Endless Belt Conductive Particle Size Distribution Control
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Solution Overview
Problem
Existing endless belts with conductive carbon particles tend to experience local discharge when a voltage is applied due to the presence of large-diameter particles, which can cause current to flow through unintended paths, leading to inefficiencies in conductive paths.
Innovation Solution
A single-layer endless belt with a resin and particles having an average primary particle diameter of 8 nm to 20 nm, where the ratio of particles with diameters over 35 nm is limited to 0.3 or less in volume frequency distribution, or 70% or more by volume in cumulative undersize distribution, reducing the occurrence of local discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional endless belts with conductive carbon particles are used, then conductivity is achieved, but local discharge occurs due to large-diameter particles
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution of conductive carbon particles. Specifically, it limits the ratio of particles with diameters over 35 nm to 0.3 or less in volume frequency distribution, and ensures 70% or more by volume in cumulative undersize distribution. This parameter optimization resolves the contradiction by eliminating large-diameter particles that cause local discharge while maintaining manufacturing feasibility through established particle control techniques.
Solution Approach 2:
The patent applies local quality by ensuring uniform distribution and controlled local concentration of conductive carbon particles with specific size characteristics. By controlling the particle size distribution locally within the endless belt structure, the patent prevents local discharge phenomena while maintaining overall conductivity, addressing the contradiction between reliability and manufacturing precision.
2Reliability
If particles with larger diameter are used, then conductivity may be improved, but local discharge increases due to unintended current paths
Solution Approach 1:
The patent applies the extraction principle by removing or eliminating large-diameter particles (over 35 nm) from the conductive carbon particle population. By extracting these harmful particles that cause local discharge and unintended current paths, the patent maintains conductivity through properly sized particles while eliminating the harmful effect of local discharge, thus resolving the contradiction between conductive path efficiency and harmful factors.
Solution Approach 2:
The patent converts the potential harm of particle size variation into a benefit by establishing specific particle size distribution criteria. Instead of allowing arbitrary particle sizes, the patent defines optimal ranges (8-20 nm average primary particle diameter) that prevent local discharge while ensuring efficient conductivity, transforming the constraint into an advantage for both reliability and conductive path 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 described configuration effectively suppresses local discharge when a voltage is applied, ensuring that current flows through the intended conductive path and reducing the ratio of coarse particles, thereby enhancing the belt's conductivity and operational efficiency.
Implementation Method 1
a single-layer type endless belt containing a resin and particles having an average primary particle diameter of 8 nm or more and 20 nm or less, and when a voltage is applied, the endless belt suppresses local discharge
Data Source
AI summary
An endless belt includes a resin, and particles having an average primary particle diameter of 8 nm or more and 20 nm or less. In a volume frequency distribution of the particles determined by small-angle X-ray scattering measurement, the ratio (area B/area A) of graph area B of a particle diameter region of over 35 nm to graph area A of a particle diameter region of 35 nm or less is 0.3 or less.