Patent Grant
9042745
This patent application is based on and claims priority pursuant to 35 U.S.C. §119 to Japanese Patent Application Nos. 2011-010015, filed on Jan. 20, 2011, and 2011-033159, filed on Feb. 18, 2011 in the Japan Patent Office, the entire disclosures of which are hereby incorporated by reference herein.
1. Field of the Invention
The present invention generally relates to a developer amount detector for detecting an amount of developer in a unit that is removably installable in an image forming apparatus by using optical elements, an image forming apparatus incorporating the developer amount detector, and a positioning structure for positioning the unit within the image forming apparatus.
2. Description of the Background Art
Image forming apparatuses such as copiers, printers, facsimile machines, plotters, and multifunction machines capable of at least two of these functions in which components in the image forming apparatus are formed as modular units and the respective units are removably installable in apparatuses have been widely developed. In particular, a process unit in which a development device, a toner cartridge, and a photoreceptor are formed as a single integrated unit is known. As developer contained in the process unit is consumed in use, however, it is necessary to notify users when it is time to replace the process unit. Accordingly, a variety of detection systems to detect an amount of the developer in the process unit have been proposed.
One type of detection system is a light transmission detector that utilizes optical elements. The light transmission-type detector for detecting the amount of the developer irradiates light into a developer container that contains the developer, and the amount of the developer is detected based on a length of time needed for the light to transverse the container and a timing with which the light is detected.
More specifically, the light-transmission detector is constituted by, for example, a light-emitting element, a light-receiving element, and first and second light-guiding members constituted by prisms and mirrors provided in a process unit. With this configuration, the light emitted from the light-emitting element is guided to the developer container in the process unit through the first light-guiding member, and the light thus guided to the developer container is then guided out of the developer container to the light-receiving element through the second light-guiding member. The amount of the developer is determined by a time period during which the light-receiving element receives the light and a timing at which the light-receiving element receives the light.
However, when the process unit is installed in the image forming apparatus, positions of the first and the second light-guiding members can be displaced relative to positions of the light-emitting element and the light-receiving element provided in the image forming apparatus, which degrades detection accuracy.
In order to solve this problem, JP-H02-284165-A proposes a configuration in which a light-receiving element is attached to the image forming apparatus via a rotary lever. With this configuration, when a process unit is installed in an image forming apparatus, the process unit contacts the rotary lever and rotates it to the light-receiving element is accurately relative to the process unit.
However, in this configuration, the rotary lever and a big link mechanism to rotate the rotary lever are required, which increases both the number of components and the size of the device, which in turn increases costs.
The present invention provides an improved developer amount detector capable of positioning optical elements relative to a removably installable unit in an image forming apparatus using an uncomplicated configuration while downsizing the image forming apparatus.
In one exemplary embodiment of the present invention, a developer amount detector detects an amount of developer contained in a developer container in a unit that is removably installable in an image forming apparatus. The developer amount detector includes optical elements, light-guiding members, a holder, and a positioning mechanism. The optical elements have a light-emitting element to emit light and a light-receiving element to receive the light for detecting the amount of the developer in the unit. The light-guiding members are provided in the unit and guide the light emitted from the light-emitting element to the light-receiving element. The holder, held in the image forming apparatus, holds the optical elements and is movable in a direction orthogonal to optical axes of the optical elements as the unit is being installed in the image forming apparatus. The positioning mechanism positions the unit within the image forming apparatus by restricting movement of the holder in the direction orthogonal to the optical axes of the optical elements relative to the unit in a state in which the unit is installed in the image forming apparatus.
In another exemplary embodiment of the present invention, an image forming apparatus includes a latent image carrier to carry a latent image; a unit removably installable in the image forming apparatus, having a developer container; and the above-described developer amount detector.
In yet another exemplary embodiment of the present invention, a positioning structure positions a unit within an image forming apparatus. The positioning structure includes optical elements, light-guiding members, a containing space, a planar holder, a projection, and a hole. The optical elements have a light-emitting element to emit light and a light-receiving element to receive the light. The light-guiding members are provided in the unit and guide the light emitted from the light-emitting elements to the light-receiving element. The containing space formed in a vertical wall of the image forming apparatus is defined by a bottom and side faces in the vertical wall. The planar holder is smaller than the containing space in a direction orthogonal to optical axes of the optical elements and is accommodated within the containing space of the image forming apparatus. The holder is movable in a direction orthogonal to the optical axes of the optical elements as the unit is being installed in the image forming apparatus. The projection is formed in one of the holder and the unit. The hole is formed in the other of the holder and the unit to accommodate the projection as the unit is being installed in the image forming apparatus. The holder is held by the bottom of the containing space in a state in which the unit is not installed in the image forming apparatus. The holder is moved by inserting the projection into the hole when the unit is being installed in the image forming apparatus. The holder is held by the projection that is fitted into the hole to restrict the movement of the holder in the direction orthogonal to the optical axes of the optical elements relative to the unit in a state in which the unit is installed in the image forming apparatus.
A more complete appreciation of the disclosure and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
In describing preferred embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner and achieve a similar result. Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views thereof, and particularly to
As illustrated in
An exposure unit 6 to expose the surface of the photoreceptor 2 is disposed above the process units 1Y, 1M, 1C, and 1Bk. The exposure unit 6 (serving as a latent image forming device) includes multiple light sources, f-θ lenses, reflection mirrors. The light sources in the exposure unit 6 emit light to the surfaces of the respective photoreceptors 2 in accordance with image data. Although the exposure unit 6 is disposed above the process units 1Y, 1M, 1C, and 1Bk as shown in
A transfer unit 7 is disposed beneath the process units 1Y, 1M, 1C, and 1Bk. The transfer unit 7 includes an intermediate transfer belt 8 formed by an endless belt. The intermediate transfer belt 8 is looped around a driving roller 9 and a driven roller 10 both serving as support rollers. As the driving roller 9 rotates in a counterclockwise direction shown in
Four primary transfer members 11, serving as a primary transfer members, are disposed facing the photoreceptors 2 via the intermediate transfer belt 8. The four primary transfer members 11 presses an internal faces of the intermediate transfer belt 8, and primary transfer nips are formed in portions contacting the intermediate transfer belt 8 with the photoreceptors 2Y, 2M, 2C, and 2Bk, respectively. The primary transfer rollers 11 are connected to a power source, and a predetermined direct current (DC) and/or alternating-current voltage (AC) is applied to the primary transfer rollers 11.
A secondary transfer roller 12, serving as a secondary transfer member, is disposed facing the driving roller 9. The secondary transfer roller 12 presses an outer circumferential surface of the intermediate transfer belt 8, and a second transfer nip is formed in a portion contacting the secondary transfer roller 12 with the intermediate transfer belt 8. The secondary transfer roller 12 is connected to a power source, and a predetermined direct current (DC) and/or alternating-current voltage (AC) is applied to the secondary transfer roller 12.
In addition, a cleaning device 13 to clean the surface of the intermediate transfer belt 8 is disposed facing to the outer circumferential surface of the intermediate transfer belt 8. A waste toner transport house extending from the cleaning device 13 is connected to an entrance of a waste-toner container 14 positioned beneath the transfer unit 7.
A sheet cassette 15 is disposed in a lower portion of the image forming apparatus 1000 and contains multiple recording media P such as paper sheet and overhead projector (OHP) sheet. A feeding roller 16 that feeds the recording medium P contained in the sheet cassette 15 is provided in the sheet cassettes 15. By contrast, a pair of discharging sheet rollers 17 to discharge the recording medium P and a discharge sheet tray 18 on which the discharged recording medium P is stacked are disposed in an upper portion of the image forming apparatus 1000.
A guide path R through which the recording medium P is transported from the sheet cassette 15 to the discharge sheet tray 18 via the secondary transfer nip is formed in the apparatus body 100 of the image forming apparatus 1000. A registration pair 19 is disposed in the guide path R on an upstream side from the second transfer roller 12 in a direction in which the recording medium P is conveyed. A fixing device 20 is disposed in the guide path R on a downstream side from the second transfer roller 12 in the direction in which the recording medium P is conveyed.
Next, a copying operation using the above-described image forming apparatus 1000 is described below with reference to
In addition, when copying operation is started, the driving roller 9 is activated, thus rotating the intermediate transfer belt 8 in a direction indicated by arrow shown in
In addition, along with these processes, when the copying operation is started, the feed roller 16 sends out the recording medium P from the sheet cassettes 15. Then, the pair of registration rollers 19 stops the recording medium P from conveying in the guide path R. The registration rollers 19 forward the recording medium P to the secondary transfer nip between the intermediate transfer belt 8 and the secondary transfer roller 12, timed to coincide with the arrival of the multicolor toner image formed on the intermediate transfer belt 8. At this time, a transfer voltage whose polarity is opposite to the toner charging polarity of the toner image on the intermediate transfer belt 8 is applied to the secondary transfer roller 12, which forms a transfer electric field in the secondary transfer nip. Then, in the secondary transfer process, a superimposed four-color toner on the intermediate transfer belt 8 is transferred onto the recording medium P at one time. The recording medium P onto which multicolor image is transferred in the secondary transfer nip is transported to the fixing device 20, where the four-color toner image thus transferred is fixed on the surface of the recording medium P with heat and pressure in a fixing process. After the fixing process, the recording medium P is discharged toward the discharge sheet tray 18 located outside of the apparatus body 100 through the guide path R by the pair of discharging sheet rollers 17 and then is stacked on the discharge sheet tray 18.
It is to be noted that, although the image forming operation when the full color image is formed is described above, monochrome image can be formed by using one of the four process units 1Y, 1M, 1C, and 1Bk or the two or three color images can be formed using two or three of these process units 1Y, 1M, 1C, and 1Bk.
As illustrated in
Next, a developer amount detector 300 to detect the amount of the toner in the process unit 1 by using optical elements is described below.
More specifically, outer end faces 31a and 32a are exposed to the housing 25 of the process unit 1. In a state in which the process unit 1 is installed in the apparatus body 100, the outer end face (exposed end face) 31a of the first light-guiding member 31 is positioned facing to the light-emitting element 21, and the outer end face (exposed end face) 32a of the second light-guiding member 32 is positioned facing to the light-receiving element 22. The inner end face 31b of the first light-guiding member 31 is disposed in face-to-face relation to the inner end face 32b of the second light-guiding member 32 in the developer container 43. With this configuration, the light emitted from the light-emitting element 21 enters into the outer end face 31a of the first light-guiding member 31 and is reflected in directions indicated by arrow shown in
It is to be noted that the positions of the light-emitting element 21 and the light-receiving element 22 can be exchanged. However, it is preferable that the light-emitting element 21 be positioned away from the photoreceptor 2 so that exposing the surface of the photoreceptor 2 by light can be prevented.
Herein, a gap of a certain size is provided between the inner end face 31b of the first light-guiding member 31 and the inner end face 32b of the second light-guiding member 32, which are facing each other. A blade 441 provided around a rotary shaft 440 of the agitator 44 passes the gap between the inner end face 31b of the first light-guiding member 31 and the inner end face 32b of the second light-guiding member 32. While the blade 441 of the agitator 44 passes through the gap between the inner end faces 31b and 32b, the blade 441 slidably contacts the inner end faces 31b and 32b. Thus, the toner adhered on the inner end faces 31b and 32b is scrapped off, and the light transmission route can be formed.
In
Then, the toner is consumed by the printing operation, and the level of the toner is lowered to the position T2 that is similar height as the inner end faces 31b and the 32b of the light-guiding members 31 and 32. In this state, the light transmission amount and the light transmission time transmitting from the first light-guiding member 31 to the second light-guiding member 32 are increased, and as a result, the time period during which the light-receiving element 22 can detect the light can be increased. More particularly, immediately after the blade 441 of the agitator 44 passes through the gap between the inner end faces 31b and 32b, because the amount of the toner presenting a position between the inner end faces 31b and 32b is the least in the states shown in
After that, when the toner is further consumed, the level of the toner is lowered to the position T3 that is lower than the inner end faces 31b and 32b. In this state, the light transmission amount and the light transmission time from the first light-guiding member 31 to the second light-guiding member 32 is further increased and the time period during which the light-receiving element 22 can detect the light is further increased.
That is, the light-guiding member 31, serving as a first light-guiding member, has the outer end face 31a facing the light emitted from the light-emitting element 21 and the inner end face 31b positioned inside the unit 1 and guides the light from the outer end face 31a to the inner end face 31b thereof. The light-guiding member 32, serving as a second light-guiding member, has the inner end face 32b facing the inner end face 31b of the first light-guiding member 31 in the unit to receive the light from the inner end face 32b of the first light-guide member 32 through the developer in the unit 1 and the outer end face 32a to output the received light to the light-receiving element 22. The second light-guiding member 32 guides the light from the inner end face 32b to the outer end face 32a thereof, and the optical elements 21 and 22 get positioned facing the outer end faces 31a and 32a of the first light-guiding member 31 and the second light-guiding member 32 as the unit 1 is being installed in the image forming apparatus 1000. Thus, the developer amount detector 300 detects the toner amount (residual amount of the toner) based on differences of the length of the time period during which the light-receiving element 22 can detect the light and the timing thereof.
As illustrated in
As described above, the containing space 101 is formed larger than the holder 50 in the lateral direction and the vertical direction, and the holder 50 can be moved arbitrarily in the lateral direction and the vertical direction in the containing space 101. That is, the holder 50 can arbitrarily moved in a direction orthogonal to optical axes L of the light-emitting element 21 and the light-receiving element 22. Herein, the optical axes L of the light-emitting element 21 and the light-receiving element 22 indicate guide routes through which the light emitted from the light-emitting element 21 is guided to the light-receiving element 22 through the first and second light-guiding members 31 and 32.
With reference to
In the present embodiment, the vertical wall 110 enveloping the containing space 101 is formed of a thermoplastic resin so that the wall 110 cannot cause signal error even when the wall 110 contacts terminals such as the light-emitting element 21 and the light-receiving element 22 in the holder 50.
Next, a positioning mechanism 300 to decide position of the light emitting element 21 and the light-receiving element 22 relative to the process unit 1 is described with reference to
With reference to
Next, with reference to
Initially, as shown in
Then, as shown in
Then, as shown in
As described above, in the present embodiment, as the process unit 1 is being installed in the apparatus body 100, the projection 52 is inserted into the hole 51, and the movement of the holder 50 in the direction orthogonal to the optical axes L is restricted. Therefore, the light-emitting element 21 and the light-receiving element 22 are accurately positioned to the respective outer end faces 31a and 32a of the light-guiding members 31 and 32. In other words, in the present embodiment, because the holder 50 is movable in the predetermined direction orthogonal to the optical axes L, even when the holder 50 is deviated relative to the process unit 1 in any direction orthogonal to the optical axes L, the positional deviation is corrected, and then accurate positioning can be performed. Thus, the toner amount can be detected with a high degree of accuracy.
In addition, when the positioning is completed, the light-shielding covers 33 and 34 are positioned in the vicinities of the light-emitting element 21 and the light-receiving element 22 respectively, unnecessary light divergence from the light-emitting element 21 and the unnecessary light incident to the light-receiving element can be prevented. More particularly, in a case in which the light-emitting element 21 is disposed adjacent to the light-receiving element 22 like the present configuration, the light-receiving element 22 can easily receive the light emitted from the adjacent light-emitting element 21, and detection error may occur. However, by providing the light-shielding covers 33 and 34, such detection error can be prevented. In addition, since a distance between the light-emitting element 21 and the photoreceptor 2 decreases as image forming apparatuses become more compact, there is a risk of adversely affecting the formation of latent image on the photoreceptor 2 when the light emitted from the light-emitting element 21 is strong. However, by providing the light-shielding cover 33 and 34, the unnecessary light irradiation to the photoreceptor 2 from the light-emitting element 21 can be prevented.
Conversely, when the process unit 1 is removed from the apparatus body 100, by moving the process unit 1 to a direction opposite to the insertion direction A, the projection 52 is released from the hole 51, and then the holder 50 is held by contacting the bottom 101a of the containing space 101.
As shown in
In other words, a positioning structure 600 positions the process unit 1 within the image forming apparatus 1000. The positioning structure 600 includes the above-described optical elements 21 and 22, the light-guiding members 31 and 32, the containing space 101, the planar holder 50, the projection 52, and the hole 51. The holder 50 is held by the bottom 101a of the containing space 101 in a state in which the unit 1 is not installed in the image forming apparatus 1000. The holder 50 is moved by inserting the projection 52 into the hole 51 when the unit 1 is being installed in the image forming apparatus 1000. The holder 50 is held by the projection 52 that is fitted into the hole 51 to restrict the movement of the holder 50 in the direction orthogonal to the optical axes L of the optical elements 21 and 22 relative to the unit 1 in a state in which the unit 1 is installed in the image forming apparatus 1000.
Therefore, the interference between the light-shielding covers 33 and 34 and the light-emitting element 21 and the light-receiving element 22 can be reliably prevented, and the damage of the light-emitting element 21 and the light-receiving element 22 can be prevented.
Next, a developer amount detector 300-α according to a second embodiment is described below with reference to
As illustrated in
A developer amount detector 300-β according to a third embodiment is described below. In the third embodiment shown in
With this configuration, as illustrated in
Then, as illustrated in
Subsequently, as illustrated in
Thus, similarly to the above-described embodiments, the light-emitting element 21 and the light-receiving element 22 are accurately positioned to the respective outer end faces 31a and 32a of the light-guiding members 31 and 32, and the amount of the toner can be detected with high degree of accuracy. In addition, in a state in which the positioning is completed, by inserting the light-emitting element 21 and the light-receiving element 22 into the light-shielding covers 33 and 34, unnecessary light divergence and light irradiation can be prevented.
In the present embodiment shown in
Next, a developer amount detector 300-γ according to a fourth embodiment is described below. In the fourth embodiment shown in
In the fourth embodiment, when the process unit 1-γ is inserted into the apparatus body 100 in order of
Although the holes 51 in the respective holders 50 in the apparatus body 100 are identical shapes in the above-described embodiments with reference to
In the present embodiment, in order to prevent the setting error of the process unit 1, arrangement of holes 51-ε in holders 50-ε and arrangement of corresponding projections 52-ε in process units 1-ε are provided at different positions thereamong, as shown in
Alternatively, the shapes or arrangement of the projections 52-ε and the hole 51-ε may also be set differ with respect to each color in the process units 1-ε in a configuration in which the projection 52-β is provided in the holder 50-β and the hole 51-β is provided in the process unit 1-β. (see
Further alternatively, the shapes or arrangement of the projections 52-ε and the corresponding holes 51-ε may be differ for different models of the image forming apparatuses to prevent a wrong type of process unit 1 from being attached to the holder 50 of the image forming apparatus 1000. With this configuration, the process unit 1 cannot be installed in the image forming apparatus 1000 in which the shape or arrangement of the projection 52-ε and the hole 51-ε are different. That is, the processes unit 1 can be distinguished from other types of the process units such as those sold by other companies, or dedicated for other types of image forming apparatuses.
In the above-described first to seventh embodiments, in order to decide the position of the holder 50, one axis engagement in which the lateral cylindrical projection 52 is inserted into the circular hole 51. Therefore, the holder 50 may rotate (pivot) around the projection 52 (in other words, the hole 51). Accordingly, in the above-described embodiments, if the holder 50 is rotated, the positions of the light-emitting element 21 and the light-receiving element 22 may be deviated relative to the light-guiding members 31 and 32. In an effort to counteract this problem, a rotary restriction mechanism to restrict rotation of the holder 50 may be provided as described below.
Next, a developer amount detector 300-η according to an eighth embodiment is described below with reference to
The engagement protrusion 55 is constituted by a pin that is shorter than the projection 52. Similarly to the projection 52, the engagement protrusion 55 includes a conical guide portion 550 formed taper shape and a cylindrical positioning portion 551 to perform positioning.
In the holder 50-η, the engagement hole 54 is a circular hole whose diameter is almost identical to an external diameter of the positioning portion 551 of the engagement protrusion 55. The two grooves 56 are provided both vertical sides of the engagement hole 54. Herein, although the engagement hole 54 and the grooves 56 penetrate through the holder 50-η shown in
As illustrated in
Next, positioning operation of the holder 50-η in a direction in which the holder 50-η is rotated around the projection 52 (hereinafter “rotary direction) is described below, with reference to
In one example, as illustrated in
In the eighth embodiment shown in
It is to be noted that in
Alternatively, the engagement protrusion 55 may be provided in the holder 50, and the engagement hole 54 and the grooves 56 may be provided in the process unit 1 side. Similar to the projection 52 and the hole 51, advantage is different in the respective cases, it can be select whether the engagement protrusion 55 and the engagement hole 54 are provided in the process unit 1 or the holder 50 in view of foregoing the advantage in the respective cases, similar to the projection 52 and the hole 51. That is, when the engagement protrusion 55 is provided in the holder 50, the engagement protrusion 55 is less likely to receive damage directly and be broken, compared to the configuration in which the engagement protrusion 55 is provided to the process unit 1. By contrast, when the engagement protrusion 55 is provided in the process unit 1, because the engagement hole 54 is not formed in the process unit 1, reducing the capacity amount of the developer in the process unit 1 can be prevented, that is, the capacity amount of the developer can be greater.
In addition, the above-described developer amount detector may be used for units that are removably installable in the apparatus body of the image forming apparatus, instead of the above-described process units. For example, the above-described developer amount detector can be used for a developer container including a developer containing portion that is installable in the image forming apparatus body, and for a development device including a developer containing portion and a development member such as development roller, which is installable in the image forming apparatus. In addition, the above-described developer amount detector can be used for a waste-toner container that is removably installable in the image forming apparatus. In those cases, the similar effects as those in the above-described embodiments can be attained.
It is to be noted that, although, in first embodiment through the eighth embodiments, the process units 1Y, 1M, 1C, and 1Bk contain only toner, when an image forming apparatus supplies two-component developer formed of toner and carrier, the process units 1Y, 1M, 1C, and 1Bk can also contain two-component developer. In this case, the similar effects as those in the above-described embodiments can be attained. Alternatively, the above-described developer amount detector may detect liquid ink instead of power type developer.
In addition, although the above-described developer amount detector is installed in a tandem-type color laser printer in which the images formed on the four photoreceptors are one transferred to the recording medium via the intermediate transfer belt 8 as shown in
For example, the above-described developer amount detector may be installed in an image forming apparatus in which the image is formed by contacting four development devices with single photoreceptor in series. Especially in this case, when the development devices contact with and separate from the photoreceptor, the holder that holds the light-emitting element and the light-receiving element can move following to the development device by using the above-described developer amount detector for a positioning structure of the light-emitting element and the light-receiving element. Accordingly, position deviation of the light-emitting element and the light-receiving element relative to the corresponding development device caused by the contact-separate operation of the development device with the photoreceptor can be prevented.
In addition, the material and shape of the developer amount detector are not limited to the above-described embodiments, and various modifications and improvements in the material and shape of the developer amount detector are possible without departing from the spirit and scope of the present invention.
As described above, the optical elements to detect the amount of the developer can be accurately positioned relative to the removably-installable units in the apparatus body of the image forming apparatus by using simple configuration. More specifically, the optical elements can be positioned relative to the removably-installable units with high degree of accuracy only by holding the optical elements in the movable holder that can move in a predetermined orthogonal to the optical axes of the optical elements and positioning the holder relative to the units by the positioning mechanisms including projections and holes. Accordingly, the number of components can be streamlined, and the device can be made more compact, thereby reducing cost.
Numerous additional modifications and variations are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the disclosure of this patent specification may be practiced otherwise than as specifically described herein.
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