Mirror Mounting Bracket with Protrusions for Laser Scanning Unit
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Solution Overview
Problem
Existing optical scanning systems in electrophotographic image forming devices face challenges in maintaining precise mirror positioning due to variability in adhesive thickness caused by tolerance stack-ups, which affects the dimensional stability and optical performance, and require additional mechanical features or high-accuracy manufacturing, increasing costs and complexity.
Innovation Solution
A mirror mounting configuration using bracket members with protrusions to control adhesive thickness, creating predetermined gaps between the mirror and frame, ensuring consistent adhesive placement and reducing reliance on tolerance gaps, thereby maintaining precise mirror positioning without additional mechanical features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If adhesives are used to replace mechanical control features for mirror positioning, then device complexity is reduced, but manufacturing precision deteriorates due to adhesive thickness variability caused by tolerance stack-ups
Solution Approach 1:
The patent applies preliminary action by pre-forming protrusions on the bracket member that define predetermined gaps before adhesive application. These protrusions are created during bracket manufacturing, establishing fixed reference points that control adhesive thickness and eliminate variability caused by tolerance stack-ups during assembly.
Solution Approach 2:
The patent changes the physical parameter of gap definition from variable (dependent on tolerance accumulation) to fixed (defined by protrusion geometry). The protrusions transform the adhesive gap from an uncontrolled dimension to a precisely controlled parameter, ensuring consistent adhesive thickness and reliable mirror positioning.
2Manufacturing precision
If mechanical features like screws or cams are added for precise mirror alignment, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts the alignment function from separate mechanical adjustment features (screws, cams) and integrates it directly into the bracket member structure through protrusions. This eliminates the need for additional mechanical components while maintaining precise positioning capability.
Solution Approach 2:
The patent merges the positioning and mounting functions into a single integrated bracket structure. The protrusions simultaneously serve as mechanical reference features for alignment and as gap-defining elements for adhesive application, combining multiple functions into one component.
3Manufacturing precision
If high-accuracy plastic injection molding is used to achieve acceptable tolerance accumulation, then manufacturing precision is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The patent segments the tolerance control function from the overall assembly and concentrates it in the protrusions on the bracket member. By localizing tolerance control to specific protrusion features rather than requiring all components to meet tight tolerances, the manufacturing difficulty is reduced while maintaining assembly precision.
Solution Approach 2:
The protrusions act as intermediary elements that mediate between the bracket and the mirror/frame. They provide fixed reference points that eliminate the need for tight tolerance accumulation across all mating surfaces, allowing standard manufacturing tolerances to be used while achieving precise final positioning.
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 achieves precise and stable mirror positioning, reducing adhesive variability, enhancing optical performance, and allowing for cost-effective manufacturing by eliminating the need for high-accuracy mechanical adjustments and exceptional plastic injection molding.
Implementation Method 1
A first adhesive in the first gap fixedly attaches the bracket to the frame. A second adhesive in the second gap fixedly attaches the bracket to the mirror.
Data Source
AI summary
A mounting assembly for mounting a mirror to a frame in a laser scanning unit of an electrophotographic image forming device includes a bracket attached between the frame and the mirror. The bracket includes a body having a first surface and a second surface transverse to the first surface. A first set of protrusions extends from the first surface for defining a first gap between the frame and the bracket that limits adhesive thickness therebetween when the first surface of the bracket is adhesively attached to the frame. A second set of protrusions extends form the second surface for defining a second gap between the mirror and the bracket that limits adhesive thickness therebetween when the second surface of the bracket is adhesively attached to the mirror.