Crosslinked Polyether Rubber for Clean Conductive Rolls
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Solution Overview
Problem
Conductive rolls using polyether rubber face challenges with photoreceptor contamination over long-term use, leading to image defects and increased costs due to the need for coatings or mixing with other rubbers, which can impair electroconductivity.
Innovation Solution
A cross-linked rubber composition is developed using a polyether rubber with an epihalohydrin monomer unit and ethylene oxide monomer unit in a specific ratio, cross-linked with a cross-linking agent, and processed to achieve a low acetone extraction amount, preventing photoreceptor contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a polyether rubber is used in a conductive roll, then electroconductivity is achieved, but photoreceptor contamination occurs over long-term use
Solution Approach 1:
The patent changes the chemical composition parameters of the polyether rubber by specifying a particular ratio of ethylene oxide units (50-80 mol%) to total units, and controlling the acetone extraction amount (3.5 wt% or less) to achieve both electroconductivity and resistance to photoreceptor contamination
Solution Approach 2:
The patent creates a composite rubber composition by combining polyether rubber with specific additives including silane coupling agents and crosslinking agents, forming a multi-component system that maintains electroconductivity while preventing contamination through controlled chemical interactions
2Object-generated harmful factors
If a coating is applied to a conductive roll to suppress photoreceptor contamination, then contamination is reduced, but manufacturing costs increase
Solution Approach 1:
The patent extracts and eliminates the need for additional protective coatings by incorporating contamination-resistant properties directly into the base rubber composition through controlled crosslinking and additive selection, thereby removing the separate coating step and associated costs
3Object-generated harmful factors
If another rubber is mixed with polyether rubber to suppress photoreceptor contamination, then contamination is reduced, but electroconductivity is impaired
Solution Approach 1:
The patent applies local quality by concentrating the anti-contamination functionality in specific additive components (such as silane-based crosslinking agents) within the rubber matrix, rather than diluting the polyether rubber with other rubber types that would compromise electroconductivity
4Reliability
If a small amount of conductivity imparting material is kneaded into rubber, then electroconductivity is achieved, but dispersibility control becomes difficult
Solution Approach 1:
The patent uses silane coupling agents as intermediary substances that facilitate uniform dispersion of conductivity imparting materials within the polyether rubber matrix, acting as a bridge that improves interfacial compatibility and prevents aggregation during kneading and processing
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 solution effectively suppresses photoreceptor contamination even after extended use, maintaining electroconductivity and reducing costs by preventing image defects and contamination in conductive rolls.
Implementation Method 1
a cross-linked rubber obtained by cross-linking a polyether rubber composition containing a polyether rubber and a cross-linking agent
Data Source
AI summary
Provided is a cross-linked rubber obtained by cross-linking a polyether rubber composition containing a polyether rubber and a cross-linking agent, wherein the polyether rubber contains an epihalohydrin monomer unit and an ethylene oxide monomer unit and has a ratio of content of the ethylene oxide monomer unit of 50 to 80 mol% in a total monomer unit, and an acetone extraction amount when the cross-linked rubber is immersed in acetone at 23°C for 72 hours is 3.5 wt% or less.