Nested Resin Supporting Member Frame for Roller Positioning
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Solution Overview
Problem
In image forming apparatuses, the compatibility issues between resin materials used for supporting members lead to inaccurate positioning and detachment of rollers, especially with the decrease in diameter of photosensitive and developing rollers, causing support accuracy problems and potential detachment during cartridge transport.
Innovation Solution
A frame design for the cartridge with a first supporting member and a second supporting member, where the second supporting member has an opening that partially exposes the first supporting member, and includes engaging portions to apply forces opposing the opening direction, ensuring stable attachment and positioning through a manufacturing method involving molten resin injection between the members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a first supporting member is formed by attaching two different types of resin materials, then functionality (conductivity, sliding property) is improved, but positioning accuracy between the first and second supporting members deteriorates
Solution Approach 1:
The first supporting member is nested within the second supporting member, with the first supporting member fitted into a hollow cylindrical space of the second supporting member. This nested configuration allows the two different resin materials to be combined while maintaining precise positioning through the fitting structure, resolving the contradiction between functionality and positioning accuracy.
Solution Approach 2:
The first supporting member is pre-formed with a specific shape including a fitting portion before being attached to the second supporting member. This preliminary formation of the first supporting member with precise geometric features enables accurate positioning when fitted into the second supporting member, while still allowing the use of different resin materials for optimal functionality.
2Productivity
If the diameter of photosensitive and developing rollers is decreased, then productivity is improved, but support accuracy deteriorates due to insufficient contact area
Solution Approach 1:
The support structure transitions from a simple point or line contact to a multi-dimensional fitting structure. The first supporting member has a complex three-dimensional shape with fitting portions that engage with the second supporting member in multiple dimensions, providing stable support for smaller diameter rollers and maintaining support accuracy despite reduced roller sizes.
Solution Approach 2:
The supporting member system uses composite construction with two different resin materials - the first supporting member made of a material suitable for roller contact and the second supporting member made of a different material providing structural support. This composite approach enables accurate support for smaller rollers while maintaining the benefits of reduced roller diameter for productivity.
3Adaptability or versatility
If the first supporting member is made of a conductive resin for electrical connection, then functionality is improved, but detachment risk increases due to poor compatibility with non-conductive second supporting member
Solution Approach 1:
The nested fitting structure where the first supporting member is inserted into the hollow cylindrical space of the second supporting member creates a mechanically interlocked connection. This nested configuration provides reliable attachment stability between the conductive resin material of the first supporting member and the non-conductive resin material of the second supporting member, preventing detachment while maintaining electrical conductivity functionality.
Solution Approach 2:
The system deliberately uses composite materials with different properties - a conductive resin for the first supporting member to provide electrical connection functionality and a non-conductive resin for the second supporting member for structural support. The fitting structure between these incompatible materials ensures reliable attachment despite the material differences, resolving the contradiction between functionality and attachment stability.
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 design enhances the positional accuracy and stability of the supporting members, preventing detachment and maintaining accurate support for rotating rollers, even under conditions of deformation or thermal contraction, thus improving the reliability of the image forming process.
Implementation Method 1
bringing a mold into contact with the second supporting member and injecting a molten resin into a space formed between the second supporting member and the mold to form the first supporting member
Data Source
AI summary
A first supporting member includes a first engaging portion and a second engaging portion that respectively engage with a first engaged portion and a second engaged portion that are provided in a second supporting member. The first engaging portion and the second engaging portion are configured to apply force in directions opposite to the directions in which the first engaged portion and the second engaged portion move when an opening opens.