Patent Grant
6854493
1. Field of the Invention
The present invention relates to an apparatus and a method of filling a desired amount of a microscopic toner powder for developing an electrostatic latent image into a second container without excess or deficiency from a first container.
2. Discussion of the Background
Conventionally, a powder toner for developing an electrostatic latent image is often filled from a first container into other second containers. For example, Japanese Laid-Open Patent Publication No. 9-193902 discloses a method of filling a toner powder into a toner receiving container from a toner feeding container equipped with an auger inside for stirring the toner and a rotary valve at the bottom. The method includes a process of increasing fluidity of the toner by feeding air into the toner stirred in the toner feeding container and a process of feeding the toner into the toner receiving container through a feeding tube and compressing the toner to fill the toner therein in the high density, wherein an exhaust tube for circulation located between the toner feeding container and the feeding tube separates the air from the toner and circulates the air including the toner into the toner feeding container.
A toner for developing an electrostatic latent image is a powder having an extremely small particle diameter and has less fluidity than other powders such as ceramic materials in spite of having a lower specific gravity than such other powders, and has a relatively high agglutinability. Recently, smaller particle diameters are required to comply with demands for a high-resolution image, and a lower-temperature melting resin is required to comply with demands for saving energy and an instant high-speed fixation. However, use of such particles results in problems of agglomeration, adherence to and filming of the toner over a surface of the other materials. Accordingly, in order to improve these properties and avoid the fluidity deterioration and agglomeration, in many cases, ultra-fine particles such as a fluidity improver, an agglomeration inhibitor and a charge controlling agent to improve chargeability of the toner are applied to a surface of the toner. Therefore, in terms of preventing these ultra-fine particles from separating and releasing from the toner and maintaining the chargeability, fluidity and agglomeration resistance thereof, it is not desirable that the toner is stirred or fed by means of an auger or a screw conveyor giving an excessive stress thereto.
Particularly, a color toner has a small particle diameter, and includes a charge controlling agent, a fluidizer, an agglomeration inhibitor and a fusion inhibitor on a surface thereof. Therefore, the color toner has poor fluidity because the particles intertangle each other, and it is not desirable to use a conventional mechanical apparatus such as a rotary valve and an auger since a strong external force applied to the toner involves the risk of impairing the properties thereof.
When a toner and air are mixed to make the toner pneumatic, a toner cloud (a nebula toner formed from a mixture of a toner and air) having floating ultra-microscopic toner is formed and a volume of the toner increases. It is difficult to quickly separate air from the toner cloud only by a structure and a location of a separation tube, and therefore it is difficult to control a compressed amount of the toner by an air separation from the toner cloud using such a tube. When air is supplied to the extremely microscopic toner, a flowing phase thereof increases quickly and easily changes to a dust phase, and it takes time to collect the toner from the dust phase and the dust contaminates the circumference. Once a toner cloud is formed, it takes up to several hours for the toner to fall onto the bottom by itself. It is not easy to fluidize the accumulated toner and fill it into a second container while moderately feeding air to prevent formation of a large toner cloud.
In addition, when the toner is distributed from a first storage container into many second containers, the toner in the second containers occasionally has an irregular ingredient due to the air fed into the storage container.
Because of these reasons, a need exists for an apparatus and a method of fluidizing a toner stored in a first container, and quickly and precisely distributing the toner into a small container without impairing the toner properties and composition and contaminating the circumference, which is easily automated and has good manageability.
Accordingly, an object of the present invention is to provide an apparatus and a method of quickly filling a desired amount of a toner into a second container without giving a particular stress thereto, contaminating the environment and/or exposing an operator to danger.
Another object of the present invention is to provide a technology which can be used for a toner feeder on a production line as well as in a distribution of the toner from a temporary storage container, and which can be used by an end-user to fill the toner into a second container on-demand.
Briefly these objects and other objects of the present invention as hereinafter will become more readily apparent can be attained by a powder filling apparatus including a first container configured to contain a powder. A weighing tank is configured to receive the powder from the first container and discharge a predetermined amount of the powder to a second container, which includes an opening configured to discharge the powder into the second container and a regulator configured to open and close the opening to discharge the predetermined amount of the powder into the second container. A connector is configured to feed the powder from the first container into the weighing tank.
In addition, the regulator of the powder filling apparatus can preferably perform at least three levels of discharging including freely discharging, stopping discharging and partially discharging the powder. Further, the weighing tank of the powder filling apparatus can include a powder fluidizer to fluidize the powder fed from the weighing tank to the second container through the opening.
These and other objects, features and advantages of the present invention will become apparent upon consideration of the following description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings.
Various other objects, features and attendant advantages of the present invention will be more fully appreciated as the same becomes better understood from the detailed description when considered in connection with the accompanying drawings in which like reference characters designate like corresponding parts throughout and wherein:
The present invention includes an apparatus and a method which can prevent problems when a second container is directly filled with a toner from a first container containing or storing the microscopic toner powder. It is difficult to constantly discharge a certain amount of the toner from the first container without giving a stress to the toner because the microscopic toner powder has a peculiar fluidity. In addition, it is difficult to precisely fill the second container with a desired amount of the toner by strongly and weakly discharging the toner, temporarily stopping discharging or discharging in drops. Further, it may be necessary to change the discharge amount of the toner, e.g., when the discharge amount comes close to a predetermined filling amount of the second container, and the discharge amount is often controlled while seeing whether the amount reaches the predetermined amount or estimating when the amount reaches the predetermined amount. The filling method of the present invention can quickly, easily and precisely fill a container.
In the present invention, a toner can be discharged into a weighing tank from a first container and a desired amount of the toner can be filled in a second container by the weighing tank. However, as mentioned later, the weighing tank does not necessarily fill the second container with the toner after the toner is discharged into the weighing tank from the first container. The weighing tank can fill the second container with the toner almost simultaneously when the toner is discharged into the weighing tank from the first container.
In the present invention, the discharge from the first container into the weighing tank is suitable for a quick discharge of a large amount of the toner and the filling from the weighing tank into the second container is suitable for filling a precise desired amount of the toner, and accordingly a combination of both discharges improves the filling operation. It can be considered that the toner is discharged from a first container into a second weighing container having a capacity of a filing amount unit. A desired amount of the toner can be filled by filling amount regulator. Although the first container and the weighing tank of the present invention do not always work in a good timing, which is not necessarily indispensable, the filling amount regulator having a precise structure and performance in the weighing tank smoothly and precisely filling the second container with a desired amount of the toner can not only have the first container and the weighing tank work in a good timing but also quickly fill the second container with the toner.
Further, when first toner fluidizer and the filling amount regulator in the weighing tank work together, the toner can more quickly and precisely be filled. In addition, controlling a feeding amount of air from the first toner fluidizer can control the filling amount of the toner into the second container. Thus, the toner can smoothly be filled without imparting a mechanical stress thereto.
In the present invention, the first container preferably has a sloped bottom surface and a third toner fluidizer feeding air thereon to slightly inflate or float a powder toner filled in the container, promote falling of the toner to a toner discharge opening on the bottom, and smooth a discharge of the toner therefrom without imparting a mechanical stress to the toner. In addition, by controlling a feeding amount of the air from the third toner fluidizer, a discharge amount of the toner from the first container into the weighing tank can be controlled and/or the discharge of the toner can be stopped. Such a construction prevents the toner from accumulating and/or agglutinating on an inside surface of the container to prevent an intermittent discharge of the toner, and prevents the toner from densely accumulating on the toner discharge opening on the bottom to smooth the discharge of the toner into the weighing tank.
The first container and the weighing tank are not necessarily unified and the toner discharged from the first container is preferably fed into the weighing tank through a connector which is a contact route between the first container and the weighing tank. The connector preferably has second toner fluidizer and controls a feeding amount of air therefrom to prevent the toner particles from crosslinking in the connector to control a discharge amount of the toner therethrough into the weighing tank and/or to stop feeding air to stop discharging the toner. In addition, a pressure controller controlling an inside air pressure can optionally be arranged either in the first container or the weighing tank.
In addition, in order to aspirate air in the second container to prevent a toner cloud (a nebula toner formed from a mixture of a toner and air) having a floating toner therein, a suction tube can be inserted into the second container to aspirate only the air without passing the filled toner particles therethrough.
The present invention preferably has a filled toner weight controller controlling a filled amount of the powder toner into the second container, which can be, e.g., a conventional load cell weighing an article loaded thereon and having a monitor displaying a weight of the article.
In addition, the present invention can optionally be arranged such that the filled toner weight controller can smoothly work based on the toner weight weighed by the load cell and the feeding amount of air from the first or third toner fluidizer. Further, a control signal for that purpose can be sent from a central processing apparatus and a timing to send the signal can be computed. The central processing apparatus can have input device giving an instruction or a change instruction thereto to fix a required filling amount and/or change the filling amount.
Hereinafter, examples of the present invention will be specifically explained based on the drawings.
In the filling apparatus of
The first container 10 has a sloped inner wall 12 to aid in a discharge of the toner stored inside to the toner discharge opening 11. In this embodiment, the slope inner wall 12 is a part of a hopper-shaped construction 13 of the first container 10.
As shown in
A first toner fluidizer 33 located in the weighing tank 30 and/or a second toner fluidizer located in the connector 20 can prevent an interruption of the toner feeding and/or falling of the toner in drops. In addition, controlling an amount of feeding air can control a feeding amount of the toner and a size of a toner cloud (a nebula toner formed from a mixture of a toner and air) having a floating ultra-microscopic toner.
The first container 10 and the weighing tank 30 are connected to each other with an upper connector 50 above the connector 20, which has a slope upward from the weighing tank 30 to the first container 10. The upper connector 50 keeps a pressure in the weighing tank 30 equal to that of the first container 10, and when a larger toner cloud than desired) for example, caused by providing too large an amount of the air from the first toner fluidizer 33) is formed, the excessive air can be extracted from the weighing tank 30 into the first container 10 through the upper connector 50. Since the upper connector 50 has a slope upward, the toner accompanied with the air can be returned into the weighing tank 30.
The toner powder discharged from the toner discharge opening 11 on the bottom of the first container 10 passes through the connector 20 into the weighing tank 30. The connector has an air slider formed of a perforated plate, i.e., the second toner fluidizer 21 at least on the bottom surface, which feeds air almost all over the surface in the long direction. The air fed from the second toner fluidizer 21 fluidizes the toner fed through the connector 20 into the weighing tank 30. The connector has a slope downward to the weighing tank 30 and helps the fluidized toner falling into the weighing tank 30.
The toner powder discharged from the toner discharge opening 11 is fed into the weighing tank 30 through the connector 20. The weighing tank 30 in this embodiment has the filling amount regulator 32 at the toner discharge opening 31 to precisely and smoothly fill a desired amount of the toner.
The filling amount regulator 32 in this embodiment is formed of an elastic ring 32a forming the discharge opening 31 and a discharge controller 32b controlling discharge of the toner from the discharge opening 31. The discharge controller 32b is formed of a discharge control member 32d fixed on a discharge control rod 32c reciprocating in the weighing tank 30. The discharge control member 32d is a conical member inserted into and released from the discharge opening 31 to open and close the discharge opening 31. An opening and closing degree of the discharge opening 31 depends on an inserting degree of the conical discharge control member 32d fixed on the discharge control rod 32c reciprocating in the weighing tank 30 into the discharge opening 31 formed by the elastic ring 32a.
When a conical tip having a small diameter of the discharge control member 32d ascends until the tip is completely released from the discharge opening 31, the discharge opening 31 is fully opened, i.e., the toner is freely discharged. When a root of the conical discharge control member 32d having a large diameter descends until the root is completely inserted into the discharge opening 31, the discharge opening 31 is completely closed, i.e., the toner discharge stops. When the conical discharge control member 32d is not completely released from the discharge opening 31 and not completely inserted thereinto, i.e., when the member is inserted thereinto such that there is a clearance between the member and the opening, the discharge opening 31 is half or partially opened according to the insert level, i.e., the toner is partially discharged. A flexible covering member 37 is located on a sleeve 30a of the discharge opening 31, however this covering member 37 can be omitted.
As shown in
However, the filling amount regulator at the discharge opening 31 in the weighing tank 30 is not required. For example, the discharge opening 31 can be formed of an elastic material and a plate member can be used as an openness regulation member, which is adjacent to the discharge opening 31 and slides ahead and backward in plane direction. In addition, a relative location between the discharge opening 31 and a movable member having an opening conformed to the opening of the discharge opening 31 can control the openness.
A drive unit 39 driven by a driving source 39b controlled by a driving control apparatus 39a reciprocates the discharge rod 32c. An air pressure cylinder, a motor, a hydraulic cylinder, etc. can be used as the drive unit 39. An air pressure cylinder is used in this embodiment. A source piping for a compressed air used for the first toner fluidizer 33, the second toner fluidizer 21 and the third toner fluidizer 15 can distribute the compressed air to the driving source 39b to drive the drive unit 39.
The first toner fluidizer 33 has one or more pores discharging air and a first air lead-in tube 33a leading the compressed air into a porous material disposed therein. Similarly, the second toner fluidizer 21 has one or more pores discharging air and a second air lead-in tube 21a leading the compressed air into a porous material disposed therein, and the third toner fluidizer 15 has one or more pores discharging air and a third air lead-in tube 15a leading the compressed air into a porous material disposed therein. In this embodiment, a porous sinter having a smooth surface is used. In addition, this embodiment of the powder filling apparatus has a discharger (not shown) to eliminate static electricity to prevent a toner dust explosion.
As shown in
The first air lead-in tube 33a has a first air feeding control valve 33b positionable to stop feeding air, start feeding air and control an amount of the feeding air. Similarly, the second air lead-in tube 21a has a second air feeding control valve 21b positionable to stop feeding air, start feeding air and control an amount of the feeding air, and the third air lead-in tube 15a has a third air feeding control valve 15b positionable to stop feeding air, start feeding air and control an amount of the feeding air. However, in the present invention, at least one of the air lead-in tubes 33a, 21a and 15a preferably has such an air feeding control valve.
In addition, as shown in
Further, the filling apparatus of the present invention can include a suction tube inserted into the second container to extract air therein filled with the toner.
As shown in
In addition, as shown in
As such a monitor, known displays such as pressure detectors detecting a voltage changed according to an elastic deformation degree due to a weight or a pressure, or a pressure detection device such as a piezoelectric device directly changing an electromotive force according to a pressure, can be used. Filling or stopping filling the toner can be made while seeing a filled amount (weight) of the toner displayed on the monitor 63.
The filled toner weigher 60 optionally has a processor 62 computing the filled toner weight from a difference between an empty weight of the second container 40 and a gross weight thereof filled with the toner.
The processor 62 has an input device 64 to which a predetermined filling weight of the toner can be input and can change the predetermined filling weight thereof while seeing the weight displayed on the monitor 63. In addition, the processor 62 sends a drive instruction signal to the driving control apparatus 39a controlling the driving source 39b of the driving apparatus 39 based on a result of the computation, and the driving control apparatus 39a reciprocates the discharge control rod 32c based on the instruction. The processor 62 can include various CPUs from a simple analog voltage comparator to a microcomputer chip. When the analog voltage comparator is used, an AD converter converts an analog signal into a digital signal, e.g., a pulse signal corresponding to a difference of a predetermined potential.
As mentioned above, when a conical tip having a small diameter of the discharge control member 32d of the discharge control rod 32c ascends until the tip is completely released from the discharge opening 31, the discharge opening 31 is fully opened. When a root of the conical discharge control member 32d having a large diameter descends until the root is completely inserted into the discharge opening 31, the discharge opening 31 is completely closed. When the conical discharge control member 32d is not completely released from the discharge opening 31 and not completely inserted thereinto, i.e., when the member is inserted thereinto such that there is a clearance between the member and the opening, the discharge opening 31 is half or partially opened according to the insert level. Therefore, it can be adjusted to provide any level. However, the discharge control rod 32c of the embodiment of the powder filling apparatus shown in
The input device 64 in this embodiment is a button-and-dial digital switch as a (binary) code generator. When the processor 62 is a CPU with a keyboard, a RAM rewritably storing various data including a weight based on a result of the computation and/or an input signal from the input device, i.e., calling the data in the CPU, computing and storing again a result of the computation and a ROM storing various programs including a processing program for processing the data and various instructing programs can be installed in the processor 62. Then, the processor 62 can be configured, e.g., so as to have a program sending an opening and closing instruction to the first to third air feeding control valves 33b, 21b and 15b. In addition, as shown in
As shown in
In the filling apparatus of the present invention, when an accumulated amount of the toner at the discharge opening of the first container increases and passing speed of the toner powder in the connector decreases due to an increased air resistance, the toner feed automatically stops in some cases. Although fluidizing the toner prevents this, an inflation degree of the toner layer increase in volume of the toner cloud by feeding air into the first container is preferably from 20 to 500% of a depth of the toner layer. When less than 20%, the toner is not smoothly discharged. When greater than 500%, excessive feeding or a blow up of the toner powder occurs in the container. An inflation degree of the toner layer (increase in volume of the toner cloud) in the weighing tank is preferably from 25 to 600% of a depth of the toner layer. In addition, as means of increasing a powder density of the fluidized toner layer, the powder can be fed in a divided pulsed form by intermittently feeding air from a divided porous air slider.
The powder filling apparatus in
A shape and material of the first container 10 are shown in FIG. 8. The first container 10 has a capacity of from 25 to 500 l, and typically has a toner containing capacity of from 10 to 200 kg. The first container 10 preferably has a bottom having a gradient angle of from 30 to 60°, and the connector 20 is preferably fixed to the first container at a gradient angle of from 30 to 60°.
The weighing tank 30 has a capacity of from 0.5 to 20 l, and it is preferable that the tank typically has a toner containing capacity of from 50 to 2,000 g. A two-component non-magnetic (color or monochrome) toner, a one-component non-magnetic (color or monochrome) toner, a one-component magnetic (monochrome) toner, a ferrite carrier developer and a magnetite carrier developer can be used in the apparatus. The apparatus starts fluidizing the toner at an air pressure from 3 to 5 kg/cm2 and an air feeding amount of 0.1 to 1 liter/min, and the fluidization typically becomes stable in 5 to 20 sec.
As previously mentioned, feeding air into the weighing tank 30 further stabilizes (fixes) an air content (a ratio between a solid content and air).
The discharge control member 32d preferably has an outer diameter of from 5 to 50 mm, and the elastic ring 32a preferably has an inner diameter of from 5 to 50 mm. A difference between the outer diameter of the discharge control member and the inner diameter of the elastic ring 32a is typically from −0.5 to +2.0 mm.
A shape and material of the discharge control member 32d are specifically shown in detail in FIG. 9. When the discharge control member 32d is lifted, a clearance between the elastic ring 32a and the discharge control member 32d expands and the toner starts falling to fill the small container 40.
The discharge opening 31 is opened or closed by inserting or releasing the discharge control member 32d into or from the elastic ring 32a. Typically, in the first stage, when an insertion level of the discharge control member 32d into the elastic ring 32a is from 0 to 10%, an opening of the discharge opening 31 is from 95 to 100%. In the second stage, when the insertion level is 40 to 60%, the opening is 5 to 30%. In the third stage, when the insertion level is 95 to 100%, the opening is 0 to 5%.
In the first stage, almost all of a specified amount of the toner is filled in the small container 40. In the second stage, the toner is precisely filled therein until the container is filled with the specified amount of the toner. In the third stage, when the container is filled with the specified amount of the toner, toner feeding is stopped.
The first container 10 needs to have a strength so as not to cut or break due to a weight of the toner contained therein, and a thickness (softness) so as to be easily handled (such that an opening of the bag can easily be tied or wrung). For example, the first container preferably has a thickness of from 30 to 200 μm. The first container made of a bag is hung above the filling apparatus or is located on an inclined plate 12 formed above the apparatus.
As
As
A discharge amount of the toner fed in the weighing tank 30 is controlled by opening and closing a discharge opening 31 and a predetermined amount of the toner is filled in the second container 40.
The powder filling apparatus in
a capacity of the first container 10: 40 to 50 l
a toner amount: 10 to 15 kg
a filling method: fluidizing the toner and the toner falls by gravitation
the toner: a two-component non-magnetic color toner, a one-component non-magnetic color toner, a one-component non-magnetic black toner and/or a one-component magnetic black toner
fluidizing time: 5 to 15 min
a shape of the first container 10: a flat bag or a tapered bag
fluidizer: a porous resin material having a hole diameter of 2 to 15 μm, a porosity of 30% and a thickness of 5 mm
feeding amount of air: 1 to 5 l/min.
The uniformity of the fluidization is visually observed, and can also be observed by a light transmittance with optical means. The second container 40 having an internal volume of 400 cm3 can be filled with the toner in 7 to 20 sec and a release or a sinkage of an external additive can be prevented.
The powder supplied to the powder filling funnel 2 is partly filled in the powder container 3 and partly remains in the powder filling funnel 2 (FIG. 1(B)). The filling speed is not high due to the air remaining in the powder container 3.
The powder amount present in both the powder filling funnel 2 and the powder container 3 is simultaneously weighed without interrupting the filling operation. The powder container 3 is quickly and precisely filled with the powder by comparing total empty weight of the powder filling funnel 2 and the powder container 3 with the powder amount present therein and the total empty weight thereof (FIG. 1C)).
In addition, based on the recognized filling powder amount, an additional filling amount which is a shortage from a target filling amount is filled at a fine-tuned refilling rate to precisely refill the target filling amount. Therefore, an additional amount filling device is separately arranged from the powder filling funnel 2, which fills a certain amount of the additional filling amount at a fine-tuned filling rate. For example, an amount which is not over or rather slightly less than the predetermined filling amount is supplied to the powder filling funnel 2, and the additional amount filling device adds a small amount of the shortage at a slow speed and fine-tuned rate while the powder remains on the powder filling funnel 2.
In addition, the powder container 3 is preferably deaerated by force with a deaerator to fill the container with the powder more smoothly, which makes the bulky powder mixed with air in the powder container 3 compact to obtain a space in which the subsequent powder can be contained.
For example, as means of forcible deaeration, as shown
In the filling apparatus of
The funnel 2 preferably has a light transmittance such that whether the powder therein is discharged into the powder container 3 can be identified from outside, and has a powder discharge portion 22 capable of fitting to a filling opening 31 of the powder container 3.
The first container 10 has a sloped inner wall 14 to aid in a discharge of the toner stored inside to the toner discharge opening 11. In this embodiment, the sloped inner wall 14 is a part of a hopper-shaped construction 13 at the bottom of the first container 10.
The first container 10 and the weighing tank 1 are also connected to each other with an upper connector 50 above the connector 20, which has a slope upward from the weighing tank 1 to the first container 10. The upper connector 50 keeps a pressure in the weighing tank 1 equal to that of the first container 10, and when a larger toner cloud than desired is formed, the excessive air can be extracted from the weighing tank 1 into the first container 10 through the upper connector 50. Since the upper connector 50 has a slope upward, the toner accompanied with the air can be returned into the weighing tank 1.
The toner powder discharged from the toner discharge opening 11 on the bottom of the first container 10 passes through the connector 20 into the weighing tank 1. The connector has an air slider formed of a perforated plate, i.e., the second toner fluidizer 33 at least on the bottom surface, which feeds air almost all over the surface in the long direction. The air fed from the second toner fluidizer 33 fluidizes the toner fed through the connector 20 into the weighing tank 1. The connector has a slope downward to the weighing tank 1 and helps the fluidized toner falling into the weighing tank 1.
The toner powder discharged from the toner discharge 20 opening 11 is fed into the weighing tank 1 through the connector 20. The weighing tank 1 in this embodiment may have the filling amount regulator 32 to precisely and smoothly fill a desired amount of the toner at the toner discharge opening 22. The desired amount can optionally be adjusted.
The filling amount regulator 32 in this embodiment is formed of a elastic ring 32a forming the discharge opening 22 and a discharge controller 32b controlling discharge of the toner from the discharge opening 22. The discharge controller 32b is formed of a discharge control member 32d fixed on a discharge control rod 32c reciprocating in the weighing tank 30. The discharge control member 32d is a conical member inserted into and released from the discharge opening 22 to open and close. An opening and closing degree of the discharge opening 22 depends on an inserting degree of the conical discharge control member 32d fixed on the discharge control rod 32c reciprocating in the weighing tank 1 into the discharge opening 22 formed by the elastic ring 32a.
When a conical tip having a small diameter of the discharge control member 32d ascends until the tip is completely released from the discharge opening 22, the discharge opening 22 is fully opened, i.e., the toner is freely discharged. When a root of the conical discharge control member 32d having a large diameter descends until the root is completely inserted into the discharge opening 22, the discharge opening 22 is completely closed, i.e., the toner discharge stops. When the conical discharge control member 32d is not completely released from the discharge opening 22 and not completely inserted thereinto, i.e., when the member is inserted thereinto such that there is a clearance between the member and the opening, the discharge opening 22 is half or partly opened according to the insert level, i.e., the toner is partially discharged. A flexible covering member 37 is located on a sleeve 30a of the discharge opening 22, however this covering member 37 can be omitted.
As shown in
However, the filling amount regulator at the discharge opening 22 in the weighing tank 1 is not required. For example, the discharge opening 22 can be formed of an elastic material and a plate member can be used as an openness regulation member, which is adjacent to the discharge opening 22 and slides ahead and backward in plane direction. In addition, a relative location between the discharge opening 22 and a movable member having an opening conformed to the opening thereof can control the openness.
A drive unit 39 driven by a driving source 39b controlled by a driving control apparatus 39a reciprocates the discharge control rod 32c. An air pressure cylinder, a motor, a hydraulic cylinder, etc. can be used as the drive unit 39. An air pressure cylinder is used in this embodiment. A source piping for a compressed air used for the first toner fluidizer 33 can distribute the compressed air to the driving source 39b to drive the drive unit 39.
The first toner fluidizer 33 has one or more pores discharging air and a first air lead-in tube 33a leading the compressed air into a porous material disposed therein. In this embodiment, a porous sinter having a smooth surface is used. In addition, this embodiment of the powder filling apparatus has a discharger (not shown) to eliminate static electricity to prevent a toner dust explosion.
As shown in
The first air lead-in tube 33a has a first air feeding control valve 33b positionable to stop feeding air, start feeding air and control an amount of the feeding air. In the present invention, at least one of the air lead-in tubes 33a preferably has such an air feeding control valve.
In addition, the weighing tank 1 of the filling apparatus of the present invention can have pressure controller increasing and decreasing an inside pressure. The first container 10 can have such pressure controller instead of the weighing tank 30 or together therewith. Such a pressure controller controls an inside pressure and/or a toner cloud in the first container 10 and/or the weighing tank 1 into which air is fed from the above-mentioned first to third toner fluidizers.
Further, the filling apparatus of the present invention can include a suction tube 23 inserted into the powder container 3 to extract air therein filled with the toner. The powder discharge portion of the funnel 2 is a hollow tube and the release tube 23 is inserted into the powder container 3 therefrom. The release tube 23 is integral with the funnel 2 such that the tube is released from and inserted into the opening 31 of the powder container 3 to release the air therein from a tip of the tube. The inserted tip of the release tube 23 has a mesh material through which the air, but not the toner particles, can pass.
In addition, the powder filling apparatus of the present invention preferably has a filled toner weigher weighing the filled powder toner in the powder container 3, and the filled toner weigher 41 in this embodiment has a load cell 61 weighing the filled toner weight in the powder container 3 thereon. The load cell 61 is located on a lifter 61a changing a distance between the weighing tank 1 and the powder container 3 while lifting and lowering the load cell. The load cell 61 has monitor 63 displaying a weight of the filled powder toner.
As such a monitor, known displays such as pressure detector detecting a voltage changed according to an elastic deformation degree due to a weight or a pressure or a pressure detection device such as a piezoelectric device directly changing an electromotive force according to a pressure, can be used. Filling or stopping filling the toner can be made while seeing a filled amount (weight) of the toner displayed on the monitor 63.
The filled toner weigher 60 optionally has a processor 62 computing the filled toner weight from a difference between an empty total weight of the powder container 3, filling funnel 2 and suction tube 23 and a gross weight thereof filled with the toner.
The processor 62 has input device 64 in which a predetermined filling weight of the toner can be input and can change the predetermined filling weight thereof while seeing the weight displayed on the monitor 63. In addition, the processor 62 sends a drive instruction signal to the driving control apparatus 39a controlling the driving source 39b of the driving apparatus 39 based on a result of the computation, and the driving control apparatus 39a reciprocates the discharge control rod 32c based on the instruction. The processor 62 can include various CPUs from a simple analog voltage comparator to a microcomputer chip. When the analog voltage comparator is used, an AD converter converts an analog signal into a digital signal, e.g., a pulse signal corresponding to a difference of a predetermined potential.
As mentioned above, when a conical tip having a small diameter of the discharge control member 32d of the discharge control rod 32c ascends until the tip is completely released from the discharge opening 31, the discharge opening 31 is fully opened. When a root of the conical discharge control member 32d having a large diameter descends until the root is completely inserted into the discharge opening 31, the discharge opening 31 is completely closed. When the conical discharge control member 32d is not completely released from the discharge opening 31 and not completely inserted thereinto, i.e., when the member is inserted thereinto such that there is a clearance between the member and the opening, the discharge opening 31 is half or partially opened according to the insert level. Therefore, it can be adjusted to provide any level. However, the discharge control rod 32c of the embodiment of the powder filling apparatus shown in
The input device 64 in this embodiment is a button-and-dial digital switch as a (binary) code generator. When the processor 62 is a CPU with a keyboard, a RAM rewritably storing various data including a weight based on a result of the computation and/or an input signal from the input device, i.e., calling the data in the CPU, computing and storing again a result of the computation and a ROM storing various programs including a processing program for processing the data and various instructing programs, can be installed in the processor 62. Then, the processor 62 can be configured, e.g., so as to have a program sending an opening and closing instruction to each of the air feeding control valves 33b.
As shown in
This document claims priority and contains subject matter related to Japanese Patent Applications Nos. 2002-020980, 2002-320749 and 2002-320632 filed on Jan. 30, 2002, Nov. 5, 2002 and Nov. 5, 2003, respectively, the entire disclosures of which are incorporated herein by reference.
Having now fully described the invention, it will be apparent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit and scope of the invention as set forth herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2002-020980 | Jan 2002 | JP | national |
| 2002-320632 | Nov 2002 | JP | national |
| 2002-320749 | Nov 2002 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 4212331 | Benatar | Jul 1980 | A |
| 5489976 | Ichikawa | Feb 1996 | A |
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