Elastomer Roll Protection Regions for Heat Resistance
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Solution Overview
Problem
Elastomer-covered rolls used in paper, board, and tissue manufacturing are prone to rapid degradation and failure due to exposure to high temperatures and moisture, leading to issues like swelling, structural degradation, and debonding when in contact with heated surfaces or experiencing temperature gradients.
Innovation Solution
A roll design featuring protection regions at both ends where the base layer forms the outer surface, uncovered by the elastomer layer, minimizes direct heat exposure and temperature gradients, combined with a base layer and elastomer layer configuration that includes blind holes in edge regions for further protection, and a heat-resistant base layer with reinforcement fibers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the elastomer layer covers the entire outer surface of the roll, then the roll provides uniform surface properties and good contact, but the elastomer layer is exposed to excessive heat and temperature gradients causing rapid degradation
Solution Approach 1:
The roll surface is segmented into different coverage zones: the elastomer layer covers the central working area while leaving the end regions exposed. This segmentation allows the elastomer to provide necessary surface properties where needed while avoiding heat exposure at the ends, thus resolving the contradiction between uniform contact and heat resistance.
Solution Approach 2:
Different regions of the roll are given different qualities: the central region has full elastomer coverage for good contact and surface properties, while the end regions have reduced or no elastomer coverage to minimize heat exposure. This local differentiation resolves the contradiction by applying the elastomer only where its benefits are needed without subjecting it to harmful thermal conditions.
2Productivity
If the elastomer layer is exposed to heated surfaces and moisture, then the roll functions as intended for water removal and heat transfer, but the elastomer layer degrades through swelling, structural degradation, and loss of strength
Solution Approach 1:
The roll design preliminarily protects the elastomer layer by limiting its exposure area to heated surfaces. By configuring the elastomer to cover only the central region and leave the ends exposed, the design proactively prevents the swelling and strength loss that would occur with full exposure, while still maintaining the necessary water removal function in the covered region.
3Stability of the object's composition
If the base layer is fully covered by the elastomer layer, then the roll provides uniform surface properties, but the bonding interface is fully exposed to heat causing debonding
Solution Approach 1:
The layered structure is segmented axially: the base layer is covered by the elastomer layer in the central region to provide uniform surface properties, while at the end regions the elastomer layer is reduced or absent to expose the base layer. This segmentation protects the bonding interface from heat exposure at the ends while maintaining surface uniformity in the working region.
Solution Approach 2:
Different axial regions have different layer configurations: the central region has full elastomer coverage for surface uniformity, while the end regions have reduced elastomer coverage to protect the bonding interface. This local quality differentiation resolves the contradiction between surface uniformity and bonding stability.
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 configuration significantly extends the operating life of the elastomer layer, reduces the risk of failure, and maintains bonding integrity while withstanding adverse environmental conditions.
Implementation Method 1
the elastomer cover comes in a direct contact with a heated surface of another cylinder or when the elastomer cover is subjected to a large temperature gradient, there is a risk for cover failure demonstrated by swelling
Implementation Method 2
there is a risk for cover failure demonstrated by swelling, structural degradation, loss of strength and/or wear resistance of the elastomer cover
Implementation Method 3
a base layer and elastomer layer configuration that includes blind holes in edge regions for further protection, and a heat-resistant base layer with reinforcement fibers
Implementation Method 4
The lubrication water simultaneously cools the mantle surface of the roll body and gives rise to a temperature gradient through the roll cover
Implementation Method 5
The same phenomenon occurs when the roll body is deliberately cooled with water
Data Source
Figure 1~2
AI summary
The invention relates to a roll for manufacture of paper, board, tissue or the like. The roll has a first end and a second end, and it comprises a cylindrical roll body with a hollow inner space and an outer mantle surface. The roll further comprises a roll cover comprising at least a base layer arranged on the outer mantle surface of the roll body, and an elastomer layer arranged on the base layer. The elastomer layer forms an outer surface of the roll cover. The first end and the second end of the roll have a protection region, where the base layer is uncovered by the elastomer layer and forms the outer surface of the roll. The invention relates also to an arrangement comprising such roll.