Cleaning Blade Coating Roughness for Low-Torque Toner Removal
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Solution Overview
Problem
Conventional cleaning blades in electrophotographic image forming apparatuses face issues with increased torque and reduced cleaning performance due to friction and abrasion, particularly when dealing with large amounts of toner, leading to defective cleaning.
Innovation Solution
A cleaning blade with a coating layer having a developed interfacial area ratio (Sdr) of 1.2% to 1.8% in a 100 μm square region, composed of particles and a binder resin, enhances slidability and prevents torque increase while maintaining effective cleaning performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cleaning blade is used, then the cleaning blade can remove residual toner from the image bearer surface, but the torque increases and cleaning performance deteriorates due to friction and abrasion
Solution Approach 1:
The patent applies parameter changes by controlling the developed interfacial area ratio (Sdr) of the coating layer to be within 1.2% to 1.8% in a 100 μm square region. This specific parameter range optimizes the balance between friction reduction and cleaning effectiveness, preventing both torque increase and cleaning performance deterioration
Solution Approach 2:
The patent uses composite materials by combining particles with a binder resin to form the coating layer. This composite structure provides both lubrication properties (reducing torque) and mechanical integrity (maintaining cleaning performance), resolving the contradiction between force reduction and reliability
2Ease of operation
If the coating layer has a high developed interfacial area ratio, then slidability improves and torque reduces, but cleaning effectiveness may be compromised
Solution Approach 1:
The patent precisely controls the developed interfacial area ratio parameter to fall within 1.2% to 1.8%, which is sufficient to ensure slidability and reduce torque while not exceeding the threshold that would compromise cleaning effectiveness. This optimized parameter range resolves the contradiction between ease of operation and reliability
3Force
If the coating layer is made smoother, then friction decreases and torque is reduced, but the coating layer may wear or allow toner slip-through
Solution Approach 1:
The patent employs composite materials consisting of particles combined with a binder resin to form the coating layer. This composite structure provides a smooth surface for low friction while the binder resin maintains coating integrity and prevents wear and toner slip-through, resolving the contradiction between force reduction and abrasion resistance
Solution Approach 2:
The patent controls the developed interfacial area ratio parameter to optimize the balance between surface smoothness (for low friction) and coating integrity (for wear resistance). By maintaining Sdr within 1.2% to 1.8%, the coating layer achieves both reduced friction and maintained reliability
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 coating layer with a specific Sdr ratio reduces torque and ensures consistent cleaning performance even under high toner loads, preventing abrasion and slip-through of toner.
Implementation Method 1
conventional cleaning blades in electrophotographic image forming apparatuses face issues with increased torque and reduced cleaning performance due to friction and abrasion
Implementation Method 2
conventional cleaning blades in electrophotographic image forming apparatuses face issues with increased torque and reduced cleaning performance due to friction and abrasion
Data Source
AI summary
A cleaning blade includes a blade substrate, a blade support, and a coating layer. The blade substrate includes an elastic body having a tip portion to be in contact with a surface of an object to clean the surface of the object. The blade support supports the blade substrate. The coating layer coats at least the tip portion of the elastic body to form a tip ridge in contact with the surface of the object. The coating layer has a developed interfacial area ratio (Sdr) of 1.2% or more and 1.8% or less in a 100 μm square region inward from the tip ridge of the coating layer on the blade substrate.