Cleaning Blade Coating Texture for Low-Torque Toner Removal
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Solution Overview
Problem
Existing cleaning blades in electrophotographic image forming apparatuses experience increased torque and friction, leading to image bearer stoppages and incomplete cleaning due to wear and toner passage through turned-up portions, especially during high-density image printing.
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, containing particles and a binder resin, which enhances slidability and reduces torque while maintaining effective cleaning performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a cleaning blade is coated with a lubricant containing a fluorine-based compound, then friction between the cleaning blade and image bearer is reduced, but the coating may wear off quickly and cleaning performance deteriorates
Solution Approach 1:
The invention uses a composite coating layer comprising fluorine-based resin particles (providing lubrication) combined with a binder resin (providing adhesion and structural integrity). This composite structure allows the coating to maintain both low friction properties and durable attachment to the elastic body, preventing premature wear while preserving cleaning effectiveness
Solution Approach 2:
The invention specifies precise parameter ranges for the coating layer including fluorine-based resin content (5-50 mass%), coating thickness (1-10 μm), and hardness (0.1-1.0 N/mm²). By controlling these parameters, the coating achieves optimal balance between lubrication performance and wear resistance, maintaining stable cleaning performance over time
2Reliability
If the elastic body of the cleaning blade is made softer to prevent turning-up and gouging wear, then the tip ridge durability improves, but the cleaning performance decreases due to reduced ability to scrape off toner
Solution Approach 1:
The coating layer combines soft fluorine-based resin particles with a binder resin matrix, creating a composite material that exhibits intermediate mechanical properties. This allows the surface to be soft enough to prevent turning-up and gouging wear while maintaining sufficient scraping capability through the lubricating effect of the fluorine-based resin
Solution Approach 2:
The invention specifies the hardness of the coating layer within a precise range of 0.1-1.0 N/mm², which is softer than the elastic body itself. This parameter control ensures the coating provides protective cushioning against turning-up while the fluorine-based resin content (5-50 mass%) maintains adequate scraping performance
3Productivity
If a cleaning blade operates continuously for high-density image printing, then productivity increases, but torque increases due to friction and wear causing image bearer stoppages
Solution Approach 1:
The coating layer is pre-applied to the elastic body before the cleaning blade enters service. This preliminary protective layer immediately reduces friction between the cleaning blade and image bearer from the start of operation, preventing torque increase and image bearer stoppages during continuous high-density printing without requiring break-in period
Solution Approach 2:
The coating layer parameters (fluorine-based resin content: 5-50 mass%, thickness: 1-10 μm, hardness: 0.1-1.0 N/mm²) are optimized to provide sustained low-friction performance under continuous high-load operating conditions, enabling prolonged productivity without torque-related failures
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 cleaning blade effectively reduces torque and maintains cleaning performance even during high-density printing by increasing the real contact surface area, preventing wear and ensuring complete residue removal.
Implementation Method 1
friction between the cleaning blade and the image bearer occurs to increase torque that is a force necessary for rotating the image bearer
Implementation Method 2
a cleaning blade coated with a lubricant containing a fluorine-based compound has been proposed
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A cleaning blade (62) includes a blade substrate (622), a blade support (621), and a coating layer (623). The blade substrate (622) includes an elastic body having a tip portion to be in contact with a surface of an object (3) to clean the surface of the object (3). The blade support (621) supports the blade substrate (622). The coating layer (623) 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 (623) 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 (623) on the blade substrate (622).