Patent Grant
12078951
The present disclosure relates to a frame of an image forming apparatus.
An electrophotographic image forming apparatus has an image formation unit that forms an image on a recording material and a frame (also called frame body) that supports a conveyance unit for conveying a sheet. It is widely known that the frame has a structure with a plurality of metal plates fastened and assembled by screws. In such a structure, the low rigidity of the frame may result in image failures, such as distortion and misalignment of colors, in an image formed in the sheet. In order to achieve the rigidity of the frame sufficient for an image forming apparatus, some measures for improving the rigidity of the frame are taken by, for example, increasing in number the screw-fastening places in the metal plates and/or thickening the metal plates.
Meanwhile, Japanese Patent Application Laid-Open No. 2003-66670 discusses a technique in which a plurality of metal plates is joined together by an adhesive to assembly a frame of an image forming apparatus, for example. Japanese Patent Application Laid-Open No. 2021-071699 discusses a technique in which a frame of an image forming apparatus is assembled by a combination of two methods, screw fastening and an adhesive. In such a manner, assembling a frame by using an adhesive achieves weight reduction of the frame due to the use of fewer screws.
However, joining a plurality of metal plates by an adhesive may have the disadvantage described below. In general, an adhesive strength is not high against force acting in the peeling direction. Thus, in the case of joining a plurality of metal plates by an adhesive, the rigidity of the frame in the peeling direction of the adhesive is to be made up by, for example, a screw fastening method.
Japanese Patent Application Laid-Open No. 2021-071699 discusses a configuration in which metal plates are fastened together with screws near the adhesive application positions, thus preventing the adhesive from peeling. According to the configuration discussed in Japanese Patent Application Laid-Open No. 2021-071699, the use of an adhesive reduces the number of screws as compared to the typical technique. However, there has been a demand for further weight reduction of a frame in recent years.
Aspects of the present disclosure provide, in a structure with a frame of an image forming apparatus assembled by using an adhesive, achieving weight reduction of the frame while securing the rigidity of the frame in the peeling direction of the adhesive.
According to an aspect of the present disclosure, an image forming apparatus includes an image forming unit configured to form an image on a recording material, a first metal plate and a second metal plate that face each other to sandwich the image forming unit, and a third metal plate that is located between the first metal plate and the second metal plate and is joined to the first metal plate and the second metal plate. The first metal plate and the third metal plate are welded together at a plurality of welding positions, an adhesive is applied to between the first metal plate and the third metal plate in a range sandwiched between two welding positions of the plurality of welding positions in a region where the first metal plate and the third metal plate are in contact with each other, and the first metal plate and the third metal plate are thereby joined together.
Further features of the present disclosure will become apparent from the following description of embodiments with reference to the attached drawings.
(General Configuration of Image Forming Apparatus)
A first embodiment of the present disclosure will be described below.
In the following description, the height direction (vertical direction) of the image forming apparatus 100 placed on a horizontal plane is defined as Z direction. A direction crossing the Z direction and parallel to the axial direction of a photosensitive member 7 described below (main scanning direction) is defined as Y direction. A direction crossing the Y direction and the Z direction is defined as X direction. It is desirable that the X direction, the Y direction, and the Z direction vertically cross with each other. For the sake of convenience, the plus side in the X direction is called right side, the minus side in the X direction is called left side. The plus side in the Y direction is called front side or frontal side, and the minus side in the Y direction is called back side or rear side. The plus side in the Z direction is called upper side and the minus side in the Z direction is called lower side.
The image forming apparatus 100 includes an apparatus main body 1, a cassette 2 that stores sheets S and is attachable to and detachable from the apparatus main body 1, and a sheet feeding unit 3. The sheets S stored by the sheet feeding unit 3 in the cassette 2 are fed one by one onto a conveyance path, and are delivered to registration rollers 5 via intermediate conveyance rollers 10. The registration rollers 5 correct the skew of the sheet S. The image forming apparatus 100 further includes a manual sheet feeding unit 4.
The image forming apparatus 100 has four image forming units 6Y, 6M, 6C, and 6K corresponding to yellow, magenta, cyan, and black. Hereinafter, for the sake of simplification, these image forming units will be described as image forming units 6 without alphabets. Other members will be described in a similar manner. The image forming units 6 have photosensitive members 7Y, 7M, 7C, and 7K (photosensitive members 7), charging units 8Y, 8M, 8C, and 8K (charging units 8) that electrically charge the surfaces of the photosensitive members 7. The image forming units 6 further include developing units 9Y, 9M, 9C, and 9K (developing units 9) that develop electrostatic latent images formed on the photosensitive members 7 by the use of toner. These photosensitive members 7 and developing units 9 are held in one container and are integrated to constitute a cartridge attachable to and detachable from the apparatus main body 1.
The image forming apparatus 100 has an optical scanning unit (scanner unit) 12 that scans the photosensitive members 7 with light in accordance with image information. The optical scanning unit 12 is provided under the photosensitive members 7 in the vertical direction (Z direction).
The optical scanning unit 12 in the present embodiment is a laser scanner unit that deflects laser light emitted from a semiconductor laser with a rotational polygon mirror to scan the photosensitive members 7.
An intermediate transfer unit 15 is provided above the developing units 9. Toner images formed on the photosensitive members 7 are transferred onto an intermediate transfer belt 17 that is a rotatable endless belt and is stretched over a plurality of stretch rollers. Primary transfer rollers 18Y, 18M, 18C, and 18K (primary transfer rollers 18) are in contact with the inner surface of the intermediate transfer belt 17. The respective primary transfer rollers 18 form primary transfer parts together with the corresponding photosensitive member 7 with the intermediate transfer belt 17 in between. At each primary transfer part, a voltage is applied to the primary transfer roller 18 to transfer a toner image from the photosensitive member 7 onto the intermediate transfer belt 17. The intermediate transfer belt 17, the plurality of stretch rollers on which the intermediate transfer belt 17 is stretched, and the plurality of primary transfer rollers 18 are unitized as the intermediate transfer unit 15 and are attachable to and detachable from the apparatus main body 1.
A secondary transfer roller 20 is in contact with the intermediate transfer belt 17 and forms a secondary transfer part 16 together with an opposing roller, with the intermediate transfer belt 17 in between. At the secondary transfer part 16, the toner images having been transferred onto the intermediate transfer belt 17 are secondarily transferred onto the sheet S. After the secondary transfer process, a cleaning unit 21 removes the residual toner on the intermediate transfer belt 17. The toner removed by the cleaning unit 21 is conveyed to a toner collection container 22 by a waste toner conveyance unit not illustrated. Arranged above the intermediate transfer unit 15 and under the toner collection container 22 is a high-voltage power supply substrate 13 for generating a voltage to be applied to the charging units 8, the developing units 9, the primary transfer rollers 18, the secondary transfer roller 20, and others.
The sheet S onto which the toner image has been transferred at the secondary transfer part 16 is conveyed to a fixing unit 23. The fixing unit 23 includes a heating unit 23a with a heat source and a pressure roller 23b that forms a fixing nip portion together with the heating unit 23a. The sheet S bearing the unfixed toner image is sandwiched and conveyed at the fixing nip part while the toner image is heated and fixed to the sheet S.
The sheet discharge tray 25 is provided above the intermediate transfer belt 17 and supports the sheet S discharged from the inside of the apparatus main body 1. The sheet S to which the toner image has been transferred at the secondary transfer part 16 is conveyed to a sheet discharge roller pair 24 via the fixing unit 23, and is discharged by the sheet discharge roller pair 24 to the sheet discharge tray 25.
(Frame of Image Forming Apparatus)
Next, a frame 200 (also called frame body) of the image forming apparatus 100 will be described in detail with reference to
The frame 200 includes a front side plate 27 (first metal plate) and a back side plate 28 (second metal plate) arranged in parallel, and a plurality of stays (third metal plate) suspended between the both side plates. The both side plates and the stays are all made of metal plates.
The front side plate 27 has a large hole 27a through which a cartridge (image forming unit 6) is insertable and removable from the front side of the apparatus. The cartridge is guided into the inside of the image forming apparatus 100 by a cartridge rail (not illustrated) provided in a main stay 29. The cartridge is then pressed upward (from the minus side to the plus side in the Z direction) by a biasing member, such as a spring, provided on the cartridge rail. Thus, a positioning part (not illustrated) of the cartridge in the longitudinal direction is brought into contact with a recess 27b of the front side plate 27 surrounded by a dotted line in
A unit that holds the intermediate conveyance rollers 10 and the registration rollers 5 (both are illustrated in
A left lower stay 32 includes therein a positioning part (not illustrated) for attaching the optical scanning unit 12 (illustrated in
(Frame Assembly Process)
Next, a process of assembling the frame 200 (manufacturing method) will be described with reference to the flowchart of
The process in the flowchart of
Initially, the application process of applying an adhesive will be described.
Cross-shaped marks (not illustrated) are put on the application places in the front side plate 27 and the back side plate 28. Each cross-shaped mark is about 0.3 mm deep and about several millimeters long and wide, for example, by which the human worker and the camera-equipped automated application robot can recognize the adhesive application positions. The marks of several millimeters are sufficient, so that it is not necessary to perforate the metal plates unlike in the case of screw fastening. This eliminates a limitation on space for the adhesive application places, thus increasing the degree of freedom in the shape of the side plates.
In the present embodiment, the adhesive is applied to the front side plate 27 at 13 places (60a to 60q), and to the back side plate 28 at 10 places (60r to 60zz), for a total of 23 places as illustrated in
The viscosity of the adhesive in the present embodiment is as relatively high as about 10000 to 20000 mPa·s. Thus, even if the both side plates are shifted from the horizontal posture for application of the adhesive to the standing posture for the assembly of the frame 200, the adhesive does not immediately flow down on the both side plates.
Next, the process of assembling the front side plate 27 and the back side plate 28 will be described.
The metal plates are fixed to and retained at framing tools (not illustrated) by magnets or the like so that the metal plates are held in posture. After that, the metal plate holding parts of the framing tools are moved to engage the metal plates with each other in predetermined order in the directions of arrows in
In the welding process, the frame 200 is held in posture by the framing tools and is conveyed into a welding apparatus. In the present embodiment, the frame 200 is welded at about 50 places. All the members except for the main stay 29 and the substrate stay 31 are fastened by welding alone.
The automated welding robot is programmed to continuously execute the welding work.
Referring to
The use of the automated welding robot in such a manner enables two metal plates to be joined together with a high joint strength, without using screws. Meanwhile, it is difficult for the automated welding robot to access the central part 75 of the frame 200. In order to weld the central part 75 of the frame 200, the arm end part 70 is to be made to enter through a gap 76 between the main stay 29 and the left lower stay 32 illustrated in
As described above, the frame 200 has been reduced in size along with the downsizing of the image forming apparatus 100, so that further widening the gaps 76 and 77 is difficult. There is also a limitation on the size reduction of the arm end part 70. Thus, a fastening means other than welding is to be taken on the central part 75 of the frame 200, so that an adhesive is used in the present embodiment.
In the frame for which the application of an adhesive and welding have been completed in the above described manner, the regions of the metal plates in contact with each other will be described in detail.
In a contact region 41 between the front side plate 27 and the substrate stay 31, welding positions 50c and 50d are located near the both ends of the contact region 41. In a range sandwiched between the two points, the adhesive is applied at three places 60a to 60c. In other words, the front side plate 27 and the substrate stay 31 are joined together by welding and the adhesive.
In a contact region 42 between the back side plate 28 and the main stay 29 illustrated in
The peel resistance of the joint between metal plates will be described.
As another example, the case where peeling force B acts near the center of the contact region 40 in
The use of the adhesive eliminates the need for perforation in the metal plates unlike in the case of fastening by screws as described above, and achieves the smooth flat shape without welding marks that would be left in the case of welding. This makes it possible to secure a favorable surface state and high rigidity of the semi-outer appearance part to be accessed by the user at an insertion port of the cartridge as in the present embodiment.
In the present embodiment, although it takes about several minutes from the start to end of welding the frame, the applied adhesive becomes hardened at the timing of completion of the welding to secure the practical strength. This eliminates the need to separately secure the waiting time until the adhesive reaches the practical strength, which is efficient in production. That is, the subsequent steps of further attaching members to the frame 200 to assemble the image forming apparatus 100 are not interrupted.
There is no hole or space for an automated welding robot to access in the range sandwiched between the plurality of welding positions 50a to 50f described above. Thus, it has been conventionally necessary to use tightening members, such as screws. However, the use of the adhesive as in the present embodiment enables efficient fastening of the metal plates.
As compared with the screw fastening method, the adhesive is continuously applied by an automated application robot, so that the working time is shortened and the material expenses are reduced, thus achieving cost reduction. It is found that the strength of the adhesive-joined metal plates against the force in the direction of shearing is 5 to 20 times greater than the shearing strength with screws (that is, the strength of the metal plates sandwiched by screws and maintained by frictional force against the direction of shearing). Therefore, it is also possible to eliminate the occurrence of phenomenon called screw misalignment caused by impact, which is a disadvantage of fastening members, such as screws.
Although the adhesive is not that high in strength against the force in the direction of peeling, the two metal plates are welded near the both ends of the contact region, so that it is possible to prevent the metal plates from becoming broken due to the peeling of the adhesive.
The adhesive itself is a non-conductive member, so that fixing of the stay and the side plate at all places results in formation of a thin film of the adhesive between the stay and the side plate, and electric current may not flow smoothly from the stay to the side plate. In other words, no ground may be established. The substrate stay 31 supporting the high-voltage power supply substrate 13 is to be securely grounded, so that in the present embodiment, the front side plate 27 and the substrate stay 31, in particular, are joined together by welding at the both ends of the contact region 41 (illustrated in
The frame 200 of the present embodiment includes combinations of metal plates joined together by both welding and an adhesive and combinations of metal plates joined together only by welding. Optimum fixing method can be selected for the members supported by the metal plates and the configuration of the frame.
As above, according to the present embodiment, in a structure of a frame of an image forming apparatus assembled by using an adhesive, it is possible to achieve weight reduction of the frame while securing the rigidity of the frame in the direction of peeling of the adhesive.
In the present embodiment, two metal plates are joined together by using an adhesive in addition to an automated welding robot, thus achieving weight reduction of the frame while securing the rigidity of the frame in the direction of peeling of the adhesive. In particular, since the both metal plates are welded together in such a manner that the positions at which the two meatal plates are joined with the adhesive are sandwiched, the force acting in the direction of peeling is received mainly at the welding positions. Thus, the adhesive is more unlikely to peel than in the conventional technique. A welding machine typified by an automated welding robot has a limited access to a region to enter, in the present exemplar embodiment, the welding positions and adhesive application positions in the two metal plates are adequately designed.
In other words, as described above, the welding is performed in such a manner that positions at which the two meatal plates are joined with the adhesive are sandwiched. Thus, the welding positions are closer to an end of the metal plates than the adhesive application positions. This allows the welding machine, such as an automated welding robot, to relatively easily access the welding positions.
In the above-described embodiment, marks indicating the adhesive application positions are placed on the metal plates. The metal plates may be subjected to a drawing process or an embossing process at the application positions as appropriate. It can be expected that subjecting both or at least one of two metal plates to be joined together to these processes produces an advantageous effect of improving the adhesion between the metal plates. Whether to perform these processes can be determined as appropriate in consideration of the balance of the space and the degree of freedom of shape.
In the above-described embodiment, the adhesive is applied in a dot pattern to the both side plates at a plurality of places. However, the present disclosure is not limited to this. The adhesive may be applied in a linear pattern as illustrated in
In the above-described embodiment, the adhesive is applied to the metal plates in advance, and then the metal plates are assembled and welded. However, the present disclosure is not necessarily limited to this order. After the welding process, the adhesive may be injected into a gap between the two metal plates. For example, it can be expected that injecting the adhesive later into the root of the bent portion of the main stay 29 illustrated in
In the above-described embodiment, as illustrated in
In relation to the above-described embodiment, the electrophotographic image forming apparatus 100 has been described. However, the present disclosure is not limited to this. The present disclosure is also applicable to the assembly of a frame of an image forming apparatus of a different printing type, such as inkjet type or offset printing type.
According to the present disclosure, it is possible to, in a configuration in which a frame of an image forming apparatus is assembled by using an adhesive, achieve weight reduction of the frame while securing the rigidity of the frame in the direction of peeling of the adhesive.
While the present disclosure has been described with reference to embodiments, it is to be understood that the disclosure is not limited to the disclosed embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of priority from Japanese Patent Application No. 2022-090633, filed Jun. 3, 2022, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2022-090633 | Jun 2022 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20210132540 | Seto | May 2021 | A1 |
| Number | Date | Country |
|---|---|---|
| H1195510 | Apr 1999 | JP |
| 2001203480 | Jul 2001 | JP |
| 2003066670 | Mar 2003 | JP |
| 2021071699 | May 2021 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20230393518 A1 | Dec 2023 | US |
