In-Situ Thermal Restoration of Nip Roll Polymer Coatings
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Solution Overview
Problem
The deformation of nip roll polymer coatings due to pressure causes vibration, leading to fluctuation of nip force and reduced end-product quality, necessitating costly and disruptive maintenance that involves disassembly and replacement, which is inefficient and costly.
Innovation Solution
A thermal treatment apparatus and method that applies heat in situ to restore the shape of the deformed viscoelastic or rubber coatings on nip rolls, using a heater and sensors to control temperature and deformation, allowing maintenance during short breaks without disassembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional maintenance methods (grinding, replacement) are used to restore nip roll coating, then coating deformation is corrected, but production is disrupted for long periods and high costs are incurred
Solution Approach 1:
The patent replaces mechanical maintenance methods (grinding, sanding, replacement) with a thermal treatment system that uses heated air to restore the coating shape. The system directs heated air onto the deformed coating surface, causing thermal expansion and shape restoration without mechanical contact, thereby eliminating the need for lengthy disassembly and replacement operations
Solution Approach 2:
The thermal treatment system enables the coating to restore its own shape through thermal energy application. The deformed viscoelastic coating undergoes thermal relaxation and returns to its original configuration when exposed to controlled heated air, allowing the coating to self-correct without external mechanical intervention
2Ease of repair
If nip rolls are disassembled and transported for maintenance, then coating can be ground or replaced, but maintenance costs and production disruption increase significantly
Solution Approach 1:
The patent introduces heated air as an intermediary medium to transfer thermal energy to the coating for shape restoration. The thermal treatment system acts as an intermediary between the energy source and the coating, enabling remote, in-situ treatment without requiring physical contact or disassembly of the nip roll
Solution Approach 2:
The thermal treatment system provides a universal maintenance solution that can restore various types of deformed coatings (viscoelastic, rubber) without requiring different equipment for each coating type or condition. The same thermal treatment apparatus can handle different nip roll sizes and coating materials, reducing the need for specialized maintenance equipment
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
Enables cost-effective and efficient maintenance by restoring the coating shape in situ, reducing production disruptions and maintenance costs by performing thermal treatment during machine operation breaks.
Implementation Method 1
heating the thermally shape-restoring coating with a heater of a thermal treatment device to cause relaxation of the thermally shape-restoring coating to restore its shape
Implementation Method 2
a non-contact temperature sensor for measuring temperature of the thermally shape-restoring coating
Data Source
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AI summary
The present invention relates to apparatuses and methods of thermal treatment for heat treating a deformed thermally shape-restoring coating, such as any of a viscoelastic polymer coating and rubber, of a nip roll in situ, without disassembling the nip roll. The thermal treatment apparatus is placed in vicinity of the nip roll. A thermal treatment device of the thermal heating apparatus comprises a heater for heating the thermally shape-restoring coating of the nip roll, a non-contact temperature sensor for measuring temperature of the thermally shape-restoring coating, and at least one processing means configured to control operation of the heater on basis of the measured temperature of the thermally shape-restoring coating. Nip of the nip roll is disengaged prior to applying heat treatment.