Cleaner Blade Frangible Tabs for Toner Removal
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Solution Overview
Problem
The cleaner blade in electrophotographic imaging devices is prone to failure due to high friction at its ends, leading to blade flip issues, which existing solutions like minimizing blade length, applying lubricants, or modifying end sealing designs either increase costs or compromise sealing performance.
Innovation Solution
The introduction of thin, low-friction tabs made of materials like Mylar between the cleaner blade and the photoconductive drum at its ends, reducing friction and preventing blade flip by eliminating relative motion between the blade and drum surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cleaner blade is pressed against the photoconductive drum to remove residual toner, then cleaning effectiveness is improved, but friction at the blade ends increases causing blade flip
Solution Approach 1:
The cleaner blade is divided into two functional segments: a central cleaning portion that contacts the photoconductive drum for toner removal, and frangible end portions that extend beyond the drum ends. This segmentation allows the main cleaning function to operate with sufficient pressure while the extended ends act as friction-reducing elements that can break off after serving their protective purpose.
Solution Approach 2:
The frangible end portions are designed as disposable elements that are intentionally made to break off after a predetermined service life. These ends serve their function of reducing friction and protecting the main blade during initial operation, then are discarded when they fracture, eliminating the need for complex adjustment mechanisms or expensive reusable components.
2Force
If the cleaner blade length is minimized to reduce end friction, then blade flip is reduced, but cleaning coverage is compromised
Solution Approach 1:
The blade is segmented into a permanent central portion and temporary end portions. The central portion maintains full length for complete cleaning coverage, while the extended end portions are designed to break off, effectively reducing the operational length after initial use. This resolves the contradiction by having both long and short blade characteristics at different times.
Solution Approach 2:
The frangible ends are pre-configured to break off after a predetermined number of operating cycles or after serving their friction-reduction purpose. This preliminary design ensures that the blade automatically transitions from a long configuration (during which the ends protect against flip) to a shorter configuration (where the ends have already served their purpose and broken off), eliminating the need for manual intervention.
3Force
If lubricants are applied to the cleaner blade to reduce friction, then blade flip is prevented, but reliability decreases due to lubricant removal and assembly variation
Solution Approach 1:
Instead of relying on consumable lubricants that degrade and require reapplication, the invention uses frangible end portions made of a different material with inherently low friction properties. These ends serve as a permanent (until breakage) friction-reduction mechanism that does not degrade over time, eliminating the reliability issues associated with lubricant application and persistence.
Solution Approach 2:
The invention changes the material parameter of the blade ends rather than applying a surface coating like lubricant. By selecting a material with naturally low friction characteristics for the frangible ends, the solution provides consistent friction reduction without the variability and degradation associated with applied lubricants, thereby improving reliability.
4Force
If end sealing designs are modified to reduce blade end forces, then blade flip is reduced, but sealing performance is compromised
Solution Approach 1:
The sealing function is separated from the friction-reduction function. The frangible ends extend beyond the sealing region and break off before interfering with the seal, while the sealing portions of the blade maintain full contact with the photoconductive drum. This segmentation allows both functions to operate optimally without compromise.
Solution Approach 2:
The frangible ends serve their friction-reduction and force-distribution function during initial operation, then break off before they would interfere with the sealing process. This preliminary action ensures that the sealing performance is never compromised, as the potentially problematic ends are eliminated before they could affect the seal.
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 solution effectively mitigates cleaner blade failures by reducing friction at the ends, enhancing reliability and reducing the likelihood of blade flip, while maintaining effective sealing and operational efficiency.
Implementation Method 1
reducing friction and preventing blade flip by eliminating relative motion between the blade and drum surfaces
Data Source
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AI summary
A device for cleaning a photoconductive member in an image forming device. The device includes a blade extending across the photoconductive member and having an edge that contacts a surface of the photoconductive member to remove toner therefrom. An elongated seal disposed adjacent the blade extends across a length of the blade such that an opening for receiving removed toner is formed between the elongated seal and the blade. The elongated seal includes at least one tab projecting at each longitudinal end thereof and extending between the blade and the photoconductive member so as to prevent a longitudinal end section of the edge of the blade from contacting the surface of the photoconductive member.