Claims
- 1. A method of making a roller, the method comprising:
processing a core to obtain a surface roughness by thermally spraying a bond coat to substantially cover a portion of the core on which a body of elastomeric material is to be bonded; wherein said bond coat is selected from a group of materials consisting of metals, metal alloys, ceramics and cermets; and applying a body of elastomeric material over the bond coat to form a bond line; and wherein said thermal spraying further comprises at least one of
thermally spraying a coating of material that is sufficiently permeable for diverting bond-degrading fluids away from the bond line; or thermally spraying a coating of material that is impermeable to said bond-degrading fluids.
- 2. The method of claim 1, wherein the bond coat material is either a metal wire, a rod, or a powder material.
- 3. The method of claim 1, wherein said bond coat is applied in a plurality of passes of a thermal spraying device to form the bond coat.
- 4. The method of claim 1, wherein the core is metal.
- 5. The method of claim 1, wherein the bond coat is impermeable to said bond-degrading fluids and has a thickness of a range 3 mils to 250 mils.
- 6. The method of claim 1, wherein said bond coat provides a surface roughness in a range from at least approximately 400 microinches Ra to approximately 2000 microinches Ra.
- 7. The method of claim 1, wherein said bond coat is applied over the core in a single layer having a thickness of at least 35 mils.
- 8. The method of claim 1, wherein the bond coat further comprises a first layer and a second layer, the first layer having a greater density and less porosity than the second layer.
- 9. The method of claim 8, wherein the first layer is applied by at least one of
plasma spraying, HVOF spraying and low velocity flame spraying; and wherein the second layer is applied by wire arc thermal spraying to form a coarser layer for mechanical bonding to the elastomeric cover.
- 10. The method of claim 8, wherein said first layer has a thickness in a range from about 20 mils to about 125 mils; and
wherein said second layer has a thickness from about 5 mils to about 15 mils.
- 11. The method of claim 1, wherein the elastomeric material is either silicone or EPDM rubber or a urethane elastomer.
- 12. The method of claim 1, wherein the core is made of a fiber-reinforced resinous composite material.
- 13. The method of claim 1, wherein the bond coat is a 300 series or 400 series stainless steel alloy.
- 14. The method of claim 1, wherein the bond coat is a nickel-chromium alloy.
- 15. The method of claim 1, wherein the bond coat is a nickel-based alloy.
- 16. The method of claim 1, wherein the elastomer is applied by casting, extrusion, or wrapping with calendered rubber sheets.
- 17. The method of claim 1, wherein the elastomeric material is made of a natural or synthetic rubber.
- 18. The method of claim 1, wherein chemical bonding agents are used to assist bonding between the thermal spray bond coat and the elastomeric material.
- 19. The method of claim 1, wherein the thermally sprayed bond coat is applied over an existing thermally sprayed bond coat after the existing coat has been cleaned of grease, oil, and contaminants.
- 20. A roller comprising:
a roller core; a bond coat bonded to the core to provide an outer surface roughness; a coat of elastomeric material bonded to the bond coat to form a bond line along which the elastomeric material is bonded to the core; wherein said bond coat comprises a thermally sprayed material selected from a group of materials consisting of 10 metals, metal alloys, ceramics and cermets; and wherein said bond coat further comprises at least one of
a thermally sprayed coating of material that is sufficiently permeable for diverting bond-degrading fluids away from the bond line; or a thermally sprayed coating of impermeable material.
- 21. The roller of claim 20, wherein the material of the bond coat is either a metal wire, a rod, or a powder material.
- 22. The roller of claim 20, wherein the bond coat comprises a plurality of coating layers.
- 23. The roller of claim 20, wherein the core is made of metal.
- 24. The roller of claim 20, wherein the bond coat is impermeable to said bond-degrading fluids and has a thickness of a range 3 mils to 250 mils.
- 25. The roller of claim 20, wherein the bond coat has a surface roughness in a range from at least approximately 400 microinches Ra to approximately 2000 microinches Ra.
- 26. The roller of claim 20, wherein the bond coat further comprises a single layer having a thickness of at least 35 mils.
- 27. The roller of claim 26, wherein the single layer is comprised of a plurality of coatings of a like material resulting from several passes of thermal spraying.
- 28. The roller of claim 20, wherein the bond coat further comprises a first layer and a second layer, the first layer having a greater density and less porosity than the second layer.
- 29. The roller of claim 28, wherein said first layer has a thickness in a range from about 20 mils to about 125 mils; and
wherein said second layer has a thickness from about 5 mils to about 15 mils.
- 30. The roller of claim 20, wherein the bond coat further comprises a first layer and a second layer which are both permeable, wherein the second layer is coarser than the first layer for the purpose of assisting mechanical bonding to the elastomeric layer; and wherein the second layer has greater permeability than the first layer.
- 31. The roller of claim 20, wherein the elastomeric material is either silicone rubber or urethane.
- 32. The roller of claim 20, wherein the core is made of a fiber-reinforced resinous composite material.
- 33. The roller of claim 20, wherein the bond coat is a 300 series or 400 series stainless steel alloy.
- 34. The roller of claim 20, wherein the bond coat is a nickel-chromium alloy.
- 35. The roller of claim 20, wherein the bond coat is a nickel-based alloy.
- 36. The roller of claim 20, wherein the elastomer is applied by casting, extrusion, or wrapping with calendered rubber sheets.
- 37. The roller of claim 20, wherein the elastomeric material is based on a natural or synthetic elastomer.
- 38. The roller of claim 20, wherein chemical bonding agents are used to assist bonding between the thermal spray bond coat and the elastomeric covering material.
- 39. The roller of claim 20, wherein the thermally sprayed bond layer is applied over an existing thermally sprayed bond layer.
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This is a continuation-in-part of U.S. patent appl. Ser. No. 09/570,250, filed May 12, 2000.
Divisions (1)
|
Number |
Date |
Country |
Parent |
09740470 |
Dec 2000 |
US |
Child |
10345425 |
Jan 2003 |
US |
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09570250 |
May 2000 |
US |
Child |
09740470 |
Dec 2000 |
US |