Patent Grant
9377715
The present invention relates to a developing unit that develops a latent image (an object to be developed) on an image bearing member. The present invention also relates to a process cartridge equipped with the developing unit and an image forming apparatus (an image recording apparatus) equipped with the developing unit, such as a printer.
A widely used example of a developing method using a magnetic one-component developer is a magnetic non-contact developing method (for example, see PTL 1 and PTL 2).
With the magnetic non-contact developing method, a developing sleeve (a developer bearing member) accommodating a magnet bears a developer. A photoconductor is opposed to the surface of the developing sleeve with a predetermined minute gap therebetween, and the developer is splashed from the developing sleeve toward the photoconductor to perform developing. The developer in the developing unit is conveyed to the developing sleeve by a mechanical stirring mechanism or gravitation. The magnetic one-component developer is supplied to the developing sleeve with a fixed magnetic force of a magnet accommodated in the developing sleeve.
Another developing method using the magnetic one-component developer is a magnetic contact developing method (see PTL 3). This magnetic contact developing method has both of the characteristics of a non-magnetic contact developing method (for example, PTL 4) and the above magnetic non-contact developing method. The magnetic contact developing method forms an elastic layer on the surface of the developing sleeve to keeping the developing sleeve and the photoconductor in contact with each other in contrast to the above magnetic non-contact developing method. The magnetic contact developing method is also configured such that a magnet is disposed in the developing sleeve, and the developer is born on the surface of the developing sleeve by the magnetic force of the magnet, as with the non-magnetic contact developing method.
The magnetic non-contact developing method, which is generally employed when a magnetic one-component developer is used, holds a magnetic developer on the surface of the developer developing sleeve by the action of the magnetic force of the magnet accommodated in the developing sleeve. End sealing members are provided at both ends of the developing sleeve. The end sealing members seal gaps between the developing sleeve and the developing unit to prevent the developer from leaking outside the developing unit.
However, the action of the magnetic force of the magnet accommodated in the developing sleeve on the areas in which the end sealing members are provided may cause the developer to enter the gaps between the end sealing members and the developing sleeve. This developer may be firmly fixed to the developing sleeve between the end sealing members and the developing sleeve to form gaps between the end sealing members and the developing sleeve, thus causing developer leakage or the like. This is one of large technical problems due to the recent increase in the speed of image formation and the life of cartridges.
Furthermore, for the magnetic non-contact developing method as described above, a sealing member that is not in contact with the developing sleeve has been proposed to prevent toner from leaking through a gap between a developer container and the longitudinal ends of the developing sleeve to the outside of the developer container. PTL 5 proposes a method in which magnetic sealing members are disposed so as to oppose the ends of the developing sleeve. This is a method in which the magnetic sealing members are disposed at the ends of the developing sleeve with a predetermined gap therebetween, and toner is held by the magnetic sealing members with the magnetic force thereof. In other words, by holding toner that is moving outside the developer container with the magnetic sealing members, leakage of the toner can be prevented.
However, the developing unit has a regulating blade serving as a developer regulating member for regulating the amount of the toner to be born on the developing sleeve to a fixed amount. The magnetic sealing members are disposed outside the regulating blade.
However, it is difficult to make the end faces of the regulating blade and the side faces of the magnetic sealing members close contact with each other because the magnetic sealing members generally have high rigidity. Thus, small gaps may be sometime formed between the end faces of the regulating blade and the magnetic sealing members. The toner born on the developing sleeve in the gaps is located outside the regulating blade and is not regulated by the regulating blade. In other words, the gaps between the end faces of the regulating blade and the magnetic sealing members cause the amount of toner born on the developing sleeve (developer amount) in the gaps to be increased, as compared with that in the other areas. Furthermore, since the toner outside the regulating blade is not subjected to friction due to the regulating blade, the toner resists being charged with electricity, thus having a low electrical charge. Thus, the toner born on the developing sleeve in the areas between the end faces of the regulating blade and the magnetic sealing members can be easily moved from these areas to the photoconductor. Such toner may move to an area of the photoconductor in which no developed image is to be formed, thus causing so-called fogging.
In other words, both of the use of the end sealing members that are in contact with the developing sleeve as sealing members and the use of magnetic sealing members that are not in contact with the developing sleeve may cause the developer born on the developing sleeve to splash or leak.
Furthermore, in the case where the non-contact sealing members are used as sealing members, another sealing member (hot-melt adhesive) is sometimes provided between the magnetic sealing members and the ends of the regulating blade. PTL 6 proposes a method for preventing a developing sleeve from bearing toner outside the ends of the regulating blade by filling the gaps between the magnetic sealing members and the regulating blade with hot melt adhesive.
However, with the contact end sealing members, excessively enhancing the adhesiveness between the end sealing members and the developing sleeve increases the frictional force generated between the developing sleeve and the end sealing members, thus increasing a torque for rotating the developing sleeve. Thus, the developer sealing performance of the end sealing members has to be ensured while the adhesiveness between the developing sleeve and the end sealing members and the torque for rotating the developing sleeve are balanced. This requires sufficiently enhancing the dimensional accuracy of the developing sleeve, the end sealing members, and so on.
Furthermore, with the magnetic sealing members, providing another sealing member (hot-melt adhesive) between the magnetic sealing members and the ends of the regulating blade may increase the cost.
PTL 1: Japanese Patent Laid-Open No. 54-43027
PTL 2: Japanese Patent Laid-Open No. 55-18656
PTL 3: Japanese Patent Laid-Open No. 2005-173485
PTL 4: Japanese Patent Laid-Open No. 2001-92201
PTL 5: Japanese Patent Laid-Open No. 10-39630
PTL 6: Japanese Patent Laid-Open No. 2006-208552
The present invention is proposed in consideration of the above circumstances and is characterized by adopting a magnetic contact method instead of the magnetic non-contact developing method. This prevents the developer from splashing or leaking from a developing unit or a process cartridge with a simple configuration. In other words, the present invention prevents a developer born on a developer bearing member from moving to an image bearing member or leaking outside from between the developer bearing member and a sealing member.
A developing unit according to a first aspect of the present invention includes a developer container accommodating a developer; a developer bearing member configured to bear the developer supplied from the developer container; a magnetic-field generation member disposed in the developer bearing member, the magnetic-field generation member having a magnetic-field generation area generating a magnetic field for attracting the developer to the developer bearing member; and at least one sealing member disposed at the developer container, the sealing member being configured to prevent the developer from leaking from a gap between a longitudinal end of the developer bearing member and the developer container. An end of the magnetic-field generation area of the magnetic-field generation member is disposed inside an inner end of the sealing member in the longitudinal direction of the developer bearing member. The developer bearing member develops a latent image formed on the image bearing member with the developer while keeping in contact with the image bearing member.
A developing unit according to a second aspect of the present invention includes a developer container accommodating a developer; a developer bearing member configured to bear the developer supplied from the developer container; a magnetic-field generation member disposed in the developer bearing member, the magnetic-field generation member having a magnetic-field generation area generating a magnetic field for attracting the developer to the developer bearing member; at least one sealing member disposed at the developer container, the sealing member being configured to prevent the developer from leaking from a gap between a longitudinal end of the developer bearing member and the developer container; and a developer regulating member configured to regulate the amount of the developer born on the developer bearing member. An end of the magnetic-field generation area of the magnetic-field generation member is disposed inside an end of the developer regulating member in the longitudinal direction of the developer bearing member. The developer bearing member develops a latent image formed on the image bearing member with the developer while keeping in contact with the image bearing member.
A process cartridge that can be attached to and detached from an image forming apparatus main body according to a third aspect of the present invention includes an image bearing member on which a latent image is formed; and a developing unit for developing the latent image. The developing unit includes a developer container accommodating a developer; a developer bearing member configured to bear the developer supplied from the developer container; a magnetic-field generation member disposed in the developer bearing member, the magnetic-field generation member having a magnetic-field generation area generating a magnetic field for attracting the developer to the developer bearing member; and at least one sealing member disposed at the developer container, the sealing member being configured to prevent the developer from leaking from a gap between a longitudinal end of the developer bearing member and the developer container. An end of the magnetic-field generation area of the magnetic-field generation member is disposed inside an inner end of the sealing member in the longitudinal direction of the developer bearing member. The developer bearing member develops a latent image formed on the image bearing member with the developer while keeping in contact with the image bearing member.
A process cartridge that can be attached to and detached from an image forming apparatus main body according to a fourth aspect of the present invention includes an image bearing member on which a latent image is formed; and a developing unit for developing the latent image. The developing unit includes a developer container accommodating a developer; a developer bearing member configured to bear the developer supplied from the developer container; a magnetic-field generation member disposed in the developer bearing member, the magnetic-field generation member having a magnetic-field generation area generating a magnetic field for attracting the developer to the developer bearing member; at least one sealing member disposed at the developer container, the sealing member being configured to prevent the developer from leaking from a gap between a longitudinal end of the developer bearing member and the developer container; and a developer regulating member configured to regulate the amount of the developer born on the developer bearing member. An end of the magnetic-field generation area of the magnetic-field generation member is disposed inside an end of the developer regulating member in the longitudinal direction of the developer bearing member. The developer bearing member develops a latent image formed on the image bearing member with the developer while keeping in contact with the image bearing member.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Reference sign 1 denotes an image bearing member, which is a negative-polarity organic photoconductor (OPC) of a rotary drum type with a diameter of 24 mm (a negative photoconductor, hereinafter referred to as a photosensitive drum). This photosensitive drum 1 is rotationally driven clockwise along an arrow Y1 in
Reference sign 2 denotes a charging roller serving as charging means for the photosensitive drum 1. This charging roller 2 is an electrically conductive elastic roller, which rotates with the rotation of the photosensitive drum 1 in the first embodiment.
The charging roller 2 is in contact with the photosensitive drum 1 to apply a direct-current voltage of −1,300 V as a charging bias to uniformly charge the surface of the photosensitive drum 1 to a charge polarity (dark polarity) of −700 V.
Reference sign 4 denotes a laser beam scanner (an exposure unit) including a laser diode polygon mirror. The laser power is adjusted so that, when the uniformly charged entire surface of the photosensitive drum 1 is exposed to light L, the polarity of the surface of the photosensitive drum 1 becomes −150 V.
This scanning light L forms a static latent image corresponding to target image information on the surface of the rotating photosensitive drum 1.
Reference sign 3 denotes a developing unit (developing unit) for developing the photo static latent image on the sensitive drum 1. Toner t is a developer for developing a latent image and assumes a certain charge due to frictional charge. Here, developing bias voltage is applied between a developing roller sleeve 3b serving as a developer bearing member (developer-bearing conveying member, toner bearing member) and the photosensitive drum 1 by a developing bias power source (not shown). The toner t moves from developing roller sleeve 3b to the photosensitive drum 1 in the developing section (developing area) a to develop the static latent image on the photosensitive drum 1 using this developing bias. This developing unit 3 will be described later.
Reference sign 6 denotes a transfer roller serving as contact transfer means, which is in pressure-contact with the photosensitive drum 1 by a predetermined force. This transfer section is fed with a transferred material P or a recording medium from a paper feed section (not shown) at a predetermined timing, and a predetermined transfer bias voltage is applied to the transfer roller 6. This causes a toner image (a developer image) on the photosensitive drum 1 to be sequentially transferred onto the surface of the transferred material P fed into the transfer nip.
Reference sign 7 denotes a fixing unit of a thermally fixing system or the like. The transferred material P to which the toner image is transferred in the transfer section is separated from the surface of the rotating photosensitive drum 1 and is guided to this fixing unit 7, where the toner image is fixed, and is discharged outside the image forming apparatus 100 as an image formed object (print copy).
Reference sign 8 denotes a photosensitive-drum cleaning unit (a drum cleaner), which scrapes transfer toner remaining on the photosensitive drum 1 with a cleaning blade 8a and collects the remaining toner into a waste-toner container 8b.
The photosensitive drum 1 is again charged by the charging unit (charging roller 2) and is repeatedly used for image formation.
Reference sign 9 denotes a process cartridge in which the photosensitive drum 1, the charging roller 2, the developing unit 3, and the drum cleaner 8 are integrated and which is detachable from the main body 100A of the image forming apparatus 100.
The developing unit 3 of the first embodiment will be described. The developing roller sleeve 3b is a developer bearing member (a developer bearing/conveying member) that accommodates a magnet roller 3a serving as a magnetic-field generation member and bears the toner (developer) t on the surface thereof. The developing roller sleeve 3b is a roller in which a non-magnetic electrically conductive elastic layer 3b2 with a thickness of 1.0 mm is formed on an aluminum cylinder (aluminum sleeve) 3b1 with a diameter of 12 mm. Hereinafter, the developing roller sleeve 3b is simply referred to as a developing sleeve 3b. The developing sleeve 3b rotates along an arrow Y2.
The electrically conductive elastic layer 3b2 can be formed of rubber containing an electrical conductor and has, in this embodiment, a two-layer structure including a base layer formed of silicon rubber that is in contact with the aluminum cylinder 3b1 and a surface layer formed of urethane rubber on the silicon rubber.
Since the electrically conductive elastic layer 3b2, if excessively thick, decreases the action of the magnetic force of the magnet roller 3a, the electrically conductive elastic layer 3b2 may be designed in consideration of balance to the magnetic force. The developing sleeve 3b is disposed in an opening 3g of a developer container 3e so as to oppose the photosensitive drum 1 and be in contact with the photosensitive drum 1 under a fixed pressure. The opening 3g of the developer container 3e extends along the longitudinal direction of the developing sleeve 3b. The longitudinal direction of the developing sleeve 3b is a direction in which the rotational axis of the developing sleeve 3b extends or a direction parallel to this direction. The longitudinal direction is hereinafter the longitudinal direction of the developing sleeve 3b unless otherwise noted.
The magnet roller 3a is a roller formed of a magnet fixed to the developer container 3e and serves as a magnetic-field generation member whose substantially entire area is a magnetic-field generation area. The magnet roller 3a generates a magnetic field for bearing the toner t on the surface of the developing sleeve 3b, which will be described later.
The magnet roller 3a has four magnetic poles arranged along the circumferential direction. These magnetic poles generate magnetic forces at predetermined peak densities at a developing section a, a conveying section, a supply section, and a collecting section.
Specifically, the magnet roller 3a has S-pole, N-pole, S-pole, and N-pole from the developing section a downstream in the rotating direction of the developing sleeve 3b, which generate peak densities of the magnetic fields at the developing section a (S-pole), the collecting section (N-pole), the supply section (S-pole), and the conveying section (N-pole). Part of the toner t that has reached the developing section a moves from the developing sleeve 3b to the photosensitive drum 1, where it develops a latent image formed on the photosensitive drum 1. The toner t that is not consumed in the developing section a moves to the collecting section located downstream from the developing section a in the rotating direction of the developing sleeve 3b and is collected into the developer container 3e. The collecting section carries a peak flux density of the magnetic field, thus preventing the toner t in the developer container 3e from blowing to the outside.
The toner t that has reached the collecting section in this way is conveyed downstream of the collecting section, that is, the supply section located in the developer container 3e. The magnetic field that the magnet roller 3b forms in the supply section attracts the toner t in the developer container 3e to the developing sleeve 3b. Thus, the toner t that has reached the collecting section without being consumed in the developing section a and toner t that is newly supplied in the supply section are mixed. The toner t thus mixed and born on the developing sleeve 3b is conveyed to the conveying section located downstream of the supply section and reaches the developing section again. Thus, continuous supply of the toner t to the developing section a is achieved.
The toner t used as a developer is a one-component magnetic toner (a magnetic one-component developer), which is, in this embodiment, produced by suspension polymerization, and whose average circularity is 0.976.
The toner t is given a fixed thickness by passing between a regulating blade 3c and the developing sleeve 3b in the process of being conveyed on the developing sleeve 3b while receiving the magnetic force of the magnet roller 3a. In other words, the regulating blade 3c is a developer regulating member that regulates the thickness of the toner layer formed on the developing sleeve 3b. The toner t is charged with the electrical charge by the regulating blade 3c.
Reference sign 3d denotes a stirring member that circulates the toner t in the developer container 3e to sequentially convey the toner t into the magnetic-force reach area in the vicinity of the developing sleeve 3b.
The toner t that has coated the developing sleeve 3b is conveyed to the developing section (developing area) a, at which the photosensitive drum 1 and the developing sleeve 3b oppose each other, by the rotation of the developing sleeve 3b. The developing sleeve 3b is given a developing bias voltage (a DC voltage of −450V) from a developing bias power source (not shown). The developing sleeve 3b is driven with respect to the photosensitive drum 1 at a predetermined circumferential speed. This causes the static latent image on the photosensitive drum 1 to be reversely developed with the toner t.
The most important sections of the magnet roller 3a of the developing method of the first embodiment are the supply section and the collecting section. The toner t is supplied to the surface of the developing sleeve 3b due to the magnetic force of the magnet roller 3a that acts on the magnetic toner t. The toner t supplied to the developing sleeve 3b is electrically charged through the regulating blade 3c and is held on the developing sleeve 3b.
The arrangement of the magnetic poles of the magnet roller 3a described above is merely an example, and any arrangement other than that may be employed. Even if the magnetic poles of the magnet roller 3a in the developing section and the conveying section have no peak flux density, there is no problem.
To prevent leakage of the toner t from the vicinity of the ends of the developing sleeve 3b, that is, toner leakage, end sealing members 3f that are in contact with the longitudinal ends of the developing sleeve 3b are provided (see
Here, the ends of the opening 3g of the developer container 3e will be further described with reference to
As shown in
The end sealing members 3f may be formed of a fabric material, such as wool felt and polytetrafluoroethylene (PTEE) pile, or a foamed material, such as polyurethane and sponge rubber. Wool felt is used in the first embodiment.
Sizes and Arrangement of Components of First Embodiment
Next, the relationship between the longitudinal length of the magnet roller 3a and the disposition of the end sealing members 3f of the first embodiment will be described. The first embodiment is characterized in that the ends of the magnet roller 3a are disposed inside the inner ends of the end sealing members 3f in the longitudinal direction of the developing sleeve 3b. In other words, the magnet roller 3a is shorter than the distance between the two end sealing members 3f disposed at both ends of the opening 3g. This prevents the toner t from leaking from the gaps between the developing sleeve 3b and the end sealing members 3f to the outside of the developing unit 3.
The distribution of the magnetic flux density decreases in the areas outside the longitudinal ends (A in
The first embodiment is configured such that the ends of the magnet roller 3a do not reach the positions of the end sealing members 3f. Thus, the magnetic force that attracts the toner t to the developing sleeve 3b decreases on the surface of the developing sleeve 3b at the positions of the end sealing members 3f. The decrease in the magnetic force of the magnet roller 3a decreases the force of bearing the toner t on the developing sleeve 3b. Since the toner t is attracted to a larger magnetic force, the toner t on the developing sleeve 3b is less prone to moving to the ends of the developing sleeve 3b at which the magnetic force decreases.
In other words, this makes it difficult to move the toner t to the positions of the end sealing members 3f. This action decreases the amount of toner t that enters the end sealing members 3f, thus preventing the toner t from leaking outside the developing unit 3 from between the end sealing members 3f and the developing sleeve 3b. This can also prevent the toner t from being fixed between the end sealing members 3f and the developing sleeve 3b, thus reliably preventing the toner t from leaking using the end sealing members 3f.
Difference Between First Embodiment and Non-Contact Developing Method
Adopting the contact developing method allows the first embodiment to achieve the above relationship between the longitudinal length of the magnet roller 3a and the disposition of the end sealing members 3f. The relationship will be specifically described hereinbelow.
With the non-contact developing method that is often used as a developing method using magnetic toner, since the developing sleeve and the photoconductor are separated from each other, the toner is splashed from the developing sleeve toward the photoconductor. At that time, the splashing of the toner is controlled by balancing the magnitude of the magnetic force that acts on the surface of the developing sleeve and the voltage applied to the developing sleeve (a developing bias).
More specifically, with the non-contact developing method, a developing bias in which an AC bias is superposed on a DC bias is applied to the developing sleeve to form an electric field between the developing sleeve and the photosensitive drum. A force due to the electric field acts upon the charged toner. If this force exceeds the magnetic force of the magnet accommodated in the developing sleeve, the toner held on the developing sleeve splashes to the photosensitive drum. In other words, by splashing toner (a developer) toward a latent image formed on the photosensitive drum, the latent image can be developed.
Thus, with the non-contact developing method, if some of the surface of the developing sleeve is under a low magnetic force of the magnet, the force with which the toner is held on the developing sleeve is also small. This causes a larger amount of toner than a desired amount to splash from the developing sleeve to the photosensitive drum. This causes defective images, such as fogging (adhesion of toner to a portion at which no image is to be formed). In other words, the non-contact developing method needs to increase the length of the magnet roller disposed in the developing sleeve sufficiently so as not to form a portion where the magnetic force due to the magnet roller decreases on the developing sleeve. Thus, the ends of the magnet roller cannot be disposed inside the inner ends of the end sealing members, in contrast to the first embodiment.
In contrast, the first embodiment uses the contact developing method, not the conventional non-contact developing method, although using magnetic toner. With this contact developing method, the developing sleeve 3b is in contact with the photosensitive drum 1, as described above, and applies only a DC bias to the developing sleeve 3b. Since the photosensitive drum 1 and the developing sleeve 3b are in contact, a larger electric field acts between the photosensitive drum 1 and the developing sleeve 3b than that of the non-contact developing method.
In other words, with the contact developing method, a dominant force acting on the toner t when developing the latent image on the photosensitive drum 1 is an electric field, and the action of the magnetic force of the magnet roller 3a is smaller. Thus, the difference in the force acting on the toner t between a portion on which the magnetic force of the magnet roller 3a acts and a portion on which no magnetic force acts is small, and the difference in influence that the magnet roller 3a exerts in terms of generation of fogging is also remarkably small.
In other words, if the developing bias and the like are appropriately set so as not to generate fogging at the center of the developing sleeve 3b in the longitudinal direction, there is a low possibility of generating fogging also in the vicinity of the end sealing members 3f at which the magnetic force of the magnet roller 3a decreases.
Next, a comparative example in which the positional relationship and the dimensional relationship between the magnet roller 3a and the end sealing members 3f in the longitudinal direction are different from the present application will be described with reference to
In this comparative example, the ends of the magnet roller 103a are provided outside the inner ends of the end sealing members 3f in contrast to the first embodiment.
In
Since the end sealing members 3f are located outside the opening 3g of the developer container 3e in the longitudinal direction, the toner t is not directly supplied, at the positions of the end sealing members 3f, from the developer container 3e to the developing sleeve 3b.
However, the toner t on the developing sleeve 3b at the positions of the end sealing members 3f is subjected to the magnetic force of the magnet roller 103a. Therefore, the toner t is also conveyed onto the developing sleeve 3b, on which the end sealing members 3f are provided, by the magnetic force of the magnet roller 103a. The toner t that has entered the gaps between the end sealing members 3f and the developing sleeve 3b is subjected to a friction with the developing sleeve 3b. This causes the toner t at this position to be firmly fixed to the surface of the developing sleeve 3b. The fixed toner t forms gaps between the end sealing members 3f and the developing sleeve 3b, which may cause toner leakage. This may also influence the amount of pressure of the developing sleeve 3b to the photosensitive drum 1, which may cause problems of the image, such as low density and banding.
Thus, the first embodiment is more effective in reducing defective images than the comparative example.
Overview of First Embodiment
In summary, the first embodiment is allowed to dispose the ends of the magnetic-field generation member (the magnet roller 3a) inside the end sealing members 3f by adopting the magnetic contact developing method, thus solving the problems of the magnetic non-contact developing method. In other words, the first embodiment can prevent the toner t from entering the gaps between the end sealing members 3f and the developing sleeve 3b while preventing the generation of fogging, thus preventing the toner t from leaking outside the developing unit 3.
The magnet roller 3a and the shaft 3j (see
Although the magnetic-field generation member (the magnet roller 3a) in the first embodiment is a cylindrical member, the shape of the magnetic-field generation member is not limited to be cylindrical.
The fixation of the toner t on the developing sleeve 3b at the positions of the end sealing members 3f is caused by a friction due to the contact of the toner t with the developing sleeve 3b and the end sealing members 3f. Thus, the fixation of the toner t is more prone to occur as the time during which the developer container 3e is used increases, thus being more prone to occur during the last half of the life of the developer container 3e.
The distance between the ends of the magnet roller 3a and the inside of the end sealing members 3f in the longitudinal direction, that is, the length of the magnet roller 3a in the longitudinal direction, can be adjusted. This allows the magnitude of the magnetic force on the developing sleeve 3b to be controlled at the positions of the end sealing members 3f. The magnitude may be controlled depending on the life of the developing unit 3.
If the developing unit 3 has a long life, the magnet roller 3a may be set short to separate the ends of the magnet roller 3a from the inside of the end sealing members 3f. This can enhance the function of preventing the fixation of the toner t.
Particularly in the first embodiment, the magnet roller 3a is set further shorter than the length of the opening 3g of the developer container 3e to reliably separate the ends of the magnet roller 3a from the end sealing members 3f. In other words, the ends of the magnet roller 3a are located inside the ends of the opening 3g in the longitudinal direction of the developing sleeve 3b.
In a second embodiment, another method for decreasing the magnetic force on the developing sleeve 3b at the positions of the end sealing members 3f will be described. Substantially the entire area of the magnet roller 3a used in the first embodiment serves as an area that generates a magnetic field (a magnetic-field generation area); in contrast, the second embodiment is characterized by using a magnet roller 3i only part of which serves as a magnetic-field generation area.
The magnet roller 3i used in the second embodiment has magnetic powder and a resin binder as the main components. The magnet roller 3i is manufactured, magnetized, and oriented by injecting these melted materials into a production die in which a magnet is disposed. Setting the magnetizing and orienting magnet in the production die shorter than the longitudinal length of the magnet roller 3i allows the longitudinal range (width) of magnetization of the magnet roller 3i to be changed.
In the second embodiment, an area in which the magnetic flux density falls within 50% of a maximum value Bp of the magnetic flux density generated by the magnet roller 3i, which is measured on the surface of the developing sleeve 3b, is defined as the magnetic-field generation area i. In other words, a position Bi in which the magnetic flux density is decreased in half to 50% of the maximum value Bp (half position) is defined as an end of the magnetic-field generation area i.
In the second embodiment, the length of the area of the magnet roller 3i that generates a magnetic field (the magnetic-field generation area i) is shorter than the distance between the two end sealing members 3f disposed at both ends of the opening 3g.
In other words, the ends of the magnetic-field generation area i are located inside the inner ends of the end sealing members 3f in the longitudinal direction of the developing sleeve 3b.
This decreases the magnetic force exerted from the magnet roller 3i onto the toner t at the positions of the end sealing members 3f. In other words, the force that holds the toner on the developing sleeve 3b is decreased at the positions. Furthermore, since the toner t is attracted to a larger magnetic force, it difficult for the toner t on the developing sleeve 3b to reach the positions of the end sealing members 3f. In other words, the magnetic-field generation area i substantially corresponds to an area that can bear the toner t on the surface of the developing sleeve 3b with the magnetic force of the magnet roller 3i (a developer bearing area). The ends of the area in which the toner is born on the developing sleeve 3b with the magnetic force of the magnet roller 3i are located inside the inner ends of the end sealing members 3f.
This decreases the amount of toner t that enters the gaps between the end sealing members 3f and the developing sleeve 3b. This can prevent the toner t from leaking from between the end sealing members 3f and the developing sleeve 3b to the outside of the developing unit 3. This can also prevent the toner t from being fixed between the end sealing members 3f and the developing sleeve 3b, thus reliably preventing the toner t from leaking with the end sealing members 3f.
Also in the second embodiment, the magnitude of the magnetic force on the developing sleeve 3b at the positions of the end sealing members 3f may be controlled depending on the life of the developing unit 3. If the developing unit 3 has a long life, the magnetic-field generation area i may be decreased in length, so that the magnetic force of the magnet roller 3i acting at the positions of the end sealing members 3f becomes as small as possible. This can enhance the function of preventing the fixation of the toner t.
Particularly in the second embodiment, to reliably separate the ends of the magnetic-field generation area i of the magnet roller 3i from the end sealing members 3f, the magnetic-field generation area i is set slightly shorter than the length of the opening 3g of the developer container 3e. In other words, the ends of the magnetic-field generation area i are located inside the ends of the opening 3g in the longitudinal direction. In other words, the ends of the developer bearing area in which the toner t is born on the developing sleeve 3b by the magnetic force of the magnet roller 3i are located slightly inside the ends of the opening 3g. This can reliably reduce leakage of the toner t born on the developing sleeve 3b from between the developing sleeve 3b and the end sealing members 3f to the outside of the developing unit 3.
The second embodiment also adopts the contact developing method that performs development by keeping the developing sleeve 3b in contact with the photosensitive drum 1, as in the first embodiment. This can prevent the generation of a defective image in the vicinity of the end sealing members 3f even if the magnetic force of the magnet roller 3i is decreased at the positions of the end sealing members 3f in contrast to the non-contact developing method.
In the second embodiment, the density of the magnetic flux that the magnet roller 3i generates is measured at a position where the developing sleeve 3b opposes the photosensitive drum 1, that is, the developing section a (see
Alternatively, the distribution of the magnetic flux density in the longitudinal direction of the magnet roller 3a has the same tendency as that of the magnetic-field generation area i also for the other S-pole and N-pole of the magnet roller 3a.
The first embodiment uses wool felt that is in contact with the developing sleeve 3b as the end sealing members 3f. The use of the end sealing members 3f in contact with the developing sleeve 3b may cause the toner t to be fixed to the developing sleeve 3b due to the friction between the developing sleeve 3b and the end sealing members 3f. Thus, it is particularly effective to decrease the length of the magnet roller 3a, thereby reducing the amount of toner t entering the gaps between the developing sleeve 3b and the end sealing members 3f.
However, decreasing the length of the magnet roller 3a is effective also for a configuration in which end sealing members are not in contact with the developing sleeve 3b. Thus, a third embodiment uses magnets (magnetic sealing members 3h) disposed at a predetermined distance from the developing sleeve 3b as end sealing members. The third embodiment will be described with reference to
Also in the third embodiment, disposing the ends of the magnet roller 3a inside the magnetic sealing members 3h by decreasing the length of the magnet roller 3a, as in the first embodiment, decreases the amount of toner t entering the gaps between the developing sleeve 3a and the magnetic sealing members 3h. This is a configuration using the magnetic sealing members 3h instead of the end sealing members 3f of the first embodiment in
Alternatively, as in the second embodiment, reducing the magnetic-field generation area i by using the magnet roller 3i to dispose the ends of the magnetic-field generation area i (the developer bearing area) inside the magnetic sealing members 3h also offers the same advantage. This is a configuration in which the magnetic sealing members 3h are disposed instead of the end sealing members 3f in
The third embodiment also adopts the contact developing method, as in the first and second embodiments. This can prevent generation of a defective image in the vicinity of the magnetic sealing members 3h even if the magnetic force of the magnet roller 3a is decreased in the vicinity of the magnetic sealing members 3h in contrast to the non-contact developing method.
A fourth embodiment will be described.
The fourth embodiment also has the magnetic sealing members 3h in the vicinity of the developing sleeve 3b to prevent leakage of the toner t from the vicinity of the ends of the developing sleeve 3b to the outside, that is, toner leakage, as in the third embodiment. A configuration different from the third embodiment will be particularly described in detail.
The fourth embodiment is characterized in the dimensional and positional relationship among the magnetic sealing members 3h, the regulating blade 3c, and the magnet roller 3a.
First, the ends of the opening 3g of the developer container 3e will be described with reference to
As shown in
Sizes and Displacement of Components in Fourth Embodiment
The fourth embodiment is characterized in that the ends of the magnet roller 3a are disposed inside the ends of the regulating blade 3c by setting the magnet roller 3a shorter than the regulating blade 3c in the longitudinal direction of the developing sleeve 3b. This prevents the toner t from being excessively born at the ends of the developing sleeve 3b, thereby preventing the generations of a defective image. This will be described hereinbelow.
The distribution of the magnetic force is decreased outside the longitudinal ends of the magnet roller 3a (A in
In the fourth embodiment, the longitudinal ends of the magnet roller 3a are located inside the ends of the regulating blade 3c, as shown in
As described above, since the regulating blade 3c is not present in the areas corresponding to the gaps G, the amount of toner t to be born on the developing sleeve 6b cannot be regulated by the regulating blade 3c. The fourth embodiment therefore does not have the magnet roller 3a in the areas corresponding to the gaps G, thereby reducing the amount of toner t to be supplied in these areas to the developing sleeve 3b.
This can prevent the toner t from being excessively born on the developing sleeve 3b even in the gaps G in which the regulating blade 3c is not disposed.
If the toner t is excessively born on the developing sleeve 3b outside the regulating blade 3c, so-called fogging in which the toner t is transferred also to a no-image portion (a portion in which no image is to be formed) can be generated. However, there is no possibility of generating fogging in the fourth embodiment, thus preventing the fogging of the toner t in the gaps G.
Difference Between Fourth Embodiment and Non-Contact Developing Method
The fourth embodiment can achieve the above relationship between the longitudinal length of the magnet roller 3a and the magnetic sealing members 3h by adopting the contact developing method.
With the non-contact developing method, if the surface of the developing sleeve has a portion acted upon by the magnetic force of the magnet, the force of bearing toner on the developing sleeve decreases. As a result, a larger amount of toner than a desired amount splashes from the developing sleeve toward the photosensitive drum. This causes a defective image, such as fogging (the toner adheres to a portion in which no image is to be formed). In other words, the non-contact developing method needs to dispose a long magnet roller in the developing sleeve so as not to form a portion at which the magnetic force of the magnet roller decreases on the developing sleeve. Therefore, the ends of the magnet roller cannot be disposed inside the ends of the regulating blade in contrast to the fourth embodiment.
In contrast, the fourth embodiment uses the contact developing method, not the conventional non-contact developing method, although using magnetic toner. With this contact developing method, the developing sleeve 3b is in contact with the photosensitive drum 1, as described above, and applies only a DC bias to the developing sleeve 3b. Since the photosensitive drum 1 and the developing sleeve 3b are in contact, an extremely larger electric field acts between the photosensitive drum 1 and the developing sleeve 3b than that of the non-contact developing method.
In other words, with the contact developing method, a dominant force for transferring the toner t onto the photosensitive drum 1 is an electric field, and the action of the magnetic force of the magnet roller 3a is smaller. Thus, the difference in the force acting on the toner t between a portion on which the magnetic force of the magnet roller 3a acts and a portion on which no magnetic force acts is small, and the difference in influence on fogging is also remarkably small.
If the developing bias and the like are appropriately set so as not to generate fogging at the center of the developing sleeve 3b in the longitudinal direction, there is a low possibility of generating fogging also in the areas of the gaps G in which the magnetic force of the magnet roller 3a decreases (areas outside the ends of the regulating blade 3c).
In other words, in the fourth embodiment, the ends of the magnet roller 3a can be disposed inside the ends of the regulating blade 3c by adopting the magnetic contact developing method instead of the conventional magnetic non-contact developing method. This can reduce the amount of the toner t born outside the ends of the regulating blade 3c, thus preventing the toner t outside the ends of the regulating blade 3c from transferring from the developing sleeve 3b to the photosensitive drum 1.
Next, the positional relationship between the longitudinal length of the magnet roller 103a and the gaps G between the sides of the magnetic sealing members 3h and the ends of the regulating blade 3c is different from that of the fourth embodiment will be described using
In this comparative example, the ends of the magnet roller 103a are disposed outside the ends of the regulating blade 3c in contrast to the fourth embodiment. In other words, the magnet roller 103a is set longer than the regulating blade 3c.
The distribution of the magnetic force decreases in the areas outside the longitudinal ends (C in
Since the comparative example has the magnet roller 103a also in the gaps G, the developing sleeve 3b in these areas is also supplied with the toner t. However, the gaps G have no member for regulating the amount of the toner t on the developing sleeve 3b (the regulating blade 3c and the magnetic sealing members 3h). Thus, the developing sleeve 3b may excessively bear the toner t in the gaps G. This may make the toner t easily move from the developing sleeve 3b toward the photosensitive drum 1 in these portions, thus causing a defective image, such as fogging.
Thus, the fourth embodiment is more effective in reducing defective images than the comparative example.
Overview of Fourth Embodiment
In summary, the fourth embodiment is allowed to dispose the ends of the magnet roller 3a inside the ends of the regulating blade 3c by adopting the magnetic contact developing method, thus solving the problems of the magnetic non-contact developing method. In other words, the fourth embodiment can prevent the toner t from being excessively born on the developing sleeve 3b outside the ends of the regulating blade 3c.
In particular, the use of the magnetic sealing members 3h as end sealing members can form the gaps G between the regulating blade 3c and the magnetic sealing members 3h. Since the amount of the toner t on the developing sleeve 3b cannot be regulated in the gaps G, the configuration of the fourth embodiment is effective in reducing the amount of toner t supplied to the developing sleeve 3b.
The magnet roller 3a and the shaft 3j (see
Although the magnetic-field generation member (the magnet roller 3a) in the fourth embodiment is a cylindrical member, the shape of the magnetic-field generation member is not limited to be cylindrical.
Increasing the distance between the longitudinal ends of the magnet roller 3a and the gaps G is effective in reducing the amount of the toner t born on the developing sleeve 3b in the gaps G. Therefore, in the fourth embodiment, the magnet roller 3a is set shorter than the length of the opening 3g of the developer container 3e. In other words, the ends of the magnet roller 3a are located inside the ends of the opening 3g in the longitudinal direction of the developing sleeve 3b.
Alternatively, the regulating blade 3c may be sufficiently longer than the magnet roller 3a. However, this increases the size of the developing unit 3, and thus, the sizes and locations of the magnet roller 3a, the regulating blade 3c, and so on may be determined as appropriate in consideration of functions required for the developing unit 3.
In a fifth embodiment, another method for reducing the magnetic force of a magnet roller accommodated in the developing sleeve 3b in the gaps G between the sides of the magnetic sealing members 3h and the ends of the regulating blade 3c. Substantially the entire area of the magnet roller 3a used in the fourth embodiment serves as an area that generates a magnetic field (a magnetic-field generation area); in contrast, the fifth embodiment is characterized by using the magnet roller 3i only part of which serves as a magnetic-field generation area.
The magnet roller 3i has magnetic powder and a resin binder as the main components. The magnet roller 3i is manufactured, magnetized, and oriented by injecting these melted materials into a production die in which a magnet is disposed.
Setting the magnetizing and orienting magnet in the production die shorter than the longitudinal length of the magnet roller 3i allows the longitudinal range (width) of magnetization of the magnet roller 3i to be changed.
In the fifth embodiment, the ends of the magnetic-field generation area i are located inside the gaps G. In other words, the ends of the magnetic-field generation area i are disposed inside the ends of the regulating blade 3c in the longitudinal direction of the developing sleeve 3b.
A decrease in the magnetic force that the magnet roller 3i generates in the vicinity of the magnetic sealing members 3h decreases the force of bearing the toner t on the developing sleeve 3b. Furthermore, the toner t is attracted to a stronger magnetic force, which makes it difficult for the toner t to move to the gaps G. This can prevent toner fogging in the gaps G.
This can prevent the toner t from moving outside the regulating blade 3c. To prevent the toner t from moving outside the regulating blade 3c more reliably, the ends of the magnetic-field generation area i may be disposed inside the ends of the opening 3g.
In the fourth and fifth embodiments, the magnetic sealing members 3h that are not in contact with the developing sleeve 3b are used as end sealing members. Since the magnetic sealing members 3h are rigid, it is difficult to dispose the magnetic sealing members 3h in contact with the regulating blade 3c, thus forming gaps between the magnetic sealing members 3h and the regulating blade 3c. Therefore, it is particularly effective to employ the magnet rollers 3a and 3i shown in fourth and fifth embodiments in the developing unit 3 using the magnetic sealing members 3h.
However, even if contact sealing members, such as wool felt, that are in contact with the developing sleeve 3b are used as end sealing members instead of the magnetic sealing members 3h, the configurations of the magnet roller 3a and the magnet roller 3i in the fourth and fifth embodiments can be used.
In other words, as shown in
The contact end sealing members 3f used in the sixth embodiment are soft in contrast to the magnetic sealing members 3h and thus can be disposed so that the ends of the contact end sealing members 3f and the ends of the regulating blade 3c overlap. In this case, the formation of gaps between the ends of the contact end sealing members 3f and the ends of the regulating blade 3c can be prevented. This can prevent the toner t from being born on the developing sleeve 3b at positions outside the regulating blade 3c more reliably.
On the other hand, the contact between the contact end sealing members 3f and the developing sleeve 3b can increase the torque necessary for rotating the developing sleeve 3b. Therefore, which to use as end sealing members, the magnetic sealing members 3h or the contact end sealing members 3f, may be determined as appropriate depending on the configuration of the developing unit 3. The use of the magnetic sealing members 3h as end sealing members generates gaps between the magnetic sealing members 3h and the developing sleeve 3b, thus eliminating the possibility that the magnetic sealing members 3h will interfere the rotation of the developing sleeve 3b.
Finally, the advantages of the first to sixth embodiments are summarized as follows. The configurations of the above embodiments can prevent the developer born on the developer bearing member from splashing or leaking. In other words, the configurations can prevent the developer born on the developer bearing member from moving to the image bearing member or leaking outside from between the developer bearing member and the sealing members.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2012-278518, filed Dec. 20, 2012, and No. 2012-278519, filed Dec. 20, 2012, which are hereby incorporated by reference herein in their entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-278518 | Dec 2012 | JP | national |
| 2012-278519 | Dec 2012 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/007343 | 12/13/2013 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2014/097593 | 6/26/2014 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5187326 | Shirai | Feb 1993 | A |
| 5742876 | Bogoshian | Apr 1998 | A |
| 20050152718 | Osada | Jul 2005 | A1 |
| 20070053713 | Kawai | Mar 2007 | A1 |
| 20120269553 | Yoshizawa | Oct 2012 | A1 |
| Number | Date | Country |
|---|---|---|
| S54-43027 | Apr 1979 | JP |
| S55-18656 | Feb 1980 | JP |
| H10-39630 | Feb 1998 | JP |
| 2001-92201 | Apr 2001 | JP |
| 2005-173485 | Jun 2005 | JP |
| 2006-208552 | Aug 2006 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20150331359 A1 | Nov 2015 | US |
