Hybrid Sheet Metal and Resin Frame Structure for Image Forming Apparatus

Solution Overview

Problem

The existing electro-photographic image forming apparatuses face challenges in reducing size while maintaining image quality due to the rigidity and design limitations of sheet metal frames, which require additional components and increase production costs, and the use of resin frames compromises positional precision.

Innovation Solution

The apparatus employs a combination of sheet metal frames for high-precision modules like the process and scanner units and resin frames for other modules, allowing efficient arrangement and reducing the apparatus size, with the metal frames providing support and positional stability and the resin frames offering design flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a sheet metal frame is used to support modules, then positional precision of modules can be secured, but the apparatus size is enlarged and production cost is increased

Engineering Contradiction:

Improvepositional precision of modulesVSAvoidapparatus size

Core Design Contradiction:

Manufacturing precisionVSVolume of stationary object

Solution Approach 1:

The frame structure is segmented into two types: sheet metal frames for supporting modules requiring high positional precision (process unit, scanner unit) and resin frames for supporting other modules. This segmentation allows the apparatus to achieve high positional precision only where needed, reducing overall material usage and apparatus size while maintaining critical precision requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different frame materials are applied to different locations based on local requirements: sheet metal frames are used locally at positions requiring high precision (process unit, scanner unit), while resin frames are used in other areas where lower precision is acceptable. This local differentiation optimizes the balance between precision and size.

Inventive Principle:

Principle #3Local quality

2Volume of stationary object

If a resin frame is used to support modules, then the apparatus size can be reduced, but positional precision of modules deteriorates

Engineering Contradiction:

Improveapparatus sizeVSAvoidpositional precision of modules

Core Design Contradiction:

Volume of stationary objectVSManufacturing precision

Solution Approach 1:

The frame structure is segmented into two types: sheet metal frames for supporting modules requiring high positional precision (process unit, scanner unit) and resin frames for supporting other modules. This segmentation allows the apparatus to achieve high positional precision only where needed, reducing overall material usage and apparatus size while maintaining critical precision requirements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different frame materials are applied to different locations based on local requirements: sheet metal frames are used locally at positions requiring high precision (process unit, scanner unit), while resin frames are used in other areas where lower precision is acceptable. This local differentiation optimizes the balance between precision and size.

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If additional attachment components are added to support modules on frames, then module positioning can be achieved, but production cost is increased

Engineering Contradiction:

Improvemodule positioningVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The frame structure is designed to integrate module support functions directly into the frame body. The sheet metal frames and resin frames incorporate built-in positioning features and support structures that eliminate the need for separate attachment components, thereby reducing part count and production cost while maintaining module positioning accuracy.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS7783226B2Image forming apparatus

Publication Date: 2010.08.24 BROTHER KOGYO KK

AI summary

An image forming apparatus includes a process unit which has an image carrier and a scanner unit which exposes the image carrier to light, a pair of sheet metal frames which support and position the process unit and the scanner unit, and a pair of resin frames which support at least one module of the image forming apparatus other than the process unit and the scanner unit.