JPH1122720A - FRP roll - Google Patents

Abstract

(57) [Solution] A sheet-shaped material such as a synthetic resin film or paper, which has a small amount of bending, is lightweight, and has a strength in the center portion in the roll axis direction that can sufficiently withstand a coating process such as rubber winding. Provided are a roll made of FRP used for conveying and winding an object, and a method for manufacturing the roll. An inner diameter of an FRP main body cylinder is gradually increased from a center toward both ends in a cylinder axis direction to increase a thickness of a central part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an FRP used for conveying or winding a sheet such as a synthetic resin film or paper.
The present invention relates to a roll and a manufacturing method thereof.

[0002]

2. Description of the Related Art In a manufacturing process of a synthetic resin film, for example, a roll used for transporting and winding the roll has a considerably longer length than an outer diameter.
If the roll is bent, the film will be wrinkled, or the winding will be displaced or uneven, so in order to prevent these inconveniences, conventional rolls are made of metal with a considerable thickness. ing. Therefore, the conventional roll is very heavy, and the work such as the roll exchange is very complicated.

The amount of deflection of a roll is the sum of the amount of deflection caused by its own weight and the amount of deflection caused by the application of an external force.
In order to suppress the deflection due to its own weight, it is effective to use a material having a large specific elastic modulus (elastic modulus / density) or to increase the diameter of the roll. Further, in order to suppress the deflection due to the application of the external force, it is effective to use a highly elastic material and to increase the diameter or the thickness of the roll. However, the solution by increasing the diameter or increasing the wall thickness causes a significant increase in weight and is difficult due to restrictions on equipment. on the other hand,
As a solution by improving the material, there is a method using CFRP or the like, which has a much higher specific elastic modulus than metal, and can be solved to some extent.

For example, JP-A-51-58504 and JP-A-56-45618 describe CFRP rolls formed by a filament winding method. This roll has a bending rigidity equivalent to that of a metal roll and is lightweight. However,
Since CFRP is a material having a large anisotropy, if the arrangement angle of the reinforcing fibers is not optimized, sufficient bending rigidity cannot be obtained, or the wall thickness is increased, and the effect of weight reduction is reduced. There is.

[0005] In order to solve such a problem, for example, Japanese Utility Model Publication No. Hei 3-14579 discloses that when a roll is manufactured by FRP, the winding angle of the helical winding continuous fiber is changed from both ends of the roll to the center. It has been proposed that the stiffness at the center of the roll is made higher than the stiffness at both ends and the amount of deflection is reduced by gradually reducing the stiffness toward both ends. However, it is very difficult to precisely change the winding angle in the roll axis direction, and the physical property values vary greatly between products.

When the angle of the helical layer is reduced in order to increase the elastic modulus at the center in the roll axis direction, the radial thermal expansion coefficient at that portion becomes about 15 to 20 × 10 ⁻⁶ / ° C. Since the coefficient of thermal expansion of carbon steel usually used as a core during molding is about 10 to 11 × 10 ⁻⁶ / ° C., when the matrix resin is a thermosetting resin, the roll tightens the core after curing. At the end of molding, the core metal may not be able to be released from the mold.

Furthermore, since the strength in the radial direction at the center in the roll axis direction is reduced, when a rubber wound roll is manufactured, the roll may be damaged by a tightening force at the time of rubber vulcanization.

[0008]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems of the prior art, to have a very small amount of deflection and light weight, and to reduce the strength at the center in the roll axis direction by a rubber. An object of the present invention is to provide an FRP roll that can sufficiently withstand a coating process such as winding, and a method for manufacturing the same.

[0009]

In order to achieve the above object, the present invention has a main body cylinder made of FRP, and the inner diameter of the main body cylinder extends from the center to both ends in the cylinder axis direction of the main body cylinder. It is characterized by a roll made of FRP, which is made smoother or gradually larger.

In the above, the main body cylinder may be composed of at least two parts having different inner diameters. Also, FRP
Preferably, at least 80% of the reinforcing fibers contained therein are carbon fibers. Further, it is also preferable that at least 50% of the reinforcing fibers contained in the FRP are carbon fibers arranged at an angle of ± 30 ° or less with respect to the cylinder axis direction of the main cylinder. Journals are usually fitted at both ends of the main body cylinder. Furthermore, when the volume of the main body tube V, and the volume of the virtual body tube to the maximum inner diameter of the inner diameter of the main body tube except the both end portions of the journal is fitted with V _0, is (V ₀ / V) 0.4 It is preferably in the range of ０．８0.8. Furthermore, it is preferable that a jacket layer made of metal, ceramic or an elastic body is provided on the main body cylinder.

As described above, the FRP roll of the present invention has a smooth outer diameter from one end to the other end so that the outer diameter smoothly increases from the center in the axial direction of the cylinder toward both ends. After forming at least two core cylinders coaxially to form a set of composite core cylinders and forming a main body cylinder made of FRP around the combined core cylinders, the core cylinders are moved in the cylinder axial direction. It can be manufactured by extracting.

At least two cores whose outer diameters increase stepwise from one end to the other end so that the outer diameter increases stepwise from the center in the cylinder axis direction toward both ends. It can also be manufactured by forming a set of combined core cylinders by coaxially combining the cylinders, forming a main body cylinder made of FRP around the combined core cylinder, and then extracting the core cylinder in the cylinder axis direction.

Furthermore, at least three core tubes having different outer diameters are coaxially combined to form a set of combined core tubes such that the outer diameters increase stepwise from the center in the cylinder axis direction toward both ends. Alternatively, it can be manufactured by forming a main body cylinder made of FRP around the combined core cylinder, and then extracting the core cylinder in the cylinder axis direction.

Preferably, the main body tube is formed by a filament winding method and / or a sheet winding method.

[0015]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS In FIG. 1, an FRP roll is an FRP main body cylinder 1 made by reinforcing a resin with reinforcing fibers.
And a jacket layer 4 provided on the outer peripheral surface of the main body cylinder 1. Journals 2 and 3 are fitted to both ends of the main body cylinder 1, and the joining of the main body cylinder 1 and the journals 2 and 3 is preferably performed by bonding. However, shrink fitting, cold fitting, press fitting, and the like are performed. Other methods can be used.

The inner diameter of the main body tube 1 is smoothly increased from the center in the axial direction of the main body tube 1 toward both ends.
In this way, by increasing the thickness of the vicinity including the center of the main body cylinder 1 in the cylinder axis direction, the secondary moment of area at the center of the main body cylinder 1 in the cylinder axis direction becomes maximum, and the bending rigidity of the main body cylinder 1 is increased. Increase. For example, when the tension of the sheet-like material acts as a distributed load in the cylinder axis direction of the roll in a sheet-like material transporting roll having both ends of the main body cylinder 1 supported by journals, the cylinder shaft of the main body cylinder 1 Although a maximum bending moment is generated at the center in the direction, the second section moment of the center of the main body cylinder 1 in the cylinder axis direction is maximized, so that the amount of bending at the center is extremely small.

The outer diameter of the main body cylinder 1 is uniform in the cylinder axis direction.
A crown of about 1.0 mm or a similar inverted crown may be provided.

It is preferable that the thermal expansion coefficients of both ends of the main body cylinder 1 in which the journals 2 and 3 are fitted are designed to be substantially equal to the thermal expansion coefficients of the journals 2 and 3. This allows
It is possible to prevent the occurrence of residual stress between the main body cylinder 1 and the journals 2 and 3 during roll production.

The reinforcing fibers include carbon fiber, glass fiber, organic high modulus fiber (for example, polyaramide fiber "Kevlar" manufactured by DuPont, USA), alumina fiber, silicon carbide fiber, and other high strength and high modulus. They are made of fibers and used alone or in combination.

Further, in order to further increase the bending rigidity of the main body tube 1, it is preferable that at least 80% of the reinforcing fibers of the main body tube 1 are carbon fibers.

Furthermore, at least 50% of the reinforcing fibers
Is preferably a carbon fiber arranged at an angle of ± 30 ° or less with respect to the cylinder axis direction of the main body cylinder 1. The carbon fiber preferably has a high tensile modulus, for example, a high modulus carbon fiber having a tensile modulus of 196 GPa or more is preferable.

As the resin constituting the matrix of the FRP, a thermosetting resin such as an epoxy resin, a phenol resin, an unsaturated polyester resin, or a vinyl ester resin, or a thermoplastic resin such as a nylon resin can be used.

It is preferable that the main body cylinder 1 is provided with a jacket layer 4 made of metal, ceramic, elastic body or the like. The outer cover layer 4 smoothes the roll surface, prevents the roll surface from being worn, and prevents the synthetic resin film, paper, or the like as a mating material from being gripped or damaged. Examples of the metal jacket layer include a metal tube such as an aluminum tube fitted on the main body tube 1 and a metal tube formed by plating. As the ceramic coating layer, there is a coating or thermal spraying of a ceramic material such as alumina or titanium. Examples of the covering layer of the elastic body include synthetic rubber such as urethane rubber, silicon rubber, and nitrile rubber, and natural rubber.

FIG. 2 shows how the roll shown in FIG. 1 is manufactured. Such a roll has two core cylinders 5 whose outer diameters increase smoothly from one end to the other end so that the outer diameter increases smoothly from the center in the cylinder axis direction toward both ends. , 6 are formed coaxially to form a set of combined core tubes 7, the main body tube 1 made of FRP is formed around the combined core tube 7, and then the core tubes 5, 6 are drawn out in the axial direction. can do. In FIG. 2, a combined core tube is formed by combining two core tubes, but a combined core tube may be formed by using three or more core tubes. The body tube 1 is preferably formed by a filament winding method and / or a sheet winding method.

FIG. 3 shows a roll of an embodiment different from that shown in FIG. In this embodiment, F
The inner diameter of the main body tube 8 made of RP gradually increases from the center in the tube axis direction toward both ends.

In the roll of the present invention, when the volume of the main body cylinder is V and the volume of the virtual main body cylinder whose inner diameter is the maximum inner diameter of the main body cylinder excluding both ends where the journals are fitted is V ₀ , ₀ / V) is preferably in the range of 0.4 to 0.8. By doing so, the bending rigidity increases,
Deflection caused by its own weight or external force is further reduced. Referring to roll as shown in Figure 3, the virtual main body tube to a maximum internal diameter D _O of the inner diameter of the main body tube 8 except the both end portions of the volume of the main body tube 8 having an outer diameter D V, the journal is fitted when the volume was _{V 0, (V 0 / V} ) is from 0.4 to 0.
8 in the range.

FIG. 4 shows how the roll shown in FIG. 3 is manufactured. This roll has two core cylinders 9 whose outer diameters increase stepwise from one end to the other end so that the outer diameter increases stepwise from the center in the cylinder axis direction toward both ends. , 10 are coaxially combined to form a set of combined core tubes 11, and a body tube 8 made of FRP is formed around the combined core tube 11,
It can be manufactured by extracting 10 in the cylinder axis direction. In FIG. 4, a combined core tube is formed by combining two core tubes, but a combined core tube may be formed by using three or more core tubes. As a method for forming the main body tube 8, a filament winding method and / or a sheet winding method can be used.

FIGS. 5 to 7 show still another method of manufacturing the roll of the present invention. 5, after forming the inner cylinder 13a made of FRP around the core tube 12 having an outer diameter D _C, withdrawn core tube 12, the length of the inner cylinder 13a is excised end such that L ₂ to give an outer diameter D _O, internal diameter D _C, the inner cylinder 13a of a length L _2. Next, as shown in FIG.
The inner cylinder 1 is attached to the core cylinder 14 which is equal to or slightly smaller than the outer diameter of
3a, the core tubes 15, 16 are fitted from both ends of the inner cylinder 13a, and the core tubes 14, 15, 16 are integrated. As a result, a combined core cylinder 17 whose outer diameter increases stepwise from the center in the cylinder axis direction toward both ends is formed. Next, as shown in FIG. 7, an outer cylinder 13b made of FRP is formed around the combined core cylinder 17, and then the core cylinders 14, 15, and 16 are extracted in the cylinder axis direction.
The main body tube 13 made of b is formed. The method for forming the main body tube 13 is preferably a filament winding method and / or a sheet winding method.

[0029]

【Example】

<Example 1> An epoxy resin was used as a matrix resin,
As the reinforcing fiber, a carbon fiber having a tensile strength of about 4220 MPa and a tensile elasticity of about 436 GPa was used, and a CFRP roll shown in FIG. 3 was manufactured by the manufacturing method shown in FIGS. The main body cylinder was formed by a filament winding method. Table 1 shows the dimensions of the main body cylinder and the manufacturing conditions.

In the first embodiment, the volume of the main body cylinder is V, and the volume of the virtual main body cylinder whose inner diameter is the maximum inner diameter D _O of the main body cylinder. In this case, the volume of the outer cylinder is V ₀ . (V ₀ /
V) is in the range of 0.4 to 0.8.

Example 2 A roll made of CFRP was manufactured in the same manner as in Example 1 except that core tubes having different outer diameters were used. Table 1 shows the dimensions of the main body cylinder and the manufacturing conditions. In the second embodiment, the value of (V ₀ / V) is 0.4 to 0.4 as in the first embodiment.
It is in the range of 0.8. <Example 3> Example 1 except that core tubes having different outer diameters were used.
In the same manner as in the above, a roll made of CFRP was produced. Table 1 shows the dimensions of the main body cylinder and the manufacturing conditions. Example 3 corresponds to Example 1
Similarly, the value of (V ₀ / V) is in the range of 0.4 to 0.8. <Comparative Example 1> Example 1 except that core tubes having different outer diameters were used.
In the same manner as in the above, a roll made of CFRP was produced. Table 1 shows the dimensions of the main body cylinder and the manufacturing conditions. However, in Comparative Example 1, the value of (V ₀ / V) was 0.211, and 0.4 to 0.
8 is out of range. <Comparative Example 2> Using the same matrix resin and reinforcing fibers as in Example 1, a roll made of CFRP was manufactured by a filament winding method so that the inner diameter of the main body cylinder was uniform in the cylinder axis direction. Table 1 shows the dimensions of the main body cylinder and the manufacturing conditions.

The following three-point bending tests were conducted to evaluate the bending stiffness of the main body cylinders of Examples 1, 2, and 3 and Comparative Examples 1 and 2.

When both ends of the main body cylinder in the cylinder axis direction are supported by fulcrums, and the concentrated load is applied to the center part of the main body cylinder in the cylinder axis direction, the amount of deflection of the central part of the main body cylinder in the cylinder axis direction Was measured, and the results in Table 1 were obtained.

The flexure amounts of Examples 1, 2, and 3 were the same as those of Comparative Example 1,
It can be seen that, compared to No. 2, extremely small and high bending rigidity can be obtained.

[0035]

[Table 1] FIG. 8 is a view showing the effect of improving the bending rigidity when the thickness of the main body cylinder is changed in the roll having the shape shown in FIG. 3. The horizontal axis represents V when the volume of the main body cylinder having the outer diameter D is V, and the volume of the virtual main body having the maximum inner diameter D _O of the main body cylinder excluding both ends where the journals are fitted is V _O. V _O /
V). The vertical axis represents the ratio of the amount of deflection of the main body cylinder measured in the three-point bending test to the amount of deflection of the main body cylinder of Comparative Example 2 having the same weight as the main body cylinder. As is clear from FIG. 8, when (V _O / V) is in the range of 0.4 to 0.8, the bending ratio becomes 0.9 or less, and the bending rigidity becomes 10%.
It improves above. From this, the (V _O / V) 0.4~0.
Area 8 is an area where the improvement in bending rigidity appears most remarkably.

[0036]

The roll made of FRP according to the present invention is a roll made of FRP.
Since the inner diameter of the main body cylinder is increased smoothly or stepwise from the center toward both ends in the cylinder axis direction of the main body cylinder, the bending rigidity is high, and the deflection generated by its own weight or external force is extremely large. Since it is small and lightweight, workability such as roll exchange is remarkably improved.

When at least 80% of the reinforcing fibers contained in the FRP are carbon fibers, the bending rigidity of the main body cylinder is further improved. This bending stiffness is further improved when at least 50% of the reinforcing fibers contained in the FRP are carbon fibers arranged at an angle of ± 30 ° or less with respect to the cylinder axis direction of the main body cylinder. when the volume V, and the volume of the virtual body tube to the maximum inner diameter of the inner diameter of the main body tube except the both end portions of the journal is fitted to the V _0, it is (V ₀ / V) 0.4~0.8 If it is made to be in the range, it is further improved.

Further, metal, ceramic,
In the case where the outer cover layer made of an elastic body is provided, the roll surface becomes smooth and the abrasion resistance of the roll surface is improved, and the synthetic resin film as the mating material, the gripping property of paper and the like are improved,
In addition, they can be prevented from being damaged.

From the above characteristics, the roll of the present invention is:
It is very suitable as a roll used for conveying or winding a sheet-like material such as a synthetic resin film or paper whose length is considerably longer than the outer diameter.

Further, the method for producing a roll according to the present invention is characterized in that the outer diameter increases from one end to the other end so as to increase smoothly from the center in the cylinder axis direction to both ends or to gradually increase. The outer diameter increases smoothly toward the portion, or at least two core cylinders that increase in a stepwise manner are coaxially combined to form a set of composite core cylinders. After forming the main body cylinder made of FRP, the core cylinder is withdrawn in the cylinder axis direction, so that the above-described roll can be easily manufactured.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of an FRP roll according to an embodiment of the present invention.

FIG. 2 is a schematic view showing a method of manufacturing the FRP roll shown in FIG.

FIG. 3 is a schematic sectional view of a roll made of FRP according to another embodiment of the present invention.

FIG. 4 is a schematic view showing another method of manufacturing the FRP roll shown in FIG.

FIG. 5 is a schematic view showing still another embodiment of the method for producing an FRP roll of the present invention.

FIG. 6 is a schematic view showing still another embodiment of the method for producing an FRP roll of the present invention.

FIG. 7 is a schematic view showing still another embodiment of the method for producing an FRP roll of the present invention.

FIG. 8 is a graph showing the effect of improving the bending rigidity when the thickness of the main body cylinder of the FRP roll is changed.

[Explanation of symbols]

 1: Body cylinder 2: Journal 3: Journal 4: Jacket layer 5: Core cylinder 6: Core cylinder 7: Combination core cylinder 8: Body cylinder 9: Core cylinder 10: Core cylinder 11: Combination core cylinder 12: Core cylinder 13 : Main body cylinder 13a: Inner cylinder 13b: Outer cylinder 14: Core cylinder 15: Core cylinder 16: Core cylinder 17: Combination core cylinder

Claims (12)

[Claims] 1. An FRP roll having an FRP main body cylinder, wherein the inner diameter of the main body cylinder increases smoothly from the center toward both ends in the cylinder axis direction of the main body cylinder. . 2. An FRP body having an FRP main body cylinder, wherein the inner diameter of the main body cylinder gradually increases from the center toward both ends in the cylinder axis direction of the main body cylinder. roll. 3. The FRP roll according to claim 2, wherein the main body cylinder is a main body cylinder having at least two portions having different inner diameters. 4. The FRP roll according to claim 1, wherein at least 80% of the reinforcing fibers contained in the FRP are carbon fibers. 5. The carbon fiber according to claim 4, wherein at least 50% of the reinforcing fibers contained in the FRP are carbon fibers arranged at an angle of ± 30 ° or less with respect to the cylinder axis direction of the main body cylinder. The roll made of the FRP described. 6. The FRP roll according to claim 1, wherein journals are fitted to both ends of the main body cylinder. 7. When the volume of the main body cylinder is V and the volume of the virtual main body cylinder whose inner diameter is the maximum inner diameter of the main body cylinder excluding the both ends where the journals are fitted is V ₀ , (V ₀ / V) is 0.4-0.
7. The FR according to claim 6, which is in the range of 8.
P roll. 8. The roll made of FRP according to claim 1, wherein a jacket layer made of metal, ceramic or elastic body is provided on the main body cylinder. 9. At least two core cylinders whose outer diameters increase smoothly from one end to the other end so that the outer diameters increase smoothly from the center in the cylinder axis direction toward both ends. Combined coaxially to form a combined core tube,
A method of manufacturing a roll made of FRP, comprising: forming a main body tube made of FRP around the combined core tube; and extracting the core tube in the cylinder axis direction. 10. At least two cores whose outer diameters increase stepwise from one end to the other end so that the outer diameter increases stepwise from the center in the cylinder axis direction toward both ends. A roll made of FRP, wherein a set of combined core cylinders is formed by coaxially combining the cylinders, a body cylinder made of FRP is formed around the combined core cylinder, and then the core cylinder is withdrawn in the cylinder axis direction. Manufacturing method. 11. A set of combined core cylinders is formed by coaxially combining at least three core cylinders having different outer diameters so that the outer diameter gradually increases from the center in the cylinder axis direction toward both ends. Forming a main body cylinder made of FRP around the combined core cylinder, and extracting the core cylinder in the cylinder axis direction. 12. A filament winding method and / or
The main body tube made of FRP is formed by a sheet winding method.
The method for producing an FRP roll according to any one of the above.