Image Developer Cleaning Roller Design for Ink Residue Removal

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Solution Overview

Problem

The wiper blade in conventional liquid electro-photographic (LEP) printer image developer units wears down and scratches the cleaning roller, leading to defects and reduced print quality, necessitating frequent replacements.

Innovation Solution

A new image developer design replaces the wiper blade with a denser, more abrasive sponge roller that mechanically removes ink residue from the cleaning roller, optimizing its density and contact area to effectively scrub the surface without causing scratches, and absorbs ink residue, eliminating the need for a squeezer roller.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If a wiper blade is used to remove ink residue from the cleaning roller, then ink removal is achieved, but the cleaning roller surface is scratched and banding defects occur

Engineering Contradiction:

Improveink residue removalVSAvoidcleaning roller surface damage

Core Design Contradiction:

Loss of substanceVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical wiper blade system with an electrical field-based cleaning mechanism. A charged cleaning roller uses electrostatic forces to attract and remove ink residue from the developer roller, eliminating the mechanical contact that causes surface damage and banding defects.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a charged cleaning roller as an intermediary between the developer roller and the ink residue. This intermediary uses its electrical charge to mediate the removal process, allowing ink residue to be transferred to the cleaning roller without direct mechanical scraping that would damage surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Loss of substance

If a wiper blade and squeezer roller are used for cleaning, then ink residue is removed, but device complexity increases

Engineering Contradiction:

Improveink residue removalVSAvoidcleaning mechanism structure

Core Design Contradiction:

Loss of substanceVSDevice complexity

Solution Approach 1:

The patent merges the functions of the wiper blade and squeezer roller into a single charged cleaning roller. This consolidation integrates ink residue removal and surface cleaning into one component, reducing the number of parts and simplifying the overall cleaning mechanism structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The charged cleaning roller performs multiple functions simultaneously: it removes ink residue from the developer roller, cleans its own surface, and prepares the developer roller for the next imaging cycle. This multi-functionality eliminates the need for separate wiper and squeezer components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Loss of substance

If a wiper blade is used to clean the cleaning roller, then ink residue is removed, but power consumption increases due to friction

Engineering Contradiction:

Improveink residue removalVSAvoidmotor power consumption

Core Design Contradiction:

Loss of substanceVSUse of energy by moving object

Solution Approach 1:

The patent replaces the high-friction mechanical wiper blade contact with an electrical field-based interaction. The charged cleaning roller removes ink residue through electrostatic attraction rather than mechanical friction, significantly reducing the torque and power required from the drive motor.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution prolongs the life of the image developer, improves print quality by eliminating banding defects, and reduces costs through simpler design and lower power consumption, as well as extending the useful life of the developer unit.

Implementation Method 1

a so-called "sponge" roller that rotates against the cleaning roller

Methodology Applied

Scientific EffectFriction: Friction

Implementation Method 2

absorbs ink residue

Methodology Applied

Scientific EffectAbsorption: Absorption (physical)

Implementation Method 3

Residual ink is removed from the developer roller electrically using a charged cleaning roller

Methodology Applied

Scientific EffectElectrostatic attraction: Electrostatics

Data Source

PatentUS8224210B2Image developer for presenting ink to a photoconductor

Publication Date: 2012.07.17 HEWLETT PACKARD DEVELOPMENT COMPANY LP

AI summary

In one embodiment, an image developer includes a developer roller rotatable along a photoconductor for presenting a layer of ink to the photoconductor and a cleaner for cleaning ink from the developer roller. The cleaner includes a first cleaning roller rotatable along the developer roller for removing ink from the developer roller and a second cleaning roller rotatable against the first cleaning roller for mechanically removing ink from the first cleaning roller. In one embodiment, the second cleaning roller deforms against the first cleaning roller such that the cross-sectional length of contact between the first and second cleaning rollers is in the range of 20% to 38% of the circumference of the first cleaning roller. In one embodiment, the second cleaning roller has a density in the range of 90 kg/m3 to 150 kg/m3.