Patent Grant
7653335
This application is based on Japanese Patent Application No. 2006-165699 filed on Jun. 15, 2006, in Japanese Patent Office, the entire content of which is hereby incorporated by reference.
The present invention relates to a development apparatus and image forming apparatus for developing a latent image on an image carrier using a developer containing toner and carrier.
In an image forming apparatus using an electrophotographic technology, two systems have been known in the conventional art to develop an electrostatic latent image formed on an image carrier. One is a one-component developing system that uses only toner as a developer, and the other is a two-component developing system that uses both toner and carrier.
In the one-component development system, a toner-supporting member and a regulating plate pressed against the toner-supporting member are generally used. The film thickness is regulated while the toner on the toner-supporting member is pressed by the regulating plate, whereby thin toner layer of a predetermined electrostatic charge can be formed. An electrostatic latent image is developed on the image carrier with this thin toner layer. This method is characterized by excellent dot reproducibility and is capable of providing uniform images with the minimum irregularity. This method also simplifies the structure, downsizes the apparatus and reduces the production cost. However, a heavy stress is applied to the toner in the regulating section made up of a toner-supporting member and a regulating plate pressed against the toner-supporting member. This will degenerate the toner surface, and the toner and external additive agent will attach to the toner regulating member and toner-supporting member surface, with the result that the electrostatic charge of toner is reduced. Thus, contamination inside the apparatus will be caused by fogging on the image and toner splashing due to poorly charged toner. This will lead to the problem of reducing the service life of the development apparatus.
In the meantime, in the two-component developing system, toner is charged by triboelectric charging through mixture between toner and carrier. This results in a smaller stress and greater resistance to possible deterioration of toner. Further, a carrier for electrostatically charging the toner has a greater surface area, and therefore, is more impervious to contamination due to toner or external additive agent. Thus, a longer service life can be expected.
However, the carrier surface is also contaminated by the toner and external additive agent even when the two-component developer is used. The electrostatic charge of toner is reduced through a long-term use, and problems of fogging and toner splashing will arise. The service life cannot be said to be sufficiently long. A still longer service life should be ensured.
A technique of ensuring a prolonged service life of the two-component developer is disclosed in the Unexamined. Japanese Patent Application Publication No. S59-100471. It discloses a development apparatus wherein the carrier, together with toner or independently, is supplied little by little, and the deteriorated developer of reduced charging property is removed accordingly, whereby the carrier is replaced by a new one and hence the percentage of the deteriorated carrier is reduced. Since the carrier is replaced in this apparatus, reduction of the electrostatic charge of toner caused by carrier deterioration is kept to a predetermined level. This technique is efficient in ensuring prolonged service life.
The Unexamined Japanese Patent Application Publication No. 2003-215855 discloses a two-component developer made up of the toner and carrier with the opposite polarity particles having the polarity opposite to that of the toner externally added thereto, and a method of development using this developer. The opposite polarity particles of this development method serve as an abrasive powder and spacer particles. The carrier deterioration can be minimized by removing the spent matters of the carrier surface.
The Unexamined Japanese Patent Application Publication No. H9-185247 discloses a so-called hybrid development method wherein a latent image on the image carrier is developed using the toner-supporting member for carrying only the toner from the two-component developer. The hybrid development method has many characters that cannot be found in the conventional two-component developing system. For example, there is no brush mark on the image by a magnetic brush, excellent dot reproducibility and image uniformity is provided, and migration of the carrier to the image carrier (carrier consumption) does not occur due to the lack of direct contact between the image carrier and magnetic brush. In the hybrid development method, the toner is provided with triboelectric charging with the carrier, and therefore, maintenance of the charge-applying property of the carrier (toner charged triboelectrically by toner and carrier) is important to stabilize the toner charging property and ensure a long-term image quality.
However, the Unexamined Japanese Patent Application Publication No. S59-100471 involves cost and environment problems because a mechanism for collecting the ejected carrier is necessary, and the carrier is a consumable product. Further, a predetermined number of printing operations must be repeated until the percentages of the old and new carrier is stabilized, and the initial characteristics cannot always be maintained. Further, in the Unexamined Japanese Patent Application Publication No. 2003-215855 and Unexamined Japanese Patent Application Publication No. H9-185247, the carrier surface is contaminated by toner and finishing agent with the increasing number of printed sheets, and the charge-applying property of the carrier is reduced.
The object of the present invention is to provide a development apparatus and an image forming apparatus capable of forming high-quality images for a long time using a two-component developer. In view of forgoing, one embodiment according to one aspect of the present invention is a development apparatus for developing an electrostatic latent image in a development area, the apparatus comprising:
a developer tank which is adapted to store developer including toner, carrier for charging the toner, and opposite polarity particles which are charged in an opposite polarity to a polarity of electrostatic charge of the toner; and
a conveyance mechanism which is adapted to convey the toner to the development area and to collect the opposite polarity particles back into the developer tank,
wherein the relative dielectric constant of the opposite polarity particles is no less than 6.7 at 25° C.
According to another aspect of the present invention, another embodiment is an image forming apparatus, comprising:
an image carrier;
an image forming mechanism which is adapted to form an electrostatic latent image on the image carrier; and
a development apparatus which is adapted to develop in a development area the electrostatic latent image formed on the image carrier, the development apparatus including:
The following describes the embodiments of the present invention with reference to drawings:
After having been charged by the charging apparatus 3, the image carrier 1 is exposed to light by the exposure apparatus equipped with the laser light emitting device at the position E of the drawing, and an electrostatic latent image is formed on the surface. The development apparatus 2a develops this electrostatic latent image into the toner image. After having transferred the toner image on this image carrier 1 to the transfer medium P, the transfer roller 4 ejects it in the C-marked direction of the drawing. Subsequent to the transfer, the cleaning blade 5 uses the mechanical force to remove the residual toner on the image carrier 1. The image carrier 1, charging apparatus 3, exposure apparatus, transfer roller 4 and cleaning blade 5 used in the image forming apparatus can use any of the conventional electrophotographic methods. For example, a charging roller is shown as a charging device in the drawing. However, it is also possible to use a charging apparatus not in contact with the image carrier 1. Further, a cleaning blade, for example, does not need to be used.
In this embodiment, the development apparatus 2a includes a developer tank 16 for storing a developer 24, a developer supporting member 11 for conveying the developer 24 supplied from the developer tank by carrying it on the surface thereof, and a separation member for separating the opposite polarity particles from the developer on the developer supporting member. The opposite polarity particles are collected and stored into the developer tank 16. This arrangement controls the consumption of the opposite polarity particles. Moreover, the opposite polarity particles ensure effective compensation for the charging property of the carrier, with the result that the deterioration of the carrier can be reduced for a long time. Thus, electrostatic charge of toner can be maintained effectively for a long time, even in the case of continuous formation of the image having a smaller image area ratio.
If the development apparatus does not have the aforementioned separation member, the effect of reducing the carrier deterioration is decreased in the development apparatus especially when the image area ratio is small. This phenomenon is considered to be caused by the following mechanism: In the two-component developing apparatus, electric field of vibration is applied in the development area to form a strong electric field, thereby improving the separability of toner from the carrier in the developer. The carrier, toner and opposite polarity particles are separated when using the developer including the opposite polarity particles. Although the carrier remains on the developer supporting member due to magnetic attraction, toner is consumed by the image portion of the electrostatic latent image, while the opposite polarity particles are consumed by the non-image portion. Thus, the balance of consumption between toner and opposite polarity particles is not stabilized due to the variety of the image area ratio. Especially when a great number of images having a greater background area have been printed, the opposite polarity particles in the developer are consumed on a priority basis. Thus, the charging property of the carrier cannot be compensated for, and the effect of reducing carrier deterioration is decreased.
The developer 24 in the present embodiment includes the toner, the carrier for charging this toner and opposite polarity particles. The opposite polarity particles are charged oppositely to toner in terms of the charging polarity in the developer. It contains the particles having a relative dielectric constant being equal to or greater than 6.7. The relative dielectric constant is only required to be equal to or greater than 6.7. If the object of the present invention can be achieved, there is no restriction to the upper limit. Such opposite polarity particles are contained in the two-component developer. The opposite polarity particles in the developer are accumulated with the increasing number of printed sheets by the separation member. Thus, even if the toner or finishing agent are deposited (as spent matters) on the carrier surface and the charging property of the carrier is reduced, the opposite polarity particles are deposited onto the carrier surface, whereby toner is triboelectrically charged. This will provide the effect of compensating for reduction in the charge-applying property of the carrier due to the increasing number of printed sheets. Thus, the toner is charged to a predetermined level of electrostatic charge, and effective compensation for carrier deterioration can be achieved.
The opposite polarity particles are deposited on the carrier surface in the developer tank by mixing and agitation. The amount of this deposition is preferably 0.01 through 0.1% by mass with respect to carrier mass. Then more stable electrostatic charge of toner can be obtained by adequate compensation for reduction in the electrostatic charge of toner resulting from the carrier deterioration.
To control the amount of deposition of the opposite polarity particles on the carrier surface, it is preferable to supply a supplemental toner to the development apparatus, the supplemental toner on the surface of which opposite polarity particles are deposited in advance by mixing a predetermined amount of opposite polarity particles. 0.2 through 4% by mass of the opposite polarity particles with respect to toner mass, deposited on this supplemental toner, having a diameter of 0.2 through 0.6 μm are preferably deposited on the toner surface. This arrangement permits uniform supply of the toner and opposite polarity particles into the developer tank. Further, particles having a diameter of 0.2 through 0.6 μm ensure easy separation of the opposite polarity particles from the toner surface by the separation member. The separated opposite polarity particles having a particle diameter of 0.2 through 0.6 μm are returned to the developer tank and are blended with the carrier and stirred in the developer tank, whereby the particles are deposited on the carrier surface. The opposite polarity particles deposited on the carrier surface compensate for the carrier deterioration resulting from an increasing number of printed sheets, and maintain the satisfactory charging property of the toner. The opposite polarity particles having a diameter of less than 0.2 μm cannot ensure easy separation from the toner surface by the separation member. The opposite polarity particles having a diameter of more than 0.6 μm cannot be easily deposited on the carrier surface.
The amount of deposition of the opposite polarity particles on carrier surfaces can be also controlled by adjusting the stirring conditions of the developer tank (the amount of the developer in the developer tank, the rotation speed of the stirring member, etc.), the separation condition by the separation member (separation voltage condition, and gap between the separation member and developer supporting member), and physical properties on the carrier surface. Other factors related to the amount of deposition can be used if any.
(Opposite Polarity Particles)
The opposite polarity particles to be used preferably is selected from among the materials to be charged oppositely to that of the toner. For example, it is possible to use inorganic particles of strontium titanate and barium titanate. It is also possible to treat the surface so as to provide negative or positive charging. Alternatively, a plurality of types of these particles can be mixed for use. In this case, it is preferable for the mixture to include the particles having a relative dielectric constant equal to or greater than 6.7.
To control the charging property and hydrophobic property of the opposite polarity particles, the surface of the inorganic particles can be treated by a silane coupling agent, titanium coupling agent, silicone oil or the like. When inorganic particles are positively charged, it is preferred to treat the surface with a coupling agent containing an amino group. When inorganic particles are negatively charged, it is preferred to treat the surface with a coupling agent containing a fluorine group.
The number average particle diameter of the opposite polarity particles is preferably 100 through 1000 nm.
(Toner)
There is no restriction to the toner to be used. It is possible to use the conventional toner commonly put into general use. The binder resin can contain a coloring agent and, if required, an electric charge controlling agent or mold releasing agent, or can be treated with an external additive agent. The toner particle diameter is not restricted to the aforementioned size. The preferred diameter is about 3 through 15 μm.
Such toner can be manufactured according to the conventional method commonly put into general use. For example, toner can be used according to the pulverization method, emulsion polymerization method, suspension polymerization method or the like.
The binder resin used for toner is not restricted to the aforementioned ones. For example, it is possible to use the styrene resin (a single polymer or copolymer including styrene or substituted styrene), polyester resin, epoxy resin, polyvinyl chloride resin, phenol resin, polyethylene resin, polypropylene resin, polyurethane resin and silicone resin. These resins are used independently or in combination, and are preferred to have a softening temperature of 80 through 160° C. or a glass transition point of 50 through 75° C.
A commonly used conventional coloring agent can be used as the coloring agent. For example, it is possible to use carbon black, aniline black, activated carbon, magnetite, benzine yellow, permanent yellow, naphthol yellow, phthalocyanine blue, first sky blue, ultra marine blue, rose bengal, lake red and others. Generally, 2 through 20 parts by mass of coloring agent is preferably used with respect to 100 parts by mass of the aforementioned binder resin.
As the aforementioned electric charge controlling agent, it is possible to use the conventional agent commonly put into practical use. The electric charge controlling agent for positively charged toner is exemplified by nigrosine dye, quaternary ammonium salt compound, triphenylmethane compound, imidazole based compound, polyamine resin. The electric charge controlling agent for negative charged toner is exemplified by azo dyes containing such metals as Cr, Co, Al and Fe, salicylic acid metal compound, alkyl salicylic acid metal compound, and Kerlix arene compound. Generally, 0.1 through 10 parts by mass of the electric charge controlling agent is preferably used with respect to 100 parts by mass of the aforementioned binder resin.
A commonly used conventional mold releasing agent can be used as the aforementioned mold releasing agent. For example, polyethylene, polypropylene, carnauba wax and sazole wax can be used independently or in combination. Generally, 0.1 through 10 parts by mass of the mold releasing agent is preferably used with respect to 100 parts by mass of the aforementioned binder resin.
A commonly used conventional additive agent can be used as the aforementioned external additive agent. It is possible to use a superplasticizer as exemplified by inorganic particles such as silica, titanium oxide and aluminum oxide, and the resin particles such as acryl resin, styrene resin, silicone resin, and fluorine resin. It is particularly preferred to use the silane coupling agent, titanium coupling agent or silicon oil having been hydrophobed. 0.1 through 5 parts by mass of such a superplasticizer should be added to 100 parts by mass of toner. The number average particle diameter of the external additive agent is preferably 10 through 100 nm.
(Carrier)
There is no particular restriction to the carrier. A commonly used conventional carrier can be used. For example, a binder type carrier and coating type carrier can be used. Although there is no particular restriction, the carrier particle diameter is preferably 15 through 100 μm.
The binder type carrier is made up of the magnetic particles dispersed in the binder resin. Positive or negative electrostatic particles can be deposited onto the carrier surface, or a surface coating layer can be provided. The charging characteristics of the binder type carrier such as polarity can be controlled according to the material of the binder resin, electrostatic particles, and type of the surface coating layer.
The binder resin used in the binder type carrier is exemplified by a vinyl resin represented by a polystyrene resin, a thermoplastic resin such as a polyester resin, nylon resin and polyolefin resin, and a curable resin such as a phenol resin.
The magnetic particles of the binder type carrier that can be used are exemplified by the particles made of: magnetite; spinel ferrite such as gamma iron oxide; spinel ferrite containing one or more metals other than iron (Mn, Ni, Mg, Ci, etc.); magnetoplumbite-type ferrite such as barium ferrite; and iron containing an oxide layer on the surface, and the alloy thereof. These particles can be granular, spherical or acicular. Especially when a high degree of magnetism is required, use of iron-based ferromagnetic particles is preferred. When chemical stability is taken into account, ferromagnetic particles of magnetoplumbite-type ferrite such as spinel ferrite and barium ferrite containing magnetite and gamma iron oxide are preferably used. A magnetic resin carrier of a desired magnetism can be obtained by properly selecting the type and the amount of ferromagnetic particles contained. 50 through 90% by mass of these magnetic particles are preferably added in the magnetic resin carrier.
Silicone resin, acryl resin, epoxy resin and fluorine resin are used as the surface coating material of the binder type carrier. These resins are coated on the surface and are cured to form a coating layer, whereby the charge-applying property is enhanced.
Deposition of the electrostatic particles or conductive particles on the surface of the binder type carrier is carried out, for example, by uniform mixing of the magnetic resin carrier and particles, followed by the process of these particles being deposited on the surface of the magnetic resin carrier and the process of applying mechanical and thermal impact, whereby the particles are driven into the magnetic resin carrier and are fixed in position. In this case, without being embedded completely into the magnetic resin carrier, the particles are partly protruded from the magnetic resin carrier surface, and are secured in position. The electrostatic particles are made of organic or inorganic insulating material. To put it more specifically, the organic material that can be used includes the organic insulating particles of polystyrene, styrene copolymer, acryl resin, various types of acryl copolymers, nylon, polyethylene, polypropylene, fluorine resin and their cross-linked substance. A desired level and polarity of charging can be obtained by proper selection of the material and polymerization catalyst as well as surface treatment. The inorganic material that can be used includes the negative inorganic electrostatic particles such as silica and titanium dioxide, and positive inorganic electrostatic particles such as strontium titanate and alumina.
In the meantime, the coating type carrier is a carrier formed by coating a resin coating on the carrier core particles made of a magnetic substance. In the coating type carrier, similarly to the case of the binder type carrier, the positive or negative electrostatic particles can be deposited on the carrier surface. The charging properties of the coating type carrier such as polarity can be controlled by proper selection of the type of the surface coating layer and electrostatic particles. It is possible to use the same material as that of the binder type carrier. The same resin as the binder type carrier binder resin can be used as the coated resin in particular.
The charging polarity of the toner and the opposite polarity particles can be easily identified, when the opposite polarity particles, toner, and carrier are combined, from the direction for separating the toner or opposite polarity particles from the developer, using the apparatus of
(Preparation of Developer)
The mixing ratio of the toner and carrier should be adjusted so as to get a desired level of electrostatic charge of toner. The toner ratio is preferably 3 through 50% by mass with respect to the total amount of the toner and carrier, more preferably 5 through 20% by mass, although it depends on the ratio of the surface area resulting from the difference between the particle diameters of the toner and carrier.
There is no particular restriction to the amount of the opposite polarity particles contained in the developer as long as the object of the present invention can be achieved. For example, 0.01 through 5.00 parts by mass, particularly 0.01 through 2.00 parts by mass is preferred with respect to 100 parts by mass of the carrier.
The developer can be prepared by mixing the toner with the carrier after the opposite polarity particles have been externally added to the toner in advance, for example.
The supplemental toner to the development apparatus is preferably the toner with opposite polarity particles added externally thereto in advance. In this case, a Henschel mixer, etc. can be used as an external addition apparatus.
(Development Apparatus 2a)
In the development apparatus 2a, the opposite polarity particle collecting member 22 for separating and collecting the opposite polarity particles from the developer on the developer supporting member 11 is adopted as the separation member for separating the opposite polarity particles from the developer on the developer supporting member 11. As shown in
The opposite polarity particle collecting member 22 is connected to the power source 27 as an electric field forming mechanism, and a predetermined opposite polarity particle separation bias is applied. The developer supporting member 11 is connected to the power source 26. Then the opposite polarity particles in the developer are electrically separated and captured on the surface of the opposite polarity particle collecting member 22.
The opposite polarity particle separation bias applied to the opposite polarity particle collecting member 22 varies according to the charging polarity of the opposite polarity particles. To be more specific, when the toner is negatively charged and the opposite polarity particles are positively charged, it is the voltage wherein the average value is lower than that of the voltages applied to the developer supporting member; whereas, when the toner is positively charged and the opposite polarity particles are negatively charged, it is the voltage wherein the average value greater than that of the voltages applied to the developer supporting member. Independently of whether opposite polarity particles are charged positively or negatively, the difference between the average voltage applied to the opposite polarity particle collecting member and the average voltage applied to the developer supporting member is preferably 20 through 500 V, particularly 50 through 300 V. When the potential difference is too small, sufficient recovery of opposite polarity particles will be difficult. In the meantime, if the potential difference is too large, the carrier held on the developer supporting member by magnetic force is separated by the electric field, and the original development function may be lost in the development area.
In the development apparatus 2a, furthermore, AC electric field is preferably formed between the opposite polarity particle collecting member and developer supporting member. Formation of the AC electric field causes the toner to be vibrated back and forth, whereby the opposite polarity particles attached on the toner surface can be separated effectively, and the collectibility of opposite polarity particles is enhanced. In this case, the electric field equal to or greater than 2.5×106 V/m is preferably formed. When the electric field equal to or greater than 2.5×106 V/m is formed, opposite polarity particles can be separated from toner by electric field as well. This further enhances the separability and collectibility of the opposite polarity particles.
In this Specification, the electric field formed between the opposite polarity particle collecting member and developer supporting member is referred to as an opposite polarity particle separation electric field. This opposite polarity particle separation electric field can normally be obtained by application of AC voltage to the opposite polarity particle collecting member and/or developer supporting member. Especially when the AC voltage is applied to the developer supporting member in order to develop the electrostatic latent image by toner, the opposite polarity particle separation electric field is preferably formed using the AC voltage applied to the developer supporting member. In this case, the maximum value of the absolute value of the opposite polarity particle separation electric field should be within the aforementioned range.
For example, assume that the charging polarity of the opposite polarity particles is positive, the DC voltage and AC voltage are applied to the developer supporting member, and only the DC voltage is applied to the opposite polarity particle collecting member. In this case, only the DC voltage lower than the average value of the voltage (DC+AC) applied to the developer supporting member is applied to the opposite polarity particle collecting member. For example, assume that the charging polarity of the opposite polarity particles is negative, DC voltage and AC voltage are applied to the developer supporting member, and only the DC voltage is applied to the opposite polarity particle collecting member. In this case, only the DC voltage higher than the average value of the voltage (DC+AC) applied to the developer supporting member is applied to the opposite polarity particle collecting member. In such cases, the maximum value of the absolute value of the opposite polarity particle separation electric field is the value obtained by dividing the maximum value of the potential difference between the voltage (DC+AC) applied to the developer supporting member and the voltage (DC) applied to the opposite polarity particle collecting member, by the gap at the closest portion between the opposite polarity particle collecting member and developer supporting member. This value is preferably within the aforementioned range.
For example, assume that the charging polarity of the opposite polarity particles is positive, only the DC voltage is applied to the developer supporting member, and the AC voltage and DC voltage are applied to the opposite polarity particle collecting member. In this case, the DC voltage with the AC voltage superimposed thereto so as to get the average voltage lower than the DC voltage applied to the developer supporting member is applied to the opposite polarity particle collecting member. For example, assume that the charging polarity of the opposite polarity particles is negative, only the DC voltage is applied to the developer supporting member, and AC voltage and DC voltage are applied to the opposite polarity particle collecting member. In this case, the DC voltage with the AC voltage superimposed thereto so as to get the average voltage higher than the DC voltage applied to the developer supporting member is applied to the opposite polarity particle collecting member. In such cases, the maximum value of the absolute value of the opposite polarity particle separation electric field is the value obtained by dividing the maximum value of the potential difference between the voltage (DC) applied to the developer supporting member and the voltage (DC+AC) applied to the opposite polarity particle collecting member, by the gap at the closest portion between the opposite polarity particle collecting member and developer supporting member. This value is preferably within the aforementioned range.
For example, assume that the charging polarity of the opposite polarity particles is positive, and the DC voltage with AC voltage superimposed thereon is applied to both the developer supporting member and opposite polarity particle collecting member. In this case, the voltage (DC+AC) wherein the average voltage is smaller than the average value of the voltage (DC+AC) applied to the developer supporting member is applied to the opposite polarity particle collecting member. For example, assume that the charging polarity of the opposite polarity particles is negative, and the DC voltage with AC voltage superimposed thereon is applied to both the developer supporting member and opposite polarity particle collecting member. In this case, the voltage (DC+AC) wherein the average voltage is greater than the average value of the voltage (DC+AC) applied to the developer supporting member is applied to the opposite polarity particle collecting member. In such cases, the value obtained by dividing the maximum value of the potential difference, resulting from the difference in the amplitude, phase, frequency, duty ratio and others of the AC voltage component applied to each of them, between the voltage (DC+AC) applied to the developer supporting member and the voltage (DC+AC) applied to the opposite polarity particle collecting member, by the gap at the closest portion between the opposite polarity particle collecting member and developer supporting member is the maximum value of the absolute value of the opposite polarity particle separation electric field. This value is preferably within the aforementioned range.
The opposite polarity particles on the surface of this member separated and captured by the opposite polarity particle collecting member 22 is collected back into the developer tank 16. When opposite polarity particles are recollected to the developer tank from the opposite polarity particle collecting member, it is only required to reverse the relationship of magnitude between the average value of the voltage applied to the opposite polarity particle collecting member and the average value of the voltage applied to the developer supporting member. This procedure can be taken before starting image formation or after termination of image formation. It can also be taken at the timing of forming non-images such as a space between sheets between image formation operations (space between the previous and succeeding pages) during continuous operation.
The opposite polarity particle collecting member 22 can be made of any material so long as the aforementioned voltage can be applied. It is exemplified by the aluminum roller provided with surface treatment. For example, the upper surface of the conductive substance such as aluminum can be coated with such resins as polyester resin, polycarbonate resin, acryl resin, polyethylene resin, polypropylene resin, urethane resin, polyamide resin, polyimide resin, polysulfone resin, polyether ketone resin, polyvinyl chloride resin, vinyl acetate resin, silicone resin and fluorine resin, or can be coated with such rubbers as silicone rubber, urethane rubber, nitrile rubber, natural rubber, isoprene rubber. Without the coating material being restricted thereto, a conductive agent can be further added to the bulk and surface of the aforementioned coating. The conductive agent is exemplified by an electron conductive agent or ion conductive agent. The electron conductive agent is exemplified by the carbon black such as kechin black, acetylene black and furnace black, and particles such as metallic powder and metallic oxide, without being restricted thereto. The ion conductive agent is exemplified by the cationic compound such as quaternary ammonium salt, amphoteric compound and other ionic high molecular materials, without being restricted thereto. Further, a conductive roller made up of metal material such as aluminum.
The developer supporting member 11 is made up of a magnetic roller 13 located at a fixed position and a freely rotatable sleeve roller 12 including the same. The magnetic roller 13 has five magnetic poles—N1, S1, N3, N2 and S2 in the rotational direction B of the sleeve roller 12. Of these magnetic poles, the main magnetic pole N1 is located in the development area 6 facing the image carrier 1. Further, the poles N3 and N2 are arranged face to face with each other inside the development tank 16, wherein the poles N3 and N2 generate the repellent magnetic field to separate the developer 24 on the sleeve roller 12.
The developer tank 16 is made of a casing 18. It normally incorporates a bucket roller 17 to supply developer to the developer supporting member 11. An ATDC (Automatic Toner Density Control) sensor 20 for detecting the toner density is preferably arranged face to face with the bucket roller 17 of the casing 18.
The development apparatus 2a normally has a supply section 7 for supply into the developer tank 16 as much toner as consumed in the development area 6, and a regulating member (regulating blade) 15 for forming a thin layer of developer to regulate the amount of developer on the developer supporting member 11. The supply section 7 is made up of a hopper 21 for storing a supplemental toner 23, and a supply roller 19 for supplying the toner to the developer tank 16.
The toner with opposite polarity particles externally added thereto is preferably used as the supplemental toner 23. Use of the toner with opposite polarity particles externally added thereto effectively compensate for the reduction of the charging property of the carrier that is gradually deteriorated with use.
In the development apparatus 2a shown in
In
In the development apparatus 2a, not all the opposite polarity particles have to be collected by the opposite polarity particle collecting member. Part of the opposite polarity particles, without being collected, can be consumed for development together with toner. Other opposite polarity particles are collected and the opposite polarity particles are replenished. This provides the effect of assisting the carrier charging by the opposite polarity particles, even if the opposite polarity particles are not completely collected.
Referring to
The development apparatus 2b shown in
As described above, in the development apparatus 2b, unlike the embodiment shown in
In the second embodiment, the same developer 24 as that in the first embodiment is used. To be more specific, the developer 24 contains toner, carrier for charging the toner, and opposite polarity particles. The opposite polarity particles in the developer are charged oppositely to the toner, and contain the particle having a relative dielectric constant equal to or greater than 6.7. The relative dielectric constant is only required to be equal to or greater than 6.7. There is no restriction to the upper limit so long as the object of the present invention can be achieved. Such opposite polarity particles are included in the two-component developer, and opposite polarity particles are accumulated in the developer by the separation member with the increasing number of printed sheets. Thus, even if the toner and finishing agent are deposited (as spent matters) on the carrier surface and the charging property of the carrier is reduced, toner is triboelectrically charged since the opposite polarity particles are deposited onto the carrier surface. This will adequately provide the effect of compensating for reduction in the charge-applying property of the carrier due to the increasing number of printed sheets. Thus, the toner is charged to a predetermined level of electrostatic charge, and effective compensation for carrier deterioration can be achieved.
Opposite polarity particles are deposited on the surface of the carrier in the developer tank by mixing and stirring. The amount of this deposition is preferably 0.01 through 0.1% by mass with respect to the mass of the carrier. This range adequately compensates for the reduction in the electrostatic charge of the toner resulting from carrier deterioration and ensures more stable electrostatic charge of the toner.
To control the amount of the opposite polarity particles deposited on the carrier surface, it is preferred that the toner to be supplied to the development apparatus should be mixed with a predetermined amount of opposite polarity particles in advance, and the supplemental toner on the surface of which adequate opposite polarity particles are deposited should be used. 0.2 through 4% by mass of the opposite polarity particles with respect to the amount of toner have a diameter of 0.2 through 0.6 μm and are preferably deposited to the surface of the supplemental toner. This arrangement permits uniform supply of the toner and opposite polarity particles to the developer tank. The opposite polarity particles having a diameter of 0.2 through 0.6 μm are more easily separated from the toner surface by the separation member. The separated opposite polarity particles having a diameter of 0.2 through 0.6 μm are returned to the developer tank and are mixed and stirred with the carrier in the developer tank, whereby these particles are deposited thereon. The opposite polarity particles deposited on the surface of the carrier compensate for the carrier deterioration resulting from the increasing number of printed sheets, whereby the charging property of the toner is maintained. If the opposite polarity particles have a diameter of less than 0.2 μm, they cannot easily be separated from the surface of the toner by the separation member. If the diameter exceeds 0.6 μm, opposite polarity particles cannot easily be deposited on the surface of the carrier.
The amount of the opposite polarity particles deposited on the surface of carrier can be also controlled by adjusting the stirring conditions in the developer tank (the amount of the developer in the developer tank, the rotation speed of the stirring member, etc.), the condition of separation by the separation member (condition of separation voltage, gap between the separation member and developer supporting member, etc.) and physical properties on the surface of the carrier. Other factors than these conditions can be used if they are related to the amount of deposition. The details of the developer 24 are the same as those described with reference to the embodiment 1, and will not be described to avoid duplication.
(Development Apparatus 2b)
In the development apparatus 2b, the toner-supporting member 25 is connected to the power source 29 as an electric field forming mechanism, and a predetermined toner separation bias is applied thereto. The developer supporting member 11 is connected to the power source 28. Thus, the toner in the developer is electrically separated and carried on the surface of the toner-supporting member 25.
The toner separation bias applied to the toner-supporting member 25 varies according to the toner charging polarity. To be more specific, when toner is negatively charged, it is the voltage wherein the average value is higher than that of the voltage applied to the developer supporting member. When toner is positively charged, it is the voltage wherein the average value is lower than that of the voltage applied to the developer supporting member. Even when the toner is charged either positively or negatively, the difference between the average voltages applied to the toner-supporting member and that applied to the developer supporting member is preferably 20 through 500 V, more preferably 50 through 300 V. If the potential difference is too small, the amount of toner on the toner-supporting member is insufficient so that sufficient image density cannot be obtained. On the other hand, if the potential difference is too large, potential difference is excessive so that excessive toner is supplied, with the result that unwanted toner consumption may increase.
In the development apparatus 2b, an AC electric field is preferably formed between the toner-supporting member and developer supporting member. Formation of the electric field causes the toner to be vibrated back and forth, thereby ensuring effective separation between the toner and opposite polarity particles. In this case, the electric field to be formed is preferably 2.5×106 V/m or more without exceeding 5.5×106 V/m. Formation of the electric field equal to or greater than 2.5×106 V/m allows the opposite polarity particles to be separated from toner by the electric field as well. This signifies a further improvement in the separability of toner. If the electric field is equal to or greater than 5.5×106 V/m, leakage will occur between the toner-supporting member and developer supporting member. This is not preferred.
In the present Specification, the electric field formed between the toner-supporting member and developer supporting member is referred to as a toner separation electric field. Such a toner separation electric field is normally obtained by applying AC voltage to the toner-supporting member and/or developer supporting member. Especially when AC is applied to the toner-supporting member to develop the electrostatic latent image with toner, toner separation electric field is preferably formed using the AC voltage applied to the toner-supporting member. In this case, the maximum value of the absolute value of the toner separation electric field is only required to be the aforementioned range.
For example, assume that the charging polarity of the toner is positive, the DC voltage and AC voltage are applied to the developer supporting member, and only the DC voltage is applied to the toner supporting member. In this case, only the DC voltage lower than the average value of the voltage (DC+AC) applied to the developer supporting member is applied to the toner supporting member. For example, assume that the charging polarity of the toner is negative, the DC voltage and AC voltage are applied to the developer supporting member, and only the DC voltage is applied to the toner supporting member. In this case, only the DC voltage higher than the average value of the voltage (DC+AC) applied to the developer supporting member is applied to the toner supporting member. In such cases, the maximum value of the absolute value of the toner separation electric field is the value obtained by dividing the maximum value of the potential difference between the voltage (DC+AC) applied to the developer supporting member and the voltage (DC) applied to the toner carrier, by the gap at the closest portion between the toner supporting member and developer supporting member. This value is preferably within the aforementioned range.
For example, assume that the charging polarity of the toner is positive, only the DC voltage is applied to the developer supporting member, and the DC voltage and AC voltage are applied to the toner supporting member. In this case, the DC voltage with the AC electric field superimposed thereon so as to get average voltage lower than the DC voltage applied to the developer supporting member is applied to the toner supporting member. For example, assume that the charging polarity of the toner is negative, only the DC voltage is applied to the developer supporting member, and the DC voltage and AC voltages are applied to the toner supporting member. In this case, the DC voltage with the AC electric field superimposed thereon so as to get average voltage higher than the DC voltage applied to the developer supporting member is applied to the toner supporting member. In such cases, the maximum value of the absolute value of the toner separation electric field is the value obtained by dividing the maximum value of the potential difference between the voltage (AC) applied to the developer supporting member and the voltage (DC+AC) applied to the toner carrier, by the gap at the closest position between the toner supporting member and developer supporting member. This value is preferably within the aforementioned range.
For example, assume that the charging polarity of the toner is positive, and the DC voltage with AC voltage superimposed thereon is applied to both the developer supporting member and the toner supporting member. In this case, the voltage (DC+AC) wherein the average voltage is smaller than that of the voltage (DC+AC) applied to the developer supporting member is applied to the toner-supporting member. For example, assume that the charging polarity of the toner is negative, and the DC voltage with AC voltage superimposed thereon is applied to both the developer supporting member and the toner supporting member. In this case, the voltage (DC+AC) wherein the average voltage is greater than that of the voltage (DC+AC) applied to the developer supporting member is applied to the toner-supporting member. In such cases, the value obtained by dividing the maximum value of the potential difference, resulting from the difference in the amplitude, phase, frequency, duty ratio and others of the AC voltage component applied to each of them, between the voltage (DC+AC) applied to the developer supporting member and the voltage (DC+AC) applied to the toner supporting member, by the gap at the closest portion between the toner supporting member and developer supporting member is the maximum value of the absolute value of the toner supporting member separation electric field. This value is preferably within the aforementioned range.
The developer remaining on the developer supporting member 11 from which toner is separated by the toner-supporting member 25, namely, the carrier and opposite polarity particles are conveyed directly by this developer supporting member 11 and is collected back into the developer tank 16. In this embodiment, the opposite polarity particles are conveyed directly by the developer supporting member 11 and is collected back into the developer tank by the developer supporting member 11. This arrangement makes it possible to eliminate the step of returning the opposite polarity particles captured by the opposite polarity particle collecting member described in the embodiment of
The toner-supporting member 25 can be made of any material so long as the aforementioned voltage can be applied. It is exemplified by the aluminum roller provided with surface treatment. For example, the upper surface of the conductive substance such as aluminum can be coated with such resins as polyester resin, polycarbonate resin, acryl resin, polyethylene resin, polypropylene resin, urethane resin, polyamide resin, polyimide resin, polysulfone resin, polyether ketone resin, polyvinyl chloride resin, vinyl acetate resin, silicone resin and fluorine resin, or can be coated with such rubbers as silicone rubber, urethane rubber, nitrile rubber, natural rubber, isoprene rubber. Without the coating material being restricted thereto, a conductive agent can be further added to the bulk and surface of the aforementioned coating. The conductive agent is exemplified by an electron conductive agent or ion conductive agent. The electron conductive agent is exemplified by the carbon black such as kechin black, acetylene black and furnace black, and particles such as metallic powder and metallic oxide, without being restricted thereto. The ion conductive agent is exemplified by the cationic compound such as quaternary ammonium salt, amphoteric compound and other ionic high molecular materials, without being restricted thereto. Further, a conductive roller made up of metal material such as aluminum.
Similarly to the case of the development apparatus 2a, in the development apparatus 2b shown in
In the development apparatus 2b, not all the opposite polarity particles have to remain on the side of the developer supporting member 11 by the electric field between the toner-supporting member 25 and developer supporting member 11. Part of the opposite polarity particles together with toner are allowed to shift to the toner-supporting member 25 so as to be supplied and consumed for development. The opposite polarity particles of other parts are collected and the opposite polarity particles are also replenished. Accordingly, even if the opposite polarity particles are not completely collected, the effect of assisting the charging of the carrier is provided by opposite polarity particles.
In the development apparatus of the embodiments using toner, carrier, and opposite polarity particles charged oppositely to the toner, the opposite polarity particles contain particles having a relative dielectric constant equal to or greater than 6.7, thereby ensuring adequate deposition of the opposite polarity particles to the surface of the carrier, even when toner and finishing agent are attached to the surface of the carrier and are changed into spent matter with the increasing number of prints. Triboelectric charging of these opposite polarity particles and toner compensates for reduction in the electrostatic charge of toner resulting from deterioration of the carrier that has raised a problem in the conventional two-component developing system. This arrangement compensates for reduction in the electrostatic charge of toner resulting from deterioration of the carrier, and hence, provides an image forming apparatus cable of ensuring a stable electrostatic charge of toner for a long time, and forming high-quality images.
The following describes the examples of the present invention:
A development apparatus of
A development apparatus of
Table 1 shows the conditions of processing toner samples 1 through 19 prepared by externally adding the opposite polarity particles to the toner. In the first place, 100% by mass of the toner base material having diameter of about 6.5 μm prepared by the wet type granulating method was surface-treated at a speed of 40 m/s for three minutes using a Henschel mixer (by Mitsui Mining and Smelting Co., Ltd.), in the first external addition, wherein 0.2% by mass of the first hydrophobic silica, 0.5% by mass of the second hydrophobic silica, and 0.5% by mass of hydrophobic titanium oxide was used as a superplasticizer. The first hydrophobic silica in this case was the silica having an average primary particle diameter of 16 nm which was treated by the hexamethyl disilazane (HMDS) as a hydrophobing agent, and was surface-treated. Further, the second hydrophobic, silica was the silica having an average primary particle diameter of 20 nm which was surface treated by HMDS. The hydrophobic titanium oxide was the anatase type titanium oxide having an average primary particle diameter of 30 nm which was surface-treated in the water-wet process by isobutyl trimethoxysilane as a hydrophobing agent. Then the Henschel mixer was used to provide the second treatment, whereby opposite polarity particles were externally added. The details of the processing conditions are given in the samples 1 through 19 of Table 1. In this Table, the amount of external addition is indicated in terms of percentage by mass of opposite polarity particles with respect to 100% by mass of toner base material.
The carrier for the bizhub C350 by Konica Minolta (particle diameter: about 33 μm) and the aforementioned toner are used as the toner and carrier used in the test. The toner ratio in the developer was 8% by mass. The toner ratio was the percentage of the total amount of the toner and finishing agent with respect to the total amount of developer.
Durability test was conducted using the aforementioned development apparatuses A and B, and toner samples 1 through 19 and the developer. The durability test was conducted using the image forming apparatus which is a modified version of the bizhub C350 by Konica Minolta. 50,000 sheets (A4 horizontal paper) of A4 chart with an image area ratio of 5% was copied to measure the amount of the electrostatic charge of toner of the developer in the initial phase and subsequent to durability test, and the amount of the opposite polarity particles deposited on the carrier surface after durability test. A test was also conducted to measure the relative dielectric constant of the opposite polarity particles used in the test and the amount of deposition of the opposite polarity particles, externally added to the toner, having a diameter of 0.2 through 0.6 μm. Table 2 shows the results of these measurements, the amount of change in the electrostatic charge of toner, and evaluation results.
The following describes the method for each measurement.
(Method of Measuring the Electrostatic Charge of Toner)
The electrostatic charge of toner was measured as follows using the apparatus of
(Method of Measuring the Relative Dielectric Constant of Opposite Polarity Particles)
The relative dielectric constant of the opposite polarity particles was measured using the powder measuring electrode made up of the upper and lower electrodes 51 and 52 and guide 53 shown in
∈r=C·L/(∈0·S) (1)
wherein C is an electrostatic capacitance, S is an area of the electrode, L is a gap between the electrodes, and ∈0 is the dielectric constant of vacuum.
(Measuring the Amount of the Opposite Polarity Particles, Having a Particle Diameter of 0.2 through 0.6 μm, Deposited on the Supplemental Toner Surface)
The supplemental toner with opposite polarity particles externally added thereto, and the carrier were mixed so that the toner density (T/C) is 8% by mass in advance. This developer of 30 g was sampled and was put into a 50 ml plastic bottle. This was rotated by a ball mill at a speed of 100 rpm for 30 minutes for mixing and stirring.
The supplemental toner with opposite polarity particles externally added thereto, and the carrier were mixed so that the toner density (T/C) is 8% by mass in advance. This developer of 30 g was sampled and was put into a 50 ml plastic bottle. This was rotated by a ball mill at a speed of 100 rpm for 30 minutes for mixing and stirring.
After that, in the apparatus of
The apparatus of
(Diameter of the Opposite Polarity Particles)
The diameter of the opposite polarity particles was measured as follows. The opposite polarity particles deposited on the aforementioned electrode were photographed by the scanning electron microscope (SEM), VE 8800 by Keyence Corp., and the image thereof was analyzed according to the method of analyzing the particle diameter with the image processing software, Image-ProPlus manufactured by Media Cybernetics (U.S.A.). The SEM image was photographed until the number of particles reached 300, and the distribution of 300 particles and the number of particles were measured. The number ratio of the opposite polarity particles having a diameter of 0.2 through 0.6 μm was calculated from this distribution of particle diameter, and the result was converted to mass ratio. The amount G (% by mass) of the opposite polarity particles having a diameter of 0.2 through 0.6 μm deposited on the supplemental toner was calculated from these values using the following calculation formula (2).
G=(Ma/M1)×k×100 (2)
(Method of Measuring the Amount of Opposite Polarity Particles Deposited on the Surface of Carrier)
The developer was taken from the developer tank, and the carrier was separated from the developer using the apparatus of
(Evaluation of the Test)
The evaluation was made according to the following criteria:
A: Change in the electrostatic charge of toner is less than 5.0 μC in terms of absolute value
B: Change in the electrostatic charge of toner is 5.0 μC or more and less than 10.0 μC in terms of absolute value
C: Change in the electrostatic charge of toner is 10.0 μC or more and less than 20 μC in terms of absolute value
D: Change in the electrostatic charge of toner is equal to or greater than 20 μC in terms of absolute value.
Table 2 shows that, if the relative dielectric constant of the opposite polarity particles is equal to or greater than 6.7, the change in the electrostatic charge of toner is a little, and sufficient stability is ensured. Further, when the relative dielectric constant of the opposite polarity particles is equal to or greater than 6.7, and the amount of opposite polarity particles deposited on the carrier surface subsequent to durability test is 0.01 through 0.1% by mass, reduction in the charging property of the carrier at the time of durability test is very small. Further, if the amount of the opposite polarity particles having a diameter of 0.2 through 0.6 μm deposited on the surface of the supplemental toner is 0.2 through 4% by mass, the amount of the opposite polarity particles deposited on the carrier surface can be kept in the optimum range.
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