The present patent application claims priority pursuant to 35 U.S.C. §119 from Japanese Patent Application No. 2010-109703, filed on May 11, 2010 in the Japan Patent Office, which is hereby incorporated herein by reference in its entirety.
1. Field
Exemplary embodiments of the present disclosure relate to an image forming apparatus, and more specifically to an image forming apparatus including a recording head that ejects liquid droplets.
2. Description of the Background Art
Image forming apparatuses are used as printers, facsimile machines, copiers, plotters, or multi-functional devices having two or more of the foregoing capabilities. As one type of image forming apparatus employing a liquid-ejection recording method, an inkjet recording apparatus is known that uses a recording head having a liquid ejection head (liquid-droplet ejection head) for ejecting droplets of ink.
Such liquid-ejection-type image forming apparatuses fall into two main types: a serial-type image forming apparatus that forms an image by ejecting droplets from the recording head while moving the recording head in a main scanning direction of the carriage, and a line-head-type image forming apparatus that forms an image by ejecting droplets from a linear-shaped recording head held stationary in the image forming apparatus.
In the serial-type image forming apparatus, a carriage may mount a recording head and a carriage circuit board, e.g., a relay board to relay between a driving circuit to drive the recording head and a control circuit board implemented as a control circuit to control the entire image forming apparatus. The control circuit board and the carriage circuit board are connected via, e.g., a flexible flat cable (FFC), and the carriage circuit board and the recording head are connected via, e.g., an FFC equipped with a driving circuit.
In such a case, the carriage circuit board is vertically disposed along the back face of the carriage, and the flexible flat cable is also vertically extended along the flat face of the carriage circuit board, that is, the flat face of the flexible flat cable is vertically disposed.
However, in the above-described configuration, when the flexible flat cable is installed in the image forming apparatus, the flexible flat cable is not accessible from the upper side of the image forming apparatus. Such a configuration makes it difficult to install the flexible flat cable to connect the recording head and the carriage circuit board, thus hindering smooth installation.
In addition, in maintenance work, such as removal of the flexible flat cable from the carriage circuit board and cleaning of an encoder sensor on the carriage circuit board, an operator cannot easily access the carriage circuit board and the encoder sensor, thus hindering smooth maintenance work.
At the back side of the carriage is also provided a metal sheet member, e.g., a rear stay forming part of a frame of the image forming apparatus. While face-to-face contacting the sheet metal, the flexible flat cable is guided and deformed in accordance with movement of the carriage. However, contacting the flexible flat cable and the sheet metal over a relatively large area tends to cause noise in the flexible flat cable.
In an aspect of this disclosure, there is provided an improved image forming apparatus including a carriage, a recording head, a carriage circuit board, a control circuit board, a board mount, and a flexible flat cable. The carriage is reciprocally movable in a main scanning direction in the image forming apparatus. The recording head is mounted on the carriage to eject droplets. The carriage circuit board is mounted on the carriage and equipped with a circuit. The control circuit board is provided in the image forming apparatus and equipped with a control circuit. The board mount is provided in the carriage on which the carriage circuit board is horizontally disposed. The flexible flat cable connects the control circuit board and the carriage circuit board and is movable in the main scanning direction below the board mount. The flexible flat cable is extended below the carriage circuit board, bent back toward the carriage circuit board, and connected to the carriage circuit board from the main scanning direction.
Additional aspects, features, and advantages of the present disclosure will be readily ascertained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:
The accompanying drawings are intended to depict exemplary embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted.
In describing 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 similar results.
In this disclosure, the term “image forming apparatus” refers to an apparatus (e.g., droplet ejection apparatus or liquid ejection apparatus) that ejects ink or any other liquid on a medium to form an image on the medium. The medium is made of, for example, paper, string, fiber, cloth, leather, metal, plastic, glass, timber, and ceramic. The term “image formation”, which is used herein as a synonym for “image recording” and “image printing”, includes providing not only meaningful images such as characters and figures but meaningless images such as patterns to the medium. The term “ink” used herein is not limited to “ink” in a narrow sense and includes anything useable for image formation, such as a DNA sample, resist, pattern material, washing fluid, storing solution, and fixing solution. The term “image” used herein is not limited to a two-dimensional image and includes, for example, an image applied to a three dimensional object and a three dimensional object itself formed as a three-dimensionally molded image. The term “sheet” used herein is not limited to a sheet of paper and includes anything such as an OHP (overhead projector) sheet or a cloth sheet on which ink droplets are attached. In other words, the term “sheet” is used as a generic term including a recording medium, a recorded medium, or a recording sheet.
Although the exemplary embodiments are described with technical limitations with reference to the attached drawings, such description is not intended to limit the scope of the invention and all of the components or elements described in the exemplary embodiments of this disclosure are not necessarily indispensable to the present invention.
Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, exemplary embodiments of the present disclosure are described below.
First, an image forming apparatus according to an exemplary embodiment of the present disclosure is described with reference to
The image forming apparatus 100 is a serial-type image forming apparatus and has a cover 19 openable/closable at an upper side thereof. By opening the cover 19, an opening 20 is opened so that an operator can access the mechanical section inside the image forming apparatus 100.
The mechanical section includes a main left-side plate 1A, a main right-side plate 1B, a main guide rod 2, a sub guide rod 3, a carriage 4, a main scan motor 5, a driving pulley 6, a driven pulley 7, and a timing belt 8. The main guide rod 2 and the sub guide rod 3 serving as guide members extend between the main side plates 1A and 1B and 100R to support the carriage 4. The carriage 4 supported on the main guide rod 1 and the sub guide member is slidable in a main scanning direction indicated by a double arrow X in
On the carriage 4 are mounted a plurality of recording head units 11 including liquid ejection heads serving as image forming devices to eject ink droplets of, for example, yellow (y), cyan (c), magenta (m), and black (k), respectively, and head tanks to supply ink to the liquid ejection heads. The recording head units 11 are mounted on the carriage 3 so that multiple nozzle rows each including a plurality of nozzle orifices are arranged parallel to a sub scanning direction (indicated by an arrow Y illustrated in
An encoder scale 15 is disposed along the main scanning direction X of the carriage 4. On the carriage 4 is mounted an encoder sensor 16 serving as a transmissive photosensor to read a scale (scale index serving as position identifier) 15a of the encoder scale 15. The encoder scale 15 and the encoder sensor 16 form a linear encoder serving as a position detector to detect the position of the carriage 4.
Below the carriage 4 is provided a conveyance belt serving as a conveyance unit to convey a sheet in the sub scanning direction Y. The conveyance belt 21 is an endless belt looped around a conveyance roller 22 and a tension roller 23. The conveyance roller 22 is rotated by a sub-scanning motor 31 via a timing belt 32 and a timing pulley 33. The rotation of the conveyance roller 22 causes the conveyance belt 21 to circulate in the sub-scanning direction Y.
At one end in the main scanning direction X of the carriage 4, a maintenance unit 41 is disposed near one lateral side of the conveyance belt 21 to maintain and recover nozzle conditions of the liquid ejection heads of the recording head units 11. At the other end, a liquid receptacle 42 is disposed near the other lateral side of the conveyance belt 21 to receive ink droplets ejected for maintenance. The maintenance unit 41 includes, for example, cap members, a wiping member, and a second liquid receptacle. Each of the cap members caps a nozzle face (i.e., a face in which nozzle orifices are formed) of the corresponding one of the recording head units 11. The wiping member wipes the nozzle faces of the recording head units 11. The second liquid receptacle receives droplets not used for image formation.
The image forming apparatus 100 further includes, for example, a sheet feeding unit to feed a recording sheet to the conveyance belt 21 and a sheet output unit to output a sheet having an image formed by liquid droplets ejected from the recording head units 11.
While moving the carriage 4 in the main scanning direction X, the image forming apparatus 100 drives the recording head units 11 in response to image signals to eject ink droplets onto the sheet conveyed intermittently by the conveyance belt 21. After a first band of an image is recorded on the sheet 10, the sheet 10 is conveyed at a certain distance by the conveyance belt 21. Then, the next band of the image is recorded on the sheet 10 and the sheet 10 is conveyed at the certain distance. Such operation is repeated to form the full image and then the sheet with the image is outputted to an output tray.
Next, electrical components of the image forming apparatus according to the present exemplary embodiment are described.
The carriage 4 includes a head mount 4A, a carriage cover 4B, and a board mount 4C. The head holder 112 to hold the recording head units 11 is mounted on the head mount 4A. The board mount 4C on which a carriage circuit board 101 is mounted in a horizontal orientation (including substantially horizontal orientation) is disposed at an opposite end (a rear side in
The carriage circuit board 101 is a relay board to relay data transmission between a control circuit board 102 and each of a driver circuit (driver IC) to drive the recording head units 11, the encoder sensor 16 mounted on the carriage 4, or other sensors. The control circuit board 102 is equipped with a control circuit to control the image forming apparatus 100, for example, the conveyance and driving of the conveyance belt 21 and other components and the maintenance operation of the maintenance unit 41.
The board mount 4C has a mount face on which the carriage circuit board 101 is mounted and an opening 50 through which the encoder sensor 16 projects from the board mount 4C. By mounting the carriage circuit board 101 on the mount face, the encoder sensor 16 is set to a position at which the encoder sensor 16 can read the encoder scale 15.
The control circuit board 102 is disposed posterior to the carriage 4 in a horizontal orientation (including substantially horizontal orientation) at substantially the same level as the carriage circuit board 101.
The control circuit board 102 is connected to the carriage circuit board 101 via a flexible flat cable (hereinafter, FFC) 103.
The FFC 103 is connected to a connector 131 of the control circuit board 102 and a connector 135 of the carriage circuit board 101. The FFC 103 is led at a lead portion 103c from the connector 131 of the control circuit board 102 in the sheet conveyance direction Y (perpendicular to the main scanning direction X), is vertically extended downward at an upright portion 103b, is bent toward the sheet conveyance direction, and is folded at a folded portion 103a in the main scanning direction. Further, the FFC 103 is extended from the folded portion 103c in the main scanning direction below the board mount 4C, is bent back upward at a bent portion 103d, and is connected to the connector 135 of the carriage circuit board 101 through a cutout portion 51 of the board mount 4C.
At the cutout portion 51 of the board mount 4C, an upper side of the board mount 4C is cut out to extend the FFC 103 in the main scanning direction, thus allowing an operation to connect and remove the FFC 103 from the upper side of the carriage.
The carriage circuit board 101 is connected to each of the recording head units 11 via a connector 132, an FFC 134, and a connector 133.
Next, to illustrate one of the distinctive features and non-predictable effects of the invention according to this patent specification, maintenance work of the above-described carriage, control circuit board, and carriage circuit board in the present exemplary embodiment are described.
For example, the cover 19 illustrated in
For example, in replacing the FFC 103, the operator can remove the FFC 103 from the connecter 135 and the connector 131 and release the folded portion 103a of the FFC 103 from a latching portion, not illustrated. Then the operator can pick the FFC 103 up from the opening 20 and install a new one according to a procedure opposite the above-described procedure. Thus, the installation and removal of the FFC 103 can be performed through the opening 20. Likewise, the removal and installation of the FFC 134 with respect to the connectors 132 and 133 can be performed through the opening 20.
In performing the maintenance work of the recording head units 11, the operator picks up the head assembly 12 from the opening 20. Then, the operator pulls a target one of the recording head units 11 from the head assembly 12 and performs maintenance work on the target one. After the maintenance, the operator mounts the recording head units 11 onto the head assembly 12 and mounts the head assembly 12 to the head mount 4A. Thus, the operator can mount and remove the head assembly 12 from the same direction as the direction from which he/she replaces the FFC 103.
For the maintenance work of the carriage circuit board 101, for example, when the encoder sensor 16 is stained, an operator can picks up the carriage circuit board 101 from the opening 20, cleans the encoder sensor 16, and mounts the carriage circuit board 101 onto the board mount 4C through the opening 20.
As described above, all the maintenance work can be performed through the opening 20, thus facilitating maintenance. In addition, for example, the operator can remove a sheet stopped on the conveyance belt 21 (for example, a jammed sheet of paper) through the opening 20. With such a configuration, the operator can access the interior of image forming apparatus 100 to perform different types of maintenance work from a common direction, thus shortening the work time of the operator and the downtime of the apparatus.
Next, the mounting of the carriage circuit board 101 is described with reference to
As described above, the carriage circuit board 101 is horizontally mounted on the board mount 4C of the carriage 4, thus allowing the carriage circuit board 101 to be fixed on the board mount 4C with fasteners 106, e.g., screws, from the upper side of the image forming apparatus 100.
Such a configuration can facilitate the mounting and removal of the carriage circuit board 101. If the carriage circuit board is disposed on the rear face of the carriage as in a conventional configuration, an operator needs to remove the carriage itself from the image forming apparatus in removing the carriage circuit board, thus reducing the workability. By contrast, in the present exemplary embodiment, the carriage circuit board 101 is horizontally disposed in the carriage, thus allowing the carriage circuit board 101 to be removed from and fixed on the carriage from the upper side of the image forming apparatus 100.
As described above, the carriage includes the board mount on which the carriage circuit board is horizontally mounted. The flexible flat cable is disposed below the board mount so as to be movable in the main scanning direction. The flexible flat cable is extended below the carriage circuit board, bent back toward the carriage circuit board, and connected to the carriage circuit board from the main scanning direction, thus facilitating maintenance.
Next, the effect of minimizing the occurrence of noise is described with reference to
The metal sheet 111 constituting the structure of the image forming apparatus 100 is vertically disposed. In the comparative example illustrated in
By contrast, in the present exemplary embodiment, as illustrated in
Next, protection of the linear encoder from droplet mist due to ejection of ink droplets from the recording head units 11 is described with reference to
As described above, the encoder sensor 16 is mounted on the carriage circuit board 101, and a stay (metal sheet) 105 constituting a structure of the image forming apparatus 100 to be mounted with the main scan motor 5 is provided between the encoder scale 15 and the head mount 4A of the carriage 4. With such a configuration, as illustrated in
Next, another exemplary embodiment is described with reference to
In the above-described exemplary embodiments, the image forming apparatus is described as a printer. However, it is to be noted that the image forming apparatus is not limited to such a printer and may be, for example, a multifunctional device having two or more capabilities of a printer, a facsimile machine, and a copier. In addition, the image forming apparatus may be an image forming apparatus using, for example, a recording liquid other than “ink” in strict meaning, fixing solution, or patterning material.
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 present disclosure may be practiced otherwise than as specifically described herein. With some embodiments having thus been described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the scope of the present disclosure and appended claims, and all such modifications are intended to be included within the scope of the present disclosure and appended claims.
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