External Heat Roll Cleaning via Concurrent Picking Action
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Solution Overview
Problem
Current fusing systems are unable to effectively clean residual toner from the valleys of the rough surface of external heater rolls in copier/printers, leading to contamination and reduced functionality.
Innovation Solution
A cleaning roller with a textured outer surface and embedded sharp grit is used in contact with the external heat rollers, rotating concurrently to dislodge and displace contamination through a picking action rather than a wiping motion, ensuring maximum cleaning efficiency while minimizing wear and tear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If web cleaning is used to remove toner from the fuser roll surface, then the cleaning process is simple and continuous, but it cannot drive contamination out of the valleys of the rough surface
Solution Approach 1:
The cleaning system is divided into multiple independent elements: a rotatable cleaner roll with cleaning elements (brushes, belts, or films) that contact the fuser roll surface. This segmentation allows the cleaning elements to access and remove contamination from valleys and rough surface areas that a single web cannot reach, while maintaining a relatively simple overall system structure
Solution Approach 2:
A cleaner roll acts as an intermediary between the fuser roll and the contamination removal process. The cleaner roll with its textured surface and cleaning elements serves as a mediator that can effectively transfer and remove bonded toner particles from the fuser roll surface, including from difficult-to-reach areas
2Reliability
If conventional wiping motion is used to clean the external heat roll, then the cleaning action is continuous, but it causes undesirable wear and tear of the bristles
Solution Approach 1:
Instead of using a wiping motion where the cleaner passively rubs against the fuser roll surface, the system inverts the approach by using a picking action where the cleaner roll rotates concurrently with the fuser roll. The cleaning elements on the cleaner roll pick up contamination as they rotate together, significantly reducing wear on the bristles while maintaining effective cleaning
Solution Approach 2:
The cleaning system transitions from a static wiping motion to a dynamic concurrent rotation system. The cleaner roll rotates at the same speed as the fuser roll, creating a dynamic picking action that reduces friction and wear on the cleaning elements while maintaining continuous cleaning effectiveness
3Reliability
If additional cleaning stations are added to effectively clean the external heat roll, then cleaning effectiveness improves, but system complexity and cost increase
Solution Approach 1:
The cleaner roll is designed as a multi-functional element that can effectively clean the entire surface of the external heat roll, including valleys and rough areas, in a single cleaning station. This universal cleaning capability eliminates the need for multiple specialized cleaning stations, reducing system complexity while maintaining high cleaning effectiveness
Solution Approach 2:
The cleaning system is designed to be self-sufficient with a single cleaner roll that performs all necessary cleaning functions. The concurrent rotation and picking action mechanism allows one cleaning station to accomplish what would otherwise require multiple stations, reducing overall system complexity and cost
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 system effectively removes debris from the entire surface of the external heat roll, preventing contamination and maintaining the roll's functionality without the need for additional cleaning stations, thus reducing downtime and costs.
Implementation Method 1
A cleaning roller in contact with the external heat rollers designed to dislodge and displace contamination products that would otherwise accumulate on and in the external heat roller rough surface
Data Source
AI summary
According to aspects of the embodiments, there is provided an apparatus and method to maintain a clean and effective external heat roll surface in a printing system. The disclosed embodiment's uses a cleaning roller in contact with the external heat rollers designed to dislodge and displace contamination products that would otherwise accumulate on and in the external heat roller rough surface. The cleaning roller rotates concurrently with the heating roller so that the cleaning media cleans the roller from a picking action as opposed to a wiping motion. This provides maximum cleaning action with the undesirable wear and tear of the bristles that would occur with the conventional method of a wiping motion.