Fiber-Reinforced Roller Shaft for Imaging Apparatus
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Solution Overview
Problem
Conventional imaging apparatus rollers made of metal are expensive, heavy, prone to rust, and have high machining costs, with resin alternatives lacking conductivity, heat resistance, and mechanical strength.
Innovation Solution
A roller comprising a shaft with reinforcing fibers and a binder resin, surrounded by an elastic body, offering improved conductivity, heat resistance, mechanical strength, and corrosion resistance, manufactured using pultrusion with a high length-to-diameter ratio reinforcing fiber and multi-layer structures for enhanced flexural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials (free-cutting steel, stainless steel) are used for functional rollers, then mechanical strength and durability are improved, but weight increases, cost increases, and susceptibility to rust occurs
Solution Approach 1:
The patent uses composite materials consisting of resin matrix combined with reinforcing fibers (glass fiber, carbon fiber, or mixed fibers) to create shafts that achieve metal-level mechanical strength while maintaining lightweight properties. The fiber reinforcement provides tensile and flexural strength comparable to metal, while the resin matrix binds the fibers and distributes loads, resolving the contradiction between strength and weight.
2Strength
If metal materials (free-cutting steel) are used for functional rollers, then mechanical strength is improved, but machining cost increases and rust resistance deteriorates
Solution Approach 1:
The composite shaft structure eliminates the need for expensive metal machining operations. The resin matrix allows for easier forming and shaping processes, while fiber reinforcement provides the necessary structural strength. This combination reduces machining costs significantly compared to metal materials while maintaining mechanical strength requirements.
3Weight of moving object
If conventional resin materials are used for shafts, then weight decreases and cost decreases, but conductivity, heat resistance, and mechanical strength deteriorate
Solution Approach 1:
The patent employs fiber-reinforced composite materials where discontinuous or continuous fibers (glass fiber, carbon fiber) are embedded in a resin matrix. This composite structure provides mechanical strength comparable to metal while maintaining the weight advantages of resin materials. The fiber reinforcement specifically addresses the strength deficiency of conventional resins.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the resin material by adding fiber reinforcements, heat-resistant additives, and conductive agents. These parameter changes enable the resin-based shaft to achieve heat resistance and mechanical strength levels previously only attainable with metal materials, while maintaining lightweight properties.
4Weight of moving object
If conventional resin materials are used for shafts, then weight decreases and cost decreases, but heat resistance and mechanical strength deteriorate
Solution Approach 1:
The patent changes the thermal parameters of the resin material by incorporating heat-resistant additives, selecting high-temperature stable resin matrices (such as polyimide or polyester resins), and using fiber reinforcements that maintain structural integrity at elevated temperatures. These modifications enable the shaft to withstand vulcanization temperatures and operating conditions without deforming or degrading.
Data Source
AI summary
A roller includes a shaft including reinforcing fiber and a binder resin; and an elastic body surrounding an outer surface of the shaft, wherein an average length to average diameter ratio (L/D) of the reinforcing fiber is from about 15,000:1 to about 50,000:1.