Developing Roller Boehmite Layer Crack Resistance
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Solution Overview
Problem
Conventional developing rollers with alumite layers suffer from variations in insulating performance due to resin infiltration into porous layers, leading to potential current leakage between the roller and image carrier, and are prone to cracking under high-temperature drying processes.
Innovation Solution
A developing roller with a boehmite layer formed on an aluminum base body, followed by a conductive resin coat layer, which reduces variations in insulating performance and minimizes cracking, ensuring stable electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an alumite layer is used to suppress current leakage, then insulating performance is improved, but resin infiltration into porous layers causes variations in insulating performance and current leakage
Solution Approach 1:
The patent replaces the porous alumite layer with a boehmite layer that has controlled porosity characteristics. The boehmite layer provides the necessary insulating function while reducing resin infiltration issues, thereby maintaining consistent insulating performance across different production batches and operating conditions.
Solution Approach 2:
The patent creates a composite structure by forming a boehmite layer (inorganic material) on the aluminum base body, followed by a resin coat layer (organic material). This composite structure combines the advantages of both materials: the boehmite provides stable insulating properties and crack resistance, while the resin layer provides smooth surface and additional protection.
2Reliability
If an alumite layer is used to suppress current leakage, then insulating performance is improved, but the layer is prone to cracking under high-temperature drying processes
Solution Approach 1:
The patent changes the material parameters by substituting alumite with boehmite, which has different thermal expansion characteristics and higher crack resistance. The boehmite layer can withstand high-temperature drying processes without cracking, thereby maintaining insulating performance throughout the manufacturing and operating lifecycle.
Solution Approach 2:
The boehmite layer acts as an intermediary between the aluminum base body and the resin coat layer. It provides a stable, crack-resistant foundation that can endure high-temperature processing, while also providing the necessary insulating properties. This intermediary layer prevents stress transmission that would cause cracking in more brittle materials like alumite.
3Shape
If a resin coat layer is applied on alumite layer, then surface smoothness is improved, but resin infiltration into porous alumite causes insulating performance variations
Solution Approach 1:
The patent utilizes the controlled porosity characteristics of the boehmite layer to prevent excessive resin infiltration. The boehmite structure allows for adequate resin adhesion and surface smoothness while maintaining sufficient insulating barriers, thus achieving both surface quality and electrical performance consistency.
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 boehmite layer and conductive resin coat combination results in a developing roller with reduced leakage-causing voltage variations and fewer cracks, enhancing the reliability of the developing process by maintaining consistent insulating performance.
Implementation Method 1
a boehmite layer has been formed on an outer circumferential surface of a base body that is made of a metal including aluminum, by a surface treatment by a boehmite method
Implementation Method 2
a resin coat layer has been formed on a surface of the boehmite layer, the resin coat layer being made of a resin material having electric conductivity
Data Source
AI summary
A developing roller includes a roller main body disposed to face, without contact, an outer circumferential surface of an image carrier. In the roller main body, a boehmite layer has been formed on an outer circumferential surface of a base body that is made of a metal including aluminum, by a surface treatment by a boehmite method, and a resin coat layer has been formed on a surface of the boehmite layer, the resin coat layer being made of a resin material having electric conductivity.