Abstract:
A flange assembly having modular mounting features for receiving and removably securing a component such as a gear thereon. The flange assembly is for use with an imaging member such as a photoreceptor drum.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a flange and more specifically to a modular flange system adaptable for use with various sized components such as gears and for use with an imaging member such as a photoreceptor that is used in electrostatographic imaging machines, devices, and processes, including digital and color systems. 
     BACKGROUND OF THE INVENTION 
     The xerographic imaging process includes charging a photoconductive member to a uniform potential, and then exposing a light image of an original document onto the surface of the photoreceptor. Exposing the charged photoreceptor to light selectively discharges areas of the surface while allowing other areas to remain unchanged, thereby creating an electrostatic latent image of the document on the surface of the photoconductive member. A developer material is then brought into contact with the surface of the photoreceptor to transform the latent image into a visible reproduction. The developer typically includes toner particles with an electrical polarity opposite that of the photoconductive member. A blank copy sheet is brought into contact with the photoreceptor and the toner particles are transferred thereto by electrostatic charging the sheet. The sheet is subsequently heated, thereby permanently affixing the reproduced image to the sheet. This results in a “hard copy” reproduction of the document or image. The photoconductive member is then cleaned to remove any charge and/or residual developing material from its surface to prepare it for subsequent imaging cycles. 
     Various imaging and photoreceptor systems are disclosed in U.S. Pat. Nos. 4,120,576; 4,386,839; 4,400,077; 4,561,763; 4,839,690; 4,914,478; 4,975,744; 5,052,090; 5,210,574; 5,357,321; 5,402,207; 5,461,464; 5,599,265; 5,630,196, 5,634,175; 5,752,136; 5,815,773; 5,893,203; and 6,104,896, the disclosures of which are incorporated by reference in their entireties. 
     The modularity of components is important for manufacturers of sophisticated electronic equipment such as electrostatographic imaging machines. Thus, a need remains for a modular flange system for use with mountable components to facilitate efficiency in manufacturing and in recycling. There is a need for a modular flange system which will accommodate modularity of components such as gears. The present invention advantageously provides such a flange system with common mounting features. 
     All documents cited herein, including the foregoing, are incorporated herein by reference in their entireties. 
     SUMMARY OF THE INVENTION 
     The present invention provides embodiments of a flange assembly with a modular mounting feature for removably securing a gear thereon. The embodiments facilitate easy assembly and reuse of components. Moreover, the embodiments allow installation of the component on the manufacturing line. 
     An aspect of the invention relates to a flange assembly including an imaging member and a flange. The imaging member includes a first end, a second end, an inside surface, and an outside surface. The flange includes a hub for securing to the imaging member and a protrusion for removably securing a component thereon. The hub has a length and fits inside the imaging member. The protrusion has a length and an outside surface and extends external to the imaging member. 
     In a further aspect, the invention relates to a flange assembly including an imaging member, at least one flange, and a least one fastening system. The imaging member extends between a first end and a second end and has an inside surface. The flange includes a hub and protrusion. The hub is for securing to the imaging member and the protrusion is for removably securing a component thereon. The hub of the flange interferencely fits inside the imaging member and the protrusion of the flange extends external to the imaging member. The fastening system is for a removably securing a component with the protrusion of the flange. 
     An additional aspect of the invention relates to a flange assembly in a marking device including a photoreceptor, at least one flange, and at least one gear. The photoreceptor extends between two ends and includes an inside surface. The photoreceptor is adapted to move in the marking device. The flange includes a hub and a protrusion. The hub of the flange interferencely fits inside the photoreceptor. The protrusion is for removably securing a gear thereon. The protrusion of the flange includes a periphery and extends external to the photoreceptor. The gear includes a diameter, a width, and a lumen therein, and is removably securable to the protrusion of the flange. 
     Another aspect of the invention relates to a process for using a modular flange including: inserting a hub of a flange in an end of an imaging member forming an imaging member flange assembly, the flange having a protrusion extending outside the imaging member; installing the imaging member and flange assembly in an imaging system; disposing an opening of a component over the protrusion; and removably securing the component to the protrusion using a fastening system. The process may further include: removing the component from the protrusion; and replacing the component with another component. 
     A further aspect of the invention relates to a xerographic apparatus including an imaging member, two flanges, and two gears. The imaging member extends between two ends and is adapted to move in the xerographic apparatus. Each flange includes a hub and a protrusion. The protrusion includes an outside surface. One of the hubs interferencely fits inside the imaging member at one end of the imaging member and the other one of the hubs interferencely fits inside the imaging member at the other end of the imaging member. The protrusion extends external to the imaging member at each of the two ends. Each gear includes a diameter, a width, and a lumen therein. The lumen includes an inside surface. The two gears are removably securable to the protrusion at the two ends. The protrusion and the gear cooperate and functionally engage the other at each of the two ends. One of the gears may transfers torque to the flange and the imaging member. The imaging member may be part of an imaging system. 
     Still other aspects and advantages of the present invention and methods of construction of the same will become readily apparent to those skilled in the art from the following detailed description, wherein embodiments are shown and described, simply by way of illustration. As will be realized, the invention is capable of other and different embodiments and methods of construction, and its several details are capable of modification and interchangeability in various obvious respects, all without departing from the invention. Accordingly, the drawing and description are to be regarded as illustrative in nature, and not as restrictive. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 depicts a schematic view of the flange assembly of the present invention; 
     FIG. 2 is a schematic side view of assembly of FIG. 1; 
     FIG. 3 depicts a side view of assembly of FIG. 1; 
     FIG. 4 depicts a schematic view of an embodiment of the flange and gear of the present invention; 
     FIG. 5 depicts a schematic view of an embodiment of the flange and gear of the present invention. 
     FIG. 6 depicts a front view of the flange and gear of FIG. 5; 
     FIG. 7 depicts a schematic view of an embodiment of the flange and gear of the present invention; 
     FIG. 8 depicts a front view of the flange and gear of FIG. 7; 
     FIG. 9 depicts an embodiment of a fastening system used to hold the gear on the flange; and 
     FIG. 10 depicts an embodiment of a fastening system used to hold the gear on the flange. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     While the principles and embodiments of the present invention will be described in connection with an imaging apparatus, it should be understood that the present invention is not limited to that embodiment or to that application. Therefore, it should be understood that the principles of the present invention and embodiments extend to all alternatives, modifications, and equivalents thereof. 
     FIG. 1 illustrates an embodiment of a modular imaging member flange assembly  10 . FIGS. 2-3 illustrate a flange  12 , imaging member  14 , gear  24 , and a fastening system such as hooks  23  and a clip  28  to removably secure the gear  24  to the flange  12 . The flange  12  includes a member  16  which is disk shaped, a hub  18  which extends axially from one side of the member  16 , and a protrusion  20  which extends axially from the other side of the member  16 . The hub  18  has an outside surface  21 . The member  16  extends radially outside the hub  18  and the protrusion  20 . In embodiments, the protrusion is of sufficient mass and strength to mount and removably secure a component such as a gear thereon. 
     FIGS. 2 and 3 further illustrate assembly of the flange  12  into an imaging member, for example, a photoreceptor  14 . The flange is designed to allow the hub  18  to be pushed and inserted into the interior of the photoreceptor  14 . As the hub  18  is pushed into the photoreceptor  14 , the member  16  acts as a stop to prevent further insertion of the hub  18  into the photoreceptor  14 . The hub  18  is inserted into the interior of the photoreceptor  14  until the end of the photoreceptor  14  and a face of the member  16  are in contact. The surface  21  of the hub  18  intimately contacts the surface  22  of the photoreceptor  14  and there is generally indiscernible clearance between the surfaces  21 ,  22 . In operation, there is indiscernible relative movement between the flange  12  and the photoreceptor  14 . 
     The contacting surfaces  21 ,  22  provide resistance against a torque applied to the flange  18  and the photoreceptor  14 . The hub  18  withstands the inner radial compression load that is exerted upon it in the photoreceptor  14 . The coefficients of thermal expansion of the photoreceptor  14  and the flange may be matched so that the interference fit is maintained independent of the temperature. Prior to assembly of the hub  18  into the photoreceptor  14 , outside diameter D 5  of the hub  18  is slightly larger than the inside diameter D 3  of photoreceptor  14 . The hub  18  is forced into the inside of photoreceptor  14  such that the surface  21  firmly contacts the surface  22  of the photoreceptor  14 . The photoreceptor  14  expands slightly in the outward radial direction as the hub  18  is inserted. The relation of the outside diameter D 5  of the hub  18  in relation to the inside diameter D 3  of photoreceptor  14  should not cause the photoreceptor  14  to bulge and affect the total indicated runout (TIR) of the photoreceptor  14 . Hub  18  may be secured to photoreceptor  14  by interference fit as disclosed in U.S. Pat. Nos. 6,104,896 and 5,815,773, the disclosures of which are incorporated by reference in their entireties. 
     After the flange is mounted to the photoreceptor  14 , the gear may be placed over the protrusion. The clip  28  is then removably secured to the hooks  23  to prevent the gear from pulling off the protrusion in the direction of the axis x. A secondary gear (not shown) may be further associated with and mate with the teeth of the gear. A motor (not shown) may be used to rotate or drive the gear about axis x as indicated by arrow y. The flange may be mounted on one end or both ends of the photoreceptor  14  and the gear may be attached to one end or both ends of the photoreceptor  14 . The flange may further include a shaft  27  which extends through the photoreceptor  14  and mounts to an imaging system. Alternatively, an individual shaft  27  at each flange may be mounted to an imaging system. 
     FIG. 4 illustrates a flange  12  having a protrusion  120  with notch mounting system  122 . A gear  124  includes tabs  125  which fit in the notches of the protrusion  120 . The tabs  125  radially protrude into the opening of the gear  124  for a distance ranging from about 0.08 inch to about 0.20 inch; extend a width ranging from about 0.04 inch to about 0.8 inch; and have a thickness ranging from about 0.07 inch to about 0.18 inch. The tabs  125  may be about 0.005 inch to about 0.05 inch smaller, such as about 0.015 inch smaller than the notch for a generally secure fit. After the gear  124  is disposed over the protrusion  20 , a ring  128  may be secured over hooks  123  to removably secure the gear  124 . 
     FIGS. 5-6 illustrate various fastening systems for embodiments of the modular imaging member flange assembly  10 . In FIG. 5, a clip  228  is secured over hooks  23  to removably secure the gear  24  on the flange  12 . In FIG. 6, a clip  328  is secured over hooks  23  to removably secure the gear  24  on the flange  12 . 
     FIGS. 7-8 illustrate an embodiment of the invention with a flange including a notch mounting system  222 . The protrusion  220  may have a rectangular or oblong shape. The gear  224  includes tabs  225  in the opening that are sized to fit and cooperate with the notches. The tabs  225  may radially protrude into the opening of the gear  224  for a distance A ranging from about 0.08 inch to about 0.20 inch, extend a width B ranging from about 0.04 inch to about 0.9 inch, and have a thickness C ranging from about 0.07 inch to about 0.18 inch. In operation, the gear  224  fits securely over the protrusion  220  and the tabs  225  fit securely and slide smoothly into their respective notch of the protrusion  220 . The tabs  225  may be about 0.005 inch to about 0.05 inch smaller, such as about 0.015 inch smaller than the notch for a generally secure fit. As the gear  224  is pushed toward the member  16  and nears the face of the member  16 , the gear  224  is twisted an angle Θ ranging from about 3 degrees to about 40 degrees, such as about 15 degrees in a clockwise direction y, and the tabs  225  are rotated and further positioned in their respective notch of the protrusion  220 . Seating the tabs  229  in the notches prevents the gear  224  from moving in the axial x direction. The gear  224  is driven by a motor or mating gear in the clockwise direction y which keeps the gear  224  in a seated position on the protrusion  220 . Alternatively, the gear  224  and protrusion  220  may be designed such that the gear  224  is locked in a counterclockwise drive system. 
     FIGS. 9-10 illustrate an embodiment of the invention with a flange including a protrusion  320  that is circular and a notch mounting system  322 . The diameter of the protrusion  320  may range from about 0.40 inch to about 2.5 inches, such as about 0.50 inches. The gear  324  includes tabs  325  in the opening that are sized to fit and cooperate with the notches. The tabs  325  may radially protrude into the opening of the gear  324  for a distance A ranging from about 0.08 inch to about 0.20 inch, extend a width B ranging from about 0.04 inch to about 0.9 inch, and have a thickness C ranging from about 0.07 inch to about 0.18 inch. In operation, the gear  324  fits securely over the protrusion  320  and the tabs  325  fit securely and slide smoothly into their respective notch of the protrusion  320 . The tabs  325  may be about 0.005 inch to about 0.05 inch smaller, such as about 0.015 inch smaller than the notch for a generally secure fit. As the gear  324  is pushed toward the member  16  and nears the face of the member  16 , the gear  324  is twisted an angle Θ ranging from about 3 degrees to about 40 degrees, such as about 15 degrees in a clockwise direction y, and the tabs  325  are rotated and further positioned in their respective notch of the protrusion  320 . Seating the tabs  325  in the to notches prevents the gear  324  from moving in the axial x direction. The gear  324  is driven by a motor or mating gear in the clockwise direction which keeps the gear in a seated position on the protrusion  320 . Alternatively, the gear  324  may be designed such that the gear  324  is locked in a counterclockwise drive system. 
     Other sizes, variations and equivalents of the flange, gear, and fastening system for an imaging machine are also envisioned. 
     The gear may have teeth on its external periphery and include an opening therein that is about 0.005 inch to about 0.05 inch larger, such as about 0.015 inch larger than the outside periphery of the protrusion to which it is removably secured. The opening of the gear generally conforms to the shape of the outside periphery of the protrusion. The gear may be comprised of: polycarbonate; acrylonitrile butadiene styrene copolymer (ABS); nylon; or combinations thereof. The gear may be mounted over the protrusion and may be removably secured with various fastening systems. The gear may have a diameter ranging from about 0.9 inch to about 3.7 inches, such as about 1.30 inches, and a width ranging from about 0.08 inch to about 1 inch, such as about 0.40 inch. 
     Other flange and gear systems are also envisioned. For example, a gear may be removably secured to a flange at one or both ends of the photoreceptor  14 ; a gear may be removably secured to a flange at one end of the photoreceptor  14  and a cap or other fitting may be used at the other end of the photoreceptor  14 ; a stepped gear may be removably secured to a flange at one or both ends of the photoreceptor  14 ; and combinations thereof are envisioned. The gears may have various widths. Moreover, the gear may be formed in one-piece and include more than one distinct outside gear surface; the gear may be formed in one-piece with two distinct outside gear surfaces, with distinct diameters such as a stepped gear; and the gear may be formed in one-piece with two distinct outside gear surfaces spaced from the other, with the same diameter. Alternatively, multiple gears of the same or distinct diameter and various widths may be stacked together on a protrusion and used. The relation between the protrusion and the component should include a generally snug fit that allows removable securement therebetween and a fit which includes centricity and generally little slackness. The gear may be of a size sufficient to fit in an imaging machine and may be made of a material compatible with other mating gears. 
     Various dimensions of the flange are envisioned. The flange may have a length L ranging from about 0.5 inch to about 3 inches, such as about 1 inch. The hub  18  may have a length L 1  ranging from about 0.25 inch to about 2 inches, such as about 0.5 inch; an outside diameter D 5  ranging from about 0.64 inch to about 3.23 inches, such as about 1.124 inches; an inside diameter D 1  ranging from about 0.5 inch to about 2.9 inches, such as about 0.65 inch; and a thickness T ranging from about 0.15 inch to about 1.5 inches, such as about 0.60 inch. Alternatively, the interior of the hub  18  may be solid. The member  16  may have a length L 3  ranging from about 0.04 inch to about 0.1 inch, such as about 0.06 inch; and a diameter D 2  ranging from about 0.80 inch to about 3.50 inches, such as about 1.12 inches. The protrusion may extend from an end of the member  16  for a distance L 2  ranging from about 0.20 inch to about 1 inch, such as about 0.40 inch. The protrusion may have an irregular or a non-circular cross-sectional shape that is, for example, square, rectangular, or oblong shape. The protrusion may have a height ranging from about 0.25 inch to about 2.5 inches, such as about 1 inch, and a width ranging from about 0.25 inch to about 2.5 inches, such as about 0.5 inch. 
     The flange may be made by fabrication processes such as injection molding, machining, or reaction injection molding. The flange may be formed in one-piece using a mold. Alternatively, the hub  18 , the member  16 , and the protrusion may be fabricated separately and from the same or different materials and then joined together. The flange may be secured without adhesives to the photoreceptor  14 . The flange may have a modular mounting feature such as a protrusion that is common for a product line or photoreceptor line which requires a certain type of gear. The protrusion of the flange may be designed to be common for a certain size product or type of product. 
     The flange may be formed from a composite material including combinations of polycarbonate, polytetrafluorethylene (PTFE) and glass. For example, the flange may be comprised of: (a) polycarbonate; (b) a composite of polycarbonate and PTFE; or (c) a composite of polycarbonate, PTFE, and carbon fiber composite. In embodiments of the invention, the flange may be comprised of about 75% polycarbonate, about 15% PTFE, and about 10% glass. Other combinations of these materials may be used, and the invention is not limited to these particular embodiments. The flange may also be comprised of a composite material including a combination of plastic and a conductive material in an amount sufficient to form an electrical ground path between the photoreceptor  14  and the flange. The plastic has a generally high impact strength and a generally high softening temperature. Those skilled in the art will recognize that it is possible to substitute similar or equivalent material for those listed such as fiberglass, plastic, and numerous other materials instead of glass. Alternative fastening designs such as tabs on the protrusion and notches on the gear are also envisioned. Notches about the perimeter of the protrusion may be used to accept and removably secure a clip or ring fastener for maintaining the gear on the protrusion. In addition, a clip or ring and post or hook system may be used in conjunction with a notch and tab system. 
     Alternative fastening system designs such as tabs on the protrusion and notches on the gear are also envisioned. In addition, notches circumferentially about the perimeter of the protrusion may be used to accept and removably secure a clip or ring fastener for maintaining the gear on the protrusion. Moreover, a clip or ring and post or hook system may be used in conjunction with a notch and tab system. 
     Various embodiment sizes and dimensions of the photoreceptor  14  are envisioned. The photoreceptor  14  may have an inside diameter D 3  ranging from about 0.59 inch to about 3.22 inches, such as about 1.122 inches; an outside diameter D 4  ranging from about 0.65 inch to about 3.31 inches, such as about 1.18 inches, a wall thickness T 1  ranging from about 0.03 inch to about 0.05 inch, such as about 0.04 inch; and a length ranging from about 9.84 inches to about 39.37 inches, such as about 13.38 inches. 
     In operation, the flange provides torsional and axial support for photoreceptor  14 . The flange transfers the torsional force applied by the gear to the photoreceptor  14 . The photoreceptor  14  often operates under torsional loads of as much as 45 lbs-in. As the gear rotates, photoreceptor  14  rotates past a corona device (not shown) for charging of the photoreceptor  14  to a uniform electrostatic potential. A light image of an original document is then exposed onto the surface of photoreceptor  14  to selectively discharge areas of the surface which correspond to blank areas in the original image. A developer material is then brought into contact with the surface of the photoreceptor  14  to transform the latent image into a visible reproduction. 
     While this invention has been described in conjunction with various embodiments, it is evident that many alternatives, modifications, and variations thereof will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations and their equivalents.