Conductive Roller Coating via Electron Beam Curing

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Solution Overview

Problem

The existing methods for producing conductive rollers require expensive molds to achieve high precision, leading to increased production costs and limitations in reducing product costs.

Innovation Solution

A method involving the application of a compound forming an elastomer through electron beam or ultraviolet ray irradiation onto a shaft member to form an elastomeric coating layer, which is then cured, eliminating the need for molds and allowing for efficient formation of conductive rollers with precise dimensions and reduced costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a mold is used to form the elastic layer with high precision, then the manufacturing precision is improved, but the device complexity and cost increase due to requiring expensive molds

Engineering Contradiction:

Improvedimension precision of outer peripheryVSAvoidcost of molds

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent extracts the elastic layer formation process from the mold-based shaping method. Instead of using a mold to form the entire elastic layer, the invention applies a coating layer onto a pre-formed shaft member, separating the shaft formation (done by molding) from the elastic layer formation (done by coating and curing). This eliminates the need for expensive precision molds while maintaining dimensional accuracy.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical mold-based shaping system with a radiation-based curing system. The elastic layer is formed by applying a coating and then curing it through electron beam or ultraviolet irradiation, substituting the mechanical constraint of a mold with an energy-based curing process that achieves precise dimensional control without requiring expensive molding equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If multiple molds are used to increase production volume, then the productivity is improved, but the device complexity and installation cost increase

Engineering Contradiction:

Improveproduction volumeVSAvoidinstallation cost of multiple molds

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent enables continuous production by applying the coating layer and curing it in a continuous process along the shaft member. The coating can be applied continuously while the shaft rotates, and the curing radiation can follow continuously, eliminating the need to stop and change molds between production batches. This continuous action increases productivity without requiring multiple expensive molds installed in parallel.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of manufacture

If a traditional drying step is used to form the elastic layer, then the manufacturing process is simplified, but the production time increases and productivity decreases

Engineering Contradiction:

Improvesimplicity of processVSAvoiddrying time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent uses radiation-induced phase transition (curing) to transform the coating layer from a liquid or paste state directly to a solid elastic layer state through electron beam or ultraviolet irradiation. This phase transition occurs instantly during the coating process, eliminating the need for a separate drying step and significantly reducing production time while maintaining process simplicity.

Inventive Principle:

Principle #36Phase transitions

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

This approach enables the cost-effective production of conductive rollers with precise dimensions and surface smoothness, reducing the need for expensive molds and eliminating the drying step, thereby significantly lowering production costs while maintaining high precision.

Implementation Method 1

applying a compound forming an elastomer by curing through an electron beam irradiation or a ultraviolet ray irradiation

Methodology Applied

Scientific EffectElectron beam irradiation: Electron Beam

Implementation Method 2

applying a compound forming an elastomer by curing through an electron beam irradiation or a ultraviolet ray irradiation

Methodology Applied

Scientific EffectUltraviolet ray irradiation: Photopolymerisation

Implementation Method 3

curing the elastomeric coating layer through an irradiation of an electron beam or a ultraviolet ray to form an elastic layer

Methodology Applied

Scientific EffectElectron beam irradiation: Electron Beam

Implementation Method 4

curing the elastomeric coating layer through an irradiation of an electron beam or a ultraviolet ray to form an elastic layer

Methodology Applied

Scientific EffectUltraviolet ray irradiation: Photopolymerisation

Data Source

PatentUS8663748B2Method of producing a conductive roller utilizing a semi-curing step

Publication Date: 2014.03.04 ARCHEM INC

AI summary

In the formation of a conductive roller 1, a compound forming an elastomer by curing through an electron beam irradiation or a ultraviolet ray irradiation is applied onto an outside of a shaft member 2 to form an elastomeric coating layer 3R and then the elastomeric coating layer is cured through an irradiation of an electron beam or a ultraviolet ray to form an elastic layer, whereby the elastic layer can be formed cheaply without sacrificing precision of peripheral dimension to largely reduce the cost of the conductive roller.