Abrasive Tape Surface Roughness for Photoreceptor Cleaning
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Solution Overview
Problem
Existing surface abrasion methods for electrophotographic photoreceptors using abrasive tapes face issues with clogging, precise control requirements, and the production of streak-like flaws, which lead to cleaning troubles and image quality deterioration.
Innovation Solution
A surface abrading method using an abrasive tape with a solid body containing abrasive grains on a backing material, where the top face of the solid body has a specific surface roughness of 4.0 μm to 8.0 μm, is employed. The abrasive tape is moved parallel to the photoreceptor's rotation axis, and an elastic backup roll ensures uniform pressure, preventing clogging and streaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an abrasive tape with smooth surface is used for abrading the photosensitive layer, then the initial abrasion quality is good, but the abrasive residue clogs the tape surface over time, causing cleaning trouble and image deterioration
Solution Approach 1:
The patent applies a porous coating layer on the abrasive tape surface with specific pore size (0.1-10 μm) and porosity (10-80%). This porous structure allows abrasive residue to be stored within the pores rather than clogging the surface, maintaining consistent abrasion quality over extended periods while preventing the clogging issue that plagues smooth-surfaced abrasive tapes
Solution Approach 2:
The patent changes the surface parameters of the abrasive tape by controlling the pore size distribution (0.1-10 μm) and porosity (10-80%) of the coating layer. These parameter changes transform the tape from a smooth surface that clogs easily to a controlled porous surface that maintains reliability while preserving abrasion precision
2Manufacturing precision
If precise control is implemented during abrasive tape application, then abrasion uniformity is improved, but the device complexity and operational difficulty increase
Solution Approach 1:
The patent makes the abrasive tape self-regulating through its porous coating layer that automatically stores abrasive residue within its pore structure. This self-service mechanism eliminates the need for complex control systems to manage clogging, as the tape maintains uniform abrasion performance automatically over extended periods without external intervention
Solution Approach 2:
The porous coating layer is pre-formed on the abrasive tape before use, with predetermined pore size and porosity parameters. This preliminary preparation allows the tape to inherently resist clogging from the start, eliminating the need for complex real-time control mechanisms during the abrasion process
3Productivity
If high abrasion force is applied to remove polymerization toner, then cleaning effectiveness is improved, but streak-like flaws and surface damage occur
Solution Approach 1:
The patent creates local quality variations on the abrasive tape surface through the porous coating layer with controlled pore size (0.1-10 μm). This local porous structure distributes the abrasion force across multiple contact points within the pores, preventing concentrated high-force contact that causes streaks and surface damage, while maintaining overall cleaning effectiveness
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
This method effectively prevents abrasive residue clogging, eliminates the need for precise control, and avoids streak-like flaws, ensuring stable and efficient removal of toner and foreign materials without damaging the photoreceptor surface.
Implementation Method 1
abrading a surface of the photosensitive layer with an abrading member entrained about a backup roll
Data Source
AI summary
A surface abrading method of an electrophotographic photoreceptor is disclosed, comprising abrading the surface of a photosensitive layer with an abrading member entrained about a backup roll with feeding the abrading member and rotating the photoreceptor, while moving the abrading member parallel to a rotating shaft of the photoreceptor with bringing the abrading member into contact with the photosensitive layer surface, wherein the abrading member comprises a solid body on a backing material, the solid body contains abrasive grains and is provided on the backing material brought into contact with the photosensitive layer surface, and the top face of the solid body exhibits a surface roughness (Ry) of from 4.0 to 8.0 μm.