Calender Roll Surface Structuring for Layer Adhesion

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Solution Overview

Problem

Existing treatment devices, such as calender rolls, face challenges in applying a new layer structure due to mechanical incompatibilities and the need for precise matching of metal cylinders, leading to difficulties in modifying or reconstructing them with new surfaces.

Innovation Solution

A roll with a hard substructure and a thick covering of paper or textile material, featuring multiple thin layers compressed and structured with grooves or depressions, where liquid plastic is applied as an adhesive and a stabilizing fibrous material layer is impregnated with plastic, forming a stable, fibre-reinforced layer for improved adhesion and mechanical connection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a precisely matching metal cylinder is slid onto the textile layer to apply a new covering, then the new layer structure can be applied, but the diameter must precisely match the roll diameter which causes mechanical problems and increases complexity

Engineering Contradiction:

Improveability to apply new layer structure to existing rollVSAvoidprecision matching requirement of metal cylinder diameter

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention divides the covering application into separate steps: first applying a thick textile or paper covering to the existing roll, then applying a thinner metal cylinder or tube over this soft covering. The soft covering acts as a compliant intermediate layer that absorbs dimensional variations, allowing the metal component to be applied without precise diameter matching while still achieving proper mechanical connection through the plastic adhesive layer.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If a thick covering of paper or textile material is applied to the substructure, then the roll can be reconstructed or modified, but multiple thin layers must be compressed and structured which increases manufacturing complexity

Engineering Contradiction:

Improveability to modify or reconstruct existing treatment devicesVSAvoidprocess of compressing and structuring multiple thin layers

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention applies the thick soft covering (paper or textile material) to the substructure before applying the metal cylinder or tube. This preliminary action creates a compliant base layer that simplifies subsequent manufacturing steps, as the soft covering can be compressed and structured in advance to provide a stable foundation that accommodates dimensional variations of the metal component.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If liquid plastic is applied as an adhesive to the structured surface, then mechanical connection and adhesion are improved, but the plastic must penetrate the paper or textile material which requires surface structuring

Engineering Contradiction:

Improveadhesion and mechanical connection strengthVSAvoidsurface structuring with grooves or depressions

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention structures the surface of the paper or textile material covering with grooves or depressions, creating a porous or textured surface that allows liquid plastic adhesive to penetrate deeply into the material. This penetration creates strong mechanical interlocking and adhesion, while the grooves also provide pathways for the plastic to reach the underlying substructure, ensuring reliable mechanical connection without requiring excessive plastic application.

Inventive Principle:

Principle #31Porous materials

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution allows for the cost-effective and technically advantageous application of a further layer structure to existing treatment devices, enhancing adhesion and mechanical stability, enabling the use of existing rolls in new applications like calender rolls for smoothing paper surfaces.

Implementation Method 1

liquid plastic applied as an adhesive to said structuring... the plastic deeply penetrates the paper or textile material and at least impregnates a portion thereof

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 2

a stabilizing fibrous material layer applied to the liquid plastic, wherein the fibrous material layer is impregnated with liquid plastic and the covering is built up

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS7669331B2Roll and method for the manufacture of such a roll

Publication Date: 2010.03.02 SCHAFER COMPOSITES

AI summary

A calender roll, which was already in use and has a metallic core with engaged textile material sheets, can be worked for a new use. In the surface of the sheets are cut grooves, to which is subsequently applied a layer structure of synthetic resin-impregnated fibrous material forming a certain thickness over each point of the roll. Onto said layer can be applied a functional covering, for example of rubber.