Binary Ink Developer Assembly Slot Angle Design
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Solution Overview
Problem
Conventional binary ink developer assemblies in printing systems experience reduced and non-uniform nip forces due to gear separation forces, leading to cleaning failures and print quality defects.
Innovation Solution
The use of end caps with slots arranged at a slot angle equal to the pressure angle of the gear teeth, which supports the radial force component of the gear force, preventing gear separation and maintaining uniform nip forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional gears with involute tooth profiles are used to transmit power, then power transmission is achieved, but radial force components cause gear separation that reduces nip force uniformity
Solution Approach 1:
The patent extracts the radial force component from the gear force by introducing a separate radial support structure (the slot in the end cap). The slot is specifically designed to carry the radial load, allowing the gear teeth to focus on tangential power transmission without generating separation forces that would compromise nip force uniformity.
Solution Approach 2:
The slot in the end cap acts as an intermediary structure that mediates between the gear force and the roller assembly. It provides a dedicated pathway for radial force transmission, preventing direct gear separation while maintaining the necessary nip forces for consistent printing quality.
2Power
If gear separation forces occur, then power transmission continues, but nip forces become reduced and non-uniform leading to cleaning failures
Solution Approach 1:
The radial support function is extracted from the gear teeth and assigned to the dedicated slot structure. This separation ensures that power transmission and radial support are independent functions, preventing gear separation forces from compromising cleaning reliability.
Solution Approach 2:
The slot structure provides beforehand support for radial forces, preventing gear separation before it can occur. By having the radial support mechanism in place prior to operation, the system maintains consistent nip forces and prevents cleaning failures proactively.
3Manufacturing precision
If the slot angle is aligned with the pressure angle, then radial force components are supported preventing gear separation, but this requires precise angular alignment
Solution Approach 1:
The patent specifies the slot angle as a critical parameter that should substantially equal the pressure angle of the gear teeth. By defining this angular parameter relationship, the design transforms a complex alignment problem into a parameter specification that can be controlled during manufacturing and assembly.
Data Source
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AI summary
A binary ink developer assembly includes a plurality of rollers, gears, and end caps. The rollers are in contact with each other to form a nip. Each roller includes a plurality of bearings. The gears include gear teeth. A respective gear has an involute tooth profile and applies a gear force at a pressure angle corresponding to the involute tooth profile to rotate at least one roller. The end caps are coupled to the bearings. At least one slot arranged to form a slot angle substantially equal to the pressure angle and to receive a respective bearing to support a respective roller.