Electrical Contact Spring Asymmetry Prevents Wire Intersection
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Solution Overview
Problem
In image forming apparatuses, the existing electrical contact configurations are prone to unstable connections due to tangling of power supply lines, which can cause the contact portions to interfere with the holding member, leading to increased thickness and width, and thus, failure in achieving a reliable electrical connection.
Innovation Solution
An electrical contact spring with a compression spring portion and a circular contact portion formed by winding the wire rod into at least a double loop, where the ring shape portion has a narrower width closer to the compression spring portion, and the winding start and end portions are designed to prevent intersection of wire rods, ensuring stable contact even under external forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double-loop contact portion is formed by bending and raising the end portion of a compression spring, then electrical connection is ensured, but wire rods may intersect and interfere with the holding member, leading to unstable connection
Solution Approach 1:
The contact portion is divided into multiple loops (first loop and second loop) with distinct functions. The first loop provides primary contact while the second loop provides secondary contact, segmenting the contact function to reduce interference between wire rods and prevent intersection issues.
Solution Approach 2:
The first loop and second loop are designed with asymmetric configurations where the first loop has a larger diameter than the second loop. This asymmetry ensures that the wire rods do not intersect by creating different spatial paths for each loop, thereby preventing interference with the holding member.
2Ease of operation
If the contact portion is designed to protrude from the holding member, then attachment workability is maintained, but the thickness and width increase when wire rods intersect, preventing proper contact pressure
Solution Approach 1:
The contact portion is segmented into multiple loops with different diameters, allowing each loop to contribute to contact pressure independently. This segmentation prevents the need for increased overall thickness and width, maintaining proper contact geometry while ensuring reliable electrical connection.
Solution Approach 2:
The contact portion is designed to be elastic and deformable, allowing it to dynamically adjust its shape under compression. This dynamic property enables the contact portion to maintain proper contact pressure with the contact member while accommodating variations in assembly tolerances and preventing interference issues.
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 design ensures reliable electrical connections by preventing wire rod intersections and maintaining contact pressure, thus stabilizing the connection and preventing contact failures during handling and operation.
Implementation Method 1
a compression spring portion formed of a coiled wire rod and configured to be compressed and deformed
Data Source
AI summary
To achieve reliable electrical connection, a width of a ring shape portion becomes narrower toward a side closer to a compression spring portion in an axis direction of the compression spring portion, and an end portion of a winding start portion is located closer to a second end portion of the ring shape portion on a side opposite to the compression spring portion.