Brush Roller PVA Foam Fluid Penetrability
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Solution Overview
Problem
Current brush rollers used for circuit substrates suffer from poor fluid penetrability and residue issues due to solid hole fillers, leading to decreased efficiency and yield, as well as potential bacterial growth when starch is used, requiring lengthy cleaning processes that reduce machine utilization.
Innovation Solution
A brush roller manufacturing method using a PVA material, cross-linking agent, and gaseous hole filler to create a PVA emulsified solution with homogeneously distributed bubbles, which form fluid passages and pores upon curing, enhancing fluid penetrability and eliminating residue problems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid hole fillers are used to manufacture brush rollers, then the physical properties of the brush roller can be improved, but the fluid penetrability deteriorates and residues remain on the brush roller
Solution Approach 1:
The patent changes the physical state of the hole filler from solid to gas. The gas-filled pores are created by introducing a foaming agent into the polymer matrix during manufacturing, then heating to generate gas bubbles that remain trapped in the cured material. This parameter change eliminates solid residues while maintaining structural integrity and improving fluid penetrability.
Solution Approach 2:
The patent uses gas (pneumatics) as the hole filler instead of solid materials. Gas bubbles are introduced into the polymer matrix during the manufacturing process, creating a porous structure that allows better fluid penetration while eliminating the problems associated with solid fillers such as residues and poor fluid dynamics.
2Ease of manufacture
If starch is used as a solid hole filler, then the brush roller can be manufactured, but bacterial growth occurs on the remaining starch
Solution Approach 1:
The patent changes the hole filler from organic starch (prone to bacterial growth) to inorganic gas bubbles. The gas-filled porous structure maintains the necessary physical properties for brush roller function while eliminating the organic substrate that supports bacterial proliferation.
Solution Approach 2:
The patent uses a foaming agent that decomposes during the manufacturing process to generate gas bubbles. The foaming agent itself is temporary and decomposes completely, leaving only inert gas bubbles in the final product, thereby eliminating persistent organic residues that would support bacterial growth.
3Reliability
If cleaning and removing programs are performed to eliminate residues, then the yield of circuit substrates is improved, but the machine utilization rate deteriorates
Solution Approach 1:
The patent eliminates residues at the source during the manufacturing process itself, rather than requiring subsequent cleaning operations. By using gas-filled pores instead of solid fillers, the brush roller is manufactured without residues that would require later removal, thereby preventing the need for downtime cleaning programs.
Solution Approach 2:
The patent converts what would normally be a harmful residue problem into a beneficial feature. The gas-filled porous structure provides excellent fluid penetrability while eliminating residues entirely, turning a manufacturing defect into a performance advantage that eliminates the need for cleaning maintenance.
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 method produces a brush roller with excellent fluid penetrability and desired compressive stress, reducing bacterial growth and cleaning times, while maintaining effective brushing efficiency and preventing damage to circuit substrates.
Implementation Method 1
adding the cross-linking agent into the PVA aqueous solution to allow the PVA material in the PVA aqueous solution for undergoing a cross-linking reaction and forming a PVA cross-linking solution
Implementation Method 2
adding the gaseous hole filler into the PVA cross-linking solution, and homogenizing the gaseous hole filler and the PVA cross-linking solution by stirring to form a PVA emulsified solution, which comprises bubbles formed by the gaseous hole filler with substantially homogeneous distribution
Implementation Method 3
placing the PVA emulsified solution into the brush roller mold until the PVA emulsified solution curing to a solid-state and forming the brush roller with desired compressive stress
Data Source
AI summary
A brush roller and its manufacturing method and brush roller mold is provided, the brush roller is manufactured by foaming a gaseous pore filler, while solving the problem of using a solid pore filler foaming method to manufacture the brush roller. In addition, the brush roller of the present invention has a plurality of fluid channels communicating between any adjacent two, and the plurality of fluid channels respectively extend to the surface of the brush roller to form pores to improve the fluid permeability of the brush roller, and in the brush roller manufacturing method of the present invention, after the PVA emulsified solution is cured, the compressive stress under the condition of the predetermined compression ratio can be formed to meet the expected brush roller, and it can be used to brush the circuit substrate.