Image processing apparatus, paper dust collection mechanism, and paper dust collection method

An image processing apparatus includes a paper feeding unit on which paper is placed; an image forming unit that forms an image on the paper supplied from the paper feeding unit; a paper conveying roller that conveys the paper from the paper feeding unit by rotation in contact with the paper; a reservoir that contains paper dust removed from the paper conveying roller and includes a bottom portion; a waste toner container that is disposed below the reservoir in a vertical direction, is detachable from the image processing apparatus, and contains a waste toner discharged from the image forming unit; and a transfer path that connects an inside portion of the reservoir and an inside portion of the waste toner container.

FIELD

Embodiments described herein relate generally to an image processing apparatus, a paper dust collection mechanism, and a paper dust collection method.

BACKGROUND

Paper used in an image processing apparatus that forms an image on paper or removes an image makes paper dust in various processes when the paper is produced, distributed, and set in the image processing apparatus. The origin of the paper dust is a chip generated from a cut edge of the paper when the paper is cut, a fiber piece peeled off from the surface of the paper, or the like. Paper dust adheres to the surface of the paper used in the image processing apparatus.

When the image processing apparatus forms an image on paper, the paper is conveyed from a paper feed cassette, a manual feed tray, or the like, to an image forming unit that performs printing. The paper is conveyed from a paper conveying roller such as a pickup roller, a registration roller, or the like to the image forming unit. The paper is conveyed in contact with the rotating paper conveying roller.

When the paper and the paper conveying roller are in contact with each other, paper dust is transferred to the paper conveying roller. The paper dust is accumulated on the surface of the paper conveying roller. The paper dust particularly accumulates at a position corresponding to the center of the paper. Therefore, for example, as small size paper is continuously conveyed, paper dust accumulates on the surface of the paper conveying roller at a position corresponding to the center of the small size paper. If paper larger than the small size paper is conveyed in a state in which paper dust is accumulated on the surface of the paper conveying roller, the paper dust accumulated on the surface of the paper conveying roller is transferred back to the surface of the large size paper. Therefore, at a position corresponding to the center of the small size paper in the large size paper, ink adheres only to paper dust and does not adhere to the paper so that printing failure occurs.

In order to prevent the printing failure, a scraping blade that abuts on the paper conveying roller is disposed on the image processing apparatus so that the paper dust that adheres to the surface of the paper conveying roller is not transferred back to the paper.

However, in order to prevent the container that stores the paper dust scraped from the paper conveying roller from being full so that the paper dust is not inserted into the image processing apparatus, the paper dust needs to be collected or the container needs to be replaced before the container becomes full, and the collection or the replacement requires time.

DETAILED DESCRIPTION

The image processing apparatus of an exemplary embodiment includes a device main body, an image forming unit, a paper feeding unit, a paper conveying roller, a reservoir, a waste toner container, and a transfer path. The paper feeding unit is provided in the device main body, and paper is placed thereon. The paper conveying roller is provided in the inside portion of the device main body, rotates in contact with paper, and conveys paper from the paper feeding unit. The reservoir contains the paper dust removed from the paper conveying roller and includes a bottom portion. The waste toner container is disposed below the reservoir in the vertical direction, is detachable from the device main body, and contains waste toner discharged from the image forming unit. The transfer path connects the inside portion of the reservoir and the inside portion of the waste toner container. A paper dust collection method involves forming an image on paper supplied from a paper feeding unit by an image forming unit; conveying paper from the paper feeding unit by rotation of a paper conveying roller in contact with the paper; removing paper dust from the paper conveying roller and delivering the paper dust to a reservoir including a bottom portion; collecting waste toner discharged from the image forming unit in a waste toner container disposed below the reservoir in a vertical direction, the waste toner container detachable from the image processing apparatus; and collecting paper dust in the waste toner container via a transfer path connecting an inside portion of the reservoir and an inside portion of the waste toner container.

Hereinafter, the image processing apparatus according to the exemplary embodiment is described with reference to drawings. In the present specification, the depth direction, the front-rear direction, and the up-down direction are defined as follows. The depth direction is a direction extending to an axis of the paper conveying roller provided in the device main body of the image processing apparatus. The front-rear direction is a direction in which paper placed on a paper feed cassette is sent to the device main body. The up-down direction is a vertical direction. The depth direction is perpendicular to the front-rear direction and the up-down direction. The arrow X direction is the near side. The arrow Y direction is the front side. The arrow Z direction is the upper side.

FIG. 1is a perspective view of an image processing apparatus1according to the exemplary embodiment. The image processing apparatus1according to the exemplary embodiment is, for example, an image forming device such as a multi function printer (MFP) or a copying machine. Hereinafter, an example in which the image processing apparatus1is the image forming device illustrated inFIG. 1is described.

FIG. 2is a diagram illustrating a configuration of an inside portion of the image processing apparatus1. As illustrated inFIGS. 1 and 2, the image processing apparatus1includes a controller1c, a display11, an image forming unit12, a control panel unit13, a paper containing unit14, an image reading unit15, a paper conveyance path6, and a paper dust collecting mechanism20.

The controller1cis a program-executable processing device that includes a processor, a memory capable of reading a program, a storage device capable of storing programs and data, and an input and output device, and also includes other dedicated hardware. The function of the image processing apparatus1is implemented by causing the processor to execute the program provided in the controller1c.

As illustrated inFIG. 1, the display11, the image forming unit12, the control panel unit13, and the image reading unit15form a main body B of the image processing apparatus1. The display11and the control panel unit13are used when a user operates the image processing apparatus1and checks or inputs operation details. The image reading unit15reads a character or an image printed on paper and forms electronic data.

The image forming unit12forms an image on a paper P. The image forming unit12forms an image on the paper P based on an operation instruction received by the main body B. As illustrated inFIG. 2, the image forming unit12has a well-known configuration and includes a photoconductor drum12a, a primary transfer roller12b, an intermediate transfer belt12c, a driven roller12d, a driving roller12f, a secondary transfer roller12g, an intermediate transfer belt cleaner12h, a photoconductor cleaner12i, a toner container12j, a waste toner container9, and the like.

The primary transfer roller12b, the intermediate transfer belt12c, the driven roller12d, the driving roller12f, and the secondary transfer roller12gform a transfer unit12u.

When an image is formed, the image forming unit12transfers a toner contained in the toner container12jat a predetermined position of the photoconductor drum12a. The image forming unit12rotates the intermediate transfer belt12cwith the driven roller12dand the driving roller12f. The image forming unit12causes the intermediate transfer belt12cto pass through a portion between the photoconductor drum12ato which a toner is transferred and the primary transfer roller12b. The image forming unit12transfers the toner from the photoconductor drum12ato the intermediate transfer belt12cwhile causing the intermediate transfer belt12cto pass through a portion between the photoconductor drum12aand the primary transfer roller12b.

The image forming unit12causes the paper P to pass through a portion between the intermediate transfer belt12cand the secondary transfer roller12g. The image forming unit12transfers the toner from the intermediate transfer belt12cto the paper P while causing the paper P to pass through a portion between the intermediate transfer belt12cand the secondary transfer roller12g.

The toner that is not transferred to the intermediate transfer belt12cand remains on the photoconductor drum12ais collected by the photoconductor cleaner12i. The toner that is not transferred to the paper P and remains on the intermediate transfer belt12cis collected by the intermediate transfer belt cleaner12h. The toner collected in the photoconductor cleaner12iand the intermediate transfer belt cleaner12his discharged into the waste toner container9as a waste toner. The waste toner container9is detachable from the image processing apparatus1. Generally, the waste toner container9is periodically replaced by a maintenance manager of a manufacturer of the image processing apparatus1.

The paper containing unit14includes a plurality of paper feeding devices (paper feeding units)2that are disposed in a space S under the main body B of the image processing apparatus1and are arranged in the up-down direction. The paper feeding device2supplies the paper P to the image forming unit12. The paper feeding device2includes a paper feed cassette3, a pickup roller4, a rotating tray (not illustrated).

The paper feed cassette3places and stores the paper P before being processed by the image processing apparatus1. The paper feed cassette3has a box-like shape in which the paper P opens upward. The paper feed cassette3is inserted into and removed from the image processing apparatus1in the depth direction.

The pickup roller4conveys the paper P backwards from the paper feed cassette3to the paper conveyance path6in the front-rear direction. As illustrated inFIG. 2, the pickup roller4is in contact with the upper surface of the paper P placed on the paper feed cassette3on the front end side. The pickup roller4includes a drive mechanism (not illustrated) including a motor and the like. The pickup roller4rotates by an action of the driving mechanism and conveys the paper P from the paper feed cassette3to the paper conveyance path6.

The rotating tray supports the paper P so that the front end is positioned above the rear end, and brings the upper surface of the paper P into contact with the pickup roller4. A rotating tray is rotatably provided in the paper feed cassette3. The rotating tray has a plate-like shape and is connected to the paper feed cassette3via a rotating shaft parallel to the depth direction. The rotating tray is disposed below the front end side of the paper P, is biased by, for example, a spring, and can rotate the paper P such that the front end is positioned above the rear end.

The paper P is conveyed from the paper feeding devices2to the image forming unit12via the paper conveyance path6. In the paper conveyance path6, between the paper feeding devices2and the image forming unit12a paper feeding roller (not illustrated) and a separating roller (not illustrated) are disposed to be adjacent to each other. In the paper conveyance path6, a pair of registration rollers (paper conveying rollers)8are disposed between the paper feeding devices2and the image forming unit12on the image forming unit12side with respect to the paper feeding roller and the separating roller.

When one or more sheets of the paper P are conveyed from the paper feeding devices2, the paper feeding roller and the separating roller convey only one sheet of the paper P to the image forming unit12side. The paper feeding roller and the separating roller include driving mechanisms including motors or the like. The paper feeding roller and the separating roller are rotated by actions of the driving mechanisms while being in contact with the paper P and convey the paper P to the image forming unit12side. The paper feeding roller and the separating roller convey only one sheet of the paper P to the image forming unit12side, for example, by a known retard system, a comb-tooth system or the like.

The pair of registration rollers8synchronizes with the transfer unit12uon which a toner image of the image forming unit12is formed, and conveys the paper P to the image forming unit12. The pair of registration rollers8includes driving mechanisms (not illustrated) including motors or the like. The pair of registration rollers8is rotated by actions of the driving mechanisms while being in contact with the paper P and conveys the paper P. The pair of registration rollers includes a first registration roller8aand a second registration roller8b. The first registration roller8aincludes an axis8oparallel to the depth direction. The first registration roller8ais in contact with a surface Pp on which an image of the paper P is formed and conveys the paper P.

FIG. 3is a front view of the paper dust collecting mechanism20included in the image processing apparatus1. As illustrated inFIG. 3, the paper dust collecting mechanism20includes a scraping blade21, a reservoir22, a conveying paddle23, a gear (reduction gear)24, and a transfer path25.

The scraping blade21removes paper dust Pw adhering to the first registration roller8a. The scraping blade21has a rectangular film-like shape. The scraping blade21is disposed so that the surface direction is parallel to the axis8oof the first registration roller8a. The scraping blade21is disposed such that a first end portion21ein the surface direction abuts on a surface8sof the first registration roller8a. The scraping blade21is disposed to abut on an entire portion of the first registration roller8ain the direction of the axis80. The scraping blade21is disposed so that a second end portion21ton the opposite side to the first end portion21ein the surface direction is positioned below the first end portion21e.

The reservoir22contains the paper dust Pw removed by the scraping blade21. The reservoir22includes a box portion22band a paper scattering prevention cover22e.

The box portion22bhas a box-like shape that opens upward. The second end portion21tof the scraping blade21is inserted into a containing space22aof the box portion22bfrom the first registration roller8aside.FIG. 4is a perspective view of the paper dust collecting mechanism20. As illustrated inFIG. 4, a circular through hole22his formed on an inner side surface22rof the box portion22b. A bottom portion22dof the box portion22bis inclined downward from the inner side toward the front side. A rectangular connection port22cis formed on the a side surface22fon the front side of the box portion22b. The connection port22cis formed in the lowermost portion of the side surface22f.

As illustrated inFIG. 3, the paper scattering prevention cover22ecovers a portion of the containing space22aof the box portion22bfrom the upper side. The paper scattering prevention cover22eprotrudes from the side surface22won the opposite side to the first registration roller8aof the box portion22b.

As illustrated inFIG. 4, the conveying paddle23conveys the paper dust Pw contained in the reservoir22to the connection port22c. The conveying paddle23is disposed to the containing space22aof the reservoir22. The conveying paddle23includes a shaft23aand a screw23s. The shaft23aincludes an axis23oparallel to the axis8oof the first registration roller8a. The shaft23apasses through the through hole22hof the inner side surface22rof the reservoir22.

The screw23srevolves in a circumferential direction of the shaft23aand is formed in a helical shape that progresses to the front side in the direction of the axis23o. The screw23sis formed to be denser as being closer to the central portion23cin the direction of the axis23oof the shaft23aand is formed to be sparser as being farther from the central portion23c.

The gear24is interposed between the first registration roller8aand the conveying paddle23, and causes the conveying paddle23to interlock with the first registration roller8a.FIG. 5is a plan view of the paper dust collecting mechanism20. As illustrated inFIG. 5, the gear24includes a small gear24sand a large gear24b. The small gear24sis mounted in the end portion on the inner side of the first registration roller8a. The large gear24bis mounted in the end portion on the inner side of the conveying paddle23. The small gear24sand the large gear24bare disposed to mesh with each other.

The transfer path25connects the containing space22aof the reservoir22and an inside portion9iof the waste toner container9. The transfer path25has a cylindrical shape. An edge25aof an opening on one side of the transfer path25is joined to an edge of the connection port22cof the reservoir22. An edge25bon the other side of the transfer path25is disposed to closely attach to an edge of an inlet9athrough the inside portion9iof the waste toner container9.

Hereinafter, an action when an image is formed by the image processing apparatus1and the paper dust collecting mechanism20operates is described. First, a user instructs through the control panel unit13or the like illustrated inFIG. 1that the controller1cof the image processing apparatus1illustrated inFIG. 2forms a predetermined image on the paper P.

The controller1cthat received the instruction operates the image forming unit12and causes a toner in a predetermined color to adhere to a portion corresponding to a predetermined image of the transfer unit12u. The controller1crotates the pickup roller4and conveys the paper P from the paper feed cassette3to the paper conveyance path6. The controller1crotates the paper feeding roller and the separating roller and conveys one sheet of paper P to the pair of registration rollers8. As illustrated inFIG. 2, the controller1crotates the pair of registration rollers8in synchronization with the transfer unit12uand conveys the paper P from the pair of registration rollers8to the transfer unit12u.

The pair of registration rollers8rotates in contact with the paper P and conveys the paper P to the transfer unit12u. The first registration roller8aof the pair of registration rollers8is in contact with the surface Pp on which the image of the paper P is formed. As illustrated inFIG. 3, the paper dust Pw is transferred from the surface Pp on which the image is formed to the surface8sof the first registration roller8a.

The paper dust Pw transferred to the surface8sof the first registration roller8ais scraped by the scraping blade21abutting to the surface8sby the rotation of the first registration roller8a. The paper dust Pw scraped by the scraping blade21slides on the upper surface of the scraping blade21and is contained in the reservoir22.

As illustrated inFIG. 4, the reservoir22moves the paper dust Pw to the front side by the gravity by the inclination of the bottom portion22dto the front side.

The conveying paddle23disposed in the containing space22aof the reservoir22rotates in connection with the rotation of the first registration roller8avia the gear24. As illustrated inFIG. 3, the conveying paddle23rotates to convey the paper dust Pw to the front side by the screw23s.

By the inclination of the bottom portion22dor the action of the conveying paddle23, the paper dust Pw moves to the connection port22cof the reservoir22. The paper dust Pw moved to the connection port22cis contained in the inside portion9iof the waste toner container9through the transfer path25.

According to the image processing apparatus1of the exemplary embodiment, the paper dust Pw transferred from the paper P to the first registration roller8ais scraped by the scraping blade21. The paper dust Pw scraped by the scraping blade21is stored in the reservoir22. The paper dust Pw stored in the reservoir22moves to the connection port22cof the reservoir22by the inclination of the bottom portion22dor the conveying paddle23. The paper dust Pw moves to the connection port22cis contained in the inside portion9iof the waste toner container9through the transfer path25. The waste toner container9is periodically removed from the image processing apparatus1and replaced. Therefore, the paper dust Pw stored in the reservoir22is removed from the image processing apparatus1with the replacement of the waste toner container9without requiring new labor.

According to the image processing apparatus1of the exemplary embodiment, by causing the reservoir22to include the paper scattering prevention cover22e, the paper dust Pw is prevented from scattering from the reservoir22.

According to the image processing apparatus1of the exemplary embodiment, the first registration roller8aand the conveying paddle23interlock via the gear24, and rotation directions are opposite to each other. The paper scattering prevention cover22eprotrudes from a side surface22won the opposite side of the first registration roller8aof the reservoir22. Therefore, even when the paper dust Pw flies due to the rotation of the conveying paddle23, the paper dust Pw hits the paper scattering prevention cover22eand is not likely to scatter from the reservoir22.

According to the image processing apparatus1of the exemplary embodiment, as the screw23sof the conveying paddle23is closer to a central portion23cin the direction of the axis23oof the shaft23a, the screw23sis formed to be denser, and as the screw23sis farther from the central portion23c, the screw23sis formed to be sparser. Therefore, a large amount of paper dust Pw moves from a portion where the paper dust Pw easily accumulates near the center position of the paper P in the reservoir22.

According to the image processing apparatus1of the exemplary embodiment, the small gear24sis mounted on the first registration roller8a, and the large gear24bis mounted on the conveying paddle23. The rotation speed of the conveying paddle23is smaller than the rotation speed of the first registration roller8a. Therefore, when the conveying paddle23conveys the paper dust Pw, the paper dust Pw can be prevented from flying.

The paper feeding unit that places and stores the paper P may not be the paper feeding devices2, but may be a manual feed tray.

The paper conveying roller provided with the paper dust collecting mechanism20may not be the registration roller8, but may be another roller in contact with the paper P near a portion between the paper feeding unit and the image forming unit12. The paper conveying roller provided with the paper dust collecting mechanism20is desirably disposed above the waste toner container9.

The paper dust collecting mechanism may not include the scraping blade21. The paper dust collecting mechanism may convey only the paper dust Pw naturally dropped to the reservoir22, to the waste toner container9, by disposing the reservoir22below the paper conveying roller.

The reservoir may not include the paper scattering prevention cover22e. As long as the rotation speed of the conveying paddle23does not reach the level of causing the paper dust Pw to fly, the paper scattering prevention cover22eis not required.

The paper dust collecting mechanism20may not include the conveying paddle23. Even if the conveying paddle23is not included, the paper dust collecting mechanism20conveys the paper dust Pw to the transfer path25by the inclination of the bottom portion22dof the reservoir22and contains the paper dust Pw in the inside portion of the waste toner container9.

The reduction gear that cause the first registration roller8aand the conveying paddle23to interlock may not be the gear24, but may be a timing pulley, a timing belt, or the like.

The transfer path25may not be joined to the reservoir22and closely attached to the waste toner container9, but may be closely attached to the reservoir22and joined to the waste toner container9.