Blade-Mediated Coating Apparatus for Fixing Belt Uniformity
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Solution Overview
Problem
Conventional primer coating methods for fixing belts in electrophotographic image forming apparatuses face challenges such as uneven gloss, rubber layer peeling, and thickness non-uniformity due to insufficient coating accuracy and high viscosity issues, leading to increased costs and operational inefficiencies.
Innovation Solution
A coating apparatus and method that uses a holding member, an impregnation member, and a nozzle to eject coating liquid onto an endless member in a controlled manner, rotating and moving the holding member to ensure uniform coverage and thickness adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spray coating is used to apply the primer, then the coating operation can be performed quickly, but the coating liquid is scattered over the peripheral portion causing great loss and the coating accuracy is poor
Solution Approach 1:
The patent introduces a blade as an intermediary element between the nozzle and the cylindrical substrate. The blade receives the coating liquid from the nozzle and transfers it to the substrate surface in a controlled manner, preventing direct spray scattering and reducing coating liquid loss while maintaining coating accuracy.
Solution Approach 2:
The patent replaces the conventional spray coating mechanism with a blade-based coating mechanism. Instead of relying on aerosolization and spray patterns, the system uses direct liquid delivery followed by blade-controlled distribution, eliminating the scattering problem inherent in spray coating.
2Ease of manufacture
If the coating liquid has high viscosity, then the coating can be applied more easily, but atomization becomes difficult and coating uniformity deteriorates
Solution Approach 1:
The patent replaces the atomization-based spray system with a blade-based mechanical distribution system. This allows high viscosity coating liquids to be applied directly without requiring atomization, while the blade ensures uniform distribution and consistent thickness across the substrate surface.
Solution Approach 2:
The patent changes the fundamental coating parameter from aerosol droplet size distribution to blade contact pressure and speed. This parameter transformation allows high viscosity liquids to be coated effectively, as the coating quality depends on mechanical control rather than fluid atomization characteristics.
3Manufacturing precision
If dip coating is used to apply the primer, then the coating liquid can be applied uniformly, but the operation takes much time and operation efficiency is lowered
Solution Approach 1:
The patent segments the coating process into two distinct stages: (1) rapid liquid delivery via nozzle to the blade, and (2) controlled distribution via blade to the substrate. This segmentation allows each stage to be optimized independently, achieving both speed and uniformity.
Solution Approach 2:
The blade serves as an intermediary that decouples the coating liquid delivery from the substrate contact. This allows the nozzle to operate at high speed while the blade ensures uniform distribution, combining the speed advantage of spray methods with the uniformity advantage of dip methods.
4Adaptability or versatility
If brush coating is used to apply the primer, then material selection flexibility is improved, but coating non-uniformity occurs when the brush is moved excessively quickly
Solution Approach 1:
The patent replaces the brush-based manual coating system with an automated blade system. This eliminates the human factor of inconsistent brush speed and motion, ensuring uniform coating application while maintaining the flexibility to work with various coating liquid materials.
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 solution achieves precise and uniform primer layer formation, reducing thickness non-uniformity and peeling issues, enhancing the durability and image quality of the fixing belts while maintaining operational efficiency and cost-effectiveness.
Implementation Method 1
a nozzle member to eject the coating liquid onto the endless member
Data Source
AI summary
A coating apparatus configured to coat a peripheral surface of an endless member with a coating liquid, includes: a holding member configured to hold the endless member; an impregnation member configured to be impregnated with the coating liquid and configured to coat the endless member with the coating liquid in contact with the endless member; a nozzle member configured to eject the coating liquid onto the endless member; a rotating mechanism configured to rotate the holding member relative to the impregnation member and the nozzle member; and a moving mechanism configured to move the holding member relative to the impregnation member and the nozzle member so that the coating liquid is ejected from the nozzle member onto the endless member in a region where the coating liquid is already coated by the impregnation member.