Optical Scanner Mirror Angle Maintenance via Wedge Mediator
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Solution Overview
Problem
Existing optical scanners in electrophotographic image-forming devices face challenges in maintaining precise angles of optical members like mirrors and lenses due to manufacturing irregularities and dust buildup, leading to poor image quality and difficulty in reassembly.
Innovation Solution
The optical scanner employs a polygon mirror and toric lenses with a scanner frame that includes a PC/ABS polymer alloy filled with isotropic thermal expansion filler, and a cover member with exit holes that allow easy cleaning and reduce dust accumulation, while using photocurable resin spacers to maintain mirror angles without requiring high surface precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manufacturing precision of screw parts is increased to reduce play between male and female screws, then angle maintenance improves, but manufacturing costs increase
Solution Approach 1:
A wedge-shaped intermediate member is introduced between the mirror and the regulating screw. This wedge member has a tapered surface that converts the small linear movement of the screw into a larger angular adjustment of the mirror, while the wedge shape provides self-locking capability that maintains the angle without requiring high precision threading. The intermediate wedge acts as a mechanical advantage device that amplifies the screw's movement while providing stable angle retention.
2Reliability
If surface precision in contact areas of regulating screw and mirror is increased to maintain mounted angle, then angle stability improves, but manufacturing costs increase
Solution Approach 1:
The wedge-shaped intermediate member concentrates the contact area to a specific localized region with a tapered surface. This localized wedge geometry provides the necessary friction and mechanical interlocking to maintain angle stability without requiring high surface precision across the entire contact area between the screw and mirror. The wedge shape creates a self-aligning contact point that tolerates variations in surface finish.
3Measurement precision
If regulating screw protruding length is adjusted continuously, then mounted angle adjustment precision improves, but reassembly difficulty increases due to play
Solution Approach 1:
The wedge-shaped intermediate member serves as a mediator that transforms the continuous linear adjustment of the screw into discrete angular positions of the mirror. The wedge geometry creates natural stopping points where the mirror locks at specific angles, providing precise angular positioning without requiring the screw to maintain continuous contact pressure. This allows the mirror to be removed and reinstalled without readjustment, as it naturally returns to the same angular position.
4Object-affected harmful factors
If optical members are removed for cleaning, then dust-related performance issues improve, but reassembly difficulty increases due to angle readjustment requirements
Solution Approach 1:
The wedge-shaped intermediate member provides a self-aligning mechanism that automatically returns the mirror to its correct angular position upon reinstallation, without requiring manual readjustment. The tapered surface of the wedge creates a unique stable equilibrium position that the mirror naturally assumes when mounted, ensuring consistent angular positioning after cleaning or maintenance operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration ensures precise angle maintenance of optical members, reduces dust-related performance issues, and facilitates easy reassembly by allowing mirrors to be remounted at correct angles without readjustment, thereby improving image quality and user-friendliness.
Implementation Method 1
The optical deflector deflects the first light beam and the second light beam
Implementation Method 2
using photocurable resin spacers to maintain mirror angles
Data Source
AI summary
An optical scanner includes a light source, optical deflector, mirror, first photosensitive drum, and second photosensitive drum. The light source emits a first light beam and a second light beam. The optical deflector deflects the first light beam and the second light beam. The mirror has a reflecting part that reflects the deflected first light beam and a passing part that passes the deflected second light beam. The passing part is displaced from the reflecting part. The first photosensitive drum performs a development with a first toner having a first color. The reflected first light beam scans the first photosensitive drum in a main scanning direction. The second photosensitive drum performs a development with a second toner having a second color different from the first color. The passed second light beam scans the second photosensitive drum in the main scanning direction. The first photosensitive drum and second photosensitive drum are arranged in a sub scanning direction orthogonal to the main scanning direction.