Patent Application
20060104676
The invention is directed to an image forming apparatus and, more particularly, e.g., to a toner cartridge of an image forming apparatus having a noise and/or vibration dampening mechanism.
Image forming devices including copiers, laser printers, facsimile machines, and the like, include a photo conductive drum (hereinafter “photoconductor”) having a rigid cylindrical surface that is coated along a defined length of its outer surface. The surface of the photoconductor is typically charged to a uniform electrical potential and then selectively exposed to light in a pattern corresponding to an original image. The areas of the photoconductive surface exposed to light are discharged, thus forming a latent electrostatic image on the photoconductive surface. A developer material, such as toner, having an electrical charge such that the toner is attracted to the photoconductive surface is used for forming the image. The toner is normally stored in a reservoir adjacent to the photoconductor and is transferred to the photoconductor by the developer roll. The thickness of the toner layer on the developer roll may be controlled by a nip, which is typically formed between a doctor blade and the developer roll. A recording sheet, such as a blank sheet of paper, may then be brought into contact with the discharged photoconductive surface and the toner therein is transferred to the recording sheet in the form of the latent electrostatic image. The recording sheet may then be heated thereby permanently fusing the toner to the sheet. In preparation for the next image forming cycle, the photoconductive surface may be discharged and residual toner removed.
Maintaining consistent contact and pressure with the developer roll may be problematic due to the fact that the developer roll profile may be non-uniform and thus, require the doctor blade to possibly move inward and outward to track the surface of the developer roll. Additionally, contact may be maintained across the entire length of the doctor blade to ensure even print quality across the entire width of the image. One problem in some prior systems, may be the undesirable vibration caused by the contact of the doctor blade with the developer roll, especially towards the end of a cartridge's life which may cause jitter. This problem has been addressed in some products by applying a foam seal behind the doctor blade. However, the geometries/configurations of some products, which also suffer from that problem and noise caused by the vibration, do not allow for the placement of seals or any dampening materials/extensions behind the blade.
The present invention according to one embodiment, may be directed to a toner cartridge for an image forming apparatus comprising the following: a doctor blade having top, back, front and bottom surfaces, the doctor blade having a vibration frequency during image forming, and first and second extensions positioned in communication with two locations on a doctor blade surface, e.g., a doctor blade front surface.
The present invention, according to another embodiment, may be comprised of a system and/or mechanism having the following: at least two extensions and/or contacts; the extensions and/or contacts in dampening communication with the front surface of a doctor blade to, e.g., substantially dampen, substantially reduce, and/or substantially eliminate audible vibration and/or noise associated with the blade of the image forming apparatus during image forming.
In addition, the present invention according to a further embodiment, provides a mechanism and/or system for substantially dampening, substantially reducing, and/or substantially eliminating vibration and/or noise associated with a doctor blade of an image forming apparatus comprising the following: at least one extension and/or contact in communication with the doctor blade, said extension and/or contact positioned relative to a doctor blade surface to, e.g., substantially dampen, reduce, and/or eliminate vibration and/or noise associated with the doctor blade.
According to another embodiment, the present invention is directed to a method for substantially reducing noise created by the movement of a doctor blade of an image forming apparatus during image forming. The method may comprise constraining a surface of the doctor blade during image forming at a point or points, e.g., two points along the front surface located, e.g., on either side of a center point of the blade such that any blade vibrations are, e.g., substantially shifted to inaudible frequencies.
While the present invention, according to same embodiments, is discussed/described herein in relation to a specific image forming apparatus and a given toner cartridge geometry/configuration, it will be apparent to persons skilled in the art, that the present invention, according to certain embodiments, is equally applicable to other image forming apparatuses and toner cartridges of various geometries and/or configurations and various other doctor blade/developer roll geometries and/or configurations. By way of example only, toner cartridges having geometries which allow for the addition of a seal behind the doctor blade, may alternatively or in addition utilize the present invention also.
A more complete understanding of embodiments of the present invention may be acquired by referring to the following description taken in conjunction with the accompanying drawings wherein:
The drawings herein illustrate doctor blade 20 substantially perpendicular to the developer roll 30, however, other orientations may also provide for transfer of proper toner amounts. The biasing member 50 may contact the top surface of the doctor 20 along the length of doctor blade 20 to ensure an even and distributed force may be applied across the entire width of the developer roll 30. According to an embodiment of the present invention, biasing member 50 may provide, e.g., about 1400 grams of force to the developer roll 30. However, depending upon the doctor blade/developer roll geometries and/or configurations, the force applied by biasing member 50 may vary to achieve varying, proper and/or appropriate toner amounts as known in the art.
As illustrated in
According to an embodiment of the present invention, and referencing
According to another embodiment, doctor blade 20 may be aligned substantially perpendicular to the surface of developer roll 30. The angle of doctor blade 20 relative to developer roll 30 may vary. Extensions 40a and 40b may be positioned relative to doctor blade 20 to provide a force on doctor blade 20 in a direction whereby vibration and/or noise of doctor blade 20 may be substantially reduced, and/or substantially eliminated.
According to a further embodiment, extensions 40a and 40b may provide a force on doctor blade 20 in a direction away from the surface of developer roll 30 depending upon the specific doctor blade/developer roll configuration/geometry, e.g., in a direction tangent to the surface of developer roll 30. However, the force provided and direction may vary as long as doctor blade vibration and/or noise is substantially reduced and/or substantially eliminated.
As noted, according to one embodiment of the present invention, extensions 40a and 40b or an extension may extend from a biasing member holder, e.g., leaf spring holder 40 illustrated in
While illustrated herein in relation to an embodiment, extensions 40a and 40b may be located at other points along the surface, e.g., front surface of the doctor blade 20 and, e.g., may include an extension on other surfaces of doctor blade 20. Extension 40a and 40b may be located at points along a surface, e.g., a front surface, of doctor blade 20 to (1) substantially reduce or eliminate audible doctor blade vibration frequencies; (2) substantially shift the vibration frequency of the doctor blade away from its natural frequency; (3) dampen doctor blade vibration and/or noise; and/or (4) substantially disrupt the doctor blade waveform while vibrating at a natural frequency.
As illustrated in an embodiment in
The present invention may be carried out in specific ways other than those described herein without departing from the scope and basic characteristics of the present invention. For example, a single extension and/or contact of a sufficient width and hence, having greater surface area contact with a doctor blade than the extensions and/or contacts illustrated, could be utilized to dampen vibration and/or noise. And a combination of extensions contacting a blade at different locations may also be utilized, e.g., including a combination of front and back contacts and extensions. Consequently, the described embodiments are to be considered in all respects as illustrative and not restrictive, and all changes and modifications coming within the meaning and equivalency of the appended claims are embraced herein.
