Cleaning Roller With Non-Uniform Elastic Layer Thickness

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Solution Overview

Problem

Existing cleaning systems for image forming apparatuses face challenges in effectively removing residual toners and contaminants from the surfaces of charging rollers, leading to inconsistent image quality and reduced apparatus performance due to inadequate contact and deformation management during the cleaning process.

Innovation Solution

A cleaning roller with a helically wound elastic layer, featuring a division portion in the central segment and varying thicknesses, is designed to provide enhanced contact and deformation management, allowing for improved removal of contaminants while maintaining stable properties and preventing image quality defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a uniform thickness elastic layer is used in the cleaning roller, then the manufacturing process is simple, but the in-plane density unevenness increases and cleaning performance deteriorates

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidin-plane density unevenness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The elastic layer is designed with non-uniform thickness where the central portion has a greater thickness than the end portions. This local variation in thickness creates corresponding variations in density and elasticity, allowing the central portion to provide better cleaning pressure while the end portions maintain appropriate contact without excessive pressure, thereby reducing in-plane density unevenness and improving overall cleaning performance.

Inventive Principle:

Principle #3Local quality

2Force

If the elastic layer thickness is increased uniformly, then the cleaning pressure is improved, but the contact uniformity and image quality deteriorate due to excessive deformation

Engineering Contradiction:

Improvecleaning pressureVSAvoidcontact uniformity

Core Design Contradiction:

ForceVSManufacturing precision

Solution Approach 1:

The elastic layer thickness is varied locally with the central portion being thicker than the end portions. This design concentrates the cleaning pressure in the central region where it is most needed, while the thinner end portions prevent excessive deformation and maintain uniform contact across the cleaning roller surface, thereby improving both cleaning pressure and contact uniformity simultaneously.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If the elastic layer thickness is decreased uniformly, then the contact uniformity is improved, but the cleaning pressure and contaminant removal capability deteriorate

Engineering Contradiction:

Improvecontact uniformityVSAvoidcleaning pressure

Core Design Contradiction:

Manufacturing precisionVSForce

Solution Approach 1:

The elastic layer is designed with a non-uniform thickness profile where the central portion has greater thickness to provide sufficient cleaning pressure and contaminant removal capability, while the end portions have reduced thickness to maintain uniform contact. This local differentiation allows the system to achieve both adequate cleaning pressure and uniform contact simultaneously.

Inventive Principle:

Principle #3Local quality

4Device complexity

If a solid elastic layer without division is used, then the structure is simple, but the cleaning efficiency is reduced due to inadequate deformation management

Engineering Contradiction:

Improvestructural simplicityVSAvoidcleaning efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The elastic layer is divided into multiple segments along its length, with division portions created by removing material at regular intervals. This segmentation allows each segment to deform independently during the cleaning process, improving contact with the cleaning roller surface and enhancing contaminant removal efficiency. The divisions enable better deformation management while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #1Segmentation

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 effectively removes contaminants, reduces in-plane density unevenness, and enhances cleaning performance, resulting in superior image quality and apparatus reliability by ensuring consistent contact and prolonged cleaning efficiency.

Implementation Method 1

an elastic layer that is helically wound around the shaft from one end side to the other end side of the shaft and fixed on the shaft and that cleans a body to be cleaned while the elastic layer rotates

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10095147B2Cleaning body providing reduced in-plane density unevenness and improved cleaning performance, assembly, and image forming apparatus

Publication Date: 2018.10.09 FUJIFILM BUSINESS INNOVATION CORP

AI summary

A cleaning body includes a shaft and an elastic layer that is helically wound around the shaft from one end side to the other end side of the shaft and fixed on the shaft and that cleans a body to be cleaned while the elastic layer rotates. The elastic layer includes a division portion having plural divided segments and having a length of from 20% to 70% of the full length of the elastic layer. The division portion is located in a longitudinal central portion of the elastic layer. In the sectional view perpendicular to the axial direction of the shaft, a minimum thickness part in the longitudinal central portion of the elastic layer is from 5% to 12% thicker than a minimum thickness part in each longitudinal end portion of the elastic layer.