Polygon mirror, image forming apparatus, and method for manufacturing a polygon mirror

• US 9,939,566 B2
• Filed: 10/03/2016
• Issued: 04/10/2018
• Est. Priority Date: 10/05/2015
• Status: Active Grant

• Current Assignee: Brother Kogyo Kabushiki Kaisha
• Original Assignee: Brother Kogyo Kabushiki Kaisha
• Inventors: Hoshino, Hidetaka, Hattori, Yutaka, Sakai, Toshio, Hayakawa, Kazuhiro
• Primary Examiner(s): THERRIEN, CARLA J
• Application Number:
  US15/283,755
• Publication Number:
  US 20170097450A1
• Time in Patent Office: 554 Days
• CPC Class Codes: B29C 2045/0027 Gate or gate mark locations
• CPC Class Codes: B29C 45/0025 Preventing defects on the moulded article, e.g. weld lines, shrinkage marks preventing defects on the preformed parts or layers B29C45/14836
• CPC Class Codes: B29C 45/2708 Gates B29C45/2703 takes precedence
• CPC Class Codes: B29D 11/00596 Mirrors
• CPC Class Codes: B29L 2011/0058 Mirrors
• CPC Class Codes: G02B 26/12 using multifaceted mirrors
• CPC Class Codes: G02B 26/121 Mechanical drive devices for polygonal mirrors
• CPC Class Codes: G02B 5/09 Multifaceted or polygonal mirrors , e.g. polygonal scanning mirrors; Fresnel mirrors
• CPC Class Codes: G03G 15/04036 Details of illuminating systems, e.g. lamps, reflectors lamp housings for copying cameras, reflex exposure lighting G03B27/542
• CPC Class Codes: G03G 15/0409 Details of projection optics for projection printing apparatus G03B27/522

Abstract

A polygon mirror made of plastic is provided. The polygon mirror has a plurality of reflecting surfaces, a first surface intersecting the plurality of reflecting surfaces at a first side, a second surface intersecting the plurality of reflecting surfaces at a second side opposite to the first side, with a through hole provided to extend through the first surface and the second surface at a center of the polygon mirror. The polygon mirror includes a plurality of gate marks of injection molding. When viewed from an extending direction of the through hole, the gate marks are located on straight lines passing through the center and vertices of the first surface, and are rotationally symmetric with respect to the center.

Claims

1. A polygon mirror made of plastic, the polygon mirror having a plurality of reflecting surfaces, and a first surface intersecting the plurality of reflecting surfaces at a first side, a second surface intersecting the plurality of reflecting surfaces at a second side opposite to the first side, the second surface facing away from the first surface, with a through hole provided to extend through the first surface and the second surface at a center of the polygon mirror, the polygon mirror comprising:

a plurality of gate marks of injection molding, wherein the gate marks are located on straight lines passing through the center and vertices of the first surface, and are rotationally symmetric with respect to the center, when viewed from an extending direction of the through hole.

2. The polygon mirror according to claim 1, wherein when viewed from the extending direction of the through hole, the gate marks are located in positions such that perpendicular bisectors of segments connecting adjacent gate marks pass through vertices of the first surface.

3. The polygon mirror according to claim 1, wherein the through hole has a circular shape as viewed from the extending direction of the through hole.

4. The polygon mirror according to claim 1, wherein the gate marks are located in positions such that a distance from a gate mark to a nearest peripheral edge of the through hole is shorter than a distance from the gate mark to a corresponding vertex of the first surface closest to the gate mark.

5. The polygon mirror according to claim 4, wherein the positions in which the gate marks are located are such that a distance from each of the gate marks to the nearest reflecting surface is longer than a shortest distance between the peripheral edge of the through hole and the reflecting surfaces.

6. The polygon mirror according to claim 1, wherein the gate marks are provided on the first surface.

7. The polygon mirror according to claim 1, wherein the gate marks are provided on an inner peripheral surface that defines the through hole.

8. The polygon mirror according to claim 1, further comprising a projection provided on a surface on which the gate marks are provided, which projection protrudes from the surface to an extent greater than extents to which the gate marks protrude from the surface.

9. The polygon mirror according to claim 6, further comprising a projection provided on the second surface, which projection protrudes from the second surface to an extent greater than extents to which the gate marks protrude from the first surface,

wherein when viewed from the extending direction of the through hole, the projection is located in a position shifted from the positions in which the gate marks are located.

10. The polygon mirror according to claim 1, further comprising projections protruding to an extent greater than extents of protrusion of the gate marks, the number of the projections being same as the number of the reflecting surfaces, wherein when viewed from the extending direction of the through hole, the projections are rotationally symmetric with respect to the center and each shifted from positions in which the gate marks are located.

11. The polygon mirror according to claim 1, further comprising a depression recessed from the second surface toward the first surface along a peripheral edge of the through hole.

12. An image forming apparatus comprising:

a light source configured to emit a light beam;

a polygon mirror made of plastic, and configured to reflect the light beam emitted by the light source;

a motor comprising a rotary shaft configured to rotate about a rotation axis; and

a scanning optical system configured to focus the light beam reflected by the polygon mirror on an image surface,

wherein the polygon mirror has a plurality of reflecting surfaces, a first surface intersecting the plurality of reflecting surfaces at a first side, and a second surface intersecting the plurality of reflecting surfaces at a second side opposite to the first side, the second surface facing away from the first surface, with a through hole provided to extend through the first surface and the second surface at a center of the polygon mirror, the through hole being configured to be coupled to the rotary shaft,

wherein the polygon mirror comprises a plurality of gate marks of injection molding, and

wherein when viewed from a direction of the rotation axis, the gate marks are located on straight lines passing through the center and vertices of the first surface, and are rotationally symmetric with respect to the center.

13. A method for manufacturing a polygon mirror made of plastic, the polygon mirror having a plurality of reflecting surfaces, a first surface intersecting the plurality of reflecting surfaces at a first side, and a second surface intersecting the plurality of reflecting surfaces at a second side opposite to the first side, the second surface facing away from the first surface, with a through hole provided to extend through the first surface and the second surface at a center of the polygon mirror, the method comprising:

providing a mold having a mold surface defining a cavity contoured to form a shape of the polygon mirror and a plurality of gates for injecting molten plastic therethrough into the cavity; and

molding the polygon mirror by injecting the molten plastic through the plurality of gates into the cavity,

wherein the plurality of gates are provided such that when viewed from an extending direction of the through hole of the polygon mirror to be molded, the gates are located on straight lines passing through the center and vertices of the first surface, and are rotationally symmetric with respect to the center.

14. The method according to claim 13, wherein when viewed from the extending direction of the through hole of the polygon mirror to be molded, the gates are located in positions such that perpendicular bisectors of segments connecting adjacent gates pass through corners formed in the cavity which correspond to vertices of the first surface of the polygon mirror to be molded.

15. The method according to claim 13, wherein the mold surface comprises a through-hole forming surface contoured to form an inner peripheral surface defining the through hole of the polygon mirror to be molded, and

wherein the gates are located in positions such that a shortest distance from a gate to the through-hole forming surface is shorter than a distance from the gate to one of corners formed in the cavity which correspond to vertices of the first surface of the polygon mirror to be molded, the one of the corners being closest to the gate among other corners.

16. The method according to claim 13, wherein the mold surface comprises a first-surface forming surface contoured to form the first surface of the polygon mirror to be molded, and

wherein the gates are provided in the first-surface forming surface.

17. The method according to claim 16, wherein the mold surface comprises a second-surface forming surface contoured to form the second surface of the polygon mirror to be molded, and a hollow provided in the second-surface forming surface, which hollow is recessed from the second-surface forming surface to an extent greater than extents to which gate marks to be left as traces of the injected plastic after the molding at positions in which the gates are located during the molding protrude from the first surface, and

wherein when viewed from the extending direction of the through hole of the polygon mirror to be molded, the hollow is located in a position shifted from the positions in which the gates are located.

18. The method according to claim 13, wherein the mold surface comprises a through-hole forming surface contoured to form an inner peripheral surface defining the through hole of the polygon mirror to be molded, and

wherein the gates are provided in the through-hole forming surface.

19. The method according to claim 13, wherein the mold surface has a hollow provided in a surface in which the gates are provided, which hollow is recessed from the surface to an extent greater than extents to which gate marks to be left as traces of the injected plastic after the molding at positions in which the gates are located during the molding protrude.

20. The method according to claim 13, wherein the mold surface has hollows recessed to an extent greater than extents of protrusion of gate marks to be left as traces of the injected plastic after the molding at positions in which the gates are located during the molding, the number of the hollows being same as the number of the reflecting surfaces of the polygon mirror to be molded, wherein when viewed from the extending direction of the through hole of the polygon mirror to be molded, the hollows are rotationally symmetric with respect to the center and each shifted from positions in which the gate marks are to be located.