Abstract:
An exterior or interior structural member in the form of a panel for an image forming or similar device is disclosed which has an integral plenum passage for fluid/air. The panel may be thermoformed and/or have mechanically connected parts, and may include other elements, such as toner bottle covers.

Description:
This application claims the benefit of U.S. Provisional Application No. 60/200,871, filed on May 1, 2000. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     This invention relates to fluid flow passages provided in a mechanical or electromechanical apparatus. 
     2. Description of Related Art 
     Many different devices, for example, computers, photocopiers, facsimile machines, telephones, printers, multifunction devices, and the like, circulate air or other ambient fluids or gases to vary the operating temperature of components in those devices and/or to remove contaminants. Typically, one or more individual fluid passages are found in such devices to bring the ambient fluids/gases to, and away from, various device components. The ambient fluid/gas provides cooling or provides heating to prevent condensation, and/or removes contaminants, such as moisture or toner particles. Often there are flow directing devices or structures, such as louvers or vanes, pipes or ducts associated with these fluid/gas passages, and blowers or compressors or accumulator tanks which may be connected to each individual fluid/gas passage for fluid transport. 
     SUMMARY OF THE INVENTION 
     Problems associated with such fluid/gas passages include finding room to fit the fluid/gas passages in the device without making access to the fluid/gas passages for servicing or repair difficult, and avoiding damaging the fluid/gas passages just in fitting the fluid/gas passages into the device. Also, in many such devices, since access to components is readily available to both users and technicians, safety concerns arise in case a fluid/gas passage breaks, or electrical components are accidentally contacted in the course of servicing or repair of the fluid/gas passages. 
     The invention is directed to a device which enables the movement of a fluid, especially air, throughout an electronic device, such as, for example, an image forming or similar device, using structural members of the device having one or more integral plenum chambers or fluid/gas passages. The structural member, which may be constructed in many ways, is cost effective, and will improve reliability throughout the electronic device, as well as reduce servicing costs. In one exemplary embodiment the structural member may be made using a blow molding process in which “tack-offs” are formed to define integral plenum chambers. In another exemplary embodiment, the structural member may be made using a thermoforming process in which ribs are formed in one structural member portion and the ribbed structural member is joined with another structural member portion, such as, for example, by any appropriate known of later developed joining technology, including, for example, adhesive joining, ultrasonic welding, and/or mechanical fastening, such as, for example, by using screws. In another exemplary embodiment, the structural member is made up of two or more portions using an injection molding process, and the structural member portions are joined together, such as, for example, by any appropriate known or later developed joining technology, including for example, adhesive joining, ultrasonic welding, and/or mechanical fastening, such as, for example, by using screws. The structural member may be used in the form of an inner or outer cover for a device such as a personal computer, photocopier, facsimile machine, printer, telephone or multifunction device. The integral construction increases the strength of the cover and provides a compact, efficient device for circulating air or other ambient fluids or gases for cooling, heating, cleaning, or the like, throughout an electronic device. A multifunction device is considered to be an electronic device which performs several different functions, such as photocopiers, printers, facsimile devices, voice telecommunication devices, and the like. 
     This invention provides one or more robust plenum fluid/gas passages integrated in structural members such as, for example, a cover of an image forming device, a computer, a printer, a facsimile machine, a multifunction device. 
     In various exemplary embodiments, the integrated plenum fluid/gas passages provide an ambient fluid, usually air, to and from the components of the device. In various exemplary embodiments the integrated plenum fluid/gas passages are typically used to cool components of the device or to remove contaminants from the device. 
     In various exemplary embodiments of the device, the structural member may also be employed as a safety barrier and may have other elements integrated into the structural member, such as, for example, a toner cover. 
     In one exemplary embodiment of the integrated fluid/gas passages of the invention, an exterior cover of an image forming device includes an integrally formed air supply/exhaust plenum duct. 
     In another exemplary embodiment of this invention, a multi-functional inner panel of an image forming device has an integrally formed air supply/exhaust plenum duct. 
     In another exemplary embodiment of this invention, an inner safety panel of an image forming device includes both toner dispenser bottle covers and an air supply/exhaust plenum duct formed in the inner safety panel. 
     These and other features and advantages of this invention are described in or are present from the following detailed description of various devices that incorporate various exemplary embodiments of the integrated fluid/gas passages according to this invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Various exemplary embodiments of this invention will be described in detail, with reference to the following figures, wherein: 
     FIG. 1 is a plan view of one exemplary embodiment of a structural member incorporating one exemplary embodiment of the integral fluid/gas passage according to this invention; 
     FIG. 2 is a side view of the first exemplary structural member; 
     FIG. 3 is cross-sectional view of the first exemplary structural member; 
     FIG. 4 is a perspective view of one side of a first portion of a second exemplary structural member incorporating a second exemplary embodiment of the integral fluid/gas passage according to this invention; 
     FIG. 5 is a perspective view of a second portion of the second exemplary structural member; 
     FIG. 6 is a plan view of the first side of the second exemplary structural member; 
     FIG. 7 is a cross-sectional view of the second exemplary structural member; 
     FIG. 8 is a another perspective view of the second exemplary structural member; 
     FIG. 9 is a perspective view of a third exemplary embodiment of a structural member incorporating a third exemplary embodiment of the integral fluid/gas passage according to this invention; 
     FIG. 10 is a plan view of a top or first side of the third exemplary structural member; 
     FIG. 11 is a first cross-sectional view of the third exemplary structural member; 
     FIG. 12 is a perspective view of the third exemplary fluid/gas passage portion separated from the third exemplary structural member; 
     FIG. 13 is a perspective view of a second or bottom side of the third exemplary structural member; 
     FIG. 14 is a plan view of the first side of the third exemplary structural member; 
     FIG. 15 is a second cross-sectional view of the third exemplary structural member. 
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS 
     FIG. 1 is a plan view of one exemplary embodiment of a structural member incorporating one exemplary embodiment of the integral fluid/gas passage according to this invention. The structural member  1  includes a plurality of intersecting plenum fluid/gas passages  11 . Each passage  11  has openings through which air or another ambient fluid flows to or from a device, such as, for example, an image forming or similar device that incorporates the structural member  1 . A blower  5  is attached to an opening  12  in an inside wall  3  of the structural member  1 . The blower may also be located at a position which is external to the structural member  1  and connected to the plenum passages  11  by an opening in the outside wall  2  of the structural member  1 . 
     FIG. 2 is a side view of a structural member  1  with the integral plenum fluid/gas passage  11  that supplies air to, or exhausts air from, the inside of a device to which the structural member  1  may be attached. The structural member  1  has an inside wall  3  and outside wall  2 . FIG. 2 shows two relatively long ribs or “tack-offs”  6  that are employed to impart structural rigidity to the integrated structural member  1  and to form the plenum passages  11 . The number of “tack-offs” may vary depending on different factors, for example, on the strength desired for the structural member, and/or on the number of plenum passages  11  desired. 
     FIG. 3 shows the ribs or long tack-offs  6  with a U-shaped cross section. The closed curved portion of the U-shaped tack-offs  6  contacts the outside wall  2  of the structural member  1 . The open end of the U-shaped tack-offs  6  face inward and constitute openings in the inside wall  3  of the structural member  1 . This particular embodiment of the structural member is shown as a unitary blow-molded version. However, it may be made up of separate portions made, such as, for example, by thermoforming or injection molding technology, and joined together by conventional known or later developed technology, such as, for example, using adhesives, ultrasonic welding and/or mechanical fasteners. Air flows between the ribs or tack-offs  6 . 
     FIG. 4 is a perspective view of a second exemplary structural embodiment of a second structural member  30 . The second structural member or panel  30  is provided inside of an image forming or similar device, and is specifically designed to provide access to toner containers, e.g. toner bottles, in an organized manner. The structural member or panel  30  contains a number of lids  36  (as shown in FIG. 8) for toner containers, and has label locations  34  to attach labels to the panel  30  to identify the toner in each container. An air duct  31  is integrally connected to or formed as part of the panel  30 . The air duct has an air inlet  37  and an air exhaust outlet (not shown in FIG. 4) on the other side of the panel  30  from the air inlet  37 . An arrow  35  labeled air exhaust indicates the direction of flow of air exhausted via the duct  31 . These directions of air exhaust and air inlet are for purposes of illustration only and they may be reversed in actual operation. The panel also contains an instruction label location  15 , on the plenum passage  31  for supporting an instruction label. In various exemplary embodiments, the panel  30  acts as a safety panel because the panel  30  provides a barrier to access to image forming device components, such as toner containers, electronic equipment, and hot surfaces for the safety of users of the device by reducing the chance of accidental contact by users with those components. 
     FIG. 5 is a perspective view of a second side of the second exemplary structural member  30 , revealing its ribbed support structure, and the ribs  32  supporting the integral plenum passage  31 , and the plenum passage opening  33 . Air flows through the integral plenum passage  31  via the opening  37  near ribs  32  and via the opening  33  in the structural member  30 . 
     FIG. 6 shows a plan view of the second side of the second exemplary structural member  30 . FIG. 7 shows the second exemplary embodiment structural member panel is shown in cross section. In FIG. 7, the section is taken along line A—A in FIG.  6 . FIG. 7 depicts the cross section of the supporting ribs  32  as well as the cross section of the plenum passage  31 . FIG. 8 shows the second exemplary structural member with hinged toner lids  36  having latching/unlatching elements  37 . 
     FIG. 9 shows a perspective view of a first side of a third exemplary embodiment, of a third structural member or panel  40  of an image forming or similar device which has an integrated air plenum passage  41  having an air inlet  42 . The directions indicated in the drawing for air entering the integrated plenum passage  41  and air being exhausted from the integrated plenum passage  41  may be reversed in actual operation. The integral plenum passage  41  is formed, as shown, on one side of the panel  40  communicates with an opening connected to the plenum so that air can be transmitted from one side of the panel  40  to the other side. Alternatively, the passage  41  may have another outlet which does not communicate with an opening in the panel or in conjunction with the opening. 
     FIG. 10 shows a plan view of a first side of the third exemplary structural member  40 . FIG. 11 shows a cross-sectional view of the third exemplary structural member  40 . In FIG. 11, the section is taken along line A—A in FIG.  10 . FIG. 11 shows the cross section of the supporting element  42  as well as the cross section of the plenum duct  41 . 
     FIG. 12 is a perspective view of the third exemplary third gas passage separated from the third exemplary structural member  40  showing the plenum passage  41  as a separate element prior to its being integrally connected to the third structural member  40 . 
     FIG. 13 shows the underside of the third exemplary structural member  40  showing the support element  42  structure, the air outlet  43  formed in the panel  40  that communicates with the integral plenum duct  41 , and a frame  44  for supporting auxiliary equipment such as a filter. In various exemplary embodiments, the third exemplary structural member can also act as a safety panel because the third exemplary structural member provides a barrier to access to image forming device components, such as toner containers, electronic equipment, and hot surfaces for the safety of users of the device by reducing the chance of accidental contact by users with those components. 
     FIG. 14 is a plan view of the first side of the third exemplary structural member, and FIG. 15 is a section taken along line B—B of the third exemplary structural member, which shows air passage  31  in detail. 
     In the various exemplary embodiments described above, the panels may be formed by any suitable methods, including blow molding, thermoforming, and injection molding, alone or in combination with conventional joining technology, such as, for example, adhesive, ultrasonic and/or mechanical assembly methods. 
     While this invention has been described in conjunction with the exemplary embodiments set forth above, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art. Accordingly, the exemplary embodiments of the invention, as set forth above, are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the invention.