CN108350658B - 用于造纸机的压光辊的聚氨酯辊包覆物 - Google Patents
用于造纸机的压光辊的聚氨酯辊包覆物 Download PDFInfo
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- CN108350658B CN108350658B CN201680048973.XA CN201680048973A CN108350658B CN 108350658 B CN108350658 B CN 108350658B CN 201680048973 A CN201680048973 A CN 201680048973A CN 108350658 B CN108350658 B CN 108350658B
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- layer
- calender roll
- polyurethane
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Abstract
用于造纸机的压光辊包括：实质圆柱形的芯；和圆周围绕芯的包覆物。所述包覆物包括：圆周覆盖芯的基底层；和包含圆周覆盖基底层的聚氨酯的顶部原料层，所述顶部原料层为纤维增强的，所述聚氨酯具有在约120和150℃之间的玻璃转化温度，所述顶部原料层具有70至90 ShD的硬度。
Description
相关申请
本申请要求2106年11月17日提交的美国临时专利申请号62/256,312的优先权和权益，其公开内容通过引用以其整体结合到本文中。
发明领域
本发明一般涉及用于工业辊的包覆物，且更特别地涉及用于工业辊的聚氨酯包覆物。
发明背景
在典型的造纸过程中，纤维素纤维(称为纸“原料(stock)”)的水浆料，或悬浮液被进料到在两个或更多个辊之间行进的编织丝线和/或合成材料的上运行(upper run)的环形带的顶部。带，通常称为"成形织物"，在其上运行的上表面上提供造纸表面，所述上表面作为滤器操作以将纸原料的纤维素纤维与水性介质分离，从而形成湿纸网格。水性介质通过成形织物的网开口(称为排放孔)，通过重力或位于织物的上运行的下表面上(即，“机器侧”)的真空排放。
在离开成形工段后，纸网格被转移到造纸机的压榨工段，在那里它通过用另一个织物(通常称为“压榨毛毯(press felt)”)覆盖的一个或多个压榨机(通常为辊压机)的夹。来自压榨机的压力从网格除去额外水分；水分除去通常通过压榨毛毯的“细毛毡”层的存在而增强。然后纸被转移到干燥器工段以进行进一步的水分除去。在干燥后，纸已准备用于二次加工(通常在造纸机的压光机工段)并包装。
圆柱形辊通常被用于造纸机的不同的工段。这样的辊处于苛刻的环境且在苛刻的环境中操作，其中它们可被暴露到高动态负载和温度和侵袭性或腐蚀性化学试剂。作为一个实例，在典型的造纸厂中，辊不仅用于将纤维网格片运输到加工台之间，而且还在压榨工段和压光辊的情况下，将网格片本身加工成纸。
通常，考虑用于造纸的辊构建在造纸机内的位置，因为需要位于造纸机内不同位置的辊来执行不同功能。由于造纸辊可具有许多不同的性能需求，并且由于替换整个金属辊可能是相当昂贵的，许多造纸辊包括围绕典型金属芯的圆周表面的聚合物包覆物。通过改变用于包覆物的材料，包覆物设计者可随着造纸应用要求提供具有不同的性能特征的辊。此外，修复、再次研磨或替换金属辊上的包覆物比替换整个金属辊可显著较不昂贵。用于包覆物的示例性聚合物材料包括天然橡胶、合成橡胶例如氯丁橡胶、苯乙烯-丁二烯(SBR)、丁腈橡胶、氯磺化聚乙烯("CSPE"--也从DuPont以商品名HYPALON®得知)、EDPM (对由乙烯-丙烯二烯单体形成的乙烯-丙烯三元共聚物给出的名称)、聚氨酯、热固性复合材料，和热塑性复合材料。
在许多情况下，辊包覆物将包括至少两个不同的层：覆盖芯并对其提供结合的基底层；和覆盖和结合到基底层并用作辊的外表面的顶部原料层(一些辊还将包括被基底和顶部原料层夹的中间“连接(tie-in)”层)。对于这些材料的层通常选择以提供具有用于操作的一组规定的物理性质的包覆物。这些可包括必要的强度、弹性模量，和对经受造纸环境的高温、水和严苛化学物质的抗性。此外，包覆物通常被设计具有预定的表面硬度，其适用于它们将执行的过程，并且它们通常需要纸片从包覆物"释放"，而不损害纸片。此外，为了经济性，包覆物应当是耐磨和耐磨损的。
通常用于位于造纸机的干燥器工段下游的压光机工段的压光辊，被用于将纸精修至所需的平滑度和光洁度。压光辊通常需要具有高弹性模量(即，刚度)、耐磨性、韧性、玻璃转化温度(Tg)和耐阻拦性(barring resistance)。用于压光辊包覆物的典型的化合物是环氧化物，考虑到其高模量和Tg，但这些化合物通常缺乏韧性。因此，用于压光机应用的备选材料可能是迫切需要的。
概述
作为第一方面，本发明的实施方案涉及一种用于造纸机的压光辊，其包括：实质圆柱形的芯；和圆周围绕芯的包覆物。所述包覆物包括：圆周覆盖芯的基底层；和包含圆周覆盖基底层的聚氨酯的顶部原料层，所述顶部原料层为纤维增强的，所述聚氨酯具有在约120和150℃之间的玻璃转化温度，所述顶部原料层具有70至90 ShD的硬度。
作为第二方面，本发明的实施方案涉及一种用于造纸机的压光辊，其包括：实质圆柱形的芯；和圆周围绕芯的包覆物。所述包覆物包括：圆周覆盖芯的基底层；和包含圆周覆盖基底层的聚氨酯的顶部原料层，所述顶部原料层为纤维增强的，所述聚氨酯具有约7和12%之间的失效应变，所述顶部原料层具有70至90 ShD的硬度。
作为第三方面，本发明的实施方案涉及一种用于造纸机的压光辊，其包括：实质圆柱形的芯；和圆周围绕芯的包覆物。所述包覆物包括：圆周覆盖芯的基底层；和包含圆周覆盖基底层的聚氨酯的顶部原料层，所述顶部原料层为纤维增强的，其中所述聚氨酯由包含异氰酸酯、催化剂和硬化剂的混合物制备，和其中包含约70和85%之间的重量%的异氰酸酯，和包含约10和20%之间的重量%的催化剂；所述聚氨酯具有在约120和150℃之间的玻璃转化温度和约7和12%之间的失效应变，所述顶部原料层具有70至90 ShD的硬度。
附图简述
图1是根据本发明的实施方案的工业辊的透视剖面图。
图2是图1的辊沿着其线2--2的显著放大的部分截面图。
本发明的实施方案的详细描述
本发明将在下文参考附图更具体地描述。本发明并不打算受限于说明性实施方案；而是打算使这些实施方案充分和完全地将本发明公开于本领域技术人员。在附图中，相同的数字自始至终指相同的要素。为了清晰起见，一些部件的厚度和尺寸可能被夸大。熟知的功能或构造为了简洁和/或清楚可能未详细描述。
此外，为了方便描述，空间相对术语，例如"在……之下"、"低于"、"较低"、"在……之上"、"上面"等可在此用于描述一个要素或特征相对于如附图中所例举的另一个要素或特征的关系。应当理解，除了附图中描述的取向外，空间相对术语还意欲涵盖在使用或操作中的装置的不同取向。例如，如果将附图中的装置翻过来看，则描述为在其它要素或特征"之下"或"下面"的要素将朝向在其它要素或特征的"上面"。因此，示例性术语"在…之下"可涵盖在上面和在下面两种取向。装置可能有另外的取向(旋转90度或在其它取向)，且相应解释此处所用的空间相对描述符。
除非另外限定，本文使用的全部技术和科学术语具有本发明所属领域普通技术人员通常理解的意义。本发明的说明书中所用的术语仅仅是为了描述具体实施方案的目的，并不意欲限制本发明。如在本发明的说明书和所附权利要求书中所用的，单数形式“一”、“一个”和“该”意欲还包括复数形式，除非上下文另外清楚地指明。如本文所用的，术语"和/或"包括一个或多个有关的所列项目的任何和所有的组合。当使用时，术语"附接"、"连接"、"互相连接"、“接触"、"偶联"、"安装"、"覆盖"等可意指要素之间的直接或间接附接或接触，除非另外说明。
如本文所用的术语"约"当指一个可测量的值，例如量或浓度时，涵盖特定的可测量值的变化以及特定值，并可涵盖± 10%、± 5%、± 1%、± 0.5%、± 0.1%等的变化。例如，"约X"在X是可测量的值时，意欲包括X以及X的变化，即可包括± 10%、± 5%、± 1%、±0.5%、± 0.1%等。对于可测量的值，本文提供的一个范围可包括其中的任何其它范围和/或各个值。
现在参考附图，压光辊(以10概括地指定)在图1和2中举例说明。辊10包括呈覆盖关系的芯12 (通常为金属)、粘合剂层14，和包覆物16。这些部件的每一个在本文下面更详细地讨论。
芯12是通常由钢、一些其它金属，或甚至复合材料形成的实质圆柱形的中空结构。芯12的长度通常是在约1.5和400英寸之间和直径在约1和70英寸之间，约100和400英寸之间的长度和约20和70英寸之间的直径对于造纸目的而言是常见的。在这些更常见的长度和直径范围，芯12通常具有在约1和5英寸之间的壁厚。部件例如轴颈和轴承(未示出)通常包括在芯12上，以有利于其在造纸机上的安装和旋转。芯12的表面可通过喷丸(blasting)、砂磨、喷砂等处理以制备用于结合到粘合剂层14的表面。
再次参考图1和2，粘合剂层14包含可将芯12附接到包覆物16的粘合剂(通常为环氧化物粘合剂)。当然，包含粘合剂层14的粘合剂应当选择与芯12和包覆物16的基底层18的材料相容(即，它应提供这些结构之间的高度完整性结合，而对任何一种材料没有过度的损害)；优选地，结合具有在约1,200和5,000 psi之间的拉伸结合强度。粘合剂可具有添加剂，例如固化剂，其有利于固化和物理性质。示例性粘合剂包括Chemlok 220X和Chemlok 205，其为从Lord Corporation, Raleigh, North Carolina购得的环氧化物粘合剂。
粘合剂层14可以按已知适合于本领域技术人员的用于施加薄层材料的任何方式施加到芯12。示例性施加技术包括喷雾、刷涂、浸渍、刮涂等。如果使用溶剂基粘合剂，优选施加粘合剂层14使得溶剂可在施加包覆物16之前蒸发，以减少在固化过程期间可造成“吹气(blows)”的捕获溶剂的出现。本领域技术人员将了解到，粘合剂层14可包括粘合剂的多个涂层，其可包括不同的粘合剂；例如，可采用性质稍有不同的两种不同的环氧化物粘合剂。还应当注意到，在一些实施方案中，粘合剂层可完全省略，使得包覆物16被直接结合到芯12。
仍参考图1和2，包覆物16包含呈覆盖关系的基底层18和顶部原料层22。在说明性实施方案中，基底层18粘附到粘合剂层14。基底层18包含通常包含填料和其它添加剂的聚合物化合物(通常为基于热固性的复合材料，例如环氧化物)。
填料通常被加入到基底层18中以改变聚合物化合物的物理性质和/或降低其成本。示例性填料材料包括，但不限于，无机氧化物例如氧化铝(Al2O3)、二氧化硅(SiO2)、氧化镁(MgO)、氧化钙(CaO)、氧化锌(ZnO)和二氧化钛(TiO2)；炭黑(也称为炉黑)；硅酸盐例如粘土、滑石粉、钙硅石(CaSiO3)、硅酸镁(MgSiO3)、无水硅酸铝，和长石(KAlSi3O8)；硫酸盐例如硫酸钡和硫酸钙；金属粉末例如铝、铁、铜、不锈钢，和碳酸镍例如碳酸钙(CaCo3)和碳酸镁(MgCo3)；云母；二氧化硅(天然的、煅制的、水合的、无水的或沉淀的)；和氮化物和碳化物，例如碳化硅(SiC)和氮化铝(AlN)。这些填料可在实质上以任何形式，例如粉末、丸料、纤维或球体存在。
此外，基底层18可任选地包含其它添加剂，例如聚合引发剂、活化剂和加速剂、固化或硫化剂、增塑剂、热稳定剂、抗氧化剂和抗臭氧剂、偶联剂、颜料等，其可有利于加工和增强物理性质。这些组分在将基底层18施加到粘合剂层14或直接施加到芯12的时间之前一般被化合为聚合物。本领域技术人员将了解到，这些试剂的特性和量及其在基底层中的用途一般是已知的且不必在此详细描述。
基底层18可通过本领域技术人员已知的适合将聚合物施加到下面表面的任何方式施加。基底层18的厚度通常是在约0.0625英寸和约1英寸之间，在一些实施方案中是在约0.1英寸和约0.5英寸之间，并且在进一步的实施方案中是在约0.1英寸和约0.25英寸之间。本领域技术人员将了解到，在一些实施方案中，基底层18可省略使得顶部原料层22直接粘附到粘合剂层14，或在粘合剂层的不存在下直接粘附到芯12。
再次参考图1和2，在说明性实施方案中，顶部原料层22圆周覆盖并(除非包含一个或多个如下所述的连接层)粘附到基底层18。顶部原料层22包含具有高Tg并用纤维增强的聚氨酯化合物，如下文更详细描述。
顶部原料层22的聚氨酯化合物通常由异氰酸酯(例如亚甲基二苯基二异氰酸酯(MDI))、多元醇催化剂(例如聚四亚甲基醚二醇)，和硬化剂(例如4,4'-亚甲基双(3-氯-2,6-二乙基苯胺))形成和制备。在一些实施方案中，异氰酸酯的重量%是在约70和85%之间，催化剂的重量%是在约10和20%之间，和硬化剂的重量%是在约2和10%之间。在一个实施方案中，聚氨酯在模制为纯树脂时，包含具有在表1中所列的性质的化合物。
示例性聚氨酯化合物是EXP 393/394/395，由Huntsman Polyurethanes (TheWoodlands, Texas)提供。该化合物具有大约80/15/5%重量的异氰酸酯/催化剂/硬化剂比率。该化合物的物理性质列于下表2中。
顶部原料层22的聚氨酯化合物通常用增强纤维增强。增强纤维可以是玻璃纤维、碳纤维、聚酯、尼龙、芳族聚酰胺，或这些材料的组合。增强纤维可呈现为多种形式，包括细丝或带，并可以是编织或无纺的。
通常顶部原料层22包括填料和其它添加剂。示例性填料包括，但不限于，粘土和其它无机填料例如二氧化硅、炭黑、粘土，和二氧化钛(TiO2)以及上文结合基底层18阐述的其它物质。其它示例性填料包括碳纤维、碳纳米管、石墨烯和金属氧化物或碳化物。通常，填料以约3和70%重量之间的顶部原料层22的量包括。填料可实质上采用任何形式，包括粉末、丸料、珠、纤维、球体、颗粒、纳米颗粒等。可包含填料以增强诸如耐磨性、热膨胀系数、导热性、导电性和介电常数的性质。在一个实施方案中，填料例如粘土可以30和60份/百份聚氨酯之间的重量%加入。
示例性添加剂包括，但不限于，聚合引发剂、活化剂和加速剂、固化或硫化剂、增塑剂、热稳定剂、抗氧化剂、偶联剂、颜料等，其可有利于加工和增强物理性质。本领域技术人员应当理解，添加剂的类型和浓度适用于包含在顶部原料层22内，所以这些不需要在此详细讨论。
对于顶部原料层22的一个示例性制剂可包含在表3中所列的组分。
顶部原料层22可通过本领域技术人员已知的适合将弹性体材料施加到圆柱形表面上的任何技术施加到基底层18上，包括铸造、挤压、浸渍盘(dip pan)、树脂传递模制(RTM)、真空辅助树脂传递模制(VARTM)、反应注射成型(RIM)、真空灌注和拉挤成型。
在一些实施方案中，施加顶部原料层22以使其厚度是在约0.25英寸和约2.5英寸之间(在更高的厚度下，可能需要多遍材料)。在一些实施方案中，顶部原料层22具有在约0.5英寸和约1.5英寸之间的厚度和在一些实施方案中在约1英寸和约1.5英寸之间的厚度。顶部原料层22的厚度在约50和90%之间的总包覆物厚度(即，合并的基底和顶部原料层18、22的总厚度)也是合适的。
基底层18和顶部原料22的化合物可被选择以使基底层18具有比顶部原料层22更高的硬度值。作为实例，基底层18可具有约80和95 ShD之间的硬度(在一些实施方案中，在约80和90 ShD之间，而在其它实施方案中，在约80和85 ShD之间)，和顶部原料层22可具有在约70和90 ShD之间(在一些实施方案中在约75和85 ShD之间)的硬度。渐变的硬度概念可减少由于在包覆物构造中的各种层的弹性性质(例如弹性模量和泊松比)的失配而可能发生的结合线剪切应力。这种界面剪切应力的减少在维持包覆物完整性方面可能是重要的。
本领域技术人员也将了解到辊10可用夹在基底层18和顶部原料层22之间的连接层来构建，使得连接层将直接位于顶部原料层22下面。连接层的典型性质对本领域技术人员而言是熟知的并不需要在此详细描述。
上述聚氨酯化合物在顶部原料层22中的用途可提供许多优点。聚氨酯化合物可提供比通常采用的环氧化物化合物更大的韧性和/或损伤容限。固化时间与环氧化物比较有所减少。聚氨酯的树脂粘度通常比环氧化物的粘度更低，其可有助于填料分散并能使更高的填料装载成为可能并可改进加工一致性和速度。
上述是本发明的示例说明并不视为对其的限制。虽然本发明的示例性实施方案已得到描述，本领域技术人员将容易地了解到在示例性实施方案中，许多修改在实质上不背离本发明的新的教导和优点下是可能的。因此，所有这样的修改均意欲包括在如在权利要求书中限定的本发明的范围内。本发明通过以下的权利要求书，及包括在其中的权利要求书的等价物限定。
Claims (11)
1.一种用于造纸机的压光辊，其包括：
圆柱形的芯；和
圆周围绕所述芯的包覆物，所述包覆物包括：
圆周覆盖所述芯的基底层；和
包含圆周覆盖所述基底层的聚氨酯的顶部原料层，所述顶部原料层为纤维增强的，所述聚氨酯具有在120℃和150℃之间的玻璃转化温度，所述顶部原料层具有70 ShD至90 ShD的硬度；
其中所述聚氨酯由包含异氰酸酯、催化剂和硬化剂的混合物制备；并且
其中包含70%和85%之间的重量%的异氰酸酯，和包含10%和20%之间的重量%的催化剂。
2.根据权利要求1所述的压光辊，其中所述聚氨酯具有至少7%的失效应变。
3.根据权利要求1所述的压光辊，其中所述异氰酸酯包括MDI。
4.根据权利要求1所述的压光辊，其中所述顶部原料层用选自以下的纤维增强：玻璃、碳、聚酯、尼龙、芳族聚酰胺，及其组合。
5.根据权利要求4所述的压光辊，其中所述纤维包括细丝或带。
6.根据权利要求1所述的压光辊，其中所述压光辊被安装在压光机工段中。
7.根据权利要求1所述的压光辊，其中所述聚氨酯具有在7%和12%之间的失效应变。
8.根据权利要求7所述的压光辊，其中所述异氰酸酯包括MDI。
9.根据权利要求7所述的压光辊，其中所述顶部原料层用选自以下的纤维增强：玻璃、碳、聚酯、尼龙、芳族聚酰胺，及其组合。
10.根据权利要求9所述的压光辊，其中所述纤维包括细丝或带。
11.根据权利要求7所述的压光辊，其中所述压光辊被安装在压光机工段中。
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| DE102016201344A1 (de) * | 2016-01-29 | 2017-08-03 | Voith Patent Gmbh | Pressmantel und Verfahren zur Herstellung eines solchen |
| US10695073B2 (en) * | 2017-08-22 | 2020-06-30 | Arthrex, Inc. | Control system for retrograde drill medical device |
| JP2022189050A (ja) * | 2021-06-10 | 2022-12-22 | ヤマウチ株式会社 | カレンダー用ロール被覆材およびカレンダー用ロール |
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| JPS55135629A (en) * | 1979-04-09 | 1980-10-22 | Fuji Photo Film Co Ltd | Supercalender |
| JPS5936133B2 (ja) * | 1979-08-10 | 1984-09-01 | 山内ゴム工業株式会社 | ポリウレタン・ゴム・ロ−ル及びその製造方法 |
| JPS6173190A (ja) | 1984-09-19 | 1986-04-15 | 横河電機株式会社 | カ−ソル表示装置 |
| DE3751815T2 (de) * | 1987-06-10 | 1997-01-23 | Kinyosha Kk | Harzhaltige kalanderwalze |
| JP2791628B2 (ja) * | 1993-06-28 | 1998-08-27 | 株式会社金陽社 | カレンダー仕上方法 |
| US5895806A (en) * | 1996-05-06 | 1999-04-20 | Uniroyal Chemical Company, Inc. | Polyurethane composition useful for coating cylindrical parts |
| US6409645B1 (en) * | 1997-06-13 | 2002-06-25 | Sw Paper Inc. | Roll cover |
| US6375602B1 (en) * | 1998-07-23 | 2002-04-23 | Sw Paper Inc. | Supercalendar roll with composite cover |
| AU2002367127B2 (en) * | 2001-12-26 | 2007-02-15 | Yamauchi Corporation | Fiber-reinforced resin roll and method of manufacturing the roll |
| US10287731B2 (en) * | 2005-11-08 | 2019-05-14 | Stowe Woodward Licensco Llc | Abrasion-resistant rubber roll cover with polyurethane coating |
| FI20070244A0 (fi) * | 2007-03-23 | 2007-03-23 | Metso Paper Inc | Tela |
| DE102007042781A1 (de) * | 2007-09-07 | 2009-03-12 | Voith Patent Gmbh | PU-Walze |
| WO2010003460A1 (en) * | 2008-07-10 | 2010-01-14 | Metso Paper, Inc. | A roll for a fiber web machine and a method for manufacturing the roll |
| US20100019062A1 (en) * | 2008-07-23 | 2010-01-28 | Root-Lowell Manufacturing Company | Tank sprayer with separate concentrate container |
| JP4616408B1 (ja) * | 2010-02-19 | 2011-01-19 | イチカワ株式会社 | 抄紙用プロセスベルト |
| FI20115400A (fi) * | 2011-04-26 | 2012-10-27 | Metso Paper Inc | Telapinnoite ja menetelmä sen valmistamiseksi |
| US9280486B2 (en) * | 2011-07-28 | 2016-03-08 | Red Hat, Inc. | Managing memory pages based on free page hints |
| DE102012205206A1 (de) * | 2012-03-30 | 2013-10-02 | Voith Patent Gmbh | Walzenbezug |
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| CN104652170A (zh) * | 2015-02-12 | 2015-05-27 | 滕州力华米泰克斯胶辊有限公司 | 低聚热高耐磨施胶辊加工工艺及产品 |
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| AU2016357211B2 (en) | 2019-10-03 |
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| WO2017087152A1 (en) | 2017-05-26 |
| AU2016357211A1 (en) | 2018-02-22 |
| US20170137998A1 (en) | 2017-05-18 |
| MX2018002285A (es) | 2018-05-28 |
| EP3377697A1 (en) | 2018-09-26 |
| CN108350658A (zh) | 2018-07-31 |
| JP6726277B2 (ja) | 2020-07-22 |
| CA2995504C (en) | 2020-01-14 |
| CA2995504A1 (en) | 2017-05-26 |
| US20170137997A1 (en) | 2017-05-18 |
| EP3377697A4 (en) | 2019-05-15 |
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