Modular Transfer Roller Units for Image Forming Apparatus
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Solution Overview
Problem
In tandem image forming apparatuses, the existing transfer roller configuration makes it difficult to replace individual transfer rollers without wasting other functional rollers, and there is a lack of effective management of their useful life, leading to inefficiencies and increased costs.
Innovation Solution
A transfer assembly with integrated individual roller units that are independently attachable and detachable, allowing for easy replacement of primary transfer rollers without removing bearings or springs, and a usage history manager to track the life of each roller unit, enabling precise management of their useful life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If transfer rollers are held in sub-frames with bearings and springs as in related art, then the transfer assembly structure is stable and functional, but replacing individual transfer rollers becomes difficult and time-consuming
Solution Approach 1:
The transfer roller assembly is segmented into modular units, where each transfer roller (including bearing and spring) forms an independent replaceable module. This allows individual transfer rollers to be replaced without affecting other rollers, resolving the contradiction by enabling easy replacement while maintaining structural integrity through standardized modular design.
Solution Approach 2:
The transfer roller modules are extracted from the complex sub-frame structure as independent units. By taking out each transfer roller assembly as a separate replaceable component, the system enables simple replacement operations without requiring disassembly of the entire sub-frame structure, thus improving ease of operation while preserving structural stability.
2Productivity
If multiple transfer rollers are held together in a single sub-frame, then the assembly is compact and structurally integrated, but replacing one roller requires removing and reinstalling all rollers and their supporting components
Solution Approach 1:
The sub-frame holding multiple transfer rollers is segmented into individual roller units. Each transfer roller with its bearing and spring becomes an independent module that can be replaced separately. This segmentation enables rapid replacement of single rollers without the time-consuming process of removing and reinstalling entire sub-frames, directly improving replacement efficiency and reducing time loss.
Solution Approach 2:
The invention enables selective discarding and recovery of individual transfer roller modules. When one roller wears out, only that specific module is discarded and replaced, while other functional rollers remain in place. This approach recovers the serviceable components and eliminates the waste of replacing entire sub-frames, improving productivity while minimizing time loss.
3Reliability
If transfer rollers are integrated into sub-frames with bearings and springs, then the transfer mechanism is reliable and durable, but the replacement process requires removing these components which increases complexity and potential for error
Solution Approach 1:
The transfer roller system is segmented into self-contained modules where each roller includes its bearing and spring as an integrated unit. This segmentation maintains reliability by ensuring each module is pre-assembled and tested, while simultaneously improving ease of repair by allowing simple module replacement without handling delicate bearing and spring components separately, reducing maintenance complexity and potential for assembly errors.
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 solution simplifies the replacement process, reduces waste, and allows for cost-effective management of transfer roller units across different image forming apparatus types, improving operational efficiency and reducing costs by using common units for various colors and apparatus configurations.
Implementation Method 1
each configured to electrostatically transfer the toner image on one of the image carriers onto one of an intermediate transfer member and a recording medium
Data Source
AI summary
An image forming apparatus includes a plurality of image carriers and a transfer assembly. The transfer assembly includes a plurality of transferees, a supporter, and a plurality of transferee holders. The plurality of transferers is each configured to electrostatically transfer a toner image carried on one of the image carriers onto an intermediate transfer member or a recording medium. The supporter is configured to support the transferers. The transferer holders are each configured to hold one of the transferers. Each of the transferee holders and the transferer held thereby form an integrated individual unit independently attachable to and detachable from the supporter.