Forming and surface treatment integrated process of rubber roller for printing

Abstract

The invention discloses a forming and surface treatment integrated process for a rubber roller for printing, and relates to the technical field of rubber roller forming and surface treatment.The integrated process comprises the following steps that a mandrel is pretreated, specifically, after being subjected to online ultrasonic cleaning, a metal mandrel is heated to 60-80 DEG C in an infrared preheating area; synchronous extrusion and reactive spraying: adopting a porous annular extrusion die head to extrude a thermosetting silicone sizing material on line to a rotary mandrel, and spraying reactive ink droplets containing isocyanate, a silane coupling agent and functional nanoparticles at the same time through an environmental micro-nozzle array to realize in-situ chemical grafting of the sizing material and a functional monomer. Synchronous extrusion and reaction spraying are designed, in-situ chemical grafting of rubber and functional ink droplets is achieved through the annular extrusion die head and the micro-nozzle array, functional layer grafting is completed through one-time forming of the rubber roller, and the problems that due to two-step preparation, the functional layer is weak in adhesion, and flaws are prone to occurring due to repeated carrying are solved; the adhesive force is improved, procedures are reduced, and the production period is shortened.

Description

Technical Field

[0001] The invention relates to the technical field of rubber roller forming and surface treatment, in particular to an integrated process of rubber roller forming and surface treatment for printing. Background Art

[0002] The manufacturing of traditional rubber rollers for printing requires three independent processes: "extrusion molding → secondary surface treatment → curing". The equipment is scattered and frequently transported. Not only is the production cycle long (often exceeding several hours), but the surface texture accuracy and functional layer adhesion are difficult to guarantee. The single curing method can easily cause thermal damage to the metal core shaft.

[0003] With the increasing demand for refined and multifunctional surface microstructures of rubber rollers (such as self-healing, antibacterial, and thermal conductivity) in high-end printing, there is an urgent need for an efficient integrated process that can tightly integrate molding, surface functionalization, micro-texture etching, and rapid curing into the same production line.

[0004] Patent CN111606116B discloses a surface treatment process for plastic product molding. The above patent realizes the use of a cleaning device to clean the surface of the coiled floor. The humidifying mechanism soaks the cleaning roller to make the coiled floor cleaner, and the decontamination mechanism scrapes the sewage from the cleaning roller to maintain the cleaning effect of the cleaning roller.

[0005] The above patent uses a burr processing device to cut the burrs on both sides of the coiled flooring, so that the layers are more closely fitted after winding. However, the manufacturing of traditional printing rollers still requires multiple steps, resulting in a long production cycle.

[0006] To this end, the present application proposes an integrated process for forming and surface treating printing rubber rollers, which uses an annular extrusion die and a micro-nozzle array to achieve in-situ chemical grafting of rubber and functional ink droplets to complete the grafting of functional layers in one step of rubber roller forming. Summary of the Invention

[0007] The object of the present invention is to provide an integrated process for forming and surface treating a printing rubber roller, so as to solve the technical problems proposed in the above background technology that the multi-step process leads to a long production cycle and poor surface adhesion.

[0008] To achieve the above object, the present invention provides the following technical solution: an integrated process for forming and surface treating a printing rubber roller, the integrated process comprising the following steps: Mandrel pretreatment: After the metal mandrel is cleaned online by ultrasonic cleaning, it is heated to 60-80℃ in an infrared preheating zone; Synchronous extrusion and reactive spraying: A multi-hole annular extrusion die is used to extrude thermosetting silicone rubber onto a rotating mandrel online, and reactive ink droplets containing isocyanate, silane coupling agent, and functional nanoparticles are sprayed simultaneously through an environmental micro-nozzle array to achieve in-situ chemical grafting of the rubber and functional monomers. Closed-loop adaptive micro-groove etching: Using a laser-atmospheric plasma coupled etching device, the laser power and etching pattern are dynamically adjusted based on real-time feedback from online roughness and pattern deviation sensors to achieve precise etching of micro-grooves and micro-dots. Inductive coupling rapid curing: After etching, the rubber roller is acted upon by a high-frequency non-contact electromagnetic induction coil, and the iron powder filler built into the lower radial direction is instantaneously heated to 140-160°C to complete the secondary cross-linking curing.

[0009] Preferably, the integrated process also includes online detection and closed-loop control: using an optical profilometer and an online pull-out adhesion strength device to monitor the surface roughness and adhesion in real time, and automatically adjust the flow rate, spray concentration, laser parameters and induction power of synchronous extrusion and reactive spraying and induction coupling rapid curing according to the detection results.

[0010] Preferably, the closed-loop adaptive micro-grain etching device further comprises: Multi-angle high-speed CCD camera array is used to collect surface height difference and color difference data of the adhesive layer; A real-time control unit based on a lookup table and deep learning model matches the collected data with a preset texture digital template, and automatically re-engraves and adjusts the scanning path when the error exceeds ±5um.

[0011] Preferably, the main colloid component of the thermosetting silicone adhesive is polydimethylsiloxane, the crosslinker content is 2-5wt%, and the filler content is 10-20wt%; it is suitable for continuous production at room temperature of 5-45°C and relative humidity of 10-80%.

[0012] Preferably, the reactive ink droplets further comprise hot-melt microcapsules, which encapsulate self-repairing hot-melt adhesive. When microcracks are generated by laser etching and plasma activation, the microcapsules rupture, releasing the self-repairing adhesive, which cross-links with the surrounding matrix to form scratch self-repairing capabilities. The nanoparticles also include nano-hydroxy apatite and metal oxides, with a loading ratio of 1:(0.5-2), which synergistically achieve antibacterial and thermal conductive composite functions.

[0013] Preferably, the laser engraving pattern supports three-dimensional special-shaped texture engraving based on the CAD model, and the texture can realize switching of multiple patterns such as spiral, honeycomb and curved grid in the same online process, and the pattern consistency deviation is ≤3%.

[0014] Preferably, the induction coupling rapid curing device includes multiple coils arranged in series, each coil has independently adjustable frequency and power, and the coil is axially provided with a high-frequency high-power zone and a low-frequency low-power zone to achieve instantaneous curing of the surface layer and cross-linking saturation of the inner layer, with a total curing time of ≤90s.

[0015] Preferably, the online detection and closed-loop control steps are based on a Bayesian optimization algorithm to automatically adjust the extrusion flow rate, spray concentration, laser scanning speed and induction power to achieve optimal convergence of process parameters between batches.

[0016] Preferably, the closed-loop adaptive micro-grain etching uses ozone plasma instead of atmospheric plasma activation treatment, and the ozone concentration is controlled at 20-50g / Nm 3 , to enhance the surface carboxyl content.

[0017] Preferably, the production line equipment used in the integrated process adopts a modular structure, and the extrusion module, spraying module, etching module, curing module and detection module can be quickly interchanged to facilitate switching between different rubber materials and functional requirements.

[0018] Compared with the prior art, the present invention has the following beneficial effects: 1. This invention utilizes simultaneous extrusion and reactive spraying, achieving in-situ chemical grafting of the rubber material and functional ink droplets through an annular extrusion die and a micro-nozzle array. This allows the rubber roller to be grafted with the functional layer in one step, solving the problems of weak adhesion of the functional layer caused by the two-step preparation process and prone to defects during repeated handling. This improves adhesion, reduces process steps, and shortens production cycles. 2. This invention uses multi-angle visual adaptive etching to achieve high-frequency precision micro-grooving and micro-dot etching, solving the problem of complex and irregular texture deviations on rubber rollers requiring multiple machining or post-processing. It also reduces texture consistency deviations, reduces rework, and enables flexible production. 3. The present invention is designed with ozone plasma surface activation to strengthen the surface carboxyl functional groups, solving the problems of insufficient chemical activity and unstable adhesion on the rubber roller surface, improving the surface adhesion of the rubber roller, making the printing transfer more uniform and extending the wear-resistant life; 4. The present invention is designed with multiple stages of inductive coupling for rapid curing, which achieves instantaneous curing of the surface layer and deep cross-linking of the inner layer, solving the problems of slow and easily damaged shafts and uneven curing caused by a single thermal curing method, thereby increasing production capacity, extending equipment service life, and improving product consistency. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 Schematic diagram of the integrated process of the present invention. DETAILED DESCRIPTION

[0020] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0021] In the description of the present invention, it should be noted that the terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," "the other end," and the like, indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limiting the present invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0022] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "installed," "provided with," "connected," etc., should be understood in a broad sense. For example, "connected" may refer to a fixed connection, a detachable connection, or an integral connection; it may refer to a mechanical connection or an electrical connection; it may refer to a direct connection or an indirect connection through an intermediate medium; it may refer to internal communication between two components. Those skilled in the art will be able to understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0023] See also Figure 1 The present invention provides an embodiment of an integrated process for forming and surface treating a printing roller, the integrated process comprising the following steps: Mandrel pretreatment: After the metal mandrel is cleaned online by ultrasonic cleaning, it is heated to 60-80℃ in an infrared preheating zone; Synchronous extrusion and reactive spraying: A multi-hole annular extrusion die is used to extrude thermosetting silicone rubber onto a rotating mandrel online, and reactive ink droplets containing isocyanate, silane coupling agent, and functional nanoparticles are sprayed simultaneously through an environmental micro-nozzle array to achieve in-situ chemical grafting of the rubber and functional monomers. Closed-loop adaptive micro-groove etching: Using a laser-atmospheric plasma coupled etching device, the laser power and etching pattern are dynamically adjusted based on real-time feedback from online roughness and pattern deviation sensors to achieve precise etching of micro-grooves and micro-dots. Inductive coupling rapid curing: After etching, the rubber roller is acted upon by a high-frequency non-contact electromagnetic induction coil, and the iron powder filler built into the lower radial direction is instantly heated to 140-160°C to complete the secondary cross-linking curing; Furthermore, the mandrel was pretreated as follows: Equipment configuration: ultrasonic cleaning system: frequency 35kHz, power 2.5kW, automatic flipping fixture in the cleaning tank; infrared preheating zone: 4 carbon fiber infrared lamps, total length 0.8m; parameter settings: cleaning medium: deionized water with 1.5wt% organic acid cleaning agent; cleaning time: 90s, power density 0.4W / cm 3 Drying: Use compressed air for 45 seconds. Preheating: The mandrel rotates at 10 rpm for 60 seconds to raise the surface temperature to 65-75°C. Organic acid cleaners improve the efficiency of oil dissolution, and the ultrasonic power is slightly lower to reduce stress on thin-walled mandrels. Preheating can reach the required temperature in 90 seconds, saving space. Synchronous extrusion and reactive spraying: Equipment configuration: Extruder: single-screw thermosetting machine, screw diameter 50mm, L / D=20; annular die: aperture 1.0mm, number of holes 64; annular micro-spray system: 48 ceramic nozzles, spray angle 45°; parameter settings: rubber composition: polymethylsiloxane + 2wt% dibenzoyl peroxide; extrusion temperature 140-155°C, screw speed 30rpm, flow rate 12g / min; synchronous control: practical real-time Ethernet field bus, spray trigger and extrusion deviation ≤3ms; single-screw extrusion machine has lower extrusion cost and simple maintenance, nano-silica replaces hydroxyapatite to improve hardness and wear resistance; ultra-short trigger delay ensures precise synchronization of chemical grafting and rubber extrusion. Closed-loop adaptive micro-grain etching: Equipment configuration: Laser: Continuous fiber laser, wavelength 1064nm, power 3-12W; Plasma head: Nitrogen plasma spray gun, power 250W, nitrogen flow 20L / min; Sensing system: Laser confocal thickness gauge, single-view CCD camera; Parameter settings: Engraving path: combination of parallel linear and curved grids, scanning rate 0.6-1.0m / s; Engraving parameters: Micro-dot diameter 30-120um, depth 8-35um, dot density 15-30 dots / mm; Plasma activation: Start with a delay of 20ms after each engraving, action time 5ms; Closed-loop adjustment: When the Ra deviation exceeds ±0.04um or the dot deviation exceeds ±4um, the system automatically reduces the laser rate by 0.05m / s or increases the power by 0.5W; Continuous laser engraving is suitable for micro-dot arrays and enhances dot transfer capability; Nitrogen plasma activation enhances the surface nitrogen content and improves ink wettability; Higher-precision sensors and shorter delays improve etching consistency; Induction coupling rapid curing: Configuration settings: dual-stage induction coil: front section diameter 55mm, rear section diameter 65mm, both with 8 turns; high-frequency generator: adjustable frequency 90-220kHz, total power 4.5kW; iron powder filler: ferrosoferric oxide nanoparticles, 5wt% premixed in the rubber compound; parameter settings: surface curing section: frequency 180kHz, power 3.5kW, action 12s; deep curing section: frequency 120kHz, power 2kW, action 15s; temperature monitoring: a thermocouple is embedded in the rubber layer to control the core shaft surface temperature rise to ≤4°C; total curing time 27s; dual-stage design reduces interference between coils and improves curing uniformity; nano iron powder has finer particle size, heats quickly and is evenly distributed; curing is completed within 27s, which is more efficient.

[0024] See also Figure 1 The present invention provides an embodiment of an integrated process for forming and surface treating a rubber roller for printing, the integrated process also including online detection and closed-loop control: using an optical profilometer and an online pull-out adhesion strength device to monitor surface roughness and adhesion in real time, and automatically adjusting the flow rate, spray concentration, laser parameters, and induction power of synchronous extrusion, reactive spraying, and inductive coupling rapid curing based on the detection results; The online detection and closed-loop control steps are based on the Bayesian optimization algorithm to automatically adjust the extrusion flow rate, spray concentration, laser scanning speed and induction power to achieve optimal convergence of process parameters between batches; Furthermore, the initial process parameter configuration: before production starts, the process experts or the last optimal result set the initial parameters: extrusion flow rate 15g / min, reactive spray concentration: isocyanate monomer 20wt%, laser scanning speed 1.0m / s, laser power 10W, induction power 4.0kW; Online data acquisition: Optical profiling: Frequency: Triggered once every 0.1 revolution; Measurement content: Surface Ra, Rz; Sampling points: 1000 points / revolution; Adhesion pull-off test: Frequency: Automatic sampling once every 10m of rubber roller length; Test content: Adhesion strength of micro-test pieces; Data processing: Data from the profilometer and pull-off device are uploaded to the control center in real time via the edge computing unit. Bayesian optimization model: modeling; input dimensions: extrusion flow rate, spray concentration, laser speed, laser power, induction power; output target: surface roughness index: Ra➡ minimized (target 0.8±0.05um), adhesion index: F -ad ➡ Maximization (target ≥ 4MPa); Sampling Gaussian process regression as a proxy model; Obtaining initial samples: Based on historical process experience, perform 5 short batch tests with different parameter combinations and collect the corresponding Ra and F -adOptimization loop: Step a: Calculate the next set of optimal "exploration-exploitation" parameters within the allowed parameter space based on the proxy model and acquisition function; Step b: Distribute these parameters to each module of the production line (extruder, spray valve, laser controller, induction power supply); Step c: Update the proxy model after receiving new measurement data in the next sampling cycle; Step d: Determine the convergence condition (for example, EI gain < 1% for three consecutive times or within the target range); if not, return to step a; Real-time parameter down-adjustment and re-optimization: During the same roll production process, if the optical measurement Ra exceeds ±0.05μm, the control center will immediately: 1. Adjust the extrusion flow rate by ±1g / min; 2. Fine-tune the laser scanning speed by ±0.1m / s. Adjustment commands are transmitted synchronously via the industrial Ethernet bus, with a feedback delay of ≤50ms. The adjustment effect is immediately verified in the next cycle and the results are fed back to the Bayesian model. Convergence and batch switching: After 5 consecutive pull-off tests with adhesion ≥4MPa and Ra deviation ≤0.05um, the system determines that the process parameters are the optimal solution for the current batch; the optimal parameters are stored in the production database and used as the initial values for the next batch, shortening the optimization time; and a report is generated at the same time: including parameter evolution curve, Ra and F -ad Trend chart for production and quality management review; Continuous self-adaptation: Process parameters can be dynamically fine-tuned during the production of a single roll of rubber roller to avoid scrapping of semi-finished products; Rapid convergence: Bayesian optimization can find the optimal or near-optimal parameter combination with a small number of samples, breaking away from the limitations of manual experience; Batch consistency: Guided by historically optimal parameters, the fluctuation of indicators between batches is less than ±2%; Improved production efficiency: The time from start-up to convergence of a single roll of rubber roller is reduced from several hours to a few minutes, shortening the overall production cycle by approximately 20%.

[0025] See also Figure 1 The present invention provides an embodiment of an integrated process for forming and surface treating a printing roller, wherein the closed-loop adaptive micro-grain etching device further comprises: Multi-angle high-speed CCD camera array is used to collect surface height difference and color difference data of the adhesive layer; A real-time control unit based on a lookup table and deep learning model matches the collected data with a preset texture digital template, automatically re-engraving and adjusting the scanning path when the error exceeds ±5um; The laser engraving pattern supports three-dimensional special-shaped texture engraving based on CAD models. The texture can realize multiple pattern switching of spiral, honeycomb and curved grid in the same online process, and the pattern consistency deviation is ≤3%; The induction coupling rapid curing device comprises multiple coils arranged in series, each coil having independently adjustable frequency and power. The coils are provided with a high-frequency, high-power zone and a low-frequency, low-power zone along the axial direction, achieving instant curing of the surface layer and cross-linking saturation of the inner layer, with a total curing time of ≤90s. The closed-loop adaptive micro-texture etching uses ozone plasma instead of atmospheric plasma activation treatment, and the ozone concentration is controlled at 20-50g / Nm 3 , to enhance the surface carboxyl content; Furthermore, multi-angle visual acquisition: Equipment: Four high-speed CCD cameras are distributed in the front, back, left, and right quadrants of the rubber roller, with viewing angles at 90 degrees to each other; Sampling: The camera array continuously shoots at a frequency of 200Hz to capture the three-dimensional surface contour and color difference information; Data processing: After image data is pre-processed by the FPGA edge unit, it is aggregated to the real-time control host via 4Gbps Ethernet; Texture matching and real-time re-engraving: Preset template: Load CAD digital texture template into the control host; Lookup table and deep learning: LUT is used to quickly map the camera coordinate system to the engraving coordinate system, and the pre-trained convolutional neural network is responsible for identifying the deviation between the engraved area and the template; Re-engraving strategy: When the deviation exceeds the limit, the control host issues a re-engraving instruction, automatically adjusts the laser scanning path, and updates the trajectory of the next scanning segment in real time; CAD special-shaped texture switching: The operator selects the desired pattern type on the HMI interface, and the system calls the corresponding CAD file from the texture library. The control host automatically generates a G-code path that conforms to the kinematics of the laser scanning head to achieve: spiral patterns, honeycomb patterns, and curved grids. When switching within the same online process, only the path needs to be switched, without stopping the machine. The pattern can be switched online 2-3 times per minute. Ozone plasma activation: Device: ozone generator + high-voltage electrode plasma spray gun, the spray gun is kept 5mm away from the surface of the rubber roller; Parameters: ozone concentration 20-50g / Nm 3 , the spray gun power is 250W, the gas flow rate is 15L / min, the treatment area moves synchronously with the laser engraving, the delay is 15ms to start, and the treatment time is 8ms; Effect: The introduction of -COOH and -C=O groups significantly enhances the surface hydrophilicity and subsequent curing adhesion; Multi-stage induction coupling rapid curing: Coil arrangement: 3 series-connected induction coils, axial spacing 100mm, with diameters of 58mm, 62mm, and 66mm respectively; Power and frequency: 220kHz, 4.5kW, 12s for the surface zone; 160kHz, 3.0kW, 10s for the middle zone; 100kHz, 2.0kW, 8s for the inner zone; Temperature monitoring: Built-in micro-thermocouples monitor the temperature of the adhesive layer and mandrel in real time, and PID control output power ensures that the substrate temperature rise is ≤3°C. The total curing time is 30s, meeting the ≤90s requirement. Closed-loop feedback and parameter optimization: After the final Ra and adhesion are measured by an optical profilometer and a micro-pulling device, if any of the indicators exceed the limit, the system will: 1. Immediately adjust the laser engraving amplitude by ±2μm or the laser power by ±0.5W; 2. Or fine-tune the induction coil power by ±200W. The system will feed back the new process results to the Bayesian optimization module to continuously improve the model. The combination of multi-angle vision and deep learning models enables high-precision online engraving of complex and special-shaped patterns, with a texture consistency deviation of ≤3%. Ozone plasma introduces carboxyl functional groups to further improve chemical grafting efficiency and adhesion. Multi-stage induction curing takes into account the cross-linking of the surface and inner layers. The curing time is only 30s, and the substrate temperature rise is weak, making it suitable for high-speed and mass production.

[0026] See also Figure 1 The present invention provides an embodiment of an integrated process for forming and surface treating a printing roller, wherein the main colloid component of the thermosetting silicone rubber material is polydimethylsiloxane, the crosslinking agent content is 2-5wt%, and the filler content is 10-20wt%. The process is suitable for continuous production at room temperature of 5-45°C and relative humidity of 10-80%. The reactive ink droplets also contain hot-melt microcapsules, which encapsulate self-repairing hot-melt adhesive. When microcracks are generated by laser etching and plasma activation, the microcapsules rupture, releasing the self-repairing adhesive, which cross-links with the surrounding matrix to form scratch self-repair capabilities. The nanoparticles also include nano-hydroxy apatite and metal oxide, with a loading ratio of 1: (0.5-2), synergistically achieving antibacterial and thermal conductive composite functions. Furthermore, the adhesive formulation is prepared as follows: main colloid configuration: raw material: polydimethylsiloxane; crosslinker: dibenzoyl peroxide, mass fraction 3wt%; filler: silicate powder, mass fraction 15wt%; mixing process: in an 80L high-shear dispersion tank, first add 50L of PDMS matrix and heat to 50°C, slowly stir at 500rpm for 5min, gradually add dibenzoyl peroxide, then high-shear at 2000rpm for 10min, and slowly add silicate powder. After stirring, let it stand for 30min to deaerate, to obtain a uniform thermosetting silicone adhesive with a viscosity of 15000-20000mPa·s; Reactive ink droplet formulation and preparation: Functional components: 20 wt% isocyanate monomer; 5 wt% silane coupling agent; Nanoparticles: 50 nm nanohydroxyapatite and 30 nm metal oxide (TiO2 or ZnO) with a loading ratio of 1:(0.5-2), with the range of 1:1.2; 5 wt% self-healing microcapsules with an average diameter of 100 μm, sealed with a hot-melt polybutylene glycol adhesive; Solvent / carrier: 70 wt% propylene oxide; Dispersion process: In a 200 L constant temperature 25°C dispersing tank, the carrier propylene oxide was first added. The high shear dispersing paddle was turned on and the isocyanate monomer and silane coupling agent mixture was slowly added. The nanohydroxyapatite and metal oxide were then added in three batches. The dispersion was repeated for 5 min per batch at a shear rate of 3000 rpm. Finally, the microcapsules were added at a low speed of 500 rpm. The mixture was gently mixed for 2 min to prevent capsule rupture and allowed to stand for 20 min for degassing. This yielded uniformly dispersed reactive ink droplets with a viscosity of 1200-1500 mPa·s. Synchronous extrusion and spraying process: extrusion temperature 155 ° C, screw speed 35 rpm, flow rate 14g / min, spraying pressure 0.55MPa, nozzle temperature maintained at 25 ° C, flow rate 5.5mL / min, sprayed microcapsules and nanoparticles are coaxially delivered with the rubber compound at the annular die with a diameter of 0.8mm to achieve in-situ chemical grafting and functional component distribution. The initial temperature of the extruded rubber layer is about 75 ° C, and the ink droplets form dispersed blocks on the rubber surface. Laser etching, plasma activation and microcrack self-repair: Etching and activation: laser parameters 10W, scanning rate 1.0m / s, microgroove width 100um, depth 30um, ozone plasma 40g / Nm 3 , power 250W, air flow 15L / min; microcrack induction and self-repair: microcracks are generated on the surface at the etching edge and plasma activation area. The microcapsules at the cracks are ruptured by stress, releasing the sealed hot-melt polybutylene glycol adhesive. The hot-melt adhesive flows instantaneously at the local temperature of about 150°C in the etching area and cross-links with the surrounding PDMS matrix to fill the cracks. The measured crack width is repaired from 1.8±0.3um to 0.1±0.05um, and the adhesion is restored to ≥4MPa; Nanocomposite functional verification: Antibacterial performance test: Samples of the sprayed surface were exposed to Staphylococcus aureus for 24 hours. The viable bacteria count results showed a 99.2% reduction in colony count, indicating synergistic antibacterial effects between the surface nanohydroxyapatite and the metal oxide. Thermal conductivity test: The thermal conductivity coefficient was measured by laser flash method: 0.25 W / (m·K), an increase of approximately 20%. The composite nanoparticles effectively increased the heat conduction rate, which is beneficial for heat distribution in subsequent induction curing. Environmental adaptability: Continuous production was carried out in an oven at 5-45°C and 10-80% relative humidity for 72 hours. The appearance and performance of the adhesive layer were measured every 12 hours: no bubbles on the surface, adhesion was stable at 4.2±0.1 MPa, and Ra was maintained at 0.8±0.05 μm. The ratio of PDMS adhesive to cross-linking and fillers is precisely controlled to ensure uniformity and extrudability of the adhesive layer. The self-healing function of the microcapsules is automatically activated at microcracks, significantly improving the product's scratch resistance. The composite of nano-hydroxyapatite and metal oxides imparts antibacterial and enhanced thermal conductivity, aiding curing efficiency. Excellent environmental adaptability ensures continuous and stable production under complex conditions in industrial sites.

[0027] See also Figure 1 The present invention provides an embodiment of an integrated process for forming and surface treating a printing rubber roller. The production line equipment used in the integrated process adopts a modular structure. The extrusion module, spray module, etching module, curing module, and detection module can be quickly interchanged to facilitate the switching of different rubber materials and functional requirements. Furthermore, the extrusion module includes a screw or twin-screw extruder and an annular die; the spraying module includes a reactive ink droplet spray array and a dispersion / feeding system; the etching module includes a laser engraving head and a plasma activation head; the curing module includes a high-frequency induction coil and a power generator; and the detection module includes an optical profiler and a pull-off adhesion strength device. The modules are connected via quick-release mechanical locks, standardized start / hydraulic interfaces, electrical plug-in boxes, and fieldbuses, supporting hot-swappable replacement. Preparation before module switching: Process offline: stop extrusion and spraying material supply, switch the conveyor belt speed to 0; execute the "safety shutdown" command, and all modules enter the waiting state for replacement; automatically store the current process parameters and online detection data in MES, and generate a switching report to facilitate traceability and process reproduction; Quick module replacement: Loosen the quick-release locks on both sides of the module rack, and the module slides out through the guide rails. The bottom guide wheels automatically detach from the ground rails. Disconnect the plug-in electrical connectors, close and remove the starter / hydraulic hose quick connectors. Slide the pre-adjusted new module into the guide rails, tighten the locks, and confirm that there is no gap between the module and the ground rails and rack. Interface reconnection and self-test: Insert the multi-contact plug, automatically register the new module node through the fieldbus, and the central control PLC reads the module type and version number and loads the corresponding driver; the quick-connect connector automatically seals, eliminating the need for manual threaded connections. The system performs a pressure leak test and automatically supplies air / liquid after confirming there are no leaks; Process parameter loading and trial run: The operator selects the new rubber material and functional requirements on the HMI, and the system automatically calls the corresponding standard process formula, runs a 5m long rubber roller, and performs online detection of Ra and adhesion. If the indicators are out of tolerance, the control center prompts adjustments or initiates Bayesian optimization for fine-tuning. Once the indicators meet the standards, the system switches to normal production mode, enters planned mass production and production instructions, and monitoring and closed-loop control of the production process proceed as usual.

[0028] Working Principle: The annular extrusion die and micro-nozzle array operate coaxially to simultaneously deliver thermosetting silicone adhesive and reactive ink droplets containing isocyanate, silane coupling agent and functional nanoparticles. Under the rotation of the core shaft, the adhesive layer is chemically grafted in situ and integrated with the substrate. The three-dimensional texture and color difference of the semi-cured adhesive layer are collected through a multi-angle high-speed CCD array, and the data is compared with the CAD digital template in real time. If the error exceeds the limit, it will be automatically re-engraved. The etching is also supplemented by ozone plasma activation to accurately introduce carboxyl functional groups. The etched and activated rubber rollers are connected in series with multiple sections of induction coil areas with adjustable frequency / power, and the built-in iron powder filler is used to instantly heat the temperature to 140-160°C to complete secondary cross-linking and curing. The entire process is subject to online detection and closed-loop regulation by the Bayesian optimization algorithm to ensure optimal parameters in each link.

[0029] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above and that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A printing roller forming and surface treatment integrated process, characterized by: The integrated process comprises the following steps: Mandrel pretreatment: After the metal mandrel is cleaned online by ultrasonic cleaning, it is heated to 60-80℃ in an infrared preheating zone; Synchronous extrusion and reactive spraying: A multi-hole annular extrusion die is used to extrude thermosetting silicone rubber onto a rotating mandrel online, and reactive ink droplets containing isocyanate, silane coupling agent, and functional nanoparticles are sprayed simultaneously through an environmental micro-nozzle array to achieve in-situ chemical grafting of the rubber and functional monomers. Closed-loop adaptive micro-groove etching: Using a laser-atmospheric plasma coupled etching device, the laser power and etching pattern are dynamically adjusted based on real-time feedback from online roughness and pattern deviation sensors to achieve precise etching of micro-grooves and micro-dots. Inductive coupling rapid curing: After etching, the rubber roller is acted upon by a high-frequency non-contact electromagnetic induction coil, and the iron powder filler built into the lower radial direction is instantaneously heated to 140-160°C to complete the secondary cross-linking curing.

2. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The integrated process also includes online detection and closed-loop control: using an optical profilometer and an online pull-out adhesion strength device to monitor surface roughness and adhesion in real time, and automatically adjusting the flow rate, spray concentration, laser parameters and induction power of synchronous extrusion and reactive spraying and induction coupling rapid curing based on the detection results.

3. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The closed-loop adaptive micro-grain etching device further comprises: Multi-angle high-speed CCD camera array is used to collect surface height difference and color difference data of the adhesive layer; A real-time control unit based on a lookup table and deep learning model matches the collected data with a preset texture digital template, and automatically re-engraves and adjusts the scanning path when the error exceeds ±5um.

4. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The main colloid component of the thermosetting silicone rubber is polydimethylsiloxane, the crosslinking agent content is 2-5wt%, and the filler content is 10-20wt%; It is suitable for continuous production at room temperature of 5-45℃ and relative humidity of 10-80%.

5. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The reactive ink droplets also contain hot-melt microcapsules, which encapsulate self-healing hot-melt adhesive. When microcracks are generated by laser etching and plasma activation, the microcapsules rupture, releasing the self-healing adhesive, which cross-links with the surrounding matrix to form scratch self-repair capabilities. The nanoparticles also include nano-hydroxy apatite and metal oxides, with a loading ratio of 1: (0.5-2), which synergistically achieve antibacterial and thermal conductive composite functions.

6. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The laser engraving pattern supports three-dimensional special-shaped texture engraving based on CAD models. The texture can realize switching of multiple patterns such as spiral, honeycomb and curved grid in the same online process, and the pattern consistency deviation is ≤3%.

7. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The induction coupling rapid curing device includes multiple coils arranged in series, each coil segment has independently adjustable frequency and power, and the coil is axially provided with a high-frequency, high-power zone and a low-frequency, low-power zone, achieving instantaneous curing of the surface layer and cross-linking saturation of the inner layer, with a total curing time of ≤90s.

8. The integrated process for forming and surface treating a printing rubber roller according to claim 2, characterized in that: The online detection and closed-loop control steps are based on a Bayesian optimization algorithm to automatically adjust the extrusion flow rate, spray concentration, laser scanning speed and induction power to achieve optimal convergence of process parameters between batches.

9. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The closed-loop adaptive micro-texture etching uses ozone plasma instead of atmospheric plasma activation treatment, and the ozone concentration is controlled at 20-50g / Nm 3 , to enhance the surface carboxyl content.

10. The integrated process for forming and surface treating a printing rubber roller according to claim 1, characterized in that: The production line equipment used in the integrated process adopts a modular structure, and the extrusion module, spray module, etching module, curing module and detection module can be quickly interchanged, which facilitates the switching of different rubber materials and functional requirements.

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