Double-Layer Cleaning Blade for Electrophotographic Apparatus
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Solution Overview
Problem
Electrophotographic image forming apparatuses face challenges in maintaining effective toner removal and reducing noise and fatigue in cleaning blades, as single-layer blades either fatigue quickly or produce noise due to high elastic power, while lower elastic power blades lead to defective cleaning.
Innovation Solution
A double-layer cleaning blade with an edge layer of lower elastic power and a backup layer of higher elastic power, where the backup layer is thicker and more elastic, absorbs vibrations and reduces plastic deformation, thereby suppressing noise and fatigue.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single-layer cleaning blade with high elastic power is used, then cleaning capability is improved, but noise and fatigue increase
Solution Approach 1:
The cleaning blade is divided into two distinct layers: an edge layer with lower elastic power (30-80 shore A) that contacts the photoconductor to reduce noise and fatigue, and a backup layer with higher elastic power (70-95 shore A) that provides the necessary cleaning capability. This segmentation allows each layer to perform its specific function optimally without the drawbacks of a single-layer design.
Solution Approach 2:
Different regions of the blade are assigned different elastic power characteristics. The edge layer has lower elastic power specifically at the contact surface to minimize noise and fatigue during operation, while the backup layer has higher elastic power to maintain effective toner removal. This local differentiation of material properties resolves the contradiction between cleaning effectiveness and noise/fatigue generation.
2Object-generated harmful factors
If a single-layer cleaning blade with low elastic power is used, then noise and fatigue are reduced, but cleaning capability deteriorates
Solution Approach 1:
The blade structure separates the functions of noise reduction and cleaning into two layers. The edge layer with lower elastic power handles the noise and fatigue aspect, while the backup layer with higher elastic power ensures adequate cleaning capability is maintained through its proximity to and support of the edge layer.
Solution Approach 2:
The cleaning blade uses a composite structure combining two rubber materials with different elastic power characteristics. This composite design allows the blade to exhibit both low noise/fatigue properties (from the softer edge layer) and high cleaning capability (from the more elastic backup layer), resolving the contradiction between these opposing requirements.
3Duration of action of moving object
If a double-layer blade with backup layer of higher elastic power is used, then operational life is extended, but device complexity increases
Solution Approach 1:
While the blade is segmented into two layers, the manufacturing process uses a single-mold co-molding technique that integrates both layers in one operation. This approach extends operational life through the functional benefits of the dual-layer structure while minimizing the increase in manufacturing complexity by combining the layer formation process.
Solution Approach 2:
The invention optimizes specific parameters including the elastic power range of each layer, their thickness ratios, and hardness differences to achieve the desired balance between extended operational life and manageable complexity. By carefully controlling these parameters within specific ranges, the design achieves maximum benefit with minimum added complexity.
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 double-layer blade design enhances the operational life and reliability of the cleaning process by reducing noise and maintaining effective toner removal, while preventing both fatigue and defective cleaning.
Implementation Method 1
the backup layer is greater in elastic power than the edge layer... absorbs vibrations and reduces plastic deformation, thereby suppressing noise and fatigue
Implementation Method 2
a cleaning device removes toner remaining on the surface of the image bearer... The edge layer includes a contact edge to contact a contact object
Data Source
AI summary
An elastic blade may include an edge layer and at least one backup layer laminated on the edge layer. The edge layer may include a contact edge to contact a contact object and an opposing face to oppose the contact object, and the backup layer may be greater in elastic power than the edge layer.