Laser-Exposed Sheet Metal Coupling for Stable Grounding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conductive sheet metals used in image forming apparatuses face challenges with unstable grounding due to insulating resin layers, leading to increased Electromagnetic Interference (EMI) and Electro-Static Discharge (ESD) susceptibility, as existing methods like scraping off the resin layer for grounding are inconsistent and require additional conductive members, increasing complexity and cost.
Innovation Solution
A coupling structure that exposes metal layers by laser processing to create conductive portions on sheet metals, allowing for stable electrical contact and grounding without the need for extensive additional conductive members, using techniques like engraving or forming conductive beads to ensure reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the resin coated layer is scraped off by sliding to expose metal for grounding, then electrical conductivity is improved, but manufacturing precision and stability are worsened
Solution Approach 1:
The patent replaces the mechanical scraping method with laser working technology. Instead of using sliding friction to remove the resin layer, a laser beam is used to precisely ablate the resin coating at coupling portions. This substitution provides superior manufacturing precision because laser working can accurately control the removal area and depth, ensuring consistent exposure of the conductive metal layer without the variability inherent in mechanical scraping methods.
2Reliability
If additional conductive members are added to achieve stable grounding, then electrical conductivity is improved, but device complexity increases
Solution Approach 1:
The patent merges the functions of the sheet metal structure and the conductive grounding element into a single integrated component. By creating conductive portions directly on the sheet metal surface through selective resin removal, the sheet metal itself serves as both the structural element and the conductive grounding path. This eliminates the need for separate conductive members, washers, or other additional components, thereby reducing assembly complexity while maintaining reliable electrical connection.
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 achieves stable electrical grounding, reduces EMI and ESD risks, and simplifies the assembly process by minimizing the number of required connection structures, thereby lowering costs and assembly time.
Implementation Method 1
a first conductive portion of which the metal layer is exposed by the insulative layer being exfoliated by laser working in the first sheet metal
Data Source
AI summary
A coupling structure is provided in an image forming apparatus that forms an image on a recording material and constituted to couple a first sheet metal and a second sheet metal having an insulative layer on a surface of a metal layer, respectively. The coupling structure includes a first conductive portion, a second conductive portion and a coupling portion. The metal layer of the first conductive portion is exposed by the insulative layer being exfoliated by laser working in the first sheet metal. The metal layer of the second conductive portion is exposed by the insulative layer being exfoliated by laser working in the second sheet metal. The coupling portion couples the first sheet metal and the second sheet metal in a state in which at least a part of the first conductive portion and at least a part of the second conductive portion are contacted with each other.