Conductive Roller Filler Layer Suppresses Foam Debris

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Solution Overview

Problem

Conductive rollers used in image formation devices face issues with cut debris generation during size and shape adjustments, leading to image defects due to exposed foam layer waste, which conventional methods like air spraying and wipe spraying cannot completely eliminate, and require enhanced durability to withstand rotation.

Innovation Solution

A conductive roller with a filler layer made of water-based urethane resin, specifically ester/ether-based or carbonate-based, applied to the cut surfaces of both the foam and film layers, providing improved adhesion and durability by matching functional groups and incorporating silicone-based additives for reduced friction and enhanced durability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a filler layer is provided on the cut surface of the foam layer to suppress cut debris generation, then image quality is improved, but the roller member loses durability due to rotation in the image forming device

Engineering Contradiction:

Improvecut debris generationVSAvoidroller durability

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The invention uses a composite filler layer combining water-based urethane resin with silicone-based additives. The urethane resin provides adhesion and durability by bonding to the polyurethane foam layer, while the silicone additives reduce friction and prevent debris generation. This composite approach allows the filler layer to simultaneously achieve both image quality improvement and roller durability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention changes the chemical and physical parameters of the filler layer by specifying water-based urethane resin with particular properties (ester/ether-based or carbonate-based) and incorporating silicone-based additives. These parameter changes enable the filler layer to maintain durability under rotational stress while effectively suppressing cut debris generation.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If conventional air spraying or wipe spraying treatment is used to remove cut debris, then some debris is removed, but complete removal is not achieved and image defects still occur

Engineering Contradiction:

Improvedebris removal processVSAvoidimage defects

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Instead of attempting to remove debris after cutting, the invention applies a filler layer to the cut surface before the roller is put into service. This preliminary action prevents cut debris from being generated in the first place by sealing the exposed foam layer, thereby eliminating the need for subsequent debris removal processes and preventing image defects.

Inventive Principle:

Principle #10Preliminary action

3Adaptability or versatility

If the foam layer is cut to adjust roller size and shape, then the roller can be customized, but exposed foam layer waste is generated that causes image defects

Engineering Contradiction:

Improveroller size adjustmentVSAvoidcut waste generation

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The invention converts the harmful effect of the cut surface (exposed foam that generates debris) into a beneficial outcome by applying a filler layer that seals the cut surface. The filler layer, containing silicone-based additives, actually improves the surface properties by reducing friction and preventing debris generation, thereby transforming the harmful cut waste into a beneficial sealed surface.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution effectively suppresses cut debris generation and prevents image failures by ensuring the roller's durability and adhesion, maintaining performance over a long period without image defects from debris adhesion.

Implementation Method 1

Methodology Applied

Scientific EffectAdhesion: Adhesive

Implementation Method 2

incorporating silicone-based additives for reduced friction and enhanced durability

Methodology Applied

Scientific EffectFriction reduction: Lubrication

Data Source

PatentUS10025222B2Roller and image forming apparatus using same

Publication Date: 2018.07.17 ARCHEM INC

AI summary

Provided is a roller, in particular a conductive roller, capable of suppressing generation of cut debris from a cut surface of an end part of a foam layer in the roller axial direction over a long period of time, and an image forming device using the roller. A roller includes a shaft 1, a foam layer 2 and at least one film layer 3 sequentially provided on the outer periphery of the shaft. Both end parts in the roller axial direction of the foam layer and the film layer are cut, a filler layer 4 is provided on the cut surface of the cut foam layer and the cut film layer, at least the cut surface of the foam layer is covered with the filler layer, and the filler layer contains a water-based urethane resin.