UV-Curable Intermediate Transfer Belt for Low VOC Manufacturing
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Solution Overview
Problem
Existing intermediate transfer members in electrophotographic printing face challenges such as environmental emissions and high costs due to complex manufacturing processes, while also requiring improved stain, abrasion, and solvent resistance, along with superior toughness and high gloss.
Innovation Solution
A method involving a UV curable mixture of chlorinated polyester resin, reactive diluent, conductive species, and photoinitiator is coated on a substrate, cured with ultraviolet energy, and then removed to form an intermediate transfer belt with dispersed conductive species, eliminating the need for complex dispersing processes and reducing VOC emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyimide resins are used for intermediate transfer members, then stain, abrasion and solvent resistance are improved, but environmental emissions occur and manufacturing cost increases due to complex processes
Solution Approach 1:
The patent changes the chemical composition parameters by replacing polyimide resins with UV-curable acrylic resins and altering the curing mechanism from thermal to photopolymerization. This parameter change eliminates VOC emissions while maintaining the required resistance properties through the specific formulation of the acrylic resin system with conductive particles.
Solution Approach 2:
The patent substitutes the thermal curing mechanism with a photopolymerization process using UV light. This replacement of the curing mechanism eliminates the need for high-temperature processing, thereby reducing VOC emissions and simplifying the manufacturing process while achieving the same crosslinked network structure required for durability.
2Reliability
If polyimide resins are used for intermediate transfer members, then stain, abrasion and solvent resistance are improved, but manufacturing cost increases due to complex processes
Solution Approach 1:
The patent replaces thermal curing with UV photopolymerization, which eliminates the need for complex high-temperature processing equipment and reduces manufacturing steps. The UV curing process can be performed at ambient temperatures, significantly simplifying the manufacturing process while maintaining product performance.
Solution Approach 2:
By changing the resin system to UV-curable acrylic resins and adjusting the formulation parameters (including the use of monomers and crosslinking agents), the patent achieves the required mechanical and chemical resistance properties through a simpler, more direct manufacturing process that reduces overall complexity and cost.
3Reliability
If conventional methods are used to form intermediate transfer members, then conductive properties are achieved, but manufacturing complexity increases and VOC emissions occur
Solution Approach 1:
The patent merges the conductive particle dispersion and curing processes into a single step. The conductive particles are incorporated into the UV-curable acrylic resin formulation before coating, and the entire layer is cured simultaneously via UV irradiation. This merging eliminates separate dispersing and curing steps, reducing manufacturing complexity while achieving uniform conductive properties.
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 intermediate transfer belt exhibits functional resistivity, mechanical strength, and improved print quality with nearly zero VOC emissions during manufacture, offering a cost-effective and environmentally friendly solution.
Implementation Method 1
coating an ultraviolet (UV) curable mixture comprising a chlorinated polyester resin, a reactive diluent, conductive species and a photoinitiator on a substrate. The UV curable mixture is cured with ultraviolet energy.
Implementation Method 2
The resulting intermediate transfer belt exhibits functional resistivity
Data Source
AI summary
There is described a method of forming a transfer member suitable for use with an image forming system. The method includes coating an ultraviolet (UV) curable mixture comprising a chlorinated polyester resin, a reactive diluent, conductive species and a photoinitiator on a substrate. The UV curable mixture is cured with ultraviolet energy. The cured mixture is then removed from the substrate.