The invention relates generally to optical systems used in laser printers, and, more particularly, to an optical lens system for correcting linearity errors associated with torsion oscillator mirrors having a sinusoidal scan angle motion.
Torsion oscillators with a mirrored surface are used in laser printers to scan a laser beam bi-directionally across a laser printer drum. Generally, the scan angle of the mirrored surface of the torsion oscillator varies sinusoidally with respect to time. At the angular extremes of the sinusoidal motion—the point at which the scan reverses direction—the rate of change of the scan angle slows to zero. Due to the decreasing rate of angular change at the scan extremes, dots imaged at a constant rate on a photoconductor of a laser printer are more closely spaced together at the scan extremes than in the middle of the scan line, if there is no optical correction of the scanned laser beam. This causes linearity errors at the ends of the scan line which results in unacceptable print defects in a laser printer application.
What is needed, therefore, is an optical system for correcting linearity errors introduced by the sinusoidal scan angle motion produced by a torsion oscillator mirror in a laser printer.
In one aspect, the invention provides an optical apparatus that compensates for imaging errors associated with the sinusoidal angular scan rate of a light beam reflected from a bidirectional scanning torsion oscillator. According to the invention, the light beam, such as produced by a laser light source, propagates along an optical path from the light source to a reflective surface of the torsion oscillator, which reflects the beam toward the imaging surface of an imaging device. Based on the sinusoidal motion of the reflective surface of the torsion oscillator, the light beam is scanned from a first edge position through a central position to a second edge position on the imaging surface.
The optical apparatus includes a post-scan optical system disposed in the optical path of the light beam between the reflective surface of the scanning torsion oscillator and the imaging surface of the optical imaging system. Based on the optical characteristics of its components, the post-scan optical system causes deflection of the light beam in the scan direction. To compensate for the sinusoidal angular scan rate introduced by the torsion oscillator, the post-scan optical system causes the deflection of the beam to be greater as the beam approaches the extreme scan positions. In this manner, the scan rate of the light beam at the first and second edge positions is substantially equivalent to the scan rate at the central position.
In preferred embodiments of the invention, the post-scan optical system comprises a first post-scan lens and a second post-scan lens. The first post-scan lens of these embodiments has at least one surface defined by a radius of curvature that varies in the scan direction. The second post-scan lens of these embodiments has at least one surface defined by a radius of curvature that varies in the process direction, which is orthogonal to the scan direction and the propagation direction.
Some preferred embodiments of the invention include a pre-scan optical system disposed in the optical path of the light beam between the light source and the scanning reflective surface of the torsion oscillator. The pre-scan optical system directs the light beam onto the reflective surface in a manner that compensates for the divergence of the light beam in the scan direction introduced by the post-scan optical system, such that the light beam is substantially focused at all points across the imaging surface.
In some preferred embodiments, the pre-scan optical system comprises, first and second pre-scan lenses. The first pre-scan lens of these embodiments has substantially the same focusing characteristics in the scan direction as in a process direction. The second pre-scan lens of these embodiments has a cylindrical first surface defined by a fixed radius of curvature in the process direction and an essentially infinite radius of curvature in the scan direction, and a planar second surface.
In another aspect, the invention provides an optical imaging system comprising a light source, pre-scan optics, a bidirectional scanning torsion oscillator, post-scan optics, and an imaging device. According to the invention, the light source, such as a laser diode, produces a light beam that propagates along an optical path. The pre-scan optics receive the light beam, directs it to a reflective surface of the scanning torsion oscillator, and modifies the divergence of the light beam in the scan direction. The scanning torsion oscillator receives the light beam from the pre-scan optics and reflects the beam from the reflective surface that oscillates according to a sinusoidal function. Based on the motion of the reflective surface, the torsion oscillator causes the reflected light beam to scan back and forth at a sinusoidal angular rate across an imaging surface of the imaging device. In this manner, the beam is scanned from a first edge position through a central position to a second edge position on the imaging surface.
The post-scan optics are positioned in the optical path of the beam between the torsion oscillator and the imaging surface of the imaging device. The post-scan optics receive the reflected light beam from the scanning torsion oscillator and cause deflection of the reflected light beam in the scan direction. According to the invention, the beam deflection in the scan direction introduced by the post-scan optics is greater at the first and second edge positions of the imaging surface than at the central position. Due to varying levels of the post-scan beam deflection, the scan rate of the light beam at the first and second edge positions is substantially equivalent to the scan rate at the central position. In this manner, the post-scan optics compensate for imaging, errors associated with the sinusoidal scan rate of the light beam reflected from the torsion oscillator.
Prior patent applications assigned to the assignee of the present invention have described the construction and operation of the torsion oscillator, including the placement of coil(s) and magnet(s) that together create rotational movement when electrical drive power is applied to the coil. These prior applications include U.S. patent application Ser. No. 10/093,754, filed Mar. 8, 2002, (published as No. US 2003-0169055 A1 on Sep. 11, 2003); Ser. No. 10/329,084, filed Oct. 23, 2002, (published as No. US 2004-0119813 A1 on Jun. 24, 2004); and Ser. No. 10/689,175, filed Oct. 20, 2003, (published as No. US 2004-0125198 A1 on Jul. 1, 2004), the entire disclosures of which are hereby expressly incorporated by reference.
The nature of the problem solved by the present invention is depicted in
The optical systems O1 and O2 are designed to accomplish three main objectives as the beam I2 scans across the plane P:
To meet objective (1), the optical system O2 modifies or deflects the path of the beam I2. To meet objectives (2) and (3), the optical system O2 changes the divergence and/or size of the beam I2. In a scanning optical system, the alteration of beam direction and beam divergence are necessarily coupled.
Without the optical system O2, the position of intersection point z is represented by
z=D tan(θn),
where D is the normal distance from the center of rotation C to the plane P. For a resonant galvanometric rotational mirror, the steady-state angular position of the mirror may approximate
θn(t)=θmax cos(2πft),
where θmax is the maximum scan angle of the mirror M. For the system depicted in
(such as occurs with a oscillating mirror) and for a constant variation in the scan rate
(such as occurs with a polygonal mirror). The results are depicted without modification by the optical system O2. The graphs of
It should be appreciated that the angular scan rates depicted in
As depicted in
during a scan at a constant scan rate (solid curve) is strikingly different from the case of a sinusoidal scan rate (dashed curve).
In printers having a constant angular rate of scan, such as provided by a polygon mirror, a single optical system in the path of the deflected beam has been effective in focusing the beam and reducing scan velocity at the edges of the scan. However, in printers having an oscillating mirror that produces a sinusoidal scan rate, lenses that increase the deflection of the beam and reduce the scan speed will cause a reduction in the portion of the scan which can be used for printing.
According to the present invention, the optimal optical design for a sinusoidally oscillating mirror includes an optical system O2 having a lower positive optical power than would be used in the case of constant angular scan rate, and in some instances having an overall negative power. Also, in preferred embodiments of the invention, the beam convergence required to produce a focal point on the plane P is provided by an optical system O1 positioned in the beam path prior to the incidence of the beam I1 on the scanning mirror M. Preferred embodiments of the optical systems O1 and O2 are described hereinafter.
Shown in
In the description of the invention herein, the term “pre-scan” refers to optical components positioned in the optical path of the laser beam between the laser source 12 and the mirror of the torsion oscillator 20. The term “post-scan” as used herein refers to optical components positioned in the optical path between the mirror of the torsion oscillator 20 and the photoconductor surface of the printer drum 28.
The term “scan direction” as used herein refers to the direction parallel to the plane in which the beam is scanned and perpendicular to the beam axis in the pre-scan and post-scan optics. In the post-scan optics, the scan direction is also parallel to the line on the photoconductor at which the dots are printed (referred to herein as the writing line). The scan direction in the post-scan optics is indicated by the arrow 30 in
The term “process direction” as used herein refers to the direction that is perpendicular to the scan direction and the beam axis in the pre-scan and post-scan optics. The process direction in the post-scan optics is indicated by the arrow 38 in
To achieve increased laser spot spacing near the extremes of the scan while maintaining uniform focus of the dots within the entire scan line, a preferred embodiment of the invention includes post-scan optics 70 as depicted in FIGS. 6, 7A-C and 8A-C. In the preferred embodiment of the invention, the post-scan optics 70 comprise a two-lens non-focusing optical system. One surface of one of the two post-scan lenses preferably has a varying radius of curvature in the scan direction, and one surface of the other of the two lenses preferably has a varying radius of curvature in the process direction. The invention also provides pre-scan optics 60 to compensate for the negative optical power of the post-scan optics 70. The combination of the pre-scan optics 60 and the post-scan optics 70 achieves the desired focus in both the scan direction and the process direction at the surface of the photoconductor drum 28.
Referring to
The torsion oscillator 20 of the preferred embodiment is designed to oscillate a reflective surface through a mechanical angle of rotation of about ±23 degrees. Because the angle of incidence of light on a mirror equals the angle of reflection, the maximum resulting laser scan angle is about ±46 degrees. Generally, only the central region of this sinusoidal scan angle range is used in the writing process. As shown in
To achieve linear dot spacing at the writing line 26, the laser beam 50 passes through first and second post-scan optical lenses 22 and 24 after reflection from the mirror of the torsion oscillator 20. The combination of lenses 22 and 24 causes deflection of the reflected light beam 50 in the scan direction, where the amount of deflection is greater at the edges of the writing line 26 (26a and 26b in
In this manner, the lenses 22 and 24 form a non-focusing lens system in the scan direction, the combination of which causes an increase in the spacing of laser dots imaged near the ends of the writing line 26. The combination of lenses 22 and 24 thereby corrects the linearity distortion caused by the sinusoidal angular scan rate of the torsion oscillator 20.
A preferred embodiment of the first post-scan lens 22 is shown in
Referring to
The second surface 36 of lens 22 is preferably quasi-toric with a unique convex variable radius of curvature (RS2) in the scan direction (X-Z plane). This variable radius of curvature of the second surface 36 in the X-Z plane (in millimeters) is depicted in
X=0.00+SAG (1)
where:
SAG=a2×Z2+a4×Z4+a6×Z6+a8×Z8+a10×Z10+a12×Z12 (2)
In the preferred embodiment, the coefficient values of equation (2) in scientific notation are:
a2=−4.07736E−3; a4=7.32924E−8; a6=1.25673E−11; a8=4.71011E−15; a10=−2.13737E−17;
and
a12=1.29462E−20.
It should be noted that the smallest radius of curvature described by the polynomial (2) is in the center of the lens 22 on the optical axis (Z=Y=0). In the preferred embodiment depicted in
As shown in the preferred embodiment of
The second surface 42 of the lens 24 is preferably quasi-toric with a very slightly convex radius of curvature (RS2) of 2970.49 mm±2% in the X-Z plane. As shown in
RP2=29.43+4.32461E−3×Z2+1.63684E−10×Z4+1.11696E−17×Z6. (3)
Due to the divergence of the beam 50 in the scan direction introduced by the combination of lenses 22 and 24, the post-scan optics 70 alone would not produce a focused spot in the scan direction near the edges 26a, 26b of the writing line 26. In the preferred embodiment of the invention, the pre-scan optics 60 complement the post-scan optics 70 to achieve the desired spot focus in the process and scan directions. In the process direction, the pre-scan optics 60 preferably focus the laser beam 50 on the reflective surface of the torsion oscillator 20. In the scan direction, the pre-scan optics 60 preferably focus the beam 50 to compensate for the diverging, unfocused, spot introduced by the post-scan optics 70 out at the edges 26a, 26b of the writing line 26. Based on the combined optical power of the pre-scan optics 60 and the post-scan optics 70, the laser spot is focused at all points along the complete length of the writing line 26 in both the process direction and the scan direction. An elliptical aperture may also be included in the pre-scan optics 60 to control the final focused spot size in both the scan direction and the process direction.
The function performed by the pre-scan optics 60 of the invention may be implemented in a number of ways. In the preferred embodiment depicted in
After exiting the collimation lens 14, the laser beam 50 passes through the pre-scan lens 16. In the preferred embodiment, the pre-scan lens 16 is a plano-cylindrical lens located about 29.5 mm from the laser source 12. The material of the pre-scan lens 16 is preferably BK7 glass having an index of refraction of 1.51119. The cylindrical first surface 46 of the pre-scan lens preferably has a radius of about 71.00 mm in the process direction and an essentially infinite radius of curvature in the scan direction. The planar second surface 48 of the pre-scan lens 16 has an essentially infinite radius of curvature in both directions and thus no optical power in either direction.
In the preferred embodiment of the invention, the radius of curvature of the first surface 46 of the pre-scan lens 16 in the process direction combined with the optical power of the collimation lens 14 in the process direction focuses the laser beam 50 in the process direction on the mirror surface of the torsion oscillator 20 at its axis of rotation. In the process direction, the combination of the lenses 22 and 24 re-images the mirror surface of the torsion oscillator at its axis of rotation onto the writing line 26. This pre-scan focusing technique in the process direction reduces the size of the mirrored target area on the torsion oscillator 20 and reduces visible jitter effects from unwanted off-axis motion of the torsion oscillator 20 as it sweeps through a laser scanning cycle.
While specific embodiments of the invention have been illustrated and described herein, it is realized that numerous modifications and changes will occur to those skilled in the art. It is therefore to be understood that the appended claims are intended to cover all such modifications and changes as follow in the true spirit and scope of the invention.
This application is a continuation-in-part of co-pending U.S. patent application Ser. No. 10/689,175, filed Oct. 20, 2003, entitled BI-DIRECTIONAL GALVONOMETRIC SCANNING AND IMAGING.
Number | Date | Country | |
---|---|---|---|
Parent | 10689175 | Oct 2003 | US |
Child | 11034168 | Jan 2005 | US |