Recycled Composite Roll Covers for Durable Fibrous Web Production
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Solution Overview
Problem
Conventional roll covers in paper, board, and tissue manufacturing consume fossil-based materials, are energy-intensive to produce, and end up as waste, necessitating a shift towards sustainable and mechanically performant alternatives.
Innovation Solution
Roll covers incorporating a polymer matrix with recycled and bio-based materials, such as recycled glass and bio-based resins, maintain or exceed mechanical properties while reducing reliance on fossil fuels and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fossil-based materials are used to manufacture roll covers, then mechanical performance and durability are achieved, but environmental sustainability deteriorates and fossil resource dependency increases
Solution Approach 1:
The patent changes the material composition parameters by replacing fossil-based polymers with bio-based polymers and recycled materials. The roll cover comprises a polymer matrix (40-80 wt%) made from bio-based or recycled polymers, filler particles (10-40 wt%) from recycled glass or natural minerals, and reinforcing fibres (5-20 wt%) from recycled or natural sources. This parameter change achieves both sustainability and mechanical performance.
Solution Approach 2:
The patent creates a composite material system combining bio-based polymers, recycled glass particles, and natural or recycled fibres. This composite structure provides the necessary mechanical strength while reducing fossil-based material dependency. The synergistic combination of materials achieves both environmental sustainability and functional performance requirements.
2Object-affected harmful factors
If recycled materials are used in roll covers, then sustainability improves, but mechanical properties may deteriorate
Solution Approach 1:
The patent uses composite materials combining bio-based polymers with recycled glass particles and reinforcing fibres to maintain mechanical properties. The filler particles and fibres compensate for any strength deficiencies in recycled polymer matrices, ensuring the roll cover meets performance requirements while using 40-80 wt% recycled or bio-based materials.
Solution Approach 2:
The patent optimizes the composition parameters of recycled materials, specifically using 40-80 wt% polymer matrix from recycled or bio-based sources, 10-40 wt% filler particles, and 5-20 wt% reinforcing fibres. This parameter optimization ensures adequate mechanical performance while maximizing sustainability.
3Reliability
If traditional polymer coatings are applied to roll bodies, then functional performance is achieved, but material consumption and waste generation increase
Solution Approach 1:
The patent recovers and reuses recycled materials in the roll cover formulation. Filler particles from recycled glass and polymer matrices from recycled roll covers are incorporated into new roll covers, reducing material consumption. This closed-loop approach minimizes waste generation while maintaining functional performance through proper material selection and composition.
Data Source
AI summary
The invention relates to a roll for use in a manufacture of a fibrous web comprising cellulosic fibres. The roll comprises a roll body with a cylindrical surface, and a roll cover, which is arranged to cover the cylindrical surface of the roll body, the cover comprising a functional layer, which comprises a polymer matrix and filler particles and/or reinforcing fibres embedded in the polymer matrix. At least one functional layer constituent selected from filler particles, reinforcing fibres, and polymer matrix comprises material originating from recycled raw material(s).