Helical Thread Drive Coupler for Electrophotographic Units

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Solution Overview

Problem

Existing drive couplers for electrophotographic image forming devices require sufficient rigidity to transfer rotational motion effectively while minimizing cost and manufacturing complexity, which is challenging due to the need for precise alignment and secure connection of components.

Innovation Solution

A drive coupler design featuring a first and second component that are coaxial, with a force receiving portion and a force transmitting portion, where one component includes angled ribs and the other includes corresponding grooves, ensuring secure engagement and preventing separation, and optionally using a male and female connector with helical threads for additional stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a drive coupler uses multiple components to ensure secure engagement and prevent separation, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvesecure engagementVSAvoidcomponent assembly

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The drive coupler is divided into multiple components: a first component with a force receiving portion, a second component with a force transmitting portion, and a fastening component. This segmentation allows each part to perform its specific function while working together to achieve secure engagement and prevent separation during operation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The fastening component is received within a recess of the first component, creating a nested structure. This nesting approach consolidates multiple elements into a compact assembly, reducing overall device complexity while maintaining the reliability needed for secure engagement and separation prevention.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Manufacturing precision

If a drive coupler uses multiple components with precise alignment, then manufacturing precision is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The first and second components are pre-formed with their respective features (force receiving portion, force transmitting portion) during manufacturing. This preliminary action ensures that when the components are assembled, the alignment precision is already built into the individual parts, reducing the need for complex alignment procedures during final assembly.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The complementary features of the first and second components (such as the recess and the fastening component) are designed to self-align and self-secure during assembly. This self-service mechanism reduces the need for complex external alignment tools or procedures, improving ease of manufacture while maintaining high alignment precision.

Inventive Principle:

Principle #25Self-service

3Strength

If a drive coupler uses fasteners to secure components, then strength is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improveconnection strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The fastening component is extracted as a separate, specialized element from the main drive coupler body. This allows the fastening function to be optimized independently while the main components focus on force transmission. The fastening component can be a simple snap-fit, clip, or other easy-to-manufacture element that provides strong connection without complex assembly procedures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The fastening component is designed as a simple, inexpensive element that can be easily manufactured and replaced if needed. Rather than using complex permanent fasteners, the design employs a simple fastening mechanism that provides sufficient connection strength while being trivial to manufacture and install, improving ease of manufacture while maintaining adequate strength.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS11249439B2Drive coupler for a replaceable unit of an electrophotographic image forming device

Publication Date: 2022.02.15 LEXMARK INTERNATIONAL INC

AI summary

An interface drive coupler for a replaceable unit of an electrophotographic image forming device according to one example embodiment includes a first component and a second component coaxial with the first component along a rotational axis of the interface drive coupler. A force receiving portion is positioned on the first component and a force transmitting portion is positioned on the second component. One of the first component and the second component includes a male connector and the other of the first component and the second component includes a female connector that matably receives the male connector. Each of the male connector and the female connector includes a helical thread that extends circumferentially around the rotational axis of the interface drive coupler and that is angled in an operative rotational direction of the interface drive coupler in a direction from the force receiving portion toward the force transmitting portion.