Description:LIGHTWEIGHT, WEAR-RESISTANT, AND ANTISTATIC COATING FOR COMPOSITE ROLLERS IN THE FILM AND FOIL INDUSTRY
FIELD OF THE INVENTION
The present invention relates to the field of roller manufacturing and coating technologies. More specifically, it pertains to the film, paper, foil, and plastic industries where lightweight, wear-resistant, and antistatic rollers with a coating called hereinafter Tufflite coating.
BACKGROUND OF THE INVENTION
In the film and foil industry, rollers play a crucial role in guiding, supporting, and conveying products during high-speed web processing operations. To meet the industry's demands, composite tubes have emerged as a favorable choice due to their lightweight nature, reducing energy consumption and enhancing production efficiency. However, conventional coating methods used to enhance the wear resistance and antistatic properties of these composite tubes have presented several challenges.
Conventionally, the film and foil industry has relied on various techniques and methods for coating rollers used in their processes. These techniques include surface treatments, such as plasma treatments or chemical coatings, and the use of traditional materials like steel or aluminium. However, these conventional methods have certain limitations and drawbacks that necessitate the development of a new system like Tufflite coating.
One conventional method involves applying surface treatments to improve the properties of rollers. Plasma treatments are commonly used to enhance the surface energy and adhesion properties. However, these treatments are often costly and time-consuming. Additionally, they may not provide sufficient wear resistance or antistatic properties required for efficient operation in the film and foil industry.
other conventional method includes a Chemical coating, such as polymer-based coatings, have been used to enhance the wear resistance and antistatic properties of rollers. However, these coatings can be prone to delamination, leading to reduced performance and shorter lifespan of the rollers. Moreover, the application of these coatings can be complex and require specialized equipment, making them less cost-effective and time-efficient, further To address wear resistance and static charge dissipation in composite tubes, industry practitioners have employed various conventional coating solutions. These coatings, such as rubber or plastic coatings, can be expensive and difficult to apply evenly. Moreover, their wear resistance may not be sufficient to withstand the demanding conditions of high-speed applications, resulting in frequent replacements and increased downtime.
Furthermore, rollers made from traditional materials like steel or aluminium has been used in the industry. While these materials offer adequate wear resistance, they are heavy leading to higher energy consumption and increased wear on other components in the machinery. Their conductivity may also be insufficient for effective static charge dissipation, leading to operational issues and also limited the speed and productivity of production lines.
The conventional methods mentioned above suffer from several problems that limit their effectiveness in meeting the requirements of the film and foil industry.
Insufficient Wear Resistance: Surface treatments and chemical coatings may not provide the desired level of wear resistance necessary for prolonged use in high-speed and abrasive applications. This results in frequent roller replacements, increased downtime, and higher maintenance costs.
Inadequate Static Charge Dissipation: Conventional methods often fail to effectively dissipate the static charge generated during the film and foil processing, leading to issues like film sticking, dust attraction, and electrical discharge. This can result in production inefficiencies, product defects, and potential safety hazards.
Heavy Weight and High Inertia: Rollers made from traditional materials like steel or aluminium are heavy, increasing energy consumption and limiting the speed and efficiency of production processes. The high inertia of these rollers can also impact the responsiveness and accuracy of the system, leading to decreased productivity.
Complex and Costly Application Processes: Conventional coating methods, such as plasma treatments or chemical coatings, can be complex, time-consuming, and require specialized equipment. These factors contribute to higher costs and longer production lead times, negatively impacting the overall efficiency and profitability of the industry.
The limitations and problems associated with conventional methods highlight the need for a new system that can overcome these challenges and provide an efficient, cost-effective, and high-performance solution for coating rollers in the film and foil industry, wherein the new system that includes Tufflite coating.
Therefore, we need a new coating for rollers in the film and foil industry that enhanced Wear Resistance, Efficient Static Charge Dissipation, Lightweight in nature, reduces energy consumption, enables faster production speeds, and improves overall system efficiency and cost effective.

SUMMARY OF THE INVENTION
The present invention introduces Tufflite coating, a solution designed to enhance the performance and lifespan of composite rollers used in the film and foil industry. Tufflite coating addresses the limitations of conventional methods by offering a lightweight, wear-resistant, and antistatic coating that effectively dissipates static charge and improves roller functionality. The coating is cost-effective and provides an attractive matt finish, further enhancing the aesthetic appeal of the rollers.
The primary objective of the present invention is to overcome the challenges associated with conventional methods and systems used in the film and foil industry. The invention aims to provide a comprehensive coating solution for composite rollers.
Other objective of the present invention is to provide a lightweight design and also aims to reduce energy consumption and increase production efficiency by offering a lightweight coating for composite rollers.
Other objective of the present invention is to enhance the wear resistance of composite rollers, extending their lifespan and reducing the need for frequent replacements. This leads to cost savings and improved overall roller performance.
Other objective of the present invention is to provide effective static charge dissipation during high-speed web processing operations. By providing excellent antistatic properties, the coating ensures smooth and efficient production processes, avoiding issues such as film sticking and dust attraction.
Other objective of the present invention is to focuses on improving the visual appeal of composite rollers by providing a matt finish coating, contributing to a more professional manufacturing environment.
Another objective of the present invention is to offer a cost-effective coating solution, providing manufacturers with an efficient and affordable method to enhance roller performance and durability.
By fulfilling these objectives, the present invention revolutionizes the film and foil industry by introducing Tufflite coating as a lightweight, wear-resistant, and antistatic coating that meets the unique requirements of composite rollers. With its innovative features and practical application method, Tufflite coating enhances roller functionality, improves product quality, reduces maintenance costs, and promotes productivity in film and foil manufacturing operations.
Other objects, advantages, and novel features of the invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
To further clarify the advantages and features of the present disclosure, a more particular description of the disclosure will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the disclosure and are therefore not to be considered limiting of its scope. The disclosure will be described and explained with additional specificity and detail with the accompanying drawings.
The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other aspects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
Figure 1 illustrates a Composite Roller Structure, in accordance with an embodiment of the present invention;
Figure 2 illustrates Tufflite Coating Composition, in accordance with an embodiment of the present invention; and
Figure 3 illustrates a step-by-step process flow for applying the Tufflite coating on the composite tube, in accordance with an embodiment of the present invention.
Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have necessarily been drawn to scale. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF THE INVENTION
For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings, and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein would be contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art. The system, methods, and examples provided herein are illustrative only and are not intended to be limiting.
The term “some” as used herein is to be understood as “none or one or more than one or all.” Accordingly, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would all fall under the definition of “some.” The term “some embodiments” may refer to no embodiments or to one embodiment or to several embodiments or to all embodiments, without departing from the scope of the present disclosure.
The terminology and structure employed herein is for describing, teaching, and illuminating some embodiments and their specific features. It does not in any way limit, restrict or reduce the spirit and scope of the claims or their equivalents.
More specifically, any terms used herein such as but not limited to “includes,” “comprises,” “has,” “consists,” and grammatical variants thereof do not specify an exact limitation or restriction and certainly do not exclude the possible addition of one or more features or elements, unless otherwise stated, and furthermore must not be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated with the limiting language “must comprise” or “needs to include.”
Whether or not a certain feature or element was limited to being used only once, either way, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do not preclude there being none of that feature or element, unless otherwise specified by limiting language such as “there needs to be one or more . . . ” or “one or more element is required.”
Unless otherwise defined, all terms, and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by one having ordinary skills in the art.
Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.
Use of the phrases and/or terms including, but not limited to, “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or variants thereof do not necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.
Any particular and all details set forth herein are used in the context of some embodiments and therefore should not be necessarily taken as limiting factors to the attached claims. The attached claims and their legal equivalents can be realized in the context of embodiments other than the ones used as illustrative examples in the description below. Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.
The present invention, Tufflite Coating, is a ground-breaking solution designed to enhance the performance of composite rollers used in the film and foil industry. It addresses the limitations of conventional methods by providing a lightweight, wear-resistant, and antistatic coating. The coating is specifically formulated to effectively dissipate static charge generated during high-speed web processing operations while extending the lifespan of the rollers.
As according to the present invention, the novel Tufflite Coating comprises several key components that contribute to its exceptional properties. The coating utilizes a specialized epoxy resin as its base, which provides a strong and durable foundation. A carefully selected hardener is incorporated to enhance the coating's wear resistance, ensuring it can withstand the demanding conditions of the film and foil industry. Filler materials are added to optimize the coating's performance, and milled carbon fiber is included to further reinforce its wear resistance and structural integrity. Additionally, the inclusion of graphene enhances the coating's antistatic properties, enabling efficient static charge dissipation. These components work synergistically to create a robust and reliable coating for composite rollers.
As according to an embodiment of the present invention, coating is further enhanced with the addition of pigment, which not only provides aesthetic appeal but also contributes to the coating's overall durability and resistance to chemical corrosion. The combination of these carefully chosen components results in a Tufflite coating that offers a comprehensive solution for the challenges faced by the film, paper, foil, and plastic industries.
As according to the present invention, First, an epoxy resin is mixed with a carefully selected hardener in a ratio of 30% - 40% hardener by weight of the resin. This resin-hardener mixture serves as the strong and durable foundation of the coating. Next, filler materials are incorporated in a ratio of 30% - 45% of the total weight of the “Epoxy Resin-hardener” mixture to optimize the coating's performance. These filler materials can include reinforcing agents or functional additives tailored to specific industry requirements.
In addition to the resin-hardener-filler mixture, the Tufflite coating formulation includes milled carbon fiber and graphene to further enhance its properties. Milled carbon fiber, added in a ratio of 1% - 5% of the total weight of the resin-hardener and filler mixture, provides exceptional strength, stiffness, and wear resistance to the coating. Simultaneously, the inclusion of graphene in a ratio of 1% - 5% of the total weight of the Epoxy resin-hardener and filler mixture contributes to the coating's antistatic properties, enabling efficient static charge dissipation during high-speed web processing operations. The synergistic effect of these components creates a robust and reliable coating that withstands the demanding conditions of the film and foil industry.
Furthermore, the Tufflite coating culminates with the addition of pigment, constituting 1% of the total weight of the resin-hardener and filler mixture. This pigment serves to provide coloration to the coating, contributing to the desired matte finish and enhancing the visual appeal of the composite rollers. With the carefully calibrated Tufflite coating composition, manufacturers can achieve superior wear resistance, antistatic properties, and overall durability for their composite rollers. The simplified and cost-effective application method ensures that Tufflite coating efficiently enhances roller functionality, reduces maintenance costs, and improves productivity in the film and foil industry. By following this best method, the present invention revolutionizes the coating process for composite rollers, providing a game-changing solution that meets the unique requirements of high-speed web processing operations and promotes efficient and reliable manufacturing processes.
In addition to its functional benefits, Tufflite Coating offers an appealing aesthetic appearance. The coating features a matt finish, which not only enhances the visual appeal of the composite rollers but also contributes to a more professional and aesthetically pleasing manufacturing environment. The matt finish also helps to reduce glare and surface imperfections, ensuring optimal performance during high-speed operations. With its unique formulation and application methodology, Tufflite Coating provides a comprehensive solution that addresses the challenges associated with conventional coating methods for composite rollers in the film and foil industry.
Figure 1 illustrate Composite Roller Structure provides a visual representation of the composite roller, emphasizing the arrangement of the composite tube, bearings, and the application of the Tufflite coating.
As according to the present invention, Figure. 1 describes about Composite Roller Structure (100), wherein figure 1 provides a detailed structure of a composite roller, showcasing its key components and their arrangement. It offers a clear visualization of how the roller is assembled and highlights the position of the Tufflite coating on the roller's surface.
In accordance with the present invention, Figure 1 illustrates a composite tube (104) that serves as the main cylindrical body of the roller. The composite tube is a key component of the roller structure, and it is specifically designed to offer a combination of strength, durability, and lightweight characteristics. The tube is constructed using a lightweight composite material, such as carbon fiber. This choice of material ensures that the roller maintains its structural integrity while minimizing its overall weight.
As according to an embodiment of the present invention, the composite tube (104) plays a critical role in the roller's performance and functionality. The lightweight nature allows for reduced inertia, making it well-suited for high-speed applications where quick and precise movements are required. The use of carbon fiber as the primary material further enhances the tube's strength and durability, enabling it to withstand the mechanical stresses and loads experienced during operation.
As according to an embodiment of the present invention, the lightweight composite tube (104) helps to achieves a roller design that combines the desirable qualities of strength, durability, and low weight and makes the roller highly suitable for various industrial applications, particularly those in which lightweight and high-performance rollers are essential, such as the paper, film, foil, and plastic industries.
The present invention incorporates bearings as essential components of the device, wherein the bearings play a crucial role in ensuring the smooth rotation of the roller. They are strategically positioned at each end of the composite tube to provide stability and support during the roller's operation.
As according to an embodiment of the present invention, the bearings enable the composite tube to rotate with minimal friction, reducing energy loss and facilitating efficient movement. They are designed to withstand the mechanical forces and loads encountered during the roller's operation, ensuring its long-term durability and performance.
The bearings contribute to the overall stability of the roller, allowing it to operate effectively in various industrial applications. Whether used in the paper, film, foil, or plastic industry, the inclusion of bearings ensures that the roller rotates with ease, providing optimal performance and enhancing the overall efficiency of the device.

The present invention incorporates Tufflite Coating (106), wherein the Tufflite coating (106) plays a critical role in enhancing the performance and functionality of the composite roller. It is specifically applied to the outer surface of the composite tube, serving as a protective layer that offers several key benefits.
As according to an embodiment of the present invention, the Tufflite coating is to provide wear resistance. As the roller comes into contact with various materials during high-speed web processing operations, it is prone to wear and abrasion. The Tufflite coating acts as a barrier, shielding the composite tube from these abrasive forces and minimizing the impact of wear. This enhances the roller's durability, prolonging its lifespan, and reducing the need for frequent maintenance or replacement.
Additionally, the Tufflite coating possesses antistatic properties. During high-speed web processing, static charges can accumulate on the roller's surface. These static charges can interfere with the production process, leading to issues such as material sticking or misalignment. The Tufflite coating is designed to efficiently dissipate these static charges, ensuring smooth and uninterrupted operation. By effectively managing static electricity, the coating contributes to the overall productivity and quality of the production process.
The application of the Tufflite coating on the composite tube (104) is crucial in achieving these desired properties. It provides a protective layer that enhances wear resistance and enables effective static charge dissipation. This ensures that the composite roller performs optimally in demanding industrial applications, such as those in the film, paper, foil, and plastic industries. The Tufflite coating not only extends the lifespan of the roller but also improves its overall functionality and reliability.
Figure 2 illustrate a detailed visual representation of the composition of the Tufflite coating, showcasing the different components and their respective ratios. It offers a schematic depiction of the formulation of the coating, highlighting the key ingredients that contribute to its properties and functionality.
As according to the present invention, the following components of the Tufflite coating includes: resin, Hardener, Filler Materials, Milled Carbon Fiber, Graphene and Pigment, wherein the resin (201) component of the coating, which is typically epoxy resin that provides a strong and durable protective layer on the composite roller. Epoxy resin is known for its excellent adhesion and durability properties, making it suitable for providing a protective layer on the composite roller.
As according to an embodiment, the Epoxy resin is widely recognized for its exceptional adhesion properties, which allow it to bond effectively with various surfaces, including the composite tube of the roller of the Tufflite coating, the present invention ensures that the composite roller receives a protective layer with exceptional adhesion and durability properties. This results in a robust and long-lasting coating that enhances the roller's performance, extends its lifespan, and provides reliable protection against wear and other external factors.
The hardener (202) is an essential component of the Tufflite coating that works in conjunction with the resin to initiate the curing process. When hardener combined with the resin, the hardener undergoes a chemical reaction, commonly referred to as curing or crosslinking, that transforms the coating from a liquid state to a solid and chemically stable form.
As according to an embodiment of the present invention, the hardener (202) is to facilitate the curing process by initiating the chemical reaction with the resin (201) and reaction leads to the formation of strong chemical bonds within the coating, resulting in enhanced strength, adhesion, and overall durability. The hardener is carefully selected to ensure compatibility with the resin and to achieve the desired curing properties for the Tufflite coating, wherein the resin is the carefully selected hardener, mixed in a ratio of 30% - 40% by weight of the resin. This hardener initiates the curing process, resulting in a chemically stable and well-adhered coating.
During the curing process, the hardener (202) and resin (201) undergo a crosslinking reaction, where the individual molecules link together to form a three-dimensional network. This network structure contributes to the coating's mechanical strength, chemical stability, and resistance to wear and degradation.
By incorporating the hardener (202) into the Tufflite coating, the present invention ensures that the coating achieves its desired properties and transforms into a robust and chemically stable protective layer on the composite roller. The combination of the resin and hardener enables the coating to withstand the mechanical stresses, impacts, and environmental factors encountered during roller operation, ultimately enhancing the roller's performance and longevity.
The filler materials (203) depicted in the figure 2 play a significant role in enhancing the properties of the Tufflite coating. Fillers are additives incorporated into the coating to augment specific characteristics and improve overall performance, wherein filler materials are incorporated into the formulation. These fillers, included in a ratio of 30% - 45% of the total weight of the Epoxy resin and hardener mixture, play a crucial role in enhancing specific properties such as mechanical strength, chemical resistance, and thermal conductivity.
As according to an embodiment of the invention, the fillers can take the form of reinforcing agents, functional additives, or other materials designed to enhance mechanical strength, chemical resistance, thermal conductivity, or other desired properties of the coating. Additionally, thermal conductive fillers can improve the coating's ability to dissipate heat, ensuring efficient thermal management in applications that involve heat generation, or other desired characteristics, enhancing the overall performance and durability of the composite roller.
By strategically selecting and incorporating filler materials (203) into the Tufflite coating, the present invention aims to optimize its performance and tailor it to the specific requirements of the application. For instance, reinforcing agents may be added to enhance the mechanical strength and durability of the coating, enabling it to withstand wear, impacts, and other mechanical stresses encountered in industrial settings.
Milled carbon fiber (204) is a significant component represented in the figure, and its incorporation into the Tufflite coating plays a crucial role in enhancing several key properties. Milled Carbon fiber (204) is known for its exceptional mechanical properties, including high strength, stiffness, and wear resistance. By adding milled carbon fiber to the Tufflite coating, the present invention aims to leverage these characteristics to improve the overall performance and durability of the coating, wherein the milled carbon fiber is integrated into the Tufflite coating at a ratio of 1% - 5% of the total weight of the resin-hardener and filler mixture. This addition reinforces the coating's wear resistance and structural integrity, making it highly durable and reliable for demanding applications.
As according to an embodiment of the invention, the milled carbon fiber (204) particles depicted in the figure are finely ground carbon fibres that are incorporated into the coating formulation. These particles provide reinforcement and act as strengthening agents within the coating matrix. When dispersed evenly throughout the coating, the milled carbon fibers contribute to enhancing the coating's mechanical strength and stiffness, making it more resistant to deformation, impacts, and other mechanical stresses.
Graphene, depicted as component 205 in the figure, plays a crucial role in enhancing the Tufflite coating's properties. Graphene is a two-dimensional thick layer of carbon atoms arranged in a hexagonal lattice structure, known for its exceptional electrical conductivity and barrier properties. The inclusion of graphene in the Tufflite coating formulation contributes to its antistatic properties and efficient static charge dissipation, wherein the graphene is added in a ratio of 1% - 5% of the total weight of the resin-hardener-filler mixture. Graphene's exceptional electrical conductivity and barrier properties contribute to the coating's antistatic features, ensuring efficient static charge dissipation during high-speed web processing operations.
Graphene's (205) high electrical conductivity allows it to effectively dissipate static charges that can accumulate on the surface of the composite roller during high-speed web processing operations. This is particularly important in industries such as film, paper, foil, and plastic, where static charges can interfere with the production process, leading to issues like material sticking or misalignment. The presence of graphene (205) in the coating enables the roller to efficiently dissipate these static charges, ensuring smooth operation and uninterrupted production.
Additionally, graphene's barrier properties make it an excellent component for preventing the accumulation and transfer of static charges. It forms a protective barrier on the surface of the composite roller, reducing the build-up of static charges by preventing the movement of electrons across its surface. This barrier effect further enhances the coating's antistatic properties and minimizes the potential for static-related issues during operation.
As according to an embodiment of the invention, by incorporating graphene (205) into the Tufflite coating, the present invention leverages its exceptional electrical conductivity and barrier properties. This ensures efficient static charge dissipation and effectively addresses the challenges associated with static charges in high-speed web processing operations. The graphene component enhances the overall performance and reliability of the coating, contributing to the smooth operation and improved productivity of the composite roller in industrial applications.
Pigment, represented as component (206) in the figure 2, is an important element in the Tufflite coating. Pigments are used to provide coloration to the coating, allowing for customization of the visual appearance based on aesthetic preferences or specific industry requirements, wherein the pigment completes the composition, representing 1% of the total weight of the Epoxy resin-hardener-filler mixture. The pigment provides coloration to the coating, resulting in the desired matte finish that enhances the visual appeal of the composite rollers.
As according to an embodiment of the invention, the pigment component is responsible for adding colour to the Tufflite coating, enabling the achievement of the desired visual appearance. This can include a matte finish or a specific color that aligns with the desired aesthetic of the composite roller or the requirements of the industry it is being used in. The choice of pigment can vary depending on factors such as UV stability, chemical resistance, or regulatory compliance.
In addition to the coloration aspect, the pigment component can also contribute to the overall durability and performance of the Tufflite coating. Certain pigments possess properties that enhance the coating's resistance to UV radiation, chemicals, or other environmental factors. These properties can further improve the coating's longevity and ability to withstand harsh conditions in specific applications.
By incorporating pigment into the Tufflite coating, the present invention allows for customization of the visual appearance while ensuring the coating's functionality and durability. The choice of pigment can be tailored to meet specific aesthetic requirements or industry standards, resulting in a visually appealing and protective coating for the composite roller.
Fig. 3 describes step by step process as according to the present invention, wherein at step 1 "Machining of the Tube" illustrates the initial stage of the coating application process. This stage involves the machining of the composite tube to eliminate any surface irregularities and achieve a smooth and functional surface.
As according to an embodiment of the invention, the process of cylindrical grinding, where a grinding tool is used to remove any imperfections or roughness on the surface of the tube. This grinding operation helps to create a uniform and smooth surface, preparing it for the subsequent coating application.
As according to an embodiment of the invention, the purpose of this machining stage is to ensure that the composite tube has an optimal surface condition before applying the Tufflite coating. By eliminating surface irregularities, such as bumps, scratches, or other imperfections, the tube's surface becomes suitable for the coating process. A smooth and uniform surface allows for better adhesion of the coating and improves the overall quality and effectiveness of the Tufflite coating on the composite tube.
In step 2 of Figure 3, "Preparation and Application of the Coating," describes a process of preparing and applying the Tufflite coating onto the surface of the composite tube.
These constituents include the resin, hardener, filler materials, milled carbon fiber, graphene, and pigment, wherein the mixing process of the Tufflite coating constituents, highlighting the appropriate ratios or proportions of each component. One aspect of this step is the degassing process, where the resin system, once the hardener is added, undergoes a process that effectively eliminates any trapped air from the mixture. This ensures a smooth and uniform coating application.
This step emphasizes the importance of accurately combining the constituents to achieve the desired coating formulation.
As according to an embodiment of the present invention, the application of the Tufflite coating onto the surface of the composite tube, wherein a specialized metering, mixing, and dispensing (MMD) machine or other suitable application methods being utilized to ensure precise and controlled coating application. The coating is evenly spread or dispensed onto the tube's surface, covering it with a layer of the Tufflite coating.
Step 2 is critical in the coating process as it determines the quality and consistency of the applied coating. Proper mixing and accurate application of the Tufflite coating ensure that the desired properties, such as wear resistance and static charge dissipation, are effectively imparted to the composite tube's surface.
As according to an embodiment of the present invention, step 2 of Figure 3, "Preparation and Application of the Coating," represents the process of preparing the Tufflite coating by mixing its constituents and subsequently applying the coating onto the composite tube's surface. The importance of proper mixing and controlled application to ensure the desired properties of the Tufflite coating are achieved.
Step 3 of Figure 3 describes "Curing Process," is a crucial stage of curing the applied Tufflite coating on the composite tube. The curing process is essential to transform the initially applied liquid or semi-liquid coating into a solid and durable state, wherein the coated composite tube being placed inside an oven or a controlled temperature environment, which is typically set around 150°C. This controlled temperature is chosen based on the specific characteristics of the Tufflite coating and its constituents to ensure optimal curing.
During the curing process, the coating undergoes a chemical reaction that leads to the formation of strong chemical bonds within the coating material. As a result, the coating solidifies and gains maximum strength, firmly adhering to the surface of the composite tube.
Moreover, the curing process ensures dimensional stability, meaning that the coating retains its shape and does not undergo significant changes in size or form. This is important to maintain the desired performance characteristics of the composite tube during its application.
Proper curing is crucial to achieve the desired properties of the Tufflite coating, such as wear resistance and antistatic properties. It also ensures the coating's longevity and durability in the demanding industrial applications of the paper, film, foil, and plastic industries.
As according to an embodiment of the present invention, step 3 of Figure 3, "Curing Process," represents the critical stage of curing the Tufflite coating on the composite tube and highlights the use of an oven or controlled temperature environment to facilitate the chemical reaction and solidification of the coating, resulting in a fully cured coating with maximum strength, adhesion, and dimensional stability.
In step 4 of Figure 3, describes "Sanding,", wherein step 4 starts after post curing operation of sanding the coated composite tube. After the curing process, the coated surface is subjected to sanding using fine to ultra-fine sandpaper.
As according to an embodiment of the present invention, the composite tube being held or supported during the sanding operation and a sandpaper or sanding tool used for this purpose. The sanding process involves gently rubbing the surface of the coated tube with the sandpaper, applying controlled pressure.
As according to an embodiment of the present invention, purpose of sanding is to smoothen the surface of the coated tube and eliminate any imperfections or irregularities that may have occurred during the curing process. It helps to create a uniform and visually appealing appearance, giving the tube a matte finish.
By using fine to ultra-fine sandpaper, the sanding operation achieves a high level of precision and control. It ensures that the coating is not excessively removed or damaged while achieving the desired smoothness and aesthetics.
Sanding plays a crucial role in enhancing the overall quality and visual appeal of the coated composite tube. It contributes to the aesthetic aspect of the Tufflite coating by providing a consistent and attractive matte finish.
As according to an embodiment of the present invention, step 4 of Figure 3, "Sanding," describes a process of sanding the coated composite tube after the curing process. The sub-figure highlights the use of fine to ultra-fine sandpaper to smoothen the surface, eliminate imperfections, and achieve a visually appealing matte finish. The sanding operation contributes to the overall quality and aesthetics of the Tufflite-coated composite tube.
In step 5 of Figure 3, "Finished Tube” the final stage of the coating process, where the composite tube is depicted as a fully coated and finished product.
As according to an embodiment of the present invention, the finished tube's surface exhibits the desired properties of the Tufflite coating, such as wear resistance, antistatic characteristics, and improved durability. It showcases the successful application of the coating methodology, ensuring that the composite tube is now equipped with the desired functional and protective features.
As according to an embodiment of the present invention, the significance of the coating process in transforming the composite tube into a finished product that meets the requirements of the paper, film, foil, and plastic industries. It visually represents the successful implementation of the Tufflite coating, which contributes to the extended lifespan and improved performance of the composite tube.
As according to an embodiment of the present invention, step 5 of Figure 3, "Finished Tube," describes the final stage of the coating process, where the composite tube is shown as a fully coated and finished product. The sub-figure emphasizes the smooth and uniformly coated surface of the tube, highlighting the improved aesthetics and protective properties provided by the Tufflite coating. It signifies the successful application of the coating methodology and the enhancement of the composite tube's overall quality and performance.
In one embodiment, the present invention provides a composite roller comprising a composite tube, bearings, and a Tufflite coating. Wherein, the structure of the composite roller, highlighting its various components. The composite tube serves as the core structure of the roller, providing lightweight and high-strength characteristics. Integrated within the tube are bearings that enable smooth rotation and movement, ensuring the roller operates with minimal friction and energy loss. The Tufflite coating is applied to the surface of the composite tube, providing enhanced wear resistance and antistatic properties. The coating is strategically positioned to ensure efficient static charge dissipation and protection against abrasion. This embodiment of the composite roller offers improved performance, longer lifespan, and enhanced aesthetics in industries such as film, foil, and paper.
Another embodiment of the present invention is the composition of the Tufflite coating, wherein the coating composition includes components and their ratios. The Tufflite coating comprises a resin, hardener, filler materials, milled carbon fiber, graphene, and pigment. These constituents are carefully selected and blended to achieve the desired properties of the coating. The resin and hardener provide structural integrity and adhesion, while the filler materials contribute to wear resistance. The inclusion of milled carbon fiber and graphene enhances strength and conductivity, enabling efficient static charge dissipation. The pigment component not only adds color but also improves the visual appeal of the coating. This embodiment of the Tufflite coating composition ensures optimal performance and durability in challenging industrial applications.
Yet another embodiment of the present invention is the step-by-step process flow for applying the Tufflite coating, as depicted in Figure 3. The coating application methodology involves several stages to ensure a high-quality and durable coating. The first step is the machining of the composite tube, where cylindrical grinding is performed to eliminate surface irregularities and achieve a smooth functional surface. Next, the Tufflite coating is prepared by mixing the coating constituents in the appropriate ratios, as illustrated in Figure 2. The coating is then applied to the surface of the composite tube using a specialized metering, mixing, and dispensing (MMD) machine or other suitable application methods. Subsequently, the coated tube undergoes a curing process, wherein it is exposed to a controlled temperature environment to chemically react and solidify the coating. After curing, the tube is subjected to sanding using fine to ultra-fine sandpaper to achieve a smooth and visually appealing matte finish. This embodiment of the Tufflite coating application methodology ensures a consistent and reliable coating process, resulting in enhanced wear resistance, improved aesthetics, and efficient static charge dissipation.
These embodiments of the present invention demonstrate the practical implementation and effectiveness of the Tufflite coating in the film, foil, and paper industry. The composite roller structure with the Tufflite coating provides improved performance, extended lifespan, and enhanced aesthetic appearance. The composition of the Tufflite coating ensures optimal properties, including wear resistance, antistatic characteristics, and corrosion resistance. The application methodology enables precise and efficient coating application, resulting in cost savings and faster production times. These embodiments highlight the innovative features and advantages of the present invention, making it a valuable solution in the industry.
The Tufflite coating offers several advantages over conventional methods and coatings used in the film, foil, and paper industry. Some of the key advantages of the Tufflite coating based on the above queries include:
Enhanced Wear Resistance: The Tufflite coating provides high resistance to wear and abrasion. This is crucial in industries where rollers are subjected to continuous use and contact with various materials. The coating ensures that the composite rollers maintain their structural integrity and longevity, resulting in reduced maintenance costs and increased operational efficiency.
Efficient Static Charge Dissipation: The Tufflite coating is designed to possess antistatic properties, allowing for effective dissipation of static charges that can accumulate during high-speed web processing operations. By dissipating static charges, the coating helps to prevent electrostatic discharge-related issues, such as damage to the processed materials or disruptions in the production process.
Improved Aesthetic Appearance: The Tufflite coating offers a matte finish, enhancing the visual appeal of the coated rollers. The smooth and uniform surface achieved through the sanding process gives the composite tubes an aesthetically pleasing look. This can be particularly important in industries where the appearance of the equipment is valued, such as the film, foil, and paper industry.
Cost-Effective and Time-Efficient Application: The application method for the Tufflite coating is both time-efficient and cost-effective. The specialized metering, mixing, and dispensing (MMD) machine allows for precise and controlled application of the coating, minimizing material waste and reducing production time. This efficient application process translates into cost savings for the manufacturer and faster turnaround times for customers.
Resistance to Chemical Corrosion: The Tufflite coating exhibits resistance against corrosion caused by chemicals. This is advantageous in industries where the rollers come into contact with corrosive substances during the production process. The coating protects the composite tubes from chemical degradation, ensuring their longevity and performance.
In summary, the Tufflite coating provides multiple advantages, including enhanced wear resistance, efficient static charge dissipation, improved aesthetic appearance, cost-effective and time-efficient application, and resistance to chemical corrosion. These advantages make the Tufflite coating a valuable solution for the film, foil, and paper industry, addressing the limitations of conventional methods and coatings and improving the performance and lifespan of composite rollers.
The figures and the forgoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. For example, orders of processes described herein may be changed and are not limited to the manner described herein. Moreover, the actions of any flow diagram need not be implemented in the order shown; nor do all of the acts necessarily need to be performed. Also, those acts that are not dependent on other acts may be performed in parallel with the other acts. The scope of the embodiments is by no means limited by these specific examples. Numerous variations, whether explicitly given in the specification or not, such as differences in structure, dimension, and use of material, are possible.
, Claims:WE CLAIM:
1) A Tufflite coating composition for providing enhanced wear resistance and antistatic properties, comprising:
a epoxy resin as the base for the coating;
a hardener, mixed with the epoxy resin in a ratio of 30% - 40% of Epoxy Resin;
a filler material mixed in a ratio of 30% - 45% of Resin and Hardener;
a milled carbon fiber mixed in a ratio of 1% - 5% of Resin and Hardener and Filler Materials;
a graphene mixed in a ratio of 1% - 5% of Resin and Hardener and Filler Materials; and
a pigment mixed in a ratio of 1% of Resin and Hardener and Filler Materials.
2) The Tufflite coating composition of claim 1, wherein the composition exhibits a matte finish, enhancing the aesthetic appearance of the coated surface.
3) The Tufflite coating composition of claim 1, wherein the Tufflite coating is applied using a specialized metering, mixing, and dispensing (MMD) machine to ensure precise and controlled coating application.
4) The Tufflite coating composition of claim 1, wherein the composition provides a non-stick effect, reducing adhesion of materials during high-speed web processing operations.
5) The Tufflite coating composition of claim 1, wherein Tufflite coating effectively dissipates static charge accumulated during high-speed web processing operations, improving production efficiency and minimizing film sticking and dust attraction.
6) A method for applying the Tufflite coating composition onto a composite tube of a composite roller, comprising:
machining the composite tube to eliminate surface irregularities and achieve a smooth functional surface;
preparing the Tufflite coating composition by combining resin, hardener, filler materials, milled carbon fiber, graphene, and pigment in appropriate ratios;
applying the Tufflite coating onto the surface of the composite tube using a specialized metering, mixing, and dispensing (MMD) machine to ensure precise and controlled coating application;
curing the applied Tufflite coating inside an oven or a controlled temperature environment; and
sanding the coated composite tube using fine to ultra-fine sandpaper to smoothen the surface, eliminate imperfections, and achieve a visually appealing matte finish.
7) The method of claim 6, wherein the curing step includes exposing the composite tube to a temperature of approximately 150°C.
8) The method of claim 6, further comprising performing a quality inspection on the finished composite tube to ensure adherence to specified dimensions, tolerances, and surface quality.
9) The method of claim 6, wherein the composite roller is used in the paper, film, foil, or plastic industry for applications requiring lightweight, wear-resistant, and antistatic rollers.
Dated this on 18th day of August 2023.

Ajay Kaushik
Agent for the Applicant [IN/PA-2159]
AKSH IP ASSOCIATES