Printed Board Slit Contact for High-Voltage Spring Assembly
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Solution Overview
Problem
The existing methods for connecting a high-voltage power supply board to an image forming apparatus using a coiled spring member result in unstable contact, increased substrate area, poor assembly workability, and difficulty in visually verifying contact reliability due to the deformation of the spring member and increased force required for assembly.
Innovation Solution
A printed board with a slit portion and a first conductive member straddling the slit, where a second conductive member with elastic force connects to the first member, reducing the contact area and assembly force while allowing for easy visual verification of contact reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the diameter of the coil portion of the spring member is reduced to decrease contact area, then the substrate area can be reduced, but the contact state becomes unstable and the spring member deforms
Solution Approach 1:
The contact portion is divided into a first contact portion (on the printed board) and a second contact portion (on the spring member). The first conductive member bridges these two separated contact portions, allowing the spring member's second contact portion to be positioned optimally for stability while the first contact portion integrates with the printed board circuit, thus resolving the conflict between reduced contact area and stable contact state.
Solution Approach 2:
The first conductive member acts as an intermediary element that connects the first contact portion on the printed board to the second contact portion on the spring member. This intermediary structure allows the spring member to maintain a larger effective contact diameter for stability while still achieving compact integration with the printed board, thereby resolving the contradiction between contact area and contact stability.
2Reliability
If multiple contact portions are provided to improve connection reliability, then the electrical connection reliability is improved, but the assembly workability deteriorates due to increased repulsive force from spring members
Solution Approach 1:
Multiple contact portions are merged into a single integrated first conductive member that spans across multiple contact points. This unified structure allows the spring member to apply pressure at multiple locations simultaneously through its elastic deformation, improving connection reliability while maintaining good assembly workability as the entire contact system acts as one integrated unit rather than multiple separate components.
Solution Approach 2:
The spring member's elastic properties allow it to dynamically adapt to multiple contact portions during assembly. When pressure is applied, the spring member deforms elastically to engage with multiple contact points, distributing the repulsive force across the elastic structure rather than concentrating it, thereby improving both connection reliability and assembly workability.
3Reliability
If the first conductive member has a large contact area with the spring member, then the contact reliability is improved, but the substrate area increases
Solution Approach 1:
The first conductive member exhibits local quality differentiation: it has a concentrated contact area with the spring member's second contact portion to ensure reliable electrical connection, while maintaining a slender overall structure that minimizes the substrate area occupied. The conductive member's cross-section is larger at the contact point with the spring member and tapers towards the printed board connection, optimizing both contact reliability and space efficiency.
4Ease of operation
If a hole is provided for visual confirmation of contact, then the ease of operation is improved, but the structural integrity of the printed board is compromised
Solution Approach 1:
Instead of providing a through-hole that compromises structural integrity, the printed board utilizes its existing surface topology (the slit portion) to enable visual verification. The first conductive member is positioned to be visible through or alongside the slit portion, allowing operators to verify contact in a different dimensional space (through the slit opening) without creating additional structural weaknesses in the printed board.
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 decreases the required contact area, reduces assembly force, and facilitates visual inspection of the contact portion, improving assembly workability and reliability by ensuring secure electrical connections with reduced stress on the printed board.
Implementation Method 1
one end of a second conductive member (203) having an elastic force is connected to the process member, and in a state in which the printed board is attached to the image forming apparatus, another end of the second conductive member contacts the first conductive member
Data Source
AI summary
The printed board includes a slit portion and a first conductive member that is provided straddling the slit portion. In a state in which the printed board is attached to an apparatus to which one end of a second conductive member having an elastic force is connected, another end of the second conductive member contacts the first conductive member, and the another end of the second conductive member passes through the slit portion.