Porous Foam Roller Toner Transfer Starvation Reduction
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Solution Overview
Problem
In image forming apparatuses, inadequate transfer of image forming substances like toner can lead to starvation, resulting in irregular printing patterns due to inefficient delivery mechanisms.
Innovation Solution
The use of a first roller with a surface capable of supplying toner and a second roller with a porous, electrically conductive surface in rotating contact, forming a nip with opposing surface speeds to enhance toner transfer and reduce starvation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional rollers are used to transfer image forming substance, then the device complexity is low, but the transfer efficiency is insufficient leading to starvation
Solution Approach 1:
The patent applies porous foam material for the second roller to improve image forming substance transfer. The porous structure allows the roller to effectively pick up and transfer toner particles from the sump to the developing location, resolving the starvation issue while maintaining reasonable device complexity.
Solution Approach 2:
The patent uses composite material construction where the second roller combines foam base material with electrically conductive additives. This composite approach enhances both the transfer efficiency and electrical properties needed for effective toner delivery without significantly increasing device complexity.
2Productivity
If the second roller is made with high porosity foam, then the image forming substance transfer is improved, but the electrical conductivity may be insufficient
Solution Approach 1:
The patent resolves this contradiction by creating a composite material where electrically conductive additives are incorporated into the porous foam structure. This allows the roller to simultaneously achieve high porosity for effective toner pickup and sufficient electrical conductivity for reliable charge transfer.
Solution Approach 2:
The patent applies local quality by concentrating electrically conductive additives in specific regions or at controlled concentrations within the foam matrix, optimizing both the porosity for transfer efficiency and the electrical conductivity for reliable operation in different functional zones of the roller.
3Productivity
If the surface speeds of the rollers are not optimized, then the device operation is simple, but starvation occurs due to inadequate toner supply
Solution Approach 1:
The patent applies dynamics by establishing specific speed ratio relationships between the first and second rollers. The system dynamically optimizes toner transfer by maintaining surface speed ratios within the range of 0.5-2.0, ensuring consistent toner supply to the developing location while avoiding starvation conditions.
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
This configuration effectively reduces toner starvation by maintaining a consistent toner supply, ensuring uniform printing quality by optimizing the surface speeds and porosity of the rollers.
Implementation Method 1
The second roller may comprise foam having greater than or equal to about 50 pores per inch
Implementation Method 2
The foam may be electrically conductive or contain electrically conductive additive
Implementation Method 3
A second roller may then be included having a surface in rotating contact with the first roller which second roller is capable of supplying image forming substance to the first roller
Data Source
AI summary
The present invention relates to a device or method which may reduce starvation in the transfer of an image forming substance to a developing location within an image forming apparatus. The device may include a first roller having a surface which is capable of supplying an image forming substance to a developing location. A second roller may then be included having a surface in rotating contact with the first roller. The second roller is capable of supplying image forming substance to the first roller. The second roller may comprise foam having a specified porosity, electrical conductivity, and/or be configured to rotate in a desired direction and/or desired speed relative to the first roller.