Molded Resin Frame Connection for Process Cartridge Downsizing
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Solution Overview
Problem
Conventional process cartridges face challenges in downsizing and require multiple disassembly steps for recycling, particularly due to interference between fixing spaces for the developing roller and cleaning drum units, and the need for resin bonding methods that complicate the disassembly process.
Innovation Solution
The use of a molded resin portion formed by injecting melted resin into a space defined by the first and second frames, which engages with limiting portions to securely connect the frames without the need for separate screw fixing spaces, allowing for a single-step disassembly and reducing the number of disassembly steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If resin bonding is used to fix the second frame to the first frame, then space efficiency is improved, but the disassembly process becomes complicated requiring multiple steps
Solution Approach 1:
The resin bonding process is segmented into distinct phases: injection of melted resin, cooling and solidification, and separation. By dividing the bonding process into these segments, the patent enables simplified disassembly where the second frame can be separated from the first frame by simply breaking the resin bonds, rather than requiring complex multi-step disassembly procedures
Solution Approach 2:
The patent changes the physical state parameter of the resin material from melted (liquid) to solidified (solid) through cooling. This parameter change allows the resin to provide strong bonding during operation while enabling easy separation during disassembly by reversing the process (heating or mechanical breaking), thus simplifying the disassembly procedure
2Reliability
If separate fixing spaces are provided for the developing blade and the second frame, then fixing reliability is improved, but the device size increases
Solution Approach 1:
The patent merges the fixing functions for the developing blade and the second frame into a single integrated resin bonding operation. The melted resin simultaneously bonds both components to the first frame, eliminating the need for separate fixing spaces and reducing the overall device volume while maintaining reliable fixing of both elements
Solution Approach 2:
The resin bonding mechanism serves multiple functions: it fixes the developing blade, fixes the second frame, and provides structural support. This multi-functional approach allows a single fixing space to accomplish what previously required separate dedicated spaces, thereby reducing device size while maintaining fixing reliability
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 enables the downsizing of the process cartridge and developing device while simplifying the disassembly process, improving recycling efficiency and reducing the complexity of resin bonding operations.
Implementation Method 1
a molded resin portion formed by injecting a melted resin material into a space defined by the first frame and the second frame
Implementation Method 2
melted resin material is poured between the first frame and the second frame and then is cooled and solidified
Data Source
AI summary
A developing device for use with an image forming apparatus, includes: a developer carrying member for carrying a developer; a developer regulating member for regulating an amount of the developer carried on the developer carrying member; a first frame for supporting the developer regulating member; a fixing member for fixing the developer regulating member to the first frame; a second frame mounted to the first frame; and a molded resin portion formed by injecting a melted resin material into a space defined by the first and second frames. The molded resin portion is engaged with a first limiting portion provided as a part of the fixing member and projected into the space and is engaged with a second limiting portion provided as a part of the second frame to connect the first and second frame.