Developing Roller Anodized Aluminum Oxide Film
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Solution Overview
Problem
Existing developing rollers in contactless two-component developing systems face issues with electrical conductivity and leak suppression, leading to potential toner fogging and reduced developability due to uneven distribution of conductive agents in the resin coat layer.
Innovation Solution
A developing roller with an aluminum oxide thin film formed through anodic oxidation on a metal base, followed by a heating process and a conductive resin coat layer with titanium oxide, which is applied using a dipping method to ensure even conductivity and prevent cracks, thereby maintaining stable insulation and preventing leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive resin coat layer with conductive agent is applied to provide electrical conductivity, then electrical conductivity is improved, but uneven distribution of conductive agent causes leak and reduces reliability
Solution Approach 1:
The patent applies a preliminary heating process to the aluminum oxide thin film surface before applying the resin coat layer. This heating treatment prepares the surface by removing organic substances and adjusting surface energy, which ensures uniform resin coating and prevents crack formation, thereby achieving even conductive agent distribution and preventing electrical leaks
Solution Approach 2:
The patent controls the heating temperature at 50-150°C and heating time at 1-30 minutes to optimize the surface state of the aluminum oxide film. These parameter adjustments ensure the resin coat layer adheres uniformly without cracking, achieving both good electrical conductivity and uniform conductive agent distribution
2Reliability
If alumite layer is used to suppress leak between image carrier and developing roller, then leak suppression is improved, but the layer may crack during resin coating process reducing reliability
Solution Approach 1:
The heating process is performed as a preliminary action before resin coating to remove organic substances from the alumite layer surface and adjust its surface energy. This preparation prevents crack formation during the subsequent resin coating process, maintaining both the leak suppression function and structural integrity
Solution Approach 2:
The heating process acts as an intermediary step between the alumite layer formation and resin coating. It mediates the transition by preparing the alumite surface to accept the resin coat layer without causing cracks, thus preserving the leak suppression capability while improving crack resistance
3Loss of energy
If developing roller operates in low-temperature, low-humidity environment, then energy saving is improved, but toner fogging and reduced developability occur
Solution Approach 1:
The patent optimizes the heating process parameters (temperature: 50-150°C, time: 1-30 minutes) to create an ideal surface state for resin coating that is not dependent on ambient conditions. This ensures consistent electrical conductivity and uniform conductive agent distribution regardless of whether the device operates in high-temperature/high-humidity or low-temperature/low-humidity environments, preventing toner fogging while maintaining energy efficiency
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 provides a developing roller with improved toner layer formation and adherence, reducing toner fogging and leaks, while maintaining effective electrical conductivity and image density, even in low-temperature, low-humidity environments.
Implementation Method 1
an aluminum oxide thin film is formed, by an anodic oxidation processing, on an outer circumferential surface of a base body
Implementation Method 2
a heating process is performed on a surface of the aluminum oxide thin film
Implementation Method 3
a resin coat layer is formed, by a dipping method, on the surface of the aluminum oxide thin film after the heating process
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. The roller main body includes an aluminum oxide thin film and a resin coat layer, the aluminum oxide thin film being formed on an outer circumferential surface of a base body that is made of a metal including aluminum, the resin coat layer being formed on a surface of the aluminum oxide thin film that has been subjected to a predetermined heating process, the resin coat layer being made of a resin material and having electric conductivity.