Development bias connector with integral bearing support

Abstract: A bearing support for use in a process cartridge including a roll rotatably mounted to a housing is provided. The roll is used for transporting marking particles to a latent image to form a developed image. The bearing support supports the roll and provides an electrical path between the roll and a voltage source. The bearing support includes a body having a first feature for cooperation with the roll and a second feature for cooperation with the housing. At least one of the first feature and the second feature provides for rotatable motion between the housing and the roll. The bearing support further includes a third feature for providing an electrical path between the roll and the voltage source.

Description: BACKGROUND This invention relates to electrostatographic reproduction machines, and more particularly to an economical and capacity-extendible all-in-one process cartridge for easy adaptive use in a family of compact electrostatographic reproduction machines having different volume capacities and consumable life cycles. Specifically this invention relates to such a cartridge including a development bias connector with integral bearing support. Generally, the process of electrostatographic reproduction, as practiced in electrostatographic reproduction machines, includes charging a photoconductive member to a substantially uniform potential so as to sensitize the surface thereof. A charged portion of the photoconductive surface is exposed at an exposure station to a light image of an original document to be reproduced. Typically, an original document to be reproduced is placed in registration, either manually or by means of an automatic document handler, on a platen for such exposure. Exposing an image of an original document as such at the exposure station, records an electrostatic latent image of the original image onto the photoconductive member. The recorded latent image is subsequently developed using a development apparatus by bringing a charged dry or liquid developer material into contact with the latent image. Two component and single component developer materials are commonly used. A typical two-component dry developer material has magnetic carrier granules with fusible toner particles adhering triobelectrically thereto. A single component dry developer material typically comprising toner particles only can also be used. The toner image formed by such development is subsequently transferred at a transfer station onto a copy sheet fed to such transfer station, and on which the toner particles image is then heated and permanently fused so as to form a "hardcopy" of the original image. It is well known to provide a number of the elements and components, of an electrostatographic reproduction machine, in the form of a customer or user replaceable unit (CRU). Typically such units are each formed as a cartridge that can be inserted or removed from the machine frame by a customer or user. Reproduction machines such as copiers and printers ordinarily include consumable materials such as toner, volume limiting components such as a waste toner container, and life cycle limiting components such as a photoreceptor and a cleaning device. Because these elements of the copying machine or printer must be replaced frequently, they are more likely to be incorporated into a replaceable cartridge as above. There are therefore various types and sizes of cartridges, varying from single machine element cartridges such as a toner cartridge, to all-in-one electrostatographic toner image forming and transfer process cartridges. The design, particularly of an all-in-one cartridge can be very costly and complicated by a need to optimize the life cycles of different elements, as well as to integrate all the included elements, while not undermining the image quality. This is particularly true for all-in-one process cartridges to be used in a family of compact electrostatographic reproduction machines having different volume capacities and elements having different life cycles. There is therefore a need for a quality image producing, economical and capacity-extendible all-in-one process cartridge that is easily adapted for use in various machines in a family of compact electrostatographic reproduction machines having different volume capacities and elements with different life cycles. For proper development of a charged surface with marking particles, preferably, an electrical bias is applied at various positions along the developing process. One of the places in which an electrical charge is applied is the development control An electrical bias is applied at the outer periphery of the developing roll. Since the outer periphery of the developer roll rotates, the electrical charge on the rotating outer periphery must be commutated in order that it be received from a power source. Attempts have been made at commutating a developer roll. For example, a metallic brush may be used between a stationary and rotating element to commutate the roll. Further, a metal rolling element bearing may be used. For a rolling element bearing a conductor grease may be required to adequately commutate the roll. The use of a brush or rubbing element to commutate a roll adds cost and provides a wear item which requires replacement. The use of a conductive bearing is expensive and also is only moderately successful at commutating due to the problems with conductive grease. US-A-5,634,175 discloses a developer roller including an improved contact device that has a conductive cylindrical member with a rim on one end. The member contacts the inner wall of the roller. GB 2214575 A describes a bearing for a rotatable metallic member. A bearing member supports a developer roll for rotation in a molding. The bearing comprises a lateral extension to enable electrical connection to the bearing. SUMMARY OF THE INVENTION It is the object of the present invention to improve a process cartridge with respect to a bias connecting member. This object is achieved by providing a process cartridge for use in a printing machine according to claim 1. BRIEF DESCRIPTION OF THE DRAWINGS In the detailed description of the invention presented below, reference is made to the drawings, in which: FIG. 1 is a front vertical illustration of an exemplary compact electrostatographic reproduction machine comprising separately framed mutually aligning modules in accordance with the present invention; FIG. 2 is a top perspective view of the module housing of the CRU or process cartridge module of the machine of FIG. 1; FIG. 3 is a bottom perspective view of the developer subassembly of the CRU or process cartridge module of the machine of FIG. 1 with the bottom of the developer housing unattached; FIG. 4 is an open bottom perspective view of the CRU or process cartridge module of the machine of FIG. 1; FIG. 5 is an exploded view of the various subassemblies of the CRU or process cartridge module of the machine of FIG. 1; FIG. 6 is a vertical section (front-to-back) of the CRU or process cartridge module of the machine of FIG. 1; FIG. 7 is a perspective view of the developer subassembly of the CRU or process cartridge module of the machine of FIG. 1 showing the development bias connector with integral bearing support of the present invention; FIG. 8 is a partial perspective view of the developer subassembly of FIG. 7; FIG 9 is a cross sectional view of FIG. 8 along the line 9-9 in the direction of the arrows; FIG. 10 is a perspective view of a waste toner sump for the process cartridge of FIG. 2 showing the electrical lead for cooperating with the integral bearing support, and FIG 11 is a perspective view of the machine of FIG. 1 DETAILED DESCRIPTION OF THE INVENTION Referring now to FIG. 1 and 9, there is illustrated a frameless exemplary compact electrostatographic reproduction machine 20 comprising separately framed mutually aligning modules according to the present invention. The compact machine 20 is frameless, meaning that it does not have a separate machine frame to which electrostatographic process subsystems are assembled, aligned to the frame, and then aligned relative to one another as is typically the case in conventional machines. Instead, the architecture of the compact machine 20 is comprised of a number of individually framed, and mutually aligning machine modules that variously include pre-aligned electrostatographic active process subsystems. As shown, the frameless machine 20 comprises at least a framed copy sheet input module (CIM) 22. Preferably, the machine 20 comprises a pair of copy sheet input modules, a main or primary module the CIM 22, and an auxiliary module the (ACIM) 24, each of which has a set of legs 23 that can support the machine 20 on a surface, therefore suitably enabling each CIM 22, 24 to form a base of the machine 20. As also shown, each copy sheet input module (CIM, ACIM) includes a module frame 26 and a copy sheet stacking and lifting cassette tray assembly 28 that is slidably movable in and out relative to the module frame 26. When as preferred here, the machine 20 includes two copy sheet input modules, the very base module is considered the auxiliary module (the ACIM), and the top module which mounts and mutually aligns against the base module is considered the primary module (the CIM). The machine 20 next comprises a framed electronic control and power supply (ECS/PS) module 30, that as shown mounts onto, and is mutually aligned against the CIM 22 (which preferably is the top or only copy sheet input module). A framed latent image forming imager module 32 then mounts over and is mutually aligned against the ECS/PS module. The ECS/PS module 30 includes all controls and power supplies (not shown) for all the modules and processes of the machine 20. It also includes an image processing pipeline unit (IPP) 34 for managing and processing raw digitized images from a Raster Input Scanner (RIS) 36, and generating processed digitized images for a Raster Output Scanner (ROS) 38. The ECS/PS module 30 also includes harnessless interconnect boards and inter-module connectors (not shown), that provide all power and logic paths to the rest of the machine modules. The framed copy sheet input modules 22, 24, the ECS/PS module 30, and the imager module 32, as mounted above, define a cavity 42. The machine 20 importantly includes a customer replaceable, all-in-one CRU or process cartridge module 44 that is insertably and removably mounted within the cavity 42, and in which it is mutually aligned with, and operatively connected to, the framed CIM, ECS/PS and imager modules 22, 30, 32. As further shown, the machine 20 includes a framed fuser module 46, that is mounted above the process cartridge module 44, as well as adjacent an end of the imager module 32. Referring now to FIGS. 1-6, the CRU or process cartridge module 44 generally comprises a module housing subassembly 72, a photoreceptor subassembly 74, a charging subassembly 76, a developer subassembly 78 including a source of fresh developer material, a cleaning subassembly 80 for removing residual toner as waste toner from a surface of the photoreceptor, and a waste toner sump subassembly 82 for storing waste toner. The module housing subassembly 72 of the CRU or process cartridge module 44 importantly provides and includes supporting, locating and aligning structures, as well as driving components for the process cartridge module 44. Still referring to FIG. 1, operation of an imaging cycle of the machine 20 using the all-in-one process cartridge module 44 generally, can be briefly described as follows. Initially, a photoreceptor in the form of a photoconductive drum 84 of the customer replaceable unit (CRU) or process cartridge module 44, rotating in the direction of the arrow 86, is charged by the charging subassembly 76. The charged portion of the drum is then transported to an imaging/exposing light 88 from the ROS 38 which forms a latent image on the drum 84, corresponding to an image of a document positioned on a platen 90, via the imager module 32. It will also be understood that the imager module 32 can easily be changed from a digital scanning module to a light lens imaging module. The portion of the drum 84 bearing a latent image is then rotated to the developer subassembly 78 where the latent image is developed with developer material such as with charged single component magnetic toner using a magnetic developer roller 92 of the process cartridge module 44. The developed image on the drum 84 is then rotated to a near vertical transfer point 94 where the toner image is transferred to a copy sheet substrate 96 fed from the CIM 22 or ACIM 22 along a copy sheet or substrate path 98. In this case, the detack device 68 of the door module 60 is provided for charging the back of the copy sheet substrate (not shown) at the transfer point 94, in order to attract the charged toner image from the photoconductive drum 84 onto the copy sheet substrate. The copy sheet substrate with the transferred toner image thereon, is then directed to the fuser module 46, where the heated fuser roll 48 and pressure roll 50 rotatably cooperate to heat, fuse and fix the toner image onto the copy sheet substrate. The copy sheet substrate then, as is well known, may be selectively transported to the output tray 54 or to another post-fusing operation. The portion of the drum 84 from which the developed toner image was transferred is then advanced to the cleaning subassembly 80 where residual toner and residual charge on the drum 84 are removed therefrom. The imaging cycle of the machine 20 using the drum 84 can then be repeated for forming and transferring another toner image as the cleaned portion again comes under the charging subassembly 76. The detailed and specific advantageous aspects of the structure and operation of the all-in-one CRU or process cartridge module 44, will now be described with particular reference to FIGS. 1 to 6. As shown, the all-in-one CRU or process cartridge module 44, generally includes six subassemblies comprising the module housing subassembly 72 (FIG. 2); the cleaning subassembly 80; the photoreceptor subassembly 74; the charging subassembly 76; the developer subassembly 78 (FIG. 3); and the waste toner sump subassembly 82. Generally, the function of the all-in-one CRU or process cartridge module 44 in the machine 20 is to electrostatically form a latent image, develop such latent image into a toner image through toner development, and transfer the toner image unfused onto a printing medium, such as a sheet of paper. The CRU or process cartridge module is left-side accessible to an operator facing the CIM 22 by opening the door module 60(FIG. 1). Once the door module is opened, an operator or customer can remove or insert the CRU or process cartridge module 44 with one hand. Referring now to FIG. 3, the developer subassembly 78 of the process cartridge module 44 is illustrated with an expandable bottom member 172 unattached in order to reveal the inside of the developer subassembly. As shown, the developer subassembly 78 comprises a generally rectangular developer housing 174 having the bottom member 172, the top 146, a first side 176, a second and opposite side 178, a front end 180 (relative to cartridge insertion), and a rear end 182. The developer housing 174 is for containing developer material, such as, single component magnetic toner (not shown), and it additionally houses the magnetic developer roll 92 (FIG. 1), a development bias application device 184, and a pair of developer material or toner agitators 186, 188. As shown in FIG. 4, the developer subassembly 78 is mounted to the module housing 100, and inside the trough region 118. With the bottom member 172 of the developer housing removed (for illustration purposes only), the agitators 186, 188 can clearly be seen. Also shown in FIG. 4 are the photoreceptor or drum 84 mounted within the raised rear end 112 of the module housing 100, as well as, the module handle 144 attached to the side walls 102, 104 at the raised rear end 112. The whole sump subassembly 82 is further shown with an outside surface 190 of its inside wall 192, mounted to the first side wall 102 of the module housing 100. The outside surface 194 of the outside wall 196 of the sump assembly is also clearly visible. The inside wall 192 and outside wall 196 partially define the sump cavity (not shown) for containing received waste toner, as above. In Fig. 6 the front 180, top 146, and bottom member 172 of the developer subassembly define a chamber 202, having an opening 204, for containing developer material (not shown). The first and second agitators 186, 188 are shown within the chamber 202 for mixing and moving developer material towards the opening 204. The developer material biasing device 184 and a charge trim and metering blade 206 are mounted at the opening 204. As also shown, the magnetic developer roll 92 is mounted at the opening 204 for receiving charged and metered developer material from such opening, and for transporting such developer material into a development relationship with the photoreceptor 84. According to the present invention and referring now to FIG. 7, conductive bearing support 300 is shown. As shown in FIG. 7, conductive bearing support 300 is utilized to support roll 92 and to rotatively mount roll 92 within housing 174 of the developer module 78. While the bearing support 300, as shown in FIG. 7, is used to support the roll 92 at first end 308 of the roll 92, it should be appreciated that the conductive bearing support 300 may likewise be utilized at, for example, second end 310 of roll 92 or to support a paddle, auger or photoreceptor drum or any other component within the process cartridge 72 (see FIG. 6). Referring now to FIG. 8, the bearing support 300 is shown in greater detail. The bearing support 300 is fixedly secured to housing 174 of the developer unit 78. The bearing support 300 is thus positioned between the housing 174 and first end 308 of the roll 92. Referring now to FIG. 9, the bearing 300 is shown in further detail. The development roll 92, as shown in FIG. 9, includes a fixedly mounted core 312 and a sleeve 314 which is rotatably mounted around core 312. The core 312 may be made of any suitable durable material which is magnetically conductive, for example, a metal or a magnetically conductive plastic. As shown in FIG. 9, the core 312 is made of ferrous steel. The core 312 includes magnetic poles 316 which are angularly positioned with respect to roll centerline 320. The poles 316 are so angularly positioned to provide an optimum magnetic field for the proper development of the marking particles. The sleeve 314 is spaced from and rotatably mounted with respect to core 312. The sleeve 314 is made of preferably a magnetically non-conductive and an electrically conductive material. For example, the sleeve 314 may be made of aluminum. The development roll 92 also preferably includes an end cao 322 which is fixedly secured to sleeve 314 and rotates therewith. The sleeve end cap 322 may be made of any suitable durable electrically conductive material. For example, the end cap 322 may be made of a conductive plastic. To provide proper spacing between the developer roll 92 and the photoconductive surface of the photoreceptor (not shown), the developer roll 92 preferably further includes a development roll sleeve or (DSR) sleeve 324. The DSR sleeve 324 has a thickness T which sets the gap between the developer roll 92 and the photoconductive surface. The DSR sleeve 324 is fixedly secured to the sleeve 314 and rotates therewith. Thus, the DSR sleeve 324 is in rolling contact with the photoconductor surface of the photoconductive drum. The conductive bearing support 300 includes a first feature 326 which cooperates with the development roll 92. According to the present invention, the first feature 326 may be in any form capable of providing support to the development roll 92. For example, the first feature 326 may be in the form of a journal or a bore cooperating with a mating feature on the development roll 92. While the development roll may be in the form of a single rotating component, preferably, as shown in FIG. 9 the development roll 92 includes the stationary core 312 as well as the rotating sleeve 314. The first feature 326 provides for the rotation of the sleeve end cap 322 which is a part of the development roll 92. The sleeve end cap 322 rotates relative to the conductive bearing support 300. As shown in FIG. 9, the sleeve end cap 322 includes an inner hub 330 which mates with middle bore 332 of conductive bearing support 300. Further, as shown in FIG. 9, the sleeve end cap 322 may include a larger hub 334 which matingly fits with large bore 336 of conductive bearing support 300 The core 312 is positioned fixedly to housing 174 by small bore 340 of the support 300 which matingly fits with journal diameter 342 of the core 312. Preferably, to angularly orient the poles 316 in the core 312 of the development roll 92, the journal 342 of the development roll 92 includes a flat 344 which mates with flat 346 within bore 340 of the housing support 300. The conductive bearing support 300 is fixedly secured to the development housing 174 by any suitable manner. For example, as shown in FIG. 9, the bearing support 300 includes small OD 350, medium OD 352, and large OD 354 which mate with corresponding bores in the housing 174. It should be appreciated that any or all of the small OD, middle OD 352, and large OD 354 may be either in clearance or matingly fitted to the respective bore of the housing. Referring to FIG. 8 and Fig. 9, to angularly orient the conductive bearings support 300 with respect to the housing 174, preferably, the bearing support 300 includes a locating feature in the form of a flat 356 formed on small OD 350. Correspondingly, the housing 174 includes a flat 360 which mates with flat 356 of the conductive bearing support 300. The flat 360 on the housing 174, the flat 356 on the exterior of the support 300, the flat 344 on the interior of the support 300, and the flat 346 on core 312 cooperate to angularly orient the poles of the core 312. Referring again to FIG. 9, preferably, the bearing support 300 further includes an outer end face 370 which contacts and restrains the development roll spacing sleeve 324 between the sleeve 314 of the development roll 92 and the housing 174. The conductive bearing support 300 further serves an important function by providing an electrical path from the power supply to the electrically conductive sleeve 314 of the roll 92. As shown in FIG. 9, the conductive bearing support 300 is in contact at large bore 336 and middle bore 332 with sleeve endcap 322. The sleeve endcap 322 is in electrical contact with the sleeve 314. The sleeve endcap 322 thus provides an electrical connection between the conductive bearing support 300 and the sleeve 314. The conductive support 300 is made of any suitable durable material which is electrically conductive. The support thus can be made of a durable metal or, as shown in FIG. 9, be made of a electrically conductive plastic. For example, the support 300 may be made of a polycarbonate with carbon fibers. The support 300 includes a feature 372 which extends outwardly from the development housing 174 and serves to provide an electrical path from the power source (not shown) to the development roll 92. For example, as shown in FIG. 9, the conductive bearing support 300 includes the central hub 372. The central hub 372 includes an outer face 374 which provides for the electrical contact for the development roll 92. The outer face 374 may be contacted with the power supply in any suitable fashion. Referring now to FIG. 10, waste toner housing 82 is shown. The waste toner housing 82 provides an electrical path from the face 374 of the conductive bearing support 300 to the power supply board 380. An electrical contact 382 is positioned such that spring loaded contact 382 contacts the face 374 of the conductive bearing support 300. An electrical contact made of a suitable material, i.e. stainless steel 384 interconnects contact 382 with the board 380. Referring now to FIG. 11, a printing machine utilizing the conductive bearing support of the present invention is shown. By providing an electrically conductive bearing support for a development roller, a low cost, simple bearing support may be provided to the development roll. By providing an electrically conductive bearing support, a simple, reliable conductive path can be had from the development roll to a power supply. By providing an electrically conductive bearing support including a centrally located hub extending therefrom, a simple, electrical connection may be had upon insertion of a development unit into a cartridge unit. By providing an electrically conductive bearing support made of an electrically conductive plastic, a simple inexpensive and low cost recyclable bearing support may be provided.

Claims: A process cartridge for use in a printing machine comprising said process cartridge for applying marking particles to a latent image to form a developed image, said cartridge comprising: a housing (174); a bearing support (300) mounted to said housing; a roll (92) rotatably mounted to said bearing support (300), said roll for transporting marking particles to the latent image to form the developed image and for receiving an electrical charge from a voltage source, said bearing support (300) supporting the roll (92) and providing an electrical path between the roll and the voltage source, said bearing support including: a first means (326) for cooperation with the roll (92) and allowing rotatable motion between the housing and the roll; a second means (350) for cooperation with the housing; and a means for providing the electrical path between the roll (92) and the voltage source, comprising a central hub (372) being coaxial with the roll (92) and having a central outer face (374) and extending outwardly from the housing (174). A cartridge according to claim 1, wherein said bearing support (300) has a generally cylindrical shape. A cartridge according to any of the claims 1 to 2, wherein said first means is defined by a bore in said bearing support (300), said bearing support operably secured to the roll (92) at said bore. A cartridge according to any of the claims 1 to 3, whereby said second means is defined by an outer periphery of said bearing support (300), said outer periphery fitted to the housing. A cartridge according to any of the claims 1 to 4, wherein said bearing support (300) comprises an electrically conductive plastic. A cartridge according to any of the claims 1 to 5, wherein said bearing support (300) comprises carbon fibers. An electrophotographic printing machine of the type including a process cartridge for applying marking particles to a latent image to form a developed image, the process cartridge being defined according to anyone of claims 1 to 6.

Inventors: CHIESA DANIEL A, DAMJI DHIRENDRA C, KUMAR AJAY, CHIESA, DANIEL A., DAMJI, DHIRENDRA C., KUMAR, AJAY
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1998
Main classification: G03G21
IPC codes: G03G15, G03G21