U.S. patent application number 10/563343 was filed with the patent office on 2006-07-27 for process for producing resin roll.
Invention is credited to Tetsuya Murakami, Kenjiro Nakayama, Atsuo Watanabe.
Application Number | 20060162163 10/563343 |
Document ID | / |
Family ID | 33562317 |
Filed Date | 2006-07-27 |
United States Patent
Application |
20060162163 |
Kind Code |
A1 |
Watanabe; Atsuo ; et
al. |
July 27, 2006 |
Process for producing resin roll
Abstract
A resin roll (1) comprises a lower winding layer (3) comprising
a fiber-reinforced resin formed on an outer periphery of a roll
core (2), and an outer sleeve (5) comprising a synthetic resin
formed on the outside through an adhesive layer (4). A non-woven
fiber aggregate layer (8) which constitutes an outer periphery of
the lower winding layer (3) is formed such that a tape-shaped
non-woven fiber aggregate in which a fiber material mainly
comprising inorganic fibers is coupled with a binder is
sequentially transferred and the non-woven fiber aggregate is
impregnated with a liquid thermosetting resin and wound around the
outer periphery of the roll core (2).
Inventors: |
Watanabe; Atsuo; (Osaka,
JP) ; Nakayama; Kenjiro; (Kyoto, JP) ;
Murakami; Tetsuya; (Osaka, JP) |
Correspondence
Address: |
Ditthavon & Carlson
Suite A
10507 Braddock Road
Fairfax
VA
22032
US
|
Family ID: |
33562317 |
Appl. No.: |
10/563343 |
Filed: |
June 16, 2004 |
PCT Filed: |
June 16, 2004 |
PCT NO: |
PCT/JP04/08447 |
371 Date: |
January 3, 2006 |
Current U.S.
Class: |
29/895.211 ;
29/895.21; 29/895.23 |
Current CPC
Class: |
B29C 70/32 20130101;
F16C 13/00 20130101; D21G 1/02 20130101; Y10T 29/49549 20150115;
B29C 63/14 20130101; Y10T 29/49558 20150115; B29C 53/8066 20130101;
Y10T 29/49551 20150115 |
Class at
Publication: |
029/895.211 ;
029/895.23; 029/895.21 |
International
Class: |
B21D 53/00 20060101
B21D053/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 2, 2003 |
JP |
2003-189992 |
Claims
1-13. (canceled)
14. A manufacturing method of a resin roll comprising: a step of
forming a lower winding layer comprising a fiber-reinforced resin
on an outer periphery of a roll core; a step of forming an outer
sleeve comprising a synthetic resin on an outer periphery of said
lower winding layer, wherein said step of forming the lower winding
layer comprises a step of transferring a tape-shaped non-woven
fiber aggregate in which a fiber material mainly comprising
inorganic fibers is coupled with a binder in a predetermined
direction so as to be wound around the outer periphery of said roll
core, and a step of impregnating said non-woven fiber aggregate
with a liquid thermosetting resin while said non-woven fiber
aggregate is being transferred.
15. The manufacturing method of the resin roll according to claim
14, wherein said lower winding layer has a laminated structure
comprising an inner layer and an outer layer, wherein said step of
forming the lower winding layer comprises: a step of forming said
inner layer of the lower winding layer on the outer periphery of
said roll core, and a step of forming said outer layer on said
inner layer on said roll core, and said outer layer is said
non-woven fiber aggregate impregnated with the thermosetting
resin.
16. The manufacturing method of the resin roll according to claim
15, wherein said inner layer comprises a layer in which a thread, a
roving or a cloth tape comprising inorganic fibers or organic
fibers is impregnated with a liquid thermosetting resin and wound
around said roll core.
17. The manufacturing method of the resin roll according to claim
14, wherein said step of forming the lower winding layer comprises
a step of lowering viscosity of the thermosetting resin material
after said non-woven fiber aggregate is impregnated with said
liquid thermosetting resin.
18. The manufacturing method of the resin roll according to claim
17, wherein the viscosity of said thermosetting resin is lowered
while said non-woven fiber aggregate is being transferred.
19. The manufacturing method of the resin roll according to claim
17, wherein the viscosity of said thermosetting resin is lowered
while said non-woven fiber aggregate is being wound around said
roll core.
20. The manufacturing method of the resin roll according to claim
14, wherein said fiber material comprises glass fibers.
21. The manufacturing method of the resin roll according to claim
14, wherein said non-woven fiber aggregate is a non-woven fabric or
a paper formed of said fiber material.
22. The manufacturing method of the resin roll according to claim
14, wherein said non-woven fiber aggregate has a length-direction
tensile strength of 50N/15 mm or more.
23. The manufacturing method of the resin roll according to claim
14, wherein said non-woven fiber aggregate has a basic weight of 30
g/m.sup.2 to 100 g/m.sup.2.
24. The manufacturing method of the resin roll according to claim
14, wherein an inorganic filler is mixed to said thermosetting
resin.
25. The manufacturing method of the resin roll according to claim
14, wherein said outer sleeve is formed on said lower winding layer
through an adhesive layer.
26. The manufacturing method of the resin roll according to claim
14, wherein said outer sleeve is formed directly on said lower
winding layer without an adhesive layer.
Description
TECHNICAL FIELD
[0001] The present invention relates to a manufacturing method of a
resin roll used in various kinds of industries such as paper
making, iron making, a film and a fiber, and more particularly, to
a manufacturing method of a large resin roll which is used as a
paper making calender roll, a paper making press roll, a fiber
calender roll, a calender roll for manufacturing a magnetic
recording medium and the like and can withstand high loading.
BACKGROUND ART
[0002] A resin roll used in the above usage has a constitution in
which a lower winding layer comprising a fiber-reinforced resin is
formed on an outer periphery of a roll core and an outer sleeve
comprising a synthetic resin is formed on the outer periphery of
the lower winding layer, in general. A manufacturing method of such
resin roll is disclosed in Japanese Unexamined Patent Publication
No. 1-260092 (patent document 1), for example.
[0003] According to the Japanese Unexamined Patent Publication No.
1-260092, the manufacturing method of the resin roll comprises a
step of forming a fiber-reinforced lower winding layer by winding a
fiber material impregnated with a thermosetting resin around an
outer periphery of a metallic roll core, a step of separately
forming an outer-layer sleeve by pouring a thermosetting synthetic
resin raw material into a cylinder mold having a predetermined size
and curing it at a predetermined temperature, and a step of bonding
and integrating the lower winding layer and the sleeve with an
adhesive layer in such a manner that the roll core having the
fiber-reinforced lower winding layer is fitted in the outer-layer
sleeve and an adhesive having low viscosity is poured into an
annular gap between the lower winding layer and the sleeve and
cured at a predetermined temperature.
[0004] According to the Japanese Unexamined Patent Publication No.
1-260092, since the manufacturing method is especially suitable for
manufacturing a large and hard resin roll, and the resin roll has
an excellent compressive strength and its surface is not easily
damaged, the manufacturing method has a good track record as a
manufacturing method for a paper making calender roll and the
like.
[0005] In the above document, a thread, a roving, a cloth tape and
the like comprising inorganic fibers or organic fibers are
described and it is also described that the above and a non-woven
fabric comprising organic fibers or inorganic fibers can be used
together.
[0006] In general, as the manufacturing method of the resin roll,
besides the above method in which the outer-layer sleeve is
previously formed and the roll core comprising the lower winding
layer is fit in the sleeve and the adhesive is poured into the gap
between the lower winding layer and the sleeve to bond and
integrate them as disclosed in the Japanese Unexamined Patent
Publication No. 1-260092, there is another well-known method in
which a roll core comprising a lower winding layer is put in a mold
and a liquid resin for an outer layer is poured directly on an
outer periphery of the lower winding layer without an adhesive and
cured. The same material is used for the lower winding layer in
either method.
[0007] As the fiber for the lower winding layer of the resin roll
which is large and can withstand high loading, a thread, a roving
or a cloth tape having tensile strength in the length direction is
used in general because it has to be wound with constant tensile
force. However, when the outer periphery of the lower winding layer
is formed of the thread, the roving or the cloth tape, the outer
periphery of the lower winding layer is not uniform. Thus, when the
resin roll is used under high loading, a crack is likely to be
generated in the outer sleeve or the adhesive layer from the fiber
of the thread, the roving or the cloth tape in the surface of the
lower winding layer. Therefore, it is preferable that at least the
outer periphery of the lower winding layer is formed of a non-woven
fabric.
[0008] In the Japanese Unexamined Patent Publication No. 1-260092,
the non-woven fabric comprising the organic fibers or the inorganic
fibers is described as a fiber material which forms the lower
winding layer. When the organic fiber is compared with the
inorganic fiber, it is preferable that the inorganic fiber is used
in view of strength against the high loading. However, according to
the non-woven fabric comprising the inorganic fibers, since its
flexibility is low as compared with the non-woven fabric comprising
the organic fibers and the fiber is likely to become loose by the
tensile force, it is very difficult to wind it around the roll
core. Thus, the non-woven fabric comprising the organic fibers is
used for the outer periphery of the lower winding layer as it
stands. For example, in the case of the paper making calender roll,
linear pressure loading of 200 kN/m to 400 kN/m is applied. When it
is used under such high loading, the resin roll in which the
non-woven fabric comprising the organic fibers is used on the outer
periphery of the lower winding layer could be damaged at an
interface between the lower winding layer and the outer sleeve or
the adhesive layer.
DISCLOSURE OF THE INVENTION
[0009] It is an object of the present invention to provide a
manufacturing method of a resin roll which can withstand high
loading and is not likely to be damaged due to a damage of an
interface between a lower winding layer and an outer sleeve or an
adhesive layer.
[0010] The manufacturing method of the resin roll according to the
present invention is such that a lower winding layer comprising a
fiber-reinforced resin is formed on an outer periphery of a roll
core and an outer sleeve comprising a synthetic resin is formed
directly on an outer periphery of the lower winding layer or formed
thereon through an adhesive layer, and it is characterized by a
method of forming the lower winding layer.
[0011] That is, the manufacturing method of the resin roll
according to the present invention comprises a step of forming the
lower winding layer comprising the fiber-reinforced resin on the
outer periphery of the roll core, a step of forming the outer
sleeve comprising the synthetic resin on the outer periphery of the
lower winding layer, in which the step of forming the lower winding
layer comprises a step of transferring a tape-shaped non-woven
fiber aggregate in which a fiber material mainly comprising
inorganic fibers is coupled with a binder in a predetermined
direction so as to be wound around the outer periphery of the roll
core, and a step of impregnating the non-woven fiber aggregate with
a liquid thermosetting resin while the non-woven fiber aggregate is
being transferred.
[0012] According to the above method, since at least the outer
periphery of the lower winding layer has a structure in which the
fiber material mainly comprising inorganic fibers is uniformly
diffused in the thermosetting resin, it does not contain a
non-uniformity element which causes the roll to be destroyed. In
addition, since the inorganic fiber is superior in strength as
compared with the organic fiber, so that even when it is used under
high loading, the roll can be prevented from being destroyed due to
destruction or a crack at the interface with the outer sleeve or
the adhesive layer. Furthermore, since the fiber material is
coupled with the binder, although the inorganic fiber is used, the
non-woven fiber aggregate has sufficient tensile strength when it
is wound around the outer periphery of the roll core. Thus, the
winding of the non-woven fiber aggregate becomes easy.
[0013] The lower winding layer may be a monolayer structure or a
multilayer structure. According to one embodiment, the lower
winding layer has a multilayer structure comprising an inner layer
and an outer layer. In this case, the step of forming the lower
winding layer comprises a step of forming the inner layer of the
lower winding layer on the outer periphery of the roll core, and a
step of forming the outer layer on the inner layer on the roll
core. According to this embodiment, the outer layer is the
non-woven fiber aggregate impregnated with the thermosetting
resin.
[0014] According to one embodiment, the inner layer comprises a
layer in which a thread, a roving or a cloth tape formed of
inorganic fibers or organic fibers is impregnated with a liquid
thermosetting resin and wound around the roll core. In this case,
only one of the thread, the roving or the cloth tape may be used or
two or more of them may be used. In this case also, at least outer
periphery of the lower winding layer comprises a layer in which the
non-woven fiber aggregate mainly comprising the inorganic fibers is
impregnated with the thermosetting resin. According to a preferable
constitution of the lower winding layer, a combination of the
multilayer is such that the roving, the cloth tape and the
non-woven fiber aggregate are laminated in this order from the
surface of the roll core in view of strength of the resin roll
against the high loading.
[0015] More preferably, the thread, the roving, and the cloth tape
are all formed of glass fibers. In addition, other than the glass
fiber, a carbon fiber, a metal fiber and the like as the inorganic
fiber, and a polyamide fiber, an aromatic polyamide fiber, a
polyimide fiber, a polyester fiber, a phenol fiber, an acrylic
fiber and the like as the organic fiber may be used for the thread,
the roving or the cloth tape.
[0016] The inorganic fiber constituting the non-woven fiber
aggregate may include a glass fiber, a carbon fiber, a ceramic
fiber, a metal fiber and the like. Among them, the glass fiber is
preferably used in view of costs and strength and the like. As the
inorganic fiber, one kind of fiber is used in general, but two or
more kinds of fibers may be mixed and used. In addition, although
the non-woven fiber aggregate comprises only the inorganic fiber in
general, an organic fiber such as polyamide or polyester may be
mixed to the inorganic fiber.
[0017] It is preferable that the non-woven fiber aggregate does not
contain a non-uniformity element such as reinforced thread or
compulsive tangles of the fibers due to a needle punch at all. In
this sense, it is preferable that a non-woven fabric or paper
formed of a fiber material may be used in the non-woven fiber
aggregate. In addition, according to the non-woven fiber aggregate
formed of the fiber material, since the fibers are hardly oriented
in the vertical direction and they are oriented in the surface
direction almost at random, the outer periphery of the lower
winding layer is uniform and the crack caused from the fibers
constituting the lower winding layer can be almost completely
prevented from being generated at the interface with the outer
sleeve or the adhesive layer.
[0018] Although the kind of the binder which couples the fiber
material of the non-woven fiber aggregate is not particularly
limited, it is an epoxy resin, polyvinyl alcohol and the like in
general. Particularly, when the thermosetting resin material with
which the non-woven fiber aggregate is impregnated and the binder
for the fiber material comprise the same kind, excellent strength
can be provided without damaging a property of the lower winding
layer. Thus, it is preferable that both thermosetting resin
material and the binder are the epoxy resin material.
[0019] The tape-shaped non-woven fiber aggregate in which the fiber
material mainly comprising the inorganic fibers is coupled by the
binder preferably has a length-direction tensile strength of 50N/15
mm or more. When the non-woven fiber aggregate has the
length-direction tensile strength of 50N/15 mm or more, the tape of
the non-woven fiber aggregate has sufficient tensile strength while
it is wound around the outer periphery of the roll core. Thus, the
winding operation becomes easy. Meanwhile, when the
length-direction tensile strength of the tape of the non-woven
fiber aggregate is lower than the above, the fibers constituting
the tape become loose or the tape is likely to be cut into strips
because of tensile force when it is wound around the outer
periphery of the roll core, so that the winding operation becomes
difficult.
[0020] In addition, it is preferable that the non-woven fiber
aggregate has a basic weight of 30 g/m.sup.2 to 100 g/m.sup.2. When
the basic weight is less than 30 g/m.sup.2, the strength of the
tape of the non-woven fiber aggregate becomes small, and the tape
could be cut into strips by the tensile force when it is wound
around the outer periphery of the roll core. In addition, when the
basic weight of the non-woven fiber aggregate is small, since a
thickness of the tape is thin, it is necessary to increase the
number of windings to provide a predetermined thickness of the
lower winding layer, which is troublesome. Meanwhile, when the
basic weight of the non-woven fiber aggregate is more than 100
g/m.sup.2, the thickness of the lower winding layer could become
uneven and it is difficult to form the uniform lower winding layer,
so that the strength of the resin roll could be lowered.
[0021] The thermosetting resin with which the non-woven fiber
aggregate is impregnated includes an epoxy resin, a polyester
resin, a polyimide resin, a urethane resin and the like. Among
them, the epoxy resin is preferable. When the epoxy resin is used
as the thermosetting resin with which the non-woven fiber aggregate
is impregnated, the lower winding layer has excellent durability
against the high loading.
[0022] Furthermore, it is preferable that an inorganic filler is
mixed to the thermosetting resin with which the non-woven fiber
aggregate is impregnated. When the inorganic filler is mixed, the
strength of the lower winding layer is further improved and the
strength of the resin roll is improved also.
[0023] The inorganic filler mixed to the thermosetting resin with
which the non-woven fiber aggregate constituting the lower winding
layer is impregnated includes powder, beads, short fibers or
whiskers of silica, quartz, glass, clay, calcium carbonate, carbon,
ceramics and the like. Only one kind may be used or two or more
kinds may be mixed and used for the inorganic filler. Among them,
silica powder is preferably used in view of property improvement
such as compressed strength and its cost. Especially, when the
inorganic fiber is the glass fiber and the inorganic filler is the
silica powder, the lower winding layer and the resin roll has
excellent strength.
[0024] Preferably, the step of forming the lower winding layer
comprises a step of lowering viscosity of the thermosetting resin
material after the non-woven fiber aggregate is impregnated with
the liquid thermosetting resin. The viscosity of the thermosetting
resin may be lowered while the non-woven fiber aggregate is being
transferred or while the non-woven fiber aggregate is being wound
around the roll core. Alternatively, the viscosity of the
thermosetting resin may be lowered at both positions while it is
transferred and while it is wound around.
[0025] When the non-woven fiber aggregate is not sufficiently
impregnated with the thermosetting resin and the non-woven fiber
aggregate contains air, the roll could be destroyed at the
interface between the lower winding layer and the outer sleeve or
the adhesive layer while the resin roll is used under the high
loading. Thus, when the viscosity of the thermosetting resin with
which the non-woven fiber aggregate is impregnated is lowered as
described above, flow of the thermosetting resin material is
promoted. Thus, the non-woven fiber aggregate can be impregnated
with resin more efficiently, so that the air can be expelled, while
the resin penetrates fibers of the non-woven fiber aggregate.
[0026] Especially, according to the present invention, since the
non-woven fiber aggregate is provided such that the fiber material
mainly comprising the inorganic fibers is coupled with the binder,
it has sufficient tensile strength when it is wound around the
outer periphery of the roll core. Thus, with synergistic
interaction between fastening force at the time of winding and
fluidization of the thermosetting resin because of lowering of the
viscosity, the air can be efficiently expelled from the non-woven
fiber aggregate and the non-woven fiber aggregate can be fully
impregnated with the thermosetting resin. As a result, the
manufactured resin roll has sufficient strength under the high
loading.
[0027] Means for lowering the viscosity of the thermosetting resin
with which the non-woven fiber aggregate is impregnated includes a
method of heating the non-woven fiber aggregate. The non-woven
fiber aggregate can be heated by a hot-air apparatus or a heater.
In addition, the viscosity of the thermosetting resin may be
lowered by a method other than heating method.
[0028] When the viscosity of the thermosetting resin is lowered by
the heating, if the reaction of the thermosetting material
progresses before the winding of the non-woven fiber aggregate
around the outer periphery of the roll core is completed, the air
cannot to be expelled from the non-woven fiber aggregate. Thus, it
is preferable that the temperature is lowered immediately after the
non-woven fiber aggregate is impregnated with the liquid
thermosetting resin material at high temperature. In this respect,
it is preferable that the heating means, that is, the heating
apparatus is locally set at least at one position when the
non-woven fiber aggregate is transported or when the non-woven
fiber aggregate is wound around the roll core, and the non-woven
fiber aggregate impregnated with the liquid thermosetting resin is
heated instantaneously when it passes through the heating
apparatus. Since the inorganic fiber which constitutes the
non-woven fiber aggregate has heat resistance as compared with the
organic fiber, it is not damaged even when it is heated by the
heating means.
[0029] Preferably, the viscosity of the thermosetting resin
material with which the non-woven fiber aggregate is impregnated is
lowered a plurality of times or at a plurality of positions. Thus,
the air can be expelled from the non-woven fiber aggregate more
effectively and the non-woven fiber aggregate can be sufficiently
impregnated with the thermosetting resin.
[0030] In addition, the outer sleeve may be formed on the lower
winding layer through an adhesive layer or the outer sleeve may be
formed directly on the lower winding layer without the adhesive
layer.
BRIEF DESCRIPTION OF DRAWINGS
[0031] FIG. 1 is a longitudinal sectional view showing a resin roll
according to the present invention;
[0032] FIG. 2 is a transverse sectional view showing the resin roll
according to the present invention; and
[0033] FIG. 3 is a conceptual view to explain a method of forming a
non-woven fiber aggregate layer of the resin roll according to the
present invention.
BEST MODE FOR CARRYING OUT THE INVENTION
[0034] An embodiment of the present invention will be described
with reference to the drawings hereinafter. FIGS. 1 and 2 are
sectional views showing a resin roll manufactured by a method of
the present invention. The resin roll 1 comprises a lower winding
layer 3 formed of a fiber-reinforced resin on an outer periphery of
a roll core 2 and an outer sleeve 5 formed of a synthetic resin on
its outer periphery through an adhesive layer 4. The lower winding
layer 3 comprises a glass roving layer 6 impregnated with a
thermosetting resin, a glass cloth layer 7 impregnated with a
thermosetting resin, and a non-woven fiber aggregate layer 8
impregnated with a thermosetting resin which are laminated from the
side of the roll core 2 in this order.
[0035] The resin roll 1 may be manufactured as follows.
[0036] First, an outer periphery of the iron roll core 2 having a
length of 5200 mm and a diameter of 480 mm is roughened by
sandblasting and a glass roving impregnated with a liquid epoxy
resin to which 20% by weight of silica powder is mixed is wound
around the outer periphery of the roll core to form the glass
roving layer 6 having a thickness of 1 mm. Then, similarly, a glass
cloth tape impregnated with a liquid epoxy resin to which 20% by
weight of silica powder is mixed is wound around the outer
periphery of the glass roving layer 6 to form the glass cloth layer
7 having a thickness of 2 mm.
[0037] Then, glass paper 10 (SYS-041 produced by ORIBEST CO., LTD.)
in which glass fibers are coupled with an epoxy resin binder is
impregnated with a liquid epoxy resin 14 to which 20% by weight of
silica powder is mixed like the above and this is wound around the
periphery of the glass cloth layer 7 to form the non-woven fiber
aggregate layer 8 having a thickness of 3.5 mm by a method shown in
FIG. 3.
[0038] The glass paper 10 used in this example has a
length-direction tensile strength of 63.7N/15 mm, a basic weight of
40.7 g/m.sup.2, a width of 50 mm and a thickness of 0.34 mm.
[0039] As shown in FIG. 3, the glass paper 10 is sequentially
rolled out from a scroll 9 and that glass paper 10 passes through a
tension bar 11 and it is soaked in the liquid epoxy resin 14 to
which the silica powder is mixed in a resin bath 15.
[0040] An amount of the liquid epoxy resin 14 with which the glass
paper 10 is impregnated in the resin bath 15 is adjusted by two
squeeze bars 12 and the glass paper 10 is wound around the glass
cloth layer 7 on the outer side of the roll core 2 which is rotated
at a predetermined speed.
[0041] At this time, the glass paper 10 is heated at about
600.degree. C. by a heater 13 such as a hot-air processing machine
at two positions just before it is wound around the roll core and
while it is being wound around the roll core. Thus, viscosity of
the liquid epoxy resin 14 with which the glass paper 10 is
impregnated is instantaneously lowered so that the glass paper 10
is fully impregnated with the liquid epoxy resin 14 and air is
removed from the glass paper 10. Here, as shown in FIG. 3, it is
preferable that the glass paper 10 is heated from its front and
back sides. Thus, the viscosity of the liquid resin can be
efficiently lowered. The moment it is heated, the viscosity of the
liquid epoxy resin becomes 300 mPas to 1000 mPas.
[0042] Then, the liquid epoxy resin is cured at 110.degree. C. and
the lower winding layer 3 comprising the glass roving layer 6, the
glass cloth layer 7 and the non-woven fiber aggregate layer 8 is
formed on the outer periphery of the roll core 2.
[0043] Separately, after an liquid epoxy resin to which the silica
powder has been mixed is poured in a cylinder mold having a
predetermined size and cured at 170 to 180.degree. C., its inner
diameter and outer diameter are processed to make the outer sleeve
5 having an outer diameter of 540 mm, an inner diameter 501 mm and
a length of 5300 mm.
[0044] The roll core 2 on which the lower winding layer is formed
is fitted in the outer sleeve 5. Then, an adhesive comprising an
epoxy resin is poured in an annular gap formed between the lower
winding layer 3 and the outer sleeve 5 and the adhesive is cured at
80.degree. C. so that the roll core 2 on which the lower winding
layer 3 is formed and the outer sleeve 5 are bonded to be
integrated through the adhesive layer 4 having a thickness of 4 mm.
Then, the outer periphery of the roll is cut and ground to complete
the resin roll having a length of 5200 mm and a diameter of 530
mm.
[0045] In addition, according to the above method, the outer sleeve
5 is separately formed and the roll core 2 comprising the lower
winding layer 3 is fit in the outer sleeve 5, and the adhesive is
poured into the gap between the lower winding layer 3 and the outer
sleeve 5 to bond and integrate them. Other than the above method, a
resin roll may be manufactured such that a roll core 2 comprising a
lower winding layer 3 similarly is put in a roll mold and a liquid
resin for an outer layer is directly poured to the outer periphery
of the lower winding layer 3 without the adhesive layer 3 and
cured.
[0046] Since the resin manufactured by the method according to the
present invention can withstand a linear pressure of 200 kN/m to
400 kN/m, it can be appropriately used under high loading.
INDUSTRIAL APPLICABILITY
[0047] The present invention can be applied to the manufacturing
method of the resin roll which is large and can withstand high
loading, and especially it can be advantageously applied to a paper
making calender roll, a paper making press roll, a fiber calender
roll, a calender roll for manufacturing a magnetic recording medium
and the like.
* * * * *