Intermediate Transfer Belt Seam Smoothing via Silane and Glycoluril Resin Coating
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Solution Overview
Problem
Ultrasonically welded seams in intermediate transfer belts often result in irregular surfaces, leading to toner trapping, blade damage, and reduced image quality due to protrusions, which affect cleaning efficiency and the service life of the belt, and require costly and labor-intensive manufacturing processes.
Innovation Solution
A process involving the post-treatment of ultrasonically welded seams using a heat and pressure tool to smooth out the rough seams, followed by coating with a silane primer layer and a crosslinked resin mixture of glycoluril and acrylic resins, enhancing seam strength and surface topology without removing material, thereby improving adhesion and electrical resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If ultrasonic welding is used to join belt edges, then manufacturing efficiency is improved, but surface regularity deteriorates due to protrusions and irregularities
Solution Approach 1:
The patent applies a coating composition to the ultrasonically welded seam before the belt is put into service. This preliminary coating action smooths the irregular surface created by ultrasonic welding, eliminating protrusions that would otherwise cause toner trapping and blade damage, while preserving the manufacturing efficiency of ultrasonic welding itself
Solution Approach 2:
The patent changes the surface properties of the welded seam by applying a coating composition with specific rheological and adhesive properties. The coating transforms the irregular physical surface into a smooth, regular surface while maintaining the structural integrity of the weld, resolving the contradiction between manufacturing efficiency and surface precision
2Productivity
If ultrasonic welding creates rough seams, then production speed is maintained, but cleaning efficiency deteriorates due to toner trapping
Solution Approach 1:
The patent converts the harmful effect of ultrasonic welding (rough seams causing toner trapping) into a beneficial outcome by applying a coating composition that fills and smooths the irregularities. The coating transforms the harmful rough surface into a smooth surface that prevents toner trapping, while the ultrasonic welding process itself remains unchanged and efficient
3Manufacturing precision
If material is removed to smooth seams, then surface regularity is improved, but seam strength deteriorates
Solution Approach 1:
The patent introduces a coating composition as an intermediary layer between the rough welded seam and the rest of the belt system. This intermediary coating fills the irregularities to provide surface regularity while the coating itself and its adhesive properties maintain and even enhance the seam strength, avoiding the need to remove any material
4Manufacturing precision
If costly post-treatment processes are applied to seams, then surface quality is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the approach from mechanical material removal to chemical/coating-based surface modification. By applying a coating composition with appropriate rheological properties, the patent achieves high surface quality without costly mechanical removal processes, maintaining manufacturing efficiency while improving surface quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process results in a smooth, robust, and electrically compatible seam with improved adhesion and extended service life, reducing toner trapping and blade damage, while maintaining seam strength and enhancing image quality.
Implementation Method 1
contacting the rough seam region with a heat and pressure applying tool; and smoothing out the rough seam region with heat and pressure applied by the heat and pressure applying tool
Implementation Method 2
coating with a silane primer layer and a crosslinked resin mixture of glycoluril and acrylic resins, enhancing seam strength and surface topology without removing material
Implementation Method 3
crosslinked resin mixture of glycoluril and acrylic resins
Implementation Method 4
coating with a silane primer layer and a crosslinked resin mixture of glycoluril and acrylic resins
Data Source
AI summary
An intermediate transfer member, such as a belt, that includes, for example, a supporting substrate, a silane first intermediate layer, and contained on the silane layer a second layer of a self crosslinking acrylic resin; a mixture of a glycoluril resin and an acrylic polyol resin; or a mixture of a glycoluril resin and a self crosslinking acrylic resin.