Helical Foam Cleaning Roller Bonding to Prevent End Peeling
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Solution Overview
Problem
The existing cleaning members for image forming apparatuses face issues with peeling of the foamed elastic layer from the core, especially under high-temperature conditions, leading to deficient cleaning and image defects such as density unevenness due to weakened bonding forces over time.
Innovation Solution
A cleaning member design featuring a foamed elastic layer wound in a helical form around a core with a bonding layer, where the area of the foamed elastic layer contacting the core is increased to 35% or more by area ratio, enhancing the bonding force and suppressing peeling, even under high-temperature storage conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the foamed elastic layer is wound helically around the core, then the cleaning performance is improved through better contact, but the bonding layer area at the ends is reduced leading to peeling
Solution Approach 1:
The patent applies local quality by creating a dual-structure foamed elastic layer where the central portion maintains a loose helical winding for optimal cleaning contact, while the end portions are compressed to increase bonding layer contact area. This local differentiation allows the cleaning surface to maintain its helical structure for performance while the ends are modified locally to prevent peeling by increasing bonding area to 35% or more.
2Stability of the object's composition
If the bonding force is increased to prevent peeling, then the stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-compressing the end portions of the foamed elastic layer before final assembly, creating a permanent deformation that increases the bonding layer contact area. This preliminary compression action is performed during manufacturing, allowing the product to achieve enhanced bonding stability without requiring complex additional bonding mechanisms or processes during operation.
3Strength
If the foamed elastic layer is compressed to increase bonding area, then the bonding force is improved, but the cleaning elasticity is reduced
Solution Approach 1:
The patent resolves this contradiction through local quality differentiation: the end portions of the foamed elastic layer are compressed to increase bonding area and strength, while the central cleaning portion maintains its original helical winding structure and elasticity. This localized compression ensures that bonding force is enhanced where needed (at the ends) without compromising the cleaning elasticity of the main body that contacts the charging member.
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 enhanced bonding force prevents peeling of the foamed elastic layer from the core, maintaining effective cleaning performance and reducing image defects like density unevenness, ensuring consistent image quality.
Implementation Method 1
a foamed elastic layer (100B) disposed by winding a strip-shaped foamed elastic member (100C) on an outer peripheral surface of the core (100A) in a helical form
Data Source
AI summary
A cleaning member for an image forming apparatus, includes a core, a foamed elastic layer disposed by winding a strip-shaped foamed elastic member on an outer peripheral surface of the core in a helical form so as to extend from one end of the core to the other end, and a bonding layer for bonding the core and the foamed elastic layer together, wherein the area of a region within a surface at one or both ends at least in a longitudinal direction of the foamed elastic layer on a side facing the outer peripheral surface of the core, contacting the outer peripheral surface of the core via the bonding layer is substantially 35% or more by area ratio per unit area.