A scanning unit in an image forming apparatus includes a light source, a coupling lens, an aperture, an image forming lens, and a polygon mirror. The light source includes a plurality of surface-emitting lasers. The coupling lens, the aperture, and the image forming lens are arranged on the optical path of light beams emitted by the light source. The polygon mirror deflects light beams of an image formed by the coupling lens towards a photosensitive drum for scanning. The focal length of the image forming lens in a sub-scanning direction is set to be equal to or smaller than an optical path length between the image forming lens and the aperture.
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0. 19. A scanning unit comprising:
a light source having a plurality of surface-emitting lasers each emitting a light beam;
an optical deflector that receives light beams from the light source and deflects the light beams for scanning a target surface, wherein
a beam diameter in a sub-scanning direction of the light received by the optical deflector is smaller than a beam diameter in a main scanning direction of the light received by the optical deflector but greater than a distance between adjacent scanning lines, for all image heights, and
at least one of outermost light-emitting members in the two-dimensional array emits a greater amount of light than remaining light-emitting members.
0. 24. An image forming apparatus comprising:
at least one unit of an image carrier; and
at least one scanning unit including:
a light source having a plurality of surface-emitting lasers each emitting a light beam;
an optical deflector that receives light beams from the light source and deflects the light beams for scanning a target surface, wherein
a beam diameter in a sub-scanning direction of the light received by the optical deflector is smaller than a beam diameter in a main scanning direction of the light received by the optical deflector but greater than a distance between adjacent scanning lines, for all image heights, and
at least one of outermost light-emitting members in the two-dimensional array emits a greater amount of light than remaining light-emitting members.
0. 12. A scanning unit comprising:
a light source having a plurality of surface-emitting lasers each emitting a light beam;
an optical deflector that receives light beams from the light source through a pre-deflection optical system and deflects the light beams for scanning a target surface; and
a scanning optical system that focuses the deflected light beams, wherein
an absolute value of lateral magnification in a main scanning direction is more than an absolute value of lateral magnification in a sub-scanning direction, and
the pre-deflection optical system and the scanning optical system are configured to satisfy the following condition that a beam diameter of the light received by the optical deflector in the sub-scanning direction is smaller than a beam diameter of the light received by the optical deflector in the main scanning direction but greater than a distance between adjacent scanning lines, for all image heights.
0. 17. An image forming apparatus comprising:
at least one unit of an image carrier; and
at least one scanning unit including:
a light source having a plurality of surface-emitting lasers each emitting a light beam;
an optical deflector that receives light beams from the light source through a pre-deflection optical system and deflects the light beams for scanning a target surface; and
a scanning optical system that focuses the deflected light beams, wherein
an absolute value of lateral magnification in a main scanning direction is more than an absolute value of lateral magnification in a sub-scanning direction, and
the pre-deflection optical system and the scanning optical system are configured to satisfy the following condition that a beam diameter in the sub-scanning direction of the light received by the optical deflector is smaller than a beam diameter in the main scanning direction of the light received by the optical deflector but greater than a distance between adjacent scanning lines, for all image heights.
1. A scanning unit that scans a scanning target surface by using light fluxes, the scanning unit comprising:
a light source having a plurality of surface-emitting lasers each emitting a light beam;
a coupling lens that receives the light beams from the light source and renders the light beams as substantially parallel light;
an aperture that receives the parallel light and defines a diameter of the parallel light thereby obtaining a diameter-defined parallel light;
an image forming lens that receives the diameter-defined parallel light and forms an image in a sub-scanning direction; and
an optical deflector that is arranged close to a focal point of the image forming lens, and that receives light beams of the image and deflects the light beams for scanning a target surface, wherein
a focal length of the image forming lens in the sub-scanning direction is smaller than an optical path length between the image forming lens and the aperture, and
a beam diameter of the diameter-defined parallel light in the sub-scanning direction is equal to or smaller than a beam diameter of the diameter-defined parallel light in the main scanning direction but greater than a distance between adjacent scanning lines, for all image heights.
8. An image forming apparatus comprising:
at least one unit of an image carrier; and
at least one scanning unit including:
a light source having a plurality of surface-emitting lasers each emitting a light beam;
a coupling lens that receives the light beams from the light source and renders the light beams as substantially parallel light;
an aperture that receives the parallel light and defines a diameter of the parallel light thereby obtaining a diameter-defined parallel light;
an image forming lens that receives the diameter-defined parallel light and forms an image in a sub-scanning direction; and
an optical deflector that is arranged close to a focal point of the image forming lens, and that receives light beams of the image and deflects the light beams for scanning a target surface, wherein
wherein a focal length of the image forming lens in the sub-scanning direction is smaller than an optical path length between the image forming lens and the aperture, and
wherein the scanning unit scans the image carrier with a plurality of light beams having image information, and
a beam diameter of the diameter-defined parallel light in the sub-scanning direction is equal to or smaller than a beam diameter of the diameter-defined parallel light in the main scanning direction but greater than a distance between adjacent scanning lines, for all image heights.
2. The scanning unit according to
3. The scanning unit according to
an absolute value of lateral magnification in a main scanning direction is more than an absolute value of lateral magnification in the sub-scanning direction.
4. The scanning unit according to
each of the surface-emitting lasers emits a linearly-polarized light beam,
an absolute value of lateral magnification in the main scanning direction is more than an absolute value of lateral magnification in the sub-scanning direction, and
an angle between a polarization direction of the linearly-polarized light beam and the main scanning direction is greater than an angle between the polarization direction and the sub-scanning direction.
5. The scanning unit according to
the surface-emitting lasers are arranged in a two-dimensional array such that M number of the surface-emitting lasers (M≧2) are arranged along the sub-scanning direction and N number of the surface-emitting lasers (N>M) are arranged along a direction of a tilt angle α between the main scanning direction and the sub-scanning direction, and
a distance between adjacent light-emitting members, when orthographically-projected on a virtual line extending in the sub-scanning direction, is equal.
6. The scanning unit according to
7. The scanning unit according to
9. The image forming apparatus according to
0. 10. The scanning unit according to claim 1, wherein
the beam diameter in the sub-scanning direction is smaller than the beam diameter in the main scanning direction such that the beam diameter in the main scanning direction is at least 1.2 times the beam diameter in the sub-scanning direction.
0. 11. The image forming apparatus according to claim 8, wherein
the beam diameter in the sub-scanning direction is smaller than the beam diameter in the main scanning direction such that the beam diameter in the main scanning direction is at least 1.2 times the beam diameter in the sub-scanning direction.
0. 13. The scanning unit according to claim 12, wherein the pre-deflection optical system includes an aperture.
0. 14. The scanning unit according to claim 13, wherein
a focal length of the coupling lens is greater than an optical path length between the coupling lens and the aperture, and
a focal length of the image forming lens in the sub-scanning direction is smaller than an optical path length between the image forming lens and the aperture.
0. 15. The scanning unit according to claim 12, wherein
each of the surface-emitting lasers emits a linearly polarized light beam, and
an angle between a polarization direction of the linearly-polarized light beam and the main scanning direction is greater than an angle between the polarization direction and the sub-scanning direction.
0. 16. The scanning unit according to claim 12, wherein
the beam diameter in the sub-scanning direction is smaller than the beam diameter in the main scanning direction such that the beam diameter in the main scanning direction is at least 1.2 times the beam diameter in the sub-scanning direction.
0. 18. The image forming apparatus according to claim 17, wherein
the beam diameter in the sub-scanning direction is smaller than the beam diameter in the main scanning direction such that the beam diameter in the main scanning direction is at least 1.2 times the beam diameter in the sub-scanning direction.
0. 20. The scanning unit according to claim 19, wherein a focal length of the coupling lens is different from an optical path length between the coupling lens and the aperture.
0. 21. The scanning unit according to claim 19, wherein
an absolute value of lateral magnification in a main scanning direction is more than an absolute value of lateral magnification in the sub-scanning direction, and
a focal length of the image forming lens in the sub-scanning direction is smaller than an optical path length between the image forming lens and the aperture.
0. 22. The scanning unit according to claim 19, wherein
each of the surface-emitting lasers emits a linearly-polarized light beam,
an absolute value of lateral magnification in the main scanning direction is more than an absolute value of lateral magnification in the sub-scanning direction, and
an angle between a polarization direction of the linearly-polarized light beam and the main scanning direction is greater than an angle between the polarization direction and the sub-scanning direction.
0. 23. The scanning unit according to claim 19, wherein
the beam diameter in the sub-scanning direction is smaller than the beam diameter in the main scanning direction such that the beam diameter in the main scanning direction is at least 1.2 times the beam diameter in the sub-scanning direction.
0. 25. The image forming apparatus according to claim 24, wherein
the beam diameter in the sub-scanning direction is smaller than the beam diameter in the main scanning direction such that the beam diameter in the main scanning direction is at least 1.2 times the beam diameter in the sub-scanning direction.
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The values of the conic constant and each coefficient of the incident surface of the first scanning lens 11a are given below in Table 3.
TABLE 3
K
0
B1
0
A4
8.885 × 10-7
B2
0
A6
−2.629 × 10−10
B3
0
A8
2.1846 × 10−14
B4
0
A10
1.368 × 10−17
B5
0
A12
−3.135 × 10−21
B6
0
B7
0
B8
0
The values of the conic constant and each coefficient of the output surface of the first scanning lens 11a are given below in Table 4.
TABLE 4
K
0
B1
−1.594 × 10−6
A4
9.2240 × 10−7
B2
−4.332 × 10−6
A6
6.7782 × 10−11
B3
4.9819 × 10−9
A8
−4.1124 × 10−14
B4
−2.8594 × 10−9
A10
1.3727 × 10−17
B5
−2.677 × 10−12
A12
2.069 × 10−21
B6
2.8778 × 10−13
B7
−1.916 × 10−15
B8
2.0423 × 10−15
B9
1.0141 × 10−13
B10
−6.729 × 10−19
The values of the conic constant and each coefficient of the incident surface of the second scanning lens 11b are given below in Table 5.
TABLE 5
K
0
B1
0
A4
3.286 × 10−7
B2
−1.1328 × 10−6
A6
−7.085 × 10−11
B3
2.60612 × 10−10
A8
6.269 × 10−15
B4
7.8961 × 10−11
A10
−2.7316 × 10−19
B5
−5.027 × 10−14
A12
4.739 × 10−24
B6
1.4051 × 10−14
B7
4.5538 × 10−18
B8
−2.0140 × 10−18
B9
−1.546 × 10−22
B10
7.4893 × 10−23
The values of the conic constant and each coefficient of the output surface of the second scanning lens 11b are given below in Table 6.
TABLE 6
K
0
B1
0
A4
1.2779 × 10−7
B2
2.311 × 10−7
A6
−4.629 × 10−11
B3
0
A8
4.049 × 10−15
B4
0
A10
−1.659 × 10−19
B5
0
A12
2.585 × 10−24
B6
0
B7
0
B8
0
The optical system arranged on the optical path between the polygon mirror 13 and the photosensitive drum 901 is referred as a scanning optical system that includes the first scanning lens 11a and the second scanning lens 11b.
The photosensitive drum 901 is arranged at a position where the optical path length between the output surface of the second scanning lens 11b and the photosensitive drum 901 is, e.g., 142.5 millimeters (‘d10’ in
The length of the portion on the surface of the photosensitive drum 901 on which scanning is possible, that is, the width in which image writing in the direction Dir_main is possible, is, e.g., 323 millimeters.
In the coupling optical system and the scanning optical system, the lateral magnification in the direction Dir_main is 5.7 times, while the lateral magnification in the direction Dir_sub is 1.2 times. That is, the absolute value of the lateral magnification in the direction Dir_main is more than the absolute value of the lateral magnification in the direction Dir_sub. As a result, the scanning-line distance narrows thereby improving the image resolution. The scanning-line distance in the scanning unit 900 is, e.g., 5.3 micrometers. Consequently, a resolution of, e.g., 4800 dots per inch (dpi) can be achieved.
Meanwhile, even if a large number of light-emitting members are arranged in a two-dimensional array, the sub-scanning beam pitch may still deviate from a predetermined beam pitch depending on the positional errors or the shape errors of the light-emitting members. It is necessary to maintain a stable sub-scanning beam pitch to prevent deterioration in the image quality.
To obtain a stable sub-scanning beam pitch, the distance between adjacent light beams, which are incident on a scanning lens having its power lens in the sub-scanning direction, is narrowed such that the incident angle of the light beams with respect to a target surface becomes smaller. As a result, irrespective of positional errors or shape errors in the light-emitting members, the deviation of the sub-scanning beam pitch can be reduced.
In
As compared to the graph shown in
Thus, it is clear that the beam diameter in the direction Dir_sub is smaller when the aperture plate 16 is used. That leads to improved granularity of an image thereby decreasing its rough feel. Thus, an image with high resolution can be output. Because the value of Ws of the apertured curve 16 is 1.6 times greater than that of the conventional aperture plate 16′, the light use efficiency of the scanning unit 900 improves by about 60%.
Meanwhile, if the center of the two-dimensional array 100 is aligned with the center of the aperture plate 16 in the direction perpendicular to the optical axis, the center of the light beams emitted by the light-emitting members 101 forming the outermost layer of the two-dimensional array 100 (i.e., from 1st to 10th, from 31st to 40th, 11th, 21st, 20th, and 30th with reference to
As described above, the scanning unit 900 includes the light source 14 having a plurality of surface-emitting lasers (i.e., light-emitting members 101), the polygon mirror 13, the coupling optical system, and the scanning optical system. The coupling optical system includes the coupling lens 15, the aperture plate 16, the image forming lens 17, and the reflecting mirror 18 that are arranged between the light source 14 and the polygon mirror 13 on the optical path of the light beams emitted by the light source 14. The polygon mirror 13 receives light beams of an image formed by the image forming lens 17 and deflects the light beams to the photosensitive drum 901 via the scanning optical system. The focal length of the image forming lens 17 in the direction Dir_sub is set to be equal to or smaller than the optical path length between the image forming lens 17 and the aperture plate 16. As a result, a stable sub-scanning beam pitch can be obtained.
Moreover, in the coupling optical system and the scanning optical system, the absolute value of the lateral magnification in the direction Dir_main is set to be more than the absolute value of the lateral magnification in the direction Dir_sub. Furthermore, over the surface of the photosensitive drum 901, the beam diameter in the direction Dir_sub is set to be equal to or smaller than the beam diameter in the direction Dir_main but greater than the scanning-line distance. As a result, the loss in the amount of light is much less in the scanning unit 900 than in a conventional scanning unit. As a result, it is possible to perform beam shaping that in turn improves the light use efficiency of the scanning unit 900.
As shown in
To solve such a problem, the beam diameter in the direction Dir_main is set to be greater than the beam diameter in the direction Dir_sub over the surface of the photosensitive drum 901. Thus, the difference between the width of the aperture 16a in the direction Dir_main and the width of the aperture 16a in the direction Dir_sub is reduced thereby improving coupling efficiency (i.e., ratio of optical power emitted by a light-emitting member to optical power output from an aperture).
Moreover, the multibeam technology implemented in the light source 14 enables high-resolution and high-speed imaging. In this case, because the scanning-line distance decreases, it is possible to set the beam diameter in the direction Dir_sub to be greater than the scanning-line distance. As a result, no gaps remain in the direction Dir_sub thereby uniformly filling the whole image.
Generally, in an scanning unit implementing the multibeam technology, two methods can be used to improve the image resolution in the direction Dir_sub: (1) to reduce the lateral magnification in the direction Dir_sub; and (2) to reduce the distance between light-emitting members in the Dir_sub. However, in the first method, the amount of light falls short of the required amount because the width of an aperture in the direction Dir_sub needs to be reduced to decrease a beam diameter over a target surface. In the second method, the light beams emitted by the light-emitting members mutually interfere and it is also difficult to secure sufficient space for wiring of each light-emitting member.
As described above, the two-dimensional array 100 in the light source 14 includes four rows of the light-emitting members 101 in the direction Dir_sub, each row including 10 light-emitting members 101 equally spaced along the direction of the tilt angle α, i.e., along the direction T, between the direction Dir_main and the direction Dir_sub. The distance between any two adjacent light-emitting members 101, when orthographically-projected on a virtual line extending in the direction Dir_sub, is equal. In this configuration, the light-emitting members 101 are mutually spread out in the direction Dir_main, which has no effect on the high-resolution of an image in the direction Dir_sub. Thus, even after reducing the distance between the light-emitting members 101 in the Dir_sub, the light beams do not mutually interfere and a sufficient space can be secured for wiring.
Moreover, the focal length of the coupling lens 15 is set to be greater than the optical path length between the coupling lens 15 and the aperture plate 16 thereby reducing the overall optical path length from the light source 14 to the photosensitive drum 901. That is, the aperture plate 16 is arranged between the coupling lens 15 and the back focal position of the coupling lens 15. Such a configuration is different than a conventional configuration in which an aperture plate is arranged at the back focal position of a coupling lens.
As described above, the laser printer 500 includes the scanning unit 900 that can achieve a stable sub-scanning beam pitch. Thus, the laser printer 500 can perform a high-quality and high-speed image forming process.
Instead of the aperture plate 16, an aperture plate having much smaller width in the direction Dir_main can also be used. In that case, the focal length of the coupling lens 15 needs to be readjusted corresponding to the smaller width of the aperture plate.
Moreover, the mesa portion in each light-emitting member 101 need not be of a circular shape and can be of an elliptical shape, a square shape, or a rectangular shape.
As described above, the two-dimensional array 100 includes four rows of the light-emitting members 101 and each row includes 10 light-emitting members 101. However, as long as the number of the light-emitting members 101 in a single row is more than the total number of rows, there is no limitation on the number of the light-emitting members 101 and the number of rows.
As described above, the distance between the light-emitting members 101 orthographically-projected on a virtual line extending in the direction Dir_sub (‘c’ in
Moreover, as described above, the distance between adjacent rows of the light-emitting members 101 in the direction Dir_sub (‘d’ in
Furthermore, instead of the two-dimensional array 100, a two-dimensional array 200 can be used as shown in
The first spacer layer 213 is made of (Al0.7Ga0.3)0.5In0.5P that is a wide-band-gap semiconductor material.
As shown in
The second spacer layer 215 is made of (Al0.7Ga0.3)0.5In0.5P that is a wide-band-gap semiconductor material.
The first spacer layer 213, the active layer 214, and the second spacer layer 215 together are referred as a resonator structure that has an optical thickness equal to one oscillation wavelength (refer to
Because the layers of the two-dimensional array 200 are made of the AlGaInP material system, it is possible to maintain a much wider band gap between the spacer layers, i.e., the first spacer layer 213 and the second spacer layer 215, and the active layer 214 as compared to the multilayered structure of the two-dimensional array 100.
In case of the VCSEL_B, it is possible to maintain a wider band gap than in case of the VCSEL_A and the VCSEL_C. More particularly, the band gap between the spacer layers and the quantum well layer in the VCSEL_B is 767.3 milli-electron volts, which is greater than the band gap of 465.9 milli-electron volts in the VCSEL_A and the band gap of 602.6 milli-electron volts in the VCSEL_C. Similarly, the band gap between the barrier wall layer and the quantum well layer in the VCSEL_B is 463.3 milli-electron volts, which is greater than the band gap of 228.8 milli-electron volts in the VCSEL_A and the band gap of 365.5 milli-electron volts in the VCSEL_C. Thus, a better carrier confinement can be achieved in case of the VCSEL_B.
Moreover, because the quantum well layer 214a in each light-emitting member 201 has a compressively-strained structure, a higher gain can be obtained due to band separation between a heavy hole and a light hole. As a result, a high optical output can be achieved at a low threshold. Furthermore, the degree of reflection of the upper reflecting mirror 117 (refer to
Because the quantum well layer 214a and the barrier wall layer 214b do not contain aluminum (Al), the active layer 214 is less oxidized thereby curbing the formation of a non-emitting recombination center. As a result, the durability of the light-emitting members 201 can be improved.
If in an optical writing device, a two-dimensional array of VCSELs having poor durability is used, the optical writing device needs to be disposed after one use. However, because the two-dimensional array 200 includes the durable light-emitting members 201, an optical device can be reused for a number of times thereby conserving resources and decreasing environmental burdens. Any other optical device can achieve such advantages by using the two-dimensional array 200.
As described above, the oscillation wavelength of the light emitted by each light-emitting member 101 or 201 is 780 nanometers. However, the oscillation wavelength is not limited to 780 nanometers and can be adjusted depending on the sensitivity characteristics of the photosensitive drum 901. In that case, the material composition or the multilayered structure of the light-emitting members 101 or 201 needs to be changed depending on the oscillation wavelength.
Meanwhile, the amount of optical output from a VCSEL is less than that from an edge-emitting laser. Thus, it is necessary to improve the light use efficiency of the VCSEL. As shown in
In the above description, the image forming apparatus was considered to be the laser printer 500. However, any other image forming apparatus including the scanning unit 900 can perform a high-quality and high-speed image forming process.
In case of a color-image forming apparatus, an scanning unit compatible to the color-image forming apparatus can be used to achieve a high-quality and high-speed image forming.
Moreover, as shown in
In this case, the light-emitting members 101 in the light source 14 are classified into four groups, each group emitting light to one of the photosensitive drums K1, C1, M1, and Y1. Alternatively, four units of the two-dimensional array 100 (or the two-dimensional array 200) can be arranged corresponding to each of the photosensitive drums K1, C1, M1, and Y1. Moreover, four units of the scanning unit 900 can also be arranged corresponding to each of the photosensitive drums K1, C1, M1, and Y1.
As shown in
Sometimes, color drift occurs in the images formed by a tandem-type color-image forming apparatus. However, by using the scanning unit 900 that includes the two-dimensional array 100 of the high-density light-emitting members 101 (VCSELs), it is possible to selectively switch ON the light-emitting members 101 to precisely correct the color drift.
Meanwhile, an image forming apparatus that includes a silver halide film as an image carrier can also be used. In that case, a latent image is formed on the silver halide film by optical scanning. The latent image can be developed by a usual developing process performed in silver halide photography. Such an image forming apparatus can be implemented as an optical plate-making apparatus or an optical lithography device to plot a computed tomography (CT) scan image.
Moreover, an image forming apparatus including a color-developing medium (e.g., a positive photographic paper), which develops colors due to heat energy of a beam spot, as an image carrier can also be used. In that case, the image can be developed directly on the image carrier by optical scanning.
Although the invention has been described with respect to specific embodiments for a complete and clear disclosure, the appended claims are not to be thus limited but are to be construed as embodying all modifications and alternative constructions that may occur to one skilled in the art that fairly fall within the basic teaching herein set forth.
Hayashi, Yoshinori, Watanabe, Naoto, Ichii, Daisuke, Kubo, Nobuaki
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