Patent Grant
6907215
The present invention relates to an image forming apparatus such as a copying machine or a printer, and particularly relates to a developing device for use in a tandem type image forming apparatus, and an image forming apparatus incorporating such a developing device.
As systems for a developing device incorporated in an image forming apparatus, there are known a two-component developing system using toner and carrier in developer, and a one-component developing system using no carrier but only toner in developer. Of the one-component developing system, as a one-component color developing system, there are known a four-cycle rotary developing system in which developing devices for respective colors rotate to intermittently abut against a photoconductor in order to perform development on the photoconductor, and a tandem developing system in which development is carried out on photoconductors for respective colors with developing devices substantially fixed.
In addition, the toner 207 supplied onto the toner guide member 211 is carried on the circumferential surface of the supply roller 201, and transferred to a photoconductor drum 215 through a developing roller 213. Then, a regulation blade 217 abuts against the circumferential surface of the developing roller 213 so as to scrape excess toner from the circumferential surface down to an area 219 under the developing roller 213. In addition, in the related art, the width of the blade member 209 is smaller than the width of the toner guide member 211 and the width of the supply roller 201.
In the example shown in
In addition, in the example shown in
When a member for returning toner to the toner receiving portion such as the return roller 223 is provided, the toner suffers mechanical stress so that the lifetime of the toner is shortened. In addition, according to a system in which a developing device is fixed, such as the tandem system, it is necessary to provide a member such as a discharge roller for accelerating the circulation of toner forcibly in order to accommodate the toner in the toner receiving portion efficiently. That results in degradation of the toner in an early stage.
Thus, fogging or solid density changes caused by the image degradation in an early stage are so conspicuous as to be a significant factor in reduction of image quality. In addition, fogging increases the toner consumption so that the running cost for expandable supplies increases
Furthermore, the width of each blade member 209 is smaller than the width of the toner guide member 211 and the width of the supply roller 201. Therefore, on the both side end portions of the toner guide member 211 and the supply roller 201, there are areas where the toner is not delivered from the blade member 209. As a result, in the opposite end portions of the supply roller 201, there is a probability that printing is impossible or printing unevenness is caused by flowing-out of the toner from the inner area.
Further, in the example shown in
Further, in the example shown in
Further, in the example shown in
When such a state occurs, not only does unevenness appear in toner volume on the surface of the developing roller, but the charge condition of the toner is also affected to cause trouble in quality of a print.
It is therefore an object of the invention to reduce mechanical stress on developer to thereby reduce fogging and density changes of the developer and keep good image quality, so that the running cost for expandable supplies can be reduced.
It is also an object of the invention to provide a developing device in which a sufficient volume of toner can be supplied to the upper portion of a supply roller stably, the circulating performance of toner scraped by a regulation blade is improved, and a uniform volume of toner can be supplied all over the lengthwise range of the supply roller stably.
It is also an object of the invention to provide a developing device in which toner existing on a toner guide member is transferred to a supply roller in just proportion so that the toner exists over the lengthwise range of the supply roller with a uniform density.
It is also an object of the invention to provide a developing device in which toner can be carried on the circumferential surface of a supply roller over its lengthwise range surely and uniformly.
It is also an object of the invention to provide a developing device in which toner supply onto a toner guide member can be suspended temporarily in accordance with necessary when the toner consumption is low, for example, in a low duty printing mode or the like.
It is also an object of the invention to provide an image forming apparatus provided with such a developing device.
In order to achieve the above objects, according to the invention, there is provided a developing device, comprising:
a carrier, which carries developer;
a regulation member, disposed at a lower portion of the carrier to control an amount of the developer carried by the carrier;
a first container, disposed below the carrier to contain the developer therein; and
a guiding path, which guides developer dropped by the regulation member from the carrier, to the first container.
Preferably, at least part of the regulation member always situates above a top level surface of the developer contained in the first container.
In such a configuration, it is possible to effectively prevent problems such as blocking of the circulating path where the developer scraped by the regulation member is returned to the first container, blocking of the function that the regulation member scrapes excess toner from the carrier to thereby control the volume of developer to be conveyed to a developing area, or blocking of the function that the regulation member charges developer properly.
Preferably, the developing device further comprises: a supplier, which supplies the developer to the carrier; and a second container, disposed in the vicinity of the supplier to temporarily contain the developer supplied from the first container.
In such configurations, the developer controlled by the regulation member can be recovered in the first container by use of the gravitation or the repose angle of the developer. Thus, stress applied to the developer is eliminated so that the lifetime of the developer can be prolonged. As a result, a stain on the white background of print or a change of density caused by fogging of the developer or lowering of charge quantity of the developer can be reduced so that good image quality can be kept. In addition, the developer consumption is also reduced so that the running cost can be reduced. In addition, the developer can be supplied to a developer carrier effectively.
According to the invention, there is also provided a developing device, comprising:
a carrier, which carries developer;
a supplier, which supplies the developer to the carrier; and
a first container, disposed below the carrier to contain the developer therein; and
a second container, disposed in the vicinity of the supplier to temporarily contain the developer supplied from the first container.
Preferably, the developing device further comprises a receiver, disposed below the supplier to receive the developer supplied from the first container. The second container is provided as a gap defined between the supplier and the receiver.
Preferably, excess developer remaining on the carrier is scraped off by the supplier and transported to the second container.
Preferably, the carrier faces a lower side of an image carrier on which an image is developed.
In such configurations, the developer is conveyed from the first container to the second container, and the developer is supplied from the second container to the supplier. Accordingly, the developer is supplied smoothly and promptly. In addition, developer left behind after development is conveyed to the second container and used smoothly.
According to the invention, there is also provided a developing device, comprising:
a carrier, which carries developer;
a supplier, which supplies the developer to the carrier;
a transporter, which transports the developer to the supplier; and
a receiver, to which the transporter is brought into contact when the transporter transports the developer to the supplier, the receiver disposed below the supplier.
Preferably, the developing device further comprises a first container, disposed below the carrier to contain the developer therein. The transporter is rotatably disposed in the first container such that the developer is transported to the receiver along an inner wall face of the first container.
Here, it is preferable that the supplier is rotatably provided, and a rotation center of the supplier always situates above a top level surface of the developer contained in the first container.
Further, it is preferable that: a portion in the receiver at which the transporter is brought into contact has a first flexibility; and the transporter has a second flexibility which is smaller than the first flexibility.
Preferably, the developing device further comprises a second container, provided as a gap defined between the receiver and the supplier, to temporarily contain the developer transported by the transporter.
Preferably, the transporter is rotatable in a first direction, and the supplier is rotatable in a second direction opposite to the first direction.
Further, it is preferable that: the transporter is rotatably provided; the receiver is angled from a horizontal line by a first angle; and a tangent line between the transporter and the receiver at a portion at which the transporter is first brought into contact with the receiver is angled from a horizontal line by a second angle which is smaller than the first angle.
Further, it is preferable that: the transporter is rotatable in a first direction; and a line connecting a rotation center of the transporter and a portion at which the transporter is first brought into contact with the receiver is angled from a vertical line in the first direction by an angle not less than zero degrees.
In such configurations, not only the developer is supplied to the supplier smoothly and promptly, but also stress on the developer is reduced so that the life of the developer can be prolonged. In addition, the developer can be supplied effectively by setting proper arrangement or rigidity of the receiver and the transporter.
Further, it is preferable that: the transporter has an arm member extended from a rotation center thereof and an elastic fin member provided on a distal end of the arm member to transport the developer situated between the inner wall face of the first container and the fin member, and to be brought into contact with the receiver; a scraper is disposed at a portion in the receiver at which the fin member is brought into contact, and has a leading end for scraping off the developer transported by the fin member; and the fin member has a first width along a rotation axis of the transporter, and the leading end of the scraper has a second width smaller than the first width.
In such a configuration, of the developer conveyed on the full-widthwise surface of the fin member, the developer in a range corresponding to the second width can be surely scraped from the fin member. As a result, there is always a constant volume of developer all over the widthwise range of the leading end of the receiver. Thus, a uniform volume of developer can be supplied to the supplier all over its lengthwise range so that printing can be attained without any variation in developer density in the width direction of a recording medium such as paper.
Here, it is preferable that the supplier is rotatable about a rotation axis, and has a third width along the rotation axis, which is smaller than the second width. In this case, printing can be carried out without any variation in developer density in the width direction of paper.
Preferably, the receiver has a slope portion facing the supplier and angled from a horizontal line by an angle not less than a repose angle of the developer.
In such a configuration, after the developer conveyed by the transporter is scraped by the scraper, the developer slides freely down on the slope portion wholly at a uniform speed. Since the slope portion has a fixed inclination at any point, the advance of the developer to the supplier becomes so uniform that a constant volume of developer can be always supplied to the supply roller stably.
Here, it is preferable that: the receiver has a curved portion continued from a lower end of the slope portion and including a portion abutted against the supplier; and a surface roughness of the slope portion and the curved portion is less than an average diameter of the developer.
In such a configuration, an area whose section is narrowed like a wedge is formed between the curved portion and the supplier. Accordingly, with the advance of the developer, the developer density increases so that the pressure force of the developer on the supplier increases. Thus, the developer becomes easy to be carried on the supplier. In addition, there is no probability that the developer stops due to the irregularities of the surface of the receiver. Thus, the developer is conveyed toward the supplier at a uniform speed all over the surface of the receiver without staying on the receiver.
Preferably, the receiver has side walls at both widthwise ends thereof. In this case, the side walls prevent the developer from being leaked to be conveyed sideways when the developer is conveyed from the scraper to the supplier through the slope portion.
Preferably, the developing device further comprising: a regulation member, disposed at a lower portion of the carrier to control an amount of the developer carried by the carrier; and a guiding path, which guides developer dropped by the regulation member from the carrier, to the first container. The guiding path is angled from a horizontal line by an angle not less than a repose angle of the developer.
In such a configuration, the developer scraped by the regulation member can be introduced into the first container by the above guiding path, stress on the developer is reduced so that the lifetime of the developer can be prolonged.
Further, it is preferable that: the receiver includes a receiving portion for receiving the developer from the transporter, and a storage space continued from the receiving portion for temporarily storing the developer to be delivered to the supplier; the supplier is rotatable about a rotation axis and has a first width along the rotation axis; and an entrance width of the storage space is identical with the first width.
In such a configuration, developer existing over the widthwise range of the storage space in just proportion is carried on the supplier likewise over the widthwise range of the supplier in just proportion. Thus, the developer can be carried on the supplier uniformly over its widthwise range. It is therefore possible to attain a print producing no variation in developer density or no unevenness of printing in the width direction of a recording medium such as paper. Incidentally, it is not limited to the case where both the widths are quite equal to each other, but includes widths in a range where the operation and effect can be obtained.
Preferably, a circularity of the developer is not less than 0.95. More preferably, the circularity of the developer is in a range of 0.95 to 0.97.
Since the developer having such a sphericity is high in fluidity, it is a matter of great technical significance to make the entrance width equal to the first width. With this configuration, the developer can be conveyed toward the supplier uniformly as a whole on the receiver. It is therefore possible to obtain a print with no printing unevenness.
Further, it is preferable that: the supplier is rotatable about a rotation axis and elongated along the rotation axis; and both longitudinal ends of the supplier are sealed to retain the developer inside an effective length of the supplier.
In such a configuration, the developer carried on the both longitudinal ends of the supplier can be prevented from falling to the outside, for example, due to vibration or the like. Accordingly, by use of the whole effective length of the supplier, it is possible to attain printing with no printing unevenness in the opposite ends of a relatively large recording medium such as paper.
Further, it is preferable that: the supplier is rotatable about a rotation axis and elongated along the rotation axis; and a longitudinal width of the supplier has a width of a recording medium on which a developed image is recorded.
In such a configuration, printing is performed on the recording medium with the developer on the supplier in just proportion. It is therefore possible to attain printing with no printing unevenness and without wasting the developer.
Further, it is preferable that: the receiver faces the supplier to define a storage space therebetween for temporarily storing the developer transported by the transporter; and the receiver includes a contact portion abutted onto the supplier so that the gap is narrowed toward the contact portion.
In such a configuration, the storage space is filled with the developer gradually so that the developer is pressed onto the circumferential surface of the supplier. Thus, the developer becomes easy to be carried on the supplier over its longitudinal range surely and uniformly.
Here, it is preferable that a first work function of the supplier is not greater than a second work function of a portion of the receiver defining the storage space.
Further, it is preferable that a first work function of the supplier is not greater than a second work function of the developer.
In such configurations, the charged condition of the developer can be kept proper.
Preferably, the developing device further comprises a shatter, disposed in the vicinity of a receiving portion at which the transporter is brought into contact, which selectively disables the reception of the developer into the receiver.
In such a configuration, continuous conveyance of developer onto the receiver by the transporter conveying the developer can be suspended temporarily by the shutter. Accordingly, it is possible to avoid occurrence of such an undesired state that developer overflows from the storage space so as to run over the supplier and flow directly into the carrier in a mode of low duty printing.
Here, it is preferable that the shutter approaches the receiving portion from thereabove to disable the reception of the developer.
In this case, the shutter makes a linear motion to thereby abut against the receiving portion, so that the developer supply onto the receiver is inhibited by the presence of the shutter.
Alternatively, the shutter may be pivotably supported above the receiving portion, so that the reception of the developer is disabled when the shutter is pivoted downward.
Still alternatively, the shutter is pivotably supported below the receiving portion, so that the reception of the developer is disabled when the shutter is pivoted upward.
Still alternatively, the shutter may be movable between a first position and a second position. Here, the transporter is brought into contact with the receiver at the receiving portion when the shutter is placed at the first position, and the transporter is deformed such that the transporter is not brought into contact with the receiver when the shutter is placed at the second position.
Preferably, the shutter is operated in accordance with a consumption amount of the developer at an image carrier on which an image is developed.
In such a configuration, the shutter is useful when the developer consumption is reduced in a low duty printing mode or the like.
Preferably, the developing device further comprises a sensor which detects an amount of the developer stored in a storage space defined between the receiver and the supplier. The shutter is operated in accordance with the amount of the developer detected by the sensor.
In such a configuration, the developer supply onto the receiver can be controlled in accordance with a real volume of developer staying in the storage space regardless of any one of various printing modes.
According to the invention, there is also provided an image forming apparatus, comprising the above-described developing devices. In this case, excellent image quality can be kept in an image forming apparatus such as a printer.
The above objects and advantages of the present invention will become more apparent by describing in detail preferred exemplary embodiments thereof with reference to the accompanying drawings, wherein:
Preferred embodiments of the invention will be described below with reference to the accompanying drawings. To describe a developing device according to the invention, description will be made first on an example of a tandem type image forming apparatus to which the developing device is incorporated. In
The image forming unit 11 has four image forming stations 21 in which four developing devices receiving different color toners can be set. Incidentally, the four image forming stations 21 are used for developing devices for yellow, magenta, cyan and black respectively, and these stations are distinguished in
The transfer belt unit 15 includes a driving roller 27, a driven roller 29, a tension roller 31, an intermediate transfer belt 33 and a cleaner 34. The driving roller 27 is driven to rotate by a not-shown drive source. The driven roller 29 is disposed obliquely above the driving roller 27. The intermediate transfer belt 33 is laid among the rollers 27, 29 and 31 so as to be driven to circulate in a counterclockwise direction X in FIG. 1. The cleaner 34 abuts against the surface of the intermediate transfer belt 33. The driven roller 29, the tension roller 31 and the intermediate transfer belt 33 are disposed in parallel so as to be inclined with respect to the driving roller 27. Thus, when the intermediate transfer belt 33 is driven, a belt surface 35 in which the belt conveying direction X looks downward is located on the lower side, while a belt surface 37 in which the conveying direction looks upward is located on the upper side.
The photoconductor drums 23 are brought into pressure contact with the belt surface 35 along an arched line, so as to be driven to rotate in the directions shown by the arrows in
Incidentally, the intermediate transfer belt 33 may be disposed in a direction inclined to the right in
The driving roller 27 also has a function as a backup roller for a secondary transfer roller 39. A rubber layer which has, for example, a thickness of about 3 mm and a volume resistivity of not higher than 105 Ω·cm is formed in the circumferential surface of the driving roller 27, and grounded through a metal shaft. Thus, the rubber layer is formed as a conductive path for secondary transfer bias supplied through the secondary transfer roller 39. In addition, the diameter of the driving roller 27 is made smaller than the diameter of the driven roller 29 and the diameter of the tension roller 31. Thus, recording paper can be easily released by the elastic force of the recording paper per se after secondary transfer. The driven roller 29 also serves as a backup roller for the cleaner 34.
Since the rubber layer having high friction and high shock absorption is provided in the driving roller 27 in such a manner, impact generated when a recording medium enters the secondary transfer portion is hard to transmit to the intermediate transfer belt 33 so that the image quality can be prevented from being deteriorated. In addition, when the diameter of the driving roller 27 is made smaller than the diameter of the driven roller 29 and the diameter of the tension roller 31, recording paper can be released easily by the elastic force of the recording paper per se after secondary transfer.
The cleaner 34 is provided on the side of the belt surface 35 having a downward conveying direction. The cleaner 34 has a cleaning blade 41 for removing toner staying on the surface of the intermediate transfer belt 33 after secondary transfer, and a toner conveying path 42 for conveying the recovered toner. The cleaning blade 41 abuts against the intermediate transfer belt 33 in the portion where the intermediate transfer belt 33 is wound on the driven roller 29. In addition, primary transfer members 43 abut against the back surface of the intermediate transfer belt 33 so as to face the photoconductor drums 23 of the image forming stations 21Y, 21M, 21C and 21K. A transfer bias is applied to the primary transfer members 43.
The exposure unit 9 is disposed in a space formed obliquely under the image forming unit 11. The air fan 13 is disposed obliquely above the exposure unit 9. The paper feeding unit 17 is disposed under the exposure unit 9. A scanner 49 constituted by a polygon mirror motor 45 and a polygon mirror 47 is disposed vertically in the bottom portion of the exposure unit 9. In addition, a single f-θ lens 51 and a reflecting mirror 53 are disposed in an optical path B. Further, a plurality of turning mirrors 55 are disposed above the reflecting mirror 53 so as to make scanning optical paths for the respective colors turn back to the photoconductor drums 23, respectively, in no parallel with one another.
In the exposure unit 9, image signals corresponding to the respective colors are emitted from the polygon mirror 47 in the form of laser beams modulated on the basis of a common data clock frequency. The photoconductor drums 23 of the image forming stations 21Y, 21M, 21C and 21K are irradiated with the laser beams passing through the f-θ lens 51, the reflecting mirror 53 and the turning mirrors 55 so that latent images are formed on the photoconductor drums 23, respectively. The length of optical path between the polygon mirror 47 of the exposure unit 9 and the photoconductor drum 23 for one image forming station 21 is set to be substantially equal to that for another image forming station 21.
Accordingly, the scanning width of the optical beam scanned in one optical path becomes substantially equal to that in another optical path. It is therefore unnecessary to provide a special configuration for forming image signals. Thus, laser light sources can form modulated signals based on the common data clock frequency though the signals are modulated with different image signals correspondingly to different color images. Color shift caused by a relative difference in the subscanning direction is prevented because the common reflecting surface is used. It is therefore possible to arrange a color image forming apparatus which is simple in structure and low in cost.
Further, since the polygon mirror motor 45 and the polygon mirror 47 are disposed horizontally in such a manner, force acting on the axial direction of the bearing can be eliminated. Accordingly, even if the number of revolutions increases with the increase in speed and resolution of the image forming apparatus so that the load on the bearing increases, heating in the bearing portion can be reduced. Thus, the change of temperature in the apparatus is reduced so that it is possible to provide an image forming apparatus having a high image quality.
In addition, the turning mirrors 55 are provided to bend the scanning optical paths y, m, c and k so that the height of the casing can be reduced Thus, the apparatus can be made compact. Incidentally, the turning mirrors 55 are disposed to make the scanning optical path lengths of the respective image forming stations Y, M, C and K to the photoconductive drum 23 identical to one another.
In addition, since the vibration of the scanning optics caused by the vibration given to frames supporting the apparatus from the driving system for the image forming unit can be minimized when the scanning optics is disposed in the lower portion of the apparatus, the image quality can be prevented from being deteriorated. Particularly, when the scanner 49 is disposed in the bottom portion of the housing 3, the vibration given to the casing as a whole from the polygon mirror motor 45 itself can be minimized so that the image quality can be prevented from being deteriorated. In addition, when the number of polygon mirror motors 45 as vibration sources is set at one, the vibration given to the casing as a whole can be minimized.
The air fan 13 serves as a cooler. The air fan 13 introduces the air in the arrow direction in
In this embodiment, the respective image forming stations Y, M, C and K are disposed obliquely, and the photoconductor drums 23 are arranged upward in parallel and along an oblique arched line so as to be brought into pressure contact with the belt surface 35 of the intermediate transfer belt 33 having a downward conveying direction. Because of such a positioning relationship, the toner container housings 26 are disposed to be inclined obliquely downward.
The paper feeding unit 17 has a paper feed cassette 57 and a pickup roller 59. In the paper feed cassette 57, a stack of recording media P are retained. The recording media P are fed one by one from the paper feed cassette 57 by the pickup roller 59. The paper conveying unit 19 has a pair of gate rollers 61, a secondary transfer roller 39, a fixer 63, a pair of paper discharge rollers 65, and a double-sided print conveying path 67. The pair of gate rollers 61 define the paper feed timing of the recording media P to the secondary transfer portion. The secondary transfer roller 39 is brought into pressure contact with the driving roller 27 and the intermediate transfer belt 33.
The fixer 63 has a pair of rotatable fixing rollers 69, and a pressure applier. At least one of the fixing rollers 69 includes a heating member such as a halogen heater. The pressure applier applies pressure to at least one of the fixing rollers 69 so as to urge it toward the other fixing roller, so that a secondary image secondary-transferred to a sheet material is pressed onto the recording medium P. The secondary image secondary-transferred to the recording medium is fixed on the recording medium at a predetermined temperature in a nip portion formed by the pair of fixing rollers 69.
In this embodiment, the fixer 63 can be disposed in a space formed obliquely above the belt surface 37 of the intermediate transfer belt 33 having an upward conveying direction, that is, in a space opposite to the image forming stations with respect to the transfer belt. Thus, heat transfer to the exposure unit 9, the intermediate transfer belt 33 and the image forming unit 11 can be reduced so that the frequency with which the operation of correcting color shift is carried out for the respective colors can be reduced. Particularly, the exposure unit 9 is placed farthest from the fixer 63 so that the displacement of components of the scanning optics by heat can be minimized. Thus, color shift can be prevented.
In this embodiment, the intermediate transfer belt 33 is disposed in a direction inclined with respect to the driving roller 27. Accordingly, there appears a wide space on the right side in FIG. 1. The fixer 63 is disposed in the space. The developing rollers 107 and the photoconductor drums 23 are rotated to move upward in the same direction. Thus, the apparatus can be made compact. In addition, the heat generated in the fixer 63 can be prevented from being transferred to the exposure unit 9, the intermediate transfer belt 33 and the respective image forming stations Y, M, C and K located on the left side. In addition, the exposure unit 9 can be disposed in a lower space on the left side of the image forming unit 11. Accordingly, the vibration of the scanning optics of the exposure unit 9 caused by the vibration given to the housing 3 from the driving system of the image forming means can be suppressed to a minimum. It is therefore possible to prevent the image quality from being deteriorated.
In addition, in this embodiment, spherical toner is used to enhance the primary transfer efficiency (approximately 100%). Thus, in each of the photoconductor drums 23, there is installed no cleaning unit for recovering toner left behind after the primary transfer. As a result, the photoconductor drums 23 constituted by photoconductor drums each having a diameter of 30 mm or smaller can be disposed closely to one another so that the apparatus can be miniaturized.
In addition, as there is no cleaning unit installed, the corona charger 25 is adopted. When the charger 25 were provided as a charging roller, a slight amount of toner left behind on the photoconductive drum 23 after the primary transfer would be deposited on the roller to thereby result in a failure in charge. However, toner is hard to adhere to the corona charger 25 which is a non-contact charging unit. It is therefore possible to prevent occurrence of a failure in charge.
The developing devices 100 according to the invention are set in the image forming stations 21Y, 21M, 21C and 21K, respectively, in use. Incidentally, in
The surface of the supply roller 105 is formed out of urethane sponge. The supply roller 105 can rotate in the same direction (counterclockwise direction in
A regulation blade 109 is always brought into pressure contact with the developing roller 107 uniformly all over the lengthwise range of the circumferential surface of the developing roller 107 by the action of a plate spring member 111 and an elastic member 112 provided on the lower side of the plate spring member 111. Thus, the regulation blade 109 scrapes excess toner of the toner adhering to the circumferential surface of the developing roller 107 so that a constant volume of toner is carried on the circumferential surface of the developing roller 107. In addition, the regulation blade 109 also charges toner 113 properly.
The scraped toner falls freely to be mixed into the toner 113 in the toner container 101. This point will be described in detail later. In addition, a seal member 115 is provided so that one end thereof is fixed to the housing 103 while the other end thereof is brought into pressure contact with the upper side of the circumferential surface of the developing roller 107. Thus, the toner 113 in the housing 103 is prevented from flying to the outside.
An agitator 119 is provided in the toner container 101 so as to rotate clockwise in
A top surface 114 of the toner 113 received in the toner container 101 is set to be lower than a place 127 where the regulation blade 109 abuts against the circumferential surface of the developing roller 107. This setting is done for the following reason. That is, if the toner volume were large enough to bury the regulation blade 109, the toner scraped by the regulation blade 109 would be close to the regulation blade so that the circulating path for returning the toner into the toner container 101 would be blocked. In addition, the function of that the regulation blade 109 scrapes excess toner from the developing roller 107 to thereby control the volume of toner to be conveyed to a developing area and the function that the regulation blade 109 charges toner properly would be blocked.
More specifically, in this embodiment, the top surface 114 of the toner 113 received in the toner container 101 is set to be lower than the lower end of the regulation blade 109, and the upper limit of the position of the top surface 114 is placed on the position of an intersecting point 128 between the plate spring member 111 and the elastic member 112. If the top surface 114 of the toner 113 in the toner container 101 were located above the intersecting point 128, the motion of the plate spring member 111 might be put under restraint. Thus, there might be a probability that a proper control pressure could not be obtained. As a result, “function of carrying a constant volume of toner on the circumferential surface of the developing roller 107” or the “function of charging the toner properly” might be blocked. However, as described above, when the upper limit of the position of the top surface 114 of the toner 113 is placed on the position of the intersecting point 128, it is possible to eliminate the probability that the respective functions are blocked.
Between the place 127 where the regulation blade 109 abuts against the circumferential surface of the developing roller 107 and the top surface 114 of the toner 113 received in the toner container 101, a toner guide surface 129 is formed as a part of the housing 103. The toner guide surface 129 is inclined obliquely to the top surface 114 of the toner at an inclination angle not smaller than the repose angle of the toner 113. The toner guide surface 129 has a function of guiding the toner 113 scraped from the circumferential surface of the developing roller 107 by the regulation blade 109 into the toner container 101.
The toner 113 scraped from the circumferential surface of the developing roller 107 by the regulation blade 109 does not have to be always guided into the toner container 101 by the toner guide surface 129. The scraped toner 113 may be designed to fall into the toner container 101 directly. In such a manner, a toner guide space 131 in which the toner 113 scraped from the circumferential surface of the developing roller 107 by the regulation blade 109 is introduced into the toner container 101 is formed under the place 127 where the regulation blade 109 abuts against the circumferential surface of the developing roller 107.
A toner guide member 133 is provided above the toner container 101. The toner guide member 133 has a scraper 135, a flat conveying portion 137, a curved portion 141 and a contact portion 143. The scraper 135 is provided in an end portion 134 more distant from the supply roller 105 and formed to be acute enough to scrape the toner 113 conveyed by the agitating fins 123. The top surface side of the flat conveying portion 137 is formed to be flat and inclined at an angle not smaller than the repose angle of the toner 113 toward the supply roller 105 rather than toward the scraper 135. The curved portion 141 is formed on the downstream side of the flat conveying portion 137 so as to be curved to form a concave surface on its upper side. The contact portion 143 is formed on the downstream side of the curved portion 141 so as to abut against the circumferential surface of the supply roller 105 with a linear pressure set properly. The toner guide member 133 is formed so that the surface roughness of the toner guide member 133 including the flat conveying portion 137, the curved portion 141 and the contact portion 143 is lower than the average particle size of the toner.
In addition, by the presence of the contact portion 143, the toner 113 adhering to the under-side surface of the supply roller 105 falls by gravitation so that the volume of toner which can be supplied to the developing roller can be prevented from being reduced. Thus, the image density can be prevented from being lowered. In addition, a temporal toner storage 139 whose section is narrowed like a wedge is formed between the curved portion 141 and the circumferential surface of the supply roller 105. Here, the phrase “section is narrowed like a wedge” means that the section on the entrance side is relatively wide while the section is narrowed as it goes in the traveling direction of the toner, and the section on the tip side of the wedge becomes narrow enough for the toner not to fall freely.
In the toner guide member 133 shaped thus, the toner 113 conveyed by the agitating fins 123 is scraped by the scraper 135. After that, the scraped toner 113 falls by gravitation along the flat conveying portion 137 at a uniform speed all over its widthwise range and at any place of its inclination-direction range so that the toner is once stored in the temporal toner storage 139. In the temporal toner storage 139 narrowed like a wedge, with the advance of the toner 113 to the narrower area, the pressure contact force against the circumferential surface of the supply roller 105 increases gradually so that the toner 113 is pressed onto the circumferential surface of the supply roller 105. Thus, it becomes easier to carry the toner 113 on the circumferential surface. Incidentally, when the toner 113 is pushed out from the contact portion 143, the toner 113 falls in the toner guide space 131 so as to be returned to the toner container 101 directly or by the guidance of the toner guide surface 129.
Although the contact portion 143 is formed integrally with the toner guide member 133 in the embodiment shown in
Here, dimensions and specifications of the respective essential members will be shown by way of example. In the embodiment, a supply roller having an electric resistance of 105-106 Ω·cm and an Asker-F hardness of 60-70 degrees is used as the supply roller 105. The supply roller 105 is made of urethane foam having a plurality of cells, which has a standard cell diameter of 300-400 μm and a thickness of 24 mm. An elastic layer is formed in the outer circumferential portion of the supply roller so that the supply roller is 15-18 mm in diameter and 297 mm in length. In addition, the gap between the supply roller 105 and the inner surface of the housing 103 above the supply roller 105 is kept about 0.5-1.5 mm. The distance between the upper portion of the temporal toner storage 139 and the inner surface of the housing 103, that is, the height of the portion where the toner is thrown is 6 mm.
In addition, the width of the agitator 119 is 330 mm, and the width of the scraper 135 of the toner guide member 133 is 300 mm. As for the regulation blade 109, conductive urethane rubber about 2 mm thick is pasted to the forward end of a phosphor bronze plate or a stainless steel plate about 0.15 mm thick. Further, a PET film about 0.1-0.2 mm thick is used for the agitating fins 123. As the toner 113, polymerized toner having an average particle size of 7 μm and a negative electrostatic property is used. The toner 113 had a circularity of 0.95-0.97 superior in fluidity.
Incidentally, the dimensions, the circularity of toner, and so on, are shown here by way of example, but not intended to limit the invention. Needless to say, the invention includes other embodiments in which the dimensions and so on are changed suitably without departing from the concept of the invention.
Here, description will be made on the circularity of toner, One-component nonmagnetic toner is obtained in a grinding method or a polymerizing method. Ground toner is produced as follows. That is, a pigment, a release agent and a charge control agent are mixed into a resin binder uniformly by a Henschel mixer, and then melt and kneaded by a biaxial extruder. The mixture is cooled, then passed through a rough grinding step and a fine grinding step, subjected to a classification step, and further added with a fluidity modifier. The ground toner suitable for use in the invention may be spheroidized in order to improve the transfer efficiency. To that end, when a machine capable of grinding into relatively round spheres, for example, Turbomill (manufactured by Kawasaki Heavy Industries, Ltd.) known as a mechanical grinding machine is used in the grinding step, the circularity of toner can be obtained up to 0.93. Further, when a commercially available hot-air spheroidizer “Surfusing System SFS-3 Model” (manufactured by Nippon Pneumatic Mfg. Co., Ltd.) is used for the ground toner, the circularity of the toner can be increased up to 1.00.
On the other hand, as the method for producing polymerized toner, there are a suspension polymerization method, an emulsion polymerization method, and so on. In the suspension polymerization method, polymerizable monomer, a coloring pigment and a release agent are compounded in accordance with necessity, and further added with dyestuffs, polymerization initiator, crosslinker, a charge control agent and other additives. A monomer composition in which such a mixture has been dissolved or dispersed is added to an aqueous phase containing a suspension stabilizer (water-soluble polymer, or water-insoluble inorganic substance) while being stirred to be thereby granulated and polymerized. Thus, colored polymerized toner particles having a desired particle size can be formed.
As for the method for adjusting the circularity of the polymerized toner, the circularity can be changed desirably in the emulsion polymerization method by controlling the temperature and the time in the step of aggregating secondary particles. The adjustable range of the circularity is 0.94-1.00. On the other hand, truly spherical toner can be produced in the suspension polymerization method. The range of the circularity is 0.98-1.00. In addition, when the toner is heated and transformed at a temperature higher than the glass transition point Tg of the toner in order to adjust the circularity of the toner, the circularity can be adjusted desirably in a range of from 0.94 to 0.98. Incidentally, the average particle size and the circularity of toner particles and so on shown in this embodiment are values measured by FPIA-2100 (manufactured by Sysmex Corp.)
In addition, a work function ψSR of the supply roller 105 is designed to have a relationship to a work function ψa of the portion of the temporal toner storage 139 abutting against the supply roller 105 and a work function ψt of the toner 113 as follows:
ψt≧ψSR
ψt≧ψa
Any work function (ψ) is measured by a surface analyzer AC-2 (manufactured by Riken Keiki Co., Ltd.) with a light amount of irradiation of 500 nW. The work function represents energy required for extracting an electron from a substance in question. As a substance has a smaller work function, the substance releases electrons more easily. On the contrary, as a substance has a larger work function, the substance is more difficult to release electrons. Therefore, when a substance having a small work function abuts against a substance having a large work function, the substance having a small work function is charged positively while the substance having a large work function is charged negatively. The work function of any substance itself is measured numerically as energy (eV) for extracting an electron from the substance.
Next, description will be made on the relationship among the width W of each agitating fin 123 of the agitator 119, the entrance width H in the scraper 135 and the width L of the supply roller 105. As shown in
W≧H(≧L)
Here, “(≧L)” means that the relationship “H≧L” is not necessarily satisfied so long as the relationship “W≧H” is satisfied, but the relationship “H≧L” may be satisfied in a preferred embodiment.
When the width W of the agitating fin 123 is not less than the entrance width H in the scraper 135, of the toner 113 placed all over the width of the agitating fin 123, only the toner 113 in a range corresponding to the entrance width H of the toner guide member 133 is scraped from the agitating fin 123 as shown in FIG. 4. Thus, in the portion of the entrance width H, a constant volume of the toner 113 is always present over the lengthwise range of the portion. Accordingly, a constant volume of the toner 113 can be supplied uniformly over the lengthwise range of the supply roller 105. It is therefore possible to attain a print having no variation in toner density in the width direction of paper which is a printing object.
In addition, when the width W of the agitating fin 123 is not less than the entrance width H, it is possible to surely avoid the situation that the toner 113 is not supplied to the both side end portions of the portion having the entrance width H in the toner guide member 133. Also in this point, a print having no variation in toner density in the width direction of paper is guaranteed.
In addition, when the condition “H≧L” is satisfied in the state where the condition “W≧H” is satisfied, a constant volume of the toner 113 is always present in the portion having the entrance width H in the toner guide member 133 as described above. Thus, a uniform volume of the toner 113 is also supplied all over the width of the supply roller 105 having a width less than the entrance width H. It is therefore possible to surely perform printing with no variation in toner density in the width direction of paper.
Next, description will be made on the width of the portion where the toner is moved from the flat conveying portion 137 to the temporary storage portion 139, that is, the relationship between the toner introduction width J to the temporary storage portion 139 and the width L of the supply roller 105.
As shown in
In
On the other hand, in
In the configurations shown in
Next, description will be made on a shutter structure for preventing the toner 113 conveyed by the agitating fin 123 from being accepted onto the toner guide member 133, with reference to
As described above, the toner 113 on the toner guide member 133 falls freely on the toner guide member 133 and then stays in the temporal toner storage 139. When the supply roller 105 rotates, the toner 113 is carried on the circumferential surface thereof and consumed. However, in a case that low duty printing is performed in accordance with the kind of paper to print on or the design to print, toner is supplied excessively to the toner guide member 133 by the agitating fins 123. In this case, it is therefore necessary to suspend the toner supply to the toner guide member 133 by the agitating fins 123. To this end, the shutter structure which will be described below is provided near the scraper 135 of the toner guide member 133.
That is, in the embodiment shown in
In addition, in the embodiment shown in
Further, in the embodiment shown in
Next, description will be made on the circulation of the toner in the developing device according to this embodiment. Of the toner 113 received in the toner container 101, the toner 113 existing in the area 125 between the inner circumferential surface of the toner container 101 and the agitating fin 123 is scooped up by the agitating fin 123 by the rotation action of the agitator 119. The scooped toner 113 is scraped by the scraper 135. The toner 113 scraped by the scraper 135 falls sliding on the flat conveying portion 137 so as to reach the temporal toner storage 139.
The toner 113 stored in the temporal toner storage 139 is successively carried on the circumferential surface of the supply roller 105. After that, the toner is moved to the developing roller 107. Then, excess toner is scraped by the regulation blade 109 while the toner carried by the developing roller 107 is charged by the regulation blade 109 so as to develop an electrostatic latent image formed on the photoconductor drum 23.
The toner 113 scraped by the regulation blade 109 falls in the toner guide space 131 by gravitation so as to be returned to the toner container 101 directly or after sliding down on the toner guide surface 129.
Next, a developing device according to a second embodiment will be described with reference to FIG. 8. In this figure, components similar to those in the first embodiment will be designated by the same reference numerals.
A developing device 100 is constituted by a container housing 103 for storing toner (meshed portion); a toner container 101 formed in the container housing 103; an agitator 119 disposed in the toner container 101; a toner guide member 133 provided above the toner container 101; a supply roller 105 disposed above the toner guide member 133; a contact sheet 149 provided on the toner guide member 133 so as to abut against the lower portion of the supply roller 105; a developing roller 107 provided to abut against the supply roller 105 and face a photoconductor drum 23 through a slight distance (about 100-300 μm); a regulation blade 109 abutting against a lower part of the developing roller 107; a toner guide surface 129 on which the regulation blade 109 is provided and which serves a toner guide path for allowing the toner controlled by the regulation blade 109 to fall on the toner guide path so as to fall freely to the toner container 101; and a seal member 115 for preventing toner leakage while abutting against the developing roller 107 in a direction to recover the toner staying on the developing roller 107 after development.
The developing roller 107 and the photoconductor drum 23 face each other through a slight distance. The developing roller 107 and the photoconductor drum 23 are driven to rotate in reverse directions to each other as shown by the arrows in FIG. 8. In a developing area where the developing roller 107 and the photoconductor drum 23 face each other, the circumferential surfaces of the developing roller 107 and the photoconductor drum 23 move upward in the same direction. A developing bias in which an AC voltage is superimposed on a DC voltage is applied from a developing bias source (not shown) to the developing roller 107 so as to make an oscillating electric field act between the developing roller 107 and the photoconductor drum 23. Thus, toner is supplied from the developing roller to an electrostatic latent image portion formed in the photoconductor, so as to perform development. Incidentally, in this embodiment, the developing roller 107 and the photoconductor drum 23 are designed to face each other through a slight distance in the developing area. However, development may be carried out with the developing roller and the photoconductor in contact with each other in the developing area.
In this embodiment, toner limited not to bury the regulation blade 109 is received in the toner container 101 for the following reasons. That is, if the toner volume were large enough to bury the regulation blade 109, the circulating path for returning the toner scraped by the regulation blade 109 to the toner container 101 smoothly would be blocked. In addition, the role of the regulation blade 109 to scrape excess toner out of the toner on the developing roller 107 to thereby control the volume of toner conveyed to the developing area would be blocked while the role of the regulation blade 109 to charge the toner properly would be blocked. Further, the agitator 119 having flexible agitating fins 123 attached to both end portions thereof is rotatably provided in the toner container 101. Incidentally, a large number of slits are formed in the agitating fins 123. Then, by rotating the agitator 119, the toner received in the toner container 101 is supplied to a temporal toner storage 139 between the toner guide member 133 and the supply roller 105 by the agitating fins 123 attached to the agitator 119.
The supply roller 105 having a conductive elastic layer with a plurality of cells provided in its outer circumferential portion is disposed closely to the temporal toner storage 139. The elastic layer of the supply roller 105 is brought into pressure contact with the developing roller 107. The supply roller 105 and the developing roller 107 are rotated in the same direction so that their circumferential surfaces are moved in reverse directions in their contact area and rubbed against each other. Thus, a voltage equal to the developing bias voltage applied from the developing bias source (not shown) to the developing roller is applied to the supply roller.
One end of the contact sheet 149 formed into a sheet is attached to the toner guide member 133 while the contact sheet 149 is brought into contact with a lower part of the supply roller 105 with a proper linear pressure. By the presence of this contact sheet 149, the toner adhering to the supply roller 105 is prevented from falling down from the lower position of the supply roller 105 by gravitation. Thus, the toner that can be supplied to the developing roller 107 is prevented from being reduced, so that the image density is prevented from being lowered.
Of the toner supplied from the supply roller 105 to the developing roller 107, excess toner is scraped from the developing roller by the regulation blade 109 so that the volume of toner to be conveyed to the developing area is controlled while the toner is charged properly. Incidentally, some of the excess toner scraped from the developing roller 107 by the regulation blade 109 falls onto the toner guide surface 129 under the regulation blade 109 by gravitation, and then slips from this wall. Thus, the toner is returned to the toner container 101. The other of the excess toner falls directly to the toner container 101 so as to be returned thereto. At this time, the angle of the toner guide surface 129 with the horizontal line is set to be larger than the repose angle of the toner. Then, the toner controlled by the regulation blade 109 and charged properly is conveyed to the developing area where the developing roller 107 and the photoconductor drum 23 face each other by the developing roller 107 so as to develop an electrostatic latent image portion on the photoconductor drum 23 by the effect of the oscillating electric field.
After the electrostatic latent image formed on the photoconductor drum 23 is developed thus, the seal member 115 is brought into slight contact with the developing roller 107 in a position where the toner staying on the developing roller 107 is to be returned the inside. Thus, leakage of the toner is prevented. After the development, the toner staying on the surface of the developing roller 107 is removed by the rubbing between the developing roller 107 and the supply roller 105. Thus, the removed toner is mixed with the collected toner in the temporal toner storage 139 between the toner guide member 133 and the supply roller 105, and then supplied from the supply roller 105 to the developing roller 107 as recycled toner.
Here, dimensions and specifications of the respective essential members will be shown by way of example. In this embodiment, the photoconductor drum 23 is 30 mm in diameter and the developing roller 107 is 18 mm in diameter. The photoconductor drum 23 is rotated at a peripheral velocity of about 100-200 mm/s while the peripheral velocity of the developing roller 107 is set to be about 1.5-2 times as high as the peripheral velocity of the photoconductor drum 23. The supply roller 105 has an electric resistance of 105-106 Ω·cm and an Asker-F hardness of 60-70 degrees. The supply roller 105 is made of urethane foam having a plurality of cells, which has a standard cell diameter of 100-150 μm and a thickness of 2-4 mm. An elastic layer is formed in the outer circumferential portion of the supply roller 105 so that the diameter of the supply roller 105 is 15-18 mm. As for the regulation blade 109, conductive urethane rubber about 2 mm thick is pasted to the tip end of a phosphor bronze plate or a stainless steel plate about 0.15 mm thick. In addition, a PET film about 0.1-0.2 mm thick is used for the contact sheet 149 and the agitating fins 123.
According to the configuration, when the toner scraped by the regulation blade 109 is recovered in the toner container 101, stress applied to the toner is eliminated by recovering the toner using its gravitation or its repose angle. As a result, the lifetime of the toner can be prolonged. Accordingly, a stain on the white background of print or a change of density caused by fogging of toner or lowering of charge quantity of toner can be reduced so that good image quality can be kept. In addition, the toner consumption is reduced so that the running cost can be reduced.
In the toner container 101, the center of the supply roller 105 is higher than the top surface of a toner deposit, and a scraper 135 (sheet of PET about 0.15 mm thick) is pasted to the leading end portion of the toner guide member 133 under the supply roller. The toner shown in black in
Incidentally, it is desired that the angle of the scraper 135 with the horizontal line is not smaller than the repose angle of the toner in the state where the scraper 135 has been attached to the toner guide member 133. However, the angle of the scraper 135 may be not larger than the repose angle of the toner. In that case, the toner may indeed stay on the scraper 135 without moving to the temporal toner storage 139, but the scraper 135 is deformed upward as described above after the agitating fin 123 abuts against the scraper 135. Thus, in this state, the angle of the scraper 135 becomes not smaller than the repose angle so that the toner moves to the temporal toner storage 139.
Each of the scraper 135 and the agitating fin 123 is made of a resin sheet. Thus, both the scraper 135 and the agitating fin 123 have a property easy to bend in response to stress. For suitable use of the scraper 135 and the agitating fin 123, it is desired that the scraper 135 has a property easier to bend than the agitating fin 123. To that end, it is desired that the scraper 135 is made thinner when the scraper 135 and the agitating fin 123 are made of the same material, and the rigidity of the scraper 135 is set to be lower when the scraper 135 and the agitating fin 123 are made of different materials. Thus, after sufficient toner is delivered from the agitating fin 123 to the scraper 135, the scraper 135 is deformed to supply the toner to the temporal toner storage 139 promptly.
On the other hand, in a section in the direction of the roller axis, assume that a tangent to the agitating fin 123 at the place where the agitating fin 123 first abuts against the toner guide member 133 is at an angle θ2 with the horizontal line, and the toner guide member 133 is at an angle θ1 with the horizontal line. Then, it is preferable that the relationship θ1>θ2 is established. If the relationship θ1<θ2 were satisfied, the angle of approach (90°−θ2) of the agitating fin 123 at which the agitating fin 123 abuts against the scraper 135 would be large so as to cause problems, that is, to block smooth deformation of the scraper 135, to place an excessive load on the agitating fin 123 to thereby shorten the lifetime of the agitating fin 123, or to increase torque required for rotating the agitator 119 to which the agitating fin 123 is fixed. Further, it can be considered that much noise is generated at the moment the agitating fin 123 abuts against the scraper 135. It is therefore preferable that the relationship θ1>θ2 is satisfied.
In addition, assume that a line segment connecting the place where the agitating fin 123 first abuts against the toner guide member 133 with the rotation center of the agitator 119 to which the agitating fin 123 is fixed is at an angle θ3 with the vertical line. When the rotation direction of the agitator 119 is regarded as positive, it is preferable that the relationship 0≦θ3 is established. If the relationship θ3<0 were established, it would be conceived that the toner at the tip end of the agitating fin 123 might fall down from the agitating fin 123 or the scraper 135 so that sufficient toner might not be supplied to the temporal toner storage 139 efficiently. Thus, there might occur a short supply of toner, resulting in lowering of image density. From the above description, good toner supply can be attained by setting proper arrangement or rigidity of the agitating fin 123 and the scraper 135.
In addition, good toner supply can be attained by setting proper arrangement or rigidity of the agitating fin 123 and the scraper 135.
In each of the above described developing devices 100, portions 100a at which the developing rollers 107 are exposed is formed as shown in FIG. 1. On the other hand, a gap 25a is formed in each corona charger 25 so as to face an associated photoconductive drum 23. At this time, if the gap 25a of the corona charger 25 were located under the portion 100a, there would occur a problem as follows. That is, toner would fall down from the portion 100a by gravitation, and enter the corona charger 25 through the gap 25a of the corona charger 25. Thus, the corona charger 25 would be contaminated with the toner.
In this embodiment, therefore, the gap 25a of the corona charger 25 is made offset toward the intermediate transfer belt 33 so that the gap 25a does not overlap the portion 100a of the developing device 100. Consequently, it is possible to solve the problem that toner falling down from the portion 100a by gravitation enters the corona charger 25 through the gap 25a so that the corona charger 25 is contaminated with the toner.
Although the present invention has been shown and described with reference to specific preferred embodiments, various changes and modifications will be apparent to those skilled in the art from the teachings herein. Such changes and modifications as are obvious are deemed to come within the spirit, scope and contemplation of the invention as defined in the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| P2001-374127 | Dec 2001 | JP | national |
| P2001-374128 | Dec 2001 | JP | national |
| P2001-374129 | Dec 2001 | JP | national |
| P2002-130342 | May 2002 | JP | national |
| P2002-130346 | May 2002 | JP | national |
| P2002-142804 | May 2002 | JP | national |
| P2002-142811 | May 2002 | JP | national |
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| 20030113139 A1 | Jun 2003 | US |
