EP2644773B1 - Roll cover - Google Patents

Roll cover Download PDF

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Publication number
EP2644773B1
EP2644773B1 EP13160419.1A EP13160419A EP2644773B1 EP 2644773 B1 EP2644773 B1 EP 2644773B1 EP 13160419 A EP13160419 A EP 13160419A EP 2644773 B1 EP2644773 B1 EP 2644773B1
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EP
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Prior art keywords
roll cover
cover according
roll
filler
fillers
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EP13160419.1A
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German (de)
French (fr)
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EP2644773A1 (en
Inventor
Thomas Breineder
Stefan Pollaschek
Franz Dr. Grohmann
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Voith Patent GmbH
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Voith Patent GmbH
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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21G—CALENDERS; ACCESSORIES FOR PAPER-MAKING MACHINES
    • D21G1/00—Calenders; Smoothing apparatus
    • D21G1/02—Rolls; Their bearings
    • D21G1/0233—Soft rolls
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F3/00—Press section of machines for making continuous webs of paper
    • D21F3/02—Wet presses
    • D21F3/08—Pressure rolls

Definitions

  • the invention relates to a roll cover, in particular for use in calenders and calenders, according to the preamble of claim 1.
  • WO 2011/015408 A1 describes a device comprising a roll cover with the features of the preamble of claim 1.
  • the proportions of fillers used are always a compromise between the various demands on the roll cover. To achieve the highest possible abrasion resistance and the desired high pressure module, the highest possible degree of filling is desirable.
  • an increasing filler content leads, starting from certain limits, to an increasing embrittlement of the material and thus an increasing risk of massive damage in case of selective overloading or occurring thermal stresses.
  • the roll cover after an intake phase has an equilibrium surface roughness less than 0.25 microns Ra.
  • the surface roughness in use is less than 15 microns Ra, so that the gloss and smoothness of the final product can be improved.
  • a first filler may have an average particle size in the range from 1 to 100 nm, preferably from 10 to 30 nm. As a result, a high crack resistance and an increase of the pressure module are achieved.
  • a second filler may have a mean grain size in the range of 50 to 2000 nm, preferably 100 to 300 nm, and advantageously performs a bridging function between large and small fillers. It reduces the erosion of the resin matrix on the free surface between the large fillers.
  • a third filler may have a mean grain size in the range of 0.5 to 7 microns, preferably from 1 to 4 microns and thus cause a further increase in the pressure modulus and an increase in the abrasion resistance.
  • the grain size distributions of the at least three fillers may be selected to be overlapping or non-overlapping.
  • the property profile of the roll cover can be further influenced.
  • At least two of the fillers, in particular three of the fillers, can be chemically identical.
  • the at least three fillers may be different.
  • suitable fillers which are commercially available in the respective particle sizes required, and it is possible to use different properties (for example high hardness or good matrix connection) and morphologies (for example spherical particles with high abrasion resistance to achieve the same in operation resulting surface roughness or rod-shaped or fibrous fillers for structural reinforcement) can be used to optimize the overall system.
  • At least one of the fillers may be selected from: oxides, carbides, nitrides, aluminum silicates, silicates of mineral or synthetic origin.
  • the first filler may further be selected from: sulphates, carbonates, phosphates, titanates, carbonanotubes, carbonanofibres, metals or mixtures thereof.
  • the fillers in particular the first filler, can be surface-modified, which allows a better attachment to the resin matrix.
  • the content of fillers in the matrix system may be between 0.5 and 30% by volume. This value represents a good middle ground for the maximum achievable smoothness at the required elasticity.
  • the content of the first filler is 2 to 25% by volume, preferably 5 to 20% by volume, while the content of the second filler is 0.5 to 5% by volume, preferably 0.5 to 3% by volume and the content of the third filler 0.5 to 10% by volume , preferably 2 to 7 percent by volume.
  • the matrix system may preferably be a duroplastic, in particular an amine or anhydride crosslinked or a self-crosslinking epoxy resin or an isocyanate ester or mixtures thereof.
  • a duroplastic in particular an amine or anhydride crosslinked or a self-crosslinking epoxy resin or an isocyanate ester or mixtures thereof.
  • Such resin systems are commercially available in a wide range and can be selected according to requirements.
  • Calenders or calenders for fibrous webs such as paper or board webs have the task of smoothing the fibrous web either directly after its production (online) or even later (offline). By this task are on the roll covers of existing in a calender rolls highest requirements on the one hand in terms of their surface quality and on the other hand in terms of their resistance to thermal and mechanical loads.
  • a plurality of rolls are arranged in a stack in a stack, wherein according to a common embodiment, a metallic heatable roll runs against an unheated elastic roll to form a nip.
  • a first side of the fibrous web is smoothed by pressure and heat in several successive nips.
  • a so-called alternating tip is usually provided approximately in the middle of the stack, after which the other side of the fibrous web comes into contact with the smoothing heating rollers. From this constellation arises immediately the need to make the roll surface of the unheated elastic rolls in the second part of the stack as smooth as possible, so that the previously achieved smoothness of the fibrous web is not nullified.
  • the roll covers of the unheated rolls usually consist of at least one, often also of several layers of various materials such as rubber, polyurethane or fiber-reinforced plastics, which are applied to a roll body.
  • Fiber-reinforced plastics are usually the material of choice for use in the calender since they have a high temperature resistance as well as a high mechanical strength and a high surface smoothness.
  • Such plastics usually have a matrix system of a resin and embedded fiber reinforcement of glass, carbon or aramid fibers or similar other suitable fibers as a reinforcement.
  • the production of such roll covers is well known, so that only a brief summary is given here.
  • the preparation can be carried out according to various known methods. On the one hand, it is possible to wrap the fibers dry and apply the matrix by a casting process. Another common method provides that fiber bundles, For example, so-called rovings, pulled by a resin bath containing the resin matrix, and then wet are wound on the roll body. Injection molding methods, in which the matrix material is applied by axially movable nozzles on a rotating roller body, are known and suitable for producing a roll cover according to the invention.
  • the structure can take place in one or more layers, and it is also possible to provide further layers, such as, for example, a base layer, which serves for the bonding between roll core and roll cover, and additional bonding layers.
  • a base layer which serves for the bonding between roll core and roll cover
  • additional bonding layers such as, for example, a base layer, which serves for the bonding between roll core and roll cover, and additional bonding layers.
  • the measures according to the invention relate to a functional layer of the roll cover, which comes into contact with the fibrous web.
  • Suitable matrix systems include amine, anhydride crosslinked but also self-crosslinking epoxy resins, isocyanate esters or other thermosets or mixtures thereof.
  • the invention thus provides for introducing at least one further filler into the resin matrix and at the same time significantly reducing the surface roughness during operation.
  • a hereinafter referred to as a first filler component having a particle size in the range between 1 to 100 nanometers takes over an effect as a crack stopper and causes an associated increase in mechanical strength and an increase in the pressure module.
  • the prerequisite for this is a good integration with the matrix and a uniform distribution of the particles in the matrix. Due to the increased pressure modulus, the substantially pressure-induced wear mechanism of a calender results in a significant later onset of heavy wear, since the deformation and thus the occurring stresses are reduced.
  • a component referred to hereinafter as the third filler which is also referred to as "large" hard materials, has an average grain size in the single-digit micrometer range, increases primarily the resistance to abrasive wear and leads to a further increase in the pressure modulus.
  • this third filler is to be kept in the lowest possible degree of filling, since a high proportion of coarse fillers affects the smoothness of the roll cover.
  • the degree of filling should be set here so that an R a value of less than 0.25 ⁇ m or, in the case of particularly high requirements of less than 0.15 ⁇ m, can be achieved.
  • a component which is referred to as a second filler and medium sized grain sizes of the order of 0.05 to 2 microns.
  • the second filler fulfills a bridging function between the other two fillers and, inter alia, reduces matrix erosion by means of indented particles originating from the fibrous web or the coating medium between the "large" hard materials.
  • Table 1 shows a summary of the mean particle sizes and the possible particle size distributions of the fillers and the respective degree of filling.
  • Table 1 First filler Second filler Third filler Nanoscale fillers Sub-micrometer-scale fillers Micrometer-scale fillers Volumes in the epoxy matrix 2 - 25% 0,5 - 5% 0,5 - 10% Preferred Vol.% 5 - 20% 0,5 - 3% 2 - 7% Average grain size 1 - 100 nm 50-2000 nm 0.5 - 7 ⁇ m Preferred average grain size 10 - 30nm 100-300 nm 1 - 4 ⁇ m
  • the materials for the third filler preferably originate from a first group comprising oxides, carbides, nitrides, aluminum silicates, silicates of mineral or synthetic origin or glasspheres or mixtures thereof.
  • Suitable materials for the first filler are the materials from the first group, but also from a second group comprising sulfates, carbonates, phosphates, titanates, Carbonanotubes, Carbonanofibres or metals or mixtures thereof in question.
  • the choice of material of the second filler can be made from two groups.
  • second and third fillers are selected from the same group, more preferably from the first group.
  • the first filler can be used with or without surface modification, eg with poly L-lactide coated SiO 2 for better attachment to the matrix.
  • the optimum composition depends both on the specific selected fillers, their mean grain sizes and morphology as well as on the desired hardness or the desired pressure modulus and the lowest possible surface roughness in operation.
  • the proportion of the first Filler over the other two fillers increased or the proportion of third filler very low. This makes it possible to optimize the surface quality of the roll cover and thus the gloss and smoothness results for the fibrous web.
  • the abrasion resistance is somewhat lower, so that grinding intervals may possibly be shorter.
  • the surface roughness should preferably be less than 0.25 ⁇ m Ra, more preferably less than 0.15 ⁇ m Ra.
  • the values are given on the surface roughness during operation, ie after a running-in phase of the roller in the respective position. After a preliminary grinding after obtaining the roller, this first passes through a certain run-in phase after its installation, which can be from a few minutes to about 24 hours. In this time, a balance in the surface roughness sets. How long the running-in phase lasts and how long the roller then runs with this approximately constant surface roughness depends i.a. from the installation position and the material of the roll cover. The equilibrium phase can be several months.
  • the three fillers can be selected from a wide range of suitable commercially available components in the particular grain sizes required. Through the selection specifically different properties, such as a high hardness or a good matrix connection can be emphasized.
  • the morphologies of the three fillers can also be chosen from a wide range.
  • spherical particles such as glass spheres with high abrasion resistance to achieve high hardness at low operating surface roughness resulting useful and feasible.
  • Rod-shaped or fibrous fillers such as carbonanotubes can be used for structural reinforcement and for optimizing the overall system.
  • the three fillers may preferably be distributed as homogeneously as possible in one layer. However, it is also possible by appropriate modification of the above order process to achieve gradients within the layer or targeted incremental changes.

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  • Paper (AREA)
  • Rolls And Other Rotary Bodies (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Description

Die Erfindung geht aus von einem Walzenbezug, insbesondere zur Verwendung in Glättwerken und Kalandern, nach dem Oberbegriff des Anspruchs 1.The invention relates to a roll cover, in particular for use in calenders and calenders, according to the preamble of claim 1.

Die Verwendung von faserverstärkten und gefüllten Epoxydharzen für Kalanderbezüge und andere abriebsbeständige Walzenbezüge zur Anwendung in der Papierindustrie und ähnlichen Anwendungen ist bereits seit längerem Stand der Technik.The use of fiber reinforced and filled epoxy resins for calender covers and other abrasion resistant roll covers for use in the paper industry and similar applications has long been prior art.

Beispielsweise ist aus der Patentschrift EP 1 612 329 B1 bekannt, durch die Verwendung von Nanopartikeln auch in Kombination mit größeren Partikeln bestimmte Eigenschaften des Walzenbezuges wie die Abriebsbeständigkeit und das Druckmodul (beispielsweise bestimmt nach EN ISO 604:2003 Pkt. 3.6) an die jeweiligen Anforderungen in der gewählten Walzenposition anzupassen und zu modellieren.For example, from the patent EP 1 612 329 B1 It is known that by using nanoparticles, in combination with larger particles, certain characteristics of the roll cover, such as the abrasion resistance and the printing modulus (for example, determined according to EN ISO 604: 2003 Point 3.6), can be adapted and modeled to the respective requirements in the selected roll position.

WO 2011/015408 A1 beschreibt eine Vorrichtung umfassend einen Walzenbezug mit den Merkmalen des Oberbegriffs des Anspruchs 1. WO 2011/015408 A1 describes a device comprising a roll cover with the features of the preamble of claim 1.

Die verwendeten Anteile an Füllstoffen sind immer ein Kompromiss zwischen den verschiedenen Anforderungen an den Walzenbezug. Zum Erreichen einer möglichst hohen Abriebsbeständigkeit und des gewünschten hohen Druckmoduls ist ein möglichst hoher Füllgrad wünschenswert.The proportions of fillers used are always a compromise between the various demands on the roll cover. To achieve the highest possible abrasion resistance and the desired high pressure module, the highest possible degree of filling is desirable.

Durch die sich im Gebrauch einstellende Oberflächenrauhigkeit ist jedoch insbesondere die Menge an harten, abriebsbeständigen Füllstoffen in einer Korngröße > 0,5 µm begrenzt, da sonst eine zu raue Oberfläche entsteht, die die gewünschte Glättung des Papiers negativ beeinflusst.However, the surface roughness which is obtained in use limits in particular the amount of hard, abrasion-resistant fillers in a grain size of> 0.5 μm, since otherwise a surface which is too rough and has a negative effect on the desired smoothing of the paper is formed.

Dies ist insbesondere bei Anwendungen, die besonders hohe Anforderungen an Glanz und/oder Glätte des Papiers stellen, ein limitierender Faktor.This is a limiting factor in particular in applications which place particularly high demands on the gloss and / or smoothness of the paper.

Des Weiteren führt ein steigender Füllstoffgehalt ab gewissen Grenzen zu einer zunehmenden Versprödung des Materials und damit steigendem Risiko massiver Beschädigungen bei punktueller Überlastung oder bei auftretenden thermischen Spannungen.Furthermore, an increasing filler content leads, starting from certain limits, to an increasing embrittlement of the material and thus an increasing risk of massive damage in case of selective overloading or occurring thermal stresses.

Es ist dementsprechend Aufgabe der Erfindung, die bekannten Nachteile des Standes der Technik zu beheben und einen Walzenbezug anzugeben, der sowohl einen hohen Druckmodul als auch gute Abriebsbeständigkeit bei gleichzeitig sehr geringer Oberflächenrauhigkeit im Betrieb und möglichst geringer Sprödigkeit zeigt.It is accordingly an object of the invention to overcome the known disadvantages of the prior art and to provide a roll cover, which shows both a high pressure modulus and good abrasion resistance at the same time very low surface roughness during operation and the lowest possible brittleness.

Die Aufgabe wird durch die kennzeichnenden Merkmale des unabhängigen Anspruchs 1 in Verbindung mit den gattungsbildenden Merkmalen gelöst.The object is achieved by the characterizing features of the independent claim 1 in conjunction with the generic features.

Erfindungsgemäß ist dabei vorgesehen, dass einerseits zumindest drei Füllstoffe vorhanden sind, welche jeweils unterschiedliche mittlere Korngrößen aufweisen, und dass andererseits der Walzenbezug nach einer Einlaufphase eine Gleichgewichts-Oberflächenrauhigkeit kleiner als 0,25 µm Ra aufweist.According to the invention, it is provided that on the one hand at least three fillers are present, each having different average grain sizes, and on the other hand, the roll cover after an intake phase has an equilibrium surface roughness less than 0.25 microns Ra.

Durch die zumindest dreifache Kombination von verschiedenen mineralischen Füllstoffen oder synthetisch hergestellten Hartstoffen mit unterschiedlichen mittleren Korngrößen wird eine hohe Abriebsbeständigkeit bei gleichzeitig sehr geringer Oberflächenrauhigkeit im Einsatz und hoher mechanischer und thermischer Beständigkeit erzielt. Die geforderte Oberflächenrauhigkeit sorgt ihrerseits für ein hervorragendes Glättungsergebnis am Endprodukt.Due to the at least triple combination of different mineral fillers or synthetically produced hard materials with different mean particle sizes a high abrasion resistance is achieved with very low surface roughness in use and high mechanical and thermal resistance. The required surface roughness in turn ensures an excellent smoothing result on the end product.

Weitere vorteilhafte Aspekte und Ausführungsformen der Erfindung gehen aus den Unteransprüchen hervor.Further advantageous aspects and embodiments of the invention will become apparent from the dependent claims.

Von Vorteil ist, wenn die Oberflächenrauhigkeit im Einsatz weniger als 15 µm Ra beträgt, so dass das Glanz- und Glätteergebnis am Endprodukt verbessert werden kann.It is advantageous if the surface roughness in use is less than 15 microns Ra, so that the gloss and smoothness of the final product can be improved.

Vorteilhafterweise kann ein erster Füllstoff eine mittlere Korngröße im Bereich von 1 bis 100 nm, bevorzugt von 10 bis 30 nm aufweisen. Hierdurch werden eine hohe Rissbeständigkeit und eine Erhöhung des Druckmoduls erzielt.Advantageously, a first filler may have an average particle size in the range from 1 to 100 nm, preferably from 10 to 30 nm. As a result, a high crack resistance and an increase of the pressure module are achieved.

Ein zweiter Füllstoff kann eine mittlere Korngröße im Bereich von 50 bis 2000 nm, bevorzugt von 100 bis 300 nm aufweisen und nimmt vorteilhafterweise eine Brückenfunktion zwischen großen und kleinen Füllstoffen wahr. Er reduziert die Erosion der Harzmatrix an der freien Oberfläche zwischen den großen Füllstoffen.A second filler may have a mean grain size in the range of 50 to 2000 nm, preferably 100 to 300 nm, and advantageously performs a bridging function between large and small fillers. It reduces the erosion of the resin matrix on the free surface between the large fillers.

Ein dritter Füllstoff kann eine mittlere Korngröße im Bereich von 0,5 bis 7 µm, bevorzugt von 1 bis 4 µm aufweisen und damit eine weitere Erhöhung des Druckmoduls sowie eine Erhöhung der Abrasionsbeständigkeit bewirken.A third filler may have a mean grain size in the range of 0.5 to 7 microns, preferably from 1 to 4 microns and thus cause a further increase in the pressure modulus and an increase in the abrasion resistance.

Gemäß vorteilhaften Aspekten der Erfindung können die Korngrößenverteilungen der zumindest drei Füllstoffe überlappend oder nicht überlappend ausgewählt sein. Dadurch kann das Eigenschaftsprofil des Walzenbezuges weiter beeinflusst werden.According to advantageous aspects of the invention, the grain size distributions of the at least three fillers may be selected to be overlapping or non-overlapping. As a result, the property profile of the roll cover can be further influenced.

Gemäß einem weiteren vorteilhaften Aspekt der Erfindung können zumindest zwei der Füllstoffe, insbesondere drei der Füllstoffe chemisch identisch sein.According to a further advantageous aspect of the invention, at least two of the fillers, in particular three of the fillers, can be chemically identical.

Dabei können die zumindest drei Füllstoffe unterschiedlich sein. Dadurch kann aus einer breiten Auswahl geeigneter Füllstoffe, die in den jeweils benötigten Korngrößen kommerziell verfügbar sind, gewählt werden und es können gezielt unterschiedliche Eigenschaften (beispielsweise hohe Härte bzw. gute Matrixanbindung) und Morphologien (beispielsweise sphärische Partikel mit hoher Abriebsbeständigkeit zur Erzielung ebendieser bei geringer im Betrieb resultierender Oberflächenrauhigkeit oder stäbchen- bzw. faserförmige Füllstoffe zur Strukturverstärkung) zur Optimierung des Gesamtsystems genutzt werden.The at least three fillers may be different. As a result, it is possible to choose from a wide selection of suitable fillers which are commercially available in the respective particle sizes required, and it is possible to use different properties (for example high hardness or good matrix connection) and morphologies (for example spherical particles with high abrasion resistance to achieve the same in operation resulting surface roughness or rod-shaped or fibrous fillers for structural reinforcement) can be used to optimize the overall system.

Bevorzugt kann zumindest einer der Füllstoffe ausgewählt sein aus: Oxide, Carbide, Nitride, Aluminiumsilikate, Silikate mineralischen oder synthetischen Ursprungs.Preferably, at least one of the fillers may be selected from: oxides, carbides, nitrides, aluminum silicates, silicates of mineral or synthetic origin.

Diese weisen eine hohe Härte und Abriebsbeständigkeit auf und sind in vielfältigen Ausprägungen kommerziell verfügbar.These have a high hardness and abrasion resistance and are commercially available in a variety of forms.

Gemäß einem vorteilhaften Aspekt der Erfindung kann der erste Füllstoff weiterhin ausgewählt sein aus: Sulfate, Karbonate, Phosphate, Titanate, Carbonanotubes, Carbonanofibres, Metalle oder Mischungen daraus.According to an advantageous aspect of the invention, the first filler may further be selected from: sulphates, carbonates, phosphates, titanates, carbonanotubes, carbonanofibres, metals or mixtures thereof.

Besonders bevorzugt können die Füllstoffe, insbesondere der erste Füllstoff, oberflächenmodifiziert sein, was eine bessere Anbindung an die Harzmatrix erlaubt.Particularly preferably, the fillers, in particular the first filler, can be surface-modified, which allows a better attachment to the resin matrix.

Gemäß einem vorteilhaften Aspekt der Erfindung kann der Gehalt an Füllstoffen in dem Matrixsystem zwischen 0,5 und 30 Volumenprozent betragen. Dieser Wert stellt einen guten Mittelweg für die maximal erreichbare Glätte bei der geforderten Elastizität dar.According to an advantageous aspect of the invention, the content of fillers in the matrix system may be between 0.5 and 30% by volume. This value represents a good middle ground for the maximum achievable smoothness at the required elasticity.

Vorteilhafterweise beträgt der Gehalt an erstem Füllstoff 2 bis 25 Volumenprozent, bevorzugt 5 bis 20 Volumenprozent, während der Gehalt an zweitem Füllstoff 0,5 bis 5 Volumenprozent, bevorzugt 0,5 bis 3 Volumenprozent und der Gehalt an drittem Füllstoff 0,5 bis 10 Volumenprozent, bevorzugt 2 bis 7 Volumenprozent beträgt.Advantageously, the content of the first filler is 2 to 25% by volume, preferably 5 to 20% by volume, while the content of the second filler is 0.5 to 5% by volume, preferably 0.5 to 3% by volume and the content of the third filler 0.5 to 10% by volume , preferably 2 to 7 percent by volume.

Bevorzugt kann das Matrixsystem ein Duroplast, insbesondere ein aminisch oder anhydridisch vernetztes oder ein selbstvernetzendes Epoxydharz oder ein Isocyanatester oder Mischungen daraus sein. Derartige Harzsysteme sind kommerziell in großer Bandbreite erhältlich und können jeweils gemäß den Anforderungen gewählt werden.The matrix system may preferably be a duroplastic, in particular an amine or anhydride crosslinked or a self-crosslinking epoxy resin or an isocyanate ester or mixtures thereof. Such resin systems are commercially available in a wide range and can be selected according to requirements.

Die Erfindung wird nachfolgend näher erläutert.The invention will be explained in more detail below.

Kalander oder Glättwerke für Faserstoffbahnen wie Papier- oder Kartonbahnen haben die Aufgabe, die Faserstoffbahn entweder direkt im Anschluss an deren Herstellung (online) oder auch zu einem späteren Zeitpunkt (offline) zu glätten. Durch diese Aufgabe werden an die Walzenbezüge der in einem Kalander vorhandenen Walzen höchste Anforderungen einerseits in Bezug auf ihre Oberflächengüte und andererseits in Bezug auf ihre Beständigkeit gegen thermische und mechanische Belastungen gestellt.Calenders or calenders for fibrous webs such as paper or board webs have the task of smoothing the fibrous web either directly after its production (online) or even later (offline). By this task are on the roll covers of existing in a calender rolls highest requirements on the one hand in terms of their surface quality and on the other hand in terms of their resistance to thermal and mechanical loads.

Gewöhnlich sind in einem Kalander mehrere Walzen zu einem Stack angeordnet, wobei gemäß einer geläufigen Ausführungsform eine metallische beheizbare Walze gegen eine nicht beheizte elastische Walze unter Bildung eines Nips läuft. Zunächst wird in mehreren aufeinanderfolgenden Nips eine erste Seite der Faserstoffbahn durch Druck- und Wärmeeinwirkung geglättet. Bei einem Superkalander oder Multinipkalander ist gewöhnlich etwa in der Mitte des Stacks ein sog. Wechselnip vorgesehen, nach welchem die andere Seite der Faserstoffbahn mit den glättenden Heizwalzen in Kontakt tritt. Aus dieser Konstellation ergibt sich sofort die Notwendigkeit, die Walzenoberfläche der nicht beheizten elastischen Walzen im zweiten Teil des Stacks so glatt wie möglich zu gestalten, damit das vorher bereits erzielte Glätteergebnis der Faserstoffbahn nicht zunichte gemacht wird.Usually, a plurality of rolls are arranged in a stack in a stack, wherein according to a common embodiment, a metallic heatable roll runs against an unheated elastic roll to form a nip. First, a first side of the fibrous web is smoothed by pressure and heat in several successive nips. In a supercalender or multinip calender, a so-called alternating tip is usually provided approximately in the middle of the stack, after which the other side of the fibrous web comes into contact with the smoothing heating rollers. From this constellation arises immediately the need to make the roll surface of the unheated elastic rolls in the second part of the stack as smooth as possible, so that the previously achieved smoothness of the fibrous web is not nullified.

Die Walzenbezüge der nicht beheizten Walzen bestehen gewöhnlich aus zumindest einer, oft auch aus mehreren Schichten aus diversen Materialen wie Gummi, Polyurethan oder faserverstärkten Kunststoffen, welche auf einen Walzenkörper aufgebracht werden. Für die Anwendung im Kalander sind gewöhnlich faserverstärkte Kunststoffe das Material der Wahl, da sie eine hohe Temperaturbeständigkeit sowie eine hohe mechanische Festigkeit und eine hohe Oberflächenglätte aufweisen.The roll covers of the unheated rolls usually consist of at least one, often also of several layers of various materials such as rubber, polyurethane or fiber-reinforced plastics, which are applied to a roll body. Fiber-reinforced plastics are usually the material of choice for use in the calender since they have a high temperature resistance as well as a high mechanical strength and a high surface smoothness.

Derartige Kunststoffe weisen gewöhnlich ein Matrixsystem aus einem Harz sowie eine darin eingebettete Faserverstärkung aus Glas-, Kohle- oder Aramidfasern oder ähnlichen anderen geeigneten Fasern als Armierung auf. Die Herstellung derartiger Walzenbezüge ist hinlänglich bekannt, so dass hier nur eine kurze Zusammenfassung gegeben wird.Such plastics usually have a matrix system of a resin and embedded fiber reinforcement of glass, carbon or aramid fibers or similar other suitable fibers as a reinforcement. The production of such roll covers is well known, so that only a brief summary is given here.

Die Herstellung kann gemäß diversen bekannten Verfahren erfolgen. Es ist einerseits möglich, die Fasern trocken zu wickeln und die Matrix durch ein Gießverfahren aufzubringen. Ein anderes gängiges Verfahren sieht vor, dass Faserbündel, beispielsweise sog. Rovings, durch ein Harzbad, welches die Harzmatrix enthält, gezogen und dann nass auf den Walzenkörper gewickelt werden. Auch Spritzgussverfahren, bei welchen das Matrixmaterial durch axial verfahrbare Düsen auf einen rotierenden Walzenkörper aufgebracht wird, sind bekannt und zur Herstellung eines erfindungsgemäßen Walzenbezuges geeignet.The preparation can be carried out according to various known methods. On the one hand, it is possible to wrap the fibers dry and apply the matrix by a casting process. Another common method provides that fiber bundles, For example, so-called rovings, pulled by a resin bath containing the resin matrix, and then wet are wound on the roll body. Injection molding methods, in which the matrix material is applied by axially movable nozzles on a rotating roller body, are known and suitable for producing a roll cover according to the invention.

Der Aufbau kann dabei ein- oder mehrschichtig erfolgen, es können auch weitere Schichten wie beispielsweise ein Baselayer, der der Haftvermittlung zwischen Walzenkern und Walzenbezug dient, und zusätzliche Bindeschichten vorgesehen sein. Die erfindungsgemäßen Maßnahmen beziehen sich auf eine Funktionsschicht des Walzenbezuges, die mit der Faserstoffbahn in Kontakt kommt.In this case, the structure can take place in one or more layers, and it is also possible to provide further layers, such as, for example, a base layer, which serves for the bonding between roll core and roll cover, and additional bonding layers. The measures according to the invention relate to a functional layer of the roll cover, which comes into contact with the fibrous web.

Als Matrixsysteme kommen aminisch, anhydridisch vernetzte aber auch selbstvernetzende Epoxyharze, Isocyanatester oder andere Duroplaste oder Mischungen daraus in Frage.Suitable matrix systems include amine, anhydride crosslinked but also self-crosslinking epoxy resins, isocyanate esters or other thermosets or mixtures thereof.

In allen Verfahren ist es möglich und üblich, die Harzmatrix mit Füllstoffen zu füllen, um so ihre mechanischen und thermischen Eigenschaften zu verbessern.In all processes, it is possible and common to fill the resin matrix with fillers so as to improve their mechanical and thermal properties.

Der Stand der Technik kennt bereits die Kombination mit zwei Füllstoffen mit unterschiedlichen Korngrößen in der Harzmatrix. Die Praxis beweist dabei sowohl die Machbarkeit als auch die positiven Effekte derartiger Kombinationen, jedoch ist die Performance der derart gestalteten Walzenbezüge noch nicht ausreichend.The prior art already knows the combination with two fillers with different grain sizes in the resin matrix. The practice proves both the feasibility and the positive effects of such combinations, however, the performance of the thus designed roller covers is not sufficient.

Erfindungsgemäß ist somit vorgesehen, zumindest einen weiteren Füllstoff in die Harzmatrix einzubringen und gleichzeitig die Oberflächenrauhigkeit im Betrieb deutlich zu senken.The invention thus provides for introducing at least one further filler into the resin matrix and at the same time significantly reducing the surface roughness during operation.

Durch die Kombination von mindestens drei zumindest in Bezug auf die mittlere Korngröße verschiedenen Füllstoffen mit deutlich unterschiedlichen durchschnittlichen Korngrößen können die Synergien zwischen den einzelnen Füllstoffen optimal genutzt werden.The combination of at least three different at least with respect to the mean grain size fillers with significantly different average grain sizes, the synergies between the individual fillers can be used optimally.

Eine im folgenden als erster Füllstoff bezeichnete Komponente, welche eine Korngröße im Bereich zwischen 1 bis 100 Nanometer aufweist, übernimmt eine Wirkung als Rissstopper und bewirkt eine damit verbundene Erhöhung der mechanischen Festigkeit sowie eine Erhöhung des Druckmoduls. Voraussetzung hierfür ist eine gute Einbindung an die Matrix und eine gleichmäßige Verteilung der Partikel in der Matrix. Durch den erhöhten Druckmodul kommt es bei dem im Wesentlichen druckinduzierten Verschleißmechanismus eines Kalanders zu einem deutlich später einsetzenden Starkverschleiß, da die Verformung und damit die auftretenden Spannungen reduziert werden.A hereinafter referred to as a first filler component having a particle size in the range between 1 to 100 nanometers, takes over an effect as a crack stopper and causes an associated increase in mechanical strength and an increase in the pressure module. The prerequisite for this is a good integration with the matrix and a uniform distribution of the particles in the matrix. Due to the increased pressure modulus, the substantially pressure-induced wear mechanism of a calender results in a significant later onset of heavy wear, since the deformation and thus the occurring stresses are reduced.

Eine im folgenden als dritter Füllstoff bezeichnete Komponente, welche auch als "große" Hartstoffe bezeichnet wird, weist eine durchschnittliche Korngröße im einstelligen Mikrometerbereich auf, erhöht primär die Beständigkeit gegen Abrasivverschleiß und führt zu einer weiteren Erhöhung des Druckmoduls. Für Anwendungen eines Walzenbezuges, die auf Glanzoptimierung ausgelegt sind, ist dieser dritte Füllstoff in einem möglichst geringen Füllgrad zu halten, da ein hoher Anteil an groben Füllstoffen die Glätte des Walzenbezuges beeinträchtigt. Der Füllgrad ist hier so einzustellen, dass ein Ra-Wert von weniger als 0,25 µm oder bei besonders hohen Anforderungen von weniger als 0,15 µm erzielt werden kann.A component referred to hereinafter as the third filler, which is also referred to as "large" hard materials, has an average grain size in the single-digit micrometer range, increases primarily the resistance to abrasive wear and leads to a further increase in the pressure modulus. For applications of a roll cover, which are designed for gloss optimization, this third filler is to be kept in the lowest possible degree of filling, since a high proportion of coarse fillers affects the smoothness of the roll cover. The degree of filling should be set here so that an R a value of less than 0.25 μm or, in the case of particularly high requirements of less than 0.15 μm, can be achieved.

Weiterhin ist eine Komponente vorgesehen, die als zweiter Füllstoff bezeichnet ist und mittelgroße Korngrößen der Größenordnung von 0,05 bis 2 Mikrometern aufweist. Der zweite Füllstoff erfüllt eine Brückenfunktion zwischen den beiden anderen Füllstoffen und reduziert unter anderem die Matrixerosion durch aus der Faserstoffbahn oder dem Strichmedium stammende eingedrückte Partikel zwischen den "großen" Hartstoffen.Furthermore, a component is provided which is referred to as a second filler and medium sized grain sizes of the order of 0.05 to 2 microns. The second filler fulfills a bridging function between the other two fillers and, inter alia, reduces matrix erosion by means of indented particles originating from the fibrous web or the coating medium between the "large" hard materials.

In Tabelle 1 ist eine Zusammenstellung der mittleren Korngrößen und der möglichen Korngrößenverteilungen der Füllstoffe und des jeweiligen Füllgrades angegeben. Tabelle 1 Erster Füllstoff Zweiter Füllstoff Dritter Füllstoff Nanoskalige Füllstoffe SubMikrometerskalige Füllstoffe Micrometerskalige Füllstoffe Volumsanteile in der Epoxydmatrix 2 - 25% 0,5 - 5% 0,5 - 10% Bevorzugte Vol. % 5 - 20% 0,5 - 3% 2 - 7% Mittlere Korngröße 1 - 100 nm 50 - 2000 nm 0,5 - 7 µm Bevorzugte mittlere Korngröße 10 - 30nm 100 - 300 nm 1 - 4 µm Table 1 shows a summary of the mean particle sizes and the possible particle size distributions of the fillers and the respective degree of filling. Table 1 First filler Second filler Third filler Nanoscale fillers Sub-micrometer-scale fillers Micrometer-scale fillers Volumes in the epoxy matrix 2 - 25% 0,5 - 5% 0,5 - 10% Preferred Vol.% 5 - 20% 0,5 - 3% 2 - 7% Average grain size 1 - 100 nm 50-2000 nm 0.5 - 7 μm Preferred average grain size 10 - 30nm 100-300 nm 1 - 4 μm

Die Materialien für den dritten Füllstoff entstammen bevorzugt einer ersten Gruppe umfassend Oxide, Carbide, Nitride, Aluminiumsilikate, Silikate mineralischen oder synthetischen Ursprungs oder auch Glasspheren oder Mischungen daraus.The materials for the third filler preferably originate from a first group comprising oxides, carbides, nitrides, aluminum silicates, silicates of mineral or synthetic origin or glasspheres or mixtures thereof.

Als Materialien für den ersten Füllstoff kommen die Materialien aus der ersten Gruppe, aber auch aus einer zweiten Gruppe umfassend Sulfate, Karbonate, Phosphate, Titanate, Carbonanotubes, Carbonanofibres oder Metalle oder Mischungen daraus in Frage.Suitable materials for the first filler are the materials from the first group, but also from a second group comprising sulfates, carbonates, phosphates, titanates, Carbonanotubes, Carbonanofibres or metals or mixtures thereof in question.

Die Materialwahl des zweiten Füllstoffes kann aus beiden Gruppen erfolgen. Bevorzugt sind zweiter und dritter Füllstoff aus der gleichen Gruppe ausgewählt, besonders bevorzugt aus der ersten Gruppe.The choice of material of the second filler can be made from two groups. Preferably, second and third fillers are selected from the same group, more preferably from the first group.

Der erste Füllstoff kann mit oder ohne Oberflächenmodifikation, z.B. mit poly L-lactide gecoatetem SiO2 zur besseren Anbindung an die Matrix verwendet werden.The first filler can be used with or without surface modification, eg with poly L-lactide coated SiO 2 for better attachment to the matrix.

Die optimale Zusammensetzung hängt sowohl von den konkret ausgewählten Füllstoffen, deren mittleren Korngrößen und Morphologie als auch von der gewünschten Härte bzw. dem gewünschten Druckmodul und einer möglichst geringen Oberflächenrauhigkeit im Betrieb ab.The optimum composition depends both on the specific selected fillers, their mean grain sizes and morphology as well as on the desired hardness or the desired pressure modulus and the lowest possible surface roughness in operation.

Für die Glanzoptimierung mit einer gleichzeitigen Erhöhung des Druckmoduls und Erreichung sehr geringer Oberflächenrauhigkeit im Betrieb ist der Anteil an erstem Füllstoff gegenüber den anderen beiden Füllstoffen erhöht bzw. der Anteil an drittem Füllstoff sehr gering. Dadurch ist es möglich, die Oberflächengüte des Walzenbezuges und somit das Glanz- und Glätteergebnis für die Faserstoffbahn zu optimieren. Allerdings ist in diesem Fall bedingt durch die Reduktion oder die Abwesenheit des grobkörnigen harten Füllstoffs die Abriebsbeständigkeit etwas geringer, so dass Schleifinterwalle möglicherweise kürzer ausfallen können.For the gloss optimization with a simultaneous increase of the pressure module and achieving very low surface roughness in operation, the proportion of the first Filler over the other two fillers increased or the proportion of third filler very low. This makes it possible to optimize the surface quality of the roll cover and thus the gloss and smoothness results for the fibrous web. However, in this case, due to the reduction or absence of the coarse-grained hard filler, the abrasion resistance is somewhat lower, so that grinding intervals may possibly be shorter.

Die Oberflächenrauhigkeit sollte bevorzugt weniger als 0,25 µm Ra betragen, besonders bevorzugt weniger als 0,15 µm Ra. Die Werte sind dabei auf die Oberflächenrauhigkeit im Betrieb angegeben, also nach einer Einlaufphase der Walze in der jeweiligen Position. Nach einem vorbereitenden Schliff nach dem Beziehen der Walze durchläuft diese nach ihrem Einbau zunächst eine gewisse Einlaufphase, welche von wenigen Minuten bis zu ca. 24 Stunden betragen kann. In dieser Zeit stellt sich ein Gleichgewicht in der Oberflächenrauhigkeit ein. Wie lang die Einlaufphase dauert und wie lang die Walze dann mit dieser ungefähr konstanten Oberflächenrauhigkeit läuft, hängt u.a. von der Einbauposition und vom Material des Walzenbezuges ab. Die Gleichgewichtsphase kann mehrere Monate betragen.The surface roughness should preferably be less than 0.25 μm Ra, more preferably less than 0.15 μm Ra. The values are given on the surface roughness during operation, ie after a running-in phase of the roller in the respective position. After a preliminary grinding after obtaining the roller, this first passes through a certain run-in phase after its installation, which can be from a few minutes to about 24 hours. In this time, a balance in the surface roughness sets. How long the running-in phase lasts and how long the roller then runs with this approximately constant surface roughness depends i.a. from the installation position and the material of the roll cover. The equilibrium phase can be several months.

Die drei Füllstoffe können aus einer breiten Auswahl geeigneter in den jeweils benötigten Korngrößen kommerziell verfügbarer Komponenten gewählt werden. Durch die Auswahl können gezielt unterschiedliche Eigenschaften, beispielsweise eine hohe Härte bzw. eine gute Matrixanbindung betont werden.The three fillers can be selected from a wide range of suitable commercially available components in the particular grain sizes required. Through the selection specifically different properties, such as a high hardness or a good matrix connection can be emphasized.

Hinsichtlich der Morphologien der drei Füllstoffe kann ebenfalls aus einem breiten Spektrum gewählt werden. Beispielsweise sind sphärische Partikel wie beispielsweise Glassphären mit hoher Abriebsbeständigkeit zur Erzielung hoher Härte bei geringer im Betrieb resultierender Oberflächenrauhigkeit sinnvoll und möglich. Stäbchen- bzw. faserförmige Füllstoffe wie Carbonanotubes können zur Strukturverstärkung und zur Optimierung des Gesamtsystems genutzt werden.Regarding the morphologies of the three fillers can also be chosen from a wide range. For example, spherical particles such as glass spheres with high abrasion resistance to achieve high hardness at low operating surface roughness resulting useful and feasible. Rod-shaped or fibrous fillers such as carbonanotubes can be used for structural reinforcement and for optimizing the overall system.

Die drei Füllstoffe können in einer Schicht vorzugsweise möglichst homogen verteilt sein. Es ist jedoch auch möglich, durch geeignete Modifikation der oben beschriebenen Auftragsverfahren Gradienten innerhalb der Schicht oder gezielte stufenweise Änderungen zu erzielen.The three fillers may preferably be distributed as homogeneously as possible in one layer. However, it is also possible by appropriate modification of the above order process to achieve gradients within the layer or targeted incremental changes.

Claims (20)

  1. Roll cover, in particular for use in a device for producing or finishing a fibrous web such as a paper or board web, where the roll cover can be formed on a roll core made of metal or of a fibre-reinforced plastic and has a matrix system in which fillers are provided, the roll cover having an equilibrium surface roughness of less than 0.25 µm Ra after a starting phase,
    characterized in that
    at least three fillers are provided, which each have different average grain sizes.
  2. Roll cover according to Claim 1,
    characterized in that
    after a starting phase, the roll cover has an equilibrium surface roughness of less than 0.15 µm Ra.
  3. Roll cover according to Claim 1 or 2,
    characterized in that
    the equilibrium surface roughness is reached after a maximum of 24 hours.
  4. Roll cover according to one of Claims 1 to 3,
    characterized in that
    the first filler has an average grain size in the range from 1 to 100 nm, preferably from 10 to 30 nm.
  5. Roll cover according to one of Claims 1 to 4,
    characterized in that
    a second filler has an average grain size in the range from 50 to 2000 nm, preferably from 100 to 300 nm.
  6. Roll cover according to one of Claims 1 to 5,
    characterized in that
    a third filler has an average grain size in the range from 0.5 to 7 µm, preferably from 1 to 4 µm.
  7. Roll cover according to one of Claims 1 to 6,
    characterized in that
    the grain size distributions of the at least three fillers are selected to be overlapping or nonoverlapping.
  8. Roll cover according to one of Claims 1 to 7,
    characterized in that
    at least two of the fillers, in particular three of the fillers, are identical.
  9. Roll cover according to one of Claims 1 to 8,
    characterized in that
    the at least three fillers are different.
  10. Roll cover according to one of Claims 1 to 9,
    characterized in that
    at least the second and/or the third filler are/is selected from: oxides, carbides, nitrides, aluminium silicates, silicates of mineral or synthetic origin or mixtures thereof.
  11. Roll cover according to one of Claims 3 to 10,
    characterized in that
    the first filler is selected from: oxides, carbides, nitrides, aluminium silicates, silicates, sulphates, carbonates, phosphates, titanates, carbon nanotubes, carbon nanofibres, metals of mineral or synthetic origin or mixtures thereof.
  12. Roll cover according to Claim 11,
    characterized in that
    the first filler is surface-modified.
  13. Roll cover according to one of the preceding claims,
    characterized in that
    the content of fillers in the matrix system is between 0.5 and 30 percent by volume.
  14. Roll cover according to Claim 13,
    characterized in that
    the content of first filler is 2 to 25 percent by volume, preferably 5 to 20 percent by volume.
  15. Roll cover according to Claim 13 or 14,
    characterized in that
    the content of second filler is 0.5 to 5 percent by volume, preferably 0.5 to 3 percent by volume.
  16. Roll cover according to one of Claims 13 to 15,
    characterized in that
    the content of third filler is 0.5 to 10 percent by volume, preferably 2 to 7 percent by volume.
  17. Roll cover according to one of the preceding claims,
    characterized in that
    the matrix system is a thermosetting plastic, in particular an amine-cross-linked or anhydride-cross-linked or a self-cross-linking epoxy resin or an isocyanate ester or mixtures thereof.
  18. Use of a roll cover according to one of the preceding claims in a device for producing or finishing a fibrous web such as a paper or board web.
  19. Roll for use in a calender or smoothing unit for fibrous webs such as paper or board webs, the roll having a roll core made of metal or of a fibre-reinforced plastic and a roll cover being formed on the roll core,
    characterized in that
    the roll cover is made in accordance with one of Claims 1 to 17.
  20. Use of a roll according to Claim 19 in a calender or smoothing unit for fibrous webs, such as paper or board webs.
EP13160419.1A 2012-03-30 2013-03-21 Roll cover Active EP2644773B1 (en)

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DE102012205221A DE102012205221A1 (en) 2012-03-30 2012-03-30 roll cover

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DE10046055A1 (en) * 2000-09-18 2002-03-28 Voith Paper Patent Gmbh Elastic roller
DE102004025116A1 (en) 2004-05-21 2005-12-08 Voith Paper Patent Gmbh Fiber composite roll cover for machines processing flat materials comprises a compound whose composition varies in different areas
AT502579A1 (en) * 2005-09-29 2007-04-15 Voith Paper Patent Gmbh FIBER COMPOSITION ROLL COVER
DE102006023235A1 (en) * 2006-05-18 2007-11-22 Voith Patent Gmbh Central roller of press arrangement for production and/or treatment of paper- or cardboard web, comprises roll cover which possesses average roughness on its outer side facing fibrous material web
DE102009028210A1 (en) * 2009-08-04 2011-02-17 Voith Patent Gmbh Self-conditioning roller Beschabung
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