Nylon Surface Layer Roll Member Crack Resistance
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Solution Overview
Problem
Existing roll members with conductive elastic layers and surface layers face issues with cracking when continuously rotated and pressed against another body, due to fatigue from repeated force application, which is not effectively addressed by existing crosslinking and thermal degradation control methods.
Innovation Solution
A roll member with a conductive elastic layer and a surface layer containing a crosslinked product of crosslinkable nylon, where the crosslinking degree is between 0.3 and 0.7, and the thermal degradation index is between 2.1 and 2.3, utilizing a sulfonic acid-based compound as a catalyst to accelerate crosslinking and suppress decomposition reactions, thereby reducing the occurrence of cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crosslinking degree of the surface layer is increased to improve crack resistance, then the surface layer becomes more rigid and resistant to deformation, but excessive crosslinking (crosslinking degree > 0.7) causes the material to become too brittle and prone to cracking under repeated stress
Solution Approach 1:
The patent applies parameter changes by precisely controlling the crosslinking degree within the range of 0.3 to 0.7 and the thermal degradation index within 2.1 to 2.3. This optimization balances the rigidity needed for crack resistance with the flexibility required to prevent brittleness, resolving the contradiction between strength and material stability.
2Stability of the object's composition
If the crosslinking degree is decreased to maintain material flexibility, then the surface layer remains more elastic and adaptable, but insufficient crosslinking (crosslinking degree < 0.3) reduces crack resistance and durability
Solution Approach 1:
The patent resolves this contradiction by establishing the crosslinking degree parameter within the optimal range of 0.3 to 0.7, which maintains sufficient material flexibility while ensuring adequate crack resistance through controlled crosslinking of the nylon-based surface layer.
3Temperature
If thermal degradation is suppressed by controlling the thermal degradation index, then the surface layer maintains its properties at elevated temperatures, but improper thermal stability control (index < 2.1 or > 2.3) leads to premature degradation and cracking
Solution Approach 1:
The patent applies parameter changes by controlling the thermal degradation index within the specific range of 2.1 to 2.3. This ensures the surface layer maintains its mechanical properties and resistance to cracking under thermal stress, thereby extending the service life and reliability of the roll member.
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 proposed configuration significantly suppresses the occurrence of cracks in the surface layer during continuous rotation and pressing, enhancing the durability and longevity of the roll member by optimizing the crosslinking and thermal stability of the surface layer.
Implementation Method 1
utilizing a sulfonic acid-based compound as a catalyst to accelerate crosslinking
Implementation Method 2
the surface layer contains a crosslinked product of crosslinkable nylon
Data Source
AI summary
A roll member includes a conductive elastic layer, and a surface layer provided on the conductive elastic layer. The surface layer contains a crosslinked product of crosslinkable nylon, the crosslinking degree of the surface layer specified by formula (1) below is 0.3 or more and 0.7 or less, and the thermal degradation index of the surface layer specified by formula (2) below is 2.1 or more and 2.3 or less.Crosslinking degree=absorbance at 1078 cm−1÷absorbance at 2935 cm−1 Formula (1):Thermal degradation index=absorbance at 1638 cm−1÷absorbance at 1543 cm−1 Formula (2):