Developing Cartridge Melt-Bonding Geometry for Ultrasonic Stability
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Solution Overview
Problem
Conventional developing cartridges face instability in ultrasonic welding due to inclined melt-bonding portions, which becomes more pronounced with increased vertical size, leading to unstable contact between the ultrasonic device and the welding surfaces.
Innovation Solution
The developing cartridge design includes a first frame with a toner accommodating portion and a developing roller support portion, featuring specific melt-bonding surfaces and a cover frame with inclined and protruding portions that form obtuse angles, allowing for stable melt-bonding of the cover frame to the base frame using ultrasonic waves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If the vertical size of the roller support portion is increased to make the developing cartridge larger in capacity, then the capacity of the developing cartridge is improved, but the contact stability between the ultrasonic wave generating device and the melt-bonding portions deteriorates
Solution Approach 1:
The invention introduces a protruding portion that extends in the axial direction (perpendicular to the vertical direction) from the second wall. This adds a new dimensional element to the melt-bonding structure, providing an additional contact surface for the ultrasonic device. The protruding portion has a surface that intersects the fourth melt-bonding surface, creating a multi-surface contact geometry that stabilizes the ultrasonic device during welding while maintaining the increased vertical capacity.
2Device complexity
If the melt-bonding portions are inclined downward toward the developing roller, then the structural configuration is simplified, but the contact stability between the ultrasonic wave generating device and the melt-bonding portions deteriorates
Solution Approach 1:
The invention applies different geometric characteristics to different parts of the melt-bonding structure. The first melt-bonding surface maintains a simpler configuration, while the second melt-bonding surface includes a protruding portion with specific geometric features (intersecting surface, axial extension) that locally enhance contact stability. This localized geometric modification allows the ultrasonic device to stably contact the melt-bonding portions without requiring complete redesign of the entire structure.
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 design ensures stable and smooth melt-bonding of the cover frame to the base frame, maintaining uniform pressure and contact, thereby enhancing the reliability and efficiency of the welding process.
Implementation Method 1
when the second frame is melt-bonded to the first frame by an ultrasonic wave
Data Source
AI summary
A developing cartridge includes: a developing roller; a first frame; and a second frame. The first frame includes: a first melt-bonding surface extending in a first direction; and a second melt-bonding surface positioned closer to the developing roller than the first melt-bonding surface. The second melt-bonding surface forms an obtuse angle with the first melt-bonding surface. The second frame is melt-bonded to the first frame. The second frame includes: a first wall having a third melt-bonding surface melt-bonded to the first melt-bonding surface and extending in parallel to the first melt-bonding surface; a second wall having a fourth melt-bonding surface melt-boned to the second melt-bonding surface and extending in parallel to the second melt-bonding surface; and a protruding portion having a surface intersecting the fourth melt-bonding surface and protruding in the first direction from the second wall toward the developing roller.