Asymmetric Charging Roller Axis for Uniform Nip Width

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Solution Overview

Problem

Conventional image forming apparatuses using the electrographic method face issues with uneven nip width and electric potential changes due to shaft distortion of the charging roller, leading to inconsistent toner image transfer and charging of the photosensitive drum.

Innovation Solution

A process unit with a charging roller and a cleaning roller, where the central axis of the photosensitive drum is positioned non-overlapping with the central axis of the charging and cleaning rollers, and biasing members are used to maintain a consistent distance and orientation, reducing shaft displacement and ensuring uniform charging without compromising pressure contact efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Force

If the charging roller is pressed against the photosensitive drum with a biasing unit, then the charging pressure is improved, but the shaft of the charging roller distorts causing uneven nip width

Engineering Contradiction:
Improvecharging pressureVSAvoidnip width uniformity
Core Design Contradiction:
ForceVSManufacturing precision

Solution Approach 1:

The patent positions the central axis of the photosensitive drum at a location that does not overlap with the central axis line passing through the charging roller and cleaning roller. This asymmetric arrangement ensures that the biasing force is distributed more uniformly along the charging roller shaft, preventing distortion and maintaining consistent nip width across the roller width while still applying sufficient charging pressure.

Inventive Principle:
Principle #4Asymmetry

2Force

If the biasing unit biases the holding member toward the object to be charged, then the contact force is improved, but the distance between charging roll and object changes due to shaft distortion

Engineering Contradiction:
Improvecontact forceVSAvoidelectric potential consistency
Core Design Contradiction:
ForceVSReliability

Solution Approach 1:

By positioning the photosensitive drum's central axis non-coincident with the charging roller's central axis line, the patent creates an asymmetric configuration that distributes the contact force more evenly across the roller shaft. This prevents the shaft distortion that would otherwise cause variations in distance and electric potential, ensuring reliable and consistent charging across the entire drum surface.

Inventive Principle:
Principle #4Asymmetry

3Device complexity

If the central axes overlap, then the structure is simplified, but the shaft distortion causes uneven charging

Engineering Contradiction:
Improvestructural complexityVSAvoidcharging uniformity
Core Design Contradiction:
Device complexityVSManufacturing precision

Solution Approach 1:

The patent deliberately adopts an asymmetric configuration where the central axis of the photosensitive drum does not overlap with the central axis line of the charging roller. While this increases structural complexity slightly, it effectively distributes the mechanical load and prevents shaft distortion, thereby achieving uniform charging across the drum surface.

Inventive Principle:
Principle #4Asymmetry

4Force

If the charging roller shaft distorts, then the nip width becomes uneven, but maintaining proper contact requires pressure

Engineering Contradiction:
Improvecontact pressureVSAvoidnip width consistency
Core Design Contradiction:
ForceVSShape

Solution Approach 1:

The asymmetric positioning of the photosensitive drum relative to the charging roller creates a more favorable load distribution pattern. This prevents the shaft from distorting under contact pressure, thereby maintaining consistent nip width across the roller width while still ensuring adequate contact pressure for effective charging.

Inventive Principle:
Principle #4Asymmetry

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 configuration allows for uniform charging of the photosensitive drum, maintaining consistent nip width and electric potential, thereby improving image transfer quality and reducing the impact of shaft distortion on the charging process.

Implementation Method 1

a charging roller being pressed against the photosensitive drum so as to charge the photosensitive drum

Methodology Applied
Scientific EffectElectrostatic charging: Electrostatics

Implementation Method 2

at least one biasing member biasing the charging roller or the cleaning roller

Methodology Applied
Scientific EffectMechanical force: Mechanical Force

Implementation Method 3

a cleaning roller being pressed against the charging roller so as to clean the charging roller

Methodology Applied
Scientific EffectMechanical cleaning: Friction

Data Source

PatentUS11625000B2Process unit and image forming apparatus
Publication Date: 2023.04.11 SHARP KK
  • US11625000B2 patent drawing
  • US11625000B2 patent drawing
  • US11625000B2 patent drawing

AI summary

A process unit includes: a photosensitive drum on a surface of which a toner image is formed; a charging roller being pressed against the photosensitive drum so as to charge the photosensitive drum; a cleaning roller being pressed against the charging roller so as to clean the charging roller; and at least one biasing member biasing the charging roller or the cleaning roller. A central axis of the photosensitive drum is located at a position not overlapping with a central axis line passing through a central axis of the charging roller and a central axis of the cleaning roller. A biasing direction of the at least one biasing member is on a same line as the central axis line.