32 wt.%, from about 27 wt.% to about 32 wt.%, from about29 wt.% to about 32 wt.%, or from about 31 wt.% to about 32 wt.%, based on a total weight of the cemented carbide. Thus, in this case, the expansion coefficient may vary in a range of from about 6 x 10’6 / K to about 12 x 10’6 / K. In some examples, the expansion coefficient of the outer shell 6 varies in a range of from about 8 x 10’6 / K to about 12 x 10’6 / K. In other examples, the expansion coefficient of the outer shell 6 varies in a range of from about 10 x 10’6 / Kto about 12 x 10’6 / K. In still other examples, the expansion coefficient of the outer shell 6 varies in a range of from about 11 x 10’6 / K to about 12 x 10’6 / K, varies from about 6 x 10’6 / K to about 8 x 10’6 / K, varies from about 8 x 10’6 / K to about 10 x 10’6 / K, varies from about 6 x 10’6 / K to about 10 x 10’6 / K, varies from about 7 x 10’6 / K to about 9 x 10’6 / K, varies from about 7 x 10’6 / K to about 10 x 10’6 / K, varies from about 9 x 10’6 / K to about 10 x 10’6 / K, varies from about 7 x 10’6 / K to about 12 x 10’6 / K, or varies from about 9 x 10’6 / K to about 12 x 10’6 / K.

[0071] With further reference to FIG. 2A, the calendering device 1 A includes an aperture 5, which may be located between the shaft 4 and the outer shell 6, such that ends of the outer shell 6 have a homogeneous displacement, when they are subjected to a load, and a thickness of the pressed web 1 by the two rolls 2 is substantially uniform. As shown in FIG. 1, the calendering force is generally localized, where the web 1 is pressed between the two rolls 2 of the calendering device 1A. This calendaring force is therefore distributed over the contact surface between each roll 2 of the calendering device 1A and the web 1. The consequence is a localized deformation of the roll 2 surface, and a deflection of the rolls 2 of the calendering device 1A due to a bending effect. These combined two phenomena thus generate local displacements on the generating lines of the rolls 2 that are in contact with the web 1 . The local displacement is higher in the middle of the rolls 2 compared to the ends of the rolls 2. This uneven displacement is subsequently transferred into the web 1 , which results in the web 1 getting an overall uneven thickness. The main purpose of having the aperture 5 located on the calendering device 1 A is to add flexibility, so that the ends of the outer shell 6 can favorably have a higher displacement. This action would then be equal to the displacement taking place in the middle of the rolls 2 when subjected to a calendering force to balance out deformations occurring on the rolls 2 due to the presence of the aperture 5.

[0072] With reference to FIG. 2B, the details of the aperture 5 on one end of a roll 2 is shown. It is characterized by a depth d1 and a length L1 . The aperture 5 can be made by a shape manufactured in the shaft 4 or in the outer shell 6, or alternatively in both the shaft 4 and the outer shell 6. The shape of the aperture 5 may ideally be a taper, a radius, or any other topological shape. In theory, the shape of the aperture 5 can be any possible shape that is not inconsistent and incompatible with the scope of the present subject matter, and that results in the previously described advantages of balancing out deformations occurring on the calendering rolls 2. The dimensions d1 and L1 of the aperture 5 are determined, so that the displacements over the generative line of the roll 2, that is in contact with the web 1 , are as even as possible. The decisive choice of the dimensions d1 and L1 depends largely on the mechanical properties of the materials constituting the roll 2, on the dimensions of the roll 2 like e.g., diameter and length, on the wall thickness of the outer shell 6, on the width of web 1 , and on the calendering-forces used in the process.

[0073] As shown in FIG. 3A, FIG. 3B, FIG.4A, and FIG. 4B in other examples, the aperture 5 may be located on one end of the roll 2 between the shaft 4 and the intermediate cylinder 7. In even other examples and configurations, the aperture 5 may be located on one end of the roll 2 between the outer shell 6 and the intermediate cylinder 7. Regardless of where the aperture 5 is located on the rolls 2 of the calendering device 1A, the main functionality of the aperture 5 is to introduce flexibility, such that displacement and deformations occurring at the ends of the rolls 2 become equal, or at the very least close to the ones occurring in the middle of the rolls 2. With further reference to FIG. 3B, the details of the aperture 5 on one end of a roll 2 are depicted. It is characterized by a depth d2 and a length L2. The aperture 5 can be made by a shape manufactured in the shaft 4, or in the intermediate cylinder 7, or alternatively in both the shaft 4 and the intermediate cylinder 7. Once again, the choice of these dimensions depends largely on the mechanical properties of the materials constituting the roll 2, the dimensions of the roll 2 such as e.g., diameter and length, on the wall thickness of the elements of the roll 2, on the width of web 1 , and on the calendering-forces used in the process.

[0074] With reference to FIG. 4A and FIG. 4B, in other examples, the calendering device 1 A may further have at least another intermediate cylinder 8, whichis located between the shaft 4 and the outer shell 6, and which is made of a material being a cemented carbide. Thus, in this embodiment, as shown in FIG. 1 , FIG. 4A, and FIG. 4B, the aperture 5 may be located between the at least another intermediate cylinder 8 and the outer shell 6 on one end of a roll 2 to generate even displacements along the generative line of the roll 2 that is in contact with the web 1 . As demonstrated in FIG. 4B, this aperture 5 is characterized by having a depth d3 and a length L3.

[0075] In still other configurations, a plurality of apertures 5 instead of a single aperture 5 may be located on one end of a roll 2 of the calendering device 1 A. Thus, in this instance, in one example the calendering device 1A may have a plurality of apertures 5 with an aperture 5 located between the at least one intermediate cylinder 7 and the shaft 4, and another aperture 5 located between the outer shell 6 and the at least one intermediate cylinder 7 as shown in FIG. 5A. In another example, the calendering device 1 A may have a plurality of apertures 5 with one aperture 5 located between the at least one intermediate cylinder 7 and the shaft 4, another aperture 5 located between the at least another intermediate cylinder 8 and the at least one intermediate cylinder 7, and still another aperture 5 located between the outer shell 6 and the at least another intermediate cylinder 8 as shown in FIG. 5B. It is fully within the scope of the present subject matter to have several of such apertures 5 that are superimposed on one end of the roll 2, such that the obtained displacements along the generative line of roll 2 in contact with the web 1 , are uniform.

[0076] A person having ordinary skill in the art of making calendering devices would know that routine assembly methods may be implemented in the manufacturing of the calendering device 1 A of the disclosure. In one particular example, the shaft 4, the at least one intermediate cylinder 7, the at least another intermediate cylinder 8, and the outer shell 6 may be assembled by shrink-fitting. Again, they may also be connected in many other manners and variations as well, such as e.g., by way of applying an epoxy, by press-fitting, by mechanical choices and so forth.

[0077] Without being bound by any particular theory, the expansion coefficient of the shaft 4 is greater than the expansion coefficient of the at least one intermediate cylinder 7. Moreover, the expansion coefficient of the at least one intermediate cylinder 7 is greater than the expansion coefficient of the at least another intermediatecylinder 8. Further, the expansion coefficient of the at least another intermediate cylinder 8 is greater than the expansion coefficient of the outer shell 6.

[0078] In sum, a physically stable calendering device 1A is presented herein with a superior mechanical stability and strength, where the outer shell 6 of the calendering device 1A is stable, and does not break apart at thermal stresses well above 100°C. Thus, the technical advantage achieved by the disclosure, is at least manifold, as it favorably allows to warm up the rolls 2 of the calendering device 1 A at high temperatures exhibiting a low level of deflection, while at the same time, it provides a uniform thickness on the calendared web 1. Although, the application of the calendering device 1A is not solely restricted to the following use, the described calendering device 1 A may be used for calendering e.g., electrodes of batteries used in electrical vehicles besides calendering of a web 1 as previously described. It should however be noted that, a person having ordinary skill in the art would know that the calendering device 1 A described herein may be implemented in connection with many other systems, which may routinely require the use of the calendering device 1A, and a method of calendering any material with the calendering device 1 A.

[0079] Although the present disclosure has been described in connection with examples thereof, it will be appreciated by those skilled in the art that additions, deletions, modifications, and substitutions not specifically described may be made without departure from the spirit and scope of the disclosure as defined in the appended claims.

[0080] The herein described subject matter sometimes illustrates different components contained within, or connected with, different other components. It is to be understood that such depicted architectures are merely exemplary, and that in fact many other architectures may be implemented which achieve the same functionality. In a conceptual sense, any arrangement of components to achieve the same functionality is effectively “associated”, such that the desired functionality is achieved. Hence, any two components herein combined to achieve a particular functionality can be seen as “associated with” each other, such that the desired functionality is achieved, irrespective of architectures or intermedial components. Likewise, any two components so associated can also be viewed as being “operably connected”, or “operably coupled,” to each other to achieve the desired functionality, and any twocomponents capable of being so associated can also be viewed as being “operably couplable,” to each other to achieve the desired functionality. Specific examples of operably couplable include but are not limited to physically mateable and / or physically interacting components, and / or wirelessly interactable, and / or wirelessly interacting components, and / or logically interacting, and / or logically interactable components.

[0081] In some instances, one or more components may be referred to herein as “configured to,” “configured by,” “configurable to,” “operable / operative to,” “adapted / adaptable,” “able to,” “conformable / conformed to,” etc. Those skilled in the art will recognize that such terms (e.g., “configured to”) can generally encompass active-state components and / or inactive-state components and / or standby-state components, unless context requires otherwise.

[0082] While particular aspects of the present subject matter described herein have been shown and described, it will be apparent to those skilled in the art that, based upon the teachings herein, changes and modifications may be made without departing from the subject matter described herein and its broader aspects and, therefore, the appended claims are to encompass within their scope all such changes and modifications as are within the true spirit and scope of the subject matter described herein. It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.).

[0083] It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and / or “an”should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations.

[0084] In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations).

[0085] Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “ a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “ a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by those within the art that typically a disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms unless context dictates otherwise. For example, the phrase “A or B” will be typically understood to include the possibilities of “A” or “B” or “A and B.”

[0086] With respect to the appended claims, those skilled in the art will appreciate that recited operations therein may generally be performed in any order. Also, although various operational flows are presented in a sequence(s), it should be understood that the various operations may be performed in other orders than those which are illustrated, or may be performed concurrently. Examples of such alternate orderings may include overlapping, interleaved, interrupted, reordered, incremental, preparatory, supplemental, simultaneous, reverse, or other variant orderings, unless context dictates otherwise. Furthermore, terms like “responsive to,” “related to,” orother past-tense adjectives are generally not intended to exclude such variants, unless context dictates otherwise.

[0087] Those skilled in the art will appreciate that the foregoing specific exemplary processes and / or devices and / or technologies are representative of more general processes and / or devices and / or technologies taught elsewhere herein, such as in the claims filed herewith and / or elsewhere in the present application.

[0088] While various aspects and examples have been disclosed herein, other aspects and examples will be apparent to those skilled in the art. The various aspects and examples disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[0089] The illustrative examples described in the detailed description, drawings, and claims are not meant to be limiting. Other examples may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented here.

[0090] Where a range of values is provided, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range is encompassed within the disclosure. The upper and lower limits of these smaller ranges which can independently be included in the smaller ranges is also encompassed within the disclosure, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits, ranges excluding either both of those included limits are also included in the disclosure.

[0091] One skilled in the art will recognize that the herein described components (e.g., operations), devices, objects, and the discussion accompanying them are used as examples for the sake of conceptual clarity and that various configuration modifications are contemplated. Consequently, as used herein, the specific exemplars set forth and the accompanying discussion are intended to be representative of their more general classes. In general, use of any specific exemplaris intended to be representative of its class, and the non-inclusion of specific components (e.g., operations), devices, and objects should not be taken as limiting.

[0092] Additionally, for example any sequence(s) and / or temporal order of sequence of the system and method that are described herein this disclosure are illustrative and should not be interpreted as being restrictive in nature. Accordingly, it should be understood that the process steps may be shown and described as being in a sequence or temporal order, but they are not necessarily limited to being carried out in any particular sequence or order. For example, the steps in such processes or methods generally may be carried out in various different sequences and orders, while still falling within the scope of the present disclosure.

[0093] Finally, the discussed application publications and / or patents herein are provided solely for their disclosure prior to the filing date of the described disclosure. Nothing herein should be construed as an admission that the described disclosure is not entitled to antedate such publication by virtue of prior disclosure.

Claims

What is claimed is:

1. A device, comprising: at least two rolls configured to rotate around each of their longitudinal axis, the at least two rolls each comprising a shaft made of a material comprising any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy and the shaft having at least one bearing mounted in a longitudinal axial end configured to rotate the shaft, the shaft having an expansion coefficient between about 10 x 10’6 / K and about 20 x 10'6 / K; an outer shell made of a material comprising a cemented carbide, the outer shell having an expansion coefficient between about 5 x 10’6 / K and about 8 x 10'6 / K; and an aperture located between the shaft and the outer shell, such that ends of the outer shell have a homogeneous displacement when subjected to a calendering force and a thickness of a pressed web by the at least two rolls is uniform.

2. The device of claim 1 , wherein the cemented carbide of the outer shell has a ceramic hard phase comprising at least one of tungsten carbide, niobium carbide, tantalum carbide, titanium carbide, silicon carbide, molybdenum carbide, or any combinations thereof.

3. The device of claim 2, wherein the cemented carbide of the outer shell has a ceramic hard phase further comprising at least one of tungsten nitride, niobium nitride, tantalum nitride, titanium nitride, silicon nitride, molybdenum nitride, tungsten carbonitride, niobium carbonitride, tantalum carbonitride, titanium carbonitride, silicon carbonitride, molybdenum carbonitride, tungsten boride, niobium boride, tantalum boride, titanium boride, silicon boride, molybdenum boride, or any combinations thereof.

4. The device of claim 1 , wherein close to an outer diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 6 wt.% to about 20 wt.% based on a total amount of the cemented carbide, the binder phase comprising at leastone of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 5 x 10’6 / K to about 8 x 10’6 / K.

5. The device of claim 1 , wherein close to an inner diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 12 wt.% to about 32 wt.% based on a total amount of the cemented carbide, the binder phase comprising at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 6 x 10’6 / K to about 12 x 10’6 / K.

6. The device of claim 4, wherein close to the outer diameter of the outer shell, the outer shell has a Young’s modulus in a range of from about 450 GPa to about 650 GPa with a lower binder content.

7. A device, comprising: at least two rolls configured to rotate around each of their longitudinal axis, the at least two rolls each comprising a shaft made of a material comprising any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy and the shaft having at least one bearing mounted in a longitudinal axial end configured to rotate the shaft, the shaft having an expansion coefficient between about 10 x 10’6 / K and about 20 x 10'6 / K; at least one intermediate cylinder made of a material comprising a cemented carbide or a nickel-iron alloy, the at least one intermediate cylinder having an expansion coefficient between about 6 x 10’6 / K and about 12 x 10’6 / K; and an outer shell made of a material comprising a cemented carbide, the outer shell having an expansion coefficient between about 5 x 10’6 / K and about 8 x 10'6 / K.

8. The device of claim 7, wherein close to an outer diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 6 wt.% to about 20 wt.% based on a total amount of the cemented carbide, the binder phase comprising at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 5 x 10’6 / K to about 8 x 10’6 / K.

9. The device of claim 7, wherein close to an inner diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 12 wt.% to about 32 wt.% based on a total amount of the cemented carbide, the binder phase comprising at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 6 x 10’6 / K to about 12 x 10’6 / K.

10. The device of claim 7, wherein the shaft, the at least one intermediate cylinder and the outer shell are assembled by shrink-fitting.11 . The device of claim 7, wherein the expansion coefficient of the shaft is greater than the expansion coefficient of the at least one intermediate cylinder.

12. The device of claim 7, wherein the expansion coefficient of the at least one intermediate cylinder is greater than the expansion coefficient of the outer shell.

13. The device of claim 7, wherein the outer shell of the device is stable and does not break apart at thermal stresses above 100°C.

14. The device of claim 7, wherein the device has one aperture between the at least one intermediate cylinder and the outer shell, such that ends of the outer shell have a homogeneous displacement when subjected to a calendering force and a thickness of a pressed web by the at least two rolls is uniform.

15. The device of claim 7, wherein the device has a plurality of apertures superimposed between the shaft and the outer shell.

16. The device of claim 7, wherein close to an outer diameter of the outer shell, the outer shell has a Young’s modulus in a range of from about 450 GPa to about 650 GPa with a lower binder content.

17. The device of claim 7, further comprising at least another intermediate cylinder located between the shaft and the outer shell made of a material comprising cemented carbide.

18. The device of claim 7, wherein close to an outer diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 6 wt.% to about 20 wt.% based on a total amount of the cemented carbide, the binder phase comprising at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 5 x 10’6 / K to about 8 x 10’6 / K.

19. The device of claim 7, wherein close to an inner diameter of the outer shell, a binder phase of the outer shell is in an amount of from about 12 wt.% to about 32 wt.% based on a total amount of the cemented carbide, the binder phase comprising at least one of cobalt, nickel, iron, nickel, chromium, molybdenum, titanium, tantalum, niobium, or any combinations thereof, and the expansion coefficient of the outer shell is in a range of from about 6 x 10’6 / K to about 12 x 10’6 / K.20 The device of claim 17, wherein the shaft, the at least one intermediate cylinder, the at least another intermediate cylinder and the outer shell are assembled by shrinkfitting.21 . The device of claim 7, wherein the expansion coefficient of the shaft is greater than the expansion coefficient of the at least one intermediate cylinder.

22. The device of claim 17, wherein the expansion of the at least one intermediate cylinder is greater than an expansion coefficient of the at least another intermediate cylinder.

23. The device of claim 22, wherein the expansion coefficient of the at least another intermediate cylinder is greater than the expansion coefficient of the outer shell24. The device of claim 7, wherein the outer shell of the device is stable and does not break apart at thermal stresses above 100°C.

25. The device of claim 17, wherein the device has one aperture between the at least one intermediate cylinder, the at least another intermediate cylinder and the outer shell, such that ends of the outer shell have a homogeneous displacement when subjected to a calendering force and a thickness of a pressed web by the at least two rolls is uniform.

26. The device of claim 7, wherein the device has a plurality of apertures superimposed between the shaft and the outer shell.

27. The device of claim 18, wherein close to an outer diameter of the outer shell, the outer shell has a Young’s modulus in a range of from about 450 GPa to about 650 GPa with a lower binder content.

28. The device of claim 1 , wherein the device is a calendering device.

29. The device of claim 7, wherein the device is a calendering device.

30. A method of calendering a web, comprising: passing the web through a calendering device to compress the web, the calendaring device comprising at least two rolls configured to rotate around each of their longitudinal axis, the at least two rolls each comprising a shaft made of a material comprising any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy and the shaft having at least one bearing mounted in a longitudinal axial end configured to rotate the shaft, the shaft having an expansion coefficient between about 10 x 10’6 / K and about 20 x 10'6 / K;an outer shell made of a material comprising a cemented carbide, the outer shell having an expansion coefficient between about 5 x 10’6 / K and about 8 x 10'6 / K; and an aperture located between the shaft and the outer shell, such that ends of the outer shell have a homogeneous displacement when subjected to a calendering force and a thickness of the pressed web by the at least two rolls is uniform.31 . A method of calendering a web, comprising: passing the web through a calendering device to compress the web, the calendaring device comprising at least two rolls configured to rotate around each of their longitudinal axis, the at least two rolls each comprising a shaft made of a material comprising any one of steel, tool steel, high speed steel, cast iron, stainless steel, or a nickel-iron alloy and the shaft having at least one bearing mounted in a longitudinal axial end configured to rotate the shaft, the shaft having an expansion coefficient between about 10 x 10’6 / K and about 20 x 10’6 / K; at least one intermediate cylinder made of a material comprising a cemented carbide or a nickel-iron alloy, the at least one intermediate cylinder having an expansion coefficient between about 6 x 10’6 / K and about 12 x 10’6 / K; and an outer shell made of a material comprising a cemented carbide, the outer shell having an expansion coefficient between about 5 x 10’6 / K and about 8 x 10’6 / K.

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