Photoconductor Surface Texture for Cleaning Blade Friction Control
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Solution Overview
Problem
Image forming apparatuses face issues with degradation of output images due to blackened photoconductor surfaces, leading to frequent replacements, which increases costs and environmental impact, primarily caused by the stick-slip motion between the cleaning blade and the photoconductor.
Innovation Solution
A photoconductor with a specific surface texture is developed, characterized by particular arithmetical mean roughness values, achieved through multi-resolution analysis and wavelet conversion, to stabilize the contact between the cleaning blade and the photoconductor, reducing background fouling and extending the life of the photoconductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cleaning blade is pressed against the photoconductor to scrape off toner, then cleaning performance is improved, but the blade edge deforms and causes stick-slip motion leading to background fouling
Solution Approach 1:
The invention changes the physical parameter of the photoconductor surface by controlling the surface roughness of the electroconductive substrate to a specific range (Ra 0.03-0.07 μm). This parameter change modifies the friction characteristics between the cleaning blade and photoconductor, preventing stick-slip motion while maintaining effective toner removal, thus resolving the contradiction between cleaning performance and background fouling prevention
Solution Approach 2:
The invention applies local quality control by specifically treating the surface roughness of the electroconductive substrate differently from other components. By creating a uniform, controlled roughness pattern only on the photoconductor surface, the invention locally modifies the interaction zone between the cleaning blade and photoconductor to eliminate stick-slip motion without affecting overall cleaning effectiveness
2Object-affected harmful factors
If the photoconductor surface is made smoother to reduce friction, then stick-slip motion is reduced, but cleaning performance deteriorates
Solution Approach 1:
The invention identifies and controls the critical parameter of surface roughness within an optimal range (Ra 0.03-0.07 μm). This precise parameter control creates a balance where the surface is smooth enough to prevent stick-slip motion but maintains sufficient micro-texture for effective toner scraping, resolving the contradiction between reducing friction and maintaining cleaning performance
3Measurement precision
If the photoconductor is replaced frequently to maintain image quality, then image quality is maintained, but cost and environmental impact increase
Solution Approach 1:
The invention applies preliminary action by pre-controlling the surface roughness of the electroconductive substrate during manufacturing to a specific range (Ra 0.03-0.07 μm). This preliminary optimization of the surface structure prevents stick-slip motion and background fouling from occurring in the first place, thereby extending photoconductor life and reducing replacement frequency while maintaining image quality
Solution Approach 2:
The invention converts the potentially harmful effect of surface friction into a beneficial controlled interaction. By carefully controlling the surface roughness, the friction between the cleaning blade and photoconductor is optimized to prevent stick-slip motion, transforming what could be a harmful force into a controlled mechanism that extends photoconductor durability while maintaining cleaning effectiveness
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 photoconductor with the optimized surface texture effectively reduces background fouling, enhancing durability and maintaining image quality over an extended period, thereby reducing the need for frequent replacements and improving environmental performance.
Implementation Method 1
a photosensitive layer provided overlying the electroconductive substrate
Implementation Method 2
The edge of the blade is provided to be in contact with a photoconductor under constant load (pressure)
Data Source
AI summary
Disclosed herein is a photoconductor containing an electroconductive substrate and a photosensitive layer, wherein, in a curve obtained by the steps (I) through (V) described herein, a surface of the photosensitive layer has a WRa (LML) of from 0.02 μm to 0.03 μm, a WRa (LHL) of from 0.006 μm to 0.01 μm, and a WRa (HLH) of 0.001 μm or less, where the arithmetical mean roughness (WRa) are defined as Ra in JIS-B0601:2001 and WRa (HHH) to WRa (LLL) represent individual Ra's as described herein.