EP1228870A1 - Beschichteter Zylinder mit Luftkanälen und Verfahren zum Beschichten eines Zylinders - Google Patents

Beschichteter Zylinder mit Luftkanälen und Verfahren zum Beschichten eines Zylinders Download PDF

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Publication number
EP1228870A1
EP1228870A1 EP01870020A EP01870020A EP1228870A1 EP 1228870 A1 EP1228870 A1 EP 1228870A1 EP 01870020 A EP01870020 A EP 01870020A EP 01870020 A EP01870020 A EP 01870020A EP 1228870 A1 EP1228870 A1 EP 1228870A1
Authority
EP
European Patent Office
Prior art keywords
roller
air
covering
covered
air channel
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP01870020A
Other languages
English (en)
French (fr)
Inventor
Paul Lucien Robert Verfaellie
Pascal Marcel Delmeiren
Marc Verbeke
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hannethane NV
Original Assignee
Hannethane NV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hannethane NV filed Critical Hannethane NV
Priority to EP01870020A priority Critical patent/EP1228870A1/de
Priority to PCT/EP2002/001151 priority patent/WO2002062580A1/en
Publication of EP1228870A1 publication Critical patent/EP1228870A1/de
Withdrawn legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41F—PRINTING MACHINES OR PRESSES
    • B41F27/00—Devices for attaching printing elements or formes to supports
    • B41F27/10—Devices for attaching printing elements or formes to supports for attaching non-deformable curved printing formes to forme cylinders
    • B41F27/105—Devices for attaching printing elements or formes to supports for attaching non-deformable curved printing formes to forme cylinders for attaching cylindrical printing formes

Definitions

  • the invention is related to rollers useful in all kinds of industries, such as transport, steel, textile, food processing, printing, etc.
  • rollers are designed to perform a continuous rotational movement.
  • the frictional forces acting upon the roll surface and other aging processes, such as wear, corrosion, etc. lead over a certain time lapse to a decrease in the diameter of the roll and to a deformation of the cylindrical shape.
  • the life span of the roll or the roll core can in general significantly be exceeded when said roll core is covered and/or recovered with a wear resistant covering material, such as rubber.
  • these rollers are in general provided with detachable functional sleeves which are co-axial rigidly mounted thereon.
  • the invention is related to a method for covering new or used rollers.
  • the invention is related to providing rollers able to co-axially airmount said functional sleeves.
  • Rollers are normally massive, made out of steel or another metal alloy and covered with an elastomer, such as a rubber or a polyurethane.
  • the covering has a specific function, i.e. a protection of the roller core. Due to for example corrosion and wear of the surface, it generally has a shorter life-span than the average life-span of the roller itself. This brings about the necessity of (re)covering. In general (re)covering consist of several time consuming steps.
  • the roller is dismantled at the customer premises and transported to a recoverer. After recovering according to the wishes of the customer, the roller is again transported to the customer and, after the wear of spared rollers, re-installed on a production line. The customer will generally grind the rollers himself in between the different recoverings, in view of attuning the covered surface correctly.
  • US 5,819,657 discloses a cylindrical spacer sleeve which is interposed between a printing sleeve and a printer roller.
  • Said spacer sleeve consists of a cylindrical inner concentric layer.
  • the interposition of said additional layer as a sleeve is a difficult operation in order to provide a precise and firm fitting in between the roller and the external printing sleeve, especially in working conditions.
  • Hollow rollers which are used in the flexographic printers described in US 5,706,731 can be able to act directly as an air supply. Airmounting of the sleeves is made possible due to perforations, which are provided directly in the material of the roller core, such that pressured air can flow from the inner part of the roller radially outwards.
  • These hollow rollers have however several drawbacks. They are not protected against an aggressive working environment, such as acids and have limitations in their diameter. Furthermore, most existing rollers are massive and can not be used as air supply means.
  • rollers which rollers may be new or may already previously be covered and used in recovering procedures, that would lower the cost and on the demand of the customer can provide for a suitable diameter.
  • the present invention pertains to a method for covering a roller having substantially a cylindrical outer surface and a longitudinal axis, with a covering material such as an elastomer e.g. rubber or polyurethane, comprising the steps of:
  • the method for covering a roller according to the invention consists of two main steps.
  • the thickness dimension of the concentric cover layer, covering the fastened air channels is chosen such that accommodation of the desired sizes of the functional sleeves to be airmounted thereon is made possible.
  • holes are provided, for example drilled through the cover layer connecting to the applied air channels. Preferably these air holes extend radially.
  • the applied air channels are provided with connecting means, able to be connected with a pressured air source. Pressured air is guided through the covering material via the embedded air channels and drilled holes towards the outer surface of the covered roller in order to facilitate the airmounting of sleeves.
  • the method of the invention provides several advantages. Airmounting becomes available for all kinds of rollers, used and new ones. Adjusting the amount of covering material makes a standardization of the applied measures possible. Old rollers can be re-used for airmounting.
  • the invention provides a complete protective cover for a roller, for example against aggressive environments, such as acid and base environments including a protective covering layer on both sides and (flanges and shoulder) of the roller.
  • the covering process of the invention contains several stages.
  • the roller can either be a newly manufactured or a used covered roller.
  • a newly manufactured roller may be cleaned and degreased before further processing.
  • the old covering will be removed, using e.g. a turning off lathe or sandbelt driven backstand device. If necessary shot-blasting or abrading the surface is performed, in order to give an adequate structure for bonding. Two specific embodiments will be described herunder.
  • a hollow cylindrical air pressure steel tube for example outer diameter 6mm, internal diameter 4 mm, thickness 1mm; DIN 2445/2 is welded onto the outer face of the core.
  • a primary tube is laid peripheral as a ring onto the roller near one of the flanges.
  • Another air tube is welded on the roll core and extends over the complete surface of the roller in the longitudinal direction. The distance or spacing of the said peripheral ring to the closest edge of the face of the roller is measured and memorized such that later after covering the drilling of holes in the air tubes is made possible.
  • a small part of the longitudinal air channel protrudes over the flange and is connectable to an air supply for airmounting sleeves. The position of the air channels is memorized.
  • additional tubes preferably radial dispersed over the outline of the surface and/or parallel to the longitudinal axes of the roller may be attached by welding.
  • one additional longitudinal air tube is provided, running up to approximately half of the length of the roller face. This air tube is preferably bent into an elbow configuration of approx. 90° and if necessary foreseen of a screw thread.
  • a hollow cylindrical air pressure steel tube for example outer diameter 6mm, internal diameter 4 mm, thickness 1mm, DIN 2445/2 is welded on the surface of the core.
  • a tube is welded peripheral and after one circular turn around the roller face - bent longitudinal to the axis of the roller and brought as such to the middle of the roller. Arriving at the middle of the roller face this air tube is bent into an elbow configuration of approx. 90° and if necessary foreseen of a screw thread.
  • a closing part with ball bearing inside, closed mechanically by a spring is fixed on this elbow edge.
  • the tube extends over the face of the roller in the longitudinal direction of the roller face, such that a small part protrudes. This part will later serve as the air inlet for pressured air.
  • the distance and position of said air channel is measured and memorized, such that drilling of the holes in the air tubes through the cover is possible.
  • rollers up to a length of 2500 mm and core a diameter of 350 mm one additional longitudinal air tube is applied extending up to approximately half of the length the roller face.
  • the method is able to calculate the number of air channels and to memorize their position.
  • the applied covering material is preferably a rubber.
  • the most preferred roller covering method according to the invention can be divided into six stages: metal or core preparation, rubber preparation, rubber application, vulcanization, finishing and inspection.
  • the covering may start with either a newly manufactured cylinder roll or a used and optionally covered roller. To ensure adequate adhesion of new rubber a chemically clean and prepared surface is needed. The following steps may be taken:
  • the rubber compound to be applied will have been formulated for its end use. It can contain as many as fifteen carefully weighed ingredients from the following material classes: base polymer or blend of polymers, reinforcing fillers, bulk fillers, plasticisers, processing acids, vulcanizing acids, anti-degradants, pigments.
  • the ingredients are mixed together in a controlled order on an open roll mill or in an internal mixer until an homogeneous compound is produced.
  • the compound is then sheeted off and tested to ensure quality. After being approved it moves on to the application stage, preferably in some cases this may involve further processing to produce physical forms suitable for the application to the core. These forms include a calendered sheet, a high quality sheet of even thickness, which is separated by fabric, plastic or coated paper liners and wound onto a mandrel and strips for strip building on the core or for feeding extruders for extruder covering
  • the standard process is a simple wrapping of calendered sheet around the core, taking great care to exclude air, until the required thickness is achieved.
  • the process can be carried out on a table, between centres, or on a purpose made building machine.
  • Extruders are more commonly used where large numbers of rollers are involved. This may be done using a cross-head machine which extrudes a tube of rubber directly onto the core, or alternatively by the application of an extruded strip onto a rotating core, building up of the required thickness by spiral wrapping.
  • a third approach is to extrude a tube and subsequently fit it to the core.
  • bandaging which may be fabric or plastic film, is normally applied as soon as possible after application to prevent flow or movement of the rubber prior to or during vulcanization.
  • the bandage may shrink and hence apply pressure to improve consolidation.
  • the vulcanization or curing process which is carried out by heat, effects a chemical change by cross-linking the polymer chains and in doing so it develops the full physical properties of the rubber. It is an irreversible reaction and cured rubber cannot be reprocessed within the factory.
  • the separate layers of rubber also consolidate together to form a homogeneous mass which is bounded to the core.
  • Steam is commonly used as the heating medium and vulcanizing vessels or autoclaves may have direct heating, where steam fills the vessels, or indirect heating where no steam contacts the rollers. The latter is used where independent control of pressure, necessary to restrict bubbles in the rubber, and temperature are required. Large rolls require the use of sophisticated control systems to cope with the stepped heating and curing cycles which are necessary to allow adequate heating up of the metal core and the uniform curing of the rubber.
  • Purpose made machines can be used to trim or grind the end faces flush with the core and produce a chamfer if required.
  • the face may be trimmed on a lathe or other cutting machine to within a few millimetres of the final diameter which is then ground to a finish.
  • a smooth finish may be required.
  • the finished roller is carefully cleaned and inspected against requirements for hardness, surface finish and dimensions.
  • the roller is finally wrapped and packaged to prevent damage in transit.
  • bonding agents such as tie coats or ebonite bonding is performed by brushing or spraying onto the metal core and air tubes. Once the pressured air tubing system is fixed to the metal roller, the covering material such as rubber or PU is applied.
  • the standard process used for rubber compounds is a simple wrapping of calendered sheets around the core and above the tubes. Great care is taken to press the calendered sheets to the core and tube surfaces in order to exclude air.
  • the required thickness depends on the internal diameter of the applied sleeve, which will be airmounted on the covered roller later on.
  • An oversize in diameter/thickness is applied in order to account for shrinkage during the vulcanization process, to allow for a grace zone for finishing and grinding to the required finishing diameter, and in order to grind a circular crib in the rubber compound at the outer edge of the roller face.
  • This crib will have a thickness equal to the thickness of the sleeve, mounted onto the rubber or PUR covered core later on.
  • Transfer or injection moulding of the cover compound around the core and tube may be applied as an alternative production process for rubber compound application extrusion.
  • bandaging such as fabric, cotton or plastic film is preferably applied as soon as possible after the application of the rubber compound, this in order to prevent flow or movement of the rubber prior to or during vulcanization.
  • the bandage may shrink and hence apply pressure to improve consolidation.
  • the vulcanization or curing process which is carried out by heat, affects a chemical change by cross-linking the polymer chains and in doing so it develops the full physical properties of the rubber. It is an irreversible reaction. During this process the separate layers consolidate to form a homogeneous mass, bonded on the core, with the air pressure tubes embedded in this mass.
  • the vulcanization process for caster PUR rollers is replaced by a curing process which takes place in electrical furnaces. After vulcanization the bandage, if applied, is removed from the roller. At the sides of the roller face the surplus material, if any, is cut off with a special knife on a turning lathe.
  • the air channels are in general complete embedded with covering material.
  • the air tube(s) parts crossing this cutting plane are, at one side of the roller, equally cut off at the same outer length.
  • a screw thread (M5) is again applied and, depending on the working environment of the roller, an inox or yellow brass plug is put onto the air tube, inserting an appropriate O-ring to seal the entirety.
  • the covered roller face is then preferably grinded and trimmed to the required finishing diameter. This is done on a precision grinding lathe, and to a precision of up to 0.02 mm in diameter and cylindricity.
  • the surface is usually made smooth using fine sandpaper.
  • a chamfer is formed by leaving on approximately 1mm of rubber or PUR. This chamfer will help to fixate the sleeve onto the covered core later on, using pressured air.
  • a number of generally 4 or more radially dispersed holes are drilled across the rubber or PUR covering into the air pressure tubes through the cover.
  • Several holes may also be drilled in the longitudinal extending air channel.
  • This set of holes will act as pressured air channels when airmounting or airdemounting a sleeve onto or off from the covered roller.
  • flanges and shoulders across the roller face are also covered with rubber compounds or PUR during the confectioning process. This allows protection of the entire roller body against infiltration of aggressive media, e.g. acids or bases, which could be present at the customer's normal working conditions.
  • aggressive media e.g. acids or bases
  • Pressured air upto 20 bar is supplied preferably via a reducer, preferably a needle valve and the inlet(s) of the air channels. Plugs screwed onto the air inlets of the air transport system embedded in the covered roller, are removed and replaced by an air supply connection piece, which is screwed herein. The pressured air is transported through the air tube system and is forced out again via the drilled holes.
  • the sleeve when pushing the sleeve over the covered metal core, the sleeve will push the ball bearing down onto the spring, allowing air to escape onto the roller face. This again produces a thin air film between covered roller face and sleeve, allowing to easily slide the sleeve over the total length of the core.
  • the sleeve shrinks slightly and fixes itself tightly around the covered core (principle of airmounting).
  • the sleeve itself may be covered with the final covering, such as rubber compound or PUR, which may be completely different from the compound applied onto the roller core, which cover is irrelevant for the understanding of the present invention.
  • the pressured air is supplied by a booster regulator, such as the type VBA 1110-F02GN.
  • the present invention is especially desired for used rollers, which are being recovered by applying the present method.
  • Figure 1 shows a roller 6 in cross-sectional view along a longitudinal axis 7.
  • Roller 6 consist essentially of a cylindrical body part 8 and two side flanges 9 forming a closed cylindrical housing through which a support axe 10 protrudes.
  • Several air channel tubes 4 are provided. These tubes are firmly attached e.g. welded on the cylindrical body part 8 of the roller 6.
  • the air channel tubes 4 can extend in the longitudinal direction such as the longitudinal air channel 15 and along the periphery such as the ring-shaped air channel 16.
  • Fig 2 is a cross section taken along II-II trhough the peripheral ring-shaped air channel 16.
  • a covering material 5 When a covering material 5 is applied (e.g. via curing or vulcanization of a rubber material) on the roller 6, it will embed and cover these air channels 4 (15 and 16), with the exception of a small part, which will constitute the air inlet 12.
  • the position of these covered tubes is memorized such that the blind drilling of holes is possible.
  • the thickness of the covering material layer 3, is chosen such that it is able to house in a sleeve 2.
  • a functional layer 1 is provided, for example a rubber lining etched with an image or a printing plate.
  • the choice of covering material is such that it will last in the process or working environment wherein it is used for a substantial time period.
  • the roller 6 is made out of steel or other metal alloys. When also the side flanges 9 are covered, the material of the roller 6 will be totally protected against corrosion and other wear.
  • a sleeve 2 on the metal support cylinder roller 6 pressured air is provided on the internal surface of said sleeve 2.
  • Said pressured air is delivered from a pump or a pressure booster via the air channels 4 and the holes 14, which act as air nozzles onto the inner surface of the sleeve 2. Due to the high pressure a small air film will result in a small increase of the diameter of the sleeve 2. This increase is only temporarily, during the mounting or the removal of said sleeve 2.
  • the outlet means for the pressured air are holes 14 which have been drilled through the covering material 5 communicating with the air supply channel 4. It is also possible to provide an open elbow part 11 protruding through the covering material 5. In general, a set of holes 14 is drilled in a radial direction once the polymer has been vulcanized or cured. Four radially extending holes 14 are provided in the peripheral ring shaped air channel 16.
  • the sleeve 2 When applying the method of the invention care needs to be taken in order to identify the place and position where air channels are attached underneath the covering material.
  • a plug 13 is provided on the air channel inlet 12. Pressured air needs only to be provided during a small time period when mounting or demounting is performed.
  • the peripheral air ring shaped channel 16 is provided in the first section. In first instance the sleeve 2 will pass through this peripheral air channel such that an extension of the diameter is provided on this position (airmounting will be in the direction from right to left in figure 1).

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  • Rolls And Other Rotary Bodies (AREA)
EP01870020A 2001-02-06 2001-02-06 Beschichteter Zylinder mit Luftkanälen und Verfahren zum Beschichten eines Zylinders Withdrawn EP1228870A1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP01870020A EP1228870A1 (de) 2001-02-06 2001-02-06 Beschichteter Zylinder mit Luftkanälen und Verfahren zum Beschichten eines Zylinders
PCT/EP2002/001151 WO2002062580A1 (en) 2001-02-06 2002-02-05 Covered rollers comprising air channels and method for covering a roller

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP01870020A EP1228870A1 (de) 2001-02-06 2001-02-06 Beschichteter Zylinder mit Luftkanälen und Verfahren zum Beschichten eines Zylinders

Publications (1)

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EP1228870A1 true EP1228870A1 (de) 2002-08-07

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EP01870020A Withdrawn EP1228870A1 (de) 2001-02-06 2001-02-06 Beschichteter Zylinder mit Luftkanälen und Verfahren zum Beschichten eines Zylinders

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EP (1) EP1228870A1 (de)
WO (1) WO2002062580A1 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005030488A1 (de) * 2003-09-25 2005-04-07 Inometa Technologie Gmbh & Co. Tragzylinder für eine austauschbare druckhülse

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0076777A1 (de) * 1981-09-30 1983-04-13 Herlitz AG Druckwalze
DE19918432A1 (de) * 1999-04-23 2000-10-26 Saueressig Gmbh & Co Dehnschicht aus kompressiblem Material

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2726786A1 (fr) 1994-11-14 1996-05-15 Francille Jean Agencement et manchon intercalaire porte-manchon mince notamment pour machine d'impression flexographique
US5819657A (en) 1996-03-11 1998-10-13 Ermino Rossini, Spa Air carrier spacer sleeve for a printing cylinder

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0076777A1 (de) * 1981-09-30 1983-04-13 Herlitz AG Druckwalze
DE19918432A1 (de) * 1999-04-23 2000-10-26 Saueressig Gmbh & Co Dehnschicht aus kompressiblem Material

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2005030488A1 (de) * 2003-09-25 2005-04-07 Inometa Technologie Gmbh & Co. Tragzylinder für eine austauschbare druckhülse
DE10344408B3 (de) * 2003-09-25 2005-05-12 Inometa Technologie Gmbh & Co. Tragzylinder für eine austauschbare Druckhülse

Also Published As

Publication number Publication date
WO2002062580A1 (en) 2002-08-15

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