Patent Application
20070052153
Media sheets for use in an image forming device are initially stored in an input area. The input area is sized to hold a predetermined number of media sheets that are stacked together. A pick mechanism is positioned adjacent to the input tray to pick individual media sheets from the stack and deliver them into a media path. The pick mechanism should accurately deliver one sheet from the input area, and should deliver the sheet in a timely manner.
The pick mechanism includes a pivoting arm having a pick roller at the distal end. The pick roller rests on the stack and rotates to drive the top-most sheet from the stack into the media path. The arm applies a downward force onto the media stack. This force applied through the roller increases the friction between the roller and top-most sheet such that the sheet is delivered to the media path by rotation of the roller.
One prior art device limited the amount of force applied to the media stack. A drawback of applying a limited force is that the roller may slip during rotation. Roller slip causes a delay in picking the media sheet from the stack and introducing the sheet into the media path. This delay may cause print errors as the toner image is not accurately aligned with the top edge of the media sheet.
Another prior art device increased the amount of force applied to the media sheet to prevent roller slip. However, increased force caused the pick roller to move multiple sheets from the media stack into the media path. This double feed results in a media jam as the combined sheets cannot be moved as a unit through the device. The jam required the operator to locate the jam, remove the media sheets, reset the device, and then resume image formation.
The present application is directed to embodiments of a pick mechanism for use in an image forming device. In one embodiment, a first mechanism individually moves each of the media sheets from a stack in the input area thereby gradually decreasing a height of the stack. The first mechanism applies a first force profile to the stack while individually moving each of the plurality of media sheets. As the media sheets are moved, the height of the stack gradually decreases from a first height to a second height. As the stack decreases below the second height, a second force profile is applied to the stack. The second force profile is different from the first profile. The first and second force profiles prevent slip as the media sheets are fed from the input area, and also prevent double sheet feeds.
The present application is directed to embodiments of a pick mechanism for applying a force to a media sheet within an image forming device. The pick mechanism, generally illustrated as numeral 20 in
The pick mechanism 20 is positioned within an image forming device 100 as illustrated in
The device 100 includes a plurality of removable image formation cartridges 103, each with a similar construction but distinguished by the toner color contained therein. In one embodiment, the device 100 includes a black cartridge (K), a magenta cartridge (M), a cyan cartridge (C), and a yellow cartridge (Y). Each cartridge 103 includes a reservoir holding a supply of toner, a developer roller for applying toner to develop a latent image on a photoconductive drum, and a photoconductive (PC) member 104. Each cartridge 103 forms an individual monocolor image on the PC member 104 that is combined in layered fashion on an intermediate transfer mechanism (ITM) belt 105. The ITM belt 105 is endless and rotates in the direction indicated by arrow G around a series of rollers adjacent to the PC members 104. Toner is deposited from each PC member 104 as needed to create a full color image on the ITM belt 105. The ITM belt 105 and each PC drum 104 are synchronized so that the toner from each PC drum 104 precisely aligns on the ITM belt 105 during a single pass.
As the toner images are being formed on the ITM belt 105, the pick mechanism 20 picks a media sheet from the input tray 101. The media sheet is transported to a transfer location 106 where it intersects the toner images on the ITM belt 105. The sheet and attached toner next travel through a fuser 107 having a pair of rollers and a heating element that heats and fuses the toner to the sheet. The sheet with fused image is then either transported out of the device 100, or forwarded to a duplex path for image formation on a second side of the media sheet.
The pick mechanism 20 should accurately introduce the media sheet into the media path. Too much force applied to the media stack by the pick mechanism may cause a double feed resulting in a media jam as the media sheets move into or along the media path. Too little force applied to the media stack by the pick mechanism 20 may result in the pick rollers 22 slipping on the top-most sheet. Slipping causes the media sheet to be delayed in the input tray 101 and delivered late to the media path and ultimately to the transfer location 106. As a result, the media sheet does not align with the toner images on the ITM belt 105. In one embodiment, the toner images are transferred to the media sheet too close to the leading edge (i.e., the toner images are not centered on the media sheet). Therefore, proper operation of the pick mechanism 20 is important.
The force applied by the pick mechanism 20 is a function in part of the weight of the pick mechanism 20, and the angle of the pick arm 21.
A gear train 29 extends through the arm 21 and includes an input gear 29a (i.e., first gear) and an output gear 29b (i.e., last gear). An input torque supplied by the driving mechanism 102 is transferred through the gear train 29 ultimately causing rotation of the rollers 22. Each gear in the gear train 29 includes a number of teeth that mesh with the adjacent gears to transfer the torque and rotate the rollers 22.
The following equations govern the function of the force applied by the pick mechanism 20 to the media sheets:
Fs=TiNo(Effn)/NiRo (Eq. 1)
FN=W+[Ti+(Fs(L sin α=Ro))/L cos α] (Eq. 2)
where
Fs=tangential force exerted on a media sheet by the pick roller;
Ti=input torque to the pick arm gears from the motor;
No=number of teeth on the output gear;
Eff=gear mesh efficiency;
n=number of gear meshes;
Ni=number of teeth on the input gear;
Ro=radius of the pick roller;
FN=normal force exerted on the pick roller by the media sheet;
W=normal force exerted on the media sheet by the pick roller;
L=length of the pick arm; and
α=angled formed between a plane of the top-most media sheet and the arm.
The force applied through the pick rollers 22 to the media stack is dependent upon the angle α. When the media stack is full, the force applied to the media sheets is small thus increasing the possibility of roller slippage. When the media stack is low, the force applied is greater thus increasing the possibility of double feeds. To compensate for this, the biasing mechanism 23 is attached to the arm 21.
The biasing mechanism 23 has a first end connected to the arm 21 and a second end connected to a body 150 of the device 100. The biasing mechanism 23 is extendable from a non-engaged orientation to an engaged orientation. In the non-engaged orientation, the biasing mechanism 23 does not apply an upward force to the arm 21. Once the biasing mechanism 23 engages, it applies an upward force. During the initial stages of engagement, the amount of force is not as great as during further stages of engagement. Therefore, as the angle α of the arm 21 becomes larger, the amount of force applied by the biasing mechanism 23 becomes greater. In one embodiment, the biasing mechanism 23 is a spring.
When the media stack is full and the angle α is large, the biasing mechanism 23 is not engaged. Therefore, the force applied to the media stack is defined by the above equations. However, as the media stack is depleted below a predetermined amount, the biasing mechanism 23 becomes engaged and counteracts the applied force. As the media stack becomes more depleted and the angle α becomes larger, the biasing mechanism applies a greater counteracting force. In this manner, the force applied to the media stack is regulated to prevent too great or too small of a force and prevent double feeds and roller slippage.
At a stack height of about 45 mm, the biasing mechanism 23 begins to engage and apply a counterbalance force. As the stack height decreases and the angle α becomes larger, the biasing mechanism 23 applies a greater force. The overall force applied to the media sheets gradually decreases as the stack height is diminished. Point B correlates to the embodiment illustrated in
The force profiles may vary as necessary to reduce or eliminate roller slippage and double feeds.
In the embodiment illustrated in
The term “image forming device” and the like is used generally herein as a device that produces images on a media sheet. Examples include but are not limited to a laser printer, ink-jet printer, fax machine, copier, and a multi-functional machine. Examples of an image forming device include Model Nos. C750 and C752 available from Lexmark International, Inc. of Lexington, Ky.
The embodiments illustrated in
These embodiments may be carried out in other specific ways than those herein set forth without departing from the scope and essential characteristics of the invention. The present embodiments are, therefore, to be considered in all respects as illustrative and not restrictive, and all changes coming within the meaning and equivalency range of the appended claims are intended to be embraced therein.
