Developer Carrying Member Flange Groove to Prevent Adhesive Leakage
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Solution Overview
Problem
The existing developer carrying members in electrophotographic image forming apparatuses face issues with adhesive leakage onto the outer circumferential surface, leading to image defects and increased manufacturing costs due to the need for additional adhesive removal processes.
Innovation Solution
A developer carrying member design featuring a flange with specific groove portions and adhesive application strategy, where adhesive is applied only to the first groove portion and press-fitted inside a sleeve, utilizing anaerobic adhesive to ensure secure bonding without spreading onto the outer surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive is applied to bond the flange and sleeve, then adhesion strength is improved, but adhesive leakage onto the outer circumferential surface occurs causing image defects
Solution Approach 1:
The groove portion is divided into a first groove portion and a second groove portion with different depths. The first groove portion has a smaller depth while the second groove portion has a greater depth, creating segmented adhesive retention zones that control adhesive flow and prevent leakage onto the outer circumferential surface.
Solution Approach 2:
Different regions of the groove portion have different depths to serve different functions. The first groove portion provides initial adhesive retention, while the deeper second groove portion provides additional containment. This local variation in groove depth optimizes adhesive bonding while preventing leakage at critical areas.
2Strength
If adhesive is applied generously to ensure strong bonding, then adhesion strength is improved, but manufacturing complexity increases due to adhesive removal processes
Solution Approach 1:
The groove portion is pre-formed on the flange before adhesive application. This preliminary structural preparation creates built-in adhesive containment features that guide and limit adhesive flow during the bonding process, eliminating the need for subsequent adhesive removal operations.
Solution Approach 2:
The groove portion converts the potentially harmful effect of excess adhesive into a beneficial feature by providing a designated reservoir that contains and utilizes the adhesive for bonding purposes, transforming what would be waste or defect into functional bonding material.
3Object-affected harmful factors
If the groove portion is made deeper to prevent adhesive leakage, then adhesive containment is improved, but adhesive amount required increases
Solution Approach 1:
The groove portion is segmented into two depths: the first groove portion with smaller depth and the second groove portion with greater depth. This segmentation allows the adhesive to be contained efficiently in the deeper second portion while the first portion provides sufficient initial bonding, optimizing adhesive usage.
Solution Approach 2:
The groove portion extends to a greater depth in the second groove portion than initially apparent, providing excessive containment capacity that ensures adhesive leakage prevention while the actual adhesive amount used remains controlled and efficient.
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
Prevents adhesive leakage, maintains strong adhesion between the sleeve and flange, and reduces manufacturing costs by eliminating the need for adhesive removal, while ensuring reliable adhesion strength and image quality.
Implementation Method 1
The adhesive bonds together the sleeve and the flange
Data Source
AI summary
A developer carrying member includes a shaft, a magnet, a sleeve, a flange, and adhesive. The flange has a first fitting portion, a second fitting portion, and a groove portion. The adhesive is disposed in the groove portion. A first groove portion and a second groove portion are formed continuously in this order from the first fitting portion side to the second fitting portion side. The height from the bottom surface of the second groove portion to the outer circumferential surface of the first fitting portion is greater than that from the bottom surface of the first groove portion to the outer circumferential surface of the first fitting portion.