Metal Transfer Roller Nip and Liquid Developer for Image Quality
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Solution Overview
Problem
Image forming apparatuses using metal rollers face challenges in preventing abnormal discharge due to intermediate transfer belt undulation while also avoiding toner dropout, especially when the metal roller is used as the transfer member, as it increases peak pressure and risks dropout.
Innovation Solution
An image forming apparatus configuration that includes a photosensitive drum, a developing device using a liquid developer, and a metal transfer roller with a physical nip formed between the transfer roller and the photosensitive drum, which reduces toner cohesion and prevents undulation-induced abnormal discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transfer member is offset with respect to the image bearing member to prevent dropout, then the risk of dropout is reduced, but the intermediate transfer belt undulates causing abnormal discharge and image quality degradation
Solution Approach 1:
A liquid developer is introduced as an intermediary substance between the image bearing member and transfer member. The liquid developer fills the gap caused by belt undulation, preventing abnormal discharge while allowing the transfer member to remain offset, thus simultaneously preventing dropout and maintaining image quality
2Manufacturing precision
If the intermediate transfer belt is nipped between the transfer member and image bearing member to eliminate undulation, then abnormal discharge is prevented, but peak pressure increases causing dropout
Solution Approach 1:
The physical state of the developer is changed from dry to liquid. The liquid developer's fluidity allows it to flow into and fill the gap caused by belt undulation, reducing the effective contact pressure on the toner image while maintaining belt contact, thus preventing both dropout and abnormal discharge
3Duration of action of stationary object
If a metal roller is used as the transfer member, then device durability is improved, but the increased peak pressure causes dropout
Solution Approach 1:
The liquid developer acts as a pressure-distributing intermediary between the hard metal transfer member and the toner image. It fills gaps and distributes pressure more evenly, reducing peak pressure on the toner while allowing the use of durable metal rollers
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 solution effectively prevents both abnormal discharge and toner dropout by forming a physical nip between the metal transfer roller and the photosensitive drum, maintaining image quality and reducing surface resistivity variations in the intermediate transfer belt.
Implementation Method 1
a liquid developer which contains a toner particle and a carrier liquid... due to a reduction in toner particle size, the liquid developer provides higher image quality compared to the dry developer
Implementation Method 2
a transfer roller... configured to apply a transfer bias to transfer the toner image, which is formed on the photosensitive drum, onto the intermediate transfer belt
Data Source
AI summary
An image forming apparatus includes an image bearing member on which a toner image is formed by a liquid developer containing a toner particle and a carrier liquid, an intermediate transfer belt onto which the toner image is transferred, and a transfer member configured to transfer the toner image from the image bearing member onto the intermediate transfer belt. The transfer member is made of a metal, and the transfer member abuts against the image bearing member with the intermediate transfer belt nipped therebetween.