Multilayer Intermediate Transfer Belt for Image Forming Apparatus
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Solution Overview
Problem
Existing image forming apparatuses with single-layer intermediate transfer belts face challenges in achieving balanced toner transfer efficiency, extended belt life, and preventing uneven image density, especially when using special sheets with lower surface smoothness.
Innovation Solution
A multilayered intermediate transfer belt is introduced, comprising a rigid base layer and an elastic layer to enhance contact with photoconductors and conform to sheet surfaces, along with a surface coating layer to improve toner transfer efficiency and prevent elongation, while maintaining stable electrical resistance for consistent primary transfer current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-layer intermediate transfer belt is used, then the device complexity is low, but the toner transfer efficiency is insufficient and image density becomes uneven
Solution Approach 1:
The patent applies composite materials by constructing the intermediate transfer belt with multiple layers: a base layer providing mechanical strength and an upper layer with optimized electrical resistance properties. This composite structure enables both high toner transfer efficiency and stable electrical resistance, resolving the contradiction between transfer quality and structural simplicity.
Solution Approach 2:
The patent implements local quality by creating layers with different properties: the base layer provides structural support while the upper layer is specifically designed with controlled electrical resistance (10^8 to 10^15 Ω·cm) to optimize toner transfer. Each layer performs its specific function, achieving high transfer efficiency without requiring the entire belt structure to be complex.
2Reliability
If the electrical resistance of the intermediate transfer belt is increased to prevent discharge, then the belt life is extended, but the primary transfer current becomes unstable
Solution Approach 1:
The patent applies parameter changes by precisely controlling the electrical resistance of the intermediate transfer belt within the range of 10^8 to 10^15 Ω·cm. This optimized resistance value prevents discharge and extends belt life while maintaining stable primary transfer current, resolving the contradiction between reliability and current stability.
Solution Approach 2:
The composite belt structure with controlled electrical resistance properties in the upper layer enables the belt to maintain stable electrical characteristics during operation, ensuring consistent primary transfer current while preventing discharge-induced degradation and extending service life.
3Manufacturing precision
If a rigid intermediate transfer belt is used, then the belt maintains dimensional accuracy, but it cannot conform to sheet surfaces with low smoothness
Solution Approach 1:
The patent implements local quality by creating a multi-layer structure where the base layer provides rigid dimensional stability while the upper layer with controlled electrical resistance adapts to surface irregularities. This allows the belt to maintain dimensional accuracy while conforming to sheets with varying surface smoothness, including those with lower smoothness.
4Adaptability or versatility
If the intermediate transfer belt is made more elastic to conform to surfaces, then surface adaptability improves, but the belt elongation increases reducing its life
Solution Approach 1:
The patent applies composite materials by combining a rigid base layer that prevents excessive elongation and maintains belt life with an upper layer that provides surface conformability. This composite structure enables the belt to adapt to various sheet surfaces while maintaining dimensional stability and extending service life through controlled elasticity.
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 multilayered belt achieves desirable toner transfer rates and extended life while reducing the likelihood of uneven image density, even on sheets with low surface smoothness, by ensuring stable primary transfer current and conforming to surface irregularities.
Implementation Method 1
with a surface coating layer to improve toner transfer efficiency and prevent elongation, while maintaining stable electrical resistance for consistent primary transfer current
Implementation Method 2
comprising a rigid base layer and an elastic layer to enhance contact with photoconductors and conform to sheet surfaces
Data Source
Figure 1~3
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Figure 6~7
AI summary
An image forming apparatus (500) includes a plurality of image bearers (1); a plurality of image forming devices (6); an endless belt (8) including a plurality of layers and disposed in contact with the plurality of image bearers (1) to form transfer nips; and a plurality of transfer bias members (9), to each of which a transfer bias is applied in a state in which the transfer bias member (9) sandwiches the endless belt (8) together with one of the plurality of image bearers (1). The plurality of transfer bias members (9) includes an upstream transfer bias member (9Y) and a downstream transfer bias member (9K) respectively located extreme upstream and extreme downstream in a sequence of transfer process, and the downstream transfer bias member (9K) is lower in electrical resistance than the upstream transfer bias member (9Y).