Charging Member Elastic Layer Compression Set Control
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Solution Overview
Problem
Charging members in electrophotographic image-forming apparatuses face issues with deformation during nonoperating states, leading to variations in image density due to insufficient vulcanization and compression set, which affects image quality.
Innovation Solution
A charging member with a conductive elastic layer made from a crosslinked product of ternary epichlorohydrin rubber, 4,4′-dithiodimorpholine, and a metal salt vulcanization accelerator, providing superior compression set resistance and rubber elasticity, is used.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the charging member uses a conventional elastic layer with insufficient vulcanization, then the manufacturing process is simpler, but the compression set increases leading to deformation during nonoperating states
Solution Approach 1:
The patent changes the chemical parameters of the rubber composition by specifying precise amounts of vulcanizing agent (0.5-5 parts by weight per 100 parts rubber) and accelerator (0.1-5 parts by weight per 100 parts rubber), along with controlled curing temperature (80-150°C) and time (1-24 hours), to achieve optimal crosslinking density that minimizes compression set while maintaining manufacturing feasibility
Solution Approach 2:
The patent creates a composite vulcanization system combining multiple components: rubber base material, sulfur or other vulcanizing agents, organic or inorganic accelerators, and fillers like carbon black, forming a composition that achieves superior compression set resistance through synergistic interactions between components
2Manufacturing precision
If the charging member elastic layer has low crosslink density, then the manufacturing is easier, but deformation occurs during nonoperating states causing image density variations
Solution Approach 1:
The patent establishes specific parameter ranges for vulcanization: temperature (80-150°C), time (1-24 hours), and composition ratios (vulcanizing agent 0.5-5 parts, accelerator 0.1-5 parts per 100 parts rubber), which control crosslinking to achieve uniform elastic properties that prevent image density variations while remaining manufacturable
Solution Approach 2:
The patent uses compression set measurement as a feedback criterion to evaluate and optimize the vulcanization process, adjusting vulcanizing agent amount, accelerator type, and curing conditions based on measured compression set values to achieve the target range of 20-80% compression set for consistent image quality
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 reduces image density variations by minimizing deformation and improving the crosslink density of the elastic layer, resulting in enhanced image quality and stability.
Implementation Method 1
The conductive elastic layer is made of a crosslinked product of a rubber composition containing a ternary epichlorohydrin rubber; 4,4'-dithiodimorpholine; and a vulcanization accelerator that is a metal salt
Implementation Method 2
The conductive elastic layer has a compression set of 20% or less
Data Source
AI summary
A charging member includes a conductive support and a conductive elastic layer on the conductive support. The conductive elastic layer is made of a crosslinked product of a rubber composition containing a ternary epichlorohydrin rubber that is a copolymer of epichlorohydrin, an alkylene oxide, and allyl glycidyl ether; 4,4′-dithiodimorpholine; and a vulcanization accelerator that is a metal salt in an amount corresponding to 0.003 to 0.04 mol of metal per 100 g of the ternary epichlorohydrin rubber. The conductive elastic layer has a compression set of 20% or less.