Patent Application
20130051852
This application claims priority from Japanese Patent Application No. 2011-190030 filed Aug. 31, 2011. The entire content of this priority application is incorporated herein by reference.
The present invention relates to a developer cartridge that mounts in an image-forming device employing an electrophotographic system.
An electrophotographic printer known in the art has drum cartridges respectively provided with photosensitive drums, and developer cartridges that supply toner to the corresponding photosensitive drums. One type of developer cartridge known in the art for use in this type of printer includes a developing roller for carrying toner, and a supply roller for supplying toner onto the developing roller.
Each developer cartridge includes an input gear into which an external drive force is inputted, a supply-roller gear for driving the corresponding supply roller by the drive force received from the input gear, and a developing-roller gear for driving the corresponding developing roller by the drive force transmitted from the input gear via the supply-roller gear. In other words, the drive force inputted into the input gear is transmitted to the developing-roller gear through the supply-roller gear.
However, in a developer cartridge having the structure described above, the supply roller rotates against a frictional force generated between the developing roller and supply roller and, thus, rotates while sliding against the developing roller at a torque greater than the frictional force. Consequently, the rotation of the supply roller is prone to variation in speed and may be unstable. Accordingly, the rotation of the developing roller may also become unstable when the force for driving the developing roller is transmitted to the developing-roller gear through the supply-roller gear.
The rotation of the developing roller can be stabilized by transmitting the drive force from the input gear separately to the supply roller and the developing roller. However, this configuration requires two separate paths for transmitting the drive force from the input gear to the supply roller and the developing roller, respectively, and is not conducive to conserving space.
Therefore, it is an object of the present invention to provide a developer cartridge capable of conserving space while achieving stable rotation of the developing roller.
In order to attain the above and other objects, the invention provides a developer cartridge. The developer cartridge includes a developing roller, a supply roller, an input gear, a developing roller gear, a supply roller gear, a first intermediate gear, and a second intermediate gear. The developing roller is configured to carry developing agent thereon and rotate about a first axis extending in a prescribed direction. The supply roller is configured to supply the developing agent to the developing roller and rotate about a second axis extending parallel to the first axis. The input gear is inputted with a drive force from an outside. The developing roller gear is configured to rotate about the first axis to drive the developing roller by the drive force inputted to the input gear. The supply roller gear is configured to rotate about the second axis to drive the supply roller by the drive force inputted to the input gear. The first intermediate gear is configured to rotate about the second axis. The first intermediate gear engages the input gear to receive the drive force therefrom. The second intermediate gear is engaged with the first intermediate gear and the developing roller gear so as to transmit the drive force from the first intermediate gear to the developing roller gear.
According to another aspect, the present invention provides a developer cartridge. The developer cartridge includes a developing roller, a supply roller, an input gear, a developing roller gear, a supply roller gear, a first intermediate gear, and a second intermediate gear. The developing roller is configured to rotate about a first axis. The supply roller is disposed in contact with the developing roller and configured to rotate about a second axis extending parallel to the first axis. The input gear is configured to receive a driving force from an outside. The developing roller gear is configured to rotate about the first axis for driving the developing roller. The supply roller gear is configured to rotate about the second axis for driving the supply roller. The first intermediate gear is configured to rotate about the second axis, the first intermediate gear engaging the input gear. The second intermediate gear is engaged with the first intermediate gear and the developing roller gear.
The particular features and advantages of the invention as well as other objects will become apparent from the following description taken in connection with the accompanying drawings, in which:
a) is a side view showing the developer cartridge according to the first embodiment;
b) is a side view showing the developer cartridge when a gear cover is removed therefrom according to the first embodiment;
A printer 1 shown in
Directions with respect to the printer 1 in the following description will be given under the assumption that the printer 1 is resting on a level surface, and the right side of the printer 1 in
Directions with respect to a developer cartridge 25 in the following description will be given under the assumption that the developer cartridge 25 is resting on a level surface, with a bottom wall 35 of the developer cartridge 25 positioned on the bottom (see
The printer 1 includes a main casing 2, a sheet-feeding unit 3 for feeding sheets S to be printed, and an image-forming unit 4 for forming images on the sheets S supplied by the sheet-feeding unit 3.
(1) Main Casing
The main casing 2 is box-shaped and substantially rectangular in a side view. The main casing 2 accommodates the sheet-feeding unit 3 and the image-forming unit 4. An access opening 5 is formed in the top portion of the main casing 2 for mounting process cartridges 11 (described later) in the main casing 2 or removing the process cartridges 11 therefrom. A top cover 6 is pivotably disposed on the top of the main casing 2. The top cover 6 is capable of pivoting about its rear end to expose or cover the access opening 5.
(2) Sheet-Feeding Unit
The sheet-feeding unit 3 includes a paper tray 7 for accommodating sheets S. The paper tray 7 is removably mounted in the bottom section of the main casing 2. The sheet-feeding unit 3 also includes a pickup roller 8, and a pair of feeding rollers 9 both disposed above the front edge of the paper tray 7; and a pair of registration rollers 10 disposed above the feeding rollers 9.
The pickup roller 8 and the feeding rollers 9 rotate to pick up the sheets S accommodated in the paper tray 7 and feed the sheets S one sheet at a time toward the registration rollers 10. The registration rollers 10 convey the sheets toward the image-forming unit 4 (between photosensitive drums 15 and a conveying belt 19 described later) at a prescribed timing.
(3) Image-Forming Unit
The image-forming unit 4 includes four each of process cartridges 11 and LED units 12 corresponding to the four colors used in the printer 1; a transfer unit 13; and a fixing unit 14.
(3-1) Process Cartridges
The process cartridges 11 are detachably mounted in the main casing 2 at positions above the sheet-feeding unit 3 so as to be arranged parallel to one another and spaced at intervals in the front-rear direction. More specifically, the process cartridges 11 include, in order from front to rear, a black process cartridge 11K, a yellow process cartridge 11Y, a magenta process cartridge 11M, and a cyan process cartridge 11C.
Each process cartridge 11 includes a drum cartridge 24, and a developer cartridge 25 detachably mounted in the drum cartridge 24.
The drum cartridge 24 is provided with a photosensitive drum 15, and a Scorotron charger 26. The photosensitive drum 15 has a cylindrical shape and is oriented with its axis aligned in the left-right direction. The photosensitive drum 15 is rotatably disposed in the drum cartridge 24. The Scorotron charger 26 is provided on the rear side of the corresponding photosensitive drum 15. The Scorotron charger 26 confronts the photosensitive drum 15 with a gap therebetween.
The developer cartridge 25 is provided with a developing roller 16. The developing roller 16 has a metal developing-roller shaft 30 aligned in the left-right direction (axial direction) as shown in
Each developer cartridge 25 also includes a supply roller 27 for supplying toner to the developing roller 16, and a thickness-regulating blade 28 for regulating the thickness of toner carried on the developing roller 16. The upper section of the developer cartridge 25 serves to accommodate toner.
The supply roller 27 includes a metal supply-roller shaft 29 oriented in the left-right direction and is positioned to contact the upper front side of the developing roller 16. The supply roller 27 rotates about a central axis A2 of the supply-roller shaft 29 (see
(3-2) LED Units
Each LED unit 12 is disposed on the upper rear side of the corresponding process cartridge 11 so as to face the top of the corresponding photosensitive drum 15. The LED unit 12 functions to expose the surface of the corresponding photosensitive drum 15 to light based on prescribed image data.
(3-3) Transfer Unit
The transfer unit 13 is disposed above the sheet-feeding unit 3 and below the process cartridges 11 and is oriented in the front-rear direction. The transfer unit 13 includes a drive roller 17 and a follow roller 18 arranged parallel to each other and separated in the front-rear direction; a conveying belt 19 placed around the drive roller 17 and follow roller 18 such that its upper portion opposes and contacts the photosensitive drums 15 from below; and four transfer rollers 20 disposed at positions confronting the corresponding photosensitive drums 15 with the upper portion of the conveying belt 19 interposed therebetween.
When the drive roller 17 is driven to rotate, the conveying belt 19 circulates so that the upper portion of the conveying belt 19 that contacts each of the photosensitive drums 15 moves in a rearward direction.
(3-4) Fixing Unit
The fixing unit 14 is disposed on the rear side of the transfer unit 13. The fixing unit 14 includes a heating roller 21, and a pressure roller 22 that contacts the heating roller 21 with pressure.
(4) Image-Forming Operation
Toner in the developer cartridge 25 is supplied onto the supply roller 27, which in turn supplies toner to the developing roller 16. The toner is positively tribocharged between the supply roller 27 and developing roller 16. The thickness-regulating blade 28 regulates the thickness of toner supplied to the developing roller 16 as the developing roller 16 rotates, maintaining the layer of toner carried on the surface of the developing roller 16 at a thin uniform thickness.
In the meantime, the Scorotron charger 26 applies a uniform charge to the surface of the corresponding photosensitive drum 15 as the photosensitive drum 15 rotates. The corresponding LED unit 12 subsequently irradiates light on the surface of the photosensitive drum 15, forming an electrostatic latent image on the surface based on image data. Next, the toner carried on the surface of the developing roller 16 is supplied to the latent image formed on the surface of the photosensitive drum 15, developing the latent image into a toner image.
At the same time, a sheet S supplied from the transfer unit 13 onto the conveying belt 19 is conveyed rearward by the conveying belt 19. The toner images of all four colors formed on the photosensitive drums 15 are sequentially superimposed onto the sheet S as the sheet S passes between the photosensitive drums 15 and transfer rollers 20 (transfer positions) to form a color image on the sheet S.
The color image transferred onto the sheet S in the transfer unit 13 is subsequently fixed to the sheet S by heat and pressure as the sheet S passes between the heating roller 21 and pressure roller 22 in the fixing unit 14.
Thereafter, the sheet S is conveyed along a U-shaped path that curves upward and forward and then is discharged onto a discharge tray 23 provided on the top cover 6.
As shown in
(1) Cartridge Frame
The cartridge frame 31 has a general box shape and is elongated in the left-right direction and open on the rear side. The cartridge frame 31 is integrally configured of a pair of left and right side walls 33, a front wall 34, a bottom wall 35, and a top wall 36.
The side walls 33 are generally rectangular in a side view and elongated in the vertical and front-rear directions. The side walls 33 are arranged parallel to each other and are spaced apart in the left-right direction. Each of the side walls 33 is provided with a developing-roller support part 37 for supporting the developing-roller shaft 30, and a supply-roller support part 38 for supporting the supply-roller shaft 29.
The developing-roller support part 37 is provided on the rear end of the side wall 33. A shaft insertion hole 41 is formed in the developing-roller support part 37 for receiving the developing-roller shaft 30. The shaft insertion hole 41 penetrates the side wall 33 to form a general C-shape in a side view that is open on the rear side. The diameter of the shaft insertion hole 41 is larger than the outer diameter of the developing-roller shaft 30. The opening formed in the rear side of the shaft insertion hole 41 has a vertical dimension greater than the outer diameter of the developing-roller shaft 30. The left and right ends of the developing-roller shaft 30 are inserted into the shaft insertion holes 41 formed in respective developing-roller support parts 37 and are supported in the developing-roller support parts 37 via bearing members (not shown). Note that the left end of the developing-roller shaft 30 protrudes out of the shaft insertion hole 41 on the left side of the left side wall 33.
The supply-roller support part 38 is provided on the lower front side of the corresponding developing-roller support part 37. A shaft insertion hole 42 is formed in the supply-roller support part 38 for receiving the supply-roller shaft 29. The shaft insertion hole 42 is generally rectangular in a side view and penetrates the side wall 33. The length of each side forming the rectangular shaft insertion hole 42 is greater than the outer diameter of the supply-roller shaft 29. The left and right ends of the supply-roller shaft 29 are inserted through the shaft insertion holes 42 formed in the corresponding supply-roller support parts 38 and are supported in the supply-roller support parts 38 via bearing members (not shown). Note that the left end of the supply-roller shaft 29 protrudes out of the shaft insertion hole 42 on the left side of the left side wall 33.
The left side wall 33 further includes an input-gear support part 39 for supporting an input gear 53 (described later), and a second-intermediate-gear support part 40 for supporting a second intermediate gear 57 (described later).
The input-gear support part 39 is disposed diagonally above and forward of the shaft insertion hole 42. The input-gear support part 39 is generally columnar in shape, extending leftward from the left side wall 33.
The second-intermediate-gear support part 40 is disposed above the shaft insertion hole 42 and forward of the shaft insertion hole 41. The second-intermediate-gear support part 40 is generally columnar in shape and extends leftward from the left side wall 33.
The front wall 34 extends in the left-right direction, bridging the front edges of the side walls 33.
The bottom wall 35 extends in the left-right direction, bridging the bottom edges of the side walls 33 and connecting to the bottom edge of the front wall 34.
The top wall 36 connects to the top edges of the side walls 33 on the front portion thereof, and the top edge of the front wall 34. The top wall 36 has a flat plate shape that is generally rectangular in a plan view. The thickness-regulating blade 28 is disposed on the rear edge of the top wall 36 so as to contact the top of the developing roller 16.
(2) Drive Unit
As shown in
(2-1) Gear Train
As shown in
The input gear 53 is integrally provided with a coupling part 58, and a gear part 59. The coupling part 58 constitutes the left portion of the input gear 53 and is generally columnar in shape elongated in the left-right direction. A fitting recess 60 is formed in the left endface of the coupling part 58 as shown in
The fitting recess 60 is recessed rightward in the left surface of the coupling part 58 and extends along a radial direction of the coupling part 58 so as to form an elongate hole that narrows in its radial center when viewed from the side. When the developer cartridge 25 is mounted in the main casing 2, the distal end of a body-side coupling (not shown) provided in the main casing 2 is inserted into the fitting recess 60 so that the body-side coupling and the fitting recess 60 cannot rotate relative to each other. A drive force is inputted from the main casing 2 via the body-side coupling.
The gear part 59 constitutes the right portion of the input gear 53. The gear part 59 is connected to the right side of the coupling part 58 and shares its central axis with the coupling part 58. The gear part 59 is generally columnar in shape and has a smaller diameter than the coupling part 58. Gear teeth are formed on the outer peripheral surface of the gear part 59. The input gear 53 is supported via the gear part 59 and cannot rotate relative to the input-gear support part 39.
The first intermediate gear 56 is disposed on the left end of the supply-roller shaft 29 and is separated from the left side of the left side wall 33. The first intermediate gear 56 is freely rotatable relative to the supply-roller shaft 29. The first intermediate gear 56 has a general disc shape, with a thick left-right dimension. Gear teeth are formed on the outer peripheral surface of the first intermediate gear 56. The first intermediate gear 56 engages with the gear part 59 of the input gear 53 from the lower rear side thereof.
The second intermediate gear 57 is integrally provided with a large-diameter part 61 and a small-diameter part 62. The large-diameter part 61 constitutes the right portion of the second intermediate gear 57 and is generally cylindrical in shape elongated in the left-right direction. Gear teeth are formed on the outer peripheral surface of the large-diameter part 61. The small-diameter part 62 is generally cylindrical in shape and extends leftward from the left surface of the large-diameter part 61. The small-diameter part 62 shares its central axis with the large-diameter part 61. Gear teeth are formed on the outer peripheral surface of the small-diameter part 62.
The second intermediate gear 57 is supported on the second-intermediate-gear support part 40 and is freely rotatable relative to the same. The small-diameter part 62 is engaged with the top of the first intermediate gear 56 (see
The supply-roller gear 55 is disposed between the left side wall 33 and the first intermediate gear 56. The supply-roller gear 55 is generally disc-shaped, with a thick left-right dimension. The supply-roller gear 55 is narrower and smaller in diameter than the first intermediate gear 56. A supply-roller-shaft fitting hole 71 having a generally D-shaped cross section penetrates the center of the supply-roller gear 55. Gear teeth are formed on the outer peripheral surface of the supply-roller gear 55.
A support part 72 having a generally D-shaped cross section is formed on the supply-roller shaft 29. The supply-roller gear 55 is fitted over the support part 72 at the supply-roller-shaft fitting hole 71 (fitted from radially outside the supply-roller shaft 29) so as to be incapable of rotating relative to the support part 72. Accordingly, the supply-roller gear 55 coaxially rotates together with the supply-roller shaft 29. The supply-roller gear 55 is engaged in the bottom side of the large-diameter part 61 constituting the second intermediate gear 57.
The developing-roller gear 54 is disposed on the left side of the left side wall 33 as shown in
A support part 74 having a generally D-shaped cross section is formed on the developing-roller shaft 30. The developing-roller gear 54 is fitted over the support part 74 at the developing-roller-shaft fitting hole 73 (fitted from radially outside the developing-roller shaft 30) and is incapable of rotating relative to the support part 74. Accordingly, the developing-roller gear 54 coaxially rotates together with the developing-roller shaft 30. The developing-roller gear 54 engages with the rear side of the large-diameter part 61 constituting the second intermediate gear 57.
(2-2) Gear Cover
As shown in
A coupling exposure opening 81 is also formed in the gear cover 52. The coupling exposure opening 81 has a generally circular shape in a side view and penetrates the left wall of the gear cover 52 in approximately the front-rear center thereof. The coupling exposure opening 81 functions to expose the left surface of the coupling part 58 constituting the input gear 53.
The gear cover 52 is fastened to the left side wall 33 with screws so as to cover the input gear 53 (excluding the left surface of the coupling part 58), the first intermediate gear 56, the second intermediate gear 57, and the supply-roller gear 55, while the left surface of the coupling part 58 is exposed through the coupling exposure opening 81.
Next, the transmission of a drive force from the input gear 53 to the supply roller 27 and the developing roller 16 will be described with reference to
When the first intermediate gear 56 is driven to rotate, the drive force is transmitted to the small-diameter part 62 of the second intermediate gear 57 engaged with the first intermediate gear 56, driving the second intermediate gear 57 to rotate. The drive force is in turn transmitted to the developing-roller gear 54 and supply-roller gear 55 engaged with the large-diameter part 61 of the second intermediate gear 57, rotating both the developing-roller gear 54 and supply-roller gear 55. Consequently, the developing-roller gear 54 inputs a drive force into the developing-roller shaft 30 to rotate the developing roller 16. Similarly, the supply-roller gear 55 inputs a drive force into the supply-roller shaft 29 for rotating the supply roller 27.
(1) As described with reference to
Further, both the first intermediate gear 56 and the supply-roller gear 55 rotate about the central axis A2 of the supply-roller shaft 29. Accordingly, the first intermediate gear 56 can be arranged more efficiently so as to overlap the supply-roller gear 55 in the left-right direction.
(2) According to the developer cartridge 25 described with reference to
In addition, since the first intermediate gear 56 is capable of freely rotating relative to the supply-roller shaft 29, the first intermediate gear 56 can be rotated without causing the supply-roller shaft 29 to rotate. As a result, the supply-roller gear 55 and the first intermediate gear 56 can be provided on the supply-roller shaft 29 to conserve space while being capable of stably rotating the supply roller 27 and the developing roller 16.
(3) According to the developer cartridge 25 shown in
(4) According to the developer cartridge 25 shown in
(5) According to the developer cartridge 25 shown in
(6) According to the developer cartridge 25 shown in
(7) According to the developer cartridge 25 shown in
(8) According to the developer cartridge 25 shown in
(9) According to the developer cartridge 25 shown in
The printer 1 according to a second embodiment of the present invention will be described next with reference to
In the first embodiment described above, the supply-roller gear 55 is formed with a smaller diameter than the first intermediate gear 56, and the second intermediate gear 57 is a two-stage gear formed of the large-diameter part 61 and the small-diameter part 62. Here, the first intermediate gear 56 engages with the small-diameter part 62 of the second intermediate gear 57, and the supply-roller gear 55 and the developing-roller gear 54 engage with the large-diameter part 61 of the second intermediate gear 57.
However, in the second embodiment, the supply-roller gear 55 is formed with the same diameter as the first intermediate gear 56. The second intermediate gear 57 has a generally cylindrical shape that extends in the left-right direction. A gear part 86 that is wide in the left-right direction is formed around the peripheral surface of the second intermediate gear 57.
With this construction, the first intermediate gear 56 engages with the left half of the gear part 86 constituting the second intermediate gear 57, and the supply-roller gear 55 and developing-roller gear 54 engage with the right half of the gear part 86.
As in the first embodiment described above, a drive force is transmitted to both the developing-roller gear 54 and the supply-roller gear 55 in the second embodiment. Specifically, when a drive force is inputted from the main casing 2 into the input gear 53, the input gear 53 is driven to rotate and transmits the drive force to the first intermediate gear 56 via the gear part 59.
Consequently, the drive force is transmitted sequentially via the first intermediate gear 56, the second intermediate gear 57, and the developing-roller gear 54 and inputted into the developing-roller shaft 30 to rotate the developing roller 16. Similarly, the drive force is transmitted sequentially via the first intermediate gear 56, the second intermediate gear 57, and the supply-roller gear 55 and inputted into the supply-roller shaft 29 to rotate the supply roller 27.
In the second embodiment, the first intermediate gear 56, the developing-roller gear 54, and the supply-roller gear 55 are all engaged with the gear part 86 of the second intermediate gear 57. With the first intermediate gear 56, the developing-roller gear 54, and the supply-roller gear 55 coupled only to the gear part 86 of the second intermediate gear 57, this configuration enables the drive force to be transmitted using fewer parts.
In the second embodiment, the first intermediate gear 56 has the same diameter as the supply-roller gear 55. Accordingly, the first intermediate gear 56 and the supply-roller gear 55 occupy the same amount of space when projected in the left-right direction. Accordingly, this configuration efficiently arranges the first intermediate gear 56 and the supply-roller gear 55.
The printer 1 according to the second embodiment can achieve the same operational advantages as described in the first embodiment.
The printer 1 according to a third embodiment of the present invention will be described next with reference to
In the first embodiment described above, the supply-roller gear 55 is formed with a smaller diameter than the first intermediate gear 56, and the second intermediate gear 57 is a two-stage gear formed of the large-diameter part 61 and small-diameter part 62. Here, the first intermediate gear 56 engages with the small-diameter part 62 of the second intermediate gear 57, and the supply-roller gear 55 and the developing-roller gear 54 engage with the large-diameter part 61 of the second intermediate gear 57.
However, in the third embodiment, the supply-roller gear 55 is formed with the same diameter as the first intermediate gear 56. In addition, the second intermediate gear 57 is formed thinner in the left-right direction in order to engage the first intermediate gear 56 but not the supply-roller gear 55.
With this construction, the first intermediate gear 56 engages with the left half of the gear part 59 constituting the input gear 53, and the supply-roller gear 55 engages with the right half of the gear part 59. The first intermediate gear 56 and developing-roller gear 54 are engaged with the second intermediate gear 57.
In the third embodiment, when a drive force is inputted from the main casing 2 into the input gear 53, the input gear 53 rotates and transmits the drive force to the supply-roller gear 55 and first intermediate gear 56 via the gear part 59. Consequently, the supply-roller gear 55 inputs the drive force into the supply-roller shaft 29 to rotate the supply roller 27.
The first intermediate gear 56 is driven to rotate about the central axis A2 of the supply-roller shaft 29. At this time, the first intermediate gear 56 freely rotates relative to the supply-roller shaft 29. In other words, the first intermediate gear 56 does not transmit a drive force to the supply-roller shaft 29.
When the first intermediate gear 56 is driven to rotate, a drive force is transmitted to the second intermediate gear 57 engaged with the first intermediate gear 56 for rotating the second intermediate gear 57. Consequently, the drive force is transmitted to the developing-roller gear 54 engaged with the second intermediate gear 57 to rotate the developing-roller gear 54. The developing-roller gear 54 in turn inputs the drive force into the developing-roller shaft 30 to rotate the developing roller 16.
With the configuration of the third embodiment, the drive force can be transmitted directly from the input gear 53 to the supply roller 27, thereby rotating the supply roller 27 with greater stability.
In the third embodiment, the first intermediate gear 56 has the same diameter as the supply-roller gear 55. Accordingly, the first intermediate gear 56 and the supply-roller gear 55 occupy the same amount of space when projected in the left-right direction. Accordingly, this configuration efficiently arranges the first intermediate gear 56 and supply-roller gear 55.
While the invention has been described in detail with reference to the embodiments thereof, it would be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the spirit of the invention.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-190030 | Aug 2011 | JP | national |
