This Nonprovisional application claims priority under 35 U.S.C. § 119(a) on Patent Application No. 128514/2005 filed in Japan on Apr. 26, 2005, the entire contents of which are hereby incorporated by reference.
The present invention relates to (i) a developing device which is used in an image forming apparatus such as a copier, a printer, a facsimile machine, or the like, and which develops, using toner, an electrostatic latent image formed on an image support section, and (ii) an image forming apparatus having the developing device. The present invention particularly relates to (i) a developing device using a two component developer including toner and carrier, and (ii) an image forming apparatus having the developing device.
There has been a problem in a two component developing system with regard to its performance degradation. One of the causes of the problem is performance degradation of a carrier. Such performance degradation of the carrier includes adhesion of toner to the carrier (so-called “spent phenomenon”), peeling of coating applied to a surface of a carrier particle, and the like. Conventionally, there have been proposed various systems for suppressing such performance degradation of carrier.
For example, Japanese Examined Patent Publication, No. 111598/1987 (Tokukohei 7-111598, publication date: Jun. 10, 1987: Patent document 1) and Japanese Examined Patent Publication, No. 21591/1984 (Tokukohei 2-21591, publication date: Jun. 9, 1984: Patent document 2) describe developing devices using a so-called “trickle” system. In the developing devices disclosed in these publications, a small amount of carrier is supplied as toner is replenished, while an excess of the carrier (or the mixture of carrier and toner) in a developing device is discharged. This allows carrier in the developing device to have performance changing within a certain range, thereby achieving stability in the performance of the carrier over time.
In the trickle system, it is important to discharge developer by an amount corresponding to an amount of replenished developer (carrier), so as to maintain a certain amount of the developer in a developing device. This is because fluctuations in amount of the developer in the developing device adversely affect image quality.
However, in the developing devices disclosed in Patent documents 1 and 2, the developer is discharged by a natural discharging system, which causes the developer to overflow (overflow system). Specifically, the developer is added by an amount of replenished developer, and the developer is discharged by an amount exceeding the level of a discharging opening. This allows fluctuations in amount of the developer in the developing device to be within a predetermined range.
In such a simple overflow system, discharge of developer is subject to an inclination of a main body of an image forming apparatus, so that discharge of developer in a developing device becomes excessive, or inhibited contrary.
With reference to
However, as shown in
On the contrary, as shown in
As a method for suppressing changes in amount of the developer due to the inclinations of a developing device, for example, an excess of the developer is discharged by (i) providing a shutter member on a wall surface of a developer tank, (ii) detecting a predetermined amount of printing or an amount of the developer in a developing device, and (iii) opening or closing the shutter member based on the detection signals. Further, Japanese Patent Publication, No. 3034736 (publication date: May 12, 1995: Patent document 3) discloses a developing device in which a discharging opening is provided on the middle portion of the developing device in its longitudinal direction, so that inclinations of the developing device have less effect on the amount of the developer.
However, in the trickle system, since an excess of the developer is a trace, there is a difficulty in accurately discharging such a minute amount of the developer using a shutter member. This causes difficulties in maintaining a predetermined amount of the developer with high accuracy.
Further, the method as disclosed in Patent document 3, in which the developer discharging opening is disposed on the middle portion of the developing device in its longitudinal direction, is not effective for a developing device that performs circulating and agitating operation using a screw and that is used in color coping machines or the like requiring high performance capabilities for the agitating operation. This is because, even in the case where the discharging opening is disposed on the middle portion of the developing device in its longitudinal direction, the circulating and agitating operation of a screw is significantly affected by inclinations of the surface of the developer. Further, in the developing device of Patent document 3, the method is not effective with regard to inclinations in a direction orthogonal to the longitudinal direction.
Further, Publication of Japanese Patent, No. 3603492/1998 (publication date: Feb. 20, 1998: Patent document 4) discloses a developing device having a plurality of discharging openings. In the developing device in this publication, the discharging openings are provided at different positions including a position where the flow of developer retains and a position where the flow of the developer is stable. This makes it difficult for the developing device to achieve stability in amount of the developer when the developing device is inclined.
The technology disclosed herein is made in view of the foregoing problems, and an object of the technology disclosed herein is to realize a developing device using the trickle system, which includes developer discharging means for (i) suppressing changes in discharge of developer due to inclinations of the developing device and (ii) maintaining the stability in amount of the developer in a developer tank.
To solve the foregoing problems, a developing device of the technology disclosed herein, in which a two component developer including toner and carrier is supplied into a developer tank, which developer tank includes developer discharging openings for discharging an excess of the two component developer in response to replenishment of the two component developer, the number of the developer discharging openings being at least one provided in the vicinity of each edge of the developing device in a longitudinal direction of the developing device.
According to the arrangement, the developer discharging openings are disposed at least one in the vicinity of each edge of the developing device in its longitudinal direction. This allows the developer discharging openings to have reverse characteristics in response to increase and decrease in amount of the developer when the developing device is inclined in its longitudinal direction. That is, when the inclination of the developing device is made in its longitudinal direction, regardless of any side the developing device is leaned to, at least one of the developer discharging openings lowers. This may cause a reduction in amount of the developer in the developer tank due to the inclination, while causing no increase in the amount. As a result, it is possible to reduce changes in amount of the developer due to the inclination of the developing device.
Additional objects, features, and strengths of the technology disclosed herein will be made clear by the description below. Further, the advantages of the technology disclosed herein will be evident from the following explanation in reference to the drawings.
a) through 5(c) are views illustrating fluctuations in amount of developer due to inclinations of the developing device of the embodiment.
a) and 6(b) are views illustrating modification examples with regard to the layout of discharging openings of the developing device of the embodiment.
a) is a graph showing a relationship between an amount of developer and a discharge rate in the developing device of the embodiment, and
a) and 11(b) are views illustrating a condition of a surface of a developer in the vicinity of an agitating screw in rotary motion.
a) through 16(c) are views illustrating fluctuations in amount of developer due to inclinations of a conventional developing device.
With reference to figures, the following describes one example embodiment of the technology disclosed herein. Referring to
The image forming apparatus shown in
In the electrophotographic process, an electrostatic latent image is formed on the photoreceptor 10 serving as an image support section by the charging member 11 and exposure member 12. Then, the electrostatic latent image is visualized by the developing device 13, so as to become a toner image.
The photoreceptor 10 includes a substrate and a photoconductive layer disposed on the substrate. The photoreceptor 10 is capable of rotating so as to face the members in the aforesaid order starting from the charging member 11. Specifically, the photoreceptor 10 rotates in a direction indicated by an arrow A in
The toner image visualized by the developing device 13 is transferred to the sheet P by the transfer member 14 and fixed on the sheet P by the fixing member 17, so that the image is formed. The cleaning member 15 serves to remove toner, paper powder, and the like which are remained on the photoreceptor 10. Further, the static eliminating member 16 serves to remove charges remained on the photoreceptor 10. Through a series of the above operations, one cycle of image formation is completed.
The photoreceptor 10 includes (i) a substrate, e.g. a metal drum made of aluminum or the like, and (ii) a thin photoconductive layer disposed on an outer surface of the substrate. The photoconductive layer is made of amorphous silicon (a-Si), amorphous selenium (Se), an organic photo conductor (OPC), or the like.
Examples of the charging member 11 are (i) a corona charging device constituted by a charging wire such as a tungsten wire or the like, a metal shielding plate, a grid plate, and the like, (ii) a charging roller, (iii) a charging brush, and (iv) the like.
Examples of the exposure member 12 are a semiconductor laser, a light emitting diode, and the like. Examples of the transfer member 14 are a corona transfer device, a transfer roller, a transfer brush, and the like. Further, the cleaning member 15 is, for example, a cleaning blade or the like, and the static eliminating member 16 is a static eliminating lamp or the like, for example.
Referring to
As illustrated in
The carrier includes a layer coated with resin provided on a surface of each magnetic particle. The layer coated with resin serves to control the electrostatic properties of the toner and to suppress the viscosity of the toner. Alternatively, the carrier may be resin-coated carrier or the like in which magnetic fine particles are distributed among the resin particles.
When the developer is agitated by the agitating screws 133 and 134, the toner becomes triboelectrically charged. Then, the development roller 132 sucks the carrier by a magnetic force, so that a magnetic brush is formed and thereby the carrier is transported. This allows toner, adhered to the carrier, to be supplied to the photoreceptor 10 and sucked onto an electrostatic latent image formed on the photoreceptor 10. As a result, development is realized. The magnetic brush in the development roller 131 is arranged such that the height of its spikes is controlled by a doctor blade 135. Further, the agitating members are not limited to the screw type such as the agitating screws 133 and 134, and other types in the form of a paddle and the like may be also used.
On an upper surface of the developer tank 131, an opening 136 for replenishing developer is provided (see
In the bottom part of the developer supplying unit 18, a developer supplying roller 181 is provided which is driven and controlled by a control device (not shown). As the developer supplying roller 181 is driven and rotated, the developer is flowed from the developer supplying unit 18 into the developer tank 131. An amount of the developer thus flowed corresponds to a time during which the developer supplying roller 181 is driven. Further, the developer, supplied into the developer tank 131, is agitated and transported by the agitating screws 133 and 134.
On the other hand, on side walls of edges of the developer tank 131, discharging openings 20A and 20B for discharging the developer are formed. The discharging openings 20A and 20B serve to discharge developer, which overflows from the developer tank 131, into collecting containers 21A and 21B. Specifically, through the discharging openings 20A and 20B formed on the side walls of the developer tank 131, an excess of the developer is overflowed and discharged, in accordance with the surface level of the developer in the developer tank 131. As to a mechanism, which includes the discharging openings 20A and 20B and the collecting containers 21A and 21B, for discharging an excess of the developer, description will be made later in more detail.
Further, in the developer tank 131, a toner concentration sensor 137 is provided that detects a concentration of toner in the developer tank 131. The toner concentration sensor 137, constituted by a magnetic permeability sensor, comes in contact with the toner and detects a magnetic permeability of toner transported into the developer tank 131. Based on the magnetic permeability thus detected by the toner concentration sensor 137, a ratio of the toner to the carrier is obtained.
For example, as a result of the detection, if the developer being in contact with the toner concentration sensor 137 contains a small amount of carrier, the toner ratio is high. On the other hand, if the developer being in contact with the toner concentration sensor 137 contains a large amount of carrier, the toner ratio is low. Further, the toner concentration sensor 137 outputs a detection signal to a control device (not shown). Based on the detection signal, the developer supplying roller 181 in the developer supplying unit 18 is driven, so that the developer is replenished into the developer tank 131.
With reference to
The developing device 13 shown in
Further, in the agitating screws 133 and 134 shown in
Further, since the developing device 13 shown in
As the developer is replenished, the amount of the developer in the developing device 13 increases. When the surface level of the developer becomes higher than the level of the discharging openings 20A and 20B, an excess of the developer overflows, so as to be discharged through the discharging openings 20A and 20B. That is, the developing device 13 employs a so-called overflow system.
Outside the discharging openings 20A and 20B, the collecting containers 21A and 21B are provided that are used for discharging the discharged developer to collecting means (not shown). Further, the collecting containers 21A and 21B contain discharging means for discharging the developer. The discharging means may be a screw type member for forcedly transporting and discharging the developer to the outside, or may be a type allowing a bottom portion of each discharging tube to be inclined downward so that the developer is automatically discharged.
As described above, the developing device 13 of the present embodiment is provided with the discharging openings 20A and 20B, which are disposed on side walls located opposite the axial directions of the agitating screws 133 and 134, respectively. In the example shown in
With reference to
When the developing device 13 is set in a normal state, i.e., when the developing device 13 is set on a horizontal plane, bottom edges of the discharging openings 20A and 20B of the developing device 13 are at a horizontal level. In this state, as shown in
Assume that the developing device, set in the foresaid horizontal and stable state, is inclined so that the discharging opening 20A becomes lower than the discharging opening 20B. In this state, the developer is discharged through the discharging opening 20A, as shown in
As a result, the amount of the developer Z(g) is reduced by an amount of X(g). When the amount of the developer in the developing device is reduced and becomes an amount of Z−X(g), the rate of discharging the developer and the rate of replenishing the developer become equal. This allows the amount of the developer in the device to be constant. In this state, the surface level of the developer in the developing device 13 is slightly higher than the bottom surface of the discharging opening 20A. Even in the conventional developing device (having the identical structure with the developing device 13 except that only the discharging opening equivalent to the discharging opening 20A is provided and no discharging opening equivalent to the discharging opening 20B is provided), when the developing device is inclined so that the end portion having the discharging opening becomes lower than the other end, the amount of the developer in the developing device becomes constant after becoming Z−X(g) (see
Assume that the developing device, set in the foresaid horizontal and stable state, is inclined so that the discharging opening 20A becomes higher than the discharging opening 20B. In this state, the developer is discharged through the discharging opening 20B, as shown in
As a result, the amount of the developer Z(g) is reduced by an amount of X(g). When the amount of the developer in the developing device is reduced and becomes the amount of Z−X(g), the rate of discharging the developer and the rate of replenishing the developer become equal. This allows the amount of the developer in the device to be constant. In this state, the surface level of the developer in the developing device 13 is slightly higher than the bottom surface of the discharging opening 20B.
On the other hand, in the conventional developing device (having the identical structure with the developing device 13 except that only the discharging opening equivalent to the discharging opening 20A is provided and no discharging opening equivalent to the discharging opening 20B is provided), when the developing device is inclined so that the end portion having the discharging opening becomes lower than the other end, the amount of the developer in the developing device becomes constant after becoming Z+Y(g) (see
As described above, according to the present embodiment, when the developing device 13 is inclined in a range shown in
In the developing device 13 shown in
Thus, the positions of the discharging openings 20A and 20B are not limited to the structure shown in
In the structure shown in
In the structure shown in
Further, in the structure shown in
In the exemplary structures shown in
That is, in the structures shown in
Further, in the structures shown in
In order to test the effects of a developing device of the technology disclosed herein, experiments were carried out using an image forming apparatus to which the developing device was applied. The following explains results of the experiments. Note that, in the following explanation, an image forming apparatus is a modified AR-450M made by Sharp corporation, and a developing device is arranged such that discharging openings for discharging an excess of developer are disposed in the middle portions between axes of agitating and transporting sections (i.e., agitating screws) (as shown in
In the experiments, development was not actually carried out and the developer was just circulated in a developer tank by rotation of the agitating and transporting sections. The developer tank was filled beforehand with the developer with an amount slightly larger than a predetermined amount, and no carrier and toner was replenished. Since the amount of the developer in the developing device was larger than the predetermined amount, an excess of the developer was discharged through the discharging openings. This caused a reduction in amount of the developer in the developing device, further causing a reduction in rate of discharging the developer.
At regular time intervals, measurements were carried out with regard to (i) the amount of the developer in the developing device and (ii) the rate of discharging the developer, and their characteristics were observed. Specifically, in order to obtain the rate of discharging the developer, the amount of the developer discharged in a measuring time was measured and then the amount of the discharged developer was divided by the measuring time. Further, in order to obtain the amount of the developer in the developing device at this point, an accumulated amount of the discharged developer was extracted from the initial amount of the developer.
In the AR-450M image forming apparatus, printing was carried out on 40 sheets of A4 size per minute at a printing rate of 2%, while a developer with a concentration of 70% was replenished. Under this condition, the developer was discharged at a rate of 0.1 (g/minute). Since a commonly used printing rate is approximately 5%, the printing rate of 2% is less than half the rate of the commonly used 5%. Thus, the discharge rate of 0.1 (g/minute) is sufficiently small amount for the rate of discharging an excess of the developer.
Regarding this, in the experiments, the measurements were finished when the discharge rate reached 0.1 (g/minute). When the discharge rate was 0.1 (g/minute), the amount of the developer became a minimum value that provides stability in amount of the developer in actual use.
a) through 7(c) show results of the experiments.
a) through 7(c) show the results of the measurements taken under the following three conditions: (i) a developing device is in a horizontal state; (ii) the developing device is inclined in the axial direction of the agitating and transporting sections so that one end having the discharging opening 20A becomes lower than the other end (the developing device is inclined rightward in
In
On the contrary,
Further, in the example shown in
Actually, in the examples shown in
Further, in the developing devices explained above, two agitating screws were provided as agitating and transporting sections by way of example. However, three or more agitating screws may be provided as agitating and transporting sections in order to improve the agitating performance.
In the structure shown in
Further, when the discharging openings are disposed between the agitating screws as shown in
The members 22 have a height equal to that of the partition 138, and may be adhered to a side wall on which the discharging openings 20A and 20B are disposed. Further, as an modification example of the members 22, a member 22′ shown in
In the above explanation, by way of example, the discharging openings 20A and 20B, through which an excess of the developer in the developing device is discharged, are disposed on the side surfaces to which the axial directions of the agitating screws serving as agitating and transporting sections extend (i.e., the side surfaces to which the axes of the agitating screws are orthogonal). However, the technology disclosed herein is not limited to this, and the discharging openings may be disposed on a side surface along which the agitating screws are provided or on the partition (i.e., a side surface being parallel to the axes of the agitating screws or on the partition).
a) and 11(b) show a condition of the surface of developer in the vicinity of an agitating screw.
In
As such, movements of the surface level of the developer are considerably different between the right side and the left side of the rotation axis of the agitating screw. This means that characteristics of a discharging opening for discharging the developer will be different depending on which side of the rotation axis of the agitating screw the developer discharging opening is disposed on.
In the structure shown in
In the structure shown in the
Further, considering a rotative direction of each development roller, there may be a case where the structure shown in
In the structures shown in
In the structures shown in
Further, in the structure shown in
In the above explanation, the discharging openings for discharging an excess of the developer serves to discharge the developer, which exceeds the level equal to the bottom surface of the discharging openings and overflows, to the outside of the developing device. Inside the discharging openings, a screw member or the like may be disposed that facilitates discharge of the developer.
As described above, a developing device of the technology disclosed herein in which a two component developer including toner and carrier is supplied into a developer tank, which developer tank includes developer discharging openings for discharging an excess of the two component developer in response to replenishment of the two component developer, the number of the developer discharging openings being at least one provided in the vicinity of each edge of the developing device in a longitudinal direction of the developing device.
Thus, when the developing device is inclined toward any side in its longitudinal direction, at least one of the developer discharging openings lowers. This may cause a reduction in amount of the developer in the developing device due to the inclination of the device. However, no increase occurs in the amount. As a result, it is possible to reduce changes in amount of the developer due to the inclinations of the developing device.
Further, the developing device may be arranged such that the excess of the developer is overflowed and discharged through the developer discharging openings when the two component developer has a level exceeding a bottom edge of the developer discharging openings.
According to the arrangement, as means for suppressing changes in amount of the developer due to the inclinations of the developing device, the developer discharging openings does not require an opening and closing mechanism such as a shutter member, and other means such as control means for the opening and closing mechanism, or the like. Thus, a developing device can be provided with low cost that has a simple structure and suppresses changes in amount of the developer.
Further, the developing device may be arranged such that said developer tank includes at least two agitating chambers which are partitioned by a partition so that communicating portions are formed at both edges of the partition, and each of the agitating chambers includes an agitating and transporting section.
According to the arrangement, the plural agitating chambers, partitioned by the partition, are communicated so that paths for circulating the developer are provided. This improves the agitating performance of the developer. Further, the partition prevents the developer not agitated from coming close to a development roller. This contributes to achieve high image quality.
Further, in the developing device, the agitating and transporting section may be a screw member.
According to the arrangement, unlike an agitator or the like, the screw member is capable of transporting the developer from a lower place to an upper place against gravity, by forcedly circulating the developer. This reduces unevenness of the developer in the developing device, thereby suppressing changes in amount of the developer in response to the inclinations of the device. Further, if the developing device is applied to a color coping machine that has a critical requirement regarding image quality, it is possible to achieve good agitating performance by using the screw member.
Further, the developing device may be arranged such that each of the developer discharging openings is provided in the vicinity of upstream of the agitating and transporting section in each transport direction of the agitating and transporting section in each of the agitating chambers.
Further, the developing device may be arranged such that each of the developer discharging openings is provided in the vicinity of downstream of the agitating and transporting section in each transport direction of the agitating and transporting section in each of the agitating chambers.
Further, the developing device may be arranged such that, in the two agitating chambers being adjacent to each other sandwiching the partition, the developer discharging openings are provided on side walls of the two agitating chambers and between axes of the two agitating and transporting sections in the two agitating chambers, the axes being attached to bearing sections of the side walls.
According to the arrangements, the two developer discharging openings are disposed so as to be, for example symmetric with respect to a point or line, i.e., the center point of the partition. This allows the two developer discharging openings to have similar characteristics for discharge, so as to lessen the dependency of the characteristics of discharging the developer on a side to which the developing device is inclined.
Further, the developing device may be arranged such that, when viewed from points to which rotation axes of the agitating and transporting section extends and from which the agitating and transporting section is seen as being rotating in a clockwise direction, the developer discharging openings are provided on a side wall of the agitating chambers or on the partition, which are located on respective left sides of the agitating and transporting section, respectively provided in the agitating chambers.
Alternatively, the developing device may be arranged such that, when viewed from points to which rotation axes of the agitating and transporting section extends and from which the agitating and transporting section is seen as being rotating in a clockwise direction, the developer discharging openings are provided on a side wall of the agitating chambers or on the partition, which are located on respective right sides of the agitating and transporting section, respectively provided in the agitating chambers.
According to the arrangement, the plural developer discharging openings are disposed at the portions around which movements of the developer are similar, facilitating suppression of the range of changes in amount of the developer.
Further, in the developing device in which the number of the agitating chambers is two, when viewed from a point to which the partition extends in a longitudinal direction thereof, an agitating and transporting section located on the right side of the partition rotates in a clockwise direction, and an agitating and transporting section located on the left side of the partition rotates in a counterclockwise direction, and the developer discharging openings are disposed on the partition in the respective agitating chambers.
Alternatively, in the developing device in which the number of the agitating chambers is two, when viewed from a point to which the partition extends in a longitudinal direction thereof, an agitating and transporting section located on the right side of the partition rotates in a counterclockwise direction, and an agitating and transporting section located on the left side of the partition rotates in a clockwise direction, and the developer discharging openings are disposed on the partition in the respective agitating chambers.
Further, the developing device may further include a transport pipe for transporting developer discharged through the discharging openings in a lump.
According to the arrangement, the developer discharged through the plural developer discharging openings in a lamp is transported to the transport pipe. This provides a simple mechanism for transporting the discharged developer to a box for discharged toner, enabling to realize a low-cost developing device.
The present invention is not limited to the description of the embodiments above, but may be altered by a skilled person within the scope of the claims. An embodiment based on a proper combination of technical means disclosed in different embodiments is encompassed in the technical scope of the present invention.
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