Patent Grant
8584312
1. Field of the Invention
The present invention generally relates to a cleaning apparatus and a cleaning method which is used in an electrophotographic type image forming apparatus such as a copier or a laser printer to remove deposits such as dust or an extraneous substance attached or fixed on a component having a complicated shape by using a solid cleaning medium. More specifically, the present invention provides an effective technique to efficiently clean a long and thin object to be cleaned.
2. Description of the Related Art
To realize a society with an environmentally-sound material cycle, business equipment manufacturers of copiers, facsimile machines, or printers actively practice recycling activities. In the activities, they collect used products or various units from users, and then disassemble, clean, and reassemble them so as to be used as components or a resin material. In order to reuse components used in these products or various units, a step of removing toner, which is minute particles, attached on the disassembled components or units has been required. Thus, it has been a great challenge to reduce cost and environmental load.
For the cleaning, in general, a wet-type cleaning method has been often employed, such as an ultrasonic wave cleaning method to dip the components or units in a water tank and apply ultrasonic waves, and a shower cleaning method to direct a high speed stream of water to an object to be cleaned by using a nozzle. When such a wet-type cleaning method is used to clean the components or units on which a stain of toner and the like are attached, processing of a waste solution including the toner and the like and a drying process after the cleaning consume a large amount of energy and are very costly.
On the other hand, a dry-type cleaning method using an air blow does not exhibit a sufficient cleaning performance with respect to toner and the like that have a strong attaching force. Therefore, a post-step of wiping with a waste cloth by hand and the like have been required. In this manner, cleaning has been one of the bottleneck steps in reusing and recycling the products.
To solve the above-described problems, a cleaning apparatus disclosed in Patent Document 1 flows air in a cleaning tank, causing lightweight, solid, and easy-to-fly cleaning media to fly in the cleaning tank, so that the cleaning media continuously contact an object to be cleaned, and a deposit attached on the object to be cleaned (attached dust, powder, or a stain fixed in a film state on the object to be cleaned) is separated without using water. In particular, by using cleaning media in flexible thin pieces, a cleaning performance equivalent to or more than the ultrasonic wave cleaning method can be exhibited even with a small amount of the cleaning media.
Moreover, there has been known a method to clean a whole surface of the object to be cleaned without using a cleaning tank for storing the object to be cleaned. By this method, the whole surface of the object to be cleaned is cleaned by removing an extraneous substance in a small spot area of the object by using a blast gun and the like and scanning a blowing position of the blast gun over the object to be cleaned. For example, a cleaning apparatus disclosed in Patent Document 2 causes flying substances formed of a sponge or a rubber sphere having a hollow center, which have a diameter of about 10 to 30 mm, to fly in a cone shaped housing by using compressed air, so as to collide with and clean a spot area of the object to be cleaned.
The dry-type cleaning apparatus as disclosed in Patent Document 1 employs a method to put the object to be cleaned in the cleaning tank so as to be collided with cleaning media. Therefore, a cleaning tank that has a volume equal to or more than the size of the object to be cleaned has been required to be prepared. Because of this, it has been difficult to clean a large object to be cleaned. Moreover, when various components in different sizes are to be cleaned by one cleaning apparatus, a cleaning tank and process conditions have had to be adjusted for the largest component. In this case, when a small object to be cleaned is put in the cleaning tank, it is inefficient since flying cleaning media which do not contribute to cleaning are increased. Further, since an optimum cleaning condition changes depending on the size of the object to be cleaned, there have been problems in that it has been troublesome to adjust the condition in cleaning various kinds of objects, and quality of the cleaning is not consistent.
In the cleaning method disclosed in Patent Document 2, the inside of the housing has a positive pressure. Therefore, it has been difficult to prevent leakage of the small and flexible flying media. Moreover, this cleaning method is more suitable for cleaning a plane surface. In the case of cleaning an object having a three-dimensionally complicated shape, there is usually a space formed between the housing and the object to be cleaned. Thus, it has been difficult to perform cleaning without leaking the cleaning medium. When the cleaning medium is leaked, there have been problems in that an operation environment is polluted, and at the same time, the number of cleaning media flying in the housing is decreased and that the cleaning performance is degraded.
According to at least one embodiment, the present invention is made to improve such disadvantages and provides a cleaning apparatus and a cleaning method which can efficiently clean even an object to be cleaned having a complicated surface shape, by causing cleaning media to fly in a cleaning tank without stagnation as well as by downsizing the volume of the cleaning tank.
Further, according to at least one embodiment, the present invention is made to obtain a consistent cleaning performance by effectively using cleaning media by quickly collecting the cleaning media into the cleaning tank when the cleaning media leak from the space in the cleaning tank where the cleaning medium fly.
According to one aspect of the present invention, a cleaning apparatus for cleaning an object to be cleaned by allowing a cleaning medium caused to fly by an air flow to collide with the object to be cleaned includes a cleaning tank in which the cleaning medium is caused to fly by the air flow and which has an opening configured to allow the object to be cleaned to pass through; a cleaning medium accelerating part provided at a bottom part of the cleaning tank and configured to inject the air flow to cause the cleaning medium to fly; a hollow elongated member configured to have substantially the same inner diameter as a diameter of the opening of the cleaning tank, connected outside the opening of the cleaning tank, and configured to form a movement path for the object to be cleaned; and a cleaning medium returning part configured to return the cleaning medium stagnant in the hollow elongated member into the cleaning tank.
According to another aspect of the present invention, a method for cleaning an object to be cleaned by colliding a cleaning medium caused to fly by an air flow with the object to be cleaned in a cleaning tank having an opening through which the object to be cleaned can pass through is provided. The method includes the steps of sucking air in the cleaning tank; inserting the object to be cleaned into the cleaning tank through a cylindrical movement path for the object to be cleaned, said cylindrical movement path having the substantially same inner diameter as a diameter of the opening and being connected outside the opening; and injecting an air flow into the cleaning tank in which the object to be cleaned is inserted so as to cause the cleaning medium to fly.
The cleaning medium 5 used in the cleaning apparatus 1 is formed of a thin piece material in a square shape having a side of 5 to 10 mm and a thickness of 0.1 to 0.2 mm, by using any flexible material having resistance against shock, such as ceramic, cloth, paper, and resin. In some cases, it is effective to change the size or material of the cleaning medium 5 depending on the object 4 to be cleaned. Appropriate conditions for the cleaning medium 5 can be selected in accordance with the object 4 to be cleaned, without being limited to the above-described conditions.
In this manner, when a force of an air flow is applied to the cleaning medium 5 having a thin piece shape in a direction where a projection area is larger, the cleaning medium 5 is easily accelerated and caused to fly because the cleaning medium 5 having a thin piece shape has quite a small mass with respect to air resistance. Moreover, the cleaning medium 5 has low air resistance in a direction where the projection area is small. When the cleaning medium 5 flies in that direction, a high speed movement is maintained for a long distance. Therefore, the cleaning medium 5 has a high energy and a large effect when contacted with the object 4 to be cleaned. Thus, the deposit (dust, powder, or a stain fixed in a film state) attached on the object 4 to be cleaned can be effectively removed. By repeating circulation of the cleaning medium 5, the cleaning medium 5 contacts the object 4 to be cleaned more frequently. Therefore, a cleaning efficiency of the cleaning apparatus 1 can be enhanced.
In addition, air resistance of the cleaning medium 5 having a thin piece shape largely changes depending on its posture. Therefore, the cleaning medium 5 repeatedly contacts the object 4 to be cleaned by moving in a complicated way such as rapidly changing directions as well as moving along the air flow. Therefore, a high cleaning performance can be exhibited for the object 4 to be cleaned, having a relatively complicated shape.
The cleaning tank unit 2 includes a cleaning tank 6, separating parts 10, and hollow elongated members 11a and 11b. The cleaning tank 6 includes the cleaning medium accelerating part 7, and the separating parts 10. The cleaning tank 6 is formed so that a cleaning medium flying space 9 in the cleaning tank 6 has, for example, a cylindrical shape. Opposing end parts of the cleaning medium flying space 9 are sealed with opposing side walls, and circular openings each having such a diameter that allows the object 4 to be cleaned to pass through are provided at centers of the opposing side walls. The separating parts 10 are formed of a porous member such as a wire mesh, a plastic mesh, a mesh, a perforated metal, or a slit plate, having small apertures or slits which allow gas or a deposit (dust, powder, or a stain fixed in a film state) to pass through but does not allow the cleaning medium 5 to pass through. The separating parts 10 are formed of the above-described member in a smooth shape such as a semi-cylindrical shape, which does not stagnate the cleaning medium 5, at parts of a wall of the cylindrical shape of the cleaning tank 6 with a predetermined distance provided from the bottommost part of the cleaning tank 6. The hollow elongated members 11a and 11b have the same inner diameters as the openings provided at the centers of the opposing side walls of the cleaning tank 6. The hollow elongated members 11a and 11b are formed of cylinders having predetermined lengths and connected outside the respective openings of the opposing side walls of the cleaning tank 6 to form a movement path of the object 4 to be cleaned. On the other hand, an opening end of the hollow elongated member 11b, which is at the opposite side to the cleaning tank 6, is covered with a porous member 12 having a mesh or slits that allows an air flow to pass through but does not allow the cleaning medium 5 to pass through.
The cleaning medium accelerating part 7 includes a cleaning medium accelerating nozzle 13 having plural injecting holes, a compressed air supplying apparatus 14 formed of a compressor, a control valve 15, and an airline 16. The cleaning medium accelerating nozzle 13 has the plural injecting holes aligned in a straight line at a bottom surface of the cleaning tank 6, passing through the cleaning tank 6. The compressed air supplying apparatus 14 supplies compressed air through the airline 16 having the control valve 15 to the cleaning medium accelerating nozzle 13 to cause the nozzle 13 to inject an air so that the cleaning media 5 fly. The control valve 15 controls the compressed air supplied by the compressed air supplying apparatus 14. The airline 16 supplies the compressed air supplied from the compressed air supplying apparatus 14 to the cleaning medium accelerating nozzle 13.
The suction part 8 includes suction ducts 17, a suction pipe 19, and a suction apparatus 18. The suction ducts 17 remove dust or a deposit (dust, powder, or a stain fixed in a film state) included in the air in the cleaning tank 6 or attached on the cleaning medium 5 by the separating parts 10 and sucks them. The suction apparatus 18 sucks the air and/or the deposit in the cleaning tank 6 through the suction pipe 19. The suction pipe 19 carries the air and/or deposit, and the like sucked by the suction ducts 17 through the separating parts 10.
As shown in a perspective view of
An operation to remove a deposit (powder or dust) attached on the object 4 to be cleaned by the cleaning apparatus 1 of the present invention is described below.
The cleaning apparatus 1 drives the suction apparatus 18 at all times to suck air in the cleaning tank 6 from the suction ducts 17 through the separating parts 10. The opening of the hollow elongated member 11a and the porous member 12 of the hollow elongated member 11b generate a suction air flow directed into the cleaning tank 6. In this state, an operator grips the object 4 to be cleaned by the grip part 21 of the holding part 3, and inserts the holding part 3 by which the object 4 to be cleaned is held, through the opening of the hollow elongated member 11a, to insert the object 4 to be cleaned into the cleaning tank 6. When the object 4 to be cleaned held by the holding part 3 reaches the cleaning medium flying space 9, the compressed air supplying apparatus 14 which constitutes the cleaning medium accelerating part 7 is driven. While driving the compressed air supplying apparatus 14, the control valve 15 is opened to supply the compressed air to the cleaning medium accelerating nozzle 13, and an air flow is generated perpendicularly upward in the cleaning medium flying space 9 from the cleaning medium accelerating nozzle 13. By this air flow, the cleaning media 5 fly and a part of them collide with the object 4 to be cleaned, thereby a deposit attached on the surface of the object 4 to be cleaned is efficiently removed.
A part of the cleaning media 5 which have collided with the object 4 to be cleaned fly in a direction of the movement path of the hollow elongated members 11a and 11b while the others fly radially to ultimately reach an inner wall of the cleaning tank 6. Further, the cleaning media 5 which have not collided with the object 4 to be cleaned fly straight as they are and collide with a ceiling of the cleaning tank 6. Here, in the vicinity of an inner wall of the cleaning tank 6, the compressed air supplied by the cleaning medium accelerating part 7 flows along an inner wall of the cylinder perpendicularly crossing the opposing side walls of the cleaning tank 6, and at the same time, a circulation air flow is generated by an air flow sucked by the suction apparatus 18 to flow to the bottom surface of the cleaning tank 6. Therefore, most of the cleaning media 5 which have reached the inner wall of the cleaning tank 6 fall due to the circulation air flow and gravity, and slide down to the vicinity of the cleaning medium accelerating nozzle 13 over the separating part 10. A centrifugal force by the circulation air flow is applied to the cleaning media 5 moving along the inner wall of the cylinder of the cleaning tank 6. Therefore, a probability that the object 4 to be cleaned moves from the openings at the centers of the opposing side walls of the cleaning tank 6 into the hollow elongated members 11a and 11b is decreased. Therefore, although a large amount of cleaning media 5 fly in the cleaning tank 6, a leakage of the cleaning media 5 into the hollow elongated members 11a and 11b is suppressed. A part of the cleaning media 5 which have leaked into the hollow elongated members 11a and 11b is reduced in speed or sucked by an air flow generated in the hollow elongated members 11a and 11b by the suction of the suction apparatus 18 to be collected into the cleaning tank 6. Further, another part of the cleaning media 5 which have leaked into the hollow elongated member 11a is prevented by the scraper part 22 of the holding part 3 to be collected into the cleaning tank 6. In this manner, the cleaning media 5 can be effectively used and a cleaning efficiency can be improved. Moreover, it can be prevented that the cleaning media 5 are leaked outside from the movement path of the object 4 to be cleaned, which is formed of the hollow elongated member 11a.
While the cleaning media 5 slide down to the vicinity of the cleaning media accelerating nozzle 13 by being sucked over the separating part 10, a deposit is separated and sucked from the cleaning media 5 when passing through the separating part 10. The deposit separated by the separating part 10 is collected by the suction apparatus 19 through the suction duct 17 and the suction pipe 19. Moreover, the cleaning media 5 which have reached the vicinity of the cleaning media accelerating nozzle 13 is caused to fly again in a perpendicular upward direction by an air flow injected by the cleaning media accelerating nozzle 13. By repeating this operation, a deposit attached on the surface of the object 4 to be cleaned is removed.
While cleaning the object 4 to be cleaned by using the flying cleaning media 5, the linear acting arm 20 of the holding part 3 is rotated to rotate the object 4 to be cleaned, and at the same time the linear acting arm 20 is moved back and forth so as to clean a whole surface of the object 4 to be cleaned. By rotating and moving back and forth the object 4 to be cleaned by the holding part 3 in this manner, the whole surface of the object 4 to be cleaned having a long size can be surely cleaned.
When the cleaning medium 5 is caused to fly by the cleaning medium accelerating nozzle 13 to clean the object 4 to be cleaned, it is more effective to repeat injecting and stopping of an air flow from the cleaning medium accelerating nozzle 13 by intermittently driving the control valve 15. By repeating injecting and stopping of the air flow in this manner, the cleaning media 5 which have entered the hollow elongated members 11a and 11b can be surely collected into the cleaning tank 6 by a suction air flow generated in the hollow elongated members 11a and 11b by suction of the suction apparatus 18. Further, by rotating the object 4 to be cleaned at a high speed by using a posture changing function of the holding part 3 when the cleaning medium accelerating nozzle 13 is not injecting an air flow, a centrifugal force is applied to the cleaning media 5. Therefore, the cleaning media 5 can be more reliably separated from the object 4 to be cleaned.
In this manner, by circulating the cleaning media 5 in the cleaning medium flying space 9 by suppressing a leakage of the cleaning media 5 from the cleaning tank 6 so as to collide with the object 4 to be cleaned at a high frequency, a cleaning performance can be enhanced. Moreover, by moving the object 4 to be cleaned straight so as to be taken in and out the cleaning tank 6, the object 4 to be cleaned with a size equal to or larger than the cleaning tank 6 can be cleaned even when the cleaning tank 6 has a small volume. Moreover, by configuring the cleaning tank 6 to have a smaller volume, a flying density of the cleaning media 5 can be increased. As a result, a cleaning performance can be considerably improved compared to a conventional cleaning tank.
The description has been made of the case where the cleaning tank 6 is formed in a cylindrical shape. However, the shape of the cleaning tank 6 is not limited to the cylindrical shape as long as the cleaning media 5 circulate along opposing side walls and an inner wall perpendicularly crossing the side walls of the cleaning tank 6 and moves to the position of the cleaning medium accelerating nozzle 13 without stagnation. For example, the cleaning tank 6 may have a front cross-section in a prism shape as shown in
The holding part 3 may have any configuration as long as it can hold the object 4 to be cleaned and change the posture of the held object 4 to be cleaned. As shown in
The above description has been made of the case of generating an air flow in a perpendicular upward direction in the cleaning medium flying space 9 from the cleaning medium accelerating nozzle 13. As shown in a front view of
In this manner, by alternately generating air flows at a certain cycle from the two systems of injecting holes 23a and 23b so as to collide the cleaning medium 5 flying along the cylindrical inner wall of the cleaning tank 6 with the object 4 to be cleaned by the air flow alternately injected from the cleaning medium accelerating nozzle 13, peaks and valleys of a surface of the object 4 to be cleaned, which has protrusions and recessions, can be cleaned. The whole surface of the object 4 to be cleaned having a complicated shape can be surely cleaned, and at the same time, a cleaning speed of the cleaning apparatus 1 can be improved.
In the above description, the two systems of the injecting holes 23a and 23b are provided for the cleaning medium accelerating nozzle 13a, however, one injecting hole 23 may be provided for the cleaning medium accelerating nozzle 13a and an angle of the cleaning medium accelerating nozzle 13a may be variably set. Moreover, a direction changing mechanism to change a direction of an injected air flow may be provided in the vicinity of the injecting hole 23. The direction changing mechanism may be formed by providing a flow control plate of which an angle is variable or plural injecting holes with different angles so that air flows are simultaneously generated and an angle of the air flow is changed by combining the air flows.
In the above description, the hollow elongated members 11a and 11b are provided at the opposing side walls of the cleaning tank 6. However, as shown in a cross-sectional view of
In this manner, in the cleaning apparatus 1 in which the hollow elongated member 11a is connected to the opening of one of the side walls of the cleaning tank 6 and the deformable mechanism 25 formed of a flexible rubber film is provided at the opening of the other side wall, the object 4 to be cleaned is inserted from the hollow elongated member 11 into the cleaning tank 6 in a state where a suction air flow is generated by the suction apparatus 18. When the object 4 to be cleaned is cleaned by the cleaning media 5 which are caused to fly by injecting an air flow from the cleaning medium accelerating nozzle 13, an influent air flow (which flows into the hollow elongated member 11a) is generated at an input slot of the hollow elongated member 11a connected to the opening of one of the side walls of the cleaning tank 6. The opening of the other side wall of the cleaning tank 6 is sealed with the deformable mechanism 25 formed of a flexible rubber film. The deformable mechanism 25 is deformed inward of the cleaning tank 6 due to the suction air flow of the suction apparatus 18. Thus, stagnation of the flying cleaning media 5 can be prevented. Therefore, the cleaning media 5 can be effectively used and a cleaning performance can be improved.
When the object 4 to be cleaned is further advanced in the cleaning apparatus 1 in this state, a leading end of the object 4 to be cleaned contacts the deformable mechanism 25 as shown in
As the deformable mechanism 25 provided at a forward direction of the advancement of the object 4 to be cleaned in the cleaning tank 6, a cornice member 26 as shown in
In this manner, by providing the deformable mechanism 25 in the forward direction of the advancement of the object 4 to be cleaned in the cleaning tank 6, the cleaning medium 5 can be caused to fly efficiently by preventing a leakage or stagnation of the cleaning medium 5. Further, the whole surface of the object 4 to be cleaned, which has a longer size than the cleaning tank 6, can be cleaned.
The description has been made on the case where the separating parts 10 are provided at the parts of the cylindrical wall of the cleaning tank 6 with a predetermined distance provided from the bottommost part of the cleaning tank 6. However, the separating part 10 may be provided along the entire surface of the cylindrical wall of the cleaning tank 6 and the suction duct 17 may be provided in an outer peripheral part of the separating part 10 as shown in a front cross-sectional view of
In the above description, one set of the cleaning tank unit 2 is provided for the cleaning apparatus 1. A description is made below on a cleaning apparatus 1a provided with three sets of cleaning tank units 2a to 2c arranged in series as shown in a configuration diagram of
The three respective sets of the cleaning tank units 2a to 2c have the hollow elongated members 11a and 11b connected to the opposing side walls of the respective cleaning tanks 6. The hollow elongated member 11b of the cleaning tank unit 2a and the hollow elongated member 11a of the cleaning tank unit 2b are connected to each other. In a manner similar to this, the hollow elongated member 11b of the cleaning tank unit 2b and the hollow elongated member 11a of the cleaning tank unit 2c are connected to each other. In this manner, the cleaning apparatus 1a is constituted.
As shown in a perspective view of
The plural cleaning medium accelerating nozzles 13 provided for the cleaning tanks 6 of the cleaning tank units 2a to 2c can have different air injecting directions from each other with respect to the movement direction of the holding part 3. For example, the air injecting direction of the cleaning medium accelerating nozzle 13 of the cleaning tank unit 2a is set 90° with respect to the movement direction of the holding part 3. The air injecting direction of the cleaning medium accelerating nozzle 13 of the cleaning tank unit 2b is set to 120° with respect to the movement direction of the holding part 3. The air injecting direction of the cleaning medium accelerating nozzle 13 of the cleaning tank unit 2c is set to 60° with respect to the movement direction of the holding part 3. In this state, the holding part 3 holding the object 4 to be cleaned is moved from the cleaning tank 2a side. When the object 4 to be cleaned that is held by the holding part 3 is at positions of the cleaning tank units 2a to 2c, air flows are injected from the cleaning medium accelerating nozzles 13 of the cleaning tank units 2a to 2c to cause the cleaning media 5 to fly, thereby the object 4 to be cleaned is cleaned.
In this manner, by providing the plural cleaning tank units 2a to 2c in the cleaning apparatus 1a and setting the cleaning medium accelerating nozzles 13 of the cleaning tank units 2a to 2c to inject air flows at different angles from each other, the cleaning media 5 can be collided with the object 4 to be cleaned at the different directions even when the object 4 to be cleaned has a complicated shape with protrusions and recessions. As a result, the object 4 to be cleaned can be cleaned evenly. When there is a sufficient number of the cleaning tank units 2, the holding part 3 is not required to be reciprocated, but is only required to be driven in one direction to obtain a required cleaning result. In this case, moreover, the plural holding parts 3 holding the objects 4 to be cleaned can be inserted in succession to be cleaned. As a result, the plural objects 4 to be cleaned can be successively cleaned in a short time.
Further, the scraper parts 22a and 22b provided at front and back of the holding part 3 can prevent a part of the cleaning media 5 collided with the object 4 from being leaked outside the cleaning tank units 2a to 2c.
Moreover, when the holding part 3 advances straight, the scraper parts 22a and 22b pushes out the cleaning media 5 accumulated on the hollow elongated members 11a and 11b, thereby the cleaning media 5 can be collected into the cleaning tank 6. Accordingly, an amount of the cleaning media 5 flying in the cleaning tank 6 can be maintained to be constant, and the cleaning performance of the cleaning apparatus 1 can be improved.
According to at least one embodiment of the present invention, cleaning media can be caused to fly in a cleaning medium flying space without stagnation. Moreover, the cleaning performance can be maintained by effectively using the cleaning media and stabilizing the amount of flying cleaning media.
According to at least one embodiment, an object to be cleaned passes through a hollow elongated member and an opening for the object to be cleaned, is inserted at a position facing a cleaning medium accelerating part, and collided with the accelerated cleaning media to be cleaned. By placing the opening for the object to be cleaned at a position that does not face the cleaning medium accelerating part, a leakage of the cleaning media from the cleaning tank is suppressed. Further, by quickly collecting the cleaning media which have leaked into the hollow elongated member connected to the opening for the object to be cleaned into the cleaning tank by a cleaning medium returning part, the number of cleaning media in the cleaning tank is stabilized and the cleaning performance is maintained.
This patent application is based on Japanese Priority Patent Application No. 2008-158618 filed on Jun. 18, 2008, and Japanese Priority Patent Application No. 2009-111799 filed on May 1, 2009, the entire contents of which are hereby incorporated herein by reference.
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