Abrasive-Coated Foam Cleaner Roller for Photoconductor Residue Removal
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Solution Overview
Problem
In electrophotographic printing processes, residues formed from the oxidation of cleaning fluids and ink components on the photoconductor surface cause severe print quality issues, requiring frequent downtime for cleaning or replacement of the photoconductor.
Innovation Solution
A cleaner roller with an open-celled foam material coated with abrasive particles and a binder, formed from an isocyanate and polyol, is used to effectively remove contaminants from the photoconductor surface, increasing the number of print cycles before maintenance is needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a photoconductor is used in electrophotographic printing, then print quality is maintained, but residues from oxidation of cleaning fluids and ink components accumulate on the surface over time, requiring frequent cleaning or replacement
Solution Approach 1:
The patent applies preliminary action by incorporating a cleaner roller that continuously removes residues from the photoconductor surface during the printing process. The cleaner roller, positioned in the printing path, proactively prevents residue accumulation rather than waiting for periodic maintenance, thereby extending the operational duration before cleaning or replacement is needed.
Solution Approach 2:
The cleaner roller enables continuous cleaning action throughout the printing operation. By integrating the cleaning function into the continuous printing process, the system maintains photoconductor surface cleanliness without interrupting production, thus reducing downtime while preserving print quality over extended periods.
2Reliability
If cleaning is performed frequently to maintain print quality, then residue accumulation is reduced, but productivity decreases due to increased downtime
Solution Approach 1:
The cleaner roller operates autonomously within the printing system, continuously cleaning the photoconductor surface without requiring external intervention or system shutdown. This self-service cleaning mechanism maintains print quality while allowing the printing process to proceed uninterrupted, thereby maximizing productivity and the number of print cycles.
Solution Approach 2:
The cleaning action continues uninterrupted throughout the printing operation, ensuring consistent photoconductor surface cleanliness. This continuous cleaning enables the system to maintain high print quality over a greater number of print cycles without requiring periodic stops for maintenance, thus improving overall productivity.
3Reliability
If an abrasive cleaner is used to remove residues, then cleaning effectiveness increases, but risk of photoconductor surface damage increases
Solution Approach 1:
The cleaner roller applies abrasive particles locally and selectively to the photoconductor surface only where residues are present. The controlled application of abrasives in the nip region between the cleaner roller and photoconductor ensures effective residue removal while limiting abrasive exposure to minimal necessary areas, thereby reducing the risk of surface damage.
Solution Approach 2:
The cleaner roller incorporates a porous structure that allows for controlled distribution of abrasive particles. The porous material enables gradual release and uniform dispersion of abrasives, preventing concentrated abrasive application that could cause surface damage while maintaining effective cleaning action on residue-contaminated areas.
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 cleaner roller significantly reduces the frequency of downtime by efficiently removing residues and maintaining print quality over a larger number of cycles without damaging the photoconductor surface.
Implementation Method 1
an open-celled foam material having thereon a coating comprising abrasive particles and a binder
Implementation Method 2
a cleaner roller with an open-celled foam material coated with abrasive particles and a binder, formed from an isocyanate and polyol, is used to effectively remove contaminants from the photoconductor surface
Data Source
Figure 1~2
Figure 3~4
AI summary
Herein is described a liquid electrophotographic a printing apparatus comprising: a photoconductor; a liquid electrophotographic ink developer unit for applying liquid electrophotographic ink to the photoconductor; a cleaner roller contactable with the photoconductor, the cleaner roller comprising an open-celled foam material having thereon a coating comprising abrasive particles and a binder. Also described herein is a cleaner roller for cleaning a liquid electrophotographic printing apparatus' photoconductor and a method of operating a liquid electrophotographic printing apparatus using a cleaner roller described herein.