Charging Blade and Charge Roller Segmentation for Printer Reliability
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Solution Overview
Problem
The frequent replacement of conductive urethane charge rollers in printers due to material deterioration increases the cost per printed page, as the current through these rollers causes ion movement and eventual degradation, complicating efforts to extend their lifetime.
Innovation Solution
Implementing a charging blade that applies a primary charge to the photo imaging plate, reducing the charge roller's current and stress, allowing it to operate at lower currents (e.g., 10 μA) and extending its life, while the charging blade is less expensive and easier to replace, shifting the charge roller's role from primary charging to charge leveling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive urethane charge roller is used to uniformly charge the photo imaging plate, then the charging function is achieved, but the roller deteriorates over time due to ion movement caused by current flow
Solution Approach 1:
The charging function is divided into two separate components: a charging blade that performs the primary charging function, and a charge roller that performs only charge leveling. This segmentation allows the charge roller to operate at much lower currents, significantly reducing ion movement and material deterioration, thereby extending its lifetime.
Solution Approach 2:
The primary charging function is extracted from the charge roller and transferred to a separate charging blade. This removes the harmful high current flow from the charge roller, eliminating the main cause of material deterioration while preserving the necessary charging function through the blade.
2Productivity
If the charge roller operates at high current to provide uniform charge, then charging effectiveness is maintained, but replacement cost increases due to frequent replacement
Solution Approach 1:
By segmenting the charging function between a blade and a roller, the roller can operate at low current for charge leveling while the blade handles primary charging. This reduces wear on the roller, extending its lifespan from 500,000 to one million impressions and reducing replacement frequency and cost.
Solution Approach 2:
The charging blade is designed as a cheaper, more replaceable component that can be easily swapped when worn, while the more expensive charge roller is protected from high current stress and extended in life. This economic strategy optimizes overall system cost.
3Ease of operation
If the charge roller is used for primary charging, then the charging function is complete, but the roller stress and current increase causing deterioration
Solution Approach 1:
The charging operation is segmented into two stages: primary charging by the blade and charge leveling by the roller. This segmentation reduces the stress and current on the roller to minimal levels, making it suitable only for the leveling function while maintaining complete charging functionality.
Solution Approach 2:
The high-stress primary charging function is extracted from the roller and assigned to the blade. The roller retains only the low-stress charge leveling function, eliminating excessive stress and current that cause material deterioration.
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 significantly extends the useful life of charge rollers, reduces production and replacement costs, and maintains print quality, with charge rollers lasting up to one million impressions instead of 500,000, and decreases the cost per printed page by up to 6%.
Implementation Method 1
The conductive layer is charged and applies a charge to the photo imaging surface
Implementation Method 2
The insulating layer contacts a photo imaging surface at an angle to apply pressure to the photo imaging surface
Data Source
AI summary
Printer charging blades and printers are disclosed. An example charging blade for a printer includes an insulating layer to contact a photo imaging surface at an angle to apply pressure to the photo imaging surface, the pressure to control an amount of material present on the photo imaging surface, and a conductive layer attached to a side of the insulating layer, the conductive layer to be charged and to apply a first charge to the photo imaging surface.