Segmented Inner Cover Duct Layout to Prevent Warping in Printers
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Solution Overview
Problem
Image forming apparatuses for commercial printing face challenges in downsizing while maintaining efficient air circulation due to the need for large fans and extended ducts, leading to warping of elongated inner covers that hinder proper duct positioning and attachment to the casing.
Innovation Solution
The apparatus employs a divided inner cover system with a first and second inner cover made of resin, each incorporating ducts, reinforced by metal plates to prevent warping, allowing for efficient air guidance to image forming units and easy attachment to the casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large-scale fan is used to take in a large amount of air for commercial printing, then air circulation efficiency is improved, but the apparatus size increases and cannot be downsized
Solution Approach 1:
The inner cover is divided into multiple separate inner covers (first inner cover, second inner cover, etc.), each equipped with its own fan and duct system. This segmentation allows each module to be compact while collectively providing sufficient air circulation for commercial printing, thus achieving downsizing without sacrificing productivity.
2Productivity
If the duct is extended to reach distant fans from charging units or developing units, then air can be supplied to remote components, but pressure loss increases and manufacturing complexity increases
Solution Approach 1:
By dividing the air supply system into multiple localized modules, each with its own fan and short ducts, the overall duct length is reduced. This minimizes pressure loss while still enabling air supply to remote components like charging units and developing units through distributed architecture rather than a single long duct.
Solution Approach 2:
The patent utilizes the vertical dimension by arranging fans and ducts in multiple levels within the apparatus. This three-dimensional arrangement allows air to reach remote components without requiring excessively long horizontal ducts, thereby reducing pressure loss while maintaining effective air supply.
3Area of stationary object
If the inner cover is made elongated to accommodate multiple image forming units in parallel, then coverage is improved, but warping occurs and attachment precision decreases
Solution Approach 1:
The elongated inner cover is segmented into multiple separate inner covers, each with a more compact shape that is less prone to warping. This segmentation maintains comprehensive coverage of multiple image forming units while ensuring each individual cover maintains high manufacturing precision and attachment accuracy.
Solution Approach 2:
The patent employs composite construction by combining resin materials with metal reinforcement plates within the inner covers. This composite approach provides the necessary structural strength to prevent warping in elongated configurations while maintaining precision for attachment to the casing.
4Loss of energy
If the duct cross-sectional area is increased to reduce pressure loss in extended ducts, then air flow efficiency is improved, but manufacturing complexity and space requirements increase
Solution Approach 1:
By segmenting the air supply system into multiple localized modules with short ducts, the patent reduces the need for large cross-sectional areas. Shorter ducts naturally exhibit lower pressure loss, allowing the use of smaller, simpler duct cross-sections that are easier to manufacture while still achieving effective air flow efficiency.
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
The solution ensures correct duct positioning, reduces manufacturing and storage costs, and facilitates easy assembly, while maintaining efficient air circulation and preventing warping, thus enabling effective air management within the apparatus.
Implementation Method 1
a fan for taking in air from an exterior, and a large number of ducts for guiding the air taken in from the exterior by the fan toward the image forming unit
Implementation Method 2
Air is sent toward the image forming unit so as to collect discharge products such as ozone that has been generated by charging the charging unit
Implementation Method 3
suppress rising of temperature of the developing unit accompanying a toner agitating operation within the developing unit
Data Source
AI summary
An image forming apparatus includes a casing, an image forming unit, an outer cover, a first inner cover arranged to face an inner side of the outer cover in a closed state, the first inner cover being made of resin, a second inner cover arranged to face the inner side of the outer cover in the closed state, the second inner cover being made of resin, a first fan, and a second fan. The first inner cover includes a first duct configured to guide air taken in from an exterior of the image forming apparatus by rotation of the first fan to the image forming unit. The second inner cover includes a second duct configured to guide air taken in from the exterior of the image forming apparatus by rotation of the second fan to the image forming unit.