Rigid Blade Coating for Image Carrier Cleaning
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Solution Overview
Problem
Blade cleaning in image forming apparatuses with elastic intermediate transfer belts experiences abrasion and reduced cleaning performance due to external toner additives, particularly silica, leading to scratches and degradation of the belt, as existing coatings alter the blade's shape and increase friction.
Innovation Solution
A rigid blade with a metal base and a coating layer, where the coating is applied only to the edge portion that contacts the intermediate transfer belt, and the upstream edge has a rounded shape with a curvature less than the average radius of toner particles to reduce friction and abrasion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the blade is coated with a harder material to reduce abrasion powder, then the blade resistance to abrasion is improved, but the blade shape changes and cleaning performance deteriorates
Solution Approach 1:
The coating layer is applied selectively only to the edge portion of the blade that contacts the intermediate transfer belt, rather than the entire blade surface. This localized coating approach protects the contact area from abrasion while preserving the original shape and cleaning performance characteristics of the uncoated blade portions.
Solution Approach 2:
The blade edge is rounded before the coating layer is formed on it. This preliminary shaping ensures that the final coated blade maintains the desired rounded edge geometry, preventing shape distortion that would occur if coating were applied to a sharp edge and then rounded afterward.
2Area of stationary object
If the blade edge is made planar to improve contact area, then cleaning coverage is improved, but friction increases and abrasion worsens
Solution Approach 1:
The upstream part of the blade edge is formed with a rounded shape having a specific radius of curvature (0.1 mm to 1.0 mm) instead of a planar or sharp edge. This curvature reduces the contact area to a line or narrow band, thereby reducing friction and abrasion while still maintaining effective cleaning contact with the intermediate transfer belt.
3Use of energy by moving object
If a rigid blade is used to reduce belt driving torque, then energy consumption is reduced, but abrasion powder increases and belt damage occurs
Solution Approach 1:
The blade is constructed as a composite structure with a metal base material providing rigidity and low driving torque, combined with a harder coating layer applied to the edge portion that resists abrasion from silica in toner. This composite structure maintains the energy efficiency benefits of rigid blades while eliminating the abrasion powder problem.
Data Source
AI summary
A cleaning apparatus cleans an image carrier including an elastic layer after a toner image formed on the image carrier is transferred to a transfer material. The cleaning apparatus includes a rigid blade that cleans a residue attached on a surface of the image carrier by contacting the image carrier from which the toner image has been transferred to the transfer material. The rigid blade includes a metal base and a coating layer formed on a surface of the metal base. The coating layer is disposed at least at an edge portion of the base that contacts the image carrier. An upstream part of the edge portion has a rounded shape with a radius of curvature that is less than an average radius of toner particles.