Roller and method for producing a roller

Abstract

A roller for use in a machine for producing and/or processing and/or finishing a fiber web, such as a paper or cardboard web. The roller has a roller core and a roller cover disposed thereon. The roller cover has at least one layer or a plurality of layers. The layer or at least one of the layers is made of a foamed metal or alloy material.

1 - 15 . (canceled) 
     
     
         16 . A roller for use in a machine for manufacturing, processing, or finishing a fibrous web, the roller comprising:
 a roller core;   a roller covering on said roller core, said roller covering being formed of at least one layer or a plurality of layers, and said at least one layer, or at least one of said plurality of layers, being formed of a foamed metallic or alloyed material.   
     
     
         17 . The roller according to  claim 16 , wherein said foamed metallic or alloyed material is configured substantially with closed pores. 
     
     
         18 . The roller according to  claim 16 , wherein said foamed metallic or alloyed material is selected from the group consisting of bronze, zinc, aluminum, aluminum alloys, zinc alloys, and mixtures thereof. 
     
     
         19 . The roller according to  claim 18 , wherein said foamed metallic or alloyed material is AlSi. 
     
     
         20 . The roller according to  claim 16 , wherein said foamed metallic or alloyed material is formed with pores. 
     
     
         21 . The roller according to  claim 20 , wherein said pores are distributed in said material with a homogeneous or substantially homogeneous distribution. 
     
     
         22 . The roller according to  claim 20 , wherein said pores are distributed with a gradient in said at least one layer, wherein said at least one layer has a relatively low pore volume per volume unit radially inwardly, and an increasing pore volume per volume unit in a direction radially outward. 
     
     
         23 . The roller according to  claim 20 , wherein said pores have an average diameter of between 0.1 mm and 1 mm. 
     
     
         24 . The roller according to  claim 16 , wherein said material has a modulus of elasticity between 2000 and 10,000 MPa. 
     
     
         25 . The roller according to  claim 24 , wherein said material has a modulus of elasticity of about 5000 MPa. 
     
     
         26 . The roller according to  claim 16 , wherein said material has a thermal conductivity of approximately 3 to 25 W/mK. 
     
     
         27 . The roller according to  claim 16 , which comprises a hermetic sealing on one fibrous-web contact side of the roller. 
     
     
         28 . The roller according to  claim 27 , wherein said hermetic sealing is a filled epoxy resin having a thickness of between 2 and 10 mm. 
     
     
         29 . The roller according to  claim 27 , wherein said hermetic sealing is a thermal coating having a thickness of between 0.05 and 0.3 mm. 
     
     
         30 . The roller according to  claim 16  configured for use in a press section or in a smoothing mill or a calender for smoothing or glazing a fibrous web. 
     
     
         31 . A method for manufacturing a roller, the method comprising the following steps:
 i) attaching a metal web containing a propellant on a roller core to form at least one layer on the roller core;   ii) fixing the metal web on the roller core by a process selected from the group consisting of pressing, cold rolling, and winding and adhesive bonding;   iii) supplying external heat for heating the layer containing the propellant so as to reach the melting range and thereby foam the material of the layer and to form a layer of foamed metallic material on the roller core; and   to thereby produce the roller for use in a machine for manufacturing and/or processing and/or finishing a fibrous web, wherein the roller has the roller core and a roller covering formed of at least one layer or a plurality of layers, with the at least one layer or at least one of the layers being composed of the foamed metallic material.   
     
     
         32 . The method according to  claim 31 , which further comprises sealing the roller covering with a hermetic sealing by:
 i) grinding or re-turning the roller covering and, on account thereof, opening pores of the foamed metallic material close to a surface thereof;   ii) attaching the hermetic sealing by pouring material that forms the hermetic sealing into the opened pores.   
     
     
         33 . A method for manufacturing a roller with a roller core and a covering, the method comprising the following steps:
 i) cold forming a planar, semi-finished product to form shell segments with a desired radius of the roller core;   ii) foaming by way of a thermal process;   iii) applying the shell segments to the roller core by way of an adhesive method, in order to produce at least one layer;   iv) connecting the segments by way of a welding method or an adhesive method;   to thereby form a roller for use in a machine for manufacturing and/or processing and/or finishing a fibrous web, such as a paper or cardboard web, with the roller having the roller core with a roller covering formed of at least one layer a plurality of layers of which at least one layer is composed of a foamed metallic material.   
     
     
         34 . The method according to  claim 33 , which further comprises sealing the roller covering with a hermetic sealing by:
 i) grinding or re-turning the roller covering and, on account thereof, opening pores of the foamed metallic material close to a surface thereof;   ii) attaching the hermetic sealing by pouring material that forms the hermetic sealing into the opened pores.