Collecting Roller Surface Roughness for Toner Removal
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Solution Overview
Problem
Existing cleaning devices for image forming apparatuses face challenges in efficiently removing toner and paper powder from intermediate transfer belts, leading to potential image failures due to toner backward flow and blade abrasion issues.
Innovation Solution
A cleaning device with a removal roller, collecting roller, and blade, where the collecting roller has distinct surface roughness regions and no integral multiple relationship with the removal roller, effectively collects and conveys toner and paper powder, preventing backward flow and blade wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the collecting roller has a uniform surface structure, then the manufacturing process is simple, but the collection efficiency of toner and paper powder is insufficient and causes blade abrasion
Solution Approach 1:
The collecting roller is designed with different surface structures in different circumferential regions. The first circumferential region has a first surface structure that facilitates toner collection, while the second circumferential region has a second surface structure that prevents paper powder accumulation. This local differentiation resolves the contradiction by optimizing collection efficiency in specific areas without requiring complete redesign of the entire roller surface.
2Device complexity
If the rotation speed or diameter of the collecting roller is an integral multiple of the removal roller, then the mechanical synchronization is simplified, but toner backward flow occurs causing image failures
Solution Approach 1:
The patent specifies that the rotation speed or diameter of the collecting roller should NOT be an integral multiple of the removal roller. By changing this parameter relationship, the patent prevents toner backward flow from occurring at regular intervals, thereby eliminating the cause of striped image failures while maintaining acceptable mechanical synchronization through alternative design considerations.
3Productivity
If the blade continuously contacts the collecting roller to scrape toner, then the toner removal is effective, but the blade experiences wear and requires frequent replacement
Solution Approach 1:
The collecting roller has different surface structures in different circumferential regions. The first region provides effective toner scraping surfaces while the second region provides low-friction surfaces that reduce blade wear. This local differentiation allows the blade to effectively remove toner from certain areas while experiencing minimal wear from other areas, thereby extending blade service life.
Solution Approach 2:
The patent converts the potentially harmful continuous contact between the blade and collecting roller into a beneficial arrangement by designing specific surface structures that reduce friction and wear. The second circumferential region with its specialized surface structure transforms the wear-causing contact into a low-wear interaction, extending blade life while maintaining cleaning effectiveness.
4Device complexity
If the cleaning device uses a single surface structure on the collecting roller, then the device complexity is reduced, but paper powder accumulates causing jamming and image failures
Solution Approach 1:
The collecting roller incorporates different surface structures in different circumferential regions. The first surface structure optimizes toner collection while the second surface structure specifically addresses paper powder prevention. This local differentiation resolves the contradiction by adding only the necessary structural variation to prevent paper powder accumulation without completely redesigning the entire cleaning device.
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 enhances toner and paper powder collection efficiency, prevents image failures, and extends blade life by optimizing surface roughness and contact configurations on the collecting roller.
Implementation Method 1
Provided on an outer circumferential surface of the collecting roller in a circumferential direction of the collecting roller are: a first outer circumferential region having a predefined first surface roughness and extending in the axial direction of the second rotary shaft; and a second outer circumferential region having a greater predefined second surface roughness than the first surface roughness and extending in the axial direction of the second rotary shaft
Data Source
AI summary
A cleaning device includes a removal roller, a collecting roller, a blade, and a toner storage section. The removal roller and the collecting roller do not have relationship such that a rotation speed or a diameter of one of the removal roller and the collecting roller is an integral multiple of a rotation speed or a diameter of the other removal roller and collecting roller. A first outer circumferential region having a first surface roughness and extending in an axial direction of a second rotary shaft and a second outer circumferential region having a greater second surface roughness than the first surface roughness and extending in the axial direction of the second rotary shaft are provided on an outer circumferential surface of the collecting roller in a circumferential direction thereof. A width of the second outer circumferential region is smaller than a width of the first outer circumferential region.