Silicone Rubber Sponge for Pressure Roller Strength
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Solution Overview
Problem
Existing silicone rubber sponges used in pressure rollers for image-forming apparatuses face challenges with low mechanical strength, particularly in high-speed and color image-forming applications, due to the use of low-viscosity liquid silicone rubber, leading to durability issues and breakage during use.
Innovation Solution
A silicone rubber sponge is produced by blending expanded resin microballoons with low-molecular-weight silicone rubber and then adding high-molecular-weight silicone rubber, ensuring uniform dispersion and curing at a temperature lower than the resin microballoons' softening point to achieve a mechanically strong and durable elastic layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If low-viscosity liquid silicone rubber is used to facilitate mixing with resin microballoons, then ease of manufacture is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of low-viscosity liquid silicone rubber (for ease of mixing), high-molecular-weight silicone rubber (for mechanical strength), and expanded resin microballoons (for porosity). This combination allows the mixture to be easily mixed while achieving sufficient mechanical strength and maintaining the required porous structure for the pressure roller application.
2Strength
If high-molecular-weight silicone rubber is used to increase mechanical strength, then strength is improved, but viscosity increases making mixing difficult
Solution Approach 1:
The patent merges two types of silicone rubber with different molecular weights into a single mixture. The low-molecular-weight component provides low viscosity for easy mixing, while the high-molecular-weight component provides mechanical strength. This merging allows both requirements to be satisfied simultaneously in the final elastic layer.
3Quantity of substance
If expanded resin microballoons are used to create porous structure, then porosity is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent creates a composite material where expanded resin microballoons are dispersed in a dual-component silicone rubber system. The unique silicone rubber composition (combining low and high molecular weight components) provides sufficient mechanical strength to support the porous structure created by the microballoons, preventing collapse while maintaining porosity for the pressure roller function.
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 resulting silicone rubber sponge provides a pressure roller with sufficient mechanical strength and durability for high-speed and color image-forming applications, enhancing the reliability and frequency of use in image-forming apparatuses.
Implementation Method 1
curing the liquid silicone rubber by conducting heating at a temperature lower than a softening point of the resin microballoons
Implementation Method 2
the shells may be broken as a result of thermal history during use of the silicone rubber sponge as a pressure roller
Data Source
AI summary
Provided are a silicone rubber sponge that forms an elastic layer of a pressure roller of an image-forming apparatus, and that has a high mechanical strength so as to be used in a high-speed image-forming apparatus or a color image-forming apparatus, and a rubber-covered roller including the silicone rubber sponge. The silicone rubber sponge is produced by mixing expanded resin microballoons with a low-molecular-weight silicone rubber to prepare a compound A, mixing a high-molecular-weight silicone rubber with the compound A to prepare a silicone rubber compound, and heating the silicone rubber compound at a temperature lower than a softening point of the resin microballoons to cure the silicone rubbers.