Electrophotographic Feed Roller Composition for Stable Resistance
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Solution Overview
Problem
Existing electrophotographic rollers experience significant changes in electrical resistance over time due to electric conduction, and their manufacturing processes are costly and complex.
Innovation Solution
An electrophotographic roller with a conductive layer comprising polyurethane as a binder and electron conductive filler, featuring voids with inner walls made of polyurethane and electron conductive filler, maintains a phase delay of AC impedance at 10 degrees or less, reducing ion conductive current and stabilizing electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam rubber with carbon nanotubes is used as the electrophotographic roller, then conductivity is achieved, but electrical resistance increases over time due to ion conductive current
Solution Approach 1:
The patent changes the conduction mechanism parameter from ionic conduction to electronic conduction by using a conductive polymer composition. This transforms the electrical conduction type, eliminating the time-dependent resistance increase caused by ion migration while maintaining the necessary conductivity for the electrophotographic roller function.
Solution Approach 2:
The patent employs a composite material system consisting of conductive polymer particles, binder resin, and optionally inorganic filler particles. This composite structure combines the advantages of polymer flexibility with enhanced electrical conductivity, achieving stable electrical properties without the degradation issues of previous foam rubber-based solutions.
2Reliability
If dip coating is used to form conductive coat layer on skeleton and cell film, then conductivity is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent merges the substrate and conductive layer into a single integrated structure. The conductive polymer composition is mixed with the substrate material itself, eliminating the need for separate dip coating processes and multiple layers. This single-integrated approach reduces manufacturing steps while maintaining stable electrical resistance.
Solution Approach 2:
The patent extracts the complex multi-step dip coating process and replaces it with a simpler formulation approach. By incorporating conductive polymer particles directly into the substrate material during manufacturing, the need for subsequent coating and curing operations is eliminated, significantly reducing process 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 solution provides a roller with minimal electrical resistance variation over time, enabling high-quality image development and stable output, while being cost-effective to manufacture.
Implementation Method 1
the conductive layer has a skeleton comprising polyurethane as a binder and an electron conductive filler in the polyurethane
Implementation Method 2
when an electrode is brought into contact with an outer surface of the conductive layer and an AC voltage with an inter-peak voltage of 50 V is applied between the electrode and the surface of the substrate in a frequency range of 0.1 to 10 Hz, an absolute value of a phase delay θ of an AC impedance with respect to the AC voltage is 10 degrees or less
Data Source
AI summary
An electrophotographic roller comprising a substrate having a conductive surface and a conductive layer on the surface of the substrate, wherein the conductive layer is a surface layer of the electrophotographic roller, and has a skeleton comprising polyurethane and an electron conductive filler in the polyurethane, the conductive layer comprises at least one void, and at least a part of an inner wall of the void is configured of the skeleton, and when an electrode is brought into contact with an outer surface of the conductive layer and an AC voltage with an inter-peak voltage of 50 V is applied between the electrode and the surface of the substrate in a frequency range of 0.1 to 10 Hz, an absolute value of a phase delay θ of an AC impedance with respect to the AC voltage is 10 degrees or less.