Polyurethane wheel with conductive layer and production method thereof

Abstract

The invention discloses a polyurethane wheel with a conductive layer and a production method, and relates to the field of polyurethane wheel production. The polyurethane wheel comprises a polyurethane wheel body, discrete conducting layers circumferentially and uniformly distributed on the axial end face of the polyurethane wheel body and a signal interface structure in a central shaft hole area, each conducting layer comprises a latticed conducting strip, an electrode and a conducting lead and is electrically connected with the signal interface structure, and a preset radial distance is formed between the outermost end of each conducting layer and the rolling working face. The production method comprises the steps of wheel blank forming, surface modification treatment, conductive slurry filling, conductive layer polishing, protective coating, gradient curing and the like. Real-time accurate wear monitoring of the polyurethane wheel is realized through resistance change of the conductive layer, and the polyurethane wheel wear monitoring device has the advantages of reliable structure, firm combination, simplicity and convenience in manufacturing and the like, and is suitable for wear monitoring requirements under various working conditions.

Description

Technical Field

[0001] This invention relates to the field of polyurethane wheel production, and more specifically to a polyurethane wheel with a conductive layer and its production method. Background Technology

[0002] Polyurethane wheels are widely used in material handling equipment, conveyor systems, industrial vehicles, and many other fields due to their excellent wear resistance, high load-bearing capacity, and good shock absorption performance. However, in actual use, the rolling surface of polyurethane wheels gradually wears down over time. When the wear reaches a critical value, failure to replace the wheel in time can lead to wheel failure, decreased equipment stability, and even safety accidents.

[0003] In existing technologies, monitoring the wear condition of polyurethane wheels largely relies on periodic manual inspections. Tools such as calipers are used to manually measure the wheel diameter or remaining thickness, and the degree of wear is determined by comparing this measurement with initial values ​​or safety thresholds. This method results in discontinuous monitoring, making it impossible to obtain real-time wear data. Unexpected excessive wear may occur between inspections. Furthermore, measurement accuracy is affected by personnel experience, and it is time-consuming and labor-intensive in managing large-scale equipment.

[0004] Therefore, there is an urgent need in this field for a polyurethane wheel with a reasonable structural design that can directly achieve stable and accurate wear detection function through its own structure, as well as a method for its production. Summary of the Invention

[0005] In view of this, the present invention provides a polyurethane wheel with a conductive layer that can monitor its own wear level in real time and accurately, and has a reliable structure and is easy to manufacture, as well as a method for producing the same.

[0006] To achieve the above objectives, the present invention provides a polyurethane wheel with a conductive layer, comprising a polyurethane wheel body, a conductive layer, and a signal interface structure.

[0007] The conductive layer is circumferentially and uniformly distributed on the axial end face of the polyurethane wheel body, forming a discrete monitoring array to ensure that the failure of a single conductive layer does not affect the overall wear monitoring function. The conductive layer has a grid-like structure, and its outermost end has a preset radial distance from the rolling working surface of the polyurethane wheel body. This distance corresponds to the maximum allowable wear depth or alarm threshold.

[0008] The signal interface structure is located in the central shaft hole area of ​​the polyurethane wheel body and is used to lead out the resistance measurement signal. Each conductive layer is electrically connected to the signal interface structure, forming a circuit channel for measuring resistance. When the wheel body wears normally, its thickness decreases until it touches the conductive layer, and the resistance value of the conductive layer will change. By monitoring this change through external circuitry, the real-time wear depth can be determined.

[0009] Furthermore, the conductive layer includes a conductive sheet, electrodes, and conductive leads. The electrodes and conductive leads are welded and fixed within a pre-designed printing groove inside the polyurethane wheel body. A mesh-like groove is provided at the bottom of the printing groove, and the conductive sheet fills the printing groove and the mesh-like groove at its bottom, forming a mesh structure that encloses the electrodes. The conductive leads are disposed in pre-designed lead grooves within the polyurethane wheel body, with one end connected to the electrode and the other end converging to the signal interface structure. This mesh-like structure of the conductive sheet increases the contact and bonding area with the wheel substrate, effectively improving its structural strength and peel resistance.

[0010] The printing groove extends radially along the polyurethane wheel body; the inner side of the printing groove near the central shaft of the polyurethane wheel body is connected to the lead wire groove, which extends to the central shaft hole area of ​​the polyurethane wheel body.

[0011] Furthermore, the signal interface structure includes an external connector composed of multi-core connectors, which is used to orderly converge the conductive leads and connect them to external instruments. The signal interface structure can also integrate a wireless signal transmission module (such as a Bluetooth, LoRa, or RFID module), which can wirelessly transmit the resistance values ​​of each conductive layer to a remote receiving device, enabling remote monitoring and early warning of the status.

[0012] Accordingly, the present invention also provides a method for producing a polyurethane wheel with a conductive layer, for producing the above-mentioned polyurethane wheel with a conductive layer, comprising the following steps: 1. Inject polyurethane material into a mold and cure it at a first temperature to obtain a polyurethane wheel blank with a printing groove and a lead groove, and the bottom of the printing groove is provided with a mesh groove. 2. Place the electrodes and conductive leads into the printing groove and lead groove of the polyurethane blank, respectively; 3. Fill the blank with conductive paste so that it covers the printing groove and the bottom mesh groove, forming a conductive layer with the electrodes and conductive leads; 4. The printed polyurethane blank is cured at a second temperature, which is higher than the first temperature; 5. The wheel blank, which has been cured at the second temperature, is demolded and then processed.

[0013] Furthermore, the steps described above for obtaining a polyurethane wheel blank with printing grooves and lead grooves include: First, the surface of the metal wheel core to be coated is polished (e.g., sandblasted) to increase roughness and cleanliness. Then, the polished metal wheel core is preheated to a preset temperature and fixed in the center of the mold. Next, the polyurethane prepolymer and curing agent are uniformly mixed to form the polyurethane material.

[0014] Finally, the uniformly mixed polyurethane material is injected into a mold with a specific raised structure. After curing and demolding, an integrated wheel blank is obtained, which covers a metal wheel core and has a printed groove and a lead wire groove formed in the polyurethane part. The opening of the lead wire groove is connected to the inner side of the printed groove near the central axis of the polyurethane wheel blank.

[0015] After obtaining the wheel blank, the printing tank and its bottom groove can be surface modified. The surface modification treatment is selected according to the type of conductive paste to be applied in the subsequent coating. If the conductive paste is a carbon-based conductive paste, the surface modification treatment is plasma activation treatment; if the conductive paste is a metal-based conductive paste, the surface modification treatment is to coat the inner wall of the printing tank with a polyurethane-modified conductive primer and pre-cur it to form a transition layer.

[0016] Furthermore, the step of filling the conductive paste includes: filling the conductive paste into the printing tank and the mesh groove at the bottom, and wrapping the electrode; curing the conductive paste; after the conductive paste has cured, polishing the conductive paste in the printing tank area to remove excess conductive paste in the tank, leaving only the conductive paste in the mesh groove, so that the conductive layer forms a preset mesh structure.

[0017] Furthermore, the depth of the printing groove is greater than the thickness of the electrode placed therein; the operation of filling the conductive paste includes filling with a scraper, which is carried out continuously, so that the conductive paste fills the printing groove and the bottom mesh groove layer by layer, and completely covers the electrode.

[0018] Furthermore, the specific steps performed before the step of filling the conductive paste include: Conductive leads that match the core wire type and conductive paste type are welded to the electrodes.

[0019] The electrode surface is modified to form a transition layer. The modification method is selected according to the type of conductive paste, including: selecting a transition layer material that matches the type of conductive paste, coating the electrode surface, and pre-curing it.

[0020] A pair of processed electrodes are placed in the printing tank and spaced apart from each other.

[0021] The conductive lead connected to the electrode is placed into the lead groove that is connected to the printed groove where the electrode is located, and one end of the lead is led out to the outside of the central shaft of the polyurethane blank.

[0022] Furthermore, after the step of forming the conductive layer and before the step of second temperature curing, a layer of polyurethane material is coated on the axial end face of the polyurethane blank to cover the conductive layer.

[0023] Furthermore, the curing at the first temperature proceeds until the polyurethane material reaches a gel state; the second temperature is higher than the first temperature, and the curing at the second temperature achieves the following: complete curing of the polyurethane blank in the gel state; and encapsulation and fixation of the conductive layer within the polyurethane blank.

[0024] Furthermore, the post-demolding processing includes, but is not limited to, precision machining of the rolling working surface of the polyurethane wheel to form a precise preset radial distance between the outermost end of the conductive layer and the rolling working surface; grinding and cleaning the installation area of ​​the signal interface structure to ensure the assembly stability of subsequent connectors; and testing the conductivity of the conductive layer to screen out products with substandard conductivity.

[0025] Beneficial effects This invention improves the accuracy of wear monitoring by uniformly distributing a conductive layer circumferentially on the axial end face of the polyurethane wheel body and maintaining a preset radial distance between the outermost end of the conductive layer and the rolling working surface. This allows for real-time and precise monitoring of the wear state through changes in resistance when the wheel body wears down to the point of contacting the conductive layer. The complete encapsulation of the electrodes by the conductive sheet ensures circuit stability and reduces interference from contact resistance. The mesh groove at the bottom of the printed groove forms an interlocking structure with the conductive layer, enhancing the bonding strength between the conductive layer and the wheel body and preventing the risk of the conductive layer detaching under long-term operating conditions. Furthermore, the polyurethane protective layer covering the conductive layer further enhances the overall structural durability.

[0026] The production method of this invention performs adaptive surface modification treatments on the printing tank and electrodes respectively. The modification method is selected according to the type of conductive paste, effectively improving the compatibility of the conductive paste with the tank and electrodes, reducing contact resistance, and ensuring stable conductivity. The process of filling, curing, and then polishing the conductive paste precisely preserves the conductive layer within the mesh groove, ensuring the consistency of its mesh structure formation and enhancing the anti-breakage effect of the conductive layer. The gradient temperature curing process achieves complete curing of the blank and robust encapsulation of the conductive layer, further ensuring the stability of product quality. Attached Figure Description

[0027] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the structure of the conductive layer of the present invention; Figure 3This is a schematic diagram of the structure of the polyurethane wheel body of the present invention; Figure 4 This is a flowchart of the production method of the present invention.

[0029] Explanation of reference numerals in the attached figures: 1. Polyurethane wheel body; 101. Printed groove; 102. Lead wire groove; 103. Rolling working surface; 2. Conductive layer; 201. Conductive sheet; 202. Electrode; 203. Conductive lead wire; 3. Signal interface structure. Detailed Implementation

[0030] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] The following is combined Figures 1 to 4 The following describes embodiments of the present invention.

[0032] Example 1 This embodiment provides a polyurethane wheel with a conductive layer, suitable for real-time and accurate monitoring of wheel wear under normal working conditions. This polyurethane wheel achieves basic wear depth monitoring and alarm functions through a discrete conductive layer array 2.

[0033] Specifically, this embodiment mainly consists of three parts: a polyurethane wheel body 1, a conductive layer 2, and a signal interface structure 3. These parts work together to achieve the wear monitoring function. Among them, the polyurethane wheel body 1 is the core load-bearing component, and its central area has a central shaft hole for assembly and connection with the drive shaft of external equipment.

[0034] The conductive layers 2 are uniformly distributed circumferentially on the axial end face of the polyurethane wheel body 1, forming a discrete array. Specifically, multiple conductive layers 2 are evenly spaced along the circumference of the polyurethane wheel body 1, with consistent spacing between adjacent conductive layers 2, ensuring effective coverage of wear conditions at all locations along the circumference of the wheel body. Each conductive layer 2 has an identical structure, including a conductive sheet 201, an electrode 202, and a conductive lead 203. The discrete array design improves the reliability of monitoring and avoids the failure of the overall wear monitoring function due to the failure of a single conductive layer 2.

[0035] To achieve a firm bond between the conductive layer 2 and the polyurethane wheel body 1, the polyurethane wheel body 1 is pre-set with a printing groove 101 and a lead wire groove 102 adapted to the structure of the conductive layer 2. The printing groove 101 extends radially along the polyurethane wheel body 1 and is used to accommodate the electrode 202 and the conductive sheet 201. The lead wire groove 102 is used to lay the conductive lead wire 203, and its opening is connected to the inner side of the printing groove 101 near the central axis of the polyurethane wheel body 1. The lead wire groove 102 extends to the central axis hole area of ​​the polyurethane wheel body 1, providing a channel for the convergence of the conductive lead wire 203. The electrode 202 and the conductive lead wire 203 are fixedly connected by welding. After welding, the electrode 202 is placed in a pre-set position within the printing groove 101, and the conductive lead wire 203 is correspondingly placed in the lead wire groove 102. The end of the conductive lead wire 203 not welded to the electrode 202 extends along the lead wire groove 102 to the central axis hole area, ultimately converging at the signal interface structure 3.

[0036] The conductive sheet 201 fills the printing groove 101 and completely encloses the electrode 202, ensuring a stable electrical connection between the electrode 202 and the conductive sheet 201, reducing the interference of contact resistance on the monitoring results. The conductive sheet 201 is prepared by screen printing with conductive paste. Its outermost end has a preset radial distance from the rolling working surface 103 of the polyurethane wheel body 1 in the initial state. This radial distance is the maximum allowable wear depth of the wheel body and also corresponds to the alarm threshold for wear monitoring. When the wheel body experiences normal wear during use, the thickness of the rolling working surface 103 gradually decreases. When the wear reaches the preset radial distance, the rolling working surface 103 will touch the conductive sheet 201, causing the conductive sheet 201 to wear, which in turn causes a change in the resistance value of the conductive layer 2.

[0037] The signal interface structure 3 is located in the central shaft hole area of ​​the polyurethane wheel body 1. Its core function is to lead the resistance measurement signals of each conductive layer 2 to external monitoring equipment. In this embodiment, the signal interface structure 3 includes an external connector composed of a multi-core connector. This multi-core connector can orderly converge the conductive leads 203, avoiding lead tangling or short circuits. At the same time, it enables detachable connection with external instruments through the multi-core connector, facilitating the installation, maintenance, and repair of the equipment. The external instrument collects the resistance signals of each conductive layer 2 in real time through the signal interface structure 3.

[0038] The polyurethane wheel of this invention requires a corresponding measurement method to achieve its wear monitoring function. The core of this method lies in monitoring the change in the resistance value of the conductive layer 2 and establishing a correlation between it and the wear depth. Specifically, it includes the following steps: Step 1: Establish a baseline. Before the polyurethane wheel is used for the first time, i.e., when it is brand new, measure and record the initial resistance value R0 of each conductive layer 2. This value will serve as the baseline for comparing all subsequent resistance changes.

[0039] Step 2: Online Monitoring. During the use of the polyurethane wheel, the current resistance value R of each conductive layer 2 is measured periodically or in real time through an external measurement circuit or integrated monitoring module connected to the signal interface structure 3. x Measurements can be triggered manually or performed automatically and continuously.

[0040] Step 3: Wear Assessment and Analysis. The measured current resistance value R... x The wear condition is compared and analyzed with the initial reference value R02 to determine the condition of the conductive layer. Its judgment logic is based on threshold alarm: A preset alarm threshold Rth is set for resistance changes. When Rth is detected... x When the change exceeds this threshold, it is determined that the wear level has reached a preset depth, thus triggering an early warning signal. This method is simple and direct, and is suitable for issuing a clear wear alarm indicating that a certain depth has been reached.

[0041] The polyurethane wheel in this embodiment enables real-time monitoring of the wheel's wear condition, solving the problems of low efficiency and easy omission of critical wear conditions in traditional manual periodic inspections. Simultaneously, the design of the discrete conductive layer 2 array improves the reliability of monitoring, and the complete encapsulation structure of the conductive sheet 201 and electrode 202 ensures the stability of the conductive path and reduces interference from contact resistance.

[0042] Example 2 The difference between this embodiment and Embodiment 1 is that the polyurethane wheel in this embodiment can monitor uneven wear of the wheel body, making it suitable for scenarios with complex working conditions and prone to uneven wear.

[0043] Regarding the design of the conductive layer 2, in this embodiment, the conductive layer 2 is circumferentially and uniformly distributed on the two axial end faces of the polyurethane wheel body 1, with each face forming a discrete array. This ensures more accurate monitoring of the wear state in different areas of the wheel body, providing richer and more accurate data support for subsequent uneven wear assessment.

[0044] Regarding the signal interface structure 3, in addition to the multi-core connector in embodiment 1, this embodiment also integrates a wireless signal transmission module, which is electrically connected to the conductive leads 203 of each conductive layer 2. This module can wirelessly transmit the resistance signals of each conductive layer 2 to a remote receiving device in real time, thereby enabling remote monitoring and early warning of wheel wear status.

[0045] The measurement method for the polyurethane wheel in this embodiment, based on Embodiment 1, adds a judgment logic for uneven wear alarm. The specific difference is as follows: In addition to the threshold alarm logic in Example 1, an uneven wear alarm logic has been added to determine whether there is uneven wear on the wheel body.

[0046] The specific implementation of the uneven wear alarm logic is as follows: based on the real-time measured R... x By substituting into the model for calculation, the resistance change (R) of each conductive layer 2 within the same array is obtained. x The standard deviation between -R0) is calculated. Simultaneously, an allowable range σ is preset for the standard deviation between the resistance changes of each conductive layer 2. When the calculated standard deviation of the real-time wear data of each conductive layer 2 within the same array exceeds this allowable range, it is determined that uneven wear exists on the wheel surface, thus triggering an uneven wear alarm signal. This method can indirectly reflect abnormal conditions in wheel installation, load distribution, or travel path, and is suitable for issuing diagnostic alarms for "abnormal wear distribution."

[0047] Example 3 This embodiment provides a method for producing a polyurethane wheel with a conductive layer, which is applicable to the production of the polyurethane wheels described in Embodiments 1 and 2.

[0048] Meanwhile, in practical applications, the polyurethane wheels described in Examples 1 and 2 have the following problems: when the wheel body bears heavy pressure, the elastic extension of the polyurethane material will cause the conductive layer 2 to stretch synchronously. Under long-term repeated action, it is very easy to cause the conductive layer 2 in planar contact to peel off from the wheel blank interface or the conductive layer itself to break, thereby causing the wear monitoring signal to be interrupted and the monitoring function to fail. In view of this, the production method provided in this embodiment adds a mesh groove in the printing groove 101 to fill and solidify the conductive paste in the groove, forming an anchoring structure that is three-dimensionally embedded with the polyurethane wheel blank. This changes the planar contact between the conductive layer 2 and the wheel blank to a mesh-like three-dimensional connection. The mesh structure can effectively improve the bonding strength and tensile strength between the conductive layer 2 and the wheel blank, ensuring the long-term stability and reliability of the wear monitoring function.

[0049] Specifically, the production method in this embodiment includes the following steps: Step S1: Prepare polyurethane wheel blank.

[0050] Specifically, step S1 above includes: Step S101: Prepare a polyurethane wheel blank with printing grooves and lead wire grooves: First, prepare polyurethane material, which is a uniform mixture of polyurethane prepolymer and curing agent. Optionally, functional fillers can be added in this step. Then, fix the polished and preheated metal wheel core into the mold, and inject the polyurethane material into the mold with a preset raised shape. The raised structure inside the mold corresponding to the printing groove 101 has a grid pattern, which enables the polyurethane wheel blank to have the printing groove 101 and the lead groove 102 at the preset position after molding, and the bottom of the printing groove 101 has an integrally formed mesh groove. Finally, place the mold at a first temperature for curing treatment until the polyurethane material reaches a gel state, to obtain a polyurethane wheel blank with the preset installation position.

[0051] Step S102, Surface modification treatment of the printing tank: The inner wall and bottom mesh groove of the printing tank 101 are modified to adapt to the subsequent conductive paste. This includes: when dealing with carbon-based conductive paste, plasma activation treatment is used to introduce active groups and improve the surface roughness of the inner wall and groove walls. When dealing with metal-based conductive paste, a polyurethane-modified conductive primer is applied to the inner wall and bottom mesh groove of the printing tank 101 for modification. After coating, a pre-curing treatment is performed to improve the adhesion between the primer and the conductive paste.

[0052] Step S2: Pre-treatment and assembly of electrodes and conductive leads.

[0053] Specifically, step S2 above includes: Step S201: Select and fix the conductive lead. Based on the type of conductive paste used, select a conductive lead 203 with a matching core wire type. Then, weld the conductive lead 203 to the electrode 202 to ensure a firm weld and avoid affecting the stability of the conductive path.

[0054] Step S202: Modify the electrode surface. Select a transition layer material that matches the type of conductive paste, coat the surface of electrode 202, and pre-cur it to eliminate defects at the interface between the electrode 202 and the conductive paste, thereby improving the bonding strength and conductive continuity between the two.

[0055] Step S203: Assemble the electrodes and conductive leads. Place a pair of processed electrodes 202 into the preset positions in the printing groove 101, ensuring that the two electrodes 202 are spaced apart to avoid short circuits; at the same time, place the conductive leads 203 connected to the electrodes 202 into the lead groove 102 that is connected to the printing groove 101 where the electrodes 202 are located, and lead the other end of the conductive leads 203 out to the outside of the polyurethane blank central shaft, preparing for subsequent connection with the signal interface structure 3.

[0056] Step S301: Filling and Polishing the Conductive Layer. This step uses a conventional filling method to fill the conductive paste into the printing tank 101 and the bottom mesh groove, forming the conductive layer 2 with the electrode 202 and conductive leads 203. The specific operation is as follows: The pre-treated polyurethane blank is fixed on the worktable, ensuring the printing tank 101 is facing upwards and horizontally to prevent paste flow during filling. Then, the conductive paste is slowly injected into the printing tank 101, while gently spreading it to ensure full penetration and filling of the bottom mesh groove, completely covering the electrode 202, and preventing residual air bubbles from affecting the bonding effect. After filling, the conductive paste is pre-cured to initially set its shape and prevent deformation or overflow during subsequent operations. After the conductive paste has pre-cured and set, the conductive paste in the printing tank 101 area is polished to remove the conductive paste that exceeds the height of the mesh grooves, leaving only the conductive paste within the mesh grooves. This precisely forms the pre-set mesh-like conductive layer 2 structure and simultaneously smooths the surface of the printing tank 101 area, laying the foundation for subsequent protective coating processes. Step S302, Protective Coating of Conductive Layer. Following step S301, a layer of polyurethane material is coated onto the axial end face of the polyurethane blank to cover the conductive layer 2. This polyurethane material is the same as the material used in step S1. By applying the protective coating, the conductive layer 2 is effectively protected, preventing damage during subsequent curing, processing, or use, while also improving the corrosion resistance and durability of the conductive layer 2. The coating process employs a scraping technique to ensure uniform coating thickness and complete coverage.

[0057] Step S4, gradient curing treatment. The polyurethane wheel blank with the conductive layer 2 printed and the protective coating completed is placed at a second temperature for curing treatment, which is higher than the first temperature mentioned above. The curing treatment at the second temperature achieves the following: the polyurethane wheel blank in the gel state is completely cured, obtaining sufficient structural strength and hardness; the conductive paste is completely cured and formed, forming a three-dimensional embedded anchoring structure with the mesh groove at the bottom of the printing groove, forming a stable conductive sheet 201; the electrode 202 and conductive lead 203 are firmly encapsulated and fixed in the polyurethane wheel blank, ensuring the bonding strength between the conductive layer 2 and the wheel body.

[0058] Step S5, Demolding and Processing. The polyurethane wheel blank is demolded and then processed, including turning the rolling working surface 103 of the wheel body to form a preset radial distance between the outermost end of the conductive layer 2 and the rolling working surface 103; precision machining the central shaft hole to ensure that the dimensional accuracy and assembly tolerance of the shaft hole meet the equipment connection requirements; grinding the axial end face and edges of the wheel body to remove burrs, flash, and other defects generated during demolding; and grinding and cleaning the mounting area of ​​the signal interface structure 3. After processing, the product is inspected, including the resistance value of the conductive layer 2, the strength of the wheel body, and the bonding force between the conductive layer and the wheel blank. Then, the qualified wheel body is assembled with the signal interface structure 3, and each conductive lead 203 is connected to the corresponding signal interface structure 3.

[0059] The production method of this embodiment effectively solves the compatibility problem between the conductive paste and the polyurethane substrate and electrode 202 by synergistically combining processes such as gradient curing and adaptability surface modification. By adding a mesh groove to the bottom of the printing groove 101 and filling and embedding it with the conductive paste, a three-dimensional anchoring structure is constructed, which solves the problem of conductive layer peeling and breakage caused by elastic polyurethane material under heavy pressure, and improves the bonding strength and conductive stability between the conductive layer 2 and the wheel body. At the same time, the process steps are closely connected and the process control is precise, which can ensure the consistency and reliability of the product, and is suitable for the large-scale production of the polyurethane wheels described in Embodiments 1 and 2.

[0060] Although embodiments of the invention have been described in conjunction with the accompanying drawings, those skilled in the art can make various modifications and variations without departing from the spirit and scope of the invention, and such modifications and variations all fall within the scope defined by the appended claims.

Claims

1. A polyurethane wheel having an electrically conductive layer, characterized in that, The polyurethane wheel comprises a polyurethane wheel body (1), a conductive layer (2), and a signal interface structure (3). The conductive layer (2) is in a grid structure and is uniformly distributed on the axial end surface of the polyurethane wheel body (1). The signal interface structure (3) is located in the central axial hole region of the polyurethane wheel body (1) and is electrically connected with the conductive layer (2) to collect resistance signals. The outermost end of the conductive layer (2) has a preset radial spacing with the rolling working surface (103) of the polyurethane wheel body (1). The conductive layer (2) comprises a conductive sheet (201), an electrode (202), and a conductive lead (203).

2. The polyurethane wheel having an electrically conductive layer of claim 1 wherein, The electrode (202) is welded with the conductive lead (203) and is fixed in a preset printing groove (101) in the polyurethane wheel body (1). The bottom of the printing groove (101) is provided with a mesh-shaped groove, the conductive sheet (201) is filled in the printing groove (101) and the mesh-shaped groove at the bottom, and the electrode (202) is wrapped to form a grid structure. The conductive lead (203) is arranged in a preset lead groove (102) in the polyurethane wheel body (1).

3. The polyurethane wheel with a conductive layer according to claim 2, wherein the printing groove (101) extends along the radial direction of the polyurethane wheel body (1). The inner side surface of the printing groove (101) near the central axis of the polyurethane wheel body (1) is connected with the lead groove (102) through connection, and the lead groove (102) extends to the central axial hole region. The method comprises the following steps: A polyurethane material is injected into a mold, and solidification is performed at a first temperature to obtain a polyurethane wheel blank with a printing groove (101) and a lead groove (102), and the bottom of the printing groove (101) is provided with a mesh-shaped groove. An electrode (202) and a conductive lead (203) are respectively arranged in the printing groove (101) and the lead groove (102) of the polyurethane wheel blank.

4. A method for producing a polyurethane wheel having an electrically conductive layer for producing a polyurethane wheel having an electrically conductive layer according to any one of claims 1 to 3, characterized in that Conductive paste is filled to cover the mesh-shaped groove at the bottom of the printing groove (101) and the electrode (202) and the conductive lead (203) to form a conductive layer (2). The filled polyurethane wheel blank is solidified at a second temperature, and the second temperature is higher than the first temperature. The wheel blank solidified at the second temperature is demolded and processed. The step of obtaining the polyurethane wheel blank with the printing groove (101) and the lead groove (102) comprises the following steps: A preheated metal wheel core is fixed in the mold. A polyurethane material is injected into the mold with a preset protruding shape to obtain a polyurethane wheel blank with a printing groove (101), a lead groove (102), and a mesh-shaped groove at the bottom of the printing groove (101), and the slot opening of the lead groove (102) is connected with the inner side surface of the printing groove (101) near the central axis of the polyurethane wheel blank.

5. The method of producing a polyurethane wheel having a conductive layer according to claim 4, wherein The printing groove (101) is subjected to surface modification treatment. The surface modification treatment is selected according to the type of conductive paste used for subsequent coating, which comprises the following steps: If the conductive paste is a carbon-based conductive paste, the surface modification treatment is plasma activation treatment. ​ ​ ​ 6. A method of producing a polyurethane wheel having an electrically conductive layer according to claim 5, characterized in that, Before injecting the polyurethane material into the mold: Mix the polyurethane prepolymer and curing agent uniformly to form the polyurethane material; Grind the surface of the metal wheel core; Preheat the ground metal wheel core to a preset temperature and fix it in the center area of the mold.

7. The method of producing a polyurethane wheel having a conductive layer according to claim 4, wherein The step of filling the conductive paste includes: Fill the conductive paste into the printing slot (101) and the meshed groove at the bottom, and wrap the electrode; Cure the conductive paste; After the conductive paste is cured, grind the conductive paste in the printing slot (101) area, remove the excess conductive paste in the slot, and retain the conductive paste in the meshed groove.

8. The method of producing a polyurethane wheel having a conductive layer according to claim 6, wherein Before the step of filling the conductive paste: Weld the conductive lead (203) of the core type matched with the type of the conductive paste to the electrode (202); Modify the surface of the electrode (202) to form a transition layer; The modification method is selected according to the type of the conductive paste, including: selecting a transition layer material matched with the type of the conductive paste to coat the surface of the electrode (202) and pre-curing; Place a pair of processed electrodes (202) in the printing slot (101) and separate from each other; Place the conductive lead (203) connected to the electrode (202) in the lead slot (102) connected through the printing slot (101) where the electrode (202) is located, and lead one end out to the outside of the polyurethane wheel blank center shaft.

9. The method of producing a polyurethane wheel having a conductive layer according to claim 4, wherein After the step of forming the conductive layer (2) and before the step of curing at the second temperature, a layer of polyurethane material is coated on the axial end face of the polyurethane wheel blank to cover the conductive layer (2).

10. The production method of a polyurethane wheel with a conductive layer according to claim 4, wherein: The curing at the first temperature is performed until the polyurethane material reaches a gel state; The second temperature is higher than the first temperature, and the curing at the second temperature realizes: The complete curing of the polyurethane wheel blank in the gel state; The encapsulation and fixation of the conductive layer (2) in the polyurethane wheel blank.

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