Auxiliary Brush Seals Developer Unit Clearance to Stop Toner Scattering
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Solution Overview
Problem
Conventional image forming apparatuses face issues with toner quality deterioration due to air leaks and toner scattering, which affect image quality, as the cooling unit's air leaks through clearances and causes toner to reattach to the intermediate transfer belt, leading to incomplete cleaning and image defects.
Innovation Solution
Incorporation of a second auxiliary brush that closes the clearance between the developer unit and the intermediate transfer belt, preventing air leaks and ensuring effective toner removal by the cleaning roller, thereby maintaining image quality and reducing toner scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the cooling unit sends air to cool the developer unit, then the developer unit temperature is reduced, but air leaks through the clearance and causes toner scattering and reattachment
Solution Approach 1:
The auxiliary brush acts as an intermediary element between the cooling air flow and the toner particles. It blocks the direct path of air leakage through the clearance, preventing toner scattering while allowing the cooling function to operate. The brush bristles serve as a mediator that separates the cooling air flow from the toner-containing regions.
Solution Approach 2:
The auxiliary brush with its flexible bristles functions as a flexible barrier that can adapt to the clearance space between the intermediate transfer belt and developer unit. The flexible nature of the brush allows it to effectively seal the clearance while accommodating mechanical movements and tolerances in the system.
2Manufacturing precision
If the cleaning roller removes remaining toner from the intermediate transfer belt, then toner removal is improved, but paper powder adheres to the intermediate transfer belt
Solution Approach 1:
The auxiliary brush serves as an intermediary cleaning element that works in conjunction with the cleaning roller. It provides an additional cleaning action that removes paper powder without the aggressive contact that might cause adhesion, complementing the toner removal function of the cleaning roller.
Solution Approach 2:
The cleaning function is segmented into two separate components: the cleaning roller for toner removal and the auxiliary brush for paper powder removal. This segmentation allows each component to be optimized for its specific function, with the auxiliary brush providing gentle cleaning that prevents paper powder adhesion while the cleaning roller ensures complete toner removal.
3Reliability
If the auxiliary brush closes the clearance between the intermediate transfer belt and developer unit, then air leaks are reduced, but the brush structure adds complexity
Solution Approach 1:
The auxiliary brush is designed as a simple, easily replaceable component with a relatively simple structure. Rather than implementing a complex sealing mechanism, the patent uses a straightforward brush structure that can be easily manufactured and replaced, reducing overall system complexity while maintaining effective air leak prevention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The second auxiliary brush effectively seals the clearance, reducing air leaks and toner scattering, resulting in improved image quality by ensuring complete toner removal and preventing reattachment, thus enhancing the overall performance of the image forming apparatus.
Implementation Method 1
a cooling unit, a cleaning roller, and an auxiliary brush. The cooling unit cools a predetermined component by sending air by a fan inside the image forming apparatus
Implementation Method 2
The auxiliary brush located on an outer surface of the developer unit so as to close the clearance between the intermediate transfer belt and the developer unit
Implementation Method 3
The cleaning roller removes remaining toner on the intermediate transfer belt at an upstream side of a region facing the developer unit
Data Source
AI summary
An image forming apparatus includes an intermediate transfer belt and a developer unit. The image forming apparatus includes a cooling unit, a cleaning roller, and an auxiliary brush. The cooling unit cools a predetermined component by sending air by a fan inside the image forming apparatus. The cleaning roller removes remaining toner on the intermediate transfer belt at an upstream side of a region facing the developer unit in a rotationally moving direction of the intermediate transfer belt and at an upstream side of a region with which the image carrier is in contact in the intermediate transfer belt. The auxiliary brush located on an outer surface of the developer unit so as to close the clearance between the intermediate transfer belt and the developer unit and is in contact with the intermediate transfer belt to clean the intermediate transfer belt.