Abstract: A fuser module of an image forming device including a pivot able end cap and a movable entry guide attached therein. The movable entry guide moves according to the pivoting end cap to ensure reduced positional variability within the fuser module. The pivoting end cap also has a wheel to axle ratio of about 18:1 to ensure reduced force variability within the fuser module.

Abstract: An Oldham coupler assembly capable of transferring rotary power between two shafts in a developer unit of an image forming apparatus that includes an input plate and an output plate made of metal and a star plate made in plastic mechanically coupled and positioned in between the input plate and the output plate. A spline component made of metal is rigidly and integrally attached to the input plate, the spline component including a tubular spline portion that includes a plurality of wear strips made of plastic, the output plate having a plastic material coated along a portion of an outside diameter of the output plate. The input and output plates further include a plurality of openings to receive a plurality of wheels and pins. This structure allows a sufficiently stiff drive system to substantially eliminate fine line jitter by raising the natural frequency of the drive system.

Abstract: A fuser assembly includes a translatable heater member and a rotatable backup member mounted against the translatable heater member. The translatable heater member includes a heater housing extending through end frames disposed at the ends of the fuser assembly. A biasing member is positioned adjacent and parallel to the translatable heater member. A support structure is positioned at each end of the biasing member for supporting the biasing member. The support structure includes bell crank members that are engaged with the ends of the biasing member. The biasing member applies force on the heater housing through the bell crank members to bias the translatable heater member against the rotatable backup member.

Abstract: A media picking mechanism includes a pair of transmission shafts rotating in opposite directions. A housing is mounted around the pair of transmission shafts such that the first transmission shaft and the second transmission shaft are positioned substantially equidistant from a centerline of the housing. During a media picking operation, the rotation of the first transmission shaft of the pair of transmission shafts provides a first moment to the housing and rotation of a second transmission shaft of the pair of transmission shafts provides a second moment to the housing, which is equal and opposite to the first moment such that a net moment on the housing is near zero minimizing twisting of the housing. The two transmission shafts rotating in opposite directions, also results in substantially equal normal force to be applied by the first and second pick tires on the media.

Abstract: The present application is directed to systems and methods to control access to an interior of an image forming device. The image forming device may include a body with a door that is movable between open and closed positions. In the open position, access is gained to an interior of the body. A controller controls a latch through a motor arrangement to lock and unlock the door. A user interface may be positioned on an exterior of the body to allow a user to enter commands to lock and unlock the door. Additional elements may also be included within the interior of the image forming device and operated with the motor arrangement.

Abstract: The present application is directed to devices and methods for moving media sheets within an image forming device. One embodiment includes a registration mechanism located along the media path. The mechanism may include a series of discrete registration nips that each includes a pair of drive rolls and idler roll. The nips are spaced at intervals across the media path. Guide ribs are arranged across the media path and may be positioned between the nips. The guide ribs further guide the media sheets through the registration mechanism and along the media path.

Abstract: A media picking mechanism includes a pair of transmission shafts rotating in opposite directions. A housing is mounted around the pair of transmission shafts such that the first transmission shaft and the second transmission shaft are positioned substantially equidistant from a centerline of the housing. During a media picking operation, the rotation of the first transmission shaft of the pair of transmission shafts provides a first moment to the housing and rotation of a second transmission shaft of the pair of transmission shafts provides a second moment to the housing, which is equal and opposite to the first moment such that a net moment on the housing is near zero minimizing twisting of the housing. The two transmission shafts rotating in opposite directions, also results in substantially equal normal force to be applied by the first and second pick tires on the media.

Abstract: A fuser assembly includes a translatable heater member and a rotatable backup member mounted against the translatable heater member. The translatable heater member includes a heater housing extending through end frames disposed at the ends of the fuser assembly. A biasing member is positioned adjacent and parallel to the translatable heater member. A support structure is positioned at each end of the biasing member for supporting the biasing member. The support structure includes bell crank members that are engaged with the ends of the biasing member. The biasing member applies force on the heater housing through the bell crank members to bias the translatable heater member against the rotatable backup member.

Abstract: A fuser module of an image forming device including a pivotable end cap and a movable entry guide attached therein. The movable entry guide moves according to the pivoting end cap to ensure reduced positional variability within the fuser module. The pivoting end cap also has a wheel to axle ratio of about 18:1 to ensure reduced force variability within the fuser module.

Abstract: An Oldham coupler assembly capable of transferring rotary power between two shafts in a developer unit of an image forming apparatus that includes an input plate and an output plate made of metal and a star plate made in plastic mechanically coupled and positioned in between the input plate and the output plate. A spline component made of metal is rigidly and integrally attached to the input plate, the spline component including a tubular spline portion that includes a plurality of wear strips made of plastic, the output plate having a plastic material coated along a portion of an outside diameter of the output plate. The input and output plates further includes a plurality of openings to receive a plurality of wheels and pins. This structure allows a sufficiently stiff drive system to substantially eliminate fine line jitter by raising the natural frequency of the drive system.

Abstract: A system for sensing a media stack to detect a given stack height includes a stack site in an output bin and a mechanical flag mounted adjacent to a side thereof in a counterbalanced state at a home position where an exposed portion of the flag extends into a media sheet delivery path where it is struck by an edge of repetitive media sheets moving to the site. The striking of the exposed portion by the sheet edge causes the flag to deflect to a displaced position outside of the delivery path, allowing the sheet to land on the site increasing the height of a media sheet stack at the site. The counterbalanced state further allows the flag to return to the home position with its exposed portion in the media path until a given stack height is reached where the stack blocks further return of the flag indicating that the output bin is full.

Abstract: A system for sensing a media stack to detect a given stack height includes a stack site in an output bin and a mechanical flag mounted adjacent to a side thereof in a counterbalanced state at a home position where an exposed portion of the flag extends into a media sheet delivery path where it is struck by an edge of repetitive media sheets moving to the site. The striking of the exposed portion by the sheet edge causes the flag to deflect to a displaced position outside of the delivery path, allowing the sheet to land on the site increasing the height of a media sheet stack at the site. The counterbalanced state further allows the flag to return to the home position with its exposed portion in the media path until a given stack height is reached where the stack blocks further return of the flag indicating that the output bin is full.

Abstract: The present application is directed to systems and methods to control access to an interior of an image forming device. The image forming device may include a body with a door that is movable between open and closed positions. In the open position, access is gained to an interior of the body. A controller controls a latch through a motor arrangement to lock and unlock the door. A user interface may be positioned on an exterior of the body to allow a user to enter commands to lock and unlock the door. Additional elements may also be included within the interior of the image forming device and operated with the motor arrangement.

Abstract: The present application includes embodiments of a connector in an image forming device that establishes an electrical connection with a cartridge. The connector may include an electrical contact that is able to rotate in a first direction when in contact with the cartridge during a first amount insertion of the cartridge into the image forming device. The electrical contact may be adapted to stop rotating after the cartridge is inserted the first amount. As a result, the electrical connector may slide across the surface of the cartridge during additional insertion. The sliding motion may scrape off an oxidation or contamination layer thus providing a reliable electrical contact between the connector and the cartridge.

Abstract: The present application is directed to devices and methods for moving media sheets within an image forming device. One embodiment includes a registration mechanism located along the media path. The mechanism may include a series of discrete registration nips that each includes a pair of drive rolls and idler roll. The nips are spaced at intervals across the media path. Guide ribs are arranged across the media path and may be positioned between the nips. The guide ribs further guide the media sheets through the registration mechanism and along the media path.

Abstract: An image forming device includes a body and one or more door assemblies. At least one door assembly may be movable between open and closed orientations. A variety of mechanical and electrical interlocks may be used to control motion of the door assemblies. A first interlock may prevent a door assembly from moving under the influence of a force between an open and closed orientation prior to a condition being satisfied. This condition may depend on the position of a second door assembly. A breakaway feature may release the first interlock when the closing force exceeds a predetermined level. A second interlock may work with the first interlock to keep a second door assembly from opening if the first door assembly is closed. An electrical interlock may disconnect power to the image forming device when the first door assembly is open.

Abstract: An image forming device with one or more door assemblies that engage locking mechanisms to secure a module in an operating position. The module may be coupled to one of the one or more door assemblies. A first locking mechanism may secure the module to the image forming device body when a first door assembly is closed. A second locking mechanism may secure the module to the body with a greater securing force than the first locking mechanism to secure the module to the body. The second locking mechanism may be engaged upon closing a second door assembly. Separate biasing members may be used to apply the securing forces. The locking mechanisms may include four-bar or over-center mechanisms to apply the securing forces.

Abstract: A removable media tray for an image forming apparatus includes a housing, an exit port in the housing, a primary media stack, and a multi-purpose tray (MPT) input. Within the tray are first and second pick mechanisms operative to select a media sheet from the primary stack or MPT stack, respectively, and move the media sheet to the image forming apparatus through the exit port. A motor is disposed within the tray housing, and first and second drive assemblies operatively connect the motor to the first and second pick mechanisms, respectively. The motor drives the first pick mechanism forward by rotating in one direction, and drives the second pick mechanism forward by rotating in the opposite direction. A media sensor in the exit port senses media sheets from a variety of sources, including the primary media stack, the MPT stack, a duplex return path, or a large-capacity media sheet supply.

Abstract: An exit roll for use in an image forming device. The exit roll may include a body and a kicker section each configured to mount to a shaft. The kicker section may include a plurality of fingers spaced around the periphery. Each of the fingers may include a first section that is substantially parallel to the shaft, and a second section that extends outward way from the shaft. The fingers may be flexible in an upwards and downwards direction into and away from the shaft. The exit roll is constructed to move media sheets out of the exit port and away from the image forming device.

Abstract: Devices and methods for directing a media sheet along a media path within an image forming apparatus. The media path includes rollers that form a media nip, one or more deflectors, and a transport belt. The media nip conveys the media sheet along the media path into one or more deflectors. The one or more deflectors are positioned between the nip and the transport belt. The one or more deflectors control the angle of the media sheet as it approaches the transport belt and facilitates attachment of the media sheet to the transport belt. The transport belt then moves the media sheet past one or more image forming units and receives a toner image.