Foamed Body Molding System for Roller Durability
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Solution Overview
Problem
Conventional elastic foamed body heat-insulating layers in image forming apparatus rollers suffer from insufficient durability due to aggregation of water particles during the molding process, leading to weld lines and surface defects, which degrade the partial strength and durability of the molded articles.
Innovation Solution
A foamed body molding system that uses a cylindrical cavity with a side mold, flange unit, upper and lower cap units, and a metal shaft to create a foamed tube with a continuous cell structure, employing a two-component heat-curing liquid silicone and water mixture, with precise control of mixing and venting to prevent air inclusion and aggregation, resulting in a durable elastic layer for the roller.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If water-blown foamed silicone rubber with continuous air bubbles is used, then the roller can maintain prescribed diameter and hardness, but the durability is still insufficient when actually employed in a fixing device
Solution Approach 1:
The patent changes the chemical composition parameters of the foam resin by specifying a two-component heat-curing liquid silicone system with precise mixing ratios. This chemical parameter change enables both the maintenance of diameter and hardness during molding and the improvement of durability through proper cross-linking and curing mechanisms.
Solution Approach 2:
The patent uses a composite material system consisting of two-component heat-curing liquid silicone and water mixture. This composite approach creates a foamed body with continuous cell structure that combines the benefits of dimensional stability with enhanced mechanical durability through the synergistic interaction of the silicone polymer matrix and the foamed structure.
2Loss of time
If soft sponge of foamed silicone rubber is used, then warm-up time is shortened and sufficient contact is obtained, but the elastic layer is quickly destroyed by external forces
Solution Approach 1:
The patent modifies the physical and chemical parameters of the foam resin by using a two-component heat-curing system with controlled cross-linking. This enables the elastic layer to achieve both the softness required for rapid warm-up and sufficient contact, and the strength to resist external forces through proper curing that creates a durable polymer network.
Solution Approach 2:
The patent employs a composite foamed body material that combines the flexibility of soft sponge with the durability of heat-cured silicone. The two-component system creates a composite structure where the cross-linked polymer matrix provides strength while the foamed structure maintains softness and thermal properties.
3Ease of manufacture
If conventional molding methods are used, then production is simpler, but water particles aggregate during molding causing weld lines and surface defects
Solution Approach 1:
The patent applies preliminary action by pre-mixing the two-component heat-curing liquid silicone and water in precise ratios before molding. This preliminary mixing ensures uniform distribution of water particles throughout the foam resin, preventing aggregation during the molding process and eliminating weld lines and surface defects while maintaining process simplicity.
Solution Approach 2:
The patent changes the rheological and chemical parameters of the foam resin by using a two-component heat-curing system. This parameter change modifies the viscosity and reactivity of the material, allowing water particles to remain uniformly dispersed during mixing and molding, thereby preventing aggregation and surface defects while keeping the manufacturing process straightforward.
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 system produces a foamed tube with enhanced durability and adhesive strength, reducing the occurrence of weld lines and surface defects, thereby improving the performance and longevity of the roller in image forming apparatuses.
Implementation Method 1
employing a two-component heat-curing liquid silicone and water mixture
Implementation Method 2
create a foamed tube with a continuous cell structure
Implementation Method 3
a first vent hole to connect the cylindrical cavity with an upper space thereof (through the upper connection member to vent air therein), and... an upper cap unit that holds the flange unit from above and connects the side mold with the flange unit while having a second vent hole to vent air ejected from the first vent hole outside the foamed body molding system
Implementation Method 4
employing a two-component heat-curing liquid silicone and water mixture
Data Source
AI summary
A foamed body molding system includes a side mold to constitute a side surface of a cylindrical cavity, a flange unit including an upper connection member to constitute an upper surface of the cylindrical cavity, a first vent hole to connect the cylindrical cavity with an upper space thereof, and a metal shaft having a diameter smaller than an inner diameter of the cylindrical cavity disposed with its lower end entering the cylindrical cavity and its upper end coaxially held with the cylindrical cavity, an upper cap unit to hold the flange unit including a second vent hole to vent air ejected from the first vent hole, and a lower cap unit including a lower connection member to constitute a lower surface of the cylindrical cavity and a raw molding material introduction cylindrical hole formed at a coaxial position with the cylindrical cavity to introduce raw molding material.