In the manufacturing of core components for printing equipment, the Primary Charge Roller (PCR) serves as a critical part regulating toner transfer and release. The uniformity, wear resistance, and compatibility of its surface coating have a decisive impact on print image quality and overall product lifespan. While traditional spray coating processes can achieve basic coating coverage, they fall short of meeting new OEM standards in terms of image resolution, density uniformity, and coating longevity. To address these challenges, CET has successfully developed an organic polymer dip-coating technology that effectively overcomes the technical and performance limitations of spray-coated PCRs.
Image Quality Optimization: Dual Breakthroughs in Enhanced Resolution and Density Control
Enhanced Resolution:Through detailed observation under a 30x industrial magnifier, the dip-coated PCR exhibits a seamless surface coating microstructure. This uniform coating distribution significantly reduces light scattering, markedly improving edge sharpness in printed images. In tests printing fine text or complex graphics, the dip-coating process consistently renders 0.1mm line details, meeting high-precision printing demands.
Density Control: Spray coating, due to droplet size variations during atomization, causes variations in coating thickness, leading to uneven image density. In contrast, dip coating achieves nanoscale precision in thickness control through precise control of coating viscosity and immersion time. Test data shows that dip-coated PCR exhibits significantly lower density standard deviation compared to spray-coated versions, ensuring consistent density from the first to the last print while enhancing print quality stability.
Color Difference Control: Random droplet distribution in spray coating may cause localized pigment accumulation, leading to color deviation. Dip coating's molecular-level, film-forming mechanism uniformly embeds pigments within the polymer matrix, eliminating the root cause of color deviation. In color-printing tests, dip-coated PCRs exhibit significantly lower ΔE（color difference） values, meeting stringent color-accuracy requirements for high-end printing.
Enhanced Environmental Adaptability: Significant Improvements in Low-Temperature Printing & Background Control
Low-Temperature Printing Performance: In low-temperature environments, spray coatings may suffer from poor toner transfer due to differential shrinkage rates, leading to background issues. The dip-coating process optimizes polymer crosslinking density, allowing the coating to maintain a stable elastic modulus at low temperatures. Tests show that dip-coated PCRs achieve significantly lower background values during continuous low-temperature printing, ensuring clearer output and cleaner equipment.
High-Temperature and High-Humidity Resistance: Under high-temperature and high-humidity conditions, spray coatings may absorb moisture and expand, leading to a separation from the substrate and potential drum breakdown issues. Dip-coating introduces hydrophobic additives to create a dense protective surface layer, effectively extending equipment lifespan in harsh environments while enhancing reliability and stability.
Enhanced Coating Durability: Dual Breakthroughs in Wear Resistance and Toner Compatibility
Wear Resistance: Weak inter-droplet bonding in spray coatings often leads to coating delamination during continuous printing. Dip-coating forms a three-dimensional network structure through chemical bonding, significantly increasing coating hardness and durability. In continuous print life tests, dip-coated PCRs show substantially reduced coating wear compared to spray-coated versions, demonstrating significantly improved wear resistance and extended PCR lifespan.
Toner compatibility: The microporous structure produced by spray coating allows wax in toner to penetrate the layer, causing whitening and degrading print quality. By tailoring polymer molecular-weight distribution, dip coating builds a dense yet elastic surface. Tests demonstrate that dip-coated PCRs are compatible with toner from multiple brands, preventing print-quality issues caused by toner incompatibility while enhancing equipment applicability and flexibility.
Technological Breakthrough & Industrial Application
CET's new dip-coated PCR technology merges materials science with precision manufacturing. Its breakthrough lies in molecular-level coating design that overcomes inherent limitations of traditional processes. This innovation not only boosts core performance of printing devices but also sets a new quality benchmark for the industry.
To sustain product competitiveness, CET has built an automated dip-coating production line safeguarded by four core systems and supported by a micron-level smart-manufacturing platform. The unmanned automatic loading/unloading system completes one efficient production cycle—50 units in 14 minutes—delivering a stable daily output of 4,000+ units to satisfy large-scale global demand.