Roller and Crosslapper and Carding Machine Comprising the Roller

Abstract

The roller comprises a covering layer made of a fibre composite material and a cylindrical roller main body having an outer first lateral surface, a first end section and a second end section. The covering layer completely surrounds the first lateral surface in the circumferential direction. A first edge region of the covering layer extends beyond the first end section, is folded over inwards and is fixed in relation to the roller main body. In a crosslapper, the roller can be provided as a deflection roller of a conveyor belt. In a carding machine, the roller can be provided as an engagement roller for engagement with fibre material.

Claims

1. A roller comprising a substantially cylindrical roller main body having an outer first lateral surface, a first end section and a second end section, which lies opposite the first end section in a longitudinal direction of the roller main body; and a covering layer made of a fibre composite material; wherein the covering layer completely surrounds the first lateral surface of the roller main body in a circumferential direction of the roller main body; and wherein a first edge region of the covering layer extends beyond the first end section of the roller main body, is folded over inwards and is fixed in relation to the roller main body.

2. The roller according to claim 1 wherein the first edge region is fixed adhesively and/or frictionally.

3. The roller according to claim 1 wherein the first end section of the roller main body has, at an end, a curvature which starts from the first lateral surface and around which the first edge region of the covering layer is folded over inwards.

4. The roller according to claim 1 wherein the roller further comprises a first end ring, which is arranged coaxially with respect to the roller main body and adjoins the roller main body at the first end section, wherein the first end ring is flush with the first lateral surface and has, on a side facing away from the roller main body, a curvature around which the first edge region of the covering layer is folded over inwards.

5. The roller according to claim 3 wherein the roller comprises at least one first clamping element, which fixes the first edge region, wherein the first clamping element is annular or disc-shaped and is arranged coaxially with respect to the roller main body.

6. The roller according to claim 4 wherein the roller comprises at least one first clamping element, which fixes the first edge region, wherein the first clamping element is annular or disc-shaped and is arranged coaxially with respect to the roller main body.

7. The roller according to claim 5 wherein the first clamping element and the first end section of the roller main body have corresponding conical contact surfaces, between which the first edge region is accommodated.

8. The roller according to claim 6 wherein the first clamping element and the first end ring have corresponding conical contact surfaces, between which the first edge region is accommodated.

9. The roller according to claim 6 wherein the first clamping element is adjustable in the longitudinal direction of the roller to set a contact pressure acting on the first edge region of the covering layer by means of the first clamping element.

10. The roller according to claim 1 wherein the roller main body is of tubular shape at least in the first end section, and the first edge region is arranged in an interior of the first end section.

11. The roller according to claim 10 wherein the roller comprises a first roller base and a second roller base, wherein the first roller base is accommodated in the first end section of the roller main body, and the second roller base is accommodated in the second end section of the roller main body, wherein the first and the second roller bases are clamped together in the longitudinal direction of the roller main body by a clamping device.

12. The roller according to claim 1 wherein the first edge region of the covering layer has a plurality of notches distributed in the circumferential direction, wherein each notch of the plurality of notches is formed in such a way, starting from an edge of the covering layer which runs in the circumferential direction, that the first edge region is formed without folds and two subsections of the first edge region which are separated from one another by a notch of the plurality of notches do not overlap.

13. The roller according to claim 1 wherein the roller has an outer second lateral surface which is formed at least partially by the covering layer, wherein the covering layer extends in the longitudinal direction of the roller over at least 50% of the second lateral surface.

14. The roller according to claim 1 wherein the roller main body is formed from metal, or from GRP or polyamide.

15. The roller according to claim 14 wherein the covering layer comprises carbon fibres, glass fibres or mineral fibres, and a matrix of plastic.

16. The roller according to claim 15 wherein the matrix of plastic is a matrix of resins of epoxy, polyester, polyurethane or melamine.

17. A crosslapper having at least one conveyor belt for conveying a fibrous batt web and a plurality of deflection rollers, around which the at least one conveyor belt is guided, wherein at least one deflection roller of the plurality of deflection rollers is configured as a roller comprising: a substantially cylindrical roller main body having an outer first lateral surface, a first end section and a second end section, which lies opposite the first end section in a longitudinal direction of the roller main body; and a covering layer made of a fibre composite material; wherein the covering layer completely surrounds the first lateral surface of the roller main body in a circumferential direction of the roller main body; and wherein a first edge region of the covering layer extends beyond the first end section of the roller main body, is folded over inwards and is fixed in relation to the roller main body.

18. A carding machine for producing a fibrous batt web, the carding machine comprising a main cylinder and a plurality of engagement rollers, wherein each engagement roller of the plurality of engagement rollers is configured for engagement with fibre material and is associated with the main cylinder, upstream or downstream thereof, wherein at least one engagement roller of the plurality of engagement rollers is configured as a roller comprising a substantially cylindrical roller main body having an outer first lateral surface, a first end section and a second end section, which lies opposite the first end section in a longitudinal direction of the roller main body; and a covering layer made of a fibre composite material; wherein the covering layer completely surrounds the first lateral surface of the roller main body in a circumferential direction of the roller main body; and wherein a first edge region of the covering layer extends beyond the first end section of the roller main body, is folded over inwards and is fixed in relation to the roller main body.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0061] FIG. 1 shows an embodiment of a roller according to the invention in a cross-sectional view;

[0062] FIGS. 2a, b show two alternatives of an embodiment of a roller according to the invention in a detail view;

[0063] FIGS. 3a, b show two alternatives of another embodiment of a roller according to the invention in a detail view;

[0064] FIG. 4 shows schematically an edge region of a covering layer of an embodiment of a roller according to the invention in a perspective view;

[0065] FIG. 5 shows schematically an embodiment of a crosslapper according to the invention in a side view; and

[0066] FIG. 6 shows schematically an embodiment of a carding machine according to the invention in a side view.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0067] FIG. 1 illustrates one embodiment of a roller 2 according to the invention in a cross-sectional view along the longitudinal axis 4 of roller 2. Roller 2 comprises a substantially cylindrical roller main body 6, which is preferably a hollow shaft. This does not necessarily have to be the case, but it is advantageous if roller main body 6 is of tubular shape at least at its ends. Roller main body 6 has an outer first lateral surface 8, a first end section 10 and a second end section 12. First and the second end section 10, 12 are each arranged at one end of roller main body 6 and lie opposite one another in the longitudinal direction. Roller main body 6 has a wall thickness W and is preferably formed from a metal, such as steel or aluminium, or a plastic.

[0068] Roller 2 further comprises a covering layer 14 made of a fibre composite material, which preferably comprises carbon fibres and a polyester resin as a matrix and, irrespective of the materials used, has a layer thickness S. By virtue of this construction, roller 2 has a high resistance to bending while having a low mass. The covering layer 14 completely surrounds first lateral surface 8 in the circumferential direction of roller main body 6 and also preferably extends completely along first lateral surface 8 in the longitudinal direction of roller main body 6. As a result, first lateral surface 8 of roller main body 6 is completely covered by covering layer 14. An outside diameter of roller 2 is designated by the reference sign DA.

[0069] A first edge region 16 of covering layer 14 extends beyond first end section 10 of roller main body 6, is folded over inwards and is fixed in relation to roller main body 6. In the embodiment illustrated, roller 2 is of symmetrical construction and, as a result, is of similar design at both ends. However, this need not necessarily be the case, and the two ends of roller 2 can also be of different designs.

[0070] A second edge region 18 of covering layer 14 extends beyond second end section 12 of roller main body 6, is folded over inwards and is fixed in relation to roller main body 6.

[0071] The fibre composite material of the covering layer 14 generally comprises fibres which are wound in the form of a woven fabric, a non-crimp fabric or in the form of prepregs in one or more plies around roller main body 6 and are then folded over or turned over inwards, that is to say in the direction of longitudinal axis 4, in the first and in the second end section 10, 12.

[0072] In this context, a first portion of fibres of the fibre composite material runs substantially in the circumferential direction of roller main body 6 and a second portion of fibres of the fibre composite material runs substantially in the longitudinal direction of roller main body 6. By virtue of the fact that covering layer 14 is folded over in the first and in the second end section 10, 12 and is fixed in relation to roller main body 6, covering layer 14 counteracts thermal expansion of roller main body 6 both in the radial direction and in the longitudinal direction, and delamination of covering layer 14 from roller main body 6 can be avoided.

[0073] In order to avoid shear stresses in covering layer 14, the first and the second edge region 16, 18 are folded over inwards around a curvature. In a first embodiment, roller main body 6 has a corresponding curvature in each case at the ends in the first and in the second end section 10, 12, as described in more detail with reference to FIGS. 2a and 2b. In a second embodiment, roller 2 comprises at least one first end ring 20 and preferably also a second end ring 22, as shown in FIG. 1 and described in more detail with reference to FIGS. 3a and 3b. The first and the second end ring 20, 22 then each have the curvature around which edge regions 16, 18 are folded over. The following statements apply both to the first and to the second embodiment, unless described otherwise.

[0074] Covering layer 14 can be adhesively fixed both in the first and in the second edge region 16, 18 and in the region of first lateral surface 8 of roller main body 6. For this purpose, the resin of the fibre composite material of covering layer 14 and/or a separate adhesive can be used. In addition or as an alternative, covering layer 14 can be fixed by frictional engagement in first edge region 16 and preferably also in second edge region 18.

[0075] In the embodiment illustrated, the roller 2 comprises a first clamping element 24 and preferably a second clamping element 26. The first clamping element 24 fixes the first edge region 16 of the covering layer 14 by frictional engagement and the second clamping element 26 fixes the second edge region 18 by frictional engagement. The first and the second clamping element 24, 26 press the first and the second edge region 16, 18, respectively, against a fastening section 28 of the roller main body 6 (see FIG. 2a, b) or, as here, of the first or second end ring 20, 22 (see FIG. 3a, b). The first and the second clamping element 24, 26 are preferably annular or disc-shaped and are arranged coaxially with respect to the longitudinal axis 4 of the roller main body 6, preferably in each case at one end of the roller 2. If the first and the second end section 10, 12 are of tubular shape or if the roller main body 6 is configured as a hollow shaft, as illustrated, the first and the second clamping element 24, 26 are preferably accommodated at least partially in the first and second end section 10, 12, respectively, of the roller main body 6.

[0076] The contact pressure on the first and the second edge region 16, 18 can be set by virtue of the adjustability of the first and the second clamping element 24, 26 in the longitudinal direction of the roller main body 6. This can be achieved by screwing the first and the second clamping element 24, 26 to a further component of the roller 2, allowing the contact pressure to be varied by means of the screw fastening. The longitudinal axes of the screws 30a-d are preferably aligned parallel to the longitudinal axis 4 of the roller main body 6, and the screws 30a-d of each clamping element 24, 26 are distributed over the circumference.

[0077] In general, the roller 2 can also have a first roller base 32 and a second roller base 34. The first and the second roller base 32, 34 each form a base of the substantially cylindrical roller main body 6, with the first roller base 32 being arranged in the first end section 10 and the second roller base 34 being arranged in the second end section 12. The first and the second clamping element 24, 26 can then be screwed to the respective roller base 32, 34, as already described.

[0078] The first and the second roller base 32, 34 can be formed integrally with the roller main body 6 or, as illustrated, can be provided as separate elements. In this case, the first and the second roller base 32, 34 are substantially annular or disc-shaped, and thus have a cylindrical shape, and are arranged coaxially with respect to the roller main body 6. An outside diameter of the first and the second roller base 32, 34 corresponds substantially to the inside diameter of the roller main body 6 in the first and the second end section 10, 12. In each of the two end sections 10, 12, the roller main body 6 can have a seat 36a, b for receiving the respective roller base 32, 34. Each seat 36a, b comprises an inner circumferential surface of the roller main body 6 in the first and the second end section 10, 12, respectively, as well as a stop surface, which positions the first and the second roller base 32, 34 in the longitudinal direction of the roller main body 6. The stop surface is formed, for example, by a step on the inner side of the roller main body 6, the roller main body 6 having a larger inside diameter on the side of the step facing the respective end than on the other side of the step.

[0079] The roller 2 can furthermore comprise a first shaft journal 38 and a second shaft journal 40, which are configured to support the roller 2 in rotation. For this purpose, the first and the second shaft journal 38, 40 are arranged coaxially with respect to the roller main body 6. The first and the second roller journal 38, 40 can, in turn, be formed integrally with the first and second roller base 32, 34, respectively, or can be separate elements.

[0080] Shaft journals 38, 40 formed as separate elements are to be centred with respect to the roller main body 6 in order to ensure the concentricity of the roller 2. In the embodiment illustrated, the first and the second roller base 32, 34 each have a through-opening 42, 44 in the longitudinal direction of the roller main body 6, in which the first and the second shaft journal 38, 40 are mounted. The through-openings 42, 44 are conically shaped and the first and the second shaft journal 38, 40 each have a corresponding, conically shaped end 38a, 40a, which is accommodated in the respective through-opening 42, 44. The first and the second clamping element 24, 26 likewise have a through-opening, through which the respective shaft journal 38, 40 passes.

[0081] A (temperature-induced) expansion of the roller 2 or of the roller main body 6 can be further counteracted by the first and the second roller base 32, 34 being clamped together in the longitudinal direction of the roller main body 6 by means of a clamping device 46. As illustrated, the clamping device 46 can comprise a rod 48, for example made of steel, and can be arranged coaxially with respect to the roller main body 6. For clamping, the rod 48 has a respective lock nut to the outside of the roller bases 32, 34 in the longitudinal direction. Here, the rod 48 extends through the first shaft journal 38, the first roller base 32, the roller main body 6, the second roller base 34 and the second shaft journal 40 coaxially with respect to the longitudinal axis 4 and has a threaded section at each of its two ends. A nut is screwed onto each of these threaded sections and bears against the respective shaft journal 38, 40.

[0082] As can be seen in FIG. 1, the roller 2 has an outer lateral surface 50, which is also referred to as the second lateral surface 50 to better distinguish it from the first lateral surface 8 of the roller main body 6. In the majority of cases and in some embodiments, the second lateral surface 50 is formed completely by the covering layer 14. For example, the covering layer 14 extends over at least 80% or at least 90% of the length L.sub.1 of the second lateral surface 50 in the longitudinal direction of the roller 2. The length of the overall roller 2 is designated as L.sub.2 and depends on the length of the shaft journals 38, 40 and thus on the mounting of the roller 2 in the respective machine. For the present consideration, the length L.sub.1 of the second lateral surface 50 is therefore of greater importance.

[0083] The second lateral surface 50 forms the actual useful surface of the roller 2. If the roller 2 is used, for example, as a deflection roller for a conveyor belt, for example in a crosslapper, the second lateral surface 50 forms the contact surface with the conveyor belt. If the roller 2 is used in a carding machine, a set of teeth can be provided on the second lateral surface 50. The set of teeth is usually formed by winding a wire around the roller 2, which wire is to be fastened to the roller ends. In this case, it is therefore advantageous if a first and a second end region 50a, 50b of the second lateral surface 50 are not formed by the covering layer 14. On the contrary, the first and the second end region 50a, 50b can be formed by the first and second clamping element 24, 26, or the first and second roller base 32, 34, respectively.

[0084] FIGS. 2a, 2b, 3a, 3b each show a detail view of the first end section 10 of different embodiments of the roller 2. All statements in this regard apply mutatis mutandis to the second end section 12.

[0085] FIGS. 2a and 2b relate to the first embodiment, in which the covering layer 14 is folded over around the first end section 10 of the roller main body 6 itself, which has the curvature 52. From the first lateral surface 8, the curvature 52 initially runs inwards in the direction of the longitudinal axis 4 of the roller main body 6 and as far as the fastening section 28 of the roller main body 6 for the first edge region 16. In the cross-sectional view, the fastening section 28 is preferably of straight design and inclined with respect to the longitudinal axis 4, and it therefore provides a substantially conical contact surface for the first edge region 16 of the covering layer 14 and is preferably arranged in the interior of the roller main body 6.

[0086] In the exemplary embodiment according to FIG. 2a, the first end region 50a of the second lateral surface 50 is formed by the first clamping element 24 or the first roller base 34, which are arranged flush with the covering layer 14, thus ensuring that a second lateral surface 50 which is as free of disruptions as possible is formed. The first clamping element 24 or the first roller base 34 can have a groove which corresponds to the curvature 52 and rests against the folded over part of the covering layer 14.

[0087] In the exemplary embodiment according to FIG. 2b, no end region 50a, b of the second lateral surface 50 is provided next to the covering layer 14. The second lateral surface 50 is formed completely by the covering layer 14. The first clamping element 24 and the first roller base 32 are at least partially and preferably completely accommodated in the roller main body 6.

[0088] FIGS. 3a and 3b relate to the second embodiment, in which the covering layer 14 is folded over around the first end ring 20, which has the curvature 52. The first end ring 20 is arranged coaxially with respect to the roller main body 6 and, at the first end section 10, directly adjoins the roller main body 6 at the end. The first end ring 20 is flush with the first lateral surface 8, and thus has an outside diameter which corresponds to the outside diameter of the roller main body 6 or first lateral surface 8.

[0089] In the embodiment illustrated, the first end ring 20 has a first section 54, which is inserted into the first end section 10 of the roller main body 6, an outside diameter of the first section 54 corresponding substantially to the inside diameter of the roller main body 6 in the first end section 10. At the end of the roller main body 6, the first end ring 20 extends radially outwards to a lateral surface section 56 of the first end ring 20, which is arranged flush with the first lateral surface 8 of the roller main body 6, that is to say has the same outside diameter as the latter. The curvature 52 extends from the lateral surface section 56 as far as the fastening section 28, which in the cross-sectional view is preferably of straight design and inclined with respect to the longitudinal axis 4 of the roller main body 6, with the result that it provides a substantially conical contact surface for the first edge region 16 of the covering layer 14.

[0090] In the exemplary embodiment according to FIG. 3a, the first end region 50a of the second lateral surface 50 is provided in a manner analogous to the exemplary embodiment according to FIG. 2a. In the exemplary embodiment according to FIG. 3b, analogously to the exemplary embodiment according to FIG. 2b, no end region 50a, b of the second lateral surface 50 is provided, and therefore the second lateral surface 50 is formed completely by the covering layer 14.

[0091] FIG. 4 shows schematically the folded-over first edge region 16 in a perspective view. As a result of the folding over of the first edge region 16, a substantially encircling first edge 16a of the covering layer 14 is arranged radially inside the first lateral surface 8. As a result, the first edge 16a has a smaller diameter and a smaller circumference than the part of the covering layer 14 which is arranged on the first lateral surface 8. This applies analogously to a second edge of the covering layer 14 in the second edge region 18. However, in order to reliably clamp the first and, if appropriate, also the second edge region 16, 18, the respective edge region 16, 18 should be configured to be free of folds and should have no overlaps of the covering layer material.

[0092] The first edge region 16 and preferably also the second edge region 18 can therefore have a plurality of notches 57 distributed in the circumferential direction. Each notch 57 of the plurality of notches 57 is configured in such a way, starting from the first edge 16a or from the second edge of the covering layer 14, that the respective edge region 16, 18 is folded over inwards without folds and without overlaps. Consequently, two subsections 16b, 16c, which are separated from one another by a notch 57, do not overlap. For this purpose, the notches 57 can be tapered, for example substantially triangular, starting from the respective edge 16a.

[0093] FIG. 5 schematically illustrates a crosslapper 58 in a side view. The crosslapper 58 comprises at least one conveyor belt for conveying a fibrous batt web (not illustrated), here a feed belt 60, a first conveyor belt 62, a second conveyor belt 64 and a draw-off belt 66. Furthermore, the crosslapper 58 preferably comprises an upper carriage 68 and a laying carriage 70. The feed belt 60 is configured to feed a fibrous batt web coming from a carding machine to the crosslapper 58 and to transfer it to the first conveyor belt 62. The first conveyor belt 62 conveys the fibrous batt web to the upper carriage 68, in which the fibrous batt web is deflected. The fibrous batt web is then transferred from the first conveyor belt 62 to the second conveyor belt 64. The second conveyor belt 64 conveys the fibrous batt web to the laying carriage 70. The laying carriage 70 is configured to move back and forth perpendicularly to the conveying direction of the draw-off belt 66, which is aligned perpendicularly to the plane of the drawing, and in the process to deposit the fibrous batt web on the draw-off belt 66.

[0094] The crosslapper 58 comprises a plurality of deflection rollers 72a-t, around which the at least one conveyor belt 60, 62, 64 is guided, wherein at least one deflection roller 72a-t of the plurality of deflection rollers 72a-t is formed by the roller 2, as described herein. All the conveyor belts 60, 62, 64 are configured to circulate and are each driven by at least one of the deflection rollers.

[0095] More precisely, in the illustrated embodiment, the feed belt 60 is guided around a first and a second deflection roller 72a, 72b. Adjacent to the feed belt 60, the first conveyor belt 62 preferably runs around a third deflection roller 72c and onwards from there to the upper carriage 68, in which the first conveyor belt 62 is deflected around a fourth and a fifth deflection roller 72d and 72e. It is preferable if both the first and the second conveyor belt 62, 64 lead from the upper carriage 68 to the laying carriage 70. A third conveyor belt 74 can be provided, which likewise leads from the other side to the laying carriage 70. In the laying carriage 70, the second and, if present, the third conveyor belt 64, 74 or alternatively the first and the second conveyor belt 62, 64 are wrapped around a sixth deflection roller 72f and a seventh deflection roller 72g, respectively, between which a laying gap is formed for discharging the fibrous batt web onto the draw-off belt 66. The third conveyor belt 74 first leads from the laying carriage 70 via a plurality of deflection rollers 72h-1 via the draw-off belt 66 and back to the laying carriage 70, an eighth deflection roller 72j being rotatably mounted in a first auxiliary carriage 76. The first auxiliary carriage 76 is provided for the length compensation of the second and the third conveyor belts 64, 74 and can be moved in the opposite direction to the laying carriage 70. The second conveyor belt 64 leads from the laying carriage 70 firstly via the draw-off belt 66 and via a plurality of deflection rollers 72m-r back to the laying carriage 70, a ninth deflection roller 72o likewise being rotatably mounted in the first auxiliary carriage 76. The first conveyor belt 62 runs from the upper carriage 68, via a tenth and an eleventh deflection roller 72s, 72t, back to the feed belt 60, the eleventh deflection roller 72t being rotatably mounted in a second auxiliary carriage 78. The second auxiliary carriage 78 is provided for the length compensation of the first conveyor belt 62. The roller described can also be used in all other known configurations of crosslappers.

[0096] FIG. 6 schematically illustrates a side view of a carding machine 80 for producing a batt web or a preliminary batt. The carding machine 80 is configured, in particular, for producing a fibrous batt web from a fibre flock mat. For this purpose, the carding machine 80 comprises a main cylinder 82, also referred to as a main roller, and a plurality of engagement rollers 84a-v, 86, 88, 90, 92, which are configured for engagement with fibre material, are associated with the main cylinder 82, upstream or downstream thereof, and of which at least one engagement roller is formed by a roller 2, as described herein.

[0097] The plurality of engagement rollers 84a-v, 86, 88, 90, 92 of the carding machine 80 may comprise, for example, a licker-in 86 and a transfer roller 88 ahead of the main cylinder 82 as well as a take-in roller 90 and a breast roller 92. The plurality of engagement rollers 84a-j can comprise a plurality of clearer and working rollers 84a-j, which are each arranged in pairs along the circumference of the main cylinder 82 and/or of the licker-in 86. The plurality of engagement rollers 84k-n can also comprise upper or lower random rollers 84k,m and/or doffer rollers 84l,n, which are provided downstream of the main cylinder 82, or upper and lower draw-off rollers 84o-r arranged downstream of the latter. Finally, the plurality of engagement rollers can comprise at least one upper and/or lower compression roller 84s-v. For example, a first and a second upper compression roller 84s,t are provided between the upper doffer roller 84l and the upper draw-off roller 84o. A first and a second lower compression roller 84u,v can furthermore be provided between the lower doffer roller 84n and the lower draw-off roller 84q.