Conductive Roller End Filler Layer for Cut Waste Suppression
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Solution Overview
Problem
In image formation devices, the contact between a developing roller and other members can lead to cut waste generation, causing image failures due to the scraping of the roller's ends, which then transfer to the photosensitizer or paper.
Innovation Solution
A conductive roller with a filler layer made of a material having a breaking strain of at least 120% and tensile stress at 100% elongation between 5 to 30 N/mm², preferably using a water-based urethane resin with a silicone-based additive, is applied to the axial ends to prevent scraping and ensure durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a developing roller is mounted on a cartridge with a ring-shaped member disposed coaxially at an axial end to maintain contact width, then the contact width (nip width) between the roller and photosensitizer is kept constant, but the ring-shaped member and the end of the roller come into contact and rub against each other during use, causing the end of the roller to be scraped and generate cut waste
Solution Approach 1:
A filler layer is pre-applied to the axial end face of the roller before mounting. This preliminary protective layer prevents the base layer material from being scraped off during contact with the ring-shaped member, thereby preventing cut waste generation while maintaining the necessary contact width for image formation.
Solution Approach 2:
The filler layer acts as a sacrificial protective layer that can be consumed or worn down without affecting the underlying base layer. This disposable protective coating prevents damage to the main roller structure, allowing the filler layer to be replaced or worn away while protecting the essential roller components.
2Reliability
If the end of the roller is scraped due to contact with the ring-shaped member, then cut waste is generated, but this cut waste transfers to the photosensitizer or paper causing image failures
Solution Approach 1:
The filler layer is applied in advance to the roller end face to create a protective barrier. This preliminary protection prevents the base layer from being scraped off, thereby preventing cut waste generation and subsequent image failures, ensuring reliable roller performance throughout operation.
Solution Approach 2:
The filler layer serves as an intermediary protective layer between the ring-shaped member and the base layer. It mediates the contact interaction, absorbing the mechanical stress and preventing direct scraping of the base layer material that would otherwise transfer to the photosensitizer and cause image defects.
3Object-generated harmful factors
If a filler layer is provided on the axial end face of the roller to prevent scraping, then cut waste generation is suppressed, but the filler layer must have specific mechanical properties (breaking strain ≥120%, tensile stress 5-30 N/mm²) to ensure effectiveness
Solution Approach 1:
The invention specifies precise parameter ranges for the filler layer material (breaking strain ≥120%, tensile stress 5-30 N/mm²) to ensure optimal protective performance. By defining these specific parameter ranges, the invention transforms the complex material selection problem into a standardized specification that ensures effectiveness while preventing cut waste generation.
Solution Approach 2:
The roller structure employs a composite design with a base layer and a filler layer having different material properties. The filler layer is specifically formulated with appropriate breaking strain and tensile stress characteristics to provide protection, while the base layer maintains the functional requirements for image formation. This composite structure optimizes both protective and functional performance.
Data Source
AI summary
Provided is a roller capable of suppressing generation of cut waste from an end of a roller due to contact with another member inside a device when mounted on an image forming device, particularly a conductive roller, and an image forming device using the same. A roller includes a shaft 1 and a base layer 2 provided on the outer periphery of the shaft. A filler layer 4 covering the base layer is provided on end faces of both ends of the base layer in the roller axial direction, and the filler layer is composed of a material having a breaking strain measured according to a tensile test of JIS K 7127 of not less than 120% and a tensile stress at 100% elongation measured according to a tensile test of JIS K 7127 of from 5 to 30 N/mm2.