Patent Grant
8596779
The entire disclosure of Japanese Patent Application No: 2010-052316, filed Mar. 9, 2010 is expressly incorporated by reference herein.
1. Technical Field
The present invention relates to a transport apparatus and a recording apparatus.
2. Related Art
Both currently and in the past, a recording apparatus recording information on a sheet-like recording medium has been used. The recording apparatus includes a transport apparatus that transports the recording medium. The transport apparatus includes a transport roller which rotates to transport the recording medium and a driven roller which is biased to be brought into contact with the transport roller, and is adapted to transport the recording medium by nipping the recording medium between the transport roller and the driven roller. As the transport roller, a solid rod-like member is generally used. On the other hand, there is a problem in that the solid material increases the weight and the cost of the recording apparatus. Here, JP-2006-289496A discloses a technology of warping a metal sheet to have a cylindrical shape.
In a cylindrical shaft disclosed in Patent Document 1, the end surfaces of the metal sheet abut on each other when the metal sheet is warped to have a cylindrical shape. For this reason, a joint is formed between the pair of end surfaces of the metal sheet throughout the entire length of the cylindrical shaft.
However, when the transport roller including the cylindrical shaft with the above-described configuration is used, for example, there is a concern that the joint will be deformed to be opened due to a torque or the like during the rotational driving operation. In the event of such deformation, transportation precision may be degraded.
An advantage of some aspects of the invention is that it provides a transport apparatus capable of suppressing degradation of transport precision and a recording apparatus having the same.
According to an aspect of the invention, there is provided a transport apparatus including: a transport roller which is formed in a cylindrical shape such that a pair of facing end portions of a metal sheet is close to each other or abuts on each other, which has a joint provided with a spot welding portion, and in which a high friction layer is formed on a surface thereof to transport a recording medium; and a support portion which supports a portion deviated from the high friction layer of the transport roller so that the transport roller rotates about the center axis thereof.
According to the transport apparatus, since the joint formed by the pair of facing end portions of the metal sheet is provided with the spot welding portion, the strength of the joint may be improved. Accordingly, deformation of the joint may be prevented. Further, in the transport apparatus, since the spot welding portion is provided instead of welding the entire joint, the transport apparatus may not be affected by internal stress generated when welding the entire joint. Accordingly, deformation of the transport roller may be prevented, so that a degradation of a transport precision may be prevented.
In the transport apparatus with such a configuration, the spot welding portion may be provided to be closer to the end portion of the rotation axis direction of the transport roller than the support portion.
According to the transport apparatus, since the spot welding portion is provided to be closer to the end portion of the rotation axis direction of the transport roller than the support portion, deformation of the end portion of the rotation axis direction of the transport roller may be prevented.
In the transport apparatus with such a configuration, the transport roller may have a connection portion which is formed at the end portion of the rotation axis direction to be connected to a rotation driving portion rotating the transport roller, and the spot welding portion may be provided in the vicinity of the connection portion.
According to the transport apparatus, the transport roller has the connection portion which is formed at the end portion in the rotation axis direction, and the spot welding portion is provided in the vicinity of the connection portion, thereby improving the strength of the driving transmission portion of the transport roller. Accordingly, deformation of the transport roller may be efficiently prevented.
In the transport apparatus with such a configuration, the spot welding portion may be provided between the support portion and the high friction layer.
According to the transport apparatus, since the spot welding portion is provided between the support portion and the high friction layer, for example, an foreign material may be prevented from intruding from the support portion to the high friction layer.
The transport apparatus with such a configuration further includes a driven roller which rotates accompanied by the rotation of the transport roller while pressing the transport roller and nips the recording medium between the transport roller and the driven roller, wherein the spot welding portion is provided in a portion deviated from a portion pressed by the driven roller in the transport roller.
According to the transport apparatus, since the spot welding portion is provided between the support portion and the high friction layer for example, a foreign material may be prevented from intruding from the support portion to the high friction layer.
In the transport apparatus with such a configuration, the pair of end portions forming the joint may have an uneven portion which allows one end portion and the other end portion of the pair of end portions to be fitted to each other, and the spot welding portion may be provided in the uneven portion.
According to the transport apparatus, the pair of end portions forming the joint has an uneven portion which allows one end portion and the other end portion of the pair of end portions to be fitted to each other, and the spot welding portion is provided in the uneven portion, thereby preventing deformation of the uneven portion.
In the transport apparatus with such a configuration, the uneven portion may have a first side which is formed along the rotation axis direction of the transport roller, and the spot welding portion may be provided in the first side.
According to the transport apparatus, the uneven portion has the first side which is formed along the rotation axis direction of the transport roller, and the spot welding portion is provided in the first side, thereby improving the strength of the uneven portion with respect to the circumferential direction of the transport roller. Accordingly, for example, deformation making the uneven portion be opened may be prevented.
In the transport apparatus with such a configuration, the uneven portion may have a second side which is formed along the circumferential direction of the transport roller, and the spot welding portion may be provided in the second side.
According to the transport apparatus, the uneven portion has a second side which is formed along the circumferential direction of the transport roller, and the spot welding portion is provided in the second side, thereby easily performing a positioning operation when performing the spot welding process. Accordingly, the precision of the spot welding formation position may be improved.
In the transport apparatus with such a configuration, the joint may be provided with a linear portion which is connected to the uneven portion, and the spot welding portion may be provided at a boundary portion between the linear portion and the uneven portion.
According to the transport apparatus, the joint is provided with a linear portion which is connected to the uneven portion, and the spot welding portion is provided at a boundary portion between the linear portion and the uneven portion, thereby improving the strength of the portion where a force easily concentrates in the joint.
In the transport apparatus with such a configuration, the uneven portion may be disposed to be closer to the end portion of the rotation axis direction of the transport roller than the support portion.
According to the transport apparatus, the uneven portion is disposed to be closer to the end portion of the rotation axis direction of the transport roller than the support portion, thereby improving the strength of the transport roller.
In the transport apparatus with such a configuration, the spot welding portion may be a portion which is formed by fusing a part of the metal sheet.
According to the transport apparatus, the spot welding portion is a portion which is formed by fusing a part of the metal sheet, so that the spot welding portion and the metal sheet are formed of the same material. Likewise, when the spot welding portion and the metal sheet are formed of the same material, for example, a difference in the thermal expansion coefficient in the spot welding portion may be prevented. Accordingly, deformation or the like caused by a thermal variation may be prevented.
In the transport apparatus with such a configuration, the spot welding portion may be a portion which is fused by emitting a laser beam to a part of the metal sheet.
According to the transport apparatus, the spot welding portion is a portion which is fused by emitting a laser beam to a part of the metal sheet, thereby easily forming the spot welding portion.
According to another aspect of the invention, there is provided a recording apparatus including: a transport unit which uses the transport apparatus according to the aspect of the invention to transport a recording medium; and a recording unit which performs a recording process on the recording medium transported by the transport apparatus.
According to the recording apparatus with such a configuration, a recording process may be performed on the recording medium while the recording medium is transported by the transport apparatus having highly precise transport precision, thereby performing the highly-precise recording process.
The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
Hereinafter, an exemplary embodiment of the invention will be described by referring to the accompanying drawings.
Furthermore, in the respective drawings to be described below, the scales of the respective members are appropriately changed so that the respective members are recognizable.
As shown in
A sheet feeding unit 5 is provided with a sheet feeding tray 11, and the sheet feeding tray 11 is used to stack plural sheets (a medium, a recording medium, and a transport medium) P. Here, as the sheet P, a normal sheet, a coated sheet, a sheet for an OHP (overhead projector), a glossy sheet, a glossy film, and the like are used. Hereinafter, in the transport path of the sheet P, the side of the sheet feeding tray 11 is set as the upstream side, and the side of the sheet discharging unit 7 is set as the downstream side. A sheet feeding roller 13 is provided at the downstream side of the sheet feeding tray 11.
The sheet feeding roller 13 is adapted to nip the sheet P located at the uppermost portion of the sheet feeding tray 11 in a manner such that the sheet is nipped between the sheet feeding roller and a separation pad (not shown) facing the roller, and sends the sheet to the downstream side. A transport roller mechanism 19 is provided at the downstream side of the sheet feeding roller 13.
The transport roller mechanism 19 includes a transport roller 15 which is disposed at the lower side and a driven roller 17 which is disposed at the upper side.
The transport roller 15 is adapted to be rotationally driven by a driving unit 30 shown in
The recording head 21 is held by a carriage 23, and the carriage 23 is adapted to move in a reciprocating manner in the direction perpendicular to the sheet feeding direction (the transport direction of the sheet P). The recording process (the printing process) performed by the recording head 21 is designed to be controlled by a control unit CONT. A platen 24 is disposed at a position facing the recording head 21.
The platen 24 includes plural diamond ribs 25 which are arranged in the movement direction of the carriage 23 at the interval therebetween.
The diamond ribs 25 are used to support the sheet P from the lower side thereof when the recording head 21 records an image on the sheet P, and each front surface thereof serves as a support surface. The distance between the diamond rib 25 and the recording head 21 is designed to be adjusted in accordance with the thickness of the sheet P. Accordingly, the sheet P may pass on a top surface of the diamond rib 25. A sheet discharging roller mechanism 29 is provided at the downstream side of the diamond rib 25 and the recording head 21.
The sheet discharging roller mechanism 29 includes a sheet discharging roller 27 which is disposed at the lower side and a sheet discharging knurled roller 28 which is disposed at the upper side. Accordingly, the sheet P is drawn out and discharged in accordance with the rotational driving operation of the sheet discharging roller 27.
Here, the relationship between the driving unit 30 of the transport roller mechanism 19 and the sheet discharging roller mechanism 29 and the driving speed of the transport roller 15 and the sheet discharging roller 27 will be described.
As shown in
With such a configuration, the transport motor 32 and the like constitute the driving unit 30 which rotationally drives the transport roller 15.
Further, the transport roller 15 is provided with the transport driving gear 35 and an inner gear 39 which is coaxially formed therewith, an intermediate gear 41 meshes with the inner gear 39, and a sheet discharging driving gear 43 meshes with the intermediate gear 41. As shown in
With such a configuration, the transport roller 15 of the transport roller mechanism 19 and the sheet discharging roller 27 of the sheet discharging roller mechanism 29 are adapted to be driven by receiving a rotational driving force from the transport motor 32 as the same driving source.
Furthermore, the rotation speed of the sheet discharging roller 27 is set to be faster than the rotation speed of the transport roller 15 by adjusting the gear ratio between the respective gears. Accordingly, the sheet discharging speed of the sheet discharging roller mechanism 29 becomes faster than the transport speed of the transport roller mechanism 19 by an increase in the speed.
Further, the nipping force (pressing force) applied to the sheet P from the transport roller mechanism 19 is set to be larger than the nipping force (pressing force) of the sheet discharging roller mechanism 29. Accordingly, when the transport roller mechanism 19 and the sheet discharging roller mechanism 29 simultaneously nip the sheet P, the sheet transport speed is set as the transport speed of the transport roller mechanism 19 regardless of the sheet discharging speed of the sheet discharging roller mechanism 29.
Next, the transport roller 15 and the transport roller mechanism 19 having the same will be described.
The transport roller 15 includes a roller body 16 which is formed in a hollow cylindrical shape and a high friction layer 50 which is formed on a part of the surface of the roller body 16 in the length direction (the axial direction).
For example, the roller body 16 is formed from a base material which is a steel sheet coil obtained by winding a metal sheet such as a zinc plating steel sheet or a stainless steel sheet. The roller body 16 is a cylindrical shaft which is formed in a manner such that the uncoiled metal sheet is bent so that a pair of end surfaces faces each other, and an inner peripheral side surface of a coil is used as an inner peripheral surface. That is, the metal sheet forming the roller body 16 is formed in a cylindrical shape while a winding tendency of a coil is left so as to be warped toward the inner peripheral surface of the cylinder.
Further, as shown in
As shown in
The high friction layer 50 is formed in a manner such that a resinous film is formed by selectively coating resinous particles at a high friction layer forming area on the surface of the roller body 16 so that the film thickness becomes uniform such as to be from about 10 μm to 30 μm, and inorganic particles are uniformly sprayed and baked on the resinous film. As the resinous particles, for example, a fine particle having a diameter of about 10 to 20 μm and formed of an epoxy resin or a polyester resin is preferably used. Further, as an inorganic particle, a ceramic particle such as aluminum oxide (alumina; Al2O3), silicon carbide (SiC), or silicon dioxide (SiO2) with a predetermined particle diameter distribution obtained through a crushing process is preferably used.
As shown in
The driven roller 17 is formed in a manner such that plural (for example, six) rollers 17a are coaxially arranged, and is disposed at a position facing and coming into contact with the high friction layer 50 of the transport roller 15. A biasing spring (not shown) is attached to the driven roller 17 including the rollers 17a, whereby the driven roller 17 is biased toward the transport roller 15.
Accordingly, the driven roller 17 contacts the high friction layer 50 of the transport roller 15 with a predetermined pressing force (a nipping force with respect to the sheet P), and is adapted to rotate in a manner of following the rotation of the transport roller 15. Further, a force nipping the sheet P between the transport roller 15 and the driven roller 17 becomes larger, so that the transport performance of the sheet P becomes satisfactory. Furthermore, the surface of each roller 17a of the driven roller 17 is subjected to, for example, a low-abrasion treatment such as coating of fluororesin in order to alleviate damage caused by contact with respect to the high friction layer 50.
In the embodiment, as shown in
The spot welding portion SP is a welding portion that is formed at a part of the joint 80 differently from the welding performed on the entire joint 80.
The spot welding portion SP is formed at, for example, plural positions in the joint 80. For example, as shown in
When the spot welding portion SP is disposed to be closer to the high friction layer 50 than the bearing 26, it is desirable that the spot welding portion is disposed at a portion pressed by, for example, the driven roller 17.
By using the transport roller 15, the bearing 26, the driving unit 30, the driven roller 17, and the like, the transport unit (the transport apparatus) 20 of the ink jet printer 1 is formed.
Next, the operation of the ink jet printer 1 will be described by referring to
The ink jet printer 1 nips the sheet P located at the uppermost portion of the sheet feeding tray 11 by using the sheet feeding roller 13, and sends the sheet to the downstream side. The sent sheet P arrives at the transport roller mechanism 19. The transport roller mechanism 19 nips the sheet P between the transport roller 15 and the driven roller 17, and transports the sheet at a constant speed toward the lower side of the recording head 21 in accordance with the sheet feeding operation performed by the rotational driving operation of the transport roller 15. The sheet P transported to the lower side of the recording head 21 smoothly passes on the top surface of the diamond rib 25, and at this time, the recording head 21 records a high-quality image thereon. The sheet P having an image recorded by the recording head 21 is sequentially discharged by the sheet discharging roller 27 of the sheet discharging unit 7.
Since the transport speed of the sheet discharging roller mechanism 29 is set to be faster than the transport speed of the transport roller mechanism 19, the sheet P is transported with a back tension applied thereto. However, when the transport roller mechanism 19 and the sheet discharging roller mechanism 29 both nip the sheet P, the sheet transport speed is set as the transport speed of the transport roller mechanism 19. Accordingly, in this manner, even when the sheet is simultaneously discharged and transported by the sheet discharging roller mechanism 29 and the transport roller mechanism 19, the sheet transport speed is set as the transport speed of the transport roller mechanism 19. For this reason, the sheet is accurately and reliably transported without any irregularity in transport.
Here, when the sheet P is transported while being supported by the high friction layer 50 of the transport roller 15, a torque acts on the roller body 16. Then, a stress acts in the direction in which the joint 80 (refer to
However, in the embodiment, the roller body 16 of the transport roller 15 is formed by a metal sheet having a winding tendency of a steel sheet coil, and is formed in a cylindrical shape of which the inner peripheral surface is the inner peripheral side of the coil. The winding tendency of the metal sheet caused by the steel sheet coil indicates the warping in which the inner peripheral surface of the steel sheet coil becomes a concave surface. That is, the metal sheet forming the roller body 16 has a winding tendency that causes a warping so that the inner peripheral surface side of the roller body 16 is warped.
For this reason, a winding tendency does not act in the direction in which at least the joint of the roller body 16 is opened. Accordingly, compared to the case where a winding tendency is left so that the outer peripheral surface side of the roller body 16 is warped, the joint of the roller body 16 may be made to be difficult to open. That is, according to the embodiment, even when a stress acts in the direction in which the joint of the roller body 16 is opened, the joint may be prevented from being opened, thereby providing the transport roller 15 having high transport precision.
Further, the circumferential direction (the warping direction) of the roller body 16 is set to be equal to the winding direction (the rolling direction of the steel sheet) of the steel sheet coil. For this reason, the warping direction of the metal sheet forming the roller body 16 may be made equal to the warping direction of the winding tendency. Accordingly, the winding tendency of the metal sheet forming the roller body 16 acts in the direction in which the joint of the roller body 16 is closed. Accordingly, the joint of the roller body 16 may be more effectively prevented from being opened.
Further, since the roller body 16 is formed by a hollow cylindrical shaft, the weight may be greatly reduced compared to the case of using a solid shaft. Further, a demand for cutting the material is reduced compared to the case of forming the roller body 16 by a solid shaft. Accordingly, as the material of the roller body 16, a material without a toxic substance such as lead may be used, thereby reducing an environmental burden.
Further, the transport roller 15 is provided with the high friction layer 50, and the driven roller 17 is disposed at a position coming into contact with the high friction layer 50. For this reason, a force nipping the sheet P between the transport roller 15 and the driven roller 17 becomes larger, so that the sheet P may be more satisfactorily transported.
Further, the transport unit 20 of the embodiment includes the transport roller 15 and the bearing 26 supporting the bearing. For this reason, the transport roller 15 having high transport precision as described above may be rotated while being supported by the bearing 26, and the sheet P may be highly precisely transported while being supported by the high friction layer 50. Further, since the transport roller 15 is formed by the hollow roller body 16, the weight of the transport unit 20 may be greatly reduced compared to the case of using the solid shaft, and the environmental burden may be reduced.
Further, the ink jet printer 1 of the embodiment may highly precisely transport the sheet P by using the transport unit 20, and perform a highly precise recording process on the sheet P. Further, since the transport roller 15 is formed by the hollow roller body 16, the weight of the entire apparatus may be greatly reduced compared to the case of using the solid shaft, and the environmental load may be reduced.
Next, a device for manufacturing the transport roller 15 will be described.
As shown in
The uncoiler 110 is used to support a cylindrical coil (steel sheet coil) C in which the metal sheet M is wound in the rolling direction to be rotatable about the axis thereof and to uncoil the coil C.
The leveler 120 includes plural upper and lower work rolls 121 which are alternately arranged, and is used to flatten the metal sheet M in a manner such that the metal sheet M passes between the upper and lower work rolls 121. The leveler 120 of the embodiment does not completely remove the winding tendency (warping) of the coil C in the metal sheet M and adjusts the winding tendency to a degree such that the metal sheet may be processed by the first press machine 130.
The first press machine 130 includes a male die (punch) 131 and a female die (die) 132, and is used to punch the metal sheet M into a predetermined shape by a pressing process, and upper and lower dies 133 and 134.
The second press machine 140 includes plural female dies (warping dies) 141 and 143 which are arranged in one direction, male dies (warping punches) 142 and 144 which are arranged in one direction, and upper and lower dies 145 and 146, and is used to warp the metal sheet M by a pressing process. Then, the metal sheet M is gradually formed in a cylindrical shape in a manner such that the metal sheet M is sequentially warped by other dies while the metal sheet M is intermittently sent in one direction by a transport unit (not shown).
Next, a method of manufacturing the transport roller 15 will be described.
First, for example, a coil C is prepared in which the metal sheet M such as a cold rolled steel sheet or an electrogalvanized steel sheet having a sheet thickness of about 0.8 mm to 1.2 mm is wound in the rolling direction. Then, the coil C is supported by the uncoiler 110 of the device 100, and the coil C is rotated about the axis so that the metal sheet M is uncoiled. The metal sheet M uncoiled from the coil C is maintained in a state in which a winding tendency is left so that the inner peripheral side surface C1 of the coil C is formed in a concave surface and the outer peripheral side surface C2 is formed in a convex surface when the coil C is seen from the side thereof. The uncoiled metal sheet M is transported in one direction (rolling direction) by a transport unit (not shown), and arrives at the leveler 120.
The metal sheet M arriving at the leveler 120 is flattened by plural upper and lower work rolls 121 so that its winding tendency is adjusted. Accordingly, the metal sheet M is flattened to a degree such that the metal sheet M may be processed by the first press machine 130, but the winding tendency making the inner peripheral side surface C1 of the coil C as a concave surface is left to a certain degree. The metal sheet M flattened by the leveler 120 is transported in one direction by a transport unit (not shown) so that it arrives at the first press machine 130.
The metal sheet M arriving at the first press machine 130 is punched through the pressing process using the male die 131 and the female die 132. In the punching process, for example, as shown in
In this case, in the punching process, even when a sag sd, a sheared surface sp, a broken surface bs, and a burr (not shown) are formed in the metal sheet M shown in
Accordingly, when the roller body 16 having the joint 80 (refer to
Accordingly, the precision of the joint 80 of the roller body 16 may be improved, and the transport roller 15 having high transport precision may be provided. Further, since it is possible to prevent the burr from being protruded from the outer peripheral surface of the roller body 16 by allowing the burr to be located at the inner peripheral surface side of the roller body 16, a burr removing process may be omitted, thereby improving productivity.
As shown in
The metal sheet M punched by the first press machine 130 is transported by a transport unit (not shown) so that it arrives at the second press machine 140 shown in
The flat sheet portion 60 of the metal sheet M arriving at the second press machine 140 is warped by a pressing process in the direction (rolling direction) parallel to the short side 60a shown in
Specifically, first, the flat sheet portion 60 of the metal sheet M is pressed by the female die (warping die) 141 and the male die (warping punch) 142 shown in
Here, the male die 142 is disposed to face the inner peripheral side surface C1 (the lower surface of the flat sheet portion 60 of
Next, after the metal sheet M is sent in one direction, the center portion of the flat sheet portion 60 in the short side direction (warping direction) is pressed by the second female die (warping die) 143 and the second male die (warping punch) 144 shown in
Next, after the metal sheet M is sent in one direction, as shown in
Here, the outer diameter of the core die 147 shown in
That is, in the state shown in
Subsequently, as shown in
Subsequently, as shown in
As shown in
Next, a spot welding process is performed on the joint 80 of the roller body 16. The spot welding process is performed to form the spot welding portion SP in the joint 80, which improves the strength of the joint 80 in the spot welding portion SP. In this configuration, for example, as shown in
In the spot forming area SA, a part of the fused metal sheet M is solidified while being connected to the end portions 61a and 61b of the metal sheet M, thereby forming the spot welding portion SP. In the embodiment, an example is shown in which a laser beam L is emitted to a part of the metal sheet M to fuse the portion, but the invention is not limited thereto. For example, the metal sheet M may be fused by using any method (for example, a heating method or the like).
Subsequently, in the embodiment, a centerless grinding process is performed on the roller body 16 so that its circularity is improved and a deviation in the product is reduced. In the grinding process, for example, as shown in
The roller body 16 is disposed between two whetstone members GD disposed with a gap smaller than the outer diameter of the roller body 16, and the roller body 16 is made to contact the outer peripheral portions of the two whetstone members GD. Subsequently, the two whetstone members GD are rotated, for example, in the same direction. By the rotation of the two whetstone members GD, a friction force is generated between each of the whetstone members GD and the roller body 16.
Furthermore, regarding the two whetstone members GD, it is desirable that the dimension in the length direction (the height direction of the cylinder) is larger than the roller body 16 so that the entire roller body 16 in the length direction may be ground at one time. Further, it is desirable that the roller body 16 is disposed at, for example, the center portion in the length direction of the whetstone members GD so that, for example, the entire roller body 16 in the length direction contacts the two whetstone members GD in order to ensure a margin in the length direction of the roller body 16 during the rotation of the whetstone members GD.
The outer peripheral surface 16a of the roller body 16 is ground while the roller body 16 is rotated in the direction opposite to the rotation direction of the whetstone members GD due to the friction force generated by the rotation of the whetstone members GD. For this reason, the entire outer peripheral surface 16a of the roller body 16 is evenly ground, and the circularity of the roller body 16 becomes more satisfactory compared to the case where the grinding process is not performed.
After the grinding process, the roller body 16 having high circularity and less deviation is obtained. Furthermore, in the roller body 16, the gap between both end surfaces 61a and 61b is further narrowed, thereby forming the joint 80 having a narrowed gap between both end surfaces 61a and 61b as shown in
Furthermore, in the pressing process or the grinding process, it is desirable that a gap between both end surfaces 61a and 61b of the flat sheet portion 60 is eliminated, that is, both end surfaces 61a and 61b come into contact with each other. However, although the circularity or the deviation of the roller body 16 may be made satisfactory, it is difficult to completely eliminate the gap. Accordingly, in the present state, a certain degree of a gap is left.
In the joint 80, since the outer peripheral surface and the inner peripheral surface of the flat sheet portion 60 have the same dimension (width), the distance between the pair of end surfaces 61a and 61b becomes relatively wider at the side of the outer peripheral surface 16a of the roller body 16 and becomes relatively narrower at the side of the inner peripheral surface 16b as shown in
In this manner, when the roller body 16 according to the invention is formed as a cylindrical shaft, the high friction layer 50 is formed on the surface of the roller body 16 as shown in
As a method of forming the high friction layer 50, a drying method and a wetting method (or a method formed by the combination thereof) may be adopted, but in the embodiment, the drying method is preferably adopted. Specifically, first, resinous particles and inorganic particles are prepared as a material forming the high friction layer 50. As the resinous particles, fine particles each having a diameter of about 10 μm and formed of an epoxy resin or a polyester resin are preferably used.
Further, as the inorganic particle, a ceramic particle such as aluminum oxide (alumina; Al2O3), silicon carbide (SiC), or silicon dioxide (SiO2) is preferably used. Among them, alumina has comparatively high hardness and satisfactorily exhibits a function of increasing a friction resistance. Further, since the price of alumina is comparatively low, a decrease in the manufacturing cost is not jeopardized. For this reason, alumina is more preferably used. Accordingly, in the embodiment, alumina particles are used as the inorganic particles.
The alumina particles used have a predetermined particle diameter distribution obtained through a crushing process. Since the alumina particles are manufactured by the crushing process, the end portions of the alumina particles are comparatively sharp and acute, so that the sharp and acute end portions exhibit a high friction force.
Further, in the embodiment, the alumina particle has a particle diameter which is greater than or equal to 15 μm and less than or equal to 90 μm and has a particle diameter (average particle diameter) as a center diameter which is adjusted to be 45 μm.
That is, in the invention, as the alumina particles (inorganic particles), the average particle diameter (center diameter) is set to be larger than the distance d1 (30 μm) from the outer peripheral surface side of the above-described joint 80.
Further, particularly regarding the particle diameter distribution (particle size range), it is desirable to contain a particle which is smaller than the distance d1 at the outer peripheral surface side of the joint 80 and is larger than the distance d2 (10 μm) at the inner peripheral surface side. Further, it is desirable that the minimum particle diameter in the particle diameter distribution is larger than the minimum distance between the pair of end portions 61a and 61b of the joint 80, for example, the distance d2 at the inner peripheral surface side.
When such resinous particles and inorganic particles are prepared, first, the above-described resinous particles are sprayed to the roller body 16. That is, the roller body 16 is disposed inside a painting booth (not shown), and the roller body 16 is integrally set to have, for example, a −(negative) potential.
Then, the resinous particles are sprayed (discharged) to the roller body 16 to be adhered thereto by using a tribo gun of an electrostatic painting device (not shown), and the sprayed particles (resinous particles) are charged to a +(positive) high potential. Then, the charged resinous particles are absorbed on the outer peripheral surface of the roller body 16, thereby forming a resinous film.
Here, the position of the resinous film formed by adhesion of the resinous particles corresponds to the formation area of the high friction layer 50 shown in
A weak static electricity of about +0.5 kV is present in the resinous film 51 after the painting process. Furthermore, in the painting process, the roller body 16 is rotated about the axis, so that the resinous film 51 is formed in the entire circumference with substantially the same thickness. The film thickness of the resinous film 51 is set to be, for example, from 10 μm to 30 μm in consideration of the particle diameter of the above-described alumina particles. The film thickness may be appropriately adjusted through the discharge amount of the resinous particles and the discharge time.
Subsequently, the roller body 16 provided with the resinous film 51 is taken out from the above-described painting booth, and is moved to another painting booth 90 shown in
Then, both end portions of the roller body 16 are held and fixed by the chucks 92 and 92, and the chucks 92 and 92 are rotated by the rotational driving member 91. Accordingly, the roller body 16 is gradually and rotationally driven about the axis thereof at the speed of, for example, about from 100 rpm to 500 rpm. Furthermore, the roller body 16 may be, of course, supported in a slightly inclined state.
Further, a corona gun 93 is disposed at the upper portion of the painting booth 90, and the corona gun 93 is adapted to be movable along a shaft 94 in the left/right direction of
With such a configuration, when the above-described alumina particles 95 are sprayed from the corona gun 93 to the roller body 16 rotating about its axis to be adhered thereto, the alumina particles 95 are selectively and electrostatically absorbed onto the resinous film 51 formed on the roller body 16. When the alumina particles are selectively and electrostatically absorbed onto the resinous film 51, both end portions of the roller body 16 are masked by using a tape or the like as in the case of forming the resinous film 51.
In such an electrostatic painting process, the surface potential of the chuck 92 and the rotational driving member 91 is set to be equal to the potential of the roller body 16, and the inner surface potential of the painting booth 90 is set to be substantially zero potential so that it becomes an electrically neutral state. Also, this is performed so that the alumina particles 95 from the corona gun 93 are not absorbed on the portion other than the roller body 16. In order that the inner surface potential of the painting booth 90 becomes an electrically neutral state, it is desirable that the painting booth 90 is made of a steel sheet having an inner surface electric resistance of, for example, about 1011Ω.
Then, the potential applied to the corona gun 93 is set to 0 V, and the pressure of air supplied to the corona gun 93 is set to be low such as to be about 0.2 MPa. Subsequently, the alumina particles 95 of substantially zero potential are sprayed from the upper side by moving the corona gun 93 in the left/right direction of
Then, as described above, since weak static electricity (about +0.5 kV) is present in the resinous film 51 of the roller body 16 due to the electrostatic painting process, the alumina particles 95 are substantially uniformly and electrostatically absorbed on the entire circumference of the resinous film 51. In the state where the alumina particles 95 electrostatically absorbed in this manner come into contact with the surface of the resinous film 51 and intrude thereinto, the alumina particles are adhered to the outer peripheral surface of the roller body 16 by using the resinous film 51 as a binder.
Here, in the embodiment, since the inner surface potential of the painting booth 90 is set to be substantially zero potential to be electrically neutral, and the slow air stream is formed inside the painting booth 90 toward the lower side thereof, the alumina particles 95 are dropped downward in the vertical direction due to their own weight. Since the horizontally supported roller body 16 slowly rotates about the axis thereof at the lower side of the dropping direction, the alumina particles 95 are substantially uniformly sprayed to the outer peripheral surface of the roller body 16.
Accordingly, the alumina particles 95 are uniformly adhered to the surface of the specifically unmasked resinous film 51, so that the alumina particles (inorganic particles) 95 are dispersed and exposed in the resinous film 51 at the center portion of the roller body 16 as shown in
Accordingly, the alumina particles 95 exhibit a high friction force by using the end portions protruding from the surface of the resinous film 51. Here, in order that the alumina particles 95 exhibit sufficient friction force necessary for the sheet P, it is desirable that the ratio of the alumina particles 95 with respect to the area of the resinous film 51 is equal to or larger than 20% and less than or equal to 80%.
Furthermore, the coating (spraying) method of the alumina particles 95 is not limited to the electrostatic painting method as long as the alumina particles 95 may be gradually sprayed downward in the vertical direction. For example, the alumina particles may be sprayed by using a sprayer.
In this manner, when the alumina particles 95 are sprayed and adhered to the resinous film 51, the roller body 16 is heated at a temperature greater than or equal to 180° C. and less than or equal to 300° C. for 20 minutes to 30 minutes, so that the resinous film 51 is baked and cured. Accordingly, the alumina particles 95 are fixed to the roller body 16. In this manner, as shown in
Furthermore, in the embodiment, the coating (spraying) of the resinous particles and the coating (spraying) of the alumina particles are respectively performed in the different painting booths, but they may be, of course, performed in the same painting booth.
When the high friction layer 50 is formed in this manner, particularly in the joint 80, a groove caused by the gap between the end surfaces 61a and 61b of the flat sheet portion 60 is not formed, and the gap between the end surfaces 61a and 61b is mainly buried by the alumina particles 95.
That is, as for the alumina particles 95 used herein, the average particle diameter is larger than the distance d1 at the outer peripheral surface side of the joint 80. Accordingly, most of the alumina particles 95 do not intrude into the joint 80, but are adhered to the outer peripheral surface of the roller body 16 with the resinous film 51 interposed therebetween as shown in
Further, the alumina particles 95 used have a particle diameter distribution (particle size range) containing the particle 95a smaller than the distance d1 (30 μm) at the outer peripheral surface side of the joint 80 and larger than the distance d2 (10 μm) at the inner peripheral surface side thereof. Accordingly, such particles 95a intrude and stay in the gap formed in the joint 80, thereby reliably preventing the groove from being formed by the joint 80.
Further, even when a force acts on the roller body 16 (the transport roller 15) in the direction in which the gap is narrowed, the alumina particles 95a intruding therein resist the force, so that the deformation of the roller body 16 (the transport roller 15) is suppressed. Accordingly, in the transport roller mechanism 19 having the transport roller 15, the transport irregularity caused by the deformation of the transport roller 15 may be prevented.
Furthermore, the alumina particles 95 used have a minimum particle diameter in the particle diameter distribution larger than the minimum distance between the pair of end surfaces 61a and 61b of the joint 80, that is, the distance d2 at the inner peripheral surface side. Accordingly, when the high friction layer 50 is formed by disposing the alumina particles 95 on the surface of the roller body 16, the alumina particles 95 may not intrude into the roller body 16 through the gap formed in the joint 80. Accordingly, a process or the like of cleaning the inside of the roller body 16 does not need to be performed, thereby improving the productivity.
Through the above-described processes, as shown in
As described above, according to the embodiment, since the spot welding portion SP is formed in the joint 80 between the pair of facing end portions 61a and 61b of the metal sheet M, the strength of the joint 80 may be improved. Accordingly, the deformation of the joint 80 may be prevented. Further, in the embodiment, since the spot welding portion SP is formed in a part of the joint 80 instead of welding the entire joint 80, the transport roller is not affected by the internal stress generated when the entire joint is welded. Accordingly, since the deformation of the transport roller 15 may be prevented, the degradation of the transport precision may be prevented.
The technical scope of the invention is not limited to the above-described embodiment, but may be appropriately modified within the range not departing from the spirit of the invention.
Further, in the above-described embodiment, a configuration has been described in which the roller body 16 is formed from a base material which is a steel sheet coil obtained by winding a metal sheet such as a zinc plating steel sheet or a stainless steel sheet, but the invention is not limited thereto. For example, a configuration may be adopted in which a plane metal sheet is used as a base material, a metal sheet substantially having the same dimension as that of the flat sheet portion 60 is formed from the planar metal sheet, and the metal sheet is processed to form the roller body 16. Accordingly, for example, in the description above or below, the flat sheet portion 60 may be replaced with the metal sheet.
Further, for example, a part of the joint 80 formed in the roller body 16 may be provided with an opening 170 as shown in
As shown in
Therefore, as shown
The opening 170 is formed in an area excluding the area supported by the bearing 26 and the area provided with the high friction layer 50 in the joint 80 that is formed in the entire length of the transport roller 15 (the roller body 16). That is, the high friction layer 50 is formed at the substantially center portion of the transport roller 15, and both end sides of the transport roller 15 are supported by the bearing 26, whereby the transport roller 15 is provided with at least two openings 170.
The opening 170 is provided for the purpose of preventing the grease G (lubricating oil) supplied (coated) onto the bearing 26 from arriving at the high friction layer 50 along the joint 80 (the gap between the end surfaces 61a and 61b). That is, the capillary phenomenon of the grease G is stopped by providing the opening 170 at a part of the joint 80. Specifically, since the opening 170 is provided in an area provided with the high friction layer 50 and the area supported by the bearing 26 in the joint 80, the grease G is prevented from arriving at the high friction layer 50. Then, the capillary phenomenon of the grease G may be reliably stopped by adjusting the size (the maximum distance d2 between the pair of notch portions 176 and 177) of the opening 170.
Furthermore, the invention is not limited to the case in which the notch portions 176 and 177 forming the opening 170 are respectively formed in the pair of end surfaces 61a and 61b forming the joint 80. That is, as shown in
Further, the shape of the joint 80 formed in the roller body 16 may have a shape shown in
Further, a first angle α formed between the first end surface 274 and the outer peripheral surface 271a and a second angle β formed between the second end surface 275 and the outer peripheral surface 271a are both set to be smaller than 90°.
The first end surface 274 and the second end surface 275 of the joint 80 are connected to each other at the side of the outer peripheral surface 271a, opposite from the inner peripheral surface 271b, and the smoothness of the outer peripheral surface 271a at the connection portion 276 is improved. For this reason, even when the transport roller 15 is rotated, the outer peripheral surface thereof may reliably contact the recording sheet P. For this reason, the recording sheet P may be transported with high precision.
As shown in
Furthermore, the shape of the joint 80 is formed by the following processes. That is, after a metal sheet 270, having a thickness t (see
As shown in
Accordingly, when the metal sheet 270 is warped in the cylindrical roller body 271, the first end surface 274 and the second end surface 275 are connected to each other at least at the side of the outer peripheral surface 271a.
Further, as described above, one or both end portions of the roller body 16 (the transport roller 15) are provided with the engagement portion which is used for the connection to various connection components such as the transport driving gear 35 or the inner gear 39 shown in
Further, as shown in
Accordingly, when a connection component (not shown) such as a gear engages with the engagement portion 73 having the D-shaped external shape, the connection component may be attached thereto without meaninglessly rotating the connection component with respect to the roller body 16 (the transport roller 15). Further, since the engagement portion 73 is provided with the groove-shaped opening 73a communicating with the inner hole of the hollow pipe (the roller body 16), the connection component may be attached to the roller body 16 without the meaningless rotation with respect thereto by using the opening 73a. Specifically, when a convex portion is formed in the connection component, and the convex portion is fitted to the opening 73a, the meaningless rotation may be prevented.
Further, as shown in
Accordingly, when a connection component (not shown) such as a gear engages with the groove 74a or the D-cut portion 74b, the connection component may be attached to the roller body 16 (the transport roller 15) without a meaningless rotation with respect thereto. Further, in the engagement portion 74, by using the opening 74c formed between the bent pieces 74d, the connection component may be attached to the roller body 16 without a meaningless rotation with respect thereto. Specifically, when the connection component is provided with a convex portion, and the convex portion is fitted to the opening 74c, a meaningless rotation may be prevented.
Further, as shown in
Accordingly, when a connection component (not shown) such as a gear engages with the groove 75a or the portion having a D-shaped external shape and formed by the opening 75b, the connection component may be attached to the roller body 16 (the transport roller 15) without a meaningless rotation with respect thereto. Further, even in the engagement portion 75, the connection component may be attached to the roller body 16 without a meaningless rotation with respect thereto by using the opening 75b as in the engagement portion 73 shown in
In order to form the engagement hole 71 or the engagement portions 73, 74, and 75, a cutting process may be further performed on the roller body 16 which is obtained by pressing the flat sheet portion 60. However, in this case, since a separate process needs to be performed on the roller body 16 to form the engagement portion, efficiency with respect to cost or time is degraded. Therefore, in the manufacturing method of the invention, the exploded engagement portion used as the engagement portion is formed in the flat sheet portion 60 by the first pressing process before the roller body 16 is pressed in the second pressing process. Then, the engagement portion is formed at the same time when the flat sheet portion 60 is pressed by the second pressing process to be formed as the roller body 16.
Specifically, the metal sheet M wound in a coil shape is punched into the flat sheet portion 60 which has a thin and long rectangular shape. At the same time when the small flat sheet portion 60 is formed from the large metal sheet M, the end portion of the obtained flat sheet portion 60 is provided with an exploded engagement portion which has a notch shape, a protrusion shape, a hole shape, or a groove shape.
For example, when the pair of penetration holes 71a and 71a is formed at a predetermined position of the end portion of the flat sheet portion 60 as shown in
Further, when the end portion of the flat sheet portion 60 is cut into a predetermined shape as shown in
In addition, when the end portion of the flat sheet portion 60 is cut into a predetermined shape as shown in
Therefore, when the end portion of the flat sheet portion 60 is cut into a predetermined shape as shown in
Here, in the examples shown in
However, the invention is not limited thereto, and as shown in
In this manner, when the exploded engagement portions 76d to 76f are formed in the vicinity of the center axis in the warping direction, the engagement portions 73 to 75 may be more precisely formed from the exploded engagement portions 76d to 76f.
As described above, in the method of manufacturing the transport roller 15 of the embodiment, the exploded engagement portion is formed at the same time when the small metal sheet (the first metal sheet) 60 is formed from the large metal sheet (the second metal sheet) M by a pressing process. Further, the engagement portions 71, 73, 74, and 75 are formed from the exploded engagement portion at the same time when the metal sheet (the first metal sheet) 60 is pressed. Accordingly, after the roller body 16 is formed, it is not necessary to further perform a separate process for forming the engagement portion.
Accordingly, since the cost or time necessary for the separate process is not necessary, the manufacturing cost of the transport roller 15 may be sufficiently reduced, and the productivity may be improved. In particular, since the exploded engagement portion is integrally formed by making a large metal sheet into a small metal sheet, the process may be further simplified.
Furthermore, as shown in
Specifically, as shown in
Furthermore, in the roller body 16 shown in
Further, as shown in
Further, as shown in
Even in the flat sheet portion 60c, when one long side is formed as a mountain portion between the corresponding positions in a pair of long sides each formed in a wavy line shape, the other long side is formed in a valley shape. On the contrary, when one long side is formed in a valley shape, the other long side is formed in a mountain shape. Furthermore, even in this example, the center axis of the joint 84 is set to be parallel to the center axis of the roller body 16, but may not be parallel to the center axis of the roller body 16 as in the case of the joint 83.
Further, the joint is not limited to the examples shown in
In this manner, the joints 81 to 84 are formed to be partially overlapped with one or plural points on the line parallel to the center axis of the cylindrical pipe (the roller body 16) instead of allowing the joints to be entirely overlapped with the line. Accordingly, when the transport roller 15 including the roller body 16 transports the sheet P together with the driven roller 17, that is, the sheet is fed, the transport speed of the sheet P becomes constant, and the transport irregularity is more reliably prevented.
That is, as shown in
However, in the joints 81 to 84 formed as shown in
Further, regarding the joint of the transport roller 15 (the roller body 16) formed as the cylindrical hollow pipe, in addition to the above-described example, for example, as shown in
Further, the bent portion 85 may be formed throughout the entire length of the roller body 16 as shown in
Further, in this manner, when the bent portion 85 is formed only at both end portions and the center linear portion 86 is formed therebetween, it is desirable that the formation area of the high friction layer 50 shown in
When the joint is provided with the bent portion 85 so that the bent portion 85 is used as a fitting portion using its uneven portion, it is difficult to perform the fitting operation at the bent portion 85 (fitting portion) so that the convex portion moves close to (abuts on) the corresponding concave portion without any gap therebetween. Accordingly, when the bent portion 85 is formed throughout the entire length of the roller body 16, distortion or skewness easily occurs in the roller body 16. Therefore, as shown in
Further, when the bent portion 85 is formed throughout the entire length of the roller body 16 as shown in
When the joint 87 having such a configuration is formed, particularly, it is desirable that the distance d3 between the pair of facing end portions of the second linear portion 87c is set to be longer than the distance d4 between the pair of facing end portions in the first linear portion 87b. Furthermore, the distances d3 and d4 between the pair of end portions mentioned herein are both set as the distance between end portions at the gap formed at the outer peripheral surface of the roller body 16.
With such a configuration, the precision in the shape or the dimension of the cylindrical hollow pipe of the roller body 16 may be more improved, whereby the transport irregularity caused by the deformation of the roller body 16 may be prevented. That is, in the metal sheet as the base material forming the roller body 16, one end portion forming the second linear portion 87c is formed as a convex piece 87d having an external shape formed by the pair of intersection portions 87a and 87a adjacent to each other and the second linear portion 87c connecting them to each other. Accordingly, when the metal sheet is pressed so that the convex piece 87d is made to be close to the facing end portion, as depicted by the two-dotted chain line in
Therefore, when the distance d3 between the end portions at the second linear portion 87c is set to be longer than the distance d4 between the end portions at the first linear portion 87b longer than the second linear portion 87c, as depicted by the solid line of
Furthermore, in
Further, when the bent portion 85 is formed at both end portions of the roller body 16 as shown in
With such a configuration, since the distance d5 is relatively short so that the gap between the end portions at the intersection portion 87a is very narrow, a deviation in the length direction (axial direction) between one end portion and the other end portion is regulated by the pair of facing end portions forming the intersection portion 87a when pressing the metal sheet as the base material forming the roller body 16. Accordingly, distortion or skewness is difficult to occur in the roller body 16 (the transport roller 15), whereby the transport irregularity caused by distortion or skewness may be prevented.
Furthermore, when the bent portion 85 is formed at only both end portions of the roller body 16 as shown in
When the distance d7 is shorter than the distance d6, the gap is more easily and uniformly formed between the pair of facing end portions when the joint is seen from the entire length thereof, whereby the precision in the shape or the dimension of the roller body 16 is improved. That is, the length of the center linear portion 86 becomes longer than the length of the second linear portion 87c of the bent portion 85, whereby the pair of end portions in the center linear portion 86 may be made to be close to each other with high precision compared to the second linear portion 87c. Accordingly, even when the distance between the pair of end portions at the center linear portion 86 capable of obtaining the relatively satisfactory precision is set to be longer than that of the second linear portion 87c so that the gap thereof is enlarged, the gap may be sufficiently uniformly formed, whereby the transport irregularity caused by distortion or skewness of the roller body 16 may be prevented.
On the other hand, when the distance d7 is longer than the distance d6, as shown in
Furthermore, the joint of the transport roller 15 (the roller body 16) formed as the cylindrical hollow pipe is not limited to the above-described example, and may be formed, for example, in a manner such that an intersection portion 88a of a bent portion 88 is set to be not parallel to the center axis of the roller body 16 as shown in
Further, in the structure in which the bent portion 85 is formed only at both end portions as shown in
Further, the joint may be formed by the combination of the bent portion 85 having a rectangular wave shape shown in
Further, hereinafter, an example of the spot welding portion SP will be described.
In the above-described embodiment, an example has been described in which the spot welding portion SP is formed in the roller body 16 having the linear joint 80, but the invention is not limited thereto. For example, the spot welding portion SP may be appropriately formed in, for example, the joints 80 having the above-described respective shapes instead of the linear joint 80.
Further, for example, as shown in
Further, for example, even when the joint 80 is provided with an uneven portion 110, the invention may be applied thereto. As shown in
In this case, it is desirable that the spot welding portion SP is formed, for example, at least one of the first side 110a and the second side 110b. For example, when the first side 110a is provided with the spot welding portion SP, for example, the strength of the uneven portion 110 with respect to the force in the circumferential direction of the roller body 16 is improved. For this reason, for example, the uneven portion 110 may be prevented from being opened in the circumferential direction and being depressed inward.
Further, when the second side 110b is provided with the spot welding portion SP, the spot welding portion may be easily formed since the formation position may be easily positioned. Of course, even when the second side 110b is provided with the spot welding portion SP, the strength with respect to the force in the circumferential direction of the roller body 16 may be improved. Further, all of the first side 110a and the second side 110b may be provided with the spot welding portion.
Further, the spot welding portion SP may be provided at a boundary portion 110c between the linear portion 80a of the joint 80 and the uneven portion 110. For example, the boundary portion 110c easily receives a force from the uneven portion 110. For this reason, since the strength of the boundary portion 110c is improved by providing the spot welding portion SP, deformation of the uneven portion 110 may be more reliably prevented.
Furthermore, in
Further, when the metal sheet M is pressed to be formed in a cylindrical shape, as shown in
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