Metal Frame Corner Design for Image Forming Apparatus Assembly
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Solution Overview
Problem
Existing metal frames for image forming apparatuses face challenges in achieving both easy assembly and improved positioning accuracy between metal plates, as increased differences in the size of openings and plate thickness and width can lead to decreased positioning accuracy.
Innovation Solution
A metal frame configuration for an image forming apparatus that includes a first support with a first and second metal plate, a second support, and a third support connecting them. The first metal plate has a first and second portion bent vertically with a right-angled corner, while the second metal plate has portions bent upward to engage with the first plate, incorporating stretched portions and corner portions for precise assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the difference between the size of the opening and plate thickness and width of the protrusion portion is increased to facilitate easy assembly, then assembly ease is improved, but positioning accuracy between metal plates deteriorates
Solution Approach 1:
The opening portion is divided into multiple sub-openings (first opening and second opening) that are positioned apart from each other. The protrusion portion is correspondingly divided into multiple protrusions (first protrusion and second protrusion). This segmentation allows each protrusion to engage with its corresponding sub-opening, providing multiple contact points that maintain positioning accuracy while facilitating easier assembly through distributed engagement rather than a single tight fit.
Solution Approach 2:
A resin member is introduced as an intermediary component between the first metal plate and second metal plate. The resin member includes a first portion engaging with the first protrusion and a second portion engaging with the second protrusion. This intermediary element absorbs dimensional variations and facilitates precise positioning while maintaining ease of assembly, as the resin can accommodate slight misalignments while still providing stable engagement.
2Ease of operation
If the opening and protrusion dimensions are made larger to enable easy assembly, then assembly ease is improved, but position accuracy between members supported by the frame deteriorates
Solution Approach 1:
The engagement interface is segmented into multiple discrete protrusions and corresponding sub-openings positioned at different locations. This segmentation distributes the positioning function across multiple points, allowing each point to maintain high precision while the overall assembly remains easy to perform. The multiple contact points collectively ensure position accuracy of supported members without requiring extremely tight dimensional tolerances on individual components.
Solution Approach 2:
The resin member serves as a compliant intermediary that bridges the first and second metal plates. It engages with multiple protrusions simultaneously, providing a flexible yet precise connection mechanism. This intermediary allows for easy assembly while maintaining position accuracy through its ability to accommodate dimensional variations while still constraining the relative positions of the metal plates and supported members.
Data Source
AI summary
A metal frame of an image forming apparatus includes a first support which includes a first metal plate and a second metal plate; a second support configured to support the image forming unit together with the first support; and a third support configured to connect the first support and the second support. The first metal plate includes a corner portion provided between a first portion and a second portion. The second metal plate includes a third portion, a fourth portion, and a fifth portion, wherein the fifth portion includes another corner portion located between a first stretched portion and a second stretched portion facing the corner portion of the first metal plate, and wherein a tip of the second stretched portion faces the fourth portion.