Cleaning Blade DLC Coating Wear Resistance
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Solution Overview
Problem
Existing cleaning blades in image forming apparatuses face issues with wear resistance and friction, leading to reduced lifespan and ineffective cleaning performance when in contact with developer belts.
Innovation Solution
A cleaning blade with a resin substrate and a coating layer containing diamond-like carbon (DLC) and titanium-based materials, where the DLC surface layer has a thickness of 0.05 μm to 0.3 μm, and a connection layer with a gradient of anchor material content, enhancing adhesion and wear resistance, and formed using Filtered Cathodic Vacuum Arc (FCVA) for improved durability and reduced friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a conventional cleaning blade is used, then the structure is simple and easy to manufacture, but the wear resistance is poor and the service life is short
Solution Approach 1:
The cleaning blade uses a composite coating structure with multiple layers including a connection layer containing diamond-like carbon and titanium-based materials, and a surface layer containing diamond-like carbon. This composite material structure significantly improves wear resistance and service life while maintaining reasonable manufacturing complexity through established PVD coating technologies.
2Ease of operation
If a conventional cleaning blade is used, then the manufacturing process is simple, but the friction is high and cleaning performance deteriorates
Solution Approach 1:
The multi-layer composite coating with diamond-like carbon provides low friction coefficients and excellent cleaning performance. The titanium-based materials in the connection layer ensure strong adhesion to the resin substrate. This composite structure achieves superior cleaning performance through established PVD manufacturing processes.
Solution Approach 2:
The coating layer is applied selectively to specific regions of the cleaning blade edge that contact the developer belt. The connection layer and surface layer are designed with specific material compositions and thicknesses (0.05-0.3 μm for surface layer) to optimize local friction and cleaning properties where needed most.
3Strength
If the DLC surface layer is made thicker, then wear resistance improves, but the coating layer adhesion deteriorates and peeling occurs
Solution Approach 1:
The coating layer is designed with spatially varying properties: the connection layer containing titanium-based materials and diamond-like carbon provides strong adhesion to the resin substrate, while the surface layer with pure or high-carbon DLC content provides wear resistance. The surface layer thickness is optimized to 0.05-0.3 μm to balance wear protection and adhesion.
Solution Approach 2:
The composite coating structure with a gradient from titanium-based materials at the substrate interface to diamond-like carbon at the surface creates optimal performance. The connection layer acts as an intermediate layer that bonds both the resin substrate and the DLC surface layer, preventing peeling while maintaining wear resistance.
4Reliability
If the cleaning blade is made more durable, then service life extends, but the device complexity increases
Solution Approach 1:
The dual-layer composite coating with specific material compositions achieves high durability through proven PVD technology. The connection layer with titanium-based materials and the surface layer with diamond-like carbon work together to provide wear resistance, low friction, and strong adhesion, extending service life without requiring overly complex manufacturing processes.
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 significantly enhances wear resistance and reduces friction, resulting in a longer-lasting cleaning blade with improved cleaning performance, even on belts with high surface roughness, and allows for a wider range of installation angles without turning up or bouncing.
Implementation Method 1
formed using Filtered Cathodic Vacuum Arc (FCVA)
Data Source
AI summary
A cleaning blade includes a resin substrate having a substantially planar shape and a coating layer that covers at least one edge of the resin substrate and that has a connection layer and a surface layer, the connection layer being formed so as to face an interface with the resin substrate and containing diamond-like carbon and at least one selected from the group consisting of titanium nitride, titanium silicon, titanium tungsten, titanium carbide, and titanium carbonitride, the surface layer covering the connection layer and containing diamond-like carbon.