Abstract:
The present invention provides a recording apparatus capable of detecting whether a transfer unit is an unused unit or not, including a cover that covers a transfer medium over which a plurality of color images is superimposed to form a color image and has an opening that exposes part of the transfer medium, pasting one end of a seal for detecting whether the transfer unit is an unused unit or not near the opening of the cover in the direction in which the transfer medium moves, pasting the other end of the unused unit detecting seal to the transfer medium through the opening. This allows one end of the unused unit detecting seal to be pasted to the transfer medium through the opening and the other end of the seal to be pasted to the cover near the opening in the direction in which the transfer medium moves. With the unused unit detecting seal pasted in this way, it is possible to detect whether this transfer unit is an unused unit or not.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a recording apparatus, and more particularly, to a recording apparatus that transfers images to a recording sheet using a transfer film. 
     2. Description of the Related Art 
     In recent years, color recording is performed based on an electrophotographic system. In this type of color recording, a transfer film is used to superimpose images in 4 colors. That is, images in 4 colors are transferred to a same position to form a color image on a transfer film. This color image is further transferred to a recording sheet. When the transfer of the color image to the recording sheet is completed, used toner remaining on the transfer film is cleaned. 
     Conventionally, the cleaned used toner is collected in a used toner box. When the used toner box is filled with used toner, this used toner box is replaced. This used toner box is normally provided in a location different from the location where the transfer film is placed. The transfer film cleaning mechanism and the used toner box are connected via a pipe that carries used toner. 
     However, when the used toner box is replaced, such a conventional configuration requires the used toner box to be removed from the pipe. In this case, there is a problem that used toner leaks from the pipe, causing the recording apparatus interior to get soiled. Moreover, providing an additional mechanism that prevents soiling when the used toner box is removed from the pipe will increase the size of the recording apparatus due to the additional mechanism as well as costs due to increased number of parts. 
     In order to solve such a problem, a unit that combines the used toner box and transfer film (hereinafter referred to as “transfer unit”) is provided in which the used toner box is housed in a space inside the transfer film circulation path. It is also possible to replace the entire transfer unit when the used toner box is filled with used toner. 
     According to such a recording apparatus, the entire transfer unit containing the used toner box is replaced, and therefore it is not necessary to remove the used toner box from the pipe. This prevents used toner from leaking, which will also prevent the recording apparatus interior, etc. from getting soiled. Housing the used toner box inside the transfer unit also reduces the size of the recording apparatus. 
     With such a recording apparatus, however, the transfer unit needs to be replaced not only when the used toner box in the transfer unit is filled with used toner, but also when the number of times the transfer film is developed reaches the maximum number of times the transfer film can be developed. Thus, since the number of times the transfer film is developed can reach the maximum number of times the transfer film can be developed before the used toner box in the transfer unit is filled with used toner, it is necessary to precisely control the development count of the transfer film. 
     Thus, every time the transfer unit is replaced it is detected whether the replaced transfer unit is an unused unit or not. If the transfer unit is an unused unit, it is necessary to reset the development count of the transfer film in this transfer unit and restart counting. Then, when this count reaches a predetermined value, the entire transfer unit is replaced. Therefore, with this recording apparatus it is necessary to detect whether the replaced transfer unit is an unused unit or not. 
     As a method for detecting whether the replaced transfer unit is an unused unit or not, it is possible to attach a fuse to the transfer unit which is blown out when the transfer unit is mounted and detect whether the transfer unit is an unused unit or not by the presence or absence of the fuse. However, such a detection method requires a circuit for burning out the fuse and a circuit for detecting the presence or absence of the fuse. This will increase the number of parts in the recording apparatus, causing a problem of increasing costs as well. Moreover, the necessity for providing an additional electric circuit will make the configuration of the recording apparatus complicated. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention to provide a recording apparatus capable of reliably detecting whether the transfer unit is an unused unit or not with a simple configuration without increasing the number of parts. 
     That is, the present invention provides a cover that covers a transfer medium on which a color image is formed by superimposing images of a plurality of colors, with an opening that exposes part of the transfer medium, pastes one end of an unused unit detection seal to near the opening in the direction in which the transfer medium moves and pastes the other end of the unused unit detection seal to the transfer medium through the opening to detect whether the transfer unit is an unused unit or not. In this way, one end of the unused unit detection seal is pasted to the transfer medium through the opening and the other end is pasted to the cover near the opening in the direction in which the transfer medium moves. Therefore, if the unused unit detection seal is pasted in such a way, it is possible to detect that this transfer unit is an unused unit. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other objects and features of the invention will appear more fully hereinafter from a consideration of the following description taken in connection with the accompanying drawing wherein one example is illustrated by way of example, in which; 
     FIG. 1 is an outlined cross-sectional view showing a configuration of a recording apparatus having a transfer unit according to an embodiment of the present invention; 
     FIG. 2 is a perspective view of the transfer unit according to the embodiment above; 
     FIG. 3 is an enlarged view around an opening of the transfer unit according to the embodiment above; 
     FIG. 4 is another enlarged view around the opening of the transfer unit according to the embodiment above; 
     FIG. 5A is an enlarged view of the front of an identification tape used for the transfer unit according to the embodiment above; 
     FIG. 5B is an enlarged view of the back of the identification tape used for the transfer unit according to the embodiment above; 
     FIG. 5C is an enlarged view of a register mark used for the transfer unit according to the embodiment above; 
     FIG. 6A is an enlarged view around the opening when the transfer unit according to the embodiment above is an unused unfit; 
     FIG. 6B is an enlarged cross-sectional view around the opening when the transfer unit according to the embodiment above is an unused unit; 
     FIG. 7A is an enlarged view around the opening when the transfer unit according to the embodiment above starts to be used; 
     FIG. 7B is an enlarged cross-sectional view around the opening when the transfer unit according to the embodiment above starts to be used; 
     FIG. 8A is an enlarged view when the identification tape of the transfer unit according to the embodiment above is peeled off; 
     FIG. 8B is an enlarged cross-sectional view when the identification tape of the transfer unit according to the embodiment above is peeled off; 
     FIG. 9A illustrates a modification example of a detection sensor in the transfer unit according to the embodiment above; and 
     FIG. 9B is another illustration of the modification example of the detection sensor in the transfer unit according to the embodiment above. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     With reference now to the attached drawings, an embodiment of the present invention is explained in detail below. 
     FIG. 1 is an outlined cross-sectional view showing a configuration of a recording apparatus according to an embodiment of the present invention. As shown in FIG. 1, this recording apparatus  100  has paper feed cassette  101  at the bottom. The top recording sheet of recording sheet bundle  102  is picked up from paper feed cassette  101  by pickup roller  103 . The recording sheet picked up from paper feed cassette  101  is handed over to register roller  104 . Transfer unit  105  is placed in an area directly ahead of register roller  104 . 
     Transfer unit  105  consists of transfer film  106  over which 4 color images are superimposed and used toner cleaning apparatus  107 . These are covered with cover  108  of transfer unit  105 . Transfer film  106  is made of a material of low optical reflectivity such as a black material. Cover  108  has openings where transfer film  106  has contact with a process unit that will be described later and a recording sheet. Through these openings, transfer film  106  has direct contact with a photosensitive material and recording sheet. Transfer film  106  is supported by three transport rollers  109  and rotates in the direction indicated by arrow A by a drive motor, which is not shown in the figure. Transfer roller  110  is placed facing transport roller  109  placed where transfer film  106  has contact with the recording sheet. Transfer roller  110  transfers images superimposed over transfer film  106  to the recording sheet. Used toner box  111  is housed inside three transport rollers  109 . Used toner box  111  is connected with cleaning apparatus  107  via a pipe. Used toner removed from transfer film  106  by cleaning apparatus  107  is conducted through the pipe and collected in used toner box  111 . This transfer unit  105  is housed in this recording apparatus  100  in a detachable manner. Thus, when used toner box  111  is filled with used toner, entire transfer unit  105  can be replaced. This prevents used toner from leaking and soiling the interior of this recording apparatus  100 . 
     Detection sensor  112  is placed in a predetermined location over transfer unit  105 . Detection sensor  112  detects a register mark provided on transfer film  106 . 
     Detection sensor  112  consists of a light-emitting device and photoreceptor device. Detection sensor  112  emits light toward a register mark through the opening on cover  108  of transfer unit  105  and detects the register mark by receiving reflected light from the register mark. 
     Process unit  113  is installed next to transfer unit  105 . Process unit  113  contains 4 color process cartridges  114 . LSU  115 , which consists of a laser drive unit and polygon mirror, etc., forms an electrostatic latent image on photosensitive material  116  provided for every cartridge. The 4 color images created by 4 color process cartridges  114  are superimposed over a same area of transfer film  106 . Transfer roller  110  transfers the images superimposed on transfer film  106  to the recording sheet. At this time, register roller  104  carries out positional adjustment between transfer film  106  and the end of the recording sheet. 
     The recording sheet with the image transferred is handed over from transfer unit  105  to fixing unit  117 . Fixing unit  117  is equipped with fixing roller  118 , pressurizing roller  119  and cleaning roller  120  that applies oil, which enhances the peeling off characteristic of toner remaining on fixing roller  118 . Fixing roller  118  heats the recording surface of the recording sheet and pressurizing roller  119  pressurizes the recording sheet against fixing roller  118 , and in this way the image is fixed to the recording sheet. Discharge roller  121  is provided at the outlet of fixing unit  117 . 
     FIG. 2 shows a perspective view of transfer unit  105  above. As shown in FIG. 2, opening  201  is provided on cover  108  of transfer unit  105 . When transfer unit  105  is mounted in recording apparatus  100 , detection sensor  112  is placed directly above opening  201 . 
     Furthermore, register mark  202  is provided in a predetermined position of transfer film  106  corresponding to opening  201 . That is, when transfer film  106  rotates, register mark  202  passes beneath opening  201 . Opening  201  is slightly bigger than register mark  202 . Register mark  202  is made of a material of high optical reflectivity. Register mark  202  is used to determine the position of transfer film  106  to prevent images from deviating from the right position when 4 color images are superimposed over transfer film  106 . 
     This recording apparatus  100  detects whether transfer unit  105  is an unused unit or not using such a configuration without increasing the number of parts. More specifically, recording apparatus  100  detects whether transfer unit  105  is an unused unit or not by adding a detection target to be detected by detection sensor  112 . This allows recording apparatus  100  to grasp timing for replacing transfer unit  105 . The following gives an explanation of the configuration and operation of recording apparatus  100  of detecting whether transfer unit  105  is an unused unit or not. 
     FIG.  3  and FIG. 4 show enlarged views before and after identification tape  301  to be detected by detection sensor  112  is pasted so that recording apparatus  100  detects whether transfer unit  105  is an unused unit or not. In recording apparatus  100 , identification tape  301  is pasted to unused transfer unit  105  near opening  201 . 
     In FIG.  3  and FIG. 4, identification tape  301  is made of a material of low optical reflectivity such as a black material as in the case of transfer film  106 . Identification mark  302 , which will be described later, is provided on one end of the identification tape. Identification tape  301  is slightly narrower than opening  201  of transfer unit  105 . One end of identification tape  301  is pasted to cover  108  beneath opening  201 . In other words, one end of identification tape  301  is pasted to cover  108  in the direction in which transfer film  106  moves from opening  201 . On the other hand, the other end of identification tape  301  is pasted to transfer film  106  through opening  201 . 
     Here, identification tape  301  is pasted so that its one end pasted to cover  108  coincides with the lower edge of cover  108  as shown in FIG.  4 . Pasting identification tape  301  in this way prevents identification tape  301  from pasting to transfer film  106  by letting it hang over the edge of cover  108 . Furthermore, since the pasting position of identification tape  301  is fixed, it is easier to paste identification tape  301 . 
     FIG. 5 shows enlarged views of identification tape  301  and register mark  202 . FIG.  5 A and FIG. 5B show enlarged views of the front and back of identification tape  301 , respectively. FIG. 5C shows an enlarged view of register mark  202 . 
     As shown in FIG. 5A, identification mark  302  is provided at one end of identification tape  301 . Identification mark  302  is made of a material of high optical reflectivity as in the case of register mark  202 . Identification mark  302  is also divided into a plurality of portions. FIG. 5A shows a case where identification mark  302  is divided into two portions. Detection sensor  112  emits light toward this identification mark  302 . Detection sensor  112  then detects reflected light from identification mark  302  twice during a predetermined time interval to detect identification tape  301 . This allows detection sensor  112  to detect that transfer unit  105  is an unused unit. 
     Here, the area between two identification marks  302  is set to be almost equal to the area of register mark  202 . This allows single detection sensor  112  to detect both identification mark  302  and register mark  202  without the need to provide any additional detection sensor. 
     Furthermore, regarding the back side of identification tape  301  shown in FIG. 5B, area  303  on the identification mark  302  side is set to have less adhesion than that of area  304  opposite to identification mark  302 . That is, area  303  on the identification mark  302  side is peeled more easily than area  304  opposite to identification mark  302 . 
     Next, the operation of detecting unused transfer unit  105  by this recording apparatus  100  is explained using FIG. 6 to FIG.  8 . FIG. 6 shows an enlarged view around opening  201  of unused transfer unit  105 . FIG. 7 shows an enlarged view around opening  201  when transfer film  106  starts to move. FIG. 8 shows an enlarged view around opening  201  when identification tape  301  is peeled off transfer film  106  as transfer film  106  moves. 
     When unused transfer unit  105  is mounted in recording apparatus  100 , as shown in FIG. 6A, one end of identification tape  301  is pasted to cover  108  and the other end is pasted to transfer film  106  through opening  201 . At this time, transfer film  106  cannot move. 
     FIG. 6B shows a cross-sectional view around this opening  201 . As shown in FIG. 6B, detection sensor  112  emits light toward predetermined detection position X through opening  201  and monitors the reflected light. When unused transfer unit  105  is mounted in recording apparatus  100 , the area other than identification mark  302  of identification tape  301  is located at detection position X. Therefore, detection sensor  112  receives no reflected light from identification tape  301 . 
     After transfer unit  105  is mounted in recording apparatus  100 , the user gives an instruction for recording an image. In response to the instruction for recording the image, the drive motor drives transport roller  109 . In synchronization with this, transfer film  106  moves in the direction shown by arrow A in FIG.  7 . When transfer film  106  moves in the direction of arrow A, the portion of identification tape  301  pasted to transfer film  106  also moves in the direction of arrow A in synchronization with transfer film  106 . Thus, identification mark  302  also moves in the direction of arrow A. 
     FIG. 7B shows a cross-sectional view around opening  201  in this case. As shown in FIG. 7B, identification mark  302  approaches detection position X of detection sensor  112  in synchronization with transfer film  106 . When identification mark  302  reaches detection position X, detection sensor  112  receives a first reflected light from identification mark  302 . Then, after a short interval of receiving no reflected light, detection sensor  112  receives a second reflected light from identification mark  302 . At this time, since detection sensor  112  receives the reflected light twice during a predetermined time interval, detection sensor  112  detects that identification tape  301  is pasted to transfer unit  105 . This allows a determination section (for example, CPU) of recording apparatus  100  to detect that transfer unit  105  is an unused unit. 
     Once transfer unit  105  detects that transfer unit  105  is an unused unit, recording apparatus  100  resets the development counter provided inside the apparatus. By doing so, recording apparatus  100  recounts the number of times development of transfer unit  105  has been carried out. As a result, recording apparatus  100  keeps track of the timing of replacing transfer unit  105 . 
     On the other hand, when transfer film  106  moves in the direction of arrow A, as shown in FIG. 8, identification tape  301  is caught in the direction of arrow A. At this time, regarding the adhesion of the back side of identification tape  301 , the area on the identification mark  302  is peeled more easily than the area opposite to identification mark  302 . For this reason, when identification tape  301  is caught in the direction of arrow A, identification tape  301  starts to peel starting from the portion of identification tape  301  pasted to transfer film  106 . Identification tape  301  peeled off transfer film  106  is caught in by cover  108  with its adhesive surface facing the back of cover  108 . 
     When transfer film  106  further moves, as shown in FIG. 8A, identification tape  301  is completely peeled off transfer film  106 . Identification tape  301 , which is peeled off transfer film  106 , is kept with its adhesive surface facing the back of cover  108  or stuck to the back of cover  108 . Because of this, peeled identification tape  301  does not interfere with the movement of transfer film  106  or the detection operation of detection sensor  112 . 
     FIG. 8B shows a cross-sectional view around opening  201 . As shown in FIG. 8B, transfer film  106  is completely released from identification tape  301 . Therefore, transfer film  106  moves singly. When transfer film  06  starts to move singly, detection sensor  112  only receives the reflected light from register mark  202  provided on transfer film  106 . Therefore, after identification tape  301  is peeled off transfer film  106 , it is possible to continue image recording operation in the same way as normal operation of transfer unit  105 . 
     As shown above, recording apparatus  100  of this embodiment is provided with identification tape  301  indicating whether transfer unit  105  is an unused unit or not pasted to opening  201  for detecting register mark  202 . Detection sensor  112  for detecting register mark  202  detects identification mark  302  of this identification tape  301 . This makes it possible to reliably detect whether transfer unit  105  is an unused unit or not with a simple configuration without increasing the number of parts. 
     Moreover, according to recording apparatus  100  of this embodiment, identification tape  301  peels off transfer film  106  as transfer film  106  moves. The adhesive surface of peeled identification tape  106  remains facing the back of cover  108  or pasted to the back of cover  108 . For this reason, identification tape  301  does not interfere with the movement of transfer film  106  or cause misoperation of detection sensor  112 . Therefore, after identification tape  301  is peeled off transfer film  106 , recording apparatus  100  can continue normal image recording operation. 
     Furthermore, according to recording apparatus  100  of this embodiment, identification mark  302  is divided into a plurality of portions and detection sensor  112  detects that transfer unit  105  is an unused unit when detection sensor  112  receives the reflected light from this identification marks  302  by the number of times corresponding to the number of identification marks  302 . At this time, the area between the plurality of identification marks  302  is set to have approximately the same area as that of register mark  202 . Therefore, it is possible to detect whether transfer unit  105  is an unused unit or not using existing detection sensor  112  for detecting register mark  202  without installing any additional sensor for detecting identification mark  302 . 
     Furthermore, this embodiment describes detection sensor  112  that detects whether transfer unit  105  is an unused unit or not by emitting light toward identification mark  302  made of a light reflecting material and receiving the reflected light. However, the present invention is not limited to such detection sensor  112  alone, but this sensor can also be replaced by a penetration type detection sensor. The apparatus with such a sensor can also attain the same effect as that of this embodiment. 
     In this case, as shown in FIG. 9A, opening  901 , which is used as a register mark, is provided at a predetermined position at one end of transfer film  106 . Then, penetration type detection sensor  902  is placed at a location where opening  901  passes in such a way that transfer film  106  is sandwiched. Penetration type detection sensor  902  consists of a light-emitting device and photoreceptor device. Penetration type detection sensor  902  detects the register mark by the photoreceptor device receiving the light from the light-emitting device only when opening  901  arrives at the detection position. On the other hand, as shown in FIG. 9B, identification tape  903  is pasted to opening  901  for unused transfer unit  105 . This identification tape  903  has two slits  904  formed, which will be placed just above opening  901 . Penetration type detection sensor  902  detects identification tape  903  when the photoreceptor device receives light from the light-emitting device twice through slits  904  during a predetermined interval. This allows the penetration type detection sensor  902  to detect whether transfer unit  105  is an unused unit or not. 
     Furthermore, this embodiment describes identification tape  301  with the adhesion on the transfer film  106  side is set to be weaker than the adhesion on the cover  108  side. However, the present invention is not limited to this, but it is also possible to set the adhesion on the transfer film  106  side to be weaker by differentiating the area of adhesive surface of identification tape  301 . The apparatus with such a modification can also attain the same effect as that of recording apparatus  100  of this embodiment. 
     As described above, the present invention allows the existing detection sensor to detect an identification tape that can detect an unused transfer unit, making it possible to reliably detect whether the transfer unit is an unused unit or not with a simple configuration without increasing the number of parts. 
     The present invention is not limited to the above described embodiments, and various variations and modifications may be possible without departing from the scope of the present invention. 
     This application is based on the Japanese Patent Application No.HEI11-197453 filed on Jul. 12, 1999, entire content of which is expressly incorporated by reference herein.