Charging Member With Variable Rigidity Intermediate Layer
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Solution Overview
Problem
Existing contact chargers for image forming apparatuses generate undesirable charge noise due to the application of AC voltage, which is difficult to mitigate while maintaining uniform charging and preventing deformation and electric leakage.
Innovation Solution
A charging member with an intermediate layer having varying rigidity, where the first portion adjacent the charging layer has greater rigidity than the second portion adjacent the metal core, supports the charging layer and reduces charge noise by managing vibration amplitudes and contact area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If AC voltage is applied to the charging member to achieve uniform charging, then charging uniformity is improved, but charge noise is generated
Solution Approach 1:
The patent changes the physical parameters of the intermediate layer, specifically its rigidity characteristics. By designing the intermediate layer with non-uniform rigidity (greater rigidity at the first portion adjacent to the charging layer and lesser rigidity at the second portion adjacent to the metal core), the system modifies how vibrations are transmitted while maintaining the AC voltage charging mechanism.
Solution Approach 2:
The charging member is designed as a composite structure with multiple layers having different properties: a charging layer, an intermediate layer with varying rigidity, and a metal core. This composite structure allows the system to simultaneously achieve uniform charging through AC voltage while the specific rigidity distribution of the intermediate layer suppresses vibration and reduces charge noise.
2Object-generated harmful factors
If the charging layer is designed to prevent charge noise, then charge noise is reduced, but it becomes difficult to maintain uniform charging and prevent deformation
Solution Approach 1:
The intermediate layer is designed with local quality variations in its rigidity distribution. The first portion adjacent to the charging layer has greater rigidity to suppress vibrations and reduce charge noise, while the second portion adjacent to the metal core has lesser rigidity to maintain charging stability and prevent permanent deformation. This spatial variation in material properties allows simultaneous achievement of noise reduction and reliable charging.
3Object-generated harmful factors
If the intermediate layer has high rigidity throughout to reduce vibration, then charge noise is reduced, but deformation prevention and charging uniformity are compromised
Solution Approach 1:
Instead of uniformly high rigidity throughout the intermediate layer, the patent applies parameter changes by creating a rigidity gradient. The rigidity is greater at the first portion (adjacent to the charging layer) to reduce vibrations and charge noise, and lesser at the second portion (adjacent to the metal core) to allow controlled deformation that prevents permanent damage and maintains charging uniformity. This graduated parameter change optimizes both noise reduction and deformation 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 solution effectively reduces charge noise, maintains uniform charging, and prevents deformation and electric leakage, making it easier to manufacture and design the charging member.
Implementation Method 1
The charge noise is a vibroacoustic signal of the charging member and/or the image bearing member, which is caused by an attractive force generated between the charging member and the image bearing member and periodically changing in synchronism with the frequency of the AC voltage.
Implementation Method 2
The intermediate layer has a first portion adjacent the charge layer and a second portion adjacent the support member, the first portion having a greater rigidity than that of the second portion.
Implementation Method 3
an AC voltage is applied upon the charging member to charge the image bearing member, which allows the portions of the image bearing member to be charged more uniformly
Data Source
AI summary
A charging member for electrically charging a substrate has a charge layer to be brought into contact with the substrate, an intermediate layer supporting the charge layer, and a support member supporting the intermediate layer. The intermediate layer has a first portion adjacent the charge layer and a second portion adjacent the support member, the first portion having a greater rigidity than that of the second portion.