Field-replaceable composite roll system for corona treatment

Abstract

A Field-Replaceable Composite Roll system (FRCR) consists of a complex composite cover and a unique mechanical mounting system, configured to allow the retrofit of existing silicone sleeved rolls, as well as manufacture new rolls, at substantially lower costs. The system of the present invention can be used for retrofitting existing dead-shaft or live-shaft rolls previously manufactured to use silicone sleeves, as well as fabricating new rolls in conjunction with the patented WINERTIA® brand tubing or conventional thin-walled tubing. The exemplary embodiment of the composite cover is fabricated of a filament wound tube bound together via a resin or the like having dielectric properties, the tube forming inner and outer walls, the inner wall coated with a conductive layer for receiving and conducting an electric current, the outer wall coated with a wear resistant layer (illustrated as ceramic coating), followed by a sealant layer. The composite cover is configured to slide over and envelope a roller body, and be anchored in place via mechanical mount formed of first and second expansion rings and associated compression bases.

I claim:  
     
         1 ). A corona electrode roller system for use with a roller having a cylindrical body having first and second ends, a length and an outer diameter, and a shaft longitudinally emanating therefrom, comprising: 
 a sleeve of dielectric material having a conductive inner wall, said sleeve having an inner diameter sufficient to enable said sleeve to slide over the outer diameter of the cylindrical body of the roller, while allowing the conductive inner wall of said sleeve to engage the outer diameter of said cylindrical body, said sleeve having a length to envelope the cylindrical body of the roller, while allowing said first and second ends of said sleeve to extend beyond the first and second ends of said cylindrical body of said roller when said sleeve is slipped over said cylindrical body of said roller, so as to provide first and second free ends of said sleeve emanating beyond the first and second ends of the cylindrical body of said roller;    first and second mechanical mounts for engaging said first and second free ends of said sleeve, and anchoring said first and second free ends to the roller, each of said first and second mechanical mounts further comprising: 
 a compression base having a central passage formed therethrough for receiving the shaft of the roller, said compression base having an outer diameter which is laterally tapered from a lesser outer diameter to a greater outer diameter;  
 a generally disc shaped expansion ring, said expansion ring having formed therethrough a passage having an inner diameter formed to engage the outer diameter of said compression base;  
 wherein tightening the engagement of said expansion ring to said compression base increases the outer diameter of said expansion ring to engage the inner diameter of said sleeve, while decreasing the inner diameter of the passage formed in said compression base, to tighten said compression base about said shaft.  
   
     
     
         2 ) The corona electrode roller system of  claim 1 , wherein said tube is formed of a conductive layer of carbon veil strip having laminated thereon a layer of filament winding bound together by resin.  
     
     
         3 ) The corona electrode system of  claim 2 , wherein the outer diameter of said sleeve has applied thereon a ceramic outer coating.  
     
     
         4 ) The coronal electrode system of  claim 3 , wherein said ceramic outer coating is a different color than the underlying filament winding and resin, so that the wearing through of said ceramic outer coating results in an observable color change.  
     
     
         5 ) The corona electrode system of  claim 4 , wherein there is applied to said ceramic outer coating a clear sealant.  
     
     
         6 ) The corona electrode system of  claim 5 , wherein the inner diameter of said passage formed through said expansion ring is tapered from a lesser inner diameter to a greater inner diameter, so as to facilitate compression of said compression base, as well as expansion of said outer diameter of said expansion ring, upon tightening of said compression base to said expansion ring.  
     
     
         7 ) The method of servicing a corona roller having a shaft and a roller body having an outer diameter, a length, and first and second ends, comprising the steps of: 
 a. providing a sleeve of dielectric material, said sleeve having an inner diameter sufficient to enable said sleeve to slide over the outer diameter of the cylindrical body of the roller, while allowing the inner wall of said sleeve to engage the outer diameter of said cylindrical body;    b. slidingly positioning said sleeve over said roller body such that said length of said sleeve envelopes the cylindrical body of the roller, while allowing first and second ends of said sleeve to extend beyond the first and second ends of said cylindrical body of said roller, so as to provide first and second free ends of said sleeve emanating beyond the first and second ends of the cylindrical body of said roller;    c. applying a first mechanical mount to said first free end of said sleeve emanating beyond the first end of the cylindrical body of said roller so as to anchor said first end of said sleeve to said roller;    d. applying a second mechanical mount to second free end of said sleeve emanating beyond the second end of the cylindrical body of said roller so as to anchor said second end of said sleeve to said roller;    e. allowing said sleeve to function as a dielectric roller, while protecting the cylindrical body of said roller.    
     
     
         8 . The method of  claim 7 , wherein said first and second mechanical mounts each comprise: 
 a compression base having a central passage formed therethrough for receiving the shaft of the roller, said compression base having an outer diameter which is laterally tapered from a lesser outer diameter to a greater outer diameter;    a generally disc shaped expansion ring, said expansion ring having formed therethrough a passage having an inner diameter formed to engage the outer diameter of said compression base;    and wherein in step “c” and “d” the step of applying said first and second mechanical mounts further comprises the steps of: 
 i. placing a first compression base about said shaft in the vicinity of the first end of said sleeve, and applying and tightening a first expansion ring to said to said first compression base so as to increase the outer diameter of said expansion ring to engage the inner diameter of said first end of said sleeve, while decreasing the inner diameter of the passage formed in said first compression base, so as to tighten said compression base about said shaft and anchor said first end of said sleeve in place; and  
 ii. placing a second compression base about said shaft in the vicinity of the second end of said sleeve, and applying and tightening a second expansion ring to said to said second compression base so as to increase the outer diameter of said expansion ring to engage the inner diameter of said second end of said sleeve, while decreasing the inner diameter of the passage formed in said second compression base, so as to tighten said compression base about said shaft and anchor said second end of said sleeve in place  
   
     
     
         9 ) The method of  claim 7 , wherein said first and second mechanical mounts each comprise: 
 an adapter ring comprising a mounting flange to engage the end of the sleeve, a first OD member having an outer diameter configured to engage the inner diameter of said sleeve, said first OD member laterally emanating from said adapter ring, and a second OD member having a second outer diameter configured to engage the inner diameter of said cylindrical body of said roller; and wherein in step “c” and “d” the step of applying said first and second mechanical mounts further comprises the steps of: 
 i. placing a first adapter ring about said shaft in the vicinity of said first end of said sleeve, engaging said first OD member to said inner diameter of said sleeve, engaging said second OD member to said inner diameter of said cylindrical body of aid roller, and fastening said adapter ring to said roller.  
 ii. placing a second adapter ring about said shaft in the vicinity of said second end of said sleeve, engaging said first OD member to said inner diameter of said sleeve, engaging said second OD member to said inner diameter of said cylindrical body of said roller, and fastening said adapter ring to said roller.  
   
     
     
         10 ) The method of  claim 7 , wherein said first and second mechanical mounts each comprise: 
 an adapter ring comprising a mounting flange to engage the end of the sleeve, a first OD member having an outer diameter configured to engage the inner diameter of said sleeve, said first OD member laterally emanating from said adapter ring, said mounting flange further having formed therein fastener apertures for receiving a fastener configured to engage and retain said adapter ring to an end of said cylindrical body of said; and wherein in step “c” and “d” the step of applying said first and second mechanical mounts further comprises the steps of: 
 i. placing a first adapter ring about said shaft in the vicinity of said first end of said sleeve, engaging said first OD member to said inner diameter of said sleeve, and fastening said mounting flange to said cylindrical body of said roller via said fastener apertures formed in said mounting flange.  
 ii. placing a second adapter ring about said shaft in the vicinity of said first end of said sleeve, engaging said first OD member to said inner diameter of said sleeve, and fastening said mounting flange to said cylindrical body of said roller via said fastener apertures formed in said mounting flange.  
   
     
     
         11 ). A corona electrode roller system for use with a roller having a cylindrical body having first and second ends, a length and an outer diameter, and a shaft longitudinally emanating therefrom, comprising: 
 a sleeve of dielectric material having a conductive inner wall, said sleeve having an inner diameter sufficient to enable said sleeve to slide over the outer diameter of the cylindrical body of the roller, while allowing the conductive inner wall of said sleeve to engage the outer diameter of said cylindrical body, said sleeve having a length to envelope the cylindrical body of the roller, while allowing said first and second ends of said sleeve to extend beyond the first and second ends of said cylindrical body of said roller when said sleeve is slipped over said cylindrical body of said roller, so as to provide first and second free ends of said sleeve emanating beyond the first and second ends of the cylindrical body of said roller;    first and second mechanical mounts for engaging said first and second free ends of said sleeve, and anchoring said first and second free ends to the roller, each of said first and second mechanical mounts further comprising: 
 fastening means for fastening said adapter ring to said first or second end of said cylindrical body of said roller.  
   
     
     
         12 ) The corona electrode roller system of  claim 11 , wherein said tube is formed of a conductive layer of carbon veil strip having laminated thereon a layer of filament winding bound together by resin.  
     
     
         13 ) The corona electrode system of  claim 12 , wherein the outer diameter of said sleeve has applied thereon a ceramic outer coating.  
     
     
         14 ) The coronal electrode system of  claim 13 , wherein said ceramic outer coating is a different color than the underlying filament winding and resin, so that the wearing through of said ceramic outer coating results in an observable color change.  
     
     
         15 ) The corona electrode system of  claim 14 , wherein there is applied to said ceramic outer coating a clear sealant.  
     
     
         16 ) The corona electrode system of  claim 15 , wherein the inner diameter of said passage formed through said expansion ring is tapered from a lesser inner diameter to a greater inner diameter, so as to facilitate compression of said compression base, as well as expansion of said outer diameter of said expansion ring, upon tightening of said compression base to said expansion ring.  
     
     
         17 ) The corona electrode system of  claim 16 , wherein said first and second mechanical mounts each further comprise: 
 an adapter ring comprising a mounting flange to engage the end of the sleeve, a first OD member having an outer diameter configured to engage the inner diameter of said sleeve, said first OD member laterally emanating from said adapter ring, and a second OD member having a second outer diameter configured to engage the inner diameter of said cylindrical body of said roller.    
     
     
         18 . The corona electrode system of  claim 17 , wherein said first and second mechanical mounts each further comprise: 
 an adapter ring comprising a mounting flange to engage the end of the sleeve, a first OD member having an outer diameter configured to engage the inner diameter of said sleeve, said first OD member laterally emanating from said adapter ring, said mounting flange further having formed therein fastener apertures for receiving a fastener configured to engage and retain said adapter ring to an end of said cylindrical body of said roller.