TECHNICAL FIELD
[0001] This invention relates to an image forming apparatus which uses a cartridge containing
an image member on which transferable toner images are formed.
BACKGROUND ART
[0002] U.S. Patent 4,876,577, Ogura et al, issued October 24, 1989, shows an electrophotographic
apparatus which receives a cartridge containing a photoconductive drum. The cartridge
includes both a charging mechanism for charging the drum and a cleaning mechanism
for cleaning it. An access opening is provided for imagewise exposure of a charged
surface of the drum to create an electrostatic image on the drum. The electrostatic
image is toned through another access opening in the cartridge by one of two toning
stations which are rotatable into position opposite the access opening to create a
toner image. The toner image is transferred to a receiving sheet fed through a receiving
sheet opening into contact with the drum. The receiving sheet is separated from the
drum by a special mechanism which is part of the cartridge and fed outside of the
cartridge to a fusing device.
[0003] U.S. Patent 4,591,258, to Nishino et al, issued May 27, 1986, shows a cartridge containing
a rotatable photoconductive drum with charging, cleaning and development stations
also within the cartridge. An access opening to the drum permits transfer of toner
images to a receiving sheet fed into engagement with the drum. Rotation of the drum
is accomplished by a driving connection at the end of the cartridge which must mate
with a drive member in the receiving apparatus. Projections are provided on the cartridge
to prevent damage to the cartridge driving connection member from careless handling.
[0004] Many other references show such image member cartridges, and they are used commercially
in personal copiers and laser printers. In general, the photoconductive drum is driven
by an end connection to the drum through an end of the cartridge. Mounting of the
cartridge in the image forming apparatus requires assuring that the drive connection
is effectively made.
[0005] U.S. Patent 4,712,906, to Bothner et al, issued December 15, 1987, shows a transfer
drum for a color printer. In one embodiment, a series of different color toner images
are transferred to a receiving sheet carried by the drum which rotates to repeatably
present the receiving sheet to an image member. In another embodiment, the different
color toner images are transferred directly to the outside surface of a transfer drum
to create a multicolor image on the transfer drum which is subsequently transferred
in a single step to a receiving sheet at a position remote from the image member.
Other references show an intermediate transfer member in the form of an endless web
rather than a drum; see for example, U.S. Patent 4,453,820, Suzuki, issued June 12,
1984.
[0006] U.S. Patent 4,299,474 to Ernst et al, issued November 10, 1981, shows a compact desk-top
copier in which space is saved by putting the motor, cooling system and drives for
a photoconductive image member inside the image member. This structure utilizes what
had previously been generally unused space to house substantial, necessary components,
thereby reducing the size of the copier.
DISCLOSURE OF THE INVENTION
[0007] It is an object of the invention to accurately position an image member loaded in
an image forming apparatus as part of an image member cartridge with respect to a
transfer surface associated with a transfer member which transfer member is not part
of the cartridge.
[0008] This and other objects are accomplished by an image forming apparatus which includes
a replaceable cartridge supporting an image member. The cartridge includes an access
opening for transfer of toner images from the image member to a transfer surface.
The image forming apparatus includes a transfer member not part of the cartridge and
having a transfer surface associated with it for receiving toner images from the image
member. The cartridge is urged toward the transfer member to urge the image member
into transfer engagement with the transfer surface. Control structure associated with
the transfer member engages the cartridge to accurately position the image member
with respect to the transfer member.
[0009] According to a preferred embodiment, the image member is drum-shaped, having a cylindrical
outer image surface upon which toner images are formed as the image member rotates
about an axis of rotation. The transfer member is a transfer drum also having an axis
of rotation and a cylindrical outer surface. The image forming apparatus includes
means for controlling the relative positions of the axes of rotation of the transfer
member and the image member to maintain them parallel. Maintenance of parallelism
between the axes of rotation of the image member and transfer member prevents image
degradation during transfer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] In the detailed description of the preferred embodiment of the invention presented
below, reference is made to the accompanying drawings, in which:
Fig. 1 is a perspective schematic of an image forming apparatus with housing and other
support parts eliminated for clarity of illustration.
Fig. 2 is a perspective view illustrating the drive train of an image forming apparatus
with some parts in phantom and other parts eliminated for clarity of illustration.
Fig. 3 is a front schematic of the image forming apparatus shown in Fig. 1 with portions
of an image member cartridge shown in cross section for clarity of illustration.
Fig. 4 is a front schematic of the drive train and cartridge portions of the image
forming apparatus with portions eliminated and broken away for clarity of illustration.
Fig. 5 is a perspective view of a cartridge and a mounting structure portion of an
alternative image forming apparatus.
Fig. 6 is a perspective view of an over-center spring mechanism forming a part of
the apparatus shown in Fig. 5.
Figs. 7 and 8 are front views of the structure shown in Fig. 5 in its partially loaded
and fully loaded conditions, respectively.
Figs. 9 and 10 are rear views of the structure shown in Figs. 7 and 8 also in its
partially loaded and fully loaded conditions, respectively.
Figs. 11 and 12 are top views of the structure shown in Figs. 5-10 in its partially
loaded and fully loaded conditions, respectively.
Figs. 13 and 14 are front and rear views, respectively, of a circular disk which forms
part of a knob 121 shown in Figs. 5 and 6.
Fig. 15 is a top section of a transfer drum illustrating an alternative drive mechanism
for the apparatus shown in Fig. 1.
BEST MODE OF CARRYING OUT THE INVENTION
[0011] An image forming apparatus, for example, a printer 1, is shown in Fig. 1 with housing
and support structures eliminated for clarity of illustration. Printer 1 includes
an image member, for example, a photoconductive drum 2 which is rotatable through
a series of stations for forming a series of toner images of different colors. Photoconductive
drum 2 has a cylindrical image surface which is first charged by a charging station
4 and then imagewise exposed by a laser 5 to create a series of electrostatic images.
The electrostatic images are toned by toners of different color by a movable development
device 6 which includes 3 or 4 separate development units. Each unit applies a different
color toner to one of the series of electrostatic images to create a series of different
color toner images on the cylindrical image surface of drum 2. The series of different
color toner images are transferred in registration to a transfer surface associated
with a transfer drum 10 to create a multicolor color image on that surface. As shown
in Fig. 1, the surface to which the toner images are transferred is a cylindrical
peripheral surface of drum 10 itself. However, the toner images could also be transferred
to a receiving sheet held on the surface of drum 10 as is well known in the art.
[0012] The multicolor image is transferred by a transfer station 21 to a receiving sheet
fed from a receiving sheet supply 45. The receiving sheet is then transported to a
fuser 23 where the multicolor image is fixed and then to an output hopper 44 through
an inverting path.
[0013] After transfer of the multicolor image from the surface of drum 10 to the receiving
sheet, the transfer surface of the transfer drum 10 is cleaned by an articulating
cleaner 30 so that it may receive a new set of images. The photoconductive drum 2
is cleaned continuously during image formation by a cleaning device 12.
[0014] As will be shown in later Figs., the photoconductive drum 2 is supplied to the printer
1 in a cartridge 3 which cartridge may also contain other portions of printer 1. For
example, the cartridge may contain the charging device 4, the developing device 6
and/or cleaning devices 30 and 12.
[0015] One example of such a cartridge 3 is shown in Fig. 3 in which the cartridge housing
is shown in section while the rest of the apparatus is shown schematically. According
to Fig. 3, a cartridge housing contains image member 2, an opening for exposure by
laser 5, charging device 4 and image member cleaning device 12. It also includes a
sump 11 for receiving toner cleaned by cleaning device 12 off image member 2 and a
sump 35 for receiving toner cleaned off transfer drum 10 by transfer drum cleaner
30. The housing also includes an opening 7 providing access to image member 2 for
development device 6 and an opening 9 providing access to image member 2 for transfer
drum 10.
[0016] Articulating cleaner 30 is moved in and out of engagement with transfer drum 10 by
a solenoid 31. It includes a cleaning roller which rolls on the surface of transfer
drum 10 which roller is biased and formed of a material which encourages removal of
toner to the roller. Cleaned toner is scraped off the roller by a scraping blade 32.
An opening 36 in the cartridge housing receives scraped toner into sump 35.
[0017] A receiving sheet is fed from a receiving sheet supply 20 into transfer relation
with transfer drum 10. In the structure shown in Fig. 3, transfer is accomplished
by a corona transfer station 21, known in the art. The transfer sheet is picked off
transfer drum 10 by a movable pick-off 22 which also directs the transfer sheet to
fuser 23.
[0018] Prior cartridges which contained image members such as photoconductive drum 2 included
a relatively complex drive connector at one end of the cartridge which must be engaged
with an appropriate drive in the receiving apparatus to rotate drum 2 past the toner
image forming stations. As shown in Figs. 2 and 3, the need for such a drive connector
is eliminated. A motor 42 drives a drive gear 40 which in turn drives a gear 44 connected
to transfer drum 10. Transfer drum 10 is made up of material somewhat softer than
photoconductive drum 2, for example, polyurethane. Photoconductive drum 2 engages
transfer drum 2 through opening 9 and is frictionally driven by transfer drum 10 for
its entire operation. Thus, opening 9 provides access to image member 2 for both transfer
and for frictional, driving engagement with transfer drum 10. With this structure,
no separate drive connection needs to be made between transfer drum 2 and the receiving
apparatus. This greatly simplifies the manufacture of the cartridge and its cost as
well as loading of the cartridge 3 in the printer 1. Fig. 2 is a perspective drawing
illustrating the drive train from motor 42 through transfer drum 10 and photoconductive
drum 2.
[0019] The term "engagement" as used herein with reference to the image member and the transfer
member is preferably direct contacting engagement of those members. However, although
not preferred, it can also be engagement through a receiving sheet carried by the
transfer member.
[0020] Although transfer drum 10 is shown with an external drive engagement between transfer
drum 10 and motor 42, motor 42 could be positioned inside transfer drum 10 and internally
engaged with drum 10 to save space in printer 1. This latter embodiment is shown in
Fig. 15.
[0021] According to Fig. 15, transfer drum 10 includes an outer layer 201 of polyurethane
cast or otherwise formed on an aluminum or steel base 202. Layer 201 defines a cylindrical
transfer surface 207 to which several single color toner images are transferred directly
to form a multicolor image. A pair of gudgeons 203 and 204 support base 202 and are
journaled for rotation about fixed shafts 205 and 206.
[0022] Shafts 205 and 206 rotate about different portions of a single axis of rotation and
are considered a single shaft for all purposes herein. Shafts 205 and 206 are fixed
in mechanism plates 208 and 209 of the printer, and support an internal drive housing
210 located inside transfer drum 10. Internal drive housing 210 includes a motor 212
and planetary gear box 213. The planetary gear box provides a suitable gear reduction
between the motor and an output shaft 221. A drive gear 222 is fixed on output shaft
221 and is rotated by output shaft 221 to drive a first idler gear 225. First idler
gear 225 is fixed to an idler shaft 226 journaled for rotation with respect to drive
housing 210. A second idler gear 227 is also fixed to and is rotated by idler shaft
226. Second idler gear 227 engages an internal gear 230 fixed to the inside of drum
base 202 to rotate drum 10 with respect to shafts 205 and 206 and housing 210. A hole
217 in the center of shaft 206 provides an exit for wiring the motor 212.
[0023] With the structure shown in Fig. 15, transfer drum 10 comes to printer 1 with its
own internal drive. That drive does not need to be separately mounted in the printer,
saving a step in printer final assembly. More importantly, the drive does not take
up space in the printer, allowing the printer to be more compact.
[0024] The structure shown in Fig. 15 is particularly useful to drive a transfer drum 10
which receives toner images directly to its surface and then transfers them to a receiving
sheet, because such a drum does not require a vacuum source or other structure for
holding a receiving sheet to the drum surface, thereby leaving the room necessary
for the transfer drum drive housing 210. It is also particularly useful with a cartridge
loading image member 2 as shown in Figs. 2-5 which image member is driven by transfer
drum 10, since, with such a structure, no usable space is taken up in printer 1 for
a drive for either of drums 10 or 2.
[0025] Although driving the image member 2 utilizing peripheral engagement with transfer
drum 10 through access opening 9 greatly simplifies cartridge 3, some precision in
the placement of cartridge 3 is important in this apparatus. In the structure shown
in Fig. 3, cartridge 3 is shown supported by receiving mechanism 50 which positions
the cartridge so that sufficient engagement between drum 2 and drum 10 is obtained
to both transfer images and drive drum 2. For best image quality, it is necessary
to control both the size of the nip between the drums and to maintain the axes of
rotation of the drums parallel. To do this with the Fig. 3 construction is feasible
for modest image quality. However, for highest image quality, tolerances in the manufacture
of cartridge 3, receiving structure 50 and the location of drum 10 become confining.
Accordingly, more precise positioning mechanisms are shown in Figs.4-14.
[0026] According to Fig. 4, cartridge 3 includes drum 2, charging station 4 and cleaning
device 12, but does not include a sump for receiving toner cleaned from drum 10. Transfer
drum 10 is supported on a shaft 51 which, in turn, is supported by a pair of mechanism
plates of the apparatus, for example, mechanism plates 208 and 209, shown in Fig.
15. Also supported on shaft 51 are a pair of triangularly shaped plates 52 at opposite
ends of drum 10. Plates 52 are also connected by an auxiliary shaft 54 and are generally
rotatable about shaft 51 but rigidly fixed with respect to each other.
[0027] Photoconductive drum 2 is supported for rotation about an axis 56 by a shaft 57 which
shaft extends beyond the end walls of cartridge 3. Drum 2 rotates with respect to
shaft 57, so shaft 57 is fixed with respect to cartridge 3. A slot 55 in each of triangular
plates 52 is shaped to receive snugly the ends of shaft 57.
[0028] To load cartridge 3 in the embodiment shown in Fig. 4, plates 52 can be rotated to
a position slightly counterclockwise from that shown in Fig. 4 to receive shaft 57
into slots 55. Plates 52, transfer drum 10 and cartridge 3 are then rotated clockwise
around shaft 51 until plates 52 rest on a stop 62 which is a permanent portion of
printer 1. The cartridge 3 can still be rotated about shaft 57 until a portion of
cartridge 3 rests on another stop 61 which is also a permanent part of printer 1.
[0029] Slots 55 in plates 52 are parallel with each other and define control surfaces which
maintain a parallel relation between the axes of rotation of drums 10 and 2. Stops
61 and 62 generally orient the cartridge in printer 1 for access to the exposing and
developing devices 5 and 6 (Figs. 1 and 3). The nip between drums 10 and 2 is controlled
by a spring 65 which urges cartridge 3 toward transfer drum 10 and the image surface
of drum 2 into engagement with the transfer surface associated with drum 10. A spring
67 may also be used to maintain the contact between cartridge 3 and stop 61, thereby
preventing rotation of the cartridge around shaft 57. Spring 67 may not in fact be
necessary, since the rotation of transfer drum 10 will also urge cartridge 3 against
stop 61. However, spring 67 can be part of an upper part of printer 1 which, after
the insertion of cartridge 3 is closed onto a lower part, which lower part holds motor
42, transfer drum 10, laser 5, development device 6 and associated support structure.
Spring 65, although part of the lower portion of the apparatus, can also be tensioned
and/or applied to cartridge 3 as part of this closing operation.
[0030] Figs. 5-12 show another approach to positioning an image member cartridge in
an image forming apparatus similar to that shown in Fig. 1. According to Fig. 5, a cartridge 103 containing an image member 2 is to be loaded
into an apparatus which includes a transfer drum 10 with the axes of rotation of drums
2 and 10 sufficiently parallel to avoid image degradation during transfer of high
quality images, which images must be registered with great accuracy to form a quality
multicolor image.
[0031] Transfer drum 10 is supported on a shaft 111, which, in turn, is supported by front
and rear guide plates 112 and 113, respectively. Shaft 111, of course, may be in two
sections as are shafts 205 and 206 shown in Fig. 15. Guide plates 112 and 113 extend
substantially to the right from transfer drum 10 and each include control surfaces
115 and support surfaces 116 which cooperate with portions of cartridge 103.
[0032] As best seen in Figs. 7-10, an over-center spring mechanism 120 is actuated to drive
cartridge 103 from an unloaded condition shown in Figs. 7 and 9 to a fully loaded
condition shown in Figs. 8 and 10.
[0033] Cartridge 103 is positioned in the apparatus by the operator resting left and right
rear support bosses 131 and 132, respectively, on rear support surface 116 as shown
in Fig. 9, a single front support boss 133 on front guide surface 116, with all three
support bosses thus resting on support surfaces 116. Support surfaces 116 are generally
horizontal.
[0034] Drum 2 is mounted in cartridge 103 on a support shaft 105 (which also may be in two
sections as shown in Fig. 15), and rotates about an axis at the center of the shaft.
Over-center spring 120 is actuated (as described below) to push cartridge 103 to the
left as shown in Fig. 8. This action pushes shaft 105 into contact with control surfaces
115 of guide plates 112 and 113. Control surfaces 115 are parallel with each other.
Their projection is generally tangent to transfer drum shaft 111. As seen in Figs.
8 and 10, over-center spring 120 pushes cartridge 103 until shaft 105 rides up control
surfaces 115 until drum 2 engages transfer drum 10. A notch 119 in guide plates 112
and 113 causes cartridge 103 to no longer be supported by bosses 131 and 133.
[0035] Thus, in its fully loaded condition shown in Figs. 8 and 10, with drum 2 engaging
drum 10, cartridge 103 is supported only by the ends of shaft 105 riding up parallel
control surfaces 115 and by boss 132 resting on support surface 116. This three-point
contact forces shaft 105 to always contact both control surfaces 115. Thus, to the
extent that the peripheral surfaces of drums 2 and 10 are cylindrical and accurately
mounted on shafts 105 and 111, and the location of control surfaces 115 are accurate,
the axes of drums 2 and 10 will be parallel.
[0036] The extent of the parallelness between the axes is a determining factor on the image
quality in transfer. If, for example, the support boss 133 were allowed to continue
to contact guide surface 116, it would be possible for either end of shaft 105 to
become out of contact with its control surface 115, thereby losing parallelness between
the axes of rotation of the drums. This might be overcome by preciseness in the manufacture
of the housing of cartridge 103 and bosses 132 and 133. However, with the structure
shown in Figs. 5-12, the only items required to be precise in the cartridge are the
drum 2 and its support shaft 105. In the receiving apparatus, control surfaces 115
also must be accurately positioned with respect to shaft 111 and shaft 111 must be
accurately positioned with respect to transfer drum 10.
[0037] A roller 160 is shown in Figs. 11 and 12, and is part of a structure to prevent movement
of cartridge 103 to the rear. A complementary roller or spring to the front of the
path of cartridge 103 is not shown.
[0038] It also may be desirable to urge the top of the cartridge gently in a downward direction
during operation to prevent engagement of the drums from unseating it. This can be
accomplished with a spring applied as part of closing the apparatus after loading
of cartridge 103.
[0039] Cartridge 103 can be pushed to the left (as seen in Fig. 8) by any appropriate spring
mechanism. However, Figs. 6, 11 and 12 illustrate an over-center spring mechanism
120 which is particularly useful for this function.
[0040] As best seen in Figs. 5, 6, 11 and 12, a support housing 125 is attached to printer
1 by suitable means, not shown, and supports the rest of over-center spring mechanism
120. Referring to Fig. 6, a customer actuated knob 121 is rotated by the person inserting
cartridge 103. Knob 121 is keyed through a shaft 122 to a drive roller or gear 128.
Rotation of knob 121 rotates drive roller 128 which in turn rotates a driven roller
123. Driven roller 123 is keyed to a lever 124 through a shaft 126. Thus, rotation
of knob 121 rotates lever 124 around shaft 126. Lever 124 pushes cartridge 103 into
its loaded condition and holds it there with the desired force urging engagement of
drums 2 and 10.
[0041] A pair of springs 127 are mounted between a spring support 141 on housing 125 and
a spring support rod 142 (Fig. 5) on lever 124. Shaft 126 is between the attaching
positions of springs 127. Thus, springs 127 have a dead-center position between latched
and unlatched conditions of lever 124 where the shaft 126 lines up with the attaching
positions. That is, as knob 121 is rotated in a counterclockwise direction as seen
in Fig. 6, lever 124 is driven in a clockwise direction toward a latching position
urging cartridge 103 to the left until photoconductive drum 2 engages transfer drum
10. In this movement, spring 127 goes through a "dead-center" position in which it
is at its maximum length and therefore its maximum stressed condition. Further clockwise
rotation of lever 124 causes springs 127 to urge lever 124 into engagement with cartridge
103 and cartridge 103 into its loaded condition as shown in Fig. 8. To unload cartridge
103, knob 121 is rotated in a clockwise direction to rotate lever 124 in a counterclockwise
direction as seen in Fig. 6 until springs 127 pass through their dead center position.
At this point, further rotation of knob 121 is aided by springs 127 urging lever 124
toward its totally unlatched position, shown in Fig. 5 with lever 124 resting against
a pair of lever stops 143 where lever 124 will not interfere with removal of the cartridge.
Thus, with the over-center spring structure 120, lever 124 is generally urged by springs
127 toward either a latched condition shown in Figs. 6, 8, 10 and 12 or toward an
unlatched condition shown in Figs. 5, 7, 9 and 11.
[0042] Knob 121 can be constructed so that the customer who is loading the cartridge does
not, in fact, feel the final positioning of the cartridge in its loaded condition
or the positioning of lever 124 against stops 143. Knob 121 includes a circular plate
149, the front and rear sides of which are shown in Figs. 13 and 14, respectively.
Drive shaft 122 is positioned in a hole 152 through plate 149. The front surface of
plate 149 includes a groove 153 contiguous with the front portion of hole 152. Shaft
122 includes a protrusion 154 which rides in groove 153 except where not permitted
by ends 156 and 157 of the groove 153.
[0043] In operation, knob 121 is turned in either direction until protrusion 154 engages
one of groove ends 156 or 157. From that point on, rotation of knob 121 rotates shaft
122 until the "over-center" condition of springs 127 occurs. At this point, the spring
accelerates the rotation of lever 124 in either a latching or unlatching direction
causing the shaft 122 to rotate ahead of either groove end 156 or 157 until lever
124 reaches its fully latched or unlatched condition. This design has the advantage
of fully positioning the lever 124 without the spring acceleration of lever 124 or
its stopping being felt by the person rotating knob 121. It also discourages over
rotation of lever 124 by the operator which can damage cartridge 103 or drums 2 or
10.
[0044] The positioning device shown in Figs. 5-14 positions the photoconductive drum 2 against
the transfer drum 10 with the axes of revolution of the two drums parallel. Precision
is required in only the manufacture and assembly of shafts 111 and 105, drums 2 and
10 and guide surfaces 115. This parallelism is important to prevent image degradation
in high-quality transfer. This makes it particularly usable in a multicolor printer
providing high-quality multicolor images which are the results of superimposing a
series of single color images. It is particularly usable when the photoconductive
drum is driven by the transfer drum (as shown in Figs. 1-4) because such driving engagement
between the two drums requires a substantial nip which increases the degradation of
the image if the axes are not parallel. However, it certainly can be used in structures
in which the photoconductive drum 2 is driven by its own drive means and either drives
the transfer drum or is driven independently of it.
[0045] Note that the manufacture and location of bosses 131, 132 and 133 are not critical
to parallelism of the axes, nor is the manufacture of guide surfaces 116. Note also
that guide surface 115 maintains parallelism of shafts 105 and 111. If the two shafts
are the same size, surfaces 115 should be parallel with each other and their extensions
should be tangent to the periphery of shaft 111. If shaft 111 is larger than shaft
105, extensions of guide surfaces 115 should intersect shaft 111 accordingly. Shaft
105 is preferably a stationary shaft with photoconductive drum 2 mounted for rotation
with respect to it. This eliminates the necessity of making guide surfaces 115 bearing
surfaces. Shaft 111 can rotate with transfer drum 10 or be stationary, with transfer
drum 10 rotating with respect to it as shown in Fig. 15.
[0046] Shaft 105 could be rotatable with photoconductive drum 2. In such a design, it would
be preferable to have shaft 105 supported for rotation in bearings, which bearings
have a housing which contacts guide surfaces 115. Alternatively, if surfaces 115 are
made of self-lubricating material, shaft 105 can rotate with drum 2 on surfaces 115.
[0047] Although each of the positioning structures shown herein has particular adaptability
and is designed for a transfer drum 10 which receives toner images directly on its
outer transfer surface, the structures can also be used with a transfer drum which
supports a receiving sheet on its outer surface.
[0048] The invention has been described in detail with particular reference to a preferred
embodiment thereof, but it will be understood that variations and modifications can
be effected within the scope of the invention as defined in the appended claims.