Ridged Paper Ejection Roller Integral Resin Coating

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing ridged paper ejection rollers for printers and facsimiles, which use press-fitted rubber rings, face high manufacturing costs and inefficiencies, making them costly to produce.

Innovation Solution

A ridged paper ejection roller with a rigid main shaft body coated with a resin body that includes integrally formed ridges and small-diameter regions, which work in conjunction with star wheels to convey paper sheets, reducing manufacturing costs by eliminating the need for press-fitting rubber rings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If rubber rings are press-fitted to the main shaft body to form ridges, then paper conveyance precision is improved, but manufacturing cost increases and manufacturing efficiency decreases

Engineering Contradiction:

Improvepaper conveyance precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent merges the ridge structure directly into the resin body coating, eliminating the need for separate rubber rings. The ridges are formed as an integral part of the coated resin layer through molding, combining what were previously separate components (rubber rings and shaft body) into a unified structure that reduces part count and assembly steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces the mechanical press-fitting process with a coating and molding process. Instead of mechanically assembling rubber rings onto the shaft body, the resin body is applied as a coating and the ridges are formed through mold shaping, substituting a complex mechanical assembly operation with a more efficient coating and forming process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If rubber rings are press-fitted to the main shaft body to form ridges, then paper conveyance precision is improved, but manufacturing productivity decreases

Engineering Contradiction:

Improvepaper conveyance precisionVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The ridge structure is merged into the resin body coating, allowing ridges to be formed simultaneously with the coating application process. This eliminates the separate step of press-fitting rubber rings, reducing the number of manufacturing operations and improving production throughput.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The ridges are pre-formed during the resin coating process itself, rather than being added as a subsequent assembly step. The molding process that applies the resin coating also shapes the ridges, performing multiple functions in one operation and eliminating the need for later ridge formation or assembly.

Inventive Principle:

Principle #10Preliminary action

3Reliability

If multiple rubber rings are press-fitted to the main shaft body, then paper conveyance function is improved, but device complexity increases

Engineering Contradiction:

Improvepaper conveyance functionVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple ridges that would require multiple separate rubber rings are instead formed as integral features of a single resin body coating. This merges multiple components into one, reducing the number of parts and simplifying the overall structure while maintaining the paper conveyance function.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The resin body coating serves multiple functions simultaneously: it provides the ridge structures for paper engagement, acts as a protective layer on the shaft body, and can be molded in various configurations to accommodate different ridge patterns. This multi-functional approach replaces what would otherwise require multiple specialized components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration allows for efficient and cost-effective manufacturing of ridged paper ejection rollers, preventing ink transfer and improving paper conveyance precision while reducing manufacturing costs compared to conventional methods.

Implementation Method 1

a step of injecting resin into a through-hole of a first metal die while continuously or intermittently moving the main shaft body in the axial direction so as to pass through the through-hole to provide the resin body on the outer surface of the main shaft body

Methodology Applied

Scientific EffectInjection molding:

Implementation Method 2

a step of forming the ridges and the small-diameter regions by a second metal die before the resin body cures

Methodology Applied

Scientific EffectCompression molding:

Implementation Method 3

before the resin body cures

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS9573785B2Manufacturing method for ridged paper ejection roller

Publication Date: 2017.02.21 SUNCALL CORP

AI summary

A ridged paper ejection roller according to the present invention conveys a paper sheet in cooperation with a plurality of star wheels disposed apart from each other in a width direction of the paper sheet, and includes a rigid main shaft body and a resin body coated on the main shaft body. The resin body integrally includes a plurality of large diameter-regions that work in conjunction with the respective star wheels to hold therebetween and convey the paper sheet, and small-diameter regions other than the large-diameter regions.