EP3006591B1 - Method for producing a coated roller and coated roller - Google Patents

Description

The invention relates to a method for producing a roller and a roller.

background

Various methods for producing coated components are known in the prior art.

The document DE 93 05 806 U1 relates to a method for producing a printing roller. Here, a layer of copper or a copper alloy is produced on a base body made of a thermoplastic fiber-reinforced plastic by means of plasma spraying.

In the document DE 10 2009 048 709 A1 describes a further method for producing a composite component from a fiber-reinforced plastic and a metal.

While metals and metal alloys can be applied directly to a fiber-reinforced plastic, this is not possible for ceramic materials. When applying a ceramic material to a base body made of fiber-reinforced plastic, an intermediate layer of an adhesive is always first formed on the base body in the prior art. For example, zinc is used as the adhesive. An additional manufacturing process step is therefore required and material for the adhesive is consumed.

The document US 4,997,704 A discloses a method of applying a ceramic coating to a fiber reinforced material. Before the ceramic is applied, an adhesive intermediate layer is applied to the fiber-reinforced material.

The document EP 0 514 640 A1 discloses a method of applying a ceramic coating to a body by a thermal spraying process. A base body has a synthetic resin layer containing particulate material. The synthetic resin layer is treated before a further layer is applied by means of a thermal spraying process.

The document EP 0 273 298 A2 discloses an erosion-resistant coating which adheres to a plastic with the aid of a binder.

The document WO 2012/113426 A1 discloses a method for joining two components. During the joining, a first component made of a carbon fiber reinforced composite material is provided with a corrosion protection layer. The corrosion protection layer can be formed from ceramic, for example aluminum oxide.

The document WO 2007/090707 A2 discloses a method for coating a substrate with at least one conductor or semiconductor layer. A metal oxide layer can be applied.

The document DE 10 2011 120 197 A1 discloses the application of an oxide ceramic by means of thermal spraying to a core made of a fiber-reinforced material.

The document DE 85 32 300 U1 discloses a roller tube for printing machines.

Summary

The task is to provide improved technologies for coating components. In particular, a corrosion-free adhesive base for a coating is to be provided.

The object is achieved by the method according to independent claim 1 and the roller according to independent claim 87. Advantageous embodiments are the subject of dependent claims.

Avoiding the application of an adhesive leads to fewer process steps, which makes the process faster and cheaper. In addition, the properties of the component are improved. Corrosion of the adhesive, which often occurred in the prior art, is avoided.

A fiber-reinforced plastic (FVK) (also: fiber-plastic composite or fiber composite plastic) is a material that contains reinforcing fibers that are embedded in a plastic matrix. The matrix surrounds the reinforcing fibers, which are bound to the matrix by adhesive or cohesive forces.

The base body can for example consist of a glass fiber reinforced plastic (GRP). Alternatively, the base body can consist of a carbon fiber reinforced plastic (CFRP), a fiber reinforced polyamide (PA) or a fiber reinforced epoxy resin (EP).

The layer of ceramic material can lead to a dielectric strength of the component of up to 40 kV. Furthermore, the layer of ceramic material enables thermal insulation of the underlying body. For example, it protects against great heat. The layer of ceramic material is also wear-resistant, very hard, pressure-resistant and has a high layer strength.

The layer of ceramic material can be applied to the base body in one or more layers. It can further be provided to apply several layers of different ceramic materials to the base body.

The layer of ceramic material can be applied with a layer thickness of 100 µm to 3 mm. After curing, the layer of ceramic material can have an adhesive tensile strength of greater than or equal to 10 N / mm ² . In another embodiment, the layer of ceramic material can have an adhesive tensile strength of greater than or equal to 5 N / mm ² after curing.

It can be provided that the base body is provided on a substrate. The substrate can contain a metal, for example aluminum, a metal alloy, for example steel, or a non-metal. The substrate can consist entirely of one of the aforementioned materials or material classes.

It is envisaged that the layer of ceramic material is sprayed onto the base body. The layer of ceramic material is applied to the base body by means of thermal spraying. In thermal spraying, filler materials, so-called spray additives, are melted, melted or melted inside or outside a spray gun. The filler materials are accelerated in a gas stream in the form of spray particles and onto the surface of the material to be coated Base body applied. A layer formation can take place here. Suitable thermal spray processes are, for example, high-speed flame spraying (HVOF), vacuum plasma spraying (VPS) and atmospheric plasma spraying (APS). Argon, hydrogen, nitrogen or a combination thereof can be used as the operating gases for atmospheric plasma spraying. In addition, nitrogen, a nitrogen-argon mixture, an argon-hydrogen mixture or argon can be used as the conveying gas in atmospheric plasma spraying. Cooling can be done by compressed air, carbon dioxide (CO2) or a combination thereof.

The layer of ceramic material is formed from an oxide ceramic material, namely aluminum oxide (Al ₂ O ₃ ).

The layer made of the ceramic material is applied to the base body by means of thermal spraying in powder form. The powder can have a degree of purity of more than 95%, preferably from 98% to 99.95%. The powder can be provided in the form of a powder form mentioned below: mixed ceramic material, water-atomized ceramic material, gas-atomized ceramic material, coated ceramic material, chemically coated ceramic material, agglomerated ceramic material, agglomerated and sintered ceramic material, agglomerated and hollow spherical ceramic material, agglomerated and compressed ceramic material, melted and broken ceramic , melted and broken and mixed ceramic material as well as sintered and broken ceramic material. Grains of the powder can have the following grain sizes: 10/5 µm, 22/5 µm, 45/16 µm, 25/5 µm, 45/20 µm and 30/10 µm. Grains of the powder can also have grain sizes in any combination of the aforementioned grain sizes. If the powder is applied to the base body by means of thermal spraying, an internal axial powder supply, an internal radial powder supply or an external powder supply can take place.

Alternatively, the layer of ceramic material can be applied in the form of a suspension, for example as a water-based suspension or as an alcohol-based suspension.

The base body can contain a resin material. The resin material may be, for example, an armin resin, a phenol resin, a polyester resin, a vinyl ester resin, a polyamide resin, an epoxy resin, an anhydride resin and a bismaleimite-triazine resin. The base body can also contain any combination of the aforementioned resins.

It can be provided that the component, that is to say both the base body and the layer of ceramic material, is formed free of an electrically conductive material. Furthermore, the component can be free of metallic materials and / or metallic alloys. In particular, the component can be formed free of a metallic adhesive. The component can thus be formed as a corrosion-free component.

The basic body is provided with fibers in cross layers. The fibers are wound in cross layers. The cross layers are formed with final circumferential layers.

The base body can have a fiber content between 20 vol.% And 80 vol.%, Between 20 vol.% And 60 vol.%, Between 30 vol.% And 60 vol.% Or between 30 vol.% and have 50 vol .-%. The fibers can consist of glass, carbon, ceramic, plastic and / or natural fibers. Glass fibers can consist, for example, of R glass, E glass, C glass, D glass and S glass.

The features described above in connection with the method also apply analogously to the component.

The component is a rotationally symmetrical component, namely a roller with a cylindrical base body, on which a layer of ceramic material is arranged directly. The component can be, for example, an anilox roller or an anilox adapter or a raster sleeve for flexographic printing, a treatment roller or a treatment adapter or a treatment sleeve for a corona treatment.

Description of exemplary embodiments

Fig. 1

eine schematische Darstellung einer Walze,

Fig. 2

eine schematische Darstellung einer weiteren Walze,

Fig. 3

eine schematische Darstellung einer anderen Walze,

Fig. 4

eine schematische Darstellung einer Walze nach einer weiteren Ausführungsform,

Fig. 5

eine schematische Darstellung einer Walze nach noch einer anderen Ausführungsform,

Fig. 6

eine schematische Darstellung eines Bauteils,

Fig. 7

eine schematische Darstellung eines weiteren Bauteils und

Fig. 8

eine schematische Darstellung eines Sleeves oder eines Adapters.

Further embodiments are explained in more detail below with reference to figures of a drawing. Here show:

Fig. 1

a schematic representation of a roller,

Fig. 2

a schematic representation of a further roller,

Fig. 3

a schematic representation of another roller,

Fig. 4

1 shows a schematic representation of a roller according to a further embodiment,

Fig. 5

1 shows a schematic illustration of a roller according to yet another embodiment,

Fig. 6

a schematic representation of a component,

Fig. 7

a schematic representation of a further component and

Fig. 8

a schematic representation of a sleeve or an adapter.

In the following, the same reference symbols are used for the same components.

Fig. 1 shows a schematic representation of a roller with a tubular substrate 1, a layer of a fiber-reinforced material 2 and a layer of a ceramic material 3. Pins 4 are arranged at both ends of the roller. The substrate 1 can be made of steel or aluminum, for example. The layer of fiber-reinforced plastic 2 serves as an insulation barrier. It can include different types of fibers, for example glass fibers, carbon fibers, ceramic fibers, plastic fibers and / or natural fibers. The fibers are embedded in an armin resin and applied to the tubular substrate 1 in wound cross layers. The layer made of a ceramic material 3 is applied directly to the fiber-reinforced layer 2. The ceramic layer 3 provides thermal insulation. In this embodiment, an oxide ceramic is provided as the ceramic.

Fig. 2 shows a further embodiment of a roller. In this embodiment, the tubular substrate 1 is shortened, so that an intermediate region 5 is formed between the ends of the substrate 1 and the pin 4.

In Fig. 3 a roller with a continuous tubular substrate 1 is shown.

Fig. 4 shows a roller with a fiber-reinforced layer 2, on which a ceramic layer 3 is arranged directly. The fiber-reinforced layer is applied to a substrate 6 made of a solid material, for example made of steel or aluminum.

Fig. 5 shows a roller with a shortened tubular substrate 1, a fiber-reinforced layer 2 and a ceramic layer 3. A receptacle 7 is formed at both ends of the roller.

6 and 7 show schematic representations for components with any shape. A layer of a ceramic material 8, for example of an oxide ceramic, is arranged directly on a fiber-reinforced base body 9. According to the embodiment according to Fig. 7 the fiber-reinforced base body 9 is arranged on a substrate 10.

Fig. 8 shows a schematic representation of an adapter or a sleeve. A layer of a ceramic material 23, for example of an oxide ceramic, is arranged directly on a fiber-reinforced base sleeve 20 with a compressible intermediate layer 21 and a fiber-reinforced base body 22 built thereon. Here, an intermediate layer 21 is arranged between the fiber-reinforced base body 22 and the fiber-reinforced base sleeve 20, which is formed with a compressible cover material.

The features disclosed in the above description, the claims and the figures can be relevant both individually and in any combination with one another for realizing the invention.

Claims (7)

1. A method for producing a roller, with the following steps:

   - providing a cylindrical base body of a fibre-reinforced plastic, wherein reinforcement fibres are embedded in a plastic matrix; and

   - applying a coating of a ceramic material to the base body by means of thermal spraying,

   characterized in that

   - the base body is provided with fibres wound in crosswise layers;

   - the crosswise layers are formed with finishing circumferential layers, to which aluminium oxide is applied as the ceramic material;

   - the coating of the ceramic material is applied directly to the base body.
2. The method according to claim 1, wherein the coating of ceramic material is applied in powder form to the base body.
3. The method according to claim 1 or 2, wherein the coating of ceramic material is applied in a single layer or in multiple layers to the base body.
4. The method according to any one of the preceding claims, wherein the base body is provided as a glass-fibre-reinforced plastic.
5. The method according to any one of the preceding claims, wherein the base body comprises a resin material.
6. The method according to any one of the preceding claims, wherein the base body comprises a fibre content of between 20 vol.-% and 80 vol.-%.
7. A roller with a cylindrical base body made of

   - a fibre-reinforced plastic, wherein reinforcement fibres are embedded in a plastic matrix; and

   - a coating of a ceramic material arranged on the base body, which is applied by means of thermal spraying,

   characterized in that

   - the base body has fibres wound in crosswise layers;

   - the crosswise layers are formed with finishing circumferential layers, onto which aluminium oxide is applied as the ceramic material;

   - the coating of the ceramic material is applied directly to the base body.

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