Ultrasonic Welded Supporting Unit for Compact Developer Assembly

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Solution Overview

Problem

Existing supporting units for rotatable members in image forming apparatuses often require additional space across the axial direction due to the use of screws for connecting bearing members to the frame, which can lead to increased size and cost.

Innovation Solution

A supporting unit that utilizes ultrasonic spot welding to connect a fixed member to a frame, eliminating the need for screws and minimizing the cross-axial size, by using a frame with surfaces extending in directions perpendicular to each other and welding them using ultrasonic spot welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If screws are used to connect bearing members to the frame, then connection strength is ensured, but the supporting unit size increases in the direction crossing the axial direction

Engineering Contradiction:

Improveconnection strengthVSAvoidsupporting unit size

Core Design Contradiction:

StrengthVSLength of stationary object

Solution Approach 1:

The patent replaces the mechanical screw connection system with an ultrasonic spot welding system. The ultrasonic welding apparatus applies ultrasonic vibration to melt and bond the bearing member directly to the frame, eliminating the need for screws and the associated recessed portions, thereby reducing the supporting unit size in the cross-axial direction while maintaining connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the connection method from mechanical (screws) to thermal-mechanical (ultrasonic welding). By applying ultrasonic vibration energy, the material properties at the interface are temporarily changed to enable bonding, achieving strong connection without increasing the cross-axial dimensions of the supporting unit.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If recessed portions are provided in bearing members for horn insertion, then ultrasonic spot welding can be performed, but the supporting unit occupies more space in the direction crossing the axial direction

Engineering Contradiction:

Improvewelding capabilityVSAvoidsupporting unit size

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

The patent extracts the horn insertion function from the bearing member structure. Instead of providing recessed portions in the bearing members for horn insertion, the ultrasonic welding is performed from the opposite side or through the frame structure, eliminating the need for additional space-consuming recessed portions while maintaining welding capability.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If screws are used for connecting bearing members, then assembly is straightforward, but material costs and device complexity increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidconnection structure complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical screw assembly process with ultrasonic spot welding. This substitution eliminates the need for threaded holes, screws, and associated fastening operations, thereby reducing device complexity and material costs while maintaining assembly straightforwardness through a single-step welding process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution prevents the upsizing of the supporting unit across the axial direction, reduces material costs, and enhances the bonding strength between the frame and the fixed member, while maintaining compatibility with resin materials for efficient assembly.

Implementation Method 1

ultrasonic spot welding

Methodology Applied

Scientific EffectUltrasonic vibration: Ultrasonic Vibration

Implementation Method 2

welded to the second surface by ultrasonic spot welding

Methodology Applied

Scientific EffectFriction heating: Viscous Heating

Data Source

PatentUS10691043B2Supporting unit, developer container, developing device, photosensitive member unit, process cartridge and manufacturing method of the supporting unit

Publication Date: 2020.06.23 CANON KK

AI summary

A supporting unit for supporting a rotatable member to feed a developer includes a frame including a first surface extending in a direction crossing an axis of the rotatable member and a second surface extending in a direction crossing the first surface, and a fixed member. The fixed member includes (i) a first opposing surface opposing and contacting the first surface, (ii) a second opposing surface opposing the second surface, and (iii) a first front side surface opposite from the second opposing surface. The second opposing surface is welded to the second surface by ultrasonic spot welding such that a first recess is formed on the first front side surface.