Three-Blade Helical Developer Conveyor Gap Management
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Solution Overview
Problem
In image forming apparatuses, the existing developer conveyor systems face issues with uneven developer distribution and density, leading to image density irregularities due to developer jumping at gaps between blades in the conveyor mechanism.
Innovation Solution
The developer conveyor system incorporates a shaft with a first blade helically wound in one direction, a second blade disposed away from the first blade with a gap in the longitudinal axial direction and wound in the opposite direction, and a third blade helically wound in the same direction as the first blade at the gap position, enhancing mechanical strength and preventing developer jumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a gap is formed between blades in the developer conveyor, then the blades can be disposed separately to simplify manufacturing, but developer jumping occurs at the gap position causing image density irregularities
Solution Approach 1:
A filler blade is introduced as an intermediary element at the gap position between the first and second blades. This filler blade serves as a mediator that prevents developer jumping across the gap while maintaining the separate disposal advantage of the first and second blades. The filler blade effectively bridges the gap without requiring the gap to be eliminated, thus resolving the contradiction between manufacturing simplicity and transport stability.
2Productivity
If the developer conveyor operates at high speed to improve productivity, then image formation efficiency increases, but developer jumping and collision become more severe causing image density unevenness
Solution Approach 1:
The filler blade is positioned in advance at the gap location to prevent developer jumping before it can occur during high-speed operation. By having the filler blade ready at the gap position, the system preemptively counteracts the tendency of developer to jump when the conveyor operates at high speed, thus maintaining image density uniformity even at high productivity levels.
3Manufacturing precision
If the gap between blades is reduced to prevent developer jumping, then image density uniformity improves, but the mechanical strength and ease of assembly of the blade structure decreases
Solution Approach 1:
The blade structure is segmented into three separate components: the first blade, the filler blade, and the second blade. This segmentation allows each blade to be manufactured and positioned independently, with the filler blade specifically addressing the gap issue without requiring the entire blade assembly to be redesigned as a single complex unit. The segmentation maintains structural simplicity while achieving the goal of preventing developer jumping.
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 configuration ensures smooth developer transport and prevents image density unevenness by retaining the developer at the gap position, reducing collisions and maintaining consistent image quality.
Implementation Method 1
a first blade (13c1) helically wound around the shaft (13c4) in a first direction, a second blade (13c2) disposed away from an end of the first blade (13c1) with a gap (M) in a longitudinal axial direction of the developer conveyor (13c) and helically wound around the shaft (13c4) in a second direction opposite the first direction
Data Source
AI summary
A developer conveyor includes a shaft; a first blade helically wound around the shaft in a first direction, a second blade disposed away from an end of the first blade with a gap in a longitudinal axial direction of the developer conveyor and helically wound around the shaft in a second direction opposite the first direction, and a third blade helically wound around the shaft in the first direction at least at a position where the gap is formed.