Laminated Body Adhesive Force via Methacryloyl Reaction
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Solution Overview
Problem
Existing conductive rollers with a polyurethane elastic layer face issues with weak adhesive force between the base and surface layers, bleeding of unreacted materials, and changes in physical properties like water-vapor permeability and electrical resistance due to the use of polar groups in the base layer formation.
Innovation Solution
A laminated body is created with a base layer of polyurethane containing (meth)acryloyl groups and a surface layer of radical curable resin obtained from (meth)acrylate, where the (meth)acryloyl groups react to enhance adhesion, using specific (meth)acrylates with hydroxyl or isocyanate groups, and ultraviolet curable resins to improve bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a component having a polar group (carboxyl group or hydroxyl group) is incorporated in the base layer to adhere the base layer and surface layer, then adhesion between layers is achieved, but adhesive force is weak and adhesion durability is insufficient when friction occurs
Solution Approach 1:
The patent changes the chemical parameter of the base layer by incorporating a silane coupling agent with specific functional groups (epoxy, amino, or isocyanate groups) instead of conventional polar groups. This chemical parameter change enables stronger chemical bonding with the ultraviolet curable resin surface layer, significantly improving adhesion durability under friction conditions while maintaining manufacturing feasibility.
Solution Approach 2:
The patent creates a composite structure by combining the polyurethane base layer containing silane coupling agent with the ultraviolet curable resin surface layer. The silane coupling agent acts as a bridge between the base layer and surface layer, forming a composite material system that achieves both strong adhesion and high durability through chemical bonding mechanisms.
2Strength
If a component having a polar group (carboxyl group or hydroxyl group) is used in the base layer formation, then adhesion between layers is achieved, but bleeding of unreacted material occurs
Solution Approach 1:
The patent changes the chemical reactivity parameter by selecting silane coupling agents with specific functional groups that react completely with the ultraviolet curable resin, eliminating unreacted material that would otherwise bleed through. The silane groups form stable chemical bonds with the resin, preventing material migration and bleeding issues.
3Strength
If a component having a polar group (carboxyl group or hydroxyl group) is used in the base layer formation, then adhesion between layers is achieved, but water-vapor permeability and electrical resistance properties change
Solution Approach 1:
The patent changes the chemical composition parameter by using silane coupling agents with specific functional groups that maintain the polyurethane base layer's inherent properties. The silane groups bond with the ultraviolet curable resin without significantly altering the base layer's water-vapor permeability and electrical resistance, preserving the conductive roller's functional composition.
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 significantly enhances the adhesive force between the base and surface layers, improving durability against friction and maintaining desired physical properties, thus extending the life of conductive rollers.
Implementation Method 1
the surface layer includes a radical curable resin obtained by polymerizing (meth)acrylate that has a (meth)acryloyl group; and the laminated body is formed by the (meth)acryloyl group in the polyurethane reacting with the (meth)acryloyl group in the (meth)acrylate
Implementation Method 2
the radical curable resin is preferably an energy ray curable resin. The energy ray curable resin is preferably ultraviolet curable resin
Data Source
AI summary
Provided are a laminated body that can improve the adhesive force between the base layer and the surface layer, a conductive roller provided with the laminated body, and a method for manufacturing a laminated body with improved adhesive force between the base layer and the surface layer. The disclosed laminated body includes a base layer and a surface layer formed on the base layer, the base layer includes polyurethane having a (meth)acryloyl group, the surface layer includes a radical curable resin obtained by polymerizing (meth)acrylate that has a (meth)acryloyl group, and the laminated body is formed by the (meth)acryloyl group in the polyurethane reacting with the (meth)acryloyl group in the (meth)acrylate.