1. Field of the Invention
The present invention relates to a developing device for use in a copier, facsimile apparatus, printer or similar image forming apparatus, an image forming apparatus using the same and a process cartridge.
2. Description of the Background Art
A developing device of the type using only toner grains, i.e., a one-component type of toner not containing carrier grains is extensively used. This type of developing device is configured to charge the toner grains in a casing by agitating them and then convey the charged toner grains to a toner carrier. The toner grains thus deposited on the toner carrier are regulated in amount by a metering member and then brought to a developing zone where the toner carrier and an image carrier face each other at the shortest distance. At the developing zone, the toner grains are transferred from the toner carrier to the image carrier to thereby develop a latent image formed on the image carrier.
While the toner grains deposited on the toner carrier should ideally be entirely charged to preselected polarity, some of such toner grains are, in practice, not fully charged. Should the toner grains with short charge be conveyed via the metering member, they would fly away from the toner carrier and would thereby smear the inside of the image forming apparatus as well as paper sheets or similar recording medium.
Further, toner and members that strongly rub against the toner, e.g., the toner carrier, a toner feeding member and the metering member vary with the elapse of time, and so does the toner electrifying ability. As a result, it soon becomes difficult for such members to electrify each other. In addition, it is likely that additives present on the surfaces of the individual toner grains are separated from or buried in the surfaces of the toner grains and fail to exhibit a fluidity enhancing function and an electrification control function expected thereof. Consequently, the ratio of toner grains with short charge to the entire toner grains is apt to increase, and toner grains of opposite polarity and short charge are also apt to increase. If such toner grains are conveyed to the developing zone by the toner carrier, then they smear the background of an image and thereby lower the quality of the image.
In light of the above, various devices have heretofore been proposed to control stress to act on toner grains or to discharge a developer from a developing device before the developer is critically deteriorated. Japanese Patent Laid-Open Publication No. 2002-333764, for example, proposes to obviate, e.g., the blow-off or the blocking of toner grains ascribable to the excessive replenishment from a toner replenishing or storing section to a developing section by returning excessive part of the toner grains to the toner replenishing section. At this instant, part of toner grains with short charge is also returned to the toner replenishing section because of the replacement of toner grains, so that image quality is maintained at a certain acceptable level.
However, the system proposed by the above document has some problems left unsolved. For example, toner grains replenished from the toner replenishing section are soon returned to the replenishing section or not smoothly returned to the replenishing section with the result that excess toner grains increase dynamic torque to an unusual level.
It is an object of the present invention to provide a developing device capable of smoothly discharging toner grains from a developing section, an image forming apparatus using the same and a process cartridge.
A developing device for developing a latent image formed on an image carrier of the present invention is generally made up of a developing section and a developer storing section. The developing section includes a developer carrier for conveying a one-component type developer deposited thereon, a feeding member for feeding the developer to the developer carrier, and a developer conveying member for conveying the developer toward the feeding member while agitating it. The developer storing section replenishes a developer stored therein to the developing section in a direction including at least a horizontal direction component. The developing section and developer storing section are formed with a plurality of openings in the lengthwise direction such that the replenishment of developer from the developer storing section to the developing section and the return of the developer from the latter to the former are executed via the openings.
Referring to
In operation, the charger 3 is applied with a high-tension voltage for uniformly charging the surface of the belt 1. An image signal processor, not shown, converts color image data, e.g., a color image signal received from a computer to an optical writing signal and sends the optical writing signals to the optical writing unit 4. The optical writing unit 4 controls a laser or light source in accordance with the optical writing signal, thereby scanning the belt 1 with a laser beam. As a result, a latent image representative of a Bk (black), a C (cyan), an M (magenta) or a Y (yellow) image is formed on the belt 1. The developing units 5Bk through 5Y, each storing fresh toner or developer of a particular color and charged to opposite polarity to the latent image, each develop one of the above latent images Bk, C, M and Y corresponding in color thereto to thereby form a toner image of a particular color.
At a position where the belts 1 and 6 contact each other, the toner image is transferred from the belt 1 to the belt 6 by a charge opposite in polarity to the toner image applied to the belt 6. Such steps of forming a toner image and transferring it from the belt 1 to the belt 6 are repeated four consecutive times for completing a composite four- or full-color image on the belt 6. The color image thus formed on the belt 6 is transferred to a paper sheet or similar recording medium selectively fed from a sheet cassette 40 or a manual feed tray 41 via a roller pair 42 by a transfer roller 43. The paper sheet, carrying the color image thereon, is conveyed to a fixing unit represented by a fixing roller pair 44 and has the color image fixed thereby.
Reference will be made to
As shown in
The developing roller 14 is partly exposed to the outside via the opening mentioned above and is rotated counterclockwise, as viewed in
The doctor roller 16 is positioned below the feed roller 15 and rotated clockwise, as viewed in
In the illustrative embodiment, a spring or biasing means, not shown, constantly presses the doctor roller 16 against the developing roller 14 in order to absorb changes in the outside diameter of the developing roller 14 and that of the doctor roller 16 ascribable varying ambient conditions including humidity. Inlet seals, not shown, are positioned on the inner periphery of the casing 13 in such a manner as to contact the developing roller 14 at their edges, preventing the toner from leaking via gaps between the developing roller 14 and the casing 13.
The toner cartridge or developer storing section 12 includes agitators 27a and 27b rotatable counterclockwise, as viewed in
The fresh toner is replenished from the toner cartridge 12 to the developing section 11 via a toner or developer replenishing opening 20, which is formed in both of the toner cartridge 12 and casing 13. The toner replenishing openings 20 of the toner cartridge 12 and casing 13 align with each other when the toner cartridge 12 is mounted to the developing unit 5Bk. In the illustrative embodiment, the mean amount of toner to be replenished from the toner cartridge 12 to the developing section 11 is selected to be greater than the mean amount of toner to be transferred from the developing roller 14 to the belt 1 during continuous operation. This configuration, however, is apt to cause an excessive amount of toner to be replenished to the developing section 11 and bring about toner blow-off or toner blocking. Also shown in
As shown in
We conducted a series of experiments and found that the toner could not be smoothly returned from the developing section 11 to the toner cartridge 12 or that the toner was immediately returned from the former to the latter after replenishment, depending on the position of the toner returning openings 21. When the toner was not smoothly returned, torque necessary for driving the developing section 11 increased to an unusual level. Also, when the toner was immediately returned after replenishment, deteriorated toner could not be replaced with the fresh toner. The position of the toner replenishing openings 20 and that of the toner returning openings 21 are the key to the solution of the above problems.
In the developing unit 5 described above, the force of the agitator 27 disposed in the toner cartridge 12 and rotated to move the toner is not directly imparted to the toner return openings 21. Therefore, part of the toner positioned above the toner returning openings 21 is surely returned to the toner cartridge 12 by the rotation of the agitator 17 disposed in the developing section 11. This is successful to protect the developing section 11 from the blow-off or the blocking of toner ascribable to the excessive replenishment of toner to the developing section 11.
Assume that the height of the toner returning openings 21 above the bottom of the developing unit 5 is hB, that the height of the toner replenishing opening 20 above the bottom of the developing unit 5 is hS, and that a height corresponding to a toner-end level Sin the developing section 11 is hO. Then, there should preferably be satisfied a relation:
hB>hO>hS
Further, assume the shortest distance between the circumference of the locus of rotation of the agitator 27 and the toner replenishing openings 20, the shortest distance between the circumference of locus of rotation of the agitator 17 disposed in the developing section 11 and the toner replenishing openings 20, the shortest distance between the circumference of the former and the toner returning openings 21, and the shortest distance between the circumference of the latter and the toner returning openings 21. Then, the circumference of the agitator 27 should preferably be closer to the toner replenishing opening 20 than the circumference of the agitator 17 while the latter should preferably be closer to the toner returning openings 21 than the former.
Moreover, it is preferable to form projections at opposite ends of the toner replenishing opening 20 of the toner cartridge 21 or to form projections 22, not shown, at opposite ends of each toner returning opening 21 of the developing section 11, so that each other's rotating forces are prevented from being imparted to the other via the opening 20 or the openings 21.
An alternative embodiment of the present invention will be described with reference to
In the developing device 5 described above, the force of the agitator 27 in rotation is not directly imparted to the toner returning openings 21, so that part of the toner positioned above the toner returning opening 21 of the developing section 11 is surely returned to the toner cartridge 12 by the agitator 17. This is also successful to protect the developing section 11 from the blow-off or the blocking of toner ascribable to the excessive replenishment of toner to the developing section 11.
In the illustrative embodiment, too, there should preferably hold a relation:
hBT>hO>hS>hB
where hBT denotes the distance or height between the top of each toner return opening 21 and the bottom of the developing unit 5.
In the illustrative embodiment, the toner, once used in the developing section 11 and therefore deteriorated, is discarded and replaced with fresh toner little by little. It is therefore possible to insure stable image quality over a long period of time by controlling the deterioration of the toner in the developing section 11. It is to be noted that the waste toner container 31 may be implemented as a single container removably mounted to the developing section 11 or as a partitioned spaced formed in the toner cartridge 12 and therefore removable integrally with the toner cartridge 12, as desired.
In the illustrative embodiments shown and described, the mean amount of toner to be replenished from the toner cartridge 12 to the developing section 11 is selected to be greater than the mean amount of toner to be transferred from the developing roller 14 to the belt 1 during continuous operation, as stated earlier. More specifically, assume that fresh toner is replenished in a greater amount than toner deposited on and therefore consumed by the photoconductive element when a latent image with a small image area ratio is repeatedly developed. For example, assume that even when the area ratio of an image is 1%, toner corresponding in the amount of consumption to 3% is replenished to the developing section 11 while excess toner is discharged from the developing section 11 via the toner discharging openings 21. Then, toner in the developing section 11 can be replaced with fresh toner little by little without increasing loads on the photoconductive drum or the cleaner. To further reduce wasteful toner replenishment, the amount of replenishment may be sensed and controlled or the amount of toner to be deposited on the photoconductive element may be calculated and subject to feedback control.
In any one of the illustrative embodiments, an arrangement may be made such that the toner or developer discharged via the toner returning openings 21 is classified into reusable toner and toner to be discarded by toner or developer classifying means. That is, toner deteriorated in the developing section 11 and then discharged does not have to be entirely discarded, but may be classified by a conventional filter, gravity, electrostatic force or the like so as to return reusable part of the toner, thereby reducing the amount of waste toner. More specifically, in the illustrative embodiment shown in
The developing device of any one of the illustrative embodiments may be used as a cleanerless system in which it plays the role of the belt cleaner 7 at the same time. In this configuration, the toner present in the developing section 11 is replaced with fresh toner little by little, protecting images from degradation ascribable to the collected toner.
In accordance with the present invention, the developing device uses toner grains on which additives are deposited in an amount of one-tenth of the mean volumetric grain size of the toner inclusive or below. Therefore, even when the additives are separated from or buried in the cores of the toner grains, replenished toner can sufficiently make up for the loss of additives. In addition, the additives separated from the cores move upward in the developing section 11 and then discharged, so that an adequate amount of additives can be stably maintained in the developing section 11 to thereby extend the life of the toner.
Toner grains to be replenished from the toner cartridge 12 to the developing section 11 may be higher in the ratio of additives deposited thereon than toner grains to be set in the developing section 11 for the first time. This prevents the additives of the toner grains present in the developing section 11 from being buried in the cores and maintains the fluidity of the toner grains relatively high, thereby insuring the desirable electrification of the toner while maintaining friction between the toner and members contacting it relatively low. Consequently, it is possible to reduce torque required of the developing device and insure high image quality at the same time.
The developing device of the present invention, effecting contact development with a one-component type developer, should preferably satisfy a relation:
0<|VD|−|VB|<|VD−VL|<400V
where VD denotes the potential of the image carrier in the dark, VL denotes a potential after exposure, and VB denotes a bias voltage for development. This relation allows development to be effected with a potential difference of 400 V or below for thereby reducing electrostatic hazards to the photoconductive element and therefore extending the life of the photoconductive element.
Further, the developing device of the present invention is capable of extending the life of toner stored in the developing section 11. Therefore, as shown in
In any one of the illustrative embodiments, a plurality of openings are formed in the lengthwise direction of the developing unit. This prevents the amount of developer in the developing unit from being irregular in the lengthwise direction and therefore obviates irregular image density. Moreover, it is possible to prevent the developer from accumulating at opposite lengthwise ends of the developing section, further enhancing the above advantages.
Specifications of the developing device in accordance with the present invention are as follows. The developing roller was provided with a diameter of 26 mm and a surface formed of polyester-melamine resin and carbon black. The surface layer of the developing roller had electric resistance of 4 LogΩ and surface roughness of 2.6 μm Rz.
The feed roller was provided with an outside diameter of 16 mm, made of foam polyurethane and carbon black, ion-conductive material or similar conductive material, and provided with electric resistance of 6 LogΩ. The feed roller bit into the developing roller by 0.5 mm.
The regulating roller or metering member was provided with an outside diameter of 14 mm, a surface made of fluoric resin and carbon black, ion conductive material or similar conductive material, electric resistance of 4 LogΩ to 7 LogΩ, hardness of 75° in JIS (Japanese Industrial Standard) K6253 scale, and surface roughness of 2.6 μm Rz. With this configuration, the regulating roller was rotated either intermittently or constantly, as the case may be.
As for black toner, 100 parts by weight of low molecular weight, polyester resin, 6 parts by weight of carbon black and one part by weight of high molecular weight, charge control agent were kneaded by a conventional screw kneader, rolled by cooling, roughly pulverized, finely pulverized by a jet mill and finally classified by an air-stream type classifier to obtain toner grains having a volume-mean grain size of 6.7 μm and a number-mean grain size of 6.1 μm. Magenta toner, cyan toner and yellow toner each were produced in the same manner as the black toner except for the color of a pigment.
Subsequently, 0.3 part by weight of silica was added to 100 parts of weight of each toner and then mixed together by a Henschel mixture for 1 minute. Thereafter, 0.3 part by weight of titania was added to the toner and then mixed together for 1 minute, and then 1.0 part of weight of silica was further added and mixed for 1 minutes. The mean amount of charge measured on the surface of the developing roller was 30 μC/g.
The photoconductive element was measured to have a mean potential (VL) of −50 V in a black, solid portion and a mean potential (Vd) of −500 V in a background portion.
In summary, it will be seen that the present invention provides a developing device using a dry one-component type developer and capable of reducing damage to toner to thereby extend the life of the developing device and toner. Further, the developing device of the present invention obviates the unusual rise of dynamic torque ascribable to erroneous toner-end sensing or excess toner present in a toner storing section, and implements toner recycling while protecting toner from deterioration. It is therefore possible to reduce required torque and realize high-quality development at the same time.
Various modifications will become possible for those skilled in the art after receiving the teachings of the present disclosure without departing from the scope thereof.
Number | Date | Country | Kind |
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2004-204722 | Jul 2004 | JP | national |
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