Integral Layer Thickness Regulating Member Molded Resin
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Solution Overview
Problem
The existing layer thickness regulating members in developing devices are costly due to separate components and prone to distortion during injection molding, leading to non-uniform developer thickness and high assembly costs.
Innovation Solution
A layer thickness regulating member is molded using a metal mold with a resin material, where the layer thickness regulating portion is integrally molded with the opposing portion, and separated by pushing from the opposite side of the opposing portion, reducing stress and distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the layer thickness regulating member and supporting members are provided as separate members, then assembly flexibility is improved, but component cost and assembly cost increase
Solution Approach 1:
The patent merges the layer thickness regulating member and the opposing member into a single integrated component formed by injection molding. This eliminates the need for separate supporting members and reduces the number of parts, thereby lowering component cost and simplifying assembly while maintaining the functional flexibility of having adjustable layer thickness regulation.
2Device complexity
If the layer thickness regulating member is integrally molded with the opposing portion, then component cost is reduced, but distortion occurs during injection molding
Solution Approach 1:
The patent applies local quality by providing reinforcing ribs at specific locations on the opposing member, particularly in regions prone to distortion during injection molding. These ribs locally strengthen the structure without requiring complete redesign of the entire component, thus maintaining manufacturing precision while benefiting from integral molding cost savings.
Solution Approach 2:
The patent modifies design parameters such as wall thickness distribution, rib placement, and gate positioning in the injection molding process to control cooling rates and stress distribution. These parameter changes prevent distortion and warpage during molding, ensuring layer thickness uniformity is maintained while still using cost-effective integral molding.
3Manufacturing precision
If the layer thickness regulating member is pushed from the side opposite from the opposing portion during separation, then distortion is reduced, but separation force requirements increase
Solution Approach 1:
The patent incorporates ejector pins and ejector plates in the mold design that automatically apply separation force in the optimal direction (from the side opposite the opposing portion) during the ejection phase. This preliminary preparation of the separation mechanism ensures distortion-free removal without requiring excessive manual force, as the mold itself provides the necessary ejection force through its built-in mechanisms.
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 approach results in a cost-effective, high-accuracy, and rigid layer thickness regulating member with reduced warpage and deformation, ensuring uniform developer thickness and stable image density, while minimizing the risk of metal powder inclusion.
Implementation Method 1
a first step of ejecting a resin material between a first split mold for molding the layer thickness regulating portion and the opposing portion at the opposing surface and a second split mold for molding the opposing portion in a side opposite from the opposing surface
Implementation Method 2
a second step of solidifying the resin material ejected in the first step
Implementation Method 3
a third step of separating, after the second step, the layer thickness regulating member from the second split mold by pushing, against the layer thickness regulating member from the side opposite from the opposing surface, a ejecting member for separating the layer thickness regulating member from the second split mold
Data Source
AI summary
A layer thickness regulating member includes: an opposing portion having an opposing surface to a peripheral surface of a developer carrying member; and a layer thickness regulating portion, projected from the opposing surface toward the developer carrying member, for regulating a layer thickness of a developer carried on the developer carrying member. The layer thickness regulating portion is integrally molded with the opposing portion. The layer thickness regulating member is, after being molded in a metal mold, separated by being pushed from a side opposite from the opposing portion of the layer thickness regulating member when the layer thickness regulating member is separated from the metal mold.