Method for and devices used in covering a roll core with a resin infused fiber reinforced adhesive under layer and a polymeric top layer, the method including the use of an improved mold tape

Abstract

A covered roll for use in calendaring web sheets, the cover roll including a metal roll core base substantially cylindrical in shape and arranged for rotation during use, the roll core base having an outer surface. An adhesive layer is disposed over and secured to the outer surface of the roll core base. A cover is formed of a thermoplastic material, the cover having a thermoset resin infused reinforcement fiber layer, the fiber layer circumferentially surrounding and secured to the adhesive layer, whereby the cover is bound to the rotatable roll core base.

What is claimed is:  
     
         1 . A covered roll for use in calendaring web sheets, said cover roll comprising: 
 (a) a metal roll core base substantially cylindrical in shape and arranged for rotation during use, said roll core base comprising an outer surface;    (b) an adhesive layer disposed over and secured to said outer surface of said roll core base; and    (c) a cover formed of a thermoplastic material, said cover comprising a thermoset resin infused reinforcement fiber layer, said fiber layer circumferentially surrounding and secured to said adhesive layer, whereby said cover is bound to said rotatable roll core base.    
     
     
         2 . The roll core of  claim 1  wherein said fiber layer comprises glass fibers.  
     
     
         3 . The covered roll of  claim 1  wherein said fiber layer comprises carbon fibers.  
     
     
         4 . The covered roll of  claim 1  wherein said fiber layer comprises aramid fibers.  
     
     
         5 . The covered roll of  claim 1  wherein said thermoplastic material includes a concentration of carbon fibers.  
     
     
         6 . The covered roll of  claim 1  wherein said thermoplastic material includes a concentration of aramid fibers.  
     
     
         7 . The covered roll of  claim 1  wherein said thermoplastic material comprises a dual layer construction comprising an understock and a top stock, said top stock comprising a glass fiber concentration between 0% and 40% by weight glass fiber.  
     
     
         8 . The covered roll of  claim 1  wherein said thermoplastic material comprises a dual layer construction comprising an understock and a top stock, said top stock comprising an aramid fiber concentration between 0% and 30% by weight aramid fiber.  
     
     
         9 . The covered roll of  claim 1  wherein said thermoplastic material comprises a dual layer construction comprising an understock and a top stock, said top stock comprising a carbon fiber concentration between 0% and 35% by weight carbon fiber.  
     
     
         10 . The covered roll of  claim 1  wherein said thermoplastic material comprises a dual layer construction comprising a top stock formed of a thermoplastic material having a predetermined fiber concentration and an understock formed of a thermoplastic material having a predetermined fiber concentration, and wherein the fiber concentration of said top stock is approximately equal to the fiber concentration of said understock.  
     
     
         11 . The covered roll of  claim 1  wherein said thermoplastic material is formed of polyetherimide.  
     
     
         12 . The covered roll of  claim 1  wherein said thermoplastic material is formed of polyethersulfone.  
     
     
         13 . The covered roll of  claim 1  wherein said thermoplastic material is formed of polyphenylene sulfide.  
     
     
         14 . The covered roll of  claim 1  wherein said thermoplastic material is formed of polyetheretherketone.  
     
     
         15 . The covered roll of  claim 1  wherein said thermoplastic material is formed of polyphenylene oxide.  
     
     
         16 . The covered roll of  claim 10  wherein said fibers are glass fibers.