Elastic Roller Coating Streak Prevention via Rotating Cleaning Member
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Solution Overview
Problem
The existing methods for manufacturing elastic rollers using circular coating heads often result in streaks on the surface of the coating film, particularly when multiple rollers are produced, due to coating material adhering to the downstream face of the coating head, leading to image failures in electrophotographic processes.
Innovation Solution
A process involving a cleaning step using a rotatable, elastically deformable cleaning member with a larger diameter than the center hole of the circular coating head is introduced, which effectively removes coating material from the downstream face before the next coating cycle, preventing streak formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a circular coating head is used to manufacture elastic rollers, then coating efficiency is improved, but streaks are generated on the coating film surface due to coating material adhering to the downstream face
Solution Approach 1:
The cleaning member is positioned to clean the downstream face of the circular coating head before the next coating operation begins. This preliminary cleaning action removes adhered coating material in advance, preventing it from being transferred to the next coating film and causing streaks, thus maintaining coating film surface quality while preserving high coating efficiency
Solution Approach 2:
A cleaning member is introduced as an intermediary element between the circular coating head and the coating material. This cleaning member selectively removes adhered coating material from the downstream face without interfering with the normal coating process, thereby preventing defect formation while maintaining productivity
2Productivity
If multiple elastic rollers are manufactured continuously, then productivity is improved, but streak generation increases due to accumulated coating material on the coating head
Solution Approach 1:
The cleaning member operates continuously or periodically between coating operations to maintain the downstream face of the circular coating head in a clean state. This continuous cleaning action ensures that each subsequent coating operation produces uniform coating films without streaks, enabling sustained high-quality production across multiple elastic rollers
Solution Approach 2:
The cleaning member performs periodic cleaning cycles between the manufacturing of different elastic rollers. This periodic intervention removes accumulated coating material at regular intervals, preventing defect accumulation and maintaining coating film uniformity throughout continuous production runs
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
This approach ensures that the elastic rollers are manufactured without streaks on the coating film surface, even at high coating speeds, thereby preventing image failures and maintaining the quality of electrophotographic outputs.
Implementation Method 1
the cleaning member being rotatable around the central axis of the circular coating head regarded as an approximate rotation center, having a rotation locus circle whose diameter is larger than a diameter of the center hole of the circular coating head, and being elastically deformable
Data Source
AI summary
Provided that a process for manufacturing an elastic roller having a mandrel and a coating film. The process comprise a first step of forming a coating film on an outer peripheral surface of a first mandrel, and a second step of forming a coating film on an outer peripheral surface of a second mandrel. The process further comprises a cleaning step between the steps. The cleaning step comprising: making a cleaning member arranged coaxially with the central axis of a circular coating head, in a downstream side in a moving direction of the first mandrel with respect to the circular coating head, making the cleaning member relatively approach the circular coating head; bringing a surface to be cleaned into contact with the cleaning member; rotating the cleaning member while the surface comes in contact with the cleaning member; and inserting the cleaning member into the center hole.