Electro-conductive Elastic Layer with Dual Rubber Phase
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Solution Overview
Problem
Electrophotographic electro-conductive members experience variations in electric resistance values due to mechanical stress, leading to unstable charging performance and image defects, especially under low temperature and humidity conditions.
Innovation Solution
An electro-conductive member with an elastic layer containing a matrix of first rubber and dispersed electro-conductive domains, where regions of second rubber are arranged around the domains, maintaining a specific elastic coefficient relationship (R1 < R2) to reduce mobility and maintain conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If electro-conductive particles are dispersed in a single-phase rubber matrix, then the electro-conductive member can be manufactured with simple structure, but the electric resistance value varies due to particle mobility under mechanical stress
Solution Approach 1:
The electro-conductive layer is segmented into multiple functional domains: a first rubber phase containing electro-conductive particles for conductivity, and a second rubber phase providing elastic restraint. This segmentation prevents particle mobility while maintaining electrical pathways, resolving the contradiction between structural simplicity and resistance stability.
Solution Approach 2:
Different regions of the electro-conductive layer are assigned different qualities: the first rubber phase provides electro-conductivity through particle dispersion, while the second rubber phase provides elastic properties and particle constraint. This local differentiation allows each phase to optimize its function without compromising the other.
2Reliability
If electro-conductive particles are dispersed in rubber matrix, then the electro-conductive member can maintain basic conductivity, but the dispersed state changes under compression causing resistance value variation
Solution Approach 1:
The second rubber phase acts as a pre-established cushioning matrix that restrains electro-conductive particles before mechanical stress is applied. This beforehand constraint prevents particle aggregation or displacement during compression, maintaining both conductivity and dispersed state stability.
3Ease of manufacture
If conventional electro-conductive members are used, then manufacturing is straightforward, but image defects occur under low temperature and humidity conditions due to resistance variation
Solution Approach 1:
The electro-conductive layer uses a composite rubber system with two distinct rubber phases, each contributing specific properties. The first rubber phase ensures conductivity while the second rubber phase provides environmental stability, preventing image defects under varying temperature and humidity conditions while maintaining manufacturability.
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 effectively stabilizes the electric resistance value over time, preventing changes in charging performance and reducing image defects, ensuring high-quality electrophotographic images.
Implementation Method 1
melting and kneading an electro-conductive elastic layer-forming rubber mixture
Implementation Method 2
high shearing device equipped with a return screw
Implementation Method 3
curing the layer of the molten and kneaded product
Implementation Method 4
electro-conductive domains dispersed in the matrix; each of the electro-conductive domains contains an electro-conductive particle
Data Source
AI summary
An electrophotographic electro-conductive member comprising an electro-conductive mandrel and an electro-conductive elastic layer on the electro-conductive mandrel, wherein the electro-conductive elastic layer has an elastic coefficient of 1 MPa or more and 100 MPa or less, as well as a matrix containing first rubber and a plurality of electro-conductive domains dispersed in the matrix. Each of the electro-conductive domains contains an electro-conductive particle, and the electro-conductive elastic layer includes regions containing second rubber in the circumferences of the electro-conductive domains. The matrix has an elastic coefficient R1, the regions containing second rubber have an elastic coefficient R2, and the elastic coefficients R1 and R2 satisfy a relationship: R1<R2.