Heating Roller Particle Scattering Control
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Solution Overview
Problem
The existing heating rollers in electro-photographic systems suffer from the scattering of minute particles with a mean particle size of not more than 300 nm from the elastic layer, which is undesirable and needs to be suppressed to ensure effective thermal fixing of toner images onto recording media.
Innovation Solution
A heating roller configuration with a cylindrical core bar, a rubber layer, and a release layer, where the core bar is heated to a temperature within a specific range to minimize the scattering of minute particles, and a method for producing such a roller involving resin composite and secondary curing to control particle scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heating roller is heated to a temperature within the fixing temperature range including the minute particle-scattering start temperature, then the toner image can be fixed to the paper, but minute particles scatter from the elastic layer
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition and physical properties of the elastic layer. Specifically, it controls the glass transition temperature (Tg) to be -50°C to -100°C and adjusts the hydroxyl value to 1-10 mg KOH/g, which changes the molecular mobility and thermal behavior of the elastic layer, thereby suppressing particle scattering at fixing temperatures
Solution Approach 2:
The patent uses composite materials by combining specific polymers with controlled molecular structures. The elastic layer is formulated as a composite system with specific Tg characteristics and hydroxyl content, creating a material that maintains structural integrity at fixing temperatures while preventing particle scattering
2Productivity
If the heating roller operates at high temperature for effective thermal fixing, then the toner image is properly fixed, but the scattering of minute particles increases
Solution Approach 1:
The patent changes the thermal parameters of the elastic layer by controlling the glass transition temperature to -50°C to -100°C range. This parameter modification allows the elastic layer to maintain dimensional stability and suppress particle scattering even when the heating roller operates at high temperatures for efficient thermal fixing
3Object-generated harmful factors
If the elastic layer is made more resistant to particle scattering, then minute particle scattering is suppressed, but the manufacturing complexity increases
Solution Approach 1:
The patent simplifies the manufacturing approach by focusing on parameter control during rubber synthesis rather than adding complex post-processing steps. By controlling the glass transition temperature and hydroxyl value during the elastomer synthesis stage, the patent achieves particle scattering suppression through material design rather than complex manufacturing processes
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 proposed solution effectively suppresses the scattering of minute particles, ensuring reliable thermal fixing of developers onto recording media by maintaining a low particle density, thereby enhancing the performance of the heating roller in electro-photographic systems.
Implementation Method 1
the heating roller is heated to a temperature within a fixing temperature range including a minute particle-scattering start temperature
Implementation Method 2
density of the minute particles measured by a test is less than 2,000 pieces/cm3... suppressing the scattering of the minute particles from the rubber layer
Data Source
AI summary
A heating roller includes: a core bar having a cylindrical shape; a rubber layer arranged on an outer circumferential surface of the core bar; and a release layer arranged on an outer circumferential surface of the rubber layer, wherein when thermally fixing a developer on a recording medium, the heating roller is heated to a temperature within a fixing temperature range including a minute particle-scattering start temperature at which minute particles start to scatter from the rubber layer. The heating roller is arranged inside a casing which is connected to a minute particle density measuring device; then the core bar of the heating roller inside the casing is heated to 230° C. by a heater; and when the density of the minute particles inside the casing is measured after elapse of 20 minutes since start of the heating, the density of the minute particles is less than 2,000 pieces/cm3.