JP2016141128A - Method and apparatus for producing rubber roll - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a rubber roll having an elastic layer excellent in shape precision.SOLUTION: A method for producing a rubber roll comprises; a first step of extruding a rubber material into a cylindrical shape from an extrusion part 20, in such an extrusion condition that a ratio W/V of the amount W (g) of the rubber material to be packed in a second compression zone to the amount V (g/min) of the rubber material to be extruded from the extrusion part 20 for one minute is 1.5-4.0 when a core metal 22 is not fed from a core metal feed part 24, and feeding the core metal 22 to the central part of the rubber material, which is extruded into the cylindrical shape, from the core metal feed part 24 to cover the outer peripheral surface of the core metal 22 with the rubber material; and a second step of performing vulcanization treatment on the rubber material with which the outer peripheral surface of the core metal 22 is covered.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a rubber roll manufacturing method and a rubber roll manufacturing apparatus.

  For example, Patent Document 1 states that “a method of manufacturing a rubber roller having a crown-shaped outer shape using a crosshead extrusion device, in which a supply amount of unvulcanized rubber material is stabilized at a predetermined amount, A method of manufacturing a rubber roller is disclosed in which the moving speed of the metal core is changed depending on the lengthwise portion of the metal core, and the outer diameter of the rubber roller is changed in the length direction.

  Patent Document 2 states that “when a rubber roller used in an image forming apparatus utilizing an electrophotographic process is extruded, a gear pump is connected between the extruder and the die head, thereby discharging a precise capacity rubber material. Thus, a rubber roller manufacturing method characterized by extruding a rubber having a uniform shape with little fluctuation in the outer diameter in the longitudinal direction is disclosed.

  Patent Document 3 states that “the first step of introducing a conductive rubber material from one end of a cylinder and transporting the conductive rubber material to the vicinity of the vent portion via a screw, and venting volatile components contained in the conductive rubber material. A second step of removing in the vicinity of the portion, and a third step of further conveying the conductive rubber material from the vicinity of the vent portion to the other end, wherein the second step is performed at 80 ° C. to 150 ° C. near the vent portion. A method of manufacturing a conductive rubber roller that is held and the screw is held at 40 ° C. to 70 ° C. is disclosed.

Patent Document 4 states that “in a method for producing a rubber molded body in which unvulcanized rubber is continuously extruded by a vent-type extruder and then vulcanized by heat treatment, the unvulcanized rubber is extruded. Extrusion is performed under the condition that the volume (Vcm ³ ) of the rubber unfilled region of the vent type extruder and the extrusion rate (W) per minute of the unvulcanized rubber satisfy the formula (1): V / W ≧ 0.9 min. "A method for producing a molded rubber product" is disclosed.

Patent Document 5 states that “in the manufacturing method of a rubber roller having an elastic layer around a core metal, an extrusion process in which a solid rubber is extruded using a vent-type extruder, and a crosslinking in which the solid rubber extruded in the extrusion process is crosslinked. And when the cylinder radius of the extruder is expressed as r (cm), the extrusion amount when the screw speed of the extruder is 25 rpm is (r2 × 1250) cm ³ / h or less, and the cylinder The ratio L / D when the length of the cylinder is L and the cylinder inner diameter is D is 22 or less. In the extrusion process, the solid rubber is adjusted to 50 μm or more and 150 μm or less in the vent type extruder. A method of manufacturing a rubber roller that allows a clearance between a dam and a cylinder to pass through is disclosed.

Japanese Patent Laid-Open No. 2003-300279 JP 2007-38475 A JP 2007-7942 A JP 2007-98800 A JP 2008-107640 A

  An object of the present invention is to provide an extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when the core metal is not supplied from the core metal supply portion, and filling the rubber material in the second compression region. A rubber material is extruded in a cylindrical shape from an extruded portion under an extrusion condition in which the ratio W / V to the amount W (g) is less than 1.5, and the core material is fed into the central portion of the rubber material extruded from the cylindrical portion. An object of the present invention is to provide a method for producing a rubber roll having an elastic layer excellent in shape accuracy as compared with a case where the first step of supplying a core metal and covering the outer peripheral surface of the core metal with a rubber material is provided.

  The above problem is solved by the following means.

The invention according to claim 1
A cylindrical main body and a screw inserted into the main body, and rotating the screw causes an unvulcanized rubber material to flow from one end to the other end of the main body, and A rubber material supply unit for supplying, a first compression region for compressing the rubber material supplied to the main body, a damming region for squeezing and extruding the rubber material compressed in the first compression region, A rubber material supply section having a vacuum region for evacuating the rubber material extruded from the damming region, and a second compression region for compressing the rubber material evacuated in the vacuum region;
An extrusion section for extruding the rubber material supplied from the rubber material supply section into a cylindrical shape;
A cored bar supplying unit for supplying a cored bar to the central part of the rubber material extruded in a cylindrical shape from the extruded unit;
Using a rubber roll manufacturing apparatus equipped with
Extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit when the core metal is not supplied from the core metal supply unit, and filling of the rubber material in the second compression region The rubber material is extruded in a cylindrical shape from the extruded portion under an extrusion condition in which the ratio W / V to the amount W (g) is 1.5 or more and 4.0 or less, and the center of the rubber material extruded into a cylindrical shape A first step of supplying a metal core from the metal core supply unit to cover an outer peripheral surface of the metal core with the rubber material;
A second step of vulcanizing the rubber material covering the outer peripheral surface of the metal core;
A method for producing a rubber roll having

The invention according to claim 2 is characterized in that the ratio L / D between the axial length L (mm) of the main body and the inner diameter D (mm) of the main body is 14 or more and 25 or less. Manufacturing method of rubber roll.

The invention according to claim 3 is, in the first step, when extruding the rubber material at both axial end portions of the core metal, rather than extruding the rubber material at the axial center portion of the core body, The method for producing a rubber roll according to claim 1 or 2, wherein a relative extrusion speed of the rubber material with respect to a supply speed of the core metal is increased.

The invention according to claim 4 has a cylindrical main body portion and a screw inserted into the main body portion, and flows the unvulcanized rubber material from one end of the main body portion to the other end by rotation of the screw. And a rubber material supply unit that supplies the rubber material, the first compression region compressing the rubber material supplied to the main body, and the rubber material compressed in the first compression region is dammed A rubber material supply unit having a damming region to be extruded while being pressed, a vacuum region for evacuating the rubber material extruded from the damming region, and a second compression region for compressing the rubber material evacuated in the vacuum region When,
An extrusion section for extruding the rubber material supplied from the rubber material supply section into a cylindrical shape;
A cored bar supplying unit for supplying a cored bar to the central part of the rubber material extruded in a cylindrical shape from the extruded unit;
With
Extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit when the core metal is not supplied from the core metal supply unit, and filling of the rubber material in the second compression region A rubber roll manufacturing apparatus for extruding the rubber material in a cylindrical shape from the extruding portion under an extruding condition in which a ratio W / V to the amount W (g) is 1.5 or more and 4.0 or less.

The invention according to claim 5 is the ratio according to claim 5, wherein the ratio L / D between the axial length L (mm) of the main body and the inner diameter D (mm) of the main body is 14 or more and 25 or less. Rubber roll manufacturing equipment.

According to a sixth aspect of the present invention, when the rubber material is extruded to both axial end portions of the core metal, the core metal supply speed is higher than when the rubber material is extruded to the axial center portion of the core body. 6. The rubber roll manufacturing method according to claim 4, further comprising a control unit that controls at least one of the rubber material supply unit and the core body supply unit so that a relative extrusion speed of the rubber material with respect to the material increases. apparatus.

According to the first or second aspect of the present invention, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when the core metal is not supplied from the core metal supply portion, and the second The center of the rubber material extruded into a cylindrical shape by extruding the rubber material from the extrusion part in a cylindrical shape under an extrusion condition where the ratio W / V to the filling amount W (g) of the rubber material in the compression region is less than 1.5 A method of manufacturing a rubber roll having an elastic layer with excellent shape accuracy is provided as compared with the case where the first step of supplying the core to the core from the core metal supply unit and covering the outer peripheral surface of the core with a rubber material is provided. The
According to the invention which concerns on Claim 3, when not supplying a metal core from a metal core supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from an extrusion part, and in a 2nd compression area | region The rubber material is extruded in a cylindrical shape from the extruded portion under the extrusion conditions where the ratio W / V to the filling amount W (g) of the rubber material is less than 1.5, and the core is centered on the central portion of the rubber material extruded in the cylindrical shape. Compared to the case where the first step of supplying the core metal from the gold supply unit and covering the outer peripheral surface of the core metal with the rubber material is used, even if the relative extrusion speed of the rubber material with respect to the supply speed of the core body is changed, A method for producing a rubber roll having an elastic layer with excellent shape accuracy is provided.

According to the invention which concerns on Claim 4 or 5, when the core metal is not supplied from the core metal supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion part and the second Elasticity with excellent shape accuracy compared to the case where the rubber material is extruded from the extruded part into a cylindrical shape under the extrusion conditions where the ratio W / V to the rubber material filling amount W (g) in the compression region is less than 1.5. An apparatus for producing a rubber roll having a layer is provided.
According to the invention which concerns on Claim 6, when not supplying a metal core from a metal core supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from an extrusion part, and in a 2nd compression area | region Compared to the case where the rubber material is extruded from the extrusion part into a cylindrical shape under the extrusion conditions where the ratio W / V to the filling amount W (g) of the rubber material is less than 1.5, the rubber material An apparatus for manufacturing a rubber roll having an elastic layer with excellent shape accuracy even when the relative extrusion speed is varied is provided.

It is a schematic block diagram which shows an example of the manufacturing apparatus of the rubber roll which concerns on this embodiment. It is a schematic block diagram which shows an example of the screw with which the manufacturing apparatus of the rubber roll which concerns on this embodiment is equipped.

  Embodiments that are examples of the present invention will be described below.

  The rubber roll manufacturing method according to the present embodiment includes a non-vulcanized rubber material (hereinafter also simply referred to as “rubber material”) extruded from an extruded portion into a cylindrical shape and a core at the center of the rubber material extruded into a cylindrical shape. A first step of supplying a cored bar from a gold supply unit and covering the outer peripheral surface of the cored bar with a rubber material; and a second step of performing a vulcanization process on the rubber material covering the outer peripheral surface of the cored bar. Have. In this first step, the amount V (g / min) of rubber material extruded per minute from the extrusion portion when no core metal is supplied from the core metal supply portion, and the rubber material filling in the second compression region The extrusion is performed under the condition that the ratio W / V to the amount W (g) is 1.5 or more and 4.0 or less.

  Moreover, in the rubber roll manufacturing method according to the present embodiment, a cylindrical main body portion and a screw inserted into the main body portion, and an unvulcanized rubber from one end of the main body portion toward the other end by rotation of the screw. A rubber material supply section for supplying a rubber material by flowing the material, an extrusion section for extruding the rubber material supplied from the rubber material supply section in a cylindrical shape, and a center of the rubber material extruded in a cylindrical shape from the extrusion section A rubber roll manufacturing apparatus (a rubber roll manufacturing apparatus according to this embodiment) including a core metal supply unit that supplies a core metal to the section is used. The rubber material supply unit is extruded from a first compression region for compressing the rubber material supplied to the main body, a dam region for squeezing the rubber material compressed in the first compression region, and a dam region. A vacuum region for evacuating the rubber material, and a second compression region for compressing the rubber material evacuated in the vacuum region. The rubber roll manufacturing apparatus includes an extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when no core metal is supplied from the core metal supply portion, and rubber in the second compression region. The rubber material is extruded in a cylindrical shape from the extruded portion under the extrusion conditions where the ratio W / V to the material filling amount W (g) is 1.5 or more and 4.0 or less.

  In the rubber roll manufacturing method (manufacturing apparatus) according to the present embodiment, a rubber roll having an elastic layer with excellent shape accuracy is manufactured by the above method (configuration). The reason is not clear, but it is presumed that the reason is as follows.

  First, as a method of manufacturing a rubber roll, a rubber material is extruded into a cylindrical shape with respect to a core metal supplied in the axial direction, and after the cylindrical rubber material is molded on the outer peripheral surface of the core metal, the cylindrical rubber material is An extrusion method for vulcanizing and forming an elastic layer is known. This extrusion molding method is an advantageous molding method in terms of manufacturing cost as compared with a molding method using a split mold such as casting or injection molding that requires a post-process such as polishing or trim cutting after molding.

  On the other hand, in the conventional extrusion molding method, the rubber material filling amount in the second compression region on the screw tip side in the cylindrical main body portion is reduced in the rubber material supply portion in order to shorten the work time when manufacturing the rubber roll. Is reduced. Thereby, the pressure loss of the rubber material is reduced, and the extrusion amount is performed by increasing the extrusion amount of the rubber material per one rotation of the screw.

However, if the filling amount of the rubber material in the second compression region is decreased, the extrusion amount of the rubber material extruded from the extrusion portion may vary. The fluctuation of the rubber material extrusion amount is caused in the rubber material supply part by 1) pressure fluctuation due to uneven biting of the rubber material in the first compression region where the rubber material supplied to the main body part is compressed. This is thought to be caused by pressure fluctuations caused by fluctuations in the amount of rubber material extruded in the damming region where the material is pushed out while damming.
And if the extrusion amount of the rubber material extruded from an extrusion part changes, the thickness of the cylindrical rubber material extruded will change in the axial direction of a metal core. For this reason, the thickness of the elastic layer composed of a vulcanized product of a cylindrical rubber material (that is, the outer diameter of the obtained rubber roll) varies in the axial direction of the core metal, and the shape accuracy of the elastic layer of the rubber roll deteriorates. End up.

  On the other hand, in the present embodiment, the extrusion condition is such that the ratio W / V between the rubber material extrusion amount V and the rubber material filling amount W is 1.5 or more and 4.0 or less. When the ratio W / V is within the above range, it indicates that the amount V of rubber material extruded from the extruding portion is suppressed and the amount W of rubber material in the second compression region of the rubber material supplying portion is increased. Yes. Then, when the filling amount W of the rubber material in the second compression region increases, it is considered that the sensitivity to pressure fluctuations in the first compression region and the damming region decreases in the second compression region. For this reason, it is thought that the fluctuation | variation of the extrusion amount of the rubber material extruded from an extrusion part is suppressed.

  From the above, it is speculated that the rubber roll manufacturing method (manufacturing apparatus) according to the present embodiment manufactures a rubber roll having an elastic layer with excellent shape accuracy.

  In particular, for example, in the first step, when the rubber material is extruded at both axial end portions of the core metal, rather than when the rubber material is extruded at the axial center portion of the core body, the rubber material with respect to the core metal supply speed. When the relative extrusion speed is increased, a rubber roll having a shape (hereinafter referred to as “crown shape”) in which the thickness of the elastic layer in the central portion in the axial direction is thicker than both ends in the axial direction is obtained. When a rubber roll is manufactured by changing the relative extrusion speed of the rubber material with respect to the supply speed of the core metal, if the extrusion amount of the rubber material changes, it is difficult to obtain a crown-shaped rubber roll having a target shape profile. However, in the rubber roll manufacturing method (manufacturing apparatus) according to the present embodiment, a rubber roll having an elastic layer with excellent shape accuracy is manufactured even if the relative extrusion speed of the rubber material with respect to the core metal supply speed is varied. The

  Hereinafter, the detail of the manufacturing method of the rubber roll which concerns on this embodiment is demonstrated in detail.

(First step)
In the first step, the rubber material is extruded in a cylindrical shape from the extrusion portion, the core metal is supplied from the core metal supply portion to the central portion of the rubber material extruded in the cylindrical shape, and the outer peripheral surface of the core metal is covered with the rubber material. .

  Specifically, for example, using a rubber roll manufacturing apparatus 10 (an example of a rubber roll apparatus according to this embodiment) shown in FIG. 1, a cylindrical rubber material is formed on the outer peripheral surface of the core metal.

-Rubber roll manufacturing equipment-
The rubber roll manufacturing apparatus 10 includes a vent-type extruder 12 constituted by a so-called cross head die, and a control unit 11 for controlling each part in the apparatus.

  The extruder 12 includes a rubber material supply unit 18 that supplies unvulcanized rubber material, an extrusion unit 20 that extrudes the rubber material supplied from the rubber material supply unit 18 into a cylindrical shape, and a cylindrical shape from the extrusion unit 20. A cored bar supply unit 24 that supplies the cored bar 22 to the central part of the rubber material to be extruded is provided.

  The rubber material supply unit 18 includes a cylindrical main body 26 and a screw 27 inserted into the main body 26. The screw 27 is rotationally driven by a drive motor 30. The rubber material supply unit 18 causes the rubber material to flow from one end of the main body 26 to the other end (from the rear end to the front end of the screw 27) by rotation of the screw 27, and supplies the rubber material to the extrusion unit 20.

On the outer peripheral surface of one end side (rear end side of the screw 27) of the main body portion 26, a charging port 32 for charging a rubber material is provided. A breaker plate 31 is provided on the end surface on the other end side of the main body 26 (the front end side of the screw 27). A vent port 28 (a deaeration port) is provided at the center of the main body 26. The vent port 28 is connected to a vacuum pump 29.
A pressure gauge 33 is disposed on the inner wall of the main body portion 26 on the tip side of the screw 27.

The inner diameter of the main body 26 is, for example, the same from the downstream side in the flow direction of the rubber material to the upstream side. The ratio L / D between the axial length L (mm) of the main body 26 and the inner diameter D (mm) of the main body 26 is the ratio W of the rubber material extrusion amount V and the rubber material filling amount W. For example, it may be set to 14 or more and 25 or less (preferably 16 or more and 22 or less) from the viewpoint that / V is in the above range and the shape accuracy of the elastic layer is improved.
The axial length L (mm) of the main body portion 26 is preferably, for example, 1000 mm or more and 1800 mm or less. Here, the axial length L (mm) of the main body portion 26 indicates the axial length of the hollow portion into which the screw 27 in the main body portion 26 is inserted.
On the other hand, the inner diameter D (mm) of the main body 26 is preferably, for example, 30 mm or more and 90 mm or less.
In FIG. 1, 26L indicates the axial length L (mm) of the main body portion 26. 26D shows the internal diameter D (mm) of the main-body part 26. FIG.

  As shown in FIG. 2, the flight 27 </ b> B is spirally arranged on the shaft portion 27 </ b> A. The pitch 27P of the flights 27B (the length along the screw 27 axial direction between adjacent flights 27B) is variable from the rear end of the screw 27 toward the front end. Further, the height 27H of the flight 27B (the maximum height along the radial direction of the screw 27 between the apex of the flight 27B and the outer surface of the shaft portion 27A between adjacent flights) is also variable from the rear end of the screw 27 toward the front end. doing.

  In particular, the flight 27B located on the tip side of the screw 27 (positioned in the second compression region 104) has a narrower pitch 27P and a height 27H than the flight 27B located in the center of the screw 27 (positioned in the vacuum region 103). It is better to lower. Thereby, the conveyance amount of the rubber material on the front end side of the screw 27 per rotation is reduced, and the rubber material is easily filled on the front end side of the screw 27 of the main body portion 26. For this reason, the ratio W / V between the extrusion amount V of the rubber material and the filling amount W of the rubber material tends to be in the above range.

Specifically, the pitch 27P of the flights 27B located on the tip side of the screw 27 (positioned in the second compression region 104) is preferably 15 mm or more and 40 mm or less (preferably 20 mm or more and 35 mm or less). The height 27H of the flight 27B located on the tip side of the screw 27 (positioned in the second compression region 104) may be, for example, 5 mm or more and 20 mm or less (preferably 10 mm or more and 15 mm or less).
On the other hand, the pitch 27P of the flights 27B located in the center portion (positioned in the vacuum region 103) of the screw 27 is preferably set to 30 mm or more and 70 mm or less (preferably 40 mm or more and 60 mm or less). The height 27H of the flight 27B located at the center of the screw 27 (located in the vacuum region 103) is preferably, for example, 10 mm to 30 mm (preferably 12 mm to 25 mm).

  The flight 27 </ b> B located on the tip side of the screw 27 (positioned in the second compression region 104) may have a larger number of stripes than the flight 27 </ b> B located in the center of the screw 27 (positioned in the vacuum region 103). For example, the number of position flights 27B on the tip side of the screw 27 is two, and the number of flights 27B in the center of the screw 27 is one. Thereby, the conveyance amount of the rubber material on the front end side of the screw 27 per rotation is reduced, and the rubber material is easily filled on the front end side of the screw 27 of the main body portion 26. For this reason, the ratio W / V between the extrusion amount V of the rubber material and the filling amount W of the rubber material tends to be in the above range.

  The screw 27 is provided with a blocking portion 27C (hereinafter referred to as “dam portion 27C”) for blocking the rubber material at a portion located in front of the vent port 28. The dam portion 27C is provided on the upstream side in the rubber material flow direction from the vent port 28 and on the downstream side in the rubber material flow direction from the supply port 32.

  In FIG. 2, 101 </ b> A indicates a portion located in the first compression region 101 of the screw 27. Reference numeral 102 </ b> A denotes a portion located in the dam region 102 of the screw 27. 103 </ b> A indicates a part located in the vacuum region 103 of the screw 27. Reference numeral 104 </ b> A denotes a portion located in the second compression region 104 of the screw 27.

  The breaker plate 31 is a disk-shaped member provided with a plurality of concentric holes, for example. Specifically, the breaker plate 31 is provided with a plurality of holes concentrically so that, for example, the hole diameter is φ1 mm or more and φ6 mm or less and the aperture ratio with respect to the breaker plate area is 30% or more and 60% or less. In addition, although not shown in figure, the metal mesh (mesh) may be provided in one surface of the breaker plate 31 in order to remove the foreign material of a rubber material.

  Here, the rubber material supply unit 18 (main body unit 26) is dammed with the first compression region 101 for compressing the rubber material supplied to the main body unit 26 and the rubber material compressed in the first compression region 101. The damming region 102 to be extruded, the vacuum region 103 for evacuating the rubber material extruded from the damming region 102, and the second compression region 104 for compressing the rubber material evacuated in the vacuum region 103 are provided. That is, in the rubber material supply unit 18 (main body part 26), the first compression region 101, the blocking region 102, the vacuum region 103, and the second compression region 104 are upstream from the downstream side in the rubber material flow direction. It has in this order toward the side (from the rear end to the front end of the screw 27).

  The first compression region 101 is a region from the input port 32 (the rear end of the screw 27) until the rubber material is dammed up by the screw 27, and the rubber material is compressed by the screw 27 into the main body portion 26. It is a region that is flowing while being filled.

  The damming region 102 is a region in which the rubber material is pushed out while the rubber material is dammed by the dam portion 27 </ b> C provided in the screw 27. Specifically, the damming region 102 is formed in a layered or linear shape from a gap between the inner wall of the main body 26 and the dam portion 27C while damming the rubber material by a dam portion 27C provided on the screw 27, for example. It is an area | region which extrudes.

In the dam region 102, the clearance (clearance) between the inner wall of the main body portion 26 and the dam portion 27C is preferably 0.15 mm or less, and more preferably 0.10 mm or less, from the viewpoint of improving the volatile component removability of the rubber material. The lower limit of the gap is preferably 0.05 mm or more from the viewpoint of suppressing the increase in rotational load of the screw 27 or the production cost of the rubber roll. The gap (gap width (length)) is a gap through which the rubber material passes, and is a distance (main body) between the inner wall surface of the main body 26 and the surface of the dam portion 27C facing the inner wall surface of the main body 26. The maximum length along the radial direction of the portion 26).
The shape of the gap between the inner wall of the main body portion 26 and the dam portion 27C is not particularly limited, and may be, for example, a shape in which a rubber material is extruded in a layer shape or a shape in which the rubber material is extruded in a linear shape.

  The vacuum region 103 is a region in which the rubber material flows into the main body portion 26 by the screw 27 in a state where the rubber material is extruded in the damming region 102 and then evacuated by the vacuum pump 29 through the vent port 28. . That is, the vacuum region 103 is a region in which the rubber material flows in the main body portion 26 in a non-filled state inside the main body portion 26 (a state in which a space exists by evacuation in the main body portion 26). In the vacuum region 103, the extruded rubber material (for example, a rubber material extruded in a layered or linear shape) is evacuated to remove volatile components in the rubber material.

  The second compression region 104 is a region in which the rubber material that has flowed in the unfilled state in the vacuum region 103 is compressed by the screw 27 and flows in a state in which the main body portion 26 is filled. That is, the second compression region 104 and the vacuum region 103 are divided according to the rubber filling state.

  In the rubber material supply unit 18, the rubber material input from the input port 32 flows from the rear end to the front end of the screw 27 while being kneaded by the screw 27 inside the main body 26 and passes through the breaker plate 31. And it is sent out toward the extrusion part 20. That is, in the rubber material supply unit 18, the rubber material charged from the charging port 32 is compressed in the first compression region 101, extruded while being dammed in the damming region 102, evacuated in the vacuum region 103, After being compressed in the two compression region, it passes through the breaker plate 31 and is sent out toward the extrusion unit 20. For example, the speed at which the rubber material is fed out is adjusted by adjusting the flight shape on the tip side of the screw 27, the rotational speed of the screw 27, and the like.

  The extrusion unit 20 includes a cylindrical case 34 connected to the rubber material supply unit 18, a columnar mandrel 36 disposed in the center of the case 34, and an extrusion die 38 disposed below the mandrel 36. I have. The mandrel 36 is held by the case 34 by a holding member 40. The extrusion die 38 is held on the case 34 by a holding member 42. Between the outer peripheral surface of the mandrel 36 (in part, the outer peripheral surface of the holding member 40) and the inner peripheral surface of the holding member 42 (in part, the inner peripheral surface of the extrusion die 38), an annular flow in which the rubber material flows annularly A path 44 is formed.

  An insertion hole 46 through which the core bar 22 is inserted is formed at the center of the mandrel 36. The lower part of the mandrel 36 has a tapered shape toward the end. A region below the tip of the mandrel 36 is a merge region 48 where the core metal 22 supplied from the insertion hole 46 and the rubber material supplied from the annular flow path 44 merge. That is, the rubber material is extruded in a cylindrical shape toward the merged region 48, and the cored bar 22 is fed into the central portion of the rubber material extruded in the cylindrical shape.

  The cored bar supply unit 24 includes a roller pair 50 disposed above the mandrel 36. A plurality of pairs (for example, three pairs) of roller pairs 50 are provided, and one roller of each roller pair 50 is connected to a driving roller 54 via a belt 52. When the driving roller 54 is driven, the cored bar 22 sandwiched between the roller pairs 50 is sent toward the insertion hole 46 of the mandrel 36. The core metal 22 has a predetermined length, and the rear core metal 22 fed by the roller pair 50 presses the front core metal 22 existing in the insertion hole 46 of the mandrel 36, whereby a plurality of core bars 22 are formed. Sequentially pass through the insertion hole 46. The driving of the driving roller 54 is temporarily stopped when the front end of the front cored bar 22 is positioned at the tip of the mandrel 36, and the cored bar 22 is moved in the junction area 48 below the mandrel 36. It is sent at intervals.

  As described above, in the extruder 12, the rubber material is extruded into a cylindrical shape in the merging region 48, and the core metal 22 is sequentially fed at a distance from the central portion of the rubber material. Thereby, the rubber roll part 56 with which the outer peripheral surface of the metal core 22 is covered with a rubber material is extruded from the extrusion die 38. In addition, a primer may be applied in advance to the outer peripheral surface of the cored bar 22 in order to improve the adhesiveness with the rubber material.

  Then, the rubber roll which cut | disconnected by the boundary part of each metal core 22 of the rubber roll part 56 continuously extruded from the extrusion die 38 with the cutting machine which is not illustrated, and coat | covered the outer peripheral surface of the metal core 22 with the unvulcanized rubber material. Get.

Here, in the extruder 12, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit 20 when the core metal is not supplied from the core metal supply unit 24, and the second compression region 104. The ratio W / V to the rubber material filling amount W (g) is from 1.5 to 4.0 (preferably from 1.8 to 3.7, more preferably from the viewpoint of improving the shape accuracy of the elastic layer) The rubber material is extruded in a cylindrical shape from the extrusion portion 20 under the extrusion conditions of 2 to 3.5.
By setting the ratio W / V to be 1.5 or more, fluctuations in the extrusion amount of the rubber material extruded from the extrusion portion are suppressed. Thereby, the shape accuracy of the elastic layer of the rubber roll is increased. On the other hand, when the ratio is 4.0 or less, the pressure loss of the excessive rubber material is suppressed, the decrease in the extrusion amount of the rubber material extruded from the extrusion unit 20 is suppressed, and the productivity of the rubber roll is easily secured.

The extrusion amount V (g / min) of the rubber material extruded per minute from the extruding unit 20 is such that the rubber material is extruded from the extruding unit 20 without supplying the cored bar 22 from the cored bar supplying unit 24, and a certain time has elapsed. This is the amount of rubber material that is measured later (after 90 minutes), and is the mass of the rubber material that is extruded in one minute.
The rubber material filling amount W (g) in the second compression region 104 is an amount measured as follows. First, a rubber material is extruded from the extrusion unit 20, and the extrusion is stopped after a lapse of a certain time (after 120 minutes). Next, the screw 27 is pulled out from the cylindrical main body portion 26 of the rubber material supply portion in a state where the main body portion 26 is filled with the rubber material. Next, the extrusion amount of the rubber material filled on the tip side of the screw 27 (the most downstream side in the rubber material flow direction) inside the main body portion 26 of the rubber material supply unit is used as the filling amount in the second compression region 104. taking measurement. That is, the filling amount W of the rubber material has a space in the state where the screw 27 is inserted in the front end side (the most downstream side in the rubber material flow direction) of the screw 27 inside the main body portion 26 of the rubber material supply unit. Extruded amount of filled rubber material that does not have space, excluding unfilled rubber material.

  In order to set the ratio W / V in the above range, for example, the shape of the screw 27 (the height of the flight 27B of the screw and the flight 27B pitch in the second compression region), the rotational speed of the drive motor 30 of the screw 27, or those This is realized by changing the combination of the above.

Moreover, in the extruder 12, the temperature of the rubber supply part 18 (its main-body part) and the temperature of the extrusion part 20 are 60 degreeC or more and 100 degrees C or less (preferably 70 degreeC) from the point of generation | occurrence | production suppression of vulcanization (scorch), for example. C. to 90 ° C.) is preferable.
The pressure for extruding the rubber material at the extruding part 20 (hereinafter also referred to as “extruding part pressure”) is, for example, 18 MPa or more and 27 MPa or less (preferably 20 MPa or more and 25 MPa or less) from the viewpoint of improving the shape accuracy of the elastic layer.

The control unit 11 is configured to control the operation of each unit of the rubber roll manufacturing apparatus 10.
Specifically, although not illustrated, the control unit 11 is configured as a computer, for example, a CPU (Central Processing Unit), various memories [for example, a RAM (Random Access Memory), a ROM (Read Only Memory), a nonvolatile memory] , And an input / output interface (I / O) are connected via a bus. The I / O is connected to each part of the rubber roll manufacturing apparatus 10 such as a drive motor 30 that rotates the screw 27, a drive motor (not shown) that rotates the drive roller 54, and a pressure gauge 33, for example. Yes.
The CPU executes, for example, a program (for example, a control program such as an extrusion molding program) stored in various memories, and controls the operation of each part of the rubber roll manufacturing apparatus 10. Note that the storage medium for storing the program executed by the CPU is not limited to various memories. For example, it may be a flexible disk, DVD disk, magneto-optical disk, USB memory (universal serial bus memory) or the like (not shown), or a storage device of another device connected to communication means (not shown). May be.

  In the control unit 11, for example, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit when the core metal is not supplied from the core metal supply unit, and the rubber material in the second compression region The rubber material supply section (specifically, the rubber material is extruded from the extrusion section into a cylindrical shape under the extrusion conditions where the ratio W / V to the filling amount W (g) is 1.5 or more and 4.0 or less. May control the drive motor 30 (drive unit) of the screw 27, for example. Specifically, the rotational speed of the screw 27 may be controlled in the range of, for example, 8 rpm to 14 rpm (preferably 10 rpm to 12 rpm).

  In particular, when a crown-shaped rubber roll is manufactured, the control unit 11 does not extrude the rubber material at both axial end portions of the core metal 22 rather than extrudes the rubber material at the axial center portion of the core metal 22. At least one of the supply speed of the core metal 22 and the extrusion speed of the rubber material (that is, the rubber material supply section 18 and the core metal supply section) so that the relative extrusion speed of the rubber material with respect to the supply speed of the core metal 22 is increased. It is preferable to control at least one of 24).

  Specifically, for example, when the cored bar 22 passes through the merging region 48, the supply speed of the cored bar 22 gradually decreases from the front end part to the central part of the cored bar 22, and the cored bar extends from the central part to the rear end part. The rotational speed of the drive roller 54 may be controlled by controlling a drive motor (not shown) that drives the drive roller 54 of the cored bar supply unit 24 so that the supply speed of 22 is gradually increased. Further, for example, when the cored bar 22 passes through the merging region 48, the rubber material extrusion speed gradually decreases from the front end part to the central part of the cored bar 22, and the rubber material extrusion speed increases from the central part to the rear end part. The rotational speed of the screw 27 may be controlled by controlling the drive motor 30 that drives the screw 27 of the rubber material supply unit 18 so as to gradually rise.

  The supply speed of the core metal 22 or the rubber material is controlled by controlling at least one of the supply speed of the core metal 22 and the extrusion speed of the rubber material (that is, at least one of the rubber material supply section 18 and the core metal supply section 24). By controlling the extrusion speed, a rubber roll portion 56 (cylindrical rubber material) having a thicker central portion than both end portions in the axial direction of the cored bar 22 is formed on the outer peripheral surface of the cored bar 22.

-Core-
As the metal core 22, for example, a metal or alloy such as aluminum, copper alloy, or stainless steel; iron plated with chromium, nickel, or the like; a metal made of a conductive material such as a conductive resin is used. It is done.

  The cored bar 22 functions as an electrode and a supporting member of the charging member. For example, the material is a metal or alloy such as iron (free cutting steel), copper, brass, stainless steel, aluminum, nickel; chromium, Iron subjected to a plating treatment with nickel or the like; Examples of the cored bar 22 include a member (for example, a resin or a ceramic member) whose outer peripheral surface is plated, a member in which a conductive agent is dispersed (for example, a resin or a ceramic member), and the like. The cored bar 22 may be a hollow member (cylindrical member) or a non-hollow member.

-Rubber material-
The rubber material (unvulcanized rubber composition) contains unvulcanized rubber and may further contain other additives as necessary. Other additives include vulcanizing agents, vulcanization accelerators, vulcanization aids, conductive agents, antioxidants, surfactants, coupling agents, fillers, acid acceptors, vulcanization retarders, etc. And materials added to the elastic layer.

・ Unvulcanized rubber Unvulcanized rubber is a material that contains elastomer. Examples of the unvulcanized rubber include those having at least a double bond in the chemical structure and cross-linked into a rubber by a vulcanization reaction.
Specific examples of rubber include isoprene rubber, chloroprene rubber, epichlorohydrin rubber, butyl rubber, polyurethane, silicone rubber, fluorine rubber, styrene-butadiene rubber, butadiene rubber, nitrile rubber, ethylene propylene rubber, and ethylene propylene homopolymer rubber. , Epichlorohydrin-ethylene oxide copolymer rubber, epichlorohydrin-ethylene oxide-allyl glycidyl ether copolymer rubber, ethylene-propylene-diene terpolymer rubber (EPDM), acrylonitrile-butadiene copolymer rubber (NBR), natural Examples thereof include rubbers and rubbers obtained by mixing these.
Among these rubbers, polyurethane, EPDM, epichlorohydrin-ethylene oxide copolymer rubber, epichlorohydrin-ethylene oxide-allyl glycidyl ether copolymer rubber, NBR, and rubbers obtained by mixing these are preferable.
The rubber may be foamed or non-foamed.

-Vulcanizing agent As the vulcanizing agent, there are vulcanizing agents that vulcanize by extracting halogen groups such as sulfur, 2,4,6-trimercapto-s-triazine, 6-methylquinoxaline-2,3-dithiocarbamate. Can be mentioned. These may be used alone or in combination of two or more.
Although there is no restriction | limiting in particular in content of a vulcanizing agent, For example with respect to 100 mass parts of unvulcanized rubbers, it may be 0.1 mass part or more and 10 mass parts or less, Preferably it is 0.3 mass part or more. 5 parts by mass or less.

-Vulcanization accelerator Examples of the vulcanization accelerator include thiazole compounds, sulfenamide compounds, thiuram compounds, dithiocarbamate compounds, xanthogenic acid compounds, and the like. These may be used alone or in combination of two or more.
Although there is no restriction | limiting in particular in content of a vulcanization accelerator, For example with respect to 100 mass parts of unvulcanized rubbers, it is good that they are 0.1 mass part or more and 10 mass parts or less, Preferably it is 0.3 mass. Part to 5 parts by mass.

-As a vulcanization | cure acceleration | stimulation adjuvant, the well-known vulcanization | cure acceleration | stimulation adjuvant of a zinc stearate, zinc oxide, a fatty acid (stearic acid, oleic acid, cottonseed fatty acid etc.) is mentioned.
The content of the vulcanization accelerating aid is not particularly limited, but for example, it is preferably 0.1 parts by mass or more and 10 parts by mass or less, preferably 0.3 parts with respect to 100 parts by mass of the unvulcanized rubber. It is not less than 5 parts by mass.

Examples of the vulcanization retarder include known vulcanization retarders such as N- (cyclohexylthio) phthalimide, phthalic anhydride, N-nitrosodiphenylamine, and 2,4-diphenyl-4-methyl-1-pentene.
The content of the vulcanization retarder is preferably 0.2 parts by mass or more and 5 parts by mass or less, and preferably 0.5 parts by mass or more and 3 parts by mass or less with respect to 100 parts by mass of the unvulcanized rubber. .

-Conductive agent As a conductive agent, an electronic conductive agent and an ionic conductive agent are mentioned, for example.
Examples of the electronic conductive agent include, for example, carbon black such as ketjen black and acetylene black; pyrolytic carbon, graphite; various conductive metals or alloys such as aluminum, copper, nickel, and stainless steel; tin oxide, indium oxide, Examples thereof include various conductive metal oxides such as titanium oxide, tin oxide-antimony oxide solid solution, tin oxide-indium oxide solid solution, and the like. Examples of ionic conductive agents include perchlorates and chlorates such as tetraethylammonium and lauryltrimethylammonium; alkali metals such as lithium and magnesium; alkaline earth metal perchlorates and chlorates; Can be mentioned. The conductive agent is not limited to these, and other well-known conductive agents are also included.
These conductive agents may be used alone or in combination of two or more.

  Although there is no restriction | limiting in particular in content of a electrically conductive agent, In the case of an electronic electrically conductive agent, 1 to 80 mass parts is good with respect to 100 mass parts of unvulcanized rubber, Preferably 15 to 80 mass parts is preferable. It is as follows. On the other hand, in the case of an ionic conductive agent, the content of the conductive agent is preferably 0.1 parts by mass or more and 5.0 parts by mass or less, preferably 0.5 parts by mass or more and 3 parts by mass with respect to 100 parts by mass of the unvulcanized rubber. 0.0 parts by mass or less.

-Filler Specific examples of the filler include calcium carbonate, carbon black, silica, and the like. These inorganic fillers may be used alone or in combination of two or more.
Although there is no restriction | limiting in particular in content of a filler, For example, it is preferable that they are 1 mass part or more and 80 mass parts or less with respect to 100 mass parts of unvulcanized rubber, and they are 10 mass parts or more and 50 mass parts or less. It is more preferable.

Acid acceptor Examples of the acid acceptor include metal compounds and hydrotalcites.
Examples of the metal compound include oxides, hydroxides, carbonates, carboxylates, silicates, borates, phosphites, periodic rules of Group 2 elements (alkaline earth metals) of the periodic table. Table 4 Group oxides, basic carbonates, basic carboxylates, basic phosphites, tribasic sulfates, etc., specifically magnesium oxide, magnesium hydroxide, water Barium oxide, magnesium carbonate, barium carbonate, calcium oxide, calcium hydroxide, calcium carbonate, calcium silicate, calcium stearate, zinc stearate, calcium phthalate, calcium phosphite, zinc white, tin oxide, tin stearate, basic sulfite Examples thereof include tin phosphate.
Although there is no restriction | limiting in particular in content of an acid acceptor, For example, it is preferable that they are 0.5 mass part or more and 20.0 mass parts or less with respect to 100 mass parts of unvulcanized rubber, and 3.0 mass parts More preferably, it is 10.0 parts by mass or less.

(Second step)
In the second step, a cylindrical rubber material is vulcanized, and an elastic layer made of a rubber material vulcanizate is formed on the outer peripheral surface of the core metal.
Specifically, for example, a cylindrical rubber material formed on the outer peripheral surface is molded under normal pressure (for example, under 1 atm), a heating temperature of 150 ° C. or more and 200 ° C. or less, and a heating time of 10 minutes or more and 120 minutes or less. The cored bar is heated to vulcanize the cylindrical rubber material. Thereby, the elastic layer comprised with the vulcanizate of rubber material is formed on the outer peripheral surface of a metal core.

  In addition, although the thickness of an elastic layer changes with uses of a rubber roll, it is preferable to set it as 0.8 mm or more and 10 mm or less, for example, and it is more preferable to set it as 1.2 mm or more and 5 mm or less.

(Third step)
After forming the elastic layer on the outer peripheral surface of the cored bar, a third step of forming the surface layer on the elastic layer may be performed. Specifically, in the third step, for example, a surface layer forming coating solution is applied onto the elastic layer, and the coating layer is heated to form the surface layer. The surface layer may be a mode in which a resin layer or the like is provided independently on the elastic layer, or a mode in which a bubble or the like is impregnated with a resin or the like in the surface layer portion of the foamed elastic layer (that is, a resin in a bubble) The surface layer portion of the elastic layer impregnated with a surface layer may be used.

  The coating liquid for forming the surface layer includes, for example, a resin, a conductive agent, a solvent, particles for imparting irregularities (specific surface roughness) to the surface of the surface layer, if necessary, and other additives. , Including.

Examples of the resin include acrylic resin, cellulose resin, polyamide resin, copolymer nylon, polyurethane resin, polycarbonate resin, polyester resin, polyethylene resin, polyvinyl resin, polyarylate resin, styrene butadiene resin, melamine resin, epoxy resin, and urethane resin. , Silicone resin, fluororesin (for example, tetrafluoroethylene perfluoroalkyl vinyl ether copolymer, tetrafluoroethylene-hexafluoropropylene copolymer, polyvinylidene fluoride, etc.), urea resin, and the like.
Here, the copolymer nylon includes one or more of 610 nylon, 11 nylon, and 12 nylon as polymerized units, and other polymer units included in the copolymer include: , 6 nylon, 66 nylon and the like.
As resin, you may apply the rubber material mix | blended with the said elastic layer.

  Examples of the conductive agent include an electronic conductive agent and an ionic conductive agent. Examples of the electronic conductive agent include carbon black such as ketjen black and acetylene black; pyrolytic carbon, graphite; various conductive metals or alloys such as aluminum, copper, nickel, stainless steel; tin oxide, indium oxide, titanium oxide And various conductive metal oxides such as tin oxide-antimony oxide solid solution and tin oxide-indium oxide solid solution; Examples of ionic conductive agents include perchlorates and chlorates such as tetraethylammonium and lauryltrimethylammonium; alkali metals such as lithium and magnesium; perchlorates and chlorates of alkaline earth metals ; These conductive agents may be used alone or in combination of two or more.

  Here, as a commercial product of carbon black, specifically, “Special Black 350”, “Special Black 100”, “Special Black 250”, “Special Black 5”, and “Special Black 4” manufactured by Degussa Co., Ltd. "Special Black 4A", "Special Black 550", "Special Black 6", "Color Black FW200", "Color Black FW2", "Color Black FW2V", "MONARCH1000" manufactured by Cabot Corporation , “MONARCH1300” manufactured by Cabot Corporation, “MONARCH1400” manufactured by Cabot Corporation, “MOGUL-L”, “REGAL400R”, and the like.

  The particles for imparting unevenness to the surface of the surface layer may be either conductive particles or non-conductive particles, but non-conductive particles are preferred. As electroconductive particle, the particle | grains of the material quoted as the said electrically conductive agent mix | blended with an elastic layer are mentioned. Non-conductive particles include resin particles (polyimide resin particles, methacrylic resin particles, polystyrene resin particles, fluorine resin particles, silicone resin particles, etc.), inorganic particles (clay particles, kaolin particles, talc particles, silica particles, alumina particles, etc.) ), Or ceramic particles. The particles may be particles composed of the same type of resin as the resin, thereby improving the compatibility between the particles and the resin and increasing the adhesion between the particles and the resin.

  Examples of other additives include materials that can be added to a normal surface layer such as a curing agent, a vulcanizing agent, a vulcanization accelerator, an antioxidant, a surfactant, and a coupling agent.

  The solvent is not particularly limited, and general solvents are used. For example, alcohols such as methanol, ethanol, propanol and butanol; ketones such as acetone and methyl ethyl ketone; tetrahydrofuran; ethers such as diethyl ether and dioxane; A solvent may be used. In addition to these, various solvents may be used. In order to apply the dip coating method generally used in the production of an electrophotographic photosensitive member, an alcohol solvent or a ketone solvent, or a mixture thereof is used. System solvents.

  Examples of the coating method of the surface layer forming coating solution include a blade coating method, a wire bar coating method, a spray coating method, a dip coating method, a bead coating method, an air knife coating method, and a curtain coating method.

The thickness of the surface layer is preferably 7 μm or more and 25 μm or less. And the volume resistivity of the surface layer is preferably 10 ³ Ωcm or more and 10 ¹⁴ Ωcm or less.

A rubber roll is obtained through the above steps.
Here, the surface layer is not limited to the above configuration, and a release layer (for example, a layer containing a fluorine-containing resin or a silicone resin) may be formed as the surface layer. Moreover, you may perform the process of forming an intermediate | middle layer (for example, resistance adjusting layer, transition prevention layer) between an elastic layer and a surface layer as needed.

  The rubber roll manufacturing method (manufacturing apparatus) according to the present embodiment is used for a rubber roll manufacturing method (manufacturing apparatus) having an elastic layer such as a charging roll, a transfer roll, and a cleaning roll.

  EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples. In the following, “part” is based on mass unless otherwise specified.

<Example 1>
(Preparation of rubber composition)
A mixture having the following composition was kneaded using a tangential pressure kneader (manufactured by Moriyama Co., Ltd .: actual volume 75 L), and then passed through a strainer to prepare a rubber material (unvulcanized rubber composition). .

-Composition of the mixture-
・ 100 parts by mass of rubber material (epichlorohydrin-ethylene oxide-allyl glycidyl ether copolymer rubber Hydrin T3106: manufactured by Nippon Zeon Co., Ltd.)
-Conductive agent (Carbon Black Asahi Thermal: Asahi Carbon Co., Ltd.) 20 parts by mass-Conductive agent (Ketjen Black EC: Lion Corp.) 2 parts by mass-Ion conductive agent 1 part by mass (Benzyltrimethylammonium chloride, trade name "BTEAC""LionAkzo"
・ Vulcanizing agent 1.5 parts by mass (Organic sulfur 4,4'-dithiodimorpholine Balnock R: Ouchi Shinsei Chemical Co., Ltd.)
・ Vulcanization accelerator 1.5 parts by mass (di-2-benzothiazolyl disulfide Noxeller DM-P: manufactured by Ouchi Shinsei Chemical Co., Ltd.)
・ 1.8 parts by mass of vulcanization accelerator (tetraethylthiuram disulfide Noxeller TET-G: manufactured by Ouchi Shinsei Chemical Co., Ltd.)
・ Vulcanization acceleration aid (Zinc oxide, 1 type of zinc oxide: manufactured by Shodo Chemical Industry Co., Ltd.) 3 parts by mass ・ Stearic acid 1.0 part by mass ・ Heavy calcium carbonate 40 parts by mass

(Production of rubber roll)
A rubber roll was produced using a “60 mm uniaxial bent rubber extruder” manufactured by Mitsuba Manufacturing Co., Ltd. having the same structure as the rubber roll manufacturing apparatus shown in FIG. Specifically, a core metal made of SUS303 having a diameter of 8 mm and a length of 330 mm is prepared, a rubber material is extruded in a cylindrical shape from an extrusion portion of a rubber roll manufacturing apparatus having the following settings, and a core is formed at the center of the extruded rubber material. Gold was supplied, and a cylindrical rubber material was coated on the outer peripheral surface of the cored bar. Specifically, when the core bar passes through the merged area with the rubber material, the core bar supply speed gradually decreases from 3000 mm / min to 2400 mm / min from the tip to the center of the core bar, The core metal is supplied to the center of the extruded rubber material so that the core metal supply speed gradually increases from 2400 mm / min to 3000 mm / min toward the end, and a cylindrical rubber is formed on the outer peripheral surface of the core metal. The material was coated. And the unvulcanized rubber roll which coat | covered the outer peripheral surface of the metal core with the rubber material was vulcanized for 60 minutes at 160 degreeC with the air heating furnace. This produced the crown-shaped rubber roll which formed the elastic layer on the outer peripheral surface of a metal core.

-Setting of rubber roll manufacturing equipment-
・ Cylindrical body (cylinder): length L = 1200mm, inner diameter D = 60mm
・ Screw: pitch of flight located in the vacuum region (located in the center) = 53 mm, height = 13 mm, pitch of flight located in the second compression region (positioned on the tip side) = 25 mm, height = 11 mm, screw Rotation = 10rpm
-Breaker plate: Φ outer diameter 1.3 mm, number of holes 60-Extrusion amount of rubber material extruded per minute from the extrusion part when no metal core is supplied from the metal core supply part V: 220 g / min
-Filling amount W (g) of rubber material in the second compression region: 771 g
・ Gap between the inner wall of the main body located in the damming area and the screw dam (damming part): 0.15 mm
Extruder pressure (head pressure): 17.2 MPa
・ Temperature: temperature of the rubber material supply section = 80 ° C., temperature of the extrusion section = 80 ° C.

<Examples 2-5, Comparative Examples 1-6>
A rubber roll was produced in the same manner as in Example 1 except that the setting conditions of the rubber roll production apparatus were changed according to the description in Table 1.

<Evaluation>
(Rubber pressure fluctuation rate)
The pressure fluctuation rate of rubber material (extrusion pressure fluctuation rate of rubber material) is the rubber roll manufacturing apparatus, after the rubber material is extruded for 20 minutes or more from the start of rubber material extrusion, the pressure of the rubber material is set at an interval of 0.1 second. Was measured for 2 minutes, and a variation σ was calculated and calculated by the formula: σ × 6 / total average. The pressure of the rubber material is measured by a pressure gauge installed on the inner wall on the tip side of the screw in a cylindrical main body (cylinder) in which a screw for applying an extrusion pressure to the rubber material is arranged in a rubber roll manufacturing apparatus. went.

(Variation of outer diameter of rubber roll)
The deviation of the shape profile of the rubber roll produced in each example was examined as follows. Using a laser outer diameter measuring machine (manufactured by Asaka Riken: ROLL2000), the outer diameter was measured at a pitch of 1 mm, and the difference in outer diameter with respect to the profile set as the target was taken as the amount of deviation of the shape profile. And the deviation | shift amount of the shape profile was evaluated as variation in the outer diameter of a rubber roll.

(Image quality evaluation)
The rubber roll produced in each example was mounted on an image forming apparatus “DocuCentre-V C5580: manufactured by Fuji Xerox Co., Ltd.” as a charging roll. Using this image forming apparatus, 10 halftone images of image density% were output on A4 paper in an environment of temperature 10 ° C. and humidity 15% RH. Then, the image quality of the last output image was evaluated. The evaluation criteria are as follows.
-Evaluation criteria-
A (◯): No defect such as density unevenness B (Δ): Minor density unevenness generated C (×): Unusable density unevenness generated

From the above results, it can be seen that the pressure fluctuation rate of the rubber material is reduced and the variation in the outer diameter (shape profile) of the rubber roll is suppressed in this example as compared with the comparative example. In particular, in Examples 1, 3, and 4, compared to Example 2, the pressure fluctuation rate of the rubber material can be suppressed to 0.5% or less, and the variation in outer diameter (shape profile) of the rubber roll is 20 μm or less. It can be seen that it is controlled. Thereby, in the present Example, it turns out that the rubber roll which has an elastic layer with high shape precision is produced compared with the comparative example.
In addition, in this example, it can be seen that good results were also obtained for image quality evaluation.

DESCRIPTION OF SYMBOLS 10 Rubber roll manufacturing apparatus, 11 Control part, 12 Extruder, 18 Rubber material supply part, 20 Extrusion part, 22 Core metal, 24 Core metal supply part, 26 Cylindrical main-body part, 27 Screw, 27A Shaft part, 27B Flight , 27C Damping part (dam part), 28 Vent port, 29 Vacuum pump, 30 Drive motor, 31 Breaker plate, 32 Input port, 33 Pressure gauge, 34 Case, 36 Mandrel, 38 Extrusion die, 40 Holding member, 42 Holding Member, 44 annular flow path, 46 insertion hole, 48 confluence area, 50 roller pair, 52 belt, 54 drive roller, 56 rubber roll, 101 compression area, 102 damming area, 103 vacuum area, 104 compression area,

In invention the first step according to claim 3, wherein than when extruding the rubber material in the axially central portion of the core, the rubber material when extruded in the axial direction ends of the core metal, The method for producing a rubber roll according to claim 1 or 2, wherein a relative extrusion speed of the rubber material with respect to a supply speed of the core metal is increased.

Than when the invention according to claim 6 extruding the rubber material in the axially central portion of the core metal also the rubber material when extruded in the axial direction both end portions of the core metal, the feed rate of the metal core The rubber roll manufacturing method according to claim 4 or 5, further comprising a control unit that controls at least one of the rubber material supply unit and the cored bar supply unit so that a relative extrusion speed of the rubber material with respect to the material increases. apparatus.

According to the first or second aspect of the present invention, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when the core metal is not supplied from the core metal supply portion, and the second The center of the rubber material extruded into a cylindrical shape by extruding the rubber material from the extrusion part in a cylindrical shape under an extrusion condition where the ratio W / V to the filling amount W (g) of the rubber material in the compression region is less than 1.5 A method of manufacturing a rubber roll having an elastic layer with excellent shape accuracy is provided as compared with the case where the first step of supplying the core to the core from the core metal supply unit and covering the outer peripheral surface of the core with a rubber material is provided. The
According to the invention which concerns on Claim 3, when not supplying a metal core from a metal core supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from an extrusion part, and in a 2nd compression area | region The rubber material is extruded in a cylindrical shape from the extruded portion under the extrusion conditions where the ratio W / V to the filling amount W (g) of the rubber material is less than 1.5, and the core is centered on the central portion of the rubber material extruded in the cylindrical shape. Compared to the case where the core bar is supplied from the gold supply unit and the first step of covering the outer peripheral surface of the metal core with the rubber material is included, even if the relative extrusion speed of the rubber material with respect to the core metal supply speed is changed, A method for producing a rubber roll having an elastic layer with excellent shape accuracy is provided.

According to the invention which concerns on Claim 4 or 5, when the core metal is not supplied from the core metal supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion part and the second Elasticity with excellent shape accuracy compared to the case where the rubber material is extruded from the extruded part into a cylindrical shape under the extrusion conditions where the ratio W / V to the rubber material filling amount W (g) in the compression region is less than 1.5. An apparatus for producing a rubber roll having a layer is provided.
According to the invention which concerns on Claim 6, when not supplying a metal core from a metal core supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from an extrusion part, and in a 2nd compression area | region a ratio W / V extrusion conditions less than 1.5 the filling amount W of the rubber material (g), compared to the case extruding the rubber material into a cylindrical shape from the extrusion, the rubber material to the feed rate of the core An apparatus for manufacturing a rubber roll having an elastic layer with excellent shape accuracy even when the relative extrusion speed is varied is provided.

In particular, for example, in the first step, than when extruding rubber material in the axial direction central portion of the core, when extruding the rubber material to the axial ends of the core metal, a rubber material to the feed rate of the core When the relative extrusion speed is increased, a rubber roll having a shape (hereinafter referred to as “crown shape”) in which the thickness of the elastic layer in the central portion in the axial direction is thicker than both ends in the axial direction is obtained. When a rubber roll is manufactured by changing the relative extrusion speed of the rubber material with respect to the supply speed of the core metal, if the extrusion amount of the rubber material changes, it is difficult to obtain a crown-shaped rubber roll having a target shape profile. However, in the rubber roll manufacturing method (manufacturing apparatus) according to the present embodiment, a rubber roll having an elastic layer with excellent shape accuracy is manufactured even if the relative extrusion speed of the rubber material with respect to the core metal supply speed is varied. The

The invention according to claim 1
A cylindrical main body and a screw inserted into the main body, and rotating the screw causes an unvulcanized rubber material to flow from one end to the other end of the main body, and A rubber material supply unit for supplying, a first compression region for compressing the rubber material supplied to the main body, a damming region for squeezing and extruding the rubber material compressed in the first compression region, A rubber material supply section having a vacuum region for evacuating the rubber material extruded from the damming region, and a second compression region for compressing the rubber material evacuated in the vacuum region;
An extrusion section for extruding the rubber material supplied from the rubber material supply section into a cylindrical shape;
A cored bar supplying unit for supplying a cored bar to the central part of the rubber material extruded in a cylindrical shape from the extruded unit;
Using a rubber roll manufacturing apparatus equipped with
An extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when the core metal is not supplied from the core metal supply portion, and the rubber material is extruded from the extrusion portion, 120 The extrusion conditions are such that the ratio W / V to the rubber material filling amount W (g) in the second compression region when extrusion is stopped after a lapse of minutes is 1.5 min to 4.0 min. The rubber material is extruded in a cylindrical shape from a portion, the core metal is supplied from the core metal supply portion to the central portion of the rubber material extruded in a cylindrical shape, and the outer peripheral surface of the core metal is covered with the rubber material. 1 process,
A second step of vulcanizing the rubber material covering the outer peripheral surface of the metal core;
A method for producing a rubber roll having

The invention according to claim 4 has a cylindrical main body portion and a screw inserted into the main body portion, and flows the unvulcanized rubber material from one end of the main body portion to the other end by rotation of the screw. And a rubber material supply unit that supplies the rubber material, the first compression region compressing the rubber material supplied to the main body, and the rubber material compressed in the first compression region is dammed A rubber material supply unit having a damming region to be extruded while being pressed, a vacuum region for evacuating the rubber material extruded from the damming region, and a second compression region for compressing the rubber material evacuated in the vacuum region When,
An extrusion section for extruding the rubber material supplied from the rubber material supply section into a cylindrical shape;
A cored bar supplying unit for supplying a cored bar to the central part of the rubber material extruded in a cylindrical shape from the extruded unit;
With
An extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when the core metal is not supplied from the core metal supply portion, and the rubber material is extruded from the extrusion portion, 120 Only under the extrusion conditions where the ratio W / V to the rubber material filling amount W (g) in the second compression region when extrusion is stopped after a lapse of minutes is 1.5 min to 4.0 min. A rubber roll manufacturing apparatus for extruding the rubber material into a cylindrical shape from an extrusion section.

According to the first or second aspect of the present invention, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when the core metal is not supplied from the core metal supply portion, and the second The rubber material is extruded in a cylindrical shape from the extrusion part under the extrusion conditions in which the ratio W / V to the filling amount W (g) of the rubber material in the compression region is less than 1.5 min . A method of manufacturing a rubber roll having an elastic layer with excellent shape accuracy is provided compared to the case where the core is supplied with a core from a core metal supply unit and the outer surface of the core is covered with a rubber material. Is done.
According to the invention which concerns on Claim 3, when not supplying a metal core from a metal core supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from an extrusion part, and in a 2nd compression area | region The rubber material is extruded from the extrusion part into a cylindrical shape under the extrusion conditions where the ratio W / V to the filling amount W (g) of the rubber material is less than 1.5 min. Compared to the case where the core bar is supplied from the core metal supply unit and the outer surface of the core metal is covered with the rubber material, the relative extrusion speed of the rubber material with respect to the core metal supply speed is changed. Moreover, the manufacturing method of the rubber roll which has an elastic layer excellent in shape accuracy is provided.

According to the invention which concerns on Claim 4 or 5, when the core metal is not supplied from the core metal supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion part and the second Excellent extrusion accuracy compared to the case where the rubber material is extruded from the extruded part into a cylindrical shape under the extrusion conditions where the ratio W / V to the filling amount W (g) of the rubber material in the compression region is less than 1.5 min . An apparatus for producing a rubber roll having an elastic layer is provided.
According to the invention which concerns on Claim 6, when not supplying a metal core from a metal core supply part, the extrusion amount V (g / min) of the rubber material extruded per minute from an extrusion part, and in a 2nd compression area | region Compared to the case where the rubber material is extruded into a cylindrical shape from the extrusion part under the extrusion conditions where the ratio W / V to the filling amount W (g) of the rubber material is less than 1.5 min , the rubber material with respect to the core bar supply speed Even if the relative extrusion speed is varied, a rubber roll manufacturing apparatus having an elastic layer with excellent shape accuracy is provided.

The rubber roll manufacturing method according to the present embodiment includes a non-vulcanized rubber material (hereinafter also simply referred to as “rubber material”) extruded from an extruded portion into a cylindrical shape and a core at the center of the rubber material extruded into a cylindrical shape. A first step of supplying a cored bar from a gold supply unit and covering the outer peripheral surface of the cored bar with a rubber material; and a second step of performing a vulcanization process on the rubber material covering the outer peripheral surface of the cored bar. Have. In this first step, the amount V (g / min) of rubber material extruded per minute from the extrusion portion when no core metal is supplied from the core metal supply portion, and the rubber material filling in the second compression region The extrusion is performed under the condition that the ratio W / V to the amount W (g) is 1.5 min to 4.0 min .

Moreover, in the rubber roll manufacturing method according to the present embodiment, a cylindrical main body portion and a screw inserted into the main body portion, and an unvulcanized rubber from one end of the main body portion toward the other end by rotation of the screw. A rubber material supply section for supplying a rubber material by flowing the material, an extrusion section for extruding the rubber material supplied from the rubber material supply section in a cylindrical shape, and a center of the rubber material extruded in a cylindrical shape from the extrusion section A rubber roll manufacturing apparatus (a rubber roll manufacturing apparatus according to this embodiment) including a core metal supply unit that supplies a core metal to the section is used. The rubber material supply unit is extruded from a first compression region for compressing the rubber material supplied to the main body, a dam region for squeezing the rubber material compressed in the first compression region, and a dam region. A vacuum region for evacuating the rubber material, and a second compression region for compressing the rubber material evacuated in the vacuum region. The rubber roll manufacturing apparatus includes an extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion portion when no core metal is supplied from the core metal supply portion, and rubber in the second compression region. The rubber material is extruded in a cylindrical shape from the extruded portion under the extrusion conditions such that the ratio W / V to the material filling amount W (g) is 1.5 min to 4.0 min .

On the other hand, in this embodiment, the extrusion conditions are such that the ratio W / V between the rubber material extrusion amount V and the rubber material filling amount W is 1.5 min or more and 4.0 min or less. When the ratio W / V is within the above range, it indicates that the amount V of rubber material extruded from the extruding portion is suppressed and the amount W of rubber material in the second compression region of the rubber material supplying portion is increased. Yes. Then, when the filling amount W of the rubber material in the second compression region increases, it is considered that the sensitivity to pressure fluctuations in the first compression region and the damming region decreases in the second compression region. For this reason, it is thought that the fluctuation | variation of the extrusion amount of the rubber material extruded from an extrusion part is suppressed.

Here, in the extruder 12, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit 20 when the core metal is not supplied from the core metal supply unit 24, and the second compression region 104. The ratio W / V to the rubber material filling amount W (g) is 1.5 min to 4.0 min (in terms of improving the shape accuracy of the elastic layer, preferably 1.8 min to 3.7 min) More preferably, the rubber material is extruded from the extrusion portion 20 into a cylindrical shape under an extrusion condition of 2 min or more and 3.5 min or less.
By setting the ratio W / V to 1.5 min or more, fluctuations in the extrusion amount of the rubber material extruded from the extrusion portion are suppressed. Thereby, the shape accuracy of the elastic layer of the rubber roll is increased. On the other hand, by setting the ratio W / V to 4.0 min or less, the pressure loss of the excessive rubber material is suppressed, the decrease in the extrusion amount of the rubber material extruded from the extrusion unit 20 is suppressed, and the productivity of the rubber roll is increased. It becomes easy to be secured.

In the control unit 11, for example, the extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit when the core metal is not supplied from the core metal supply unit, and the rubber material in the second compression region The rubber material supply section (specifically, the rubber material is extruded from the extrusion section into a cylindrical shape under the extrusion conditions such that the ratio W / V to the filling amount W (g) is 1.5 min to 4.0 min. Specifically, for example, the drive motor 30 (drive unit) of the screw 27 may be controlled. Specifically, the rotational speed of the screw 27 may be controlled in the range of, for example, 8 rpm to 14 rpm (preferably 10 rpm to 12 rpm).

Claims (6)

A cylindrical main body and a screw inserted into the main body, and rotating the screw causes an unvulcanized rubber material to flow from one end to the other end of the main body, and A rubber material supply unit for supplying, a first compression region for compressing the rubber material supplied to the main body, a damming region for squeezing and extruding the rubber material compressed in the first compression region, A rubber material supply section having a vacuum region for evacuating the rubber material extruded from the damming region, and a second compression region for compressing the rubber material evacuated in the vacuum region;
An extrusion section for extruding the rubber material supplied from the rubber material supply section into a cylindrical shape;
A cored bar supplying unit for supplying a cored bar to the central part of the rubber material extruded in a cylindrical shape from the extruded unit;
Using a rubber roll manufacturing apparatus equipped with
Extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit when the core metal is not supplied from the core metal supply unit, and filling of the rubber material in the second compression region The rubber material is extruded in a cylindrical shape from the extruded portion under an extrusion condition in which the ratio W / V to the amount W (g) is 1.5 or more and 4.0 or less, and the center of the rubber material extruded into a cylindrical shape A first step of supplying a metal core from the metal core supply unit to cover an outer peripheral surface of the metal core with the rubber material;
A second step of vulcanizing the rubber material covering the outer peripheral surface of the metal core;
A method for producing a rubber roll having   2. The method for producing a rubber roll according to claim 1, wherein a ratio L / D between an axial length L (mm) of the main body and an inner diameter D (mm) of the main body is 14 or more and 25 or less.   In the first step, when the rubber material is extruded to both axial end portions of the core metal, rather than when the rubber material is extruded to the axial center portion of the core body, The method for producing a rubber roll according to claim 1 or 2, wherein a relative extrusion speed of the rubber material is increased. A cylindrical main body and a screw inserted into the main body, and rotating the screw causes an unvulcanized rubber material to flow from one end to the other end of the main body, and A rubber material supply unit for supplying, a first compression region for compressing the rubber material supplied to the main body, a damming region for squeezing and extruding the rubber material compressed in the first compression region, A rubber material supply section having a vacuum region for evacuating the rubber material extruded from the damming region, and a second compression region for compressing the rubber material evacuated in the vacuum region;
An extrusion section for extruding the rubber material supplied from the rubber material supply section into a cylindrical shape;
A cored bar supplying unit for supplying a cored bar to the central part of the rubber material extruded in a cylindrical shape from the extruded unit;
With
Extrusion amount V (g / min) of the rubber material extruded per minute from the extrusion unit when the core metal is not supplied from the core metal supply unit, and filling of the rubber material in the second compression region A rubber roll manufacturing apparatus for extruding the rubber material in a cylindrical shape from the extruding portion under an extruding condition in which a ratio W / V to the amount W (g) is 1.5 or more and 4.0 or less.   The apparatus for manufacturing a rubber roll according to claim 4, wherein a ratio L / D between an axial length L (mm) of the main body portion and an inner diameter D (mm) of the main body portion is 14 or more and 25 or less.   Relative to the supply speed of the core metal when the rubber material is extruded to both ends of the core metal in the axial direction, rather than when the rubber material is extruded to the central part of the core body in the axial direction. The apparatus for manufacturing a rubber roll according to claim 4 or 5, further comprising a control unit that controls at least one of the rubber material supply unit and the core body supply unit so that a proper extrusion speed is increased.