ID Sensor Integral Board Welding for Toner Detection
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Solution Overview
Problem
In image forming apparatuses, the existing methods for mounting ID sensors to boards are prone to positional changes, which affect detection accuracy and allow foreign matter to enter, due to inadequate fixing methods.
Innovation Solution
The ID sensor is integrally formed with a board and includes a sensor body, lens, and holding member, where the lens is controlled by a case and cover with multiple pins for direct welding and fixing to the board, preventing positional changes and foreign matter ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the holding member and lid member are mounted to the board using pins inserted into through holes and welded, then the ID sensor can be fixed to the board, but the sensor body may change position relative to the board, affecting detection accuracy
Solution Approach 1:
The sensor body is integrally formed with the board, merging two previously separate components into a single unit. This eliminates the need for separate mounting structures (pins, holding members, lid members) and ensures the sensor body cannot change position relative to the board, thereby maintaining detection accuracy while simplifying the overall structure.
2Ease of manufacture
If the holding member and lid member are mounted using pins and welding, then the components can be assembled, but foreign matter can enter through the through holes
Solution Approach 1:
By integrally forming the sensor body with the board, the patent eliminates the through holes and separate mounting components. This merging of components closes potential entry points for foreign matter while maintaining ease of manufacture through integral formation, likely achieved through molding or other manufacturing processes that create the integrated structure in one step.
3Ease of operation
If multiple separate components (holding member, lid member, pins) are used to mount the sensor, then the sensor can be installed on the board, but the structure becomes complex and prone to positional changes
Solution Approach 1:
The patent integrates the sensor body directly with the board into a single component, eliminating the need for separate holding members, lid members, and mounting pins. This merging reduces the number of parts and assembly steps while ensuring stable positioning, thereby simplifying the overall structure and improving ease of operation.
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 configuration enhances detection accuracy by stabilizing the sensor's position and preventing foreign matter entry, thereby improving the reliability of toner concentration detection on the intermediate transfer belt.
Implementation Method 1
The ID sensor emits inspection light toward the intermediate transfer belt, and detects the concentration of the toner images on the intermediate transfer belt on the basis of a light receiving amount of the inspection light reflected by the intermediate transfer belt.
Data Source
AI summary
An image forming apparatus includes an ID sensor arranged to face an intermediate transfer belt, and a board provided with the ID sensor. The ID sensor is integrally formed with the board and while emitting light toward the intermediate transfer belt, the ID sensor includes a sensor body that individually receives light regularly reflected and light diffused and reflected by the intermediate transfer belt, a lens that is arranged between the sensor body and the intermediate transfer belt to control emitted light from the sensor body and incident light to the sensor body, and a holding member that holds the lens. The holding member is directly welded and fixed to the board.