Wire Contact Portion for Image Forming Apparatus
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Solution Overview
Problem
The existing image forming apparatus faces challenges in securely establishing electrical connections between the frame member and the replacement unit due to the low strength of contact portions formed by a metal wire bent into a plane shape, leading to potential damage during mounting and dismounting, which can result in unreliable electrical connections.
Innovation Solution
The image forming apparatus employs a contact portion formed by a metal wire bent along an intersection plane, with a directional setting that intersects with other planes at angles smaller than the acute intersection angle, and includes a resilient portion like a coil spring to bias the contact portion, reducing production costs and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal wire bent into a plane shape is used to form the contact portion, then production cost is reduced, but the contact portion strength is insufficient leading to damage during mounting and dismounting
Solution Approach 1:
The contact portion is configured to extend in three-dimensional space rather than being confined to a plane. Specifically, the wire extends in a first direction parallel to the side face, then bends in a second direction perpendicular to the side face to contact the other electrode. This spatial configuration increases contact strength while maintaining manufacturing simplicity.
2Ease of manufacture
If the contact portion is formed by a metal wire bent into a plane shape, then production cost is reduced, but electrical connection reliability deteriorates due to potential damage during mounting and dismounting
Solution Approach 1:
The contact portion transitions from a two-dimensional plane configuration to a three-dimensional spatial configuration. The wire extends parallel to the side face and then bends perpendicular to it, creating a spatial structure that is more resistant to damage during mounting and dismounting operations, thereby ensuring reliable electrical connection.
3Strength
If a cup-shaped metal member is used for the contact portion, then contact portion strength is sufficient, but production cost increases
Solution Approach 1:
The invention changes the geometric parameters of the contact portion from a complex cup-shaped three-dimensional form to a simpler wire configuration that extends and bends in specific directions. This parameter change maintains sufficient contact strength through proper spatial orientation while dramatically reducing manufacturing complexity and cost.
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 configuration ensures secure electrical connections between the frame member and the replacement unit while reducing production costs, minimizing the risk of contact portion damage during mounting and dismounting, and maintaining reliable electrical connections.
Implementation Method 1
a coil spring for biasing the contact portion against the outside (toward the frame member) of the replacement unit
Data Source
AI summary
An image forming apparatus including: a frame member including a first electrode and a replacement unit including a second electrode that electrically contacts the first electrode. The replacement unit is movable relative to the frame member along a moving direction. The moving direction includes a first direction and a second direction that intersects the first direction. The first electrode is formed by a wire and includes a contact portion. The contact portion, which is bent along an intersection plane, is movable in a third direction that is perpendicular to the first direction and the second direction. A direction of the contact portion is set so that the intersection plane intersects with a first plane and a second plane at angles smaller than an intersection angle formed by the intersection of the first plane and the second plane.