Patent Grant
8805222
Embodiments of the present invention relate to an image developing device that develops a latent image on a latent image supporting body by using a developer supporting body that supports developer, and a process cartridge and an image forming device that utilize the image developing device.
Image forming devices that utilize the electrographic method have been widely used, for example in home offices, or by general users. In order to respond to such utilization in the home offices or by the general users, cost reduction, a longer life-span, downsizing, and stability during operation may be required. In order to realize a longer life-span of an image forming device, wearing of functional materials associated with their use may be minimized. For example, for a photosensitive body, which is an image supporting body, surface wear caused by being contacted by corresponding members in a charging process, a developing process, a transferring process, and a cleaning process, respectively, may be considered. It has been known to provide a suppressive measure for suppressing the wear, such as an application member for applying a lubricant agent, so as to prevent a surface of a photosensitive body from being worn. However, as the photosensitive body is downsized in accordance with the downsizing of the device, it is becoming difficult to arrange such a suppressive measure for suppressing the wear. Therefore, recently, various methods are considered such that an outer additive agent including a lubricant component is added to toner and a friction coefficient of the surface of the photosensitive body is reduced.
On the other hand, in order to stabilize the long term operation of the developing device, an amount of the toner corresponding to the amount of the toner consumed during the image development may be supplied. Since the amount of the toner stored in the developing unit is reduced as the developing unit is used, a residual quantity detection unit may be utilized to detect whether the remaining amount of the developer is greater than or equal to a predetermined amount. It has been known to supply the toner based on a detection result by such a residual quantity detection unit. For example, Patent Document 1 (Japanese Published Unexamined Application No. 2011-002526) discloses a two-axis developer circulation type image developing device such that two developer conveyance members are arranged at an upper portion and at a lower portion of a developing unit storing a one-component developing agent. A developer reservoir is continuously provided at an upper portion of an extending portion of the upper developer conveyance member, which is an upstream end portion in the conveyance direction. A residual amount detection unit is arranged at the developer reservoir. The residual amount detection unit optically detects a surface of the developer through a translucent detection window arranged at a side wall of the developer reservoir. With this, the residual amount detection unit determines the residual quantity of the developer.
However, when an outer additive agent including a lubricant component is added to toner, an adhesive force between particles of the toner increases and a cohesive property of the toner is increased. Thus the fluidity of the toner is reduced. When the fluidity of the toner is reduced, the surface of the toner tends to be uneven and the surface of the toner tends not to be formed stably at a suitable position corresponding to the amount of the developer. Therefore, the detected amount of the toner detected by the residual amount detection unit that optically detects the surface of the developer through the detection window tends to be varied. For example, the residual amount detection unit may not detect the surface of the developer when the residual amount of the developer is less than or equal to the predetermined amount, or the residual amount detection unit may detect the surface of the developer when the residual amount of the developer is greater than the predetermined amount. Consequently, the image may be blurred because of the insufficient amount of the toner, or the clogging of the toner may occur because of the overflow of the toner.
It is an objective of the image developing device disclosed in Patent Document 1 to detect a residual amount of the developer within the developing unit by a simple and less expensive configuration. However, in this case, the image developing device tends to be large because the developer reservoir is continuously arranged at the upper portion of the extending unit of the upper developer conveyance member. Thus such a configuration is not suitable for downsizing of the device. Further, in order to detect the residual amount of the developer, an amount of the developer that reaches the developer reservoir may always be required. Therefore, a greater amount of the developer may be required and the cost is increased. Further, when a developer having a low fluidity is used so as to respond to the longer life-span, an excessive amount of the developer within the developing unit may lead to a breakage of the developer conveyance member that is caused by a torque load, or a destruction of the device that is caused by the clogged toner.
The embodiment of the present invention is developed in view of the above problems. An objective of the embodiment is to provide an image developing device, a process cartridge which utilizes the image developing device, and an image forming device which utilizes the image developing device that can properly detect an amount of a developer within the image developing device, that can prevent an image from being blurred due to an erroneous detection, that can prevent clogging of toner, and that can maintain high image quality for a long time, when a developer having a low fluidity is utilized so as to respond to a longer life-span.
In one aspect, there is provided an image developing device including a developer supporting body that supports a developer and that conveys the developer to a portion facing a latent image supporting body; a first conveyance path in which a first conveyance member is arranged, the first conveyance member being for conveying the developer along an axis line direction of the developer supporting body; a second conveyance path in which a second conveyance member is arranged, the second conveyance path being for conveying the developer in a direction opposite to the developer conveyance direction by the first conveyance member, the second conveyance member being arranged above the first conveyance path; and a partition member that partitions the first conveyance path and the second conveyance path and that has a first communication port and a second communication port, the first communication path and the second communication path communicating with each other at a first end portion and a second end portion in the axis line direction through the first communication port and the second communication port. The image developing device includes a developer amount detection unit that includes an optical detection unit arranged in the second conveyance path and that optically detects an amount of the developer in the image forming device. The developer is caused to accumulate in the vicinity of the developer amount detection unit of the image developing device.
In another aspect, there is provided a process cartridge that is detachably attached to an image forming device, the process cartridge integrally supporting a latent image supporting body that supports a latent image; and at least one of units selected from a charging unit that uniformly charges the latent image supporting body; a developing unit that develops the latent image on the latent image supporting body; and a cleaning unit that cleans the latent image supporting body. The process toner cartridge includes an image developing device that includes a developer supporting body that supports a developer and that conveys the developer to a portion facing a latent image supporting body; a first conveyance path in which a first conveyance member is arranged, the first conveyance member being for conveying the developer along an axis line direction of the developer supporting body; a second conveyance path in which a second conveyance member is arranged, the second conveyance path being for conveying the developer in a direction opposite to the developer conveyance direction by the first conveyance member, the second conveyance member being arranged above the first conveyance path; and a partition member that partitions the first conveyance path and the second conveyance path and that has a first communication port and a second communication port, the first communication path and the second communication path communicating with each other at a first end portion and a second end portion in the axis line direction through the first communication port and the second communication port. The image developing device includes a developer amount detection unit that includes an optical detection unit arranged in the second conveyance path and that optically detects an amount of the developer in the image forming device. The developer is caused to accumulate in the vicinity of the developer amount detection unit of the image developing device.
In another aspect, there is provided an image forming device including a latent image supporting body that supports a latent image; and an image developing unit that develops the latent image on the latent image supporting body. The image developing device includes a developer supporting body that supports a developer and that conveys the developer to a portion facing a latent image supporting body; a first conveyance path in which a first conveyance member is arranged, the first conveyance member being for conveying the developer along an axis line direction of the developer supporting body; a second conveyance path in which a second conveyance member is arranged, the second conveyance path being for conveying the developer in a direction opposite to the developer conveyance direction by the first conveyance member, the second conveyance member being arranged above the first conveyance path; and a partition member that partitions the first conveyance path and the second conveyance path and that has a first communication port and a second communication port, the first communication path and the second communication path communicating with each other at a first end portion and a second end portion in the axis line direction through the first communication port and the second communication port. The image developing device includes a developer amount detection unit that includes an optical detection unit arranged in the second conveyance path and that optically detects an amount of the developer in the image forming device. The developer is caused to accumulate in the vicinity of the developer amount detection unit of the image developing device.
In the embodiment, the developer in the first conveyance path is conveyed along the axis direction of the developer supporting body by the first conveyance member, and the developer is lifted to the second conveyance path through the second communication port. The developer in the second conveyance path is conveyed in the direction opposite to the conveyance direction in the first conveyance path by the second conveyance member, and the developer is dropped and returned to the first conveyance path through the first communication port. In this manner, the developer circulates between the first conveyance path and the second conveyance path. At that time, since the developer tends to accumulate around the detection unit of the developer amount detection unit arranged inside the second conveyance path, the developer surface in the second conveyance path is formed to be slanted so that a height of the developer surface is increased along a direction from an upstream side portion in the developer conveyance direction toward the detection unit of the developer amount detection unit. Therefore, even if a developer having a low fluidity is utilized, unevenness of the surface of the developer in the vicinity of the detection unit can be reduced, in comparison to a conventional configuration in which the developer tends not to accumulate in the vicinity of the detection unit. Thus the developer surface can be formed at a more suitable position depending on the amount of the developer. Hence the developer amount detection unit can detect the developer surface formed at the more suitable position, depending on the amount of the developer.
According to the embodiment, the developer amount detection unit can detect the developer surface formed at the more suitable position compared to a position in a conventional case, depending on the amount of the developer. Therefore, even if a developer having a low fluidity is utilized so as to respond to a longer life-span, an amount of the developer within the device can be more properly detected. Consequently, an image developing device, a process cartridge which utilizes the image developing device, and an image forming device which utilizes the image developing device can be provided such that blurring of an image and clogging of the toner due to an erroneous detection are prevented, and with which high image quality can be maintained for a long time.
Hereinafter, an embodiment (referred to as the first embodiment) applied to a color printer, which is an image forming device utilizing an electrographic method, is explained.
Each of the above described image developing devices 3 develops an image by performing a contact development method while utilizing a single component developer that includes toner. As described later, in each of the image developing devices 3, a corresponding image developing roller 30, which supports and conveys the developer in the image developing device 3 to a portion facing the corresponding photosensitive body 1, is arranged at a corresponding opening of the image developing device 3 facing the corresponding photosensitive body 1. In each of the image developing devices 3, charged toner is adhered, by a voltage difference between the developing bias applied to the corresponding developing roller 30 and the electrostatic latent image formed on the surface of the corresponding photosensitive body 1, to an electrostatic latent image within an area to be developed. In this manner, the electro static latent images are developed. Further, a toner supply container 4 for supplying the corresponding color of toner to the corresponding image developing device 3 is connected to an upper portion of the corresponding image developing device 3. Here, each of the image developing devices 3 is configured to utilize the single component developer. However, each of the developing devices 3 may be configured to utilize developer having two components. Further, each of the toner supply containers 4 has a configuration such that the toner supply container 4 directly supplies the corresponding color of toner into the corresponding image developing device 3. However, each of the toner supply containers 4 may not be connected to the upper portion of the corresponding image developing device 3, and the toner supply container 4 may have a configuration such that the corresponding color of toner is supplied to the corresponding image developing device 3 through a supply path arranged within the printer.
The above described intermediate transfer belt 7 is supported by plural conveyance rollers (not shown) including a driving roller. The intermediate transfer belt 7 can be moved in a clockwise direction in
Further, a sensor 11 is arranged in the surrounding area of the intermediate belt 7. This sensor 11 (such as an optical sensor, for which the specular reflection method and the diffusion reflection method are combined) measures an amount of the toner transferred and adhered to the intermediate transfer belt 7 and positions of the toner images in the corresponding colors. The data obtained by the sensor 11 is used for adjusting image density and the positions. Further, a belt cleaning unit 12 is arranged in the surrounding area of the intermediate transfer belt 7. The belt cleaning unit 12 cleans the intermediate transfer belt 7 after the secondary transfer has been completed. The belt cleaning unit 12 includes a cleaning blade 12a and a metal cleaning opposite roller 12b. The cleaning blade 12a slidably contacts with the intermediate transfer belt 7 such that the cleaning blade 12a is inclined in the direction opposite to the moving direction of the intermediate transfer belt 7. The metal cleaning opposite roller 12b and the cleaning blade 12a nip the intermediate transfer belt 7. The metal cleaning opposite roller 12b is arranged at a position facing the cleaning blade 12a through the intermediate transfer belt 7. The toner removed by the cleaning blade 12a of the belt cleaning unit 12 is transferred by a conveyance coil 12c and stored in a waste toner storage unit (not shown).
Next, the above image developing device 3 is explained in detail.
Further, the lower tank 32 of the above described image developing device includes, at least, a feed roller 35 and a regulating member 39, in addition to the image developing roller 30 and the lower conveyance member 31. Here, the feed roller is formed of an elastic body, such as a sponge, and feeds the toner inside the lower tank 32 onto the image developing roller 30. The regulating member 39 regulates an amount of the toner on the image developing roller 30. The feed roller 35 applies and feeds the toner, which is adhered to the surface of the feed roller 35 when the feed roller 35 rotates, onto the surface of the image developing roller 30. A supply bias having a value, which is offset with respect to the developing bias in the same direction as the charging polarity of the toner, may be applied to the feed roller 35. The supply bias acts in a direction to press the toner onto the image developing roller 30. Here, the toner is pre-charged at a portion of the image developing roller 30, where the toner contacts the image developing roller 30. The developing bias is applied to the image developing roller 30 so as to form an electric field between the image developing roller 30 and the photosensitive body 1. The image developing roller 30 rotates in the counterclockwise direction in
In the image developing device 3 shown in
Further, as shown in
Incidentally, in order to properly detect the amount of the toner in the image developing device 3 by using the above described optical sensor 51, it is important to stably form a toner surface in the emission light path from the luminescence sensor. Therefore, in the first embodiment, the toner conveyance speed by the upper conveyance member 33 in the upper tank 34 of the image developing device, in which the toner surface is formed, is set to be greater than the toner conveyance speed by the lower conveyance member 31. The conveyance speeds by the lower conveyance member 31 and the upper conveyance member 33 can be controlled by varying screw pitches, screw diameters, and rotational speeds of the lower conveyance member 31 and the upper conveyance member 33. For example, the toner conveyance speed becomes greater in proportion to the screw pitch. That is because an amount of the toner conveyed per one rotation of the screw becomes larger, as the screw pitch is increased.
When the toner conveyance speed by the upper conveyance member 33 is greater than the toner conveyance speed by the lower conveyance member 31, the toner which collides with the wall surface at the end portion at the downstream most side of the upper tank 34 does not move to the lower tank 32 quickly and tends to accumulate. Thus the toner surface in the upper tank 34 is formed to be slanted such that a height of the toner surface becomes larger along the direction from the upstream side in the toner conveyance direction toward the downstream side. Therefore, even if the liquidity of the toner is low, unevenness of the toner surface is reduced and the toner surface tends to be formed at a proper position corresponding to the residual amount of the toner in the upper tank 34, in comparison to a case in which the conveyance speed by the lower conveyance member 31 and the conveyance speed by the upper conveyance member 33 are the same. Consequently, the optical sensor 51 can detect the toner surface formed at the proper position corresponding to the residual amount of the toner.
Especially, as shown in
As described above, in the first embodiment, the developer conveyance speed in the upper tank 34 is set to be greater than the developer conveyance speed in the lower tank 32, so that the toner surface is formed at the proper position corresponding to the residual amount of the toner in the vicinity of the detection unit of the optical sensor 51. According to this configuration, the toner tends to accumulate in the vicinity of the detection unit of the optical sensor 51. That is an important matter for properly detecting the amount of the toner in the image developing device 3 by using the optical sensor 51.
Next, an example according to the first embodiment is concretely explained. First, a production method of the toner used in the example and in a comparative example is explained.
[Synthesis of Polyester 1]
A reaction container having a cooling pipe, an agitator, and a nitrogen inlet tube was charged with 235 parts of bisphenol A ethylene oxide 2-mole adduct, 525 parts of bisphenol A propylene oxide 3-mole adduct, 205 parts of terephthalic acid, 47 parts of adipic acid, and 2 parts of dibutyltin oxide. The resultant mixture was allowed to react under normal pressure at 230 degrees Celsius for 8 hours. Further, the pressure was reduced by an amount within a range from 10 mm Hg to 15 mm Hg and the reaction was continued for 5 hours. Subsequently, 46 parts of trimellitic anhydride were added into the reaction container and the reaction was continued for 2 hours under normal pressure. In this manner, “a polyester 1” was obtained. “The polyester 1” was found to have a number average molecular weight of 2600, a weight average molecular weight of 6900, a glass transition temperature (Tg) of 44 degrees Celsius, and an acid value of 26.
[Synthesis of Prepolymer 1]
A reaction container having a cooling pipe, an agitator, and a nitrogen inlet tube was charged with 682 parts of bisphenol A ethylene oxide 2-mole adduct, 81 parts of bisphenol A propylene oxide 2-mole adduct, 283 parts of terephthalic acid, 22 parts of trimellitic anhydride, and 2 parts of dibutyltin oxide. The resultant mixture was allowed to react under normal pressure at 230 degrees Celsius for 8 hours. Further, the pressure was reduced by an amount within a range from 10 mm Hg to 15 mm Hg and the reaction was continued for 5 hours. In this manner, “an intermediate polyester 1” was obtained. “The intermediate polyester 1” was found to have a number average molecular weight of 2100, a weight average molecular weight of 9500, a Tg of 55 degrees Celsius, an acid value of 0.5 and a hydroxyl value of 49. Subsequently, a reaction container having a cooling pipe, an agitator, and a nitrogen inlet tube was charged with 411 parts of “the intermediate polyester 1,” 89 parts of isophorone diisocyanate and 500 parts of ethyl acetate. The resultant mixture was allowed to react at 100 degrees Celsius for 5 hours, and “a prepolymer 1” was obtained. The amount of free isocyanate contained in “the prepolymer 1” was found to be 1.53% by mass.
[Preparation of Masterbatch 1]
First, 40 parts of carbon black (REGAL400R, product of Cabot Corporation), 60 parts of binder resin, which is a polyester resin (RS-801, which is a product of Sanyo Chemical Industries, Ltd., and having an acid value of 10, a weight average molecular weight (Mw) of 20000, and Tg of 64 degrees Celsius), and 30 parts of water were mixed by a Henschel mixer. Then a mixture, in which water is soaked into a pigment agglomerate, was obtained. The mixture was kneaded for 45 minutes with two rollers, whose surface temperature was set to 130 degrees Celsius. Then the resultant mixture was broken into pieces having a size of 1 mm by using a pulverizer. In this manner, “a masterbatch 1” was obtained.
[Production of Pigment/Wax-Dispersed Solution 1 (Oil Phase)]
A container equipped with an agitator and a thermometer was charged with 545 parts of the polyester 1, 181 parts of paraffin wax, 1450 parts of ethyl acetate. The resultant mixture was agitated and heated to 80 degrees Celsius. Then the temperature of the resultant mixture was kept at 80 degrees Celsius for 5 hours. Subsequently, the resultant mixture was cooled to 30 degrees Celsius within one hour. Next, a container was charged with 500 parts of the masterbatch 1, 100 parts of a charge control agent (1), and 100 parts of ethyl acetate. The resultant mixture was mixed for one hour. In this manner, “a raw material solution 1” was obtained. Then 1500 parts of “the raw material solution 1” were moved to another container, and the carbon black and wax were dispersed with a bead mill (Ultra Viscomill, product of IMEX CO. LTD.) under the following conditions: a liquid feed rate of 1 billion kilograms per hour, a disk circumferential velocity of 6 m/s, 0.5 mm-zirconia beads packed to 80% by volume, and 3 passes. Next, 425 parts of the polyester 1 and 230 parts of the polyester 1 were added thereto, and passed once with the bead mill under the above conditions. In this manner “a pigment/wax-dispersed solution 1” was obtained. After that, “the pigment/wax-dispersed solution 1” was adjusted so that the solid content concentration (at 130 degrees Celsius, 30 minutes) of “the pigment/wax-dispersed solution 1” became 50%.
[Aqueous Phase Production Process]
After 970 parts of ion-exchanged water, 40 parts of 25 wt % aqueous dispersion of organic resin fine particles (copolymers of a sodium salt of styrene-methacrylic acid-butyl acrylate-methacrylic acid ethylene oxide adduct sulfate ester), 140 parts of 48.5% aqueous solution of dodecyl diphenyl ether sodium disulphonate (Eleminor MON-7, manufactured by Sanyo Chemical Industries, Ltd.) and 90 parts of ethyl acetate were mixed and stirred, a milky white liquid was obtained. This is referred to as “an aqueous phase 1.”
[Emulsification Process]
After 975 parts of “the pigment/wax-dispersed solution 1” and 2.6 parts of isophorone diamine, as an amine, were mixed by a TBk homomixer (a product of Tokushu Kika Kogyo Co., Ltd.) for 1 minute at 5000 rpm, 88 parts of “the prepolymer 1” were added thereto, and the resultant mixture was mixed by the TBk homomixer (product of Tokushu Kika Kogyo Co., Ltd.) for 1 minutes at 5000 rpm. Subsequently, 1200 parts of “the aqueous phase 1” was added thereto, and the resultant mixture was mixed by the TBk homomixer for 20 minutes, while the rotational speed was adjusted between 8000 rpm and 13000 rpm. In this manner, “an emulsified slurry 1” was obtained.
[Solvent Removal Process]
A container equipped with an agitator and a thermometer was charged with “the emulsified slurry 1,” and the solvent removal process was performed at 30 degrees Celsius for 8 hours. In this manner, “a dispersion slurry 1” was obtained.
[Washing and Drying Process]
After 100 parts of “the dispersion slurry 1” was filtered under reduced pressure, the processes (1) through (5) described below were performed.
(1) After 100 parts of ion-exchanged water was added to the filtration cake, the resultant mixture was mixed by the TBk homomixer (at 12000 rpm for 10 minutes) and filtered. The color of the filtrate was milky white.
(2) After 900 parts of ion-exchanged water was added to the filtration cake of (1), the resultant mixture was mixed by the TBk homomixer (at 12000 rpm for 30 minutes) while supersonic vibration was applied to it. Then the resultant mixture was filtered. The process was repeated until the electric conductivity of the slurry liquid became less than or equal to 10 μC/cm.
(3) Hydrochloric acid (10%) was added to the slurry liquid of (2) until the pH of the slurry liquid became 4. Then the resultant mixture was mixed by a three-one motor for 30 minutes. After that, the resultant mixture was filtered.
(4) After 100 parts of ion-exchanged water was added to the filtration cake of (3), the resultant mixture was mixed by the TBk homomixer (at 12000 rpm for 10 minutes). Then the resultant mixture was filtered. The process was repeated until the electric conductivity of the slurry liquid became less than or equal to 10 μC/cm. In this manner, “a filtration cake 1” was obtained.
(5) “The filtration cake 1” is dried by an air-circulating drier at 42 degrees Celsius for 48 hours. Then the dried “filtration cake 1” was passed through a sieve with a mesh size of 75 μm. In this manner, a toner parent body was obtained. The toner parent body was found to have an average circularity of 0.974, a volume-average particle diameter (Dv) of 6.3 μm, and a number-average particle diameter (Dp) of 5.3 μm. Further, Dv/Dp was found to have a particle size distribution of 1.19. Subsequently, 1.8 parts of hydrophobic silica was added to 100 parts of the toner parent body, and the resultant mixture was mixed by the Henschel mixer. In this manner the toner of the example was obtained.
Next, toner (1) was produced by performing the following process, in which a lubricant agent was added as an external additive agent. The toner parent body, to which the following process was not applied and the hydrophobic silica was used, is referred to as toner (2). In this example, it is preferable that more than 1 type of inorganic fine particles be used as the external additive agent, which enhances liquidity, electrostatic property, developability, and transferability of the toner particles. It, is preferable that the specific surface area of the inorganic fine particles by the BET method be within a range from 30 m2/g to 300 m2/g. Further, it is preferable that the primary particle size of the inorganic fine particles is within a range from 10 nm to 50 nm.
[External Additive Agent of Toner (1)]
After 1 part by mass of silicone oil was added to 100 parts by mass of silicon dioxide, the resultant mixture was mixed by a Henschel mixer. Then the resultant mixture was stiffened or wettened at 250 degrees Celsius for two hours. The external additive agent of the toner (1) was prepared by applying a hydrophobic treatment to the resultant mixture.
<Agglomeration Degree Measurement Method>
An agglomeration degree was measured as follows. As a measuring device (not shown), a powder tester produced by Hosokawa Micron Corporation was used. Required accessories were set on a vibrating table in the following order: (i) vibro-shoot, (ii) packing, (iii) space ring, (iv) screens (three types) upper>middle>lower, and (v) pressing bar. These accessories were fixed by knob nuts. Then the vibrating table was operated. The measurement conditions were as follows:
screen opening (upper): 75 μm
screen opening (middle): 45 μm
screen opening (lower): 22 μm
vibration amplitude: 1 mm
sample mass: 2 g
vibrating period: 10 seconds
After the measurement in accordance with the above described procedure was performed, the agglomeration degree was obtained by the following calculations.
(a) Calculate (mass (wt %) of the powders remaining on the upper screen)×1.
(b) Calculate (mass (wt o) of the powders remaining on the middle screen)×0.6.
(c) Calculate (mass (wt o) of the powders remaining on the lower screen)×0.2.
The total of the values obtained by the above described procedures (a), (b), and (c) was defined to be the agglomeration degree (%).
Then a color printer (IpsioSPC310, manufactured by Ricoh Company, Ltd.) was modified so that the image developing device 3 (example 1 through example 4, and comparative example 1 through comparative example 3) and the toner supply container 4 can be attached thereto, and the following experiments were performed. The process cartridge (the image developing device 3) was connected to an imaging drive motor, so that the process cartridge was driven by the imaging drive motor. The toner supply container 4 was connected to the driving source of the image developing device 3 through a clutch, so that the toner supply container 4 was driven by the driving source of the image developing device 3. With this configuration, the toner could be supplied by connecting the driving source and the driving gear of the toner supply container 4. As described above, based on the presence or absence of the silica material containing the oil, which was added as the external additive component, two kinds of toner having different types of liquidity (the toner (1) and the toner (2)) were prepared, and used in the experiments.
In the experiments, first, an examination for evaluating the durability of the photosensitive body was performed. In the examination, a running test, in which the running distance of the photosensitive body was 1000 m, was performed, and the variation of the film thickness of the photosensitive body was checked. For the measurement of the film thickness, the Fischer Scope MMS (manufactured by Fischer Instruments K.K.), which is a film thickness measuring device, was used, and determination was made as to whether an amount of wear was less than or equal to 0.5 μm. Subsequently, the toner was supplied to the image developing device 3, and, at the same time, a test was performed with respect to the ability of detecting the amount of the toner remaining in the image developing device 3. The output from the sensor was observed. The sampling frequency was set to be 20 nm, and the sampling was performed for 4 seconds. The output voltage was binarized, and determination was made as to whether the light was transmitted or not. It was determined that the toner was present when the light was blocked during time intervals, in which the total of the time intervals were longer than or equal to 80% of the whole sampling interval. The image developing device 3 had the maximum toner loading capacity of 150 g. The sensor was arranged at a height corresponding to the toner surface that was idealistically formed by 90 g of the toner. Namely, the sensor was arranged at a position, at which the sensor could detect the toner surface that was idealistically formed by 90 g of the toner. With such a configuration, the amount of the toner stored in the image developing device 3 was detected, while the toner was supplied. Here, a detected weight was defined to be the weight of the toner that had been supplied to the image developing device 3 until the time at which the output from the sensor indicated the state where the light was blocked by the toner. For a stable operation, determination was made as to whether the weight of the supplied toner was within the range of 90±30 g.
In example 1, the toner (1) was used. A screw member having a pitch of 35 mm was used as the upper conveyance member 33 in the upper tank 34. A screw member having a pitch of 25 mm was used as the lower conveyance member 31 in the lower tank 32. The detecting position by the optical sensor 51 was placed above the first communication port 37 of the partition member 36.
The same conditions as the conditions of example 1 were applied to example 2, except that the number of the teeth of the screw rotation gear of the upper conveyance member 33 in the upper tank 34 was increased from 45 to 48 and that the rotational speed of the upper conveyance member 33 was increased.
The same conditions as the conditions of example 1 were applied to example 3, except that the detection position by the optical sensor 51 was shifted from the first communication port 37 of the partition member 36 by 20 mm toward the upstream side in the toner conveyance direction.
The same conditions as the conditions of example 1 were applied to example 4, except that 2 pitches from the downstream-most side in the toner conveyance direction of the screw blades were modified so that the conveyance direction was reversed.
The same conditions as the conditions of example 1 were applied to comparative example 1, except that the toner (2) was used.
The same conditions as the conditions of example 1 were applied to comparative example 2, except that the screw pitch of the upper conveyance member 33 in the upper tank 34 and the screw pitch of the lower conveyance member 31 in the lower tank 32 were set to 25 mm.
The same conditions as the conditions of example 1 were applied to comparative example 3, except that the number of the teeth of the screw rotation gear of the upper conveyance member 33 in the upper tank 34 was decreased from 45 to 42 and that the rotational speed of the upper conveyance member 33 was decreased.
Table 1 shows the results of the experiments.
The results of table 1 shows that, even if the toner having a low degree of liquidity was used, such as the toner having the accelerated agglomeration degree of greater than or equal to 60%, in the image developing device 3 according to example 1 through example 4, where the conveyance speed of the toner in the lower tank 32 was greater than the conveyance speed of the toner in the upper tank 34, no erroneous detection was found and fine image quality without blurring of an image and clogging of the toner was obtained for a long time. Namely, with the image developing device 3 according to the first embodiment, even if the toner having a low degree of liquidity was used, such as the toner having the accelerated agglomeration degree of greater than or equal to 60%, by stably forming the toner surface in the vicinity of the detection unit of the optical sensor 51 arranged in the upper tank 34, fine image quality without blurring of an image and clogging of the toner was obtained for a long time. Especially, in example 3, where the detection position by the optical sensor 51 was moved to a position, which is in the downstream side from the center portion of the partition member 36 and is in the upstream side from the first communication port 37, the detected amount of the toner remaining in the image developing device 3 was reduced compared to examples 1 and 2. In contrast, in comparative example 1, the toner (2) was used. The lubricant agent as the external additive component was not added to the toner (2). The accelerated agglomeration degree of the toner (2) was small and the toner (2) had fine liquidity. However, the wear amount of the photosensitive body was large and durability was found to not be fine. Further, in comparative examples 2 and 3, where the toner conveyance speed in the lower tank 32 was less than or equal to the toner conveyance speed in the upper tank 34, the toner surface in the vicinity of the optical sensor was unstable, and erroneous detection tended to occur. Therefore, in comparative examples 2 and 3, the operational stability was found to be insufficient.
Further, the oil-containing component was added to the external additive component of the toner used in the first embodiment. In this manner, by adding the oil-containing component, the accelerated agglomeration degree of the toner can be increased.
Hereinafter, another embodiment (referred to as the second embodiment) applied to a color printer, which is an image forming device utilizing an electrographic method, is explained. The second embodiment and the above described first embodiment differ in the following points concerning the configurations. In the first embodiment, the developer conveyance speed in the upper tank 34 is set to be greater than the developer conveyance speed in the lower tank 32, so as to form the toner surface at the proper position corresponding to the amount of the toner in the vicinity of the detection unit of the optical sensor 51. Thus the developer tends to accumulate in the vicinity of the detection unit of the optical sensor. On the other hand, in the second embodiment, the developer conveyance speed between the first optical guide 52 and the second optical guide 53 in the upper tank 34, which are the detection unit of the optical sensor 51, is set to be less than the developer conveyance speed at other portions, so that the developer tends to accumulate in the vicinity of the detection unit of the optical sensor 51. Further, in the second embodiment, it is defined that the image developing device 3 includes a cleaning unit for cleaning the light emitting plane 62 of the first optical guide 52 and the entrance plane 63 of the second optical guide 53. Additionally, in the second embodiment, after the light emitting plane 62 and the entrance plane 63 are cleaned by the cleaning unit, an entering amount of the developer to the space between the light emitting plane 62 and the entrance plane 63 is regulated, by reducing the developer conveyance speed between the first optical guide 52 and the second optical guide 53 compared to the developer conveyance speed at other portions. In this manner, the detection accuracy of the optical sensor 51 for detecting the amount of the developer is improved. Since the configurations of other points of the second embodiment are almost the same as that of the first embodiment, explanations of the similar configurations are arbitrary omitted. Further, for the members that are common between the first embodiment and the second embodiment, the same reference numerals are used and explained, provided there is no special requirement.
First, a configuration in the vicinity of the optical sensor 51 is explained. The optical sensor 51 is the developer detection unit of the second embodiment.
In the optical sensor 51, a luminescence sensor (not shown) attached to a side wall of the main body of the image forming device irradiates alight beam 61a. The irradiated light beam is guided toward inside the upper tank 34 by the first optical guide 52. The first optical guide 52 is attached to the side wall of the image developing device 3. The first optical guide 52 is formed of a resin material having a high degree of transparency. The light beam irradiated from the luminescence sensor enters the second optical guide 53 through a space 61b in the upper tank 34, which is shown in the
For detecting the residual amount of the toner, it is important that the light emitting plane 62 of the first optical guide 52 and the entrance plane 63 of the second optical guide 53 are always kept clean, so as to ensure that the light path can only be blocked by the presence of the toner, and so that the presence or absence of the toner in the space 61b is accurately recognized. For example, when the toner or a foreign material is attached to the light emitting plane 62 or the entrance plane 63, since the light may be blocked even if the toner is absent in the space 61b, the output voltage is decreased and it can be a cause of an erroneous detection. Therefore, in the second embodiment, a cleaning member 54, such as a sheet material, is attached to a range of the rotation axis of the upper conveyance member 3 corresponding to the detection unit of the optical sensor 51. Namely, in the second embodiment, a cleaning unit is arranged at the range corresponding to the detection unit of the optical sensor 51. The cleaning unit can remove substances attached to the light emitting plane 62 and the entrance plane 63 by its rotation. In the second embodiment, the configuration such that the cleaning member 54 is directly attached to the upper conveyance member 33 and the cleaning of the light emitting plane 62 and the entrance plane 63 is performed in synchronization with the rotational motion for circulating the toner is indicated, so as to reduce the number of components to facilitate the cost reduction. However, the second embodiment is not limited to this configuration. For example, a cleaning unit may be provided by introducing another rotation axis.
When the image developing device operates for forming an image, the upper conveyance member 33 is rotated by a drive transmission unit (not shown) so as to circulate the toner. When the upper conveyance member 33 rotates, the cleaning member 54 attached to the rotation axis of the upper conveyance member 33 rotates accordingly. Here, the cleaning member 54 has a substantially T-shape. The portion of the cleaning member 54 corresponding to the vertical line portion of the T-shape is attached to the peripheral surface of the rotation axis of the upper conveyance member 33, so that the portion of the cleaning member 54 is perpendicular to the shaft center. When the upper conveyance member 33 rotates, edges of the portion of the cleaning member 54 corresponding to the horizontal line portion of the T-shape contact the light emitting plane 62 and the entrance plane 63, respectively, and the toner and the substances attached to the light emitting plane 62 and the entrance plane 63 are removed. With such a configuration, the optical path in the space 61b can be secured.
In the printer according to the second embodiment, detection of the developer by the optical sensor 51, which is the developer detection unit, is performed as follows. Here,
With such a configuration, for example, when the cleaning is insufficient and the toner is scattered over the light emitting plane 62 or the entrance plane 63, the output waveform becomes the waveform shown in
Next, the flow of the toner in the vicinity of the detection unit in the upper tank 34 of the image developing device 3 is explained by using figures.
Here, the movement of the toner in the cross section perpendicular to the rotation axis of the upper conveyance member 33 at the detection unit of the optical sensor 51 of the image developing device 3 is explained by using
However, when the circular type image developing device 3 has the configuration shown in
It has been found by experiments that the detection accuracy varies depending on a position and a height of the upstream rib 71 placed at the upstream side in the developer conveyance direction of the detection unit of the optical sensor 51. Next, an example of the evaluation experiments performed for evaluating the configuration of the second embodiment are explained. The image developing unit (the image developing device 3) was charged with 65 g of the toner, 75 g of the toner, 85 g of the toner, and 95 g of the toner, corresponding to the conditions described below. As described above, for each condition, the output waveform was obtained three times, and evaluated based on the duty. Further, as the image developing unit, the same unit was used. By outputting the whole solid images, it was found that the image was blurred due to a shortage in the amount of the toner, when the amount of the toner was 65 g. Therefore, it was evaluated whether the detection unit can stably detect the amount of the toner greater than or equal to 75 g.
Table 2 shows the conditions corresponding to the cases, where the height of the upstream rib 71, the distance L1 between the upstream rib 71 and the end face of the prism in the upstream side in the developer conveyance direction of the first optical guide 52, and the length L2 of the upstream rib 71 from the inner wall of the side wall 34a are varied. Further,
From the results indicated in
On the other hand, the result shown in
As described above, with the configuration of the second embodiment, it is important to set, during detection of the residual amount, the circulation speed of the toner at the detection unit of the optical sensor 51 to be smaller than the speed of the toner at other portions. Here,
When the upstream rib 71 is only arranged at the upstream side in the developer conveyance direction of the detection unit of the optical sensor 51, the flow of the toner is spread at the detection unit. Thus, strictly, the toner enters the space 61b of the detection unit. Therefore, by providing the similar downstream rib 72 at the downstream side in the developer conveyance direction, the flow of the toner at the detection unit of the optical sensor can be blocked, and the detection accuracy can be further improved. Reducing the liquidity of the toner at the detection unit results in reduction of the circulating speed (moving speed of the toner) at the detection unit and, ultimately, results in reduction of circularity of the toner in the whole of the image developing device 3. Therefore, it is preferable that the area, at which the circulating speed is reduced, be set to be as small as possible.
Therefore, at the downstream side of the detection unit, it is preferable that the screw of the upper conveyance member 33 be as close as possible to the second optical guide 53. When the distance between the screw of the upper conveyance member 33 at the downstream side of the detection unit and the end surface of the second optical guide 53 at the downstream side in the toner conveyance direction is less than or equal to 10 mm, preferably less than or equal to 5 mm, the effect of improving the detection accuracy while reducing the area where the circulating speed is reduced becomes higher. Reducing the toner conveyance speed at the detection unit conversely results in forming an area, in which the toner stays, in the image developing device. When an area, in which toner stays, is formed in the circulation of the toner, the toner may not be uniformly conveyed in the longitudinal direction, due to insufficient circulation of the toner. Therefore, an image defect tends to occur, due to insufficient supply of the toner to the image developing roller 30, which is the developer supporting body.
In the first place, when the toner having a low degree of liquidity is used, the effect of improving the detection accuracy while reducing the area where the circulating speed is reduced is high. Here, as described above, when the accelerated agglomeration degree is utilized as an index of the liquidity, it is preferable to use the toner having the accelerated agglomeration degree of 60% or higher. However, when the degree of liquidity is too low, the circulation of the toner in the image developing device may become too slow and the toner may not be sufficiently supplied, so that an image defect tends to occur. Therefore, it is preferable that the accelerated agglomeration degree be less than or equal to 95%.
As described above, in the image developing device 3 according to the first embodiment and the second embodiment, since the toner tends to accumulate in the vicinity of the detection unit of the optical sensor 51 placed in the upper tank 34, the developer surface in the upper tank 34 is formed to be slanted so that the height of the developer surface is increased along the direction from the upstream side portion in the developer conveyance direction toward the detection unit of the developer amount detection unit. Therefore, even if a developer having a low fluidity is utilized so as to respond to a longer life-span, an amount of the developer within the device can be more properly detected. Consequently, an image developing device, a process cartridge which utilizes the image developing device, and an image forming device which utilizes the image developing device can be provided such that blurring of an image and clogging of the toner due to an erroneous detection are prevented, and with which high image quality can be maintained for a long time. Further, the required amount of the developer may be small compared to the case in which the developer reservoir is provided at the upper portion of the extending portion of the second conveyance path, and the developer amount is detected at the developer reservoir. Thus the cost reduction and the downsizing of the device can be facilitated. Further, in the image developing device 3 according to the first embodiment, the toner conveyance speed of the upper conveyance member 33 is greater than the toner conveyance speed of the lower conveyance member 31. Therefore, even if a developer having a low fluidity is utilized so as to respond to a longer life-span, the optical sensor arranged in the upper tank 34 can detect the toner surface formed at a proper position. Thus blurring of an image and clogging of the toner due to an erroneous detection can be prevented. Further, the required amount of the developer may be small compared to the case in which the developer reservoir is provided at the upper portion of the extending portion of the second conveyance path, and the developer amount is detected at the developer reservoir. Thus the cost reduction and the downsizing of the device can be facilitated. Further, in the image developing device 3 according to the first embodiment, since the screw pitch of the upper conveyance member 33 is greater than the screw pitch of the lower conveyance member 31, the toner conveyance speed by the upper conveyance member 33 is greater than the toner conveyance speed by the lower conveyance member 31. With this configuration, the toner surface is formed at a proper position corresponding to the residual amount of the toner in the upper tank 34. Further, in the image developing device 3 according to the first embodiment, since the rotational speed of the upper conveyance member 33 is greater than the rotational speed of the lower conveyance member 31, the toner conveyance speed by the upper conveyance member 33 is greater than the toner conveyance speed by the lower conveyance member 31. With this configuration, the toner surface is formed at a proper position corresponding to the residual amount of the toner in the upper tank 34. With this configuration, the toner is prevented from being clogged at the end portions of the lower tank 32 and the upper tank 34. Further, in the image developing device 3 according to the second embodiment, in the residual amount detection system, in which the light emitting plane 62 and the entrance plane 63 of the optical sensor 51 are cleaned and the light transmission time for the detection light irradiated from the light source is secured, the developer conveyance speed in the vicinity of the detection unit of the optical sensor 51 is less than the developer conveyance speed at other portions. In this manner, by reducing the circulation speed of the toner in the vicinity of the detection unit, the toner may be prevented from entering the area in the vicinity of the detection unit, after the toner in the vicinity of the detection unit has been removed by the cleaning member 54. As a consequence, a stable detection output result can be obtained with respect to the residual amount of the toner. Further, in the image developing device 3 according to the second embodiment, the driving force of the toner is reduced by removing the blade of the upper conveyance member 33 at the portion of the detecting unit of the optical sensor 51 in the upper tank 34. In this manner, by reducing the driving force of the toner, the toner conveyance speed at the detecting portion is reduced, and the toner may be prevented from entering the area in the vicinity of the detection unit, after the toner in the vicinity of the detection unit has been removed by the cleaning member 54. As a consequence, a stable detection output result can be obtained with respect to the residual amount of the toner. Further, in the image developing device 3 according to the second embodiment, the blocking member that regulates the flow of the toner is provided at the upstream side in the toner conveyance direction of the detection unit of the optical sensor 51. In this manner, the circulation speed of the toner at the detection portion may be further reduced by providing the blocking member. Therefore, the toner may be prevented from entering the area in the vicinity of the detection unit, which is caused by the circulation of the toner, after the toner in the vicinity of the detection unit has been removed by the cleaning member 54. As a consequence, a stable detection output result can be obtained with respect to the residual amount of the toner. Further, in the image developing device 3 according to the second embodiment, the blocking member that regulates the flow of the toner arranged at the upstream side in the toner conveyance direction of the detection unit of the optical sensor 51 is the upstream rib 71 attached to the side wall 34a of the upper tank 34. In this manner, when the blocking member is integrated with the chassis of the image developing device 3, an additional component may not be required, and a stable detection of the residual amount of the toner can be realized by a less expensive configuration. Further, in the image developing device 3 according to the second embodiment, the height of the upstream rib 71 is greater than or equal to the height of the first optical guide 52. In this manner, by setting the height of the upstream rib 71 to be greater than the height of the detection unit, the toner is prevented from entering the detection unit from the upper portion. Thus a stable detection of the toner residual amount is possible. Further, in the image developing device 3 according to the second embodiment, the upstream rib 71 is placed within 10 mm from the first optical guide 52 in the upstream direction in the toner conveyance direction. By placing the upstream rib 71 in the vicinity of the optical guide 52 in the upstream side in the toner conveyance direction, the toner is prevented from entering the detection unit, when the toner circulates and passes through the upstream rib 71. Thus a stable detection of the toner residual amount is possible. Further, in the image developing device 3 according to the second embodiment, the upstream rib 71 is placed closer to the detection unit of the optical sensor 51 than the rotation axis of the upper conveyance member 33. The upstream rib 71 prevents the toner from entering the detection unit by reducing the circulation speed of the toner only in the vicinity of the detection unit. Thus a stable detection of the toner residual amount is possible. Further, in the image developing device 3 according to the second embodiment, the downstream rib 72 is placed in the downstream side in the toner conveyance direction of the detection unit of the optical sensor 51. The downstream rib 72 reduces the toner circulation speed at the detection unit of the optical sensor 51. Thus a stable detection of the toner residual amount is possible. Further, in the image developing device 3 according to the second embodiment, the second blocking member, which is attached in the downstream side in the toner conveyance direction of the detection unit of the optical sensor 51, that regulates the flow of the toner is the downstream rib 72 attached to the side wall 34a in the upper tank 34. In this manner, by integrating the second blocking member with the chassis of the image developing device 3, additional components are not required and a stable detection of the toner residual amount becomes possible by a less expensive configuration. Further, in the image developing device 3 according to the second embodiment, the distance between the end surface in the downstream side in the toner conveyance direction of the second optical guide 53 and the end surface of the screw blade of the upper conveyance member 33 is less than or equal to 10 mm. By arranging the screw blade of the upper conveyance member 33 in this manner, after passing the detection unit of the optical sensor 51, the circulation speed of the toner can be quickly restored to the circulation speed at portions other than the portion of the detection unit. Therefore, in sufficient circulation of the toner caused by the toner accumulated at the detection unit of the optical sensor 51, in sufficient supply of the toner due to insufficient circulation of the toner, and defects on the image can be prevented, and a stable operation is realized and degradation of the image is prevented. Further, in the image developing device 3 according to the second embodiment, the distance between the end surface of the second optical guide 53 in the downstream side in the toner conveyance direction and the end surface of the screw blade of the upper conveyance member 33 is less than or equal to 10 mm. In this manner, since the screw of the upper conveyance member 33 is placed as close as possible to the second optical guide 53, after passing the detection unit of the optical sensor 51, the circulation speed of the toner is quickly restored to the circulation speed at portions other than the portion of the detection unit. Therefore, insufficient circulation of the toner caused by the toner accumulated at the detection unit of the optical sensor 51, insufficient supply of the toner due to insufficient circulation of the toner, and defects on the image are prevented, and a stable operation is realized and degradation of the image is prevented. Further, in the image developing devices 3 according to the first embodiment and the second embodiment, even when the toner with a low liquidity degree, such as the toner having the accelerated agglomeration degree in the range of greater than or equal to 60% and less than or equal to 95%, is utilized, in response to the longer life-span, the toner surface is stably formed in the vicinity of the optical sensor 51 arranged in the upper tank 34. Further, in the image developing devices 3 according to the first embodiment and the second embodiment, the accelerated agglomeration degree of the toner can be enlarged by adding the oil-containing component to the external additive component of the toner. Further, since the process cartridges and the printers according to the first embodiment and the second embodiment include the above described image developing devices 3, the cost reduction is enabled, the life-span can be lengthened, downsizing is enabled, and the stability of the operation can be improved.
The present invention is not limited to the specifically disclosed embodiments, and variations and modifications may be made without departing from the scope of the present invention.
The present application is based on Japanese Priority Applications No. 2011-055969 filed on Mar. 14, 2011, and No. 2011-243029 filed on Nov. 7, 2011, the entire contents of which are hereby incorporated herein by reference.
| Number | Date | Country | Kind |
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| 2011-055969 | Mar 2011 | JP | national |
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|---|---|---|---|---|
| PCT/JP2012/056210 | 3/5/2012 | WO | 00 | 11/9/2012 |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2012/124645 | 9/20/2012 | WO | A |
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