Staple-Less Binding Unit Projection Alignment for Consistent Binding
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Solution Overview
Problem
Existing staple-less binding units face issues with inconsistent binding force due to variations in the center positions and outer shapes of projecting portions, leading to incomplete or torn bindings, especially when binding sheets with varying thicknesses or types.
Innovation Solution
A manufacturing method for a staple-less binding unit involving the formation of binding units with recesses and projections, where the center positions and outer shapes of projecting portions are adjusted using dies to ensure precise alignment and contact, thereby improving the binding force and preventing sheet tearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If binding units are formed using a die without adjustment, then manufacturing process is simple, but center positions of projecting portions vary leading to inconsistent binding force
Solution Approach 1:
The patent applies preliminary action by adjusting the center positions of projecting portions on the binding units before actual binding operations. The adjustment process is performed in advance during manufacturing, ensuring that subsequent binding operations consistently achieve proper alignment and uniform binding force across all sheets, regardless of variations in sheet thickness or type.
2Adaptability or versatility
If projecting portions have fixed outer shapes, then manufacturing is easier, but binding effectiveness varies with different sheet thicknesses and types
Solution Approach 1:
The patent applies local quality by adjusting the outer shapes of specific projecting portions based on their individual positions and functions. Different projecting portions are customized with optimized shapes and dimensions to effectively bind various sheet types and thicknesses, rather than using a uniform design for all portions.
Solution Approach 2:
The patent applies parameter changes by systematically varying the outer shape parameters (dimensions, curvature, orientation) of projecting portions during the adjustment process. This allows the binding units to adapt to different sheet characteristics while maintaining consistent manufacturing through controlled parameter modification.
3Manufacturing precision
If center positions of projecting portions are not adjusted, then manufacturing is simpler, but alignment between binding units is poor causing incomplete bindings
Solution Approach 1:
The patent applies preliminary action by performing center position adjustments of projecting portions during the manufacturing stage. This preliminary alignment ensures that when binding units are used, the projecting portions from both units precisely align with corresponding recesses, eliminating misalignment issues during actual binding operations.
4Reliability
If outer shapes of projecting portions are not optimized, then manufacturing is easier, but pressure distribution is uneven causing sheet tearing
Solution Approach 1:
The patent applies local quality by optimizing the outer shapes of individual projecting portions to create appropriate local pressure distribution characteristics. Each projecting portion is shaped to effectively contact and compress specific regions of the sheets, ensuring uniform pressure distribution that prevents sheet tearing while maintaining manufacturing feasibility.
Data Source
AI summary
A manufacturing method of a staple-less binding unit that includes a first binding unit that has plural recesses and projections and a second binding unit that is arranged to face the first binding unit and has recesses and projections that fit to the recesses and the projections of the first binding unit and in which mediums are bound by being interposed between the first binding unit and the second binding unit in a thickness direction of the mediums includes forming the binding units with a die, adjusting center positions of projecting portions of the binding units formed by the die and removed from the die, and adjusting outer shapes of the projecting portions of which the center positions have been adjusted.