Dual-Contact Toner Cartridge Chip Module for Contact Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing toner cartridges experience poor electrical contact with the reading head due to deformation of communication and grounding conductive strips, leading to alignment issues and increased manufacturing costs.
Innovation Solution
A chip module with terminals having two contact ends and a secure mounting system ensures positive electrical contact by allowing each terminal to connect with both ends of the conductive strips, reducing the need for individual alignment and welding, and using identical terminal designs to lower manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single-contact terminals are used, then manufacturing cost is reduced, but electrical contact reliability deteriorates due to conductive strip deformation
Solution Approach 1:
Each terminal is segmented into two separate contact ends (first contact end and second contact end) instead of a single contact point. This segmentation allows the terminal to independently contact different portions of the conductive strip, ensuring that even if one contact area experiences deformation, the other contact end can still maintain reliable electrical connection.
Solution Approach 2:
The terminal structure transitions from a single-point contact (zero-dimensional) to a multi-point contact along the conductive strip length (one-dimensional). By distributing contact points along the longitudinal dimension of the conductive strip, the terminal can accommodate deformations and misalignments that occur during repeated cartridge installations.
2Manufacturing precision
If complex alignment structures are implemented, then electrical contact accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The terminal structure performs self-alignment through its dual contact end design. When the cartridge is installed, the flexible terminal automatically adjusts its position to establish contact with the conductive strip at both contact ends, eliminating the need for complex external alignment mechanisms or precision positioning features.
Solution Approach 2:
The terminal utilizes changes in its physical state (flexibility and elasticity) to adapt to variations in the conductive strip position. By designing the terminal with appropriate mechanical compliance, it can accommodate positional deviations without requiring high-precision alignment features, thereby reducing manufacturing complexity.
3Reliability
If multiple different terminal designs are used, then contact reliability is improved, but manufacturing cost increases
Solution Approach 1:
A single universal terminal design with two contact ends serves multiple functions: it can contact different portions of the conductive strip, compensate for various types of deformations, and maintain reliable electrical connection across multiple installation cycles. This universal design eliminates the need for multiple specialized terminal types.
Solution Approach 2:
All terminals in the chip module use the same homogeneous structure and material properties. This uniformity simplifies the manufacturing process by requiring only one type of terminal component, while the inherent dual-contact-end design ensures that each terminal can independently handle contact reliability requirements without needing variations in design.
Data Source
AI summary
A chip module of a toner cartridge includes a substrate, a memory, and a plurality of terminals. The substrate is provided with a plurality of circuit traces thereon. The memory is mounted to the substrate and electrically connected with the circuit traces. The terminals are spacedly arranged with respect to each other. Each of the terminals includes a connection portion mounted to the substrate and electrically connected with one of the circuit traces, and two contact ends electrically connected with the connection portion and spaced from each other. Because each terminal has two contact ends to be electrically connected and mechanically contacted with a conductive strip of a reading head of an electronic image-forming apparatus, the electrical connection between the chip module and the reading head of the electronic image-forming apparatus can be secured, thereby avoiding poor electrical contact.