Pliable Print Roller Elastomer Composition for Can Printing
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Solution Overview
Problem
High-speed industrial printing machines, such as those used for printing drink cans, face frequent breakdowns and maintenance issues due to the wear and tear on pliable form rollers, which require frequent replacement, disrupting production and efficiency.
Innovation Solution
A pliable print roller composed of a homogeneous mixture of polyisoprene and polybutadiene elastomers, silica filler, and dicumyl peroxide curing agent, with optional additives, is developed, featuring a manufacturing process that includes slow mill mixing, powder coating, and extended curing to create a durable, low-oil composition that reduces hardness and increases resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the hardness of pliable rollers is increased to improve durability, then the roller lifespan is extended, but the roller requires higher pressure to apply the desired ink coating thickness, which increases energy consumption and heat generation
Solution Approach 1:
The patent modifies the chemical composition parameters of the roller material by incorporating specific ratios of polyisoprene and polybutadiene elastomers along with silica filler and curing agents. This changes the physical properties of the roller to achieve optimal hardness that balances durability with energy efficiency, allowing the roller to maintain desired ink coating thickness without requiring excessive pressure
Solution Approach 2:
The patent employs a composite material system consisting of multiple elastomers (polyisoprene and polybutadiene) combined with inorganic filler (silica) and curing agents. This composite structure provides enhanced durability through the reinforcing silica particles while the elastomer matrix maintains the necessary flexibility and resilience, achieving a balance between lifespan extension and energy consumption reduction
2Strength
If the hardness of pliable rollers is increased to reduce wear and tear, then the roller durability is improved, but the surface resiliency decreases causing poor performance at higher pressures and machine speeds
Solution Approach 1:
The patent utilizes a composite material system where silica filler particles are dispersed within an elastomer matrix of polyisoprene and polybutadiene. The silica provides structural strength and wear resistance, while the elastomer phase maintains surface resiliency and flexibility. This composite architecture allows the roller to withstand high pressures and machine speeds while retaining durability
Solution Approach 2:
The patent creates local quality differentiation within the roller structure by strategically distributing silica filler particles throughout the elastomer matrix. The filler concentration and distribution are optimized to provide enhanced durability in contact zones while preserving surface resiliency in areas requiring flexibility, achieving both durability and reliability simultaneously
3Use of energy by moving object
If conventional pliable rollers are used to maintain reasonable roller pressure, then energy consumption is kept at acceptable levels, but the rollers require frequent replacement every six to eight hours
Solution Approach 1:
The patent changes the material parameters by formulating a roller composition with specific ratios of polyisoprene (75%) and polybutadiene (25%) elastomers, along with silica filler and curing agents. This composition achieves optimal mechanical properties that extend roller lifespan to 72 or more hours while maintaining reasonable pressure requirements, thereby extending the machine duty cycle without significantly increasing energy consumption
4Loss of time
If harder rollers are used to reduce replacement frequency, then fewer shutdowns are required, but the increased pressure requirements generate more heat within the roller
Solution Approach 1:
The patent optimizes the material composition parameters to achieve a hardness level that balances durability with thermal management. The specific elastomer blend and silica filler content create a material structure that dissipates heat effectively, allowing the roller to operate for extended periods (72+ hours) without excessive heat generation that would require shutdowns for cooling or replacement
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 new rollers demonstrate a five- to ten-fold increase in usable life, reduced energy consumption, and improved print quality, with a 25% reduction in energy usage and extended operational hours, while maintaining crisp image quality and high-speed printing capabilities.
Implementation Method 1
a roller body or a cover layer of the roller body includes a homogeneous composition of elastomers
Implementation Method 2
a roller body or a cover layer of the roller body includes a homogeneous composition of elastomers, filler, curing agent
Implementation Method 3
a roller body or a cover layer of the roller body includes a homogeneous composition of elastomers, filler, curing agent
Data Source
AI summary
Improved pliable print rollers for high speed drink can printing machines increase the pliable roller life five- to ten-fold at comparable ink thickness and machine speed. The improved performance results from the selection of materials utilized including a combination of elastomers, and in some case an essentially oil-free composition, and an associated manufacturing process not previously utilized to create pliable print rollers for high speed drink can printing machines. In particular a particular embodiment, the composition includes a combination of elastomers (e.g., 75% polyisoprene and 25% polybutadiene), a filler (e.g., silica), a curing agent (e.g., peroxided), and other additives (e.g., pigment, antioxidant, antiozonant) with little or no oil added as a softener. An illustrative composition including 150 parts by weight contains 100 parts elastomer, 35 parts filler, 4 parts curing agent, and 11 parts other additives (i.e., zero parts oil softener).