CA2313656C - Flange device with finished surface - Google Patents
Flange device with finished surface Download PDFInfo
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- CA2313656C CA2313656C CA 2313656 CA2313656A CA2313656C CA 2313656 C CA2313656 C CA 2313656C CA 2313656 CA2313656 CA 2313656 CA 2313656 A CA2313656 A CA 2313656A CA 2313656 C CA2313656 C CA 2313656C
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Abstract
An end flange device is capable of translating an externally-supplied rotational or torque drive force to a hollow cylindrical electrophotographic imaging member in a copying or printing machine. The flange device includes a flange support member and flange made from a conductive plastic and preferably from a composition including polycarbonate and carbon fiber. The flange has a specified outer surface finish that insures an optimum frictional relationship between the flange outer diameter and the imaging member inner surface. Mounting the flange device to the imaging member does net require an adhesive material due to an interference fit, nor the use of a separate ground member. since the flange device is conductive.
Matching the coefficients of thermal expansion of the flange and imaging member results in maintaining the interference fit buying the machine operation.
Matching the coefficients of thermal expansion of the flange and imaging member results in maintaining the interference fit buying the machine operation.
Description
Patent Application Attorney Docket No. D/991571 FLANGE DEVICE WITH FINISHED SURFACE
This invention relates in general to a conductive composite flange device for supporting a hollow cylindrical member without the use of an adhesive or additional grounding member.
The xerographic imaging process begins by charging a photoconductive member to a uniform potential, and then exposing a light image of an original document onto the surface of the photoreceptor, either directly or via a digital image driven laser. 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.
Electrostatographic imaging members are well known in the art.
One type of photoreceptor conventionally utilized for copiers and printers comprises a hollow electrically conductive drum substrate which has been dip coated with various coatings including at least one photoconductive coating comprising pigment particles dispersed in a film-forming binder. These photoreceptors are usually supported on an electrically conductive shaft by drum supporting hubs or end flanges. The hubs are usually constructed of plastic material and have a hole through their center into which a supporting axle shaft is inserted. Since hubs are usually constructed of electrically insulating plastic material, an electrical grounding means comprising a flexible spring metal strip is secured to the hub and positioned to contact both the electrically conductive axle shaft and the electrically conductive metal substrate of the photoreceptor drum.
Unfortunately, this metal ground shim is often bent out of alignment when inserted into one end of a photoreceptor drum. Such misalignment can result in the metal strip not contacting the interior of the drum or the axle or both after insertion of the hub into the end of the drum is completed. Further, coatings electrically insulating in the dark that are formed on the surface of the interior of the drum during dip coating can adversely affect electrical grounding of the drum to the electrically conductive drum axle shaft. If inadequate electrical grounding of the drum to the axle shaft is detected after the drum has been inserted into a modular replacement unit in which photoreceptor and various other subsystems such as cleaning and charging units are permanently mounted, repair of the drum is usually impossible without destruction of the module.
Accordingly, a need remains for an apparatus which is capable of supporting hollow cylindrical members without the use of an adhesive, to facilitate recycling.
In one aspect of the invention, a flange device is arranged for forming a conductive interference fit with a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the flange length and diameter being sized so that, when the flange is inserted in the photoreceptor cavity, an interference fit is formed between the flange surface and the photoreceptor inner surface; the flange surface being finished so that sufficient friction exists between the flange surface and the photoreceptor inner surface to enable the flange to rotatably drive the photoreceptor.
In another aspect of the invention, a method of forming a ground circuit between a photoreceptor and an electrostatographic machine, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, comprises the steps of:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange; sizing the flange with respect to the photoreceptor inner diameter; fitting the flange in the photoreceptor cavity, where the flange is sized and shaped with respect to the inner diameter so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine;
where the forming step includes a step of finishing the flange surface so that sufficient friction is established between the flange surface and the inner diameter of the photoreceptor.
In still another aspect of the invention, a flange device and a photoreceptor are combined, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the flange extending in the photoreceptor cavity, the flange length and diameter being sized so that a conductive interference fit is formed between the flange surface and the photoreceptor inner surface; the flange surface being finished so that sufficient friction exists between the photoreceptor inner surface and the flange surface to enable the photoreceptor to be rotatably driven by the flange.
In another aspect of the present invention, there is provided a flange device capable of translating a rotational force from an outside source to a hollow cylindrical member having an inner surface comprising: a flange support member for applying the rotational force; and a flange connected to the flange support member, the flange being made from a conductive plastic and having a length, an inner diameter, and an outer diameter, wherein the outer diameter of the flange is sized with respect to the inner surface of the hollow cylindrical member and the length of the flange is such that an interference fit is formed between the flange and the inner surface of the hollow cylindrical member, the interference fit being maintained in the absence of an adhesive and thereby forming an electrical path between the flange and the hollow cylindrical member.
In another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising: forming a flange device made of conductive plastic, the flange device including a flange support member and a flange; sizing the flange with respect to the inner diameter of the photoreceptor; fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
In another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising: forming a flange device made of conductive plastic the conductive plastic including approximately 82 wt. % polycarbonate, 12 wt. % carbon and 6 wt. % TefIonTM, the flange device including a flange support member and a flange; sizing the flange with respect to the inner diameter of the photoreceptor, fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device;
and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
According to an aspect of the present invention, there is provided a flange device arranged for forming a conductive interference fit with a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange length and diameter being sized so that, when the flange is inserted in the photoreceptor cavity, an interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the flange surface and the photoreceptor inner surface to enable the flange to rotatably drive the photoreceptor.
According to another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor and an electrostatographic machine, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the method comprising the steps of:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
4a sizing the flange with respect to the photoreceptor inner diameter;
fitting the flange in the photoreceptor cavity, where the flange is sized and shaped with respect to the inner diameter so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine;
where the forming step includes a step of finishing the flange surface so that sufficient friction is established between the flange surface and the inner diameter of the photoreceptor.
According to a further aspect of the present invention, there is provided in combination:
a flange device and a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange extending in the photoreceptor cavity, the flange length and diameter being sized so that a conductive interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the photoreceptor inner surface and the flange surface to enable the photoreceptor to be rotatably driven by the flange.
According to another aspect of the present invention, there is provided a flange device capable of translating a rotational force from an outside source to a hollow cylindrical member having an inner surface comprising:
a flange support member for applying the rotational force; and 4b a flange connected to the flange support member, the flange being made from a conductive plastic and having a length, an inner diameter, and an outer diameter, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes; the outer diameter of the flange is sized with respect to the inner surface of the hollow cylindrical member and the length of the flange is such that an interference fit is formed between the flange and the inner surface of the hollow cylindrical member, the interference fit being maintained in the absence of an adhesive and thereby forming an electrical path between the flange and the hollow cylindrical member.
According to a further aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
According to another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising:
forming a flange device made of conductive plastic, the conductive plastic comprising approximately 82 wt.% polycarbonate, 12 wt.%
4c carbon fiber and 6 wt.% PolyTetraFluoroEthylene (PTFE), the flange device including a flange support member and a flange;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
In one embodiment, the conductive plastic includes approximately 82 wt. % polycarbonate, 12 wt. % carbon fiber and 6 wt.
TeflonTM.
FIG. 1 depicts a three dimensional view of a conductive flange device 102 of the present invention as mounted to an electrostatographic photoreceptor 10.
FIG. 2 is a front view of the flange of the present invention.
FIG. 3 is a rear view of the conductive composition flange of the present invention.
FIG. 4 is a side view of the conductive composite flange device 102 of the present invention, the flange device 102 including an outer diameter 106 and a corresponding outer diameter surface 106A.
FIG. 5 is a front view of the flange device 102, including the foregoing outer diameter 106 and the corresponding outer diameter surface 106A.
FIG. 6 is a schematic view of the assembly device for inserting the flange device.
While the present invention may be employed in any suitable device that requires support for a drum, it will be described herein with reference to and more specifically to a conductive composite end flange for 4d supporting hollow cylindrical support members in an electrostatographic imaging system without the use of an adhesive.
Referring now to the drawings, FIG. 1 depicts a schematic, three dimensional view of the conductive photoreceptor flange of the present invention, mounted to an electrostatographic photoreceptor as indicated by 10. Flange 102 is connected to flange support member 104. Flange and flange support member form flange device 110.
4e As shown, photoreceptor 12 comprises a hollow cylindrical member with inner diameter 18 and corresponding inner surface 18A, the photoreceptor 12 enclosing a cavity or hollow 12A. Also, flange 102 has outer diameter 106 with corresponding outer surface 106A. As explained below, the magnitude of flange 102's outer diameter 106 and the physical finish of flange 102's outer surface 106A are selectively arranged so that when flange 102 is inserted substantially inside photoreceptor 12's inner cavity or hollow 12A
sufficiently so that flange 102 is substantially surrounded by photoreceptor 12, photoreceptor 12's inner surface 18A and flange 102's outer surface 106A are caused to sufficiently engage and contact each other, thus forming an interference fit.
Photoreceptor support 22 supports flange device 110.
Photoreceptor support 22 is conductive and completes the electrical ground circuit between photoreceptor 12 and flange device 110 and the xerographic system. Of course photoreceptor support 22 need not pass through the entire length of the photoreceptor, it being well-known to have a shaft on each end of a photoreceptor to separately support each flange device. Photoreceptor support 22 could also take the form of a drive dog, a conductive shoe or a conductive roller which contact flange support 104 to drive photoreceptor 12, rather than a gear as shown and discussed below.
In the embodiment shown, flange support member 104 includes a gear 20 or similar device mounted to an externally-supplied rotational or torque drive force such as an electric motor (not shown) to cause rotation of gear 20 about axis x as indicated by arrow y. Gear 20 is attached to one or both ends 14 and 16 of photoreceptor 12, causing photoreceptor 12 to rotate past corona device 24 for charging of the photoreceptor to a uniform electrostatic potential. A light image of an original document is exposed onto the surface of photoreceptor 12 to form an image on the photoreceptor s surface. A developer material is then brought into contact with the surface of the photoreceptor to transform the latent image into a visible reproduction.
FIGS. 2 and 3 depict front and rear views of conductive photoreceptor flange 102 of the present invention. As shown, flange 102 has an outer diameter 106, and a thickness 108.
Referring to FIGS. 4 and 5 it is seen that flange 102 has a length 112, to assist in providing torsional and axial support for photoreceptor 12.
As mentioned above, flange 102's outer diameter surface 106A is purposely finished in such a manner as to encourage frictional contact and gripping of photoreceptor 12's inner surface 18A, the foregoing surface finishing being specially depicted in FIG. 5 by a series of uneven, bumpy or "wiggley" lines on an upper portion of outer diameter surface 106A.
As shown, flange support 104 has opening 120 formed therethrough for insertion of photoreceptor support 22 in the xerographic machine. As indicated above, photoreceptor 12 rotates about axis x in the y direction, due to the rotation of gear 20. As shown, photoreceptor support 22 is a shaft, however may be any type of well-known supports and may include a dog that attaches directly to flange support 104 and transmits the torsional force. Flange 102 serves to transfer the torsional force applied by the outside source from gear 20 to photoreceptor 12. While flange 102 provides axial as well as torsional support, the primary loads applied to it result from the torque from the outside source. Photoreceptor 12 must often operate under torsional loads of as much as 45 Ibs-in. Thus, flange 102 must be able to withstand loads of this magnitude in order to successfully transfer the required torque from an outside source, such as a motor (not shown), to photoreceptor 12.
It will be appreciated that the magnitudes of length 112, the magnitude of outer diameter 106, and the finish of outer diameter surface 106A must all be considered when flange 102 is being designed. If design constraints unrelated to rotation of photoreceptor 12 (such as the configuration of the cavity of the machine) place limitations on either or both of these dimensions, length 112 can be changed as long as the outer diameter 106's magnitude and the finish of outer diameter surface 106A are altered accordingly.
For example, a longer photoreceptor 12 with a relatively small diameter can be supported by flange 102 as long as flange 102's decrease in outer diameter 106 is accompanied by a proportional increase in length 112, increase in roughness of outer diameter surface 106A, or both. Similarly, a relatively shorter photoreceptor 12 can be supported by flange 102 as long as flange 102's outer diameter 106 magnitude is increased and the roughness of outer diameter surface 106A is increased along with any required decrease in length 112.
Prior to assembly, outer diameter 106 is slightly larger than the inner diameter 18 of photoreceptor 12. Flange 102 must be forced into the inside of photoreceptor 12 such that outer diameter 106 will come in firm contact with the inside surface of photoreceptor 12. This requires photoreceptor 12 to be manufactured such that it will expand slightly in the outward radial direction as flange 102 is inserted into its inside surface.
This also requires flange 102 to be strong enough to withstand the inner radial compression load that will then be exerted upon it, once it has been press fit into the inside of photoreceptor 12 and maintain the interference fit throughout the printer operating temperature range. Preferably, the outer surface of flange 102 is controlled in order to prevent scratching or gouging of the inner surface of photoreceptor 12 and to optimize the friction between the inner surface of photoreceptor 12 and the surface of flange 102.
In one embodiment, flange 102 is formed by a molding process using a composite material which is a combination of plastic and a conductive material compatible with the plastic in an amount sufficient to form an electrical ground path between the photoreceptor 12 and the flange 102.
A required degree of micro-roughness of the flange 102 outer diameter surface 106A is necessary to achieve the necessary friction to maintain the interference fit between the flange 102 and the photoreceptor 12.
A degree of surface roughness of at least Society of the Plastics Industry-Society of Plastics Engineers ("SPI-SPE") level 4 is required, corresponding to surface variations of 0.4 to 0.48 micrometers in magnitude. This degree of roughness is only a minimum. Some applications may require even higher degrees of roughness, such as SPI-SPE levels 5 and 6.
The desired degree of roughness of outer diameter surface 106A
of flange 102 may be achieved in a number of ways, including without limitation the following.
In a first, pre-molding process embodiment, before forming flange 102 by the molding process, corresponding variations are created in the inner surface of the mold which is later used to form flange 102. These variations in the mold surface can be formed by any convenient means, such as machining, treating with abrasives, or the like. Once the desired surface variations are created in the mold, the mold is then used in the molding process to form the flange 102. As a result, the molded flange 102 contains the desired level of variations in its surface 106A.
In a second, molding process embodiment, while forming flange 102 by the molding process, one or more parameters in the plastic molding process itself such as, for example, mold temperature, mold pressure and mold flow, are adjusted as needed to form the required variations in texture of flange 102 surface 106A.
In a third, post-molding process embodiment, after forming flange 102 by the molding process, a secondary post-molding process is used to create the desired surface finish variations directly in the post-molded flange 102 surface 106A. These variations in flange 102 surface 106A can be g created by any convenient means, such as machining, treating with abrasives, or the like.
The plastic must have a high mechanical strength and high softening temperature. This combination of component materials provides strength, dimensional stability and friction coefficient to withstand the torsional force that is applied to the photoreceptor/flange mating surface during the printing operation and to the inner compression load that is applied to the flange during and after assembly.
The coefficients of thermal expansion of the photoreceptor drum and the flange need to be matched so that the interference fit is maintained independent of the temperature. The coefficient . of thermal expansion depends upon the type of material used and the dimensions of the material affect the amount of thermal expansion. Matching the coefficients of thermal expansion of the flange 102 and photoreceptor 12 is critical in electrophotographic systems where the temperature can range between 40 to 150 degrees Fahrenheit. Of course, the coefficients of thermal expansion will change with the type of material used, however it is possible to match the thermal coefficients of thermal expansion for differing flange and photoreceptor materials.
Minimizing the mass of the flange while providing for the necessary surface area contact between the flange 102 and photoreceptor 12 inner diameter 18 allows for optimum heat transfer. It is desired that flange thickness 108 be as thin as possible, however flange thickness must be adequate to support the torque it must withstand during insertion and machine operation..
In one embodiment, flange 102 is made from 82 wt.
polycarbonate, 12 wt. % carbon fiber, and 6 wt. % PolyTetraFluoroEthylene (PTFE), referred to as M2386 and which is supplied by DSM Engineering Plastics, Evansville, Indiana. The M2386 product provides good thermal loading characteristics but other combinations of these elements may be used, and the invention is not limited to this embodiment. In a preferred embodiment, the thermal coefficient of expansion for a photoreceptor made of aluminum is approximately 13.6 millionths of an inch per inch per degree Fahrenheit, while for the flange made of M2386 the thermal coefficient of expansion is approximately 15 millionths of an inch per inch per degree Fahrenheit. Those skilled in the art will also recognize that it is even possible to practice the invention by substituting similar or equivalent material for those listed. For example, the plastic may be any polymer plastic which can be mixed with carbon fiber or metal flakes to create a conductive polymer mix. Various other non-stick materials which may be substituted for PTFE are FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), Ethylene ChIoroTrifluoroEthylene (ECTFE), PerFIuoroAlkoxy resin (PFA), Ethylene TetraFluoroEthylene (ETFE), PolyChIoroTrifIuorEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
Flange device 110 may be formed by any well-known fabrication processes such as injection molding, machining or reaction injection molding.
Preferably, flange 102 and flange support 104 are integrally formed, however they may be fabricated separately from the same or different materials and then joined together to form flange device 110.
In one embodiment, flange length 112 is 7.5 mm, flange thickness 108 is 3.54 mm, flange inner diameter is 28.5 mm, flange outer diameter is 35.4 mm, flange outer diameter surface finish has a roughness between 0.3 and 1.2 micrometers, photoreceptor inner diameter is 28.5 mm and photoreceptor outer diameter is 30.0 mm, with the thickness of photoreceptor being .75 mm.
Turning now to FIG. 6, where an assembling apparatus 200 for assembling flange device 110 to photoreceptor 12 is shown. There is a need to assure that after flange device 110 is assembled to photoreceptor 12 that the interference fit formed therebetween will meet the torque and proper assembly requirements between the photoreceptor 12 and flange 102.
Photoreceptor 12 is supported by V-block 210 and stop block 212, which hold the photoreceptor in place during insertion of flange 102. Stop block is fixed in place. Assembling apparatus 200 uses a displacement sensor 220 to monitor the assembly stroke or the distance d flange 102 is inserted and a force sensor 230 to measure assembly force F. Threshold values of the displacement and assembly force are set for each device and detected by assembly indicator 240. A force and/or displacement value above or below the threshold value will trigger a signal which alerts an operator to improper assembly of the flange device 110 with photoreceptor 12.
As set forth above, with correct material, diameter and thickness choices for flange 102 and photoreceptor 12, and flange length 112 for flange 102 an interference fit can be formed to withstand the torsional forces to which the flange and photoreceptor are subjected during machine operation. The amount of torque the interference fit can withstand is directly related to the tightness of the interference fit. There are problems if the interference fit is too low or too high.
One aspect of the interference fit depends upon the size of the outer diameter 106 of flange 102 with respect to the inner diameter 18 of photoreceptor 12. Where the flange outer diameter is about the same as the photoreceptor inner diameter, a relatively low insertion force is required, which results in a relatively low interference fit. There is a minimum interference fit that will support the torque requirements of the operating flange and photoreceptor.
To withstand the operating torque requirements, outer diameter 106 of flange 102 must be larger than inner diameter 18 of photoreceptor 12.
As the outer diameter of flange 102 increases in size with respect to the inner diameter of photoreceptor 12, the interference fit increases and thus the n torque the assembled flange and photoreceptor can withstand increases.
However, there is a point where the interference fit becomes too high. This occurs when the inserted flange causes the photoreceptor end 14 to bulge excessively at its end due to the fact that the flange outer diameter 106 is sized too large with respect to the photoreceptor inner diameter 18. In the case of photoreceptors, the maximum interference fit occurs when the inserted flange diameter begins to affect the total indicated runout (TIR) of the photoreceptor. It is important to keep the TIR below specified parameters in order to insure the proper operation of the photoreceptor. See the above preferred embodiment for an example of sizing the flange with respect to the photoreceptor.
Another aspect of the interference fit depends upon the distance flange 102 is inserted into photoreceptor 12. The further the flange is inserted into the photoreceptor, the greater the surface contact area. It is important that distance d is the same as flange length 112 to assure proper seating and alignment of flange 102 into photoreceptor 12.
A third aspect of the interference fit is the surface finish of the flange outer diameter surface 106A. A roughness similar to that cited in the above embodiment is necessary to assure proper coefficient of friction between the flange outer diameter surface 106A and the hollow cylindrical member inner surface 18A.
To insure that the proper interference fit is achieved between flange 102 and photoreceptor 12 assembly apparatus 200 is used. Flange 102 of flange device 110 is initially placed in photoreceptor end 14 as shown in FIG. 6 by any known placement method such as manually or robotically.
Assembly force F is then applied to the end of flange device 110 as shown, which pushes flange 102 a distance d. The desired assembly force F has been previously determined based on the size of the outer diameter 106 of flange 102 and the size of the inner diameter of the photoreceptor so that a good i2 interference fit is obtained. The desired insertion distance d has also been designed based on the flange outer diameter and photoreceptor inner diameter to insure the desired interference forces. The optimum size of the outer diameter of the flange with respect to the inner diameter of the photoreceptor and distance d are specified to achieve an interference fit that can withstand up to 45 Ibs-inch torque during operating conditions.
During the flange insertion, distance d is measured by displacement detector 220 such as a linear variable differential transformer (LVDT) and assembly force F is measured by force sensor 230 such as a load cell. Force sensor is rigidly attached to stop block 212. In the preferred embodiment described above, the assembly force is approximately 60 Ibs-in.
All force exerted axially on the photoreceptor is measured by force sensor 230. This information is then communicated to assembly indicator 240 which uses the measured assembly force F and the measured distance d to insure that the correct force has been applied over the correct distance. If both the measured assembly force F and measured distance d meet the previously determined desired measurements, then the interference fit will withstand the operating torque requirements. If either of these parameters is not met during the flange assembly process, then the assembly is deemed to have been improper. The defective interference fit information is indicated by assembly indicator 240. The assembly apparatus provides for very valuable quality control that measures the interference fit during, rather than after, the assembly process.
Flange 102 may be inserted in the photoreceptor ends one at a time or two at the same time. If two flange devices are inserted at the same time, then additional care must be taken to insure that the photoreceptor is sufficiently held in place by V-block 210 in order to withstand the forces applied at both ends. Also, when two flange devices are inserted at the same time or the photoreceptor is held in place, another component of the assembly device at the other end is necessary to measure the assembly force and distance d.
The present invention has significant advantages over prior methods and apparatus for supporting hollow cylindrical members without using an adhesive or additional grounding members. First, the present invention maintains excellent electrical grounding of an electrostatographic substrate solely by the conductive composite flange device.
Also, the present invention quickly achieves excellent anchoring of the flange device to a hollow cylindrical member, while also facilitating recycling of the flange device and hollow cylindrical member. This is possible because the flange device does not score, scratch, or dig into the inner surface of the hollow cylindrical member.
A further advantage of the present invention is improved ease with which intentional separation of the flange 102 and photoreceptor 12 can be achieved for purposes of re-use or re-cycling. This advantage is achieved based on the fact that no adhesive is used to fit the flange 102 to the photoreceptor 12.
While various embodiments of a flange device with finished surface, in accordance with the present invention, have been described hereinabove, the scope of the invention is defined by the following claims.
This invention relates in general to a conductive composite flange device for supporting a hollow cylindrical member without the use of an adhesive or additional grounding member.
The xerographic imaging process begins by charging a photoconductive member to a uniform potential, and then exposing a light image of an original document onto the surface of the photoreceptor, either directly or via a digital image driven laser. 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.
Electrostatographic imaging members are well known in the art.
One type of photoreceptor conventionally utilized for copiers and printers comprises a hollow electrically conductive drum substrate which has been dip coated with various coatings including at least one photoconductive coating comprising pigment particles dispersed in a film-forming binder. These photoreceptors are usually supported on an electrically conductive shaft by drum supporting hubs or end flanges. The hubs are usually constructed of plastic material and have a hole through their center into which a supporting axle shaft is inserted. Since hubs are usually constructed of electrically insulating plastic material, an electrical grounding means comprising a flexible spring metal strip is secured to the hub and positioned to contact both the electrically conductive axle shaft and the electrically conductive metal substrate of the photoreceptor drum.
Unfortunately, this metal ground shim is often bent out of alignment when inserted into one end of a photoreceptor drum. Such misalignment can result in the metal strip not contacting the interior of the drum or the axle or both after insertion of the hub into the end of the drum is completed. Further, coatings electrically insulating in the dark that are formed on the surface of the interior of the drum during dip coating can adversely affect electrical grounding of the drum to the electrically conductive drum axle shaft. If inadequate electrical grounding of the drum to the axle shaft is detected after the drum has been inserted into a modular replacement unit in which photoreceptor and various other subsystems such as cleaning and charging units are permanently mounted, repair of the drum is usually impossible without destruction of the module.
Accordingly, a need remains for an apparatus which is capable of supporting hollow cylindrical members without the use of an adhesive, to facilitate recycling.
In one aspect of the invention, a flange device is arranged for forming a conductive interference fit with a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the flange length and diameter being sized so that, when the flange is inserted in the photoreceptor cavity, an interference fit is formed between the flange surface and the photoreceptor inner surface; the flange surface being finished so that sufficient friction exists between the flange surface and the photoreceptor inner surface to enable the flange to rotatably drive the photoreceptor.
In another aspect of the invention, a method of forming a ground circuit between a photoreceptor and an electrostatographic machine, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, comprises the steps of:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange; sizing the flange with respect to the photoreceptor inner diameter; fitting the flange in the photoreceptor cavity, where the flange is sized and shaped with respect to the inner diameter so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine;
where the forming step includes a step of finishing the flange surface so that sufficient friction is established between the flange surface and the inner diameter of the photoreceptor.
In still another aspect of the invention, a flange device and a photoreceptor are combined, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the flange extending in the photoreceptor cavity, the flange length and diameter being sized so that a conductive interference fit is formed between the flange surface and the photoreceptor inner surface; the flange surface being finished so that sufficient friction exists between the photoreceptor inner surface and the flange surface to enable the photoreceptor to be rotatably driven by the flange.
In another aspect of the present invention, there is provided a flange device capable of translating a rotational force from an outside source to a hollow cylindrical member having an inner surface comprising: a flange support member for applying the rotational force; and a flange connected to the flange support member, the flange being made from a conductive plastic and having a length, an inner diameter, and an outer diameter, wherein the outer diameter of the flange is sized with respect to the inner surface of the hollow cylindrical member and the length of the flange is such that an interference fit is formed between the flange and the inner surface of the hollow cylindrical member, the interference fit being maintained in the absence of an adhesive and thereby forming an electrical path between the flange and the hollow cylindrical member.
In another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising: forming a flange device made of conductive plastic, the flange device including a flange support member and a flange; sizing the flange with respect to the inner diameter of the photoreceptor; fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
In another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising: forming a flange device made of conductive plastic the conductive plastic including approximately 82 wt. % polycarbonate, 12 wt. % carbon and 6 wt. % TefIonTM, the flange device including a flange support member and a flange; sizing the flange with respect to the inner diameter of the photoreceptor, fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device;
and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
According to an aspect of the present invention, there is provided a flange device arranged for forming a conductive interference fit with a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange length and diameter being sized so that, when the flange is inserted in the photoreceptor cavity, an interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the flange surface and the photoreceptor inner surface to enable the flange to rotatably drive the photoreceptor.
According to another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor and an electrostatographic machine, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the method comprising the steps of:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
4a sizing the flange with respect to the photoreceptor inner diameter;
fitting the flange in the photoreceptor cavity, where the flange is sized and shaped with respect to the inner diameter so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine;
where the forming step includes a step of finishing the flange surface so that sufficient friction is established between the flange surface and the inner diameter of the photoreceptor.
According to a further aspect of the present invention, there is provided in combination:
a flange device and a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange extending in the photoreceptor cavity, the flange length and diameter being sized so that a conductive interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the photoreceptor inner surface and the flange surface to enable the photoreceptor to be rotatably driven by the flange.
According to another aspect of the present invention, there is provided a flange device capable of translating a rotational force from an outside source to a hollow cylindrical member having an inner surface comprising:
a flange support member for applying the rotational force; and 4b a flange connected to the flange support member, the flange being made from a conductive plastic and having a length, an inner diameter, and an outer diameter, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes; the outer diameter of the flange is sized with respect to the inner surface of the hollow cylindrical member and the length of the flange is such that an interference fit is formed between the flange and the inner surface of the hollow cylindrical member, the interference fit being maintained in the absence of an adhesive and thereby forming an electrical path between the flange and the hollow cylindrical member.
According to a further aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
According to another aspect of the present invention, there is provided a method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising:
forming a flange device made of conductive plastic, the conductive plastic comprising approximately 82 wt.% polycarbonate, 12 wt.%
4c carbon fiber and 6 wt.% PolyTetraFluoroEthylene (PTFE), the flange device including a flange support member and a flange;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
In one embodiment, the conductive plastic includes approximately 82 wt. % polycarbonate, 12 wt. % carbon fiber and 6 wt.
TeflonTM.
FIG. 1 depicts a three dimensional view of a conductive flange device 102 of the present invention as mounted to an electrostatographic photoreceptor 10.
FIG. 2 is a front view of the flange of the present invention.
FIG. 3 is a rear view of the conductive composition flange of the present invention.
FIG. 4 is a side view of the conductive composite flange device 102 of the present invention, the flange device 102 including an outer diameter 106 and a corresponding outer diameter surface 106A.
FIG. 5 is a front view of the flange device 102, including the foregoing outer diameter 106 and the corresponding outer diameter surface 106A.
FIG. 6 is a schematic view of the assembly device for inserting the flange device.
While the present invention may be employed in any suitable device that requires support for a drum, it will be described herein with reference to and more specifically to a conductive composite end flange for 4d supporting hollow cylindrical support members in an electrostatographic imaging system without the use of an adhesive.
Referring now to the drawings, FIG. 1 depicts a schematic, three dimensional view of the conductive photoreceptor flange of the present invention, mounted to an electrostatographic photoreceptor as indicated by 10. Flange 102 is connected to flange support member 104. Flange and flange support member form flange device 110.
4e As shown, photoreceptor 12 comprises a hollow cylindrical member with inner diameter 18 and corresponding inner surface 18A, the photoreceptor 12 enclosing a cavity or hollow 12A. Also, flange 102 has outer diameter 106 with corresponding outer surface 106A. As explained below, the magnitude of flange 102's outer diameter 106 and the physical finish of flange 102's outer surface 106A are selectively arranged so that when flange 102 is inserted substantially inside photoreceptor 12's inner cavity or hollow 12A
sufficiently so that flange 102 is substantially surrounded by photoreceptor 12, photoreceptor 12's inner surface 18A and flange 102's outer surface 106A are caused to sufficiently engage and contact each other, thus forming an interference fit.
Photoreceptor support 22 supports flange device 110.
Photoreceptor support 22 is conductive and completes the electrical ground circuit between photoreceptor 12 and flange device 110 and the xerographic system. Of course photoreceptor support 22 need not pass through the entire length of the photoreceptor, it being well-known to have a shaft on each end of a photoreceptor to separately support each flange device. Photoreceptor support 22 could also take the form of a drive dog, a conductive shoe or a conductive roller which contact flange support 104 to drive photoreceptor 12, rather than a gear as shown and discussed below.
In the embodiment shown, flange support member 104 includes a gear 20 or similar device mounted to an externally-supplied rotational or torque drive force such as an electric motor (not shown) to cause rotation of gear 20 about axis x as indicated by arrow y. Gear 20 is attached to one or both ends 14 and 16 of photoreceptor 12, causing photoreceptor 12 to rotate past corona device 24 for charging of the photoreceptor to a uniform electrostatic potential. A light image of an original document is exposed onto the surface of photoreceptor 12 to form an image on the photoreceptor s surface. A developer material is then brought into contact with the surface of the photoreceptor to transform the latent image into a visible reproduction.
FIGS. 2 and 3 depict front and rear views of conductive photoreceptor flange 102 of the present invention. As shown, flange 102 has an outer diameter 106, and a thickness 108.
Referring to FIGS. 4 and 5 it is seen that flange 102 has a length 112, to assist in providing torsional and axial support for photoreceptor 12.
As mentioned above, flange 102's outer diameter surface 106A is purposely finished in such a manner as to encourage frictional contact and gripping of photoreceptor 12's inner surface 18A, the foregoing surface finishing being specially depicted in FIG. 5 by a series of uneven, bumpy or "wiggley" lines on an upper portion of outer diameter surface 106A.
As shown, flange support 104 has opening 120 formed therethrough for insertion of photoreceptor support 22 in the xerographic machine. As indicated above, photoreceptor 12 rotates about axis x in the y direction, due to the rotation of gear 20. As shown, photoreceptor support 22 is a shaft, however may be any type of well-known supports and may include a dog that attaches directly to flange support 104 and transmits the torsional force. Flange 102 serves to transfer the torsional force applied by the outside source from gear 20 to photoreceptor 12. While flange 102 provides axial as well as torsional support, the primary loads applied to it result from the torque from the outside source. Photoreceptor 12 must often operate under torsional loads of as much as 45 Ibs-in. Thus, flange 102 must be able to withstand loads of this magnitude in order to successfully transfer the required torque from an outside source, such as a motor (not shown), to photoreceptor 12.
It will be appreciated that the magnitudes of length 112, the magnitude of outer diameter 106, and the finish of outer diameter surface 106A must all be considered when flange 102 is being designed. If design constraints unrelated to rotation of photoreceptor 12 (such as the configuration of the cavity of the machine) place limitations on either or both of these dimensions, length 112 can be changed as long as the outer diameter 106's magnitude and the finish of outer diameter surface 106A are altered accordingly.
For example, a longer photoreceptor 12 with a relatively small diameter can be supported by flange 102 as long as flange 102's decrease in outer diameter 106 is accompanied by a proportional increase in length 112, increase in roughness of outer diameter surface 106A, or both. Similarly, a relatively shorter photoreceptor 12 can be supported by flange 102 as long as flange 102's outer diameter 106 magnitude is increased and the roughness of outer diameter surface 106A is increased along with any required decrease in length 112.
Prior to assembly, outer diameter 106 is slightly larger than the inner diameter 18 of photoreceptor 12. Flange 102 must be forced into the inside of photoreceptor 12 such that outer diameter 106 will come in firm contact with the inside surface of photoreceptor 12. This requires photoreceptor 12 to be manufactured such that it will expand slightly in the outward radial direction as flange 102 is inserted into its inside surface.
This also requires flange 102 to be strong enough to withstand the inner radial compression load that will then be exerted upon it, once it has been press fit into the inside of photoreceptor 12 and maintain the interference fit throughout the printer operating temperature range. Preferably, the outer surface of flange 102 is controlled in order to prevent scratching or gouging of the inner surface of photoreceptor 12 and to optimize the friction between the inner surface of photoreceptor 12 and the surface of flange 102.
In one embodiment, flange 102 is formed by a molding process using a composite material which is a combination of plastic and a conductive material compatible with the plastic in an amount sufficient to form an electrical ground path between the photoreceptor 12 and the flange 102.
A required degree of micro-roughness of the flange 102 outer diameter surface 106A is necessary to achieve the necessary friction to maintain the interference fit between the flange 102 and the photoreceptor 12.
A degree of surface roughness of at least Society of the Plastics Industry-Society of Plastics Engineers ("SPI-SPE") level 4 is required, corresponding to surface variations of 0.4 to 0.48 micrometers in magnitude. This degree of roughness is only a minimum. Some applications may require even higher degrees of roughness, such as SPI-SPE levels 5 and 6.
The desired degree of roughness of outer diameter surface 106A
of flange 102 may be achieved in a number of ways, including without limitation the following.
In a first, pre-molding process embodiment, before forming flange 102 by the molding process, corresponding variations are created in the inner surface of the mold which is later used to form flange 102. These variations in the mold surface can be formed by any convenient means, such as machining, treating with abrasives, or the like. Once the desired surface variations are created in the mold, the mold is then used in the molding process to form the flange 102. As a result, the molded flange 102 contains the desired level of variations in its surface 106A.
In a second, molding process embodiment, while forming flange 102 by the molding process, one or more parameters in the plastic molding process itself such as, for example, mold temperature, mold pressure and mold flow, are adjusted as needed to form the required variations in texture of flange 102 surface 106A.
In a third, post-molding process embodiment, after forming flange 102 by the molding process, a secondary post-molding process is used to create the desired surface finish variations directly in the post-molded flange 102 surface 106A. These variations in flange 102 surface 106A can be g created by any convenient means, such as machining, treating with abrasives, or the like.
The plastic must have a high mechanical strength and high softening temperature. This combination of component materials provides strength, dimensional stability and friction coefficient to withstand the torsional force that is applied to the photoreceptor/flange mating surface during the printing operation and to the inner compression load that is applied to the flange during and after assembly.
The coefficients of thermal expansion of the photoreceptor drum and the flange need to be matched so that the interference fit is maintained independent of the temperature. The coefficient . of thermal expansion depends upon the type of material used and the dimensions of the material affect the amount of thermal expansion. Matching the coefficients of thermal expansion of the flange 102 and photoreceptor 12 is critical in electrophotographic systems where the temperature can range between 40 to 150 degrees Fahrenheit. Of course, the coefficients of thermal expansion will change with the type of material used, however it is possible to match the thermal coefficients of thermal expansion for differing flange and photoreceptor materials.
Minimizing the mass of the flange while providing for the necessary surface area contact between the flange 102 and photoreceptor 12 inner diameter 18 allows for optimum heat transfer. It is desired that flange thickness 108 be as thin as possible, however flange thickness must be adequate to support the torque it must withstand during insertion and machine operation..
In one embodiment, flange 102 is made from 82 wt.
polycarbonate, 12 wt. % carbon fiber, and 6 wt. % PolyTetraFluoroEthylene (PTFE), referred to as M2386 and which is supplied by DSM Engineering Plastics, Evansville, Indiana. The M2386 product provides good thermal loading characteristics but other combinations of these elements may be used, and the invention is not limited to this embodiment. In a preferred embodiment, the thermal coefficient of expansion for a photoreceptor made of aluminum is approximately 13.6 millionths of an inch per inch per degree Fahrenheit, while for the flange made of M2386 the thermal coefficient of expansion is approximately 15 millionths of an inch per inch per degree Fahrenheit. Those skilled in the art will also recognize that it is even possible to practice the invention by substituting similar or equivalent material for those listed. For example, the plastic may be any polymer plastic which can be mixed with carbon fiber or metal flakes to create a conductive polymer mix. Various other non-stick materials which may be substituted for PTFE are FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), Ethylene ChIoroTrifluoroEthylene (ECTFE), PerFIuoroAlkoxy resin (PFA), Ethylene TetraFluoroEthylene (ETFE), PolyChIoroTrifIuorEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
Flange device 110 may be formed by any well-known fabrication processes such as injection molding, machining or reaction injection molding.
Preferably, flange 102 and flange support 104 are integrally formed, however they may be fabricated separately from the same or different materials and then joined together to form flange device 110.
In one embodiment, flange length 112 is 7.5 mm, flange thickness 108 is 3.54 mm, flange inner diameter is 28.5 mm, flange outer diameter is 35.4 mm, flange outer diameter surface finish has a roughness between 0.3 and 1.2 micrometers, photoreceptor inner diameter is 28.5 mm and photoreceptor outer diameter is 30.0 mm, with the thickness of photoreceptor being .75 mm.
Turning now to FIG. 6, where an assembling apparatus 200 for assembling flange device 110 to photoreceptor 12 is shown. There is a need to assure that after flange device 110 is assembled to photoreceptor 12 that the interference fit formed therebetween will meet the torque and proper assembly requirements between the photoreceptor 12 and flange 102.
Photoreceptor 12 is supported by V-block 210 and stop block 212, which hold the photoreceptor in place during insertion of flange 102. Stop block is fixed in place. Assembling apparatus 200 uses a displacement sensor 220 to monitor the assembly stroke or the distance d flange 102 is inserted and a force sensor 230 to measure assembly force F. Threshold values of the displacement and assembly force are set for each device and detected by assembly indicator 240. A force and/or displacement value above or below the threshold value will trigger a signal which alerts an operator to improper assembly of the flange device 110 with photoreceptor 12.
As set forth above, with correct material, diameter and thickness choices for flange 102 and photoreceptor 12, and flange length 112 for flange 102 an interference fit can be formed to withstand the torsional forces to which the flange and photoreceptor are subjected during machine operation. The amount of torque the interference fit can withstand is directly related to the tightness of the interference fit. There are problems if the interference fit is too low or too high.
One aspect of the interference fit depends upon the size of the outer diameter 106 of flange 102 with respect to the inner diameter 18 of photoreceptor 12. Where the flange outer diameter is about the same as the photoreceptor inner diameter, a relatively low insertion force is required, which results in a relatively low interference fit. There is a minimum interference fit that will support the torque requirements of the operating flange and photoreceptor.
To withstand the operating torque requirements, outer diameter 106 of flange 102 must be larger than inner diameter 18 of photoreceptor 12.
As the outer diameter of flange 102 increases in size with respect to the inner diameter of photoreceptor 12, the interference fit increases and thus the n torque the assembled flange and photoreceptor can withstand increases.
However, there is a point where the interference fit becomes too high. This occurs when the inserted flange causes the photoreceptor end 14 to bulge excessively at its end due to the fact that the flange outer diameter 106 is sized too large with respect to the photoreceptor inner diameter 18. In the case of photoreceptors, the maximum interference fit occurs when the inserted flange diameter begins to affect the total indicated runout (TIR) of the photoreceptor. It is important to keep the TIR below specified parameters in order to insure the proper operation of the photoreceptor. See the above preferred embodiment for an example of sizing the flange with respect to the photoreceptor.
Another aspect of the interference fit depends upon the distance flange 102 is inserted into photoreceptor 12. The further the flange is inserted into the photoreceptor, the greater the surface contact area. It is important that distance d is the same as flange length 112 to assure proper seating and alignment of flange 102 into photoreceptor 12.
A third aspect of the interference fit is the surface finish of the flange outer diameter surface 106A. A roughness similar to that cited in the above embodiment is necessary to assure proper coefficient of friction between the flange outer diameter surface 106A and the hollow cylindrical member inner surface 18A.
To insure that the proper interference fit is achieved between flange 102 and photoreceptor 12 assembly apparatus 200 is used. Flange 102 of flange device 110 is initially placed in photoreceptor end 14 as shown in FIG. 6 by any known placement method such as manually or robotically.
Assembly force F is then applied to the end of flange device 110 as shown, which pushes flange 102 a distance d. The desired assembly force F has been previously determined based on the size of the outer diameter 106 of flange 102 and the size of the inner diameter of the photoreceptor so that a good i2 interference fit is obtained. The desired insertion distance d has also been designed based on the flange outer diameter and photoreceptor inner diameter to insure the desired interference forces. The optimum size of the outer diameter of the flange with respect to the inner diameter of the photoreceptor and distance d are specified to achieve an interference fit that can withstand up to 45 Ibs-inch torque during operating conditions.
During the flange insertion, distance d is measured by displacement detector 220 such as a linear variable differential transformer (LVDT) and assembly force F is measured by force sensor 230 such as a load cell. Force sensor is rigidly attached to stop block 212. In the preferred embodiment described above, the assembly force is approximately 60 Ibs-in.
All force exerted axially on the photoreceptor is measured by force sensor 230. This information is then communicated to assembly indicator 240 which uses the measured assembly force F and the measured distance d to insure that the correct force has been applied over the correct distance. If both the measured assembly force F and measured distance d meet the previously determined desired measurements, then the interference fit will withstand the operating torque requirements. If either of these parameters is not met during the flange assembly process, then the assembly is deemed to have been improper. The defective interference fit information is indicated by assembly indicator 240. The assembly apparatus provides for very valuable quality control that measures the interference fit during, rather than after, the assembly process.
Flange 102 may be inserted in the photoreceptor ends one at a time or two at the same time. If two flange devices are inserted at the same time, then additional care must be taken to insure that the photoreceptor is sufficiently held in place by V-block 210 in order to withstand the forces applied at both ends. Also, when two flange devices are inserted at the same time or the photoreceptor is held in place, another component of the assembly device at the other end is necessary to measure the assembly force and distance d.
The present invention has significant advantages over prior methods and apparatus for supporting hollow cylindrical members without using an adhesive or additional grounding members. First, the present invention maintains excellent electrical grounding of an electrostatographic substrate solely by the conductive composite flange device.
Also, the present invention quickly achieves excellent anchoring of the flange device to a hollow cylindrical member, while also facilitating recycling of the flange device and hollow cylindrical member. This is possible because the flange device does not score, scratch, or dig into the inner surface of the hollow cylindrical member.
A further advantage of the present invention is improved ease with which intentional separation of the flange 102 and photoreceptor 12 can be achieved for purposes of re-use or re-cycling. This advantage is achieved based on the fact that no adhesive is used to fit the flange 102 to the photoreceptor 12.
While various embodiments of a flange device with finished surface, in accordance with the present invention, have been described hereinabove, the scope of the invention is defined by the following claims.
Claims (58)
1. A flange device arranged for forming a conductive interference fit with a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange length and diameter being sized so that, when the flange is inserted in the photoreceptor cavity, an interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the flange surface and the photoreceptor inner surface to enable the flange to rotatably drive the photoreceptor.
the flange surface being finished so that sufficient friction exists between the flange surface and the photoreceptor inner surface to enable the flange to rotatably drive the photoreceptor.
2. The flange device of claim 1, the interference fit being devoid of adhesive.
3. The flange device of claim 1 or 2, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and carbon fiber.
4. The flange device of any one of claims 1 to 3, wherein the non-stick material is selected from the group consisting of PolyTetraFluoroEthylene (PTFE), FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), EthyleneChloroTriFluoroEthylene (ECTFE), PerFluoroAlkoxy resin (PFA), EthyleneTetraFluoroEthylene (ETFE), PolyChloroTriFluoroEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
5. The flange device of any one of claims 1 to 4, wherein the polymer plastic is polycarbonate.
6. The flange device of any one of claims 1 to 5, wherein the non-stick material is PolyTetraFluoroEthylene (PTFE).
7. The flange device of claim 1, wherein the conductive plastic comprises polycarbonate, PolyTetraFluoroEthylene (PTFE), and carbon fiber.
8. The flange device of claim 1, wherein the conductive plastic comprises approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.%
PolyTetraFluoroEthylene (PTFE).
PolyTetraFluoroEthylene (PTFE).
9. The flange device of any one of claims 1 to 8, including an integrally-formed flange support member coupled to the flange.
10. The flange device of claim 9 wherein the flange support member is made of conductive plastic.
11. The flange device of claim 9, further comprising a photoreceptor support attached to the flange support member.
12. The flange device of claim 11, wherein the flange, flange support member and photoreceptor support are integrally formed of conductive plastic.
13. A method of forming a ground circuit between a photoreceptor and an electrostatographic machine, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the method comprising the steps of:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
sizing the flange with respect to the photoreceptor inner diameter;
fitting the flange in the photoreceptor cavity, where the flange is sized and shaped with respect to the inner diameter so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine;
where the forming step includes a step of finishing the flange surface so that sufficient friction is established between the flange surface and the inner diameter of the photoreceptor.
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
sizing the flange with respect to the photoreceptor inner diameter;
fitting the flange in the photoreceptor cavity, where the flange is sized and shaped with respect to the inner diameter so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine;
where the forming step includes a step of finishing the flange surface so that sufficient friction is established between the flange surface and the inner diameter of the photoreceptor.
14. The method of claim 13, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and carbon fiber.
15. The method of claim 13 or 14, wherein the non-stick material is selected from the group consisting of PolyTetraFluoroEthylene (PTFE), FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), EthyleneChloroTriFluoroEthylene (ECTFE), PerFIuoroAlkoxy resin (PFA), EthyleneTetraFluoroEthylene (ETFE), PolyChloroTriFluoroEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
16. The method of any one of claims 13 to 15, wherein the polymer plastic is polycarbonate.
17. The method of any one of claims 13 to 16, wherein the non-stick material is PolyTetraFluoroEthylene (PTFE).
18. The method of claim 13, wherein the conductive plastic comprises polycarbonate, PolyTetraFluoroEthylene (PTFE), and carbon fiber.
19. The method of claim 13, wherein the conductive plastic comprises approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.%
PolyTetraFluoroEthylene (PTFE).
PolyTetraFluoroEthylene (PTFE).
20. The method of any one of claims 13 to 19, the flange formed by a molding process using a mold such that the flange surface is finished based on variations in the mold surface.
21. The method of any one of claims 13 to 19, the flange being formed by a molding process such that the flange surface is finished based on parameters of the molding process.
22. The method of any one of claims 13 to 19, the flange surface being finished by machining or by treating with abrasives.
23. The method of any one of claims 13 to 19, wherein the coefficients of thermal expansion of the flange and photoreceptor are matched so that the interference fit is maintained during the operation of the electrostatographic machine.
24. In combination:
a flange device and a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange extending in the photoreceptor cavity, the flange length and diameter being sized so that a conductive interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the photoreceptor inner surface and the flange surface to enable the photoreceptor to be rotatably driven by the flange.
a flange device and a photoreceptor, the photoreceptor comprising a hollow cylindrical member having an inner diameter, an inner surface and enclosing a cavity, the flange device comprising a flange, the flange comprising a conductive plastic and having a length, a diameter and a surface, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes, the flange extending in the photoreceptor cavity, the flange length and diameter being sized so that a conductive interference fit is formed between the flange surface and the photoreceptor inner surface;
the flange surface being finished so that sufficient friction exists between the photoreceptor inner surface and the flange surface to enable the photoreceptor to be rotatably driven by the flange.
25. The combination of claim 24, the interference fit being devoid of adhesive.
26. The combination of claim 24 or 25, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and carbon fiber.
27. The combination of any one of claims 24 to 26, wherein the non-stick material is selected from the group consisting of PolyTetraFluoroEthylene (PTFE), FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), EthyleneChloroTriFluoroEthylene (ECTFE), PerFluoroAlkoxy resin (PFA), EthyfeneTetraFluoroEthylene (ETFE), PolyChloroTriFluoroEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
28. The combination of any one of claims 24 to 27, wherein the polymer plastic is polycarbonate.
29. The combination of any one of claims 24 to 28, wherein the non-stick material is PolyTetraFluoroEthylene (PTFE).
30. The combination of claim 24, wherein the conductive plastic comprises polycarbonate, PolyTetraFluoroEthylene (PTFE), and carbon fiber.
31. The combination of claim 24, wherein the conductive plastic comprises approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.%
PolyTetraFluoroEthylene (PTFE).
PolyTetraFluoroEthylene (PTFE).
32. The combination of any one of claims 24 to 31, the flange device including an integrally-formed flange support member coupled to the flange.
33. The combination of claim 32, further comprising a photoreceptor support attached to the flange support member, the flange, flange support member and photoreceptor support being integrally formed of conductive plastic.
34. A flange device capable of translating a rotational force from an outside source to a hollow cylindrical member having an inner surface comprising:
a flange support member for applying the rotational force; and a flange connected to the flange support member, the flange being made from a conductive plastic and having a length, an inner diameter, and an outer diameter, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes; the outer diameter of the flange is sized with respect to the inner surface of the hollow cylindrical member and the length of the flange is such that an interference fit is formed between the flange and the inner surface of the hollow cylindrical member, the interference fit being maintained in the absence of an adhesive and thereby forming an electrical path between the flange and the hollow cylindrical member.
a flange support member for applying the rotational force; and a flange connected to the flange support member, the flange being made from a conductive plastic and having a length, an inner diameter, and an outer diameter, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes; the outer diameter of the flange is sized with respect to the inner surface of the hollow cylindrical member and the length of the flange is such that an interference fit is formed between the flange and the inner surface of the hollow cylindrical member, the interference fit being maintained in the absence of an adhesive and thereby forming an electrical path between the flange and the hollow cylindrical member.
35. The flange device of claim 34, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and carbon fiber.
36. The flange device of claim 34 or 35, wherein the non-stick material is selected from the group consisting of PolyTetraFluoroEthylene (PTFE), FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), EthyleneChloroTriFluoroEthylene (ECTFE), PerFluoroAlkoxy resin (PFA), EthyleneTetraFluoroEthylene (ETFE), PolyChloroTriFluoroEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
37. The flange device of any one of claims 34 to 36, wherein the polymer plastic is polycarbonate.
38. The flange device of any one of claims 34 to 37, wherein the non-stick material is PolyTetraFluoroEthylene (PTFE).
39. The flange device of claim 34, wherein the conductive plastic comprises polycarbonate, PolyTetraFluoroEthylene (PTFE), and carbon fiber.
40. The flange device of claim 34, wherein the conductive plastic comprises approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.% PolyTetraFluoroEthylene (PTFE).
41. The flange device of any one of claims 34 to 40, wherein flange support member has gear teeth.
42. The flange device of any one of claims 34 to 40, wherein the flange support member is made of conductive plastic.
43. The flange device of claim 42, wherein the flange and flange support member are integrally formed.
44. The flange device of any one of claims 34 to 40, wherein surface of the flange has a microroughness sufficient to maintain the interference fit without scarring the inner surface of the hollow cylindrical member.
45. The flange device of any one of claims 34 to 40, further comprising:
a photoreceptor support attached to the flange support member.
a photoreceptor support attached to the flange support member.
46. The flange device of claim 45, wherein the flange, flange support member and photoreceptor support are integrally formed of conductive plastic.
47. A method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising:
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
forming a flange device made of conductive plastic, the flange device including a flange support member and a flange, the conductive plastic comprising a polymer plastic, a non-stick material, and one of carbon fiber and metal flakes;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
48. The method of claim 47, wherein the conductive plastic comprises a polymer plastic, a non-stick material, and carbon fiber.
49. The method of claim 47 or 48, wherein the non-stick material is selected from the group consisting of PolyTetraFluoroEthylene (PTFE), FluorinatedEthylenePropylene (FEP), TetraFluoroEthylene (TFE), EthyleneChloroTriFluoroEthylene (ECTFE), PerFluoroAlkoxy resin (PFA), EthyleneTetraFluoroEthylene (ETFE), PolyChloroTriFluoroEthylene (PCTFE) and PolyVinyladeneFluoride (PVDF).
50. The method of any one of claims 47 to 49, wherein the polymer plastic is polycarbonate.
51. The method of any one of claims 47 to 50, wherein the non-stick material is PolyTetraFluoroEthylene (PTFE).
52. The method of claim 47, wherein the conductive plastic comprises polycarbonate, PolyTetraFluoroEthylene (PTFE), and carbon fiber.
53. The method of claim 47, wherein the conductive plastic comprises approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.%
PolyTetraFluoroEthylene (PTFE).
PolyTetraFluoroEthylene (PTFE).
54. The method of any one of claims 47 to 53, wherein forming includes forming gear teeth on the flange support member.
55. The method of any one of claims 47 to 53, wherein the coefficients of thermal expansion of the flange and photoreceptor are matched so that the interference fit is maintained during the operation of the electrostatographic machine.
56. The method of claim 55, wherein electrostatographic machine operating conditions include temperatures ranging from about 45 to 150 degrees Fahrenheit.
57. A method of forming a ground circuit between a photoreceptor having an inner diameter and an electrostatographic machine, comprising:
forming a flange device made of conductive plastic, the conductive plastic comprising approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.% PolyTetraFluoroEthylene (PTFE), the flange device including a flange support member and a flange;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
forming a flange device made of conductive plastic, the conductive plastic comprising approximately 82 wt.% polycarbonate, 12 wt.% carbon fiber and 6 wt.% PolyTetraFluoroEthylene (PTFE), the flange device including a flange support member and a flange;
sizing the flange with respect to the inner diameter of the photoreceptor;
fitting the flange in the photoreceptor, wherein the flange is sized and shaped with respect to the inner diameter of the photoreceptor so as to provide an interference fit to withstand compressional and torsional forces applied to the flange device; and contacting a conductive photoreceptor support to the flange device, thereby completing the electrical ground circuit between the photoreceptor, flange device and electrostatographic machine.
58. A method as claimed in claim 57, further comprising:
finishing the surface of the flange so that a sufficient coefficient of friction is established between the flange surface and the inner diameter of the photoreceptor.
finishing the surface of the flange so that a sufficient coefficient of friction is established between the flange surface and the inner diameter of the photoreceptor.
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US35612199A | 1999-07-16 | 1999-07-16 | |
| US09/356,121 | 1999-07-16 | ||
| US51584100A | 2000-02-29 | 2000-02-29 | |
| US09/515,841 | 2000-02-29 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2313656A1 CA2313656A1 (en) | 2001-01-16 |
| CA2313656C true CA2313656C (en) | 2004-09-28 |
Family
ID=26999132
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2313656 Expired - Fee Related CA2313656C (en) | 1999-07-16 | 2000-07-10 | Flange device with finished surface |
Country Status (2)
| Country | Link |
|---|---|
| BR (1) | BR0002922A (en) |
| CA (1) | CA2313656C (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102015112173A1 (en) | 2015-07-27 | 2017-02-02 | Cotesa Gmbh | Connecting part for a tubular component made of fiber-reinforced plastic and method for its preparation |
-
2000
- 2000-07-10 CA CA 2313656 patent/CA2313656C/en not_active Expired - Fee Related
- 2000-07-17 BR BR0002922A patent/BR0002922A/en not_active Application Discontinuation
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102015112173A1 (en) | 2015-07-27 | 2017-02-02 | Cotesa Gmbh | Connecting part for a tubular component made of fiber-reinforced plastic and method for its preparation |
| DE102015112173A8 (en) | 2015-07-27 | 2017-03-30 | Cotesa Gmbh | Connecting part for a tubular component made of fiber-reinforced plastic and method for its preparation |
| DE102015112173B4 (en) | 2015-07-27 | 2023-12-28 | Cotesa Gmbh | Method for producing a connecting part for a tubular component made of fiber-reinforced plastic |
Also Published As
| Publication number | Publication date |
|---|---|
| BR0002922A (en) | 2001-05-02 |
| CA2313656A1 (en) | 2001-01-16 |
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| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |
Effective date: 20180710 |