Stapler Refill Sidewall Structure to Prevent Staple Sheet Blocking
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Solution Overview
Problem
Existing refills for electric staplers experience blocking issues where staple sheets adhere to each other, preventing successful feeding during the stapling process.
Innovation Solution
The refill design includes inclined walls on either side, angled in the axial direction, with at least part of these walls at the same height from the bottom surface, facilitating staple sheet separation and preventing adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If staple sheets are stacked closely together in the refill, then the refill capacity is improved, but adhesion between staple sheets occurs causing blocking
Solution Approach 1:
The side walls are divided into multiple sections: a lower section that is inclined to separate staple sheets, and an upper section that is vertical to contain them. This segmentation allows the refill to both accommodate multiple staple sheets and prevent their adhesion through the inclined portion.
Solution Approach 2:
The side walls are designed with inclination in the axial direction (stacking direction) rather than only in the discharge direction. This dimensional change in wall orientation creates separation between staple sheets stacked in the axial direction, preventing adhesion while maintaining refill capacity.
2Ease of manufacture
If the refill structure is simplified, then the manufacturing cost is reduced, but blocking occurs due to lack of separation mechanism
Solution Approach 1:
The separating function and containing function are merged into a single side wall structure. The side wall simultaneously performs separation (through its inclined lower portion) and containment (through its upper vertical portion), eliminating the need for separate separation mechanisms and simplifying manufacturing.
Solution Approach 2:
The side walls incorporate inclined surfaces that create a gradual transition rather than sharp angles. This curved/angled design facilitates smooth separation of staple sheets while maintaining structural simplicity and ease of manufacture.
3Device complexity
If staple sheets are discharged horizontally, then the discharge mechanism is simplified, but adhesion between sheets occurs during discharge
Solution Approach 1:
The inclined side walls perform preliminary separation action on staple sheets before they reach the discharge opening. By separating sheets in advance during their passage through the refill, the discharge mechanism remains simple while adhesion is prevented beforehand.
Data Source
Figure 1A
Figure 1B
Figure 2A~2B
AI summary
A refill includes: a bottom wall; a first side wall; a second side wall; and a front wall in which a discharge opening is formed. The first side wall includes, in a part thereof in a stacking direction, a first inclined wall extending in a coupling direction of staples and inclined in an axial direction. The second side wall includes, in a part thereof in the stacking direction, a second inclined wall extending in the coupling direction of the staples and inclined in the axial direction. The first inclined wall and the second inclined wall are inclined in the same direction, and at least a part of the first inclined wall and at least a part of the second inclined wall are formed at the same height from a bottom surface of the bottom wall in the stacking direction.