Patent Application
20050207793
1. Field of the Invention
The present invention relates to an image forming apparatus that forms an image using a developer.
2. Description of the Related Art
In an image forming apparatus that forms an image using, e.g. a developer including a toner, an electrostatic latent image is formed on a photosensitive drum that serves as an image carrying body. The electrostatic latent image is developed by a developer unit, and a developed toner image is transferred to paper by a transfer unit. The transferred toner image is fixed on the paper by a fuser.
There is known an image forming apparatus of this kind, wherein toner, which remains on the photoconductive drum after the toner image is transferred to the paper, is removed and recovered by a cleaning device. The recovered toner (hereinafter referred to as “recycle toner”) is reused.
For example, a toner recycle mechanism is known. According to this mechanism, recycle toner, which is conveyed by a recovery mixer that is provided in a cleaning device, is directly brought back into the developer unit by a coupling mixer that is provided between the cleaning device and the developer unit.
In this case, the recovered toner is always supplied to the developer unit while the recovery mixer and the coupling mixer are being rotated.
As regards the recycle toner to be reused, there are problems: external additive that is inherently provided on toner particles is partly removed, external additive that is removed from other toner particles may adhere to recycle toner, or paper dust is mixed in recycle toner. Compared to fresh toner, the amount of external additive of which is properly set, an initial rise in charge amount of the recycle toner is not good. If frictional charge that is provided by stirring is deficient, toner that is not charged may be fed to the photosensitive drum.
If the non-charged toner is transferred to paper via the photosensitive drum, such problems as fogging of image or dispersion of toner would occur.
According to an aspect of the present invention, there is provided an image forming apparatus comprising: a first chamber including a first mixer disposed in a first axial direction that coincides with an axial direction of an image carrying body which carries an electrostatic latent image, the first mixer stirring and conveying a developer containing at least a toner in a first direction and supplying the toner to the image carrying body; a second chamber disposed adjacent to the first chamber and including a second mixer disposed in parallel to the first mixer, the second mixer stirring and conveying the developer in a second direction different from the first direction; a third chamber disposed adjacent to the second chamber and including a third mixer, the third mixer stirring and conveying the developer in the second direction; a recycle toner supply section that is disposed on an upstream side of the third chamber and is supplied with a recycle toner recovered from a surface of the image carrying body; and a fresh toner supply section that is disposed on an upstream side of the second chamber and is supplied with a fresh toner, wherein an upstream side of an axis of the third mixer is lower than an upstream side of an axis of the second mixer.
According to another aspect of the present invention, there is provided an image forming apparatus comprising: a first chamber including a first mixer disposed in a first axial direction that coincides with an axial direction of an image carrying body which carries an electrostatic latent image, the first mixer stirring and conveying a developer containing at least a toner in a first direction and supplying the toner to the image carrying body; a second chamber disposed adjacent to the first chamber and including a second mixer disposed in parallel to the first mixer, the second mixer stirring and conveying the developer in a second direction different from the first direction; a third chamber disposed adjacent to the second chamber and including a third mixer, the third mixer stirring and conveying the developer in the second direction; a recycle toner supply section that is disposed on an upstream side of the third chamber and is supplied with a recycle toner recovered from a surface of the image carrying body; and a fresh toner supply section that is disposed on an upstream side of the second chamber and is supplied with a fresh toner, wherein a downstream side of an axis of the third mixer is higher than a downstream side of an axis of the second mixer.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
An image forming apparatus according to an embodiment of the present invention will now be described with reference to the accompanying drawings.
As is shown in
The image forming section 102 includes a photosensitive drum 103, a charger 104, an exposing device 105, a developer unit 106, sheet cassettes 107, pickup rollers 108, a convey roller 109, an aligning roller 110, a transfer device 111, a fuser 112, an output roller 113, an output tray 114, a fresh toner supply device 115, and a photosensitive drum cleaner 116.
The photosensitive drum 103 has a photosensitive body on its periphery. The photosensitive body is illuminated in the state in which a predetermined potential is applied thereto. The potential of the illuminated region varies, and an electrostatic latent image, which is formed by the variation in potential, is retained on the photosensitive body for a predetermined time period.
The charger 104 charges the surface of the photosensitive drum 103 with a predetermined potential.
The exposing device 105 is disposed on a downstream side of the charger 104 in the rotational direction of the photosensitive drum 103. The exposing device 105 applies a laser beam LB, which has a light intensity varying in accordance with the image signal supplied from the scanner 101, to the photosensitive drum 103. The laser beam LB can have a predetermined light intensity corresponding to, e.g. the density of an image.
The developer unit 106 is disposed on the downstream side of the exposing device 105 in the rotational direction of the photosensitive drum 103. The developer unit 106 contains a two-component developer that comprises a carrier and a toner. The developer unit feeds developer (e.g. toner) to the surface of the photosensitive drum 103, thereby developing an electrostatic latent image on the surface of photosensitive drum 103 into a visible toner image.
Each sheet cassette 107 contains paper sheets Q, and the pickup roller 108 picks up them one by one. The picked-up sheet is conveyed to the aligning roller 110 by means of the convey roller 109.
The aligning roller 110 rotates at a predetermined timing and conveys the sheet Q to the position for image transfer, thereby to register the positions of the sheet Q and the toner image formed on the photosensitive drum 103.
The transfer device 111 applies a predetermined potential to the paper sheet Q and transfers the toner image formed on the photosensitive drum 103 to the sheet Q.
The fuser 112 applies predetermined heat and pressure to the sheet Q on which the toner image is formed, and fuses the toner image and fixes it on the sheet Q.
The output roller 113 conveys the sheet Q that is output from the fuser 112 to the output tray 114.
The fresh toner supply device 115 supplies fresh toner, which has not been used for image formation, to the developer unit 106 at a predetermined timing.
The photosensitive drum cleaner 116 is disposed on a downstream side of the transfer position, where the transfer device 111 faces the photosensitive drum 103, in the rotational direction of the photosensitive drum 103. The photosensitive drum cleaner 116 recovers toner, or the like, which adheres to the surface of the photosensitive drum 103.
As is shown in
The fresh toner supply device 115 includes a fresh toner cartridge 115a that contains fresh toner, and a supply roller 115b that is rotated at a predetermined timing and supplies fresh toner to a predetermined position in a second chamber 25.
The photosensitive drum 116 includes a recycle toner convey roller 116a that conveys recovered recycle toner to the rear side.
The developer unit 106 includes a developer container 20 that contains a two-component developer (hereinafter referred to as “developer”) that comprises a carrier and a toner, and a magnetic sensor 21 that detects the concentration of toner contained in the developer container 20. The magnetic sensor 21 should preferably be disposed at a lower part of the developer container 20.
The developer container 20 is partitioned by a first partition 22 and a second partition 23, each having a predetermined length in the axial direction of the photosensitive drum 103, and comprises a first chamber 24, the second chamber 25 and a third chamber 26. The first partition 22 has such a predetermined length that the first chamber 24 and second chamber 25 are coupled at the rear and front sides. The second partition 23 has such a predetermined length that the second chamber 25 and third chamber 26 are coupled at the rear and front sides (see
The first chamber 24 includes a first mixer 24a that has an axis A1 parallel to an axial direction A (see
The third chamber 26 includes a third mixer 26a with an axis α that is set in a predetermined direction relative to an imaginary axis A3, which is parallel to the axial direction A of photosensitive drum 103, as shown in
In other words, the axis α of the third mixer 26a is a non-parallel skew line, relative to the axis A1 of first mixer 24a and the axis A2 of second mixer 25a.
(1) For example, the axis α of the third mixer 26a crosses the imaginary axis A3 near the center point thereof. The axis α is shifted downward by a predetermined degree on the front side and is shifted upward by a predetermined degree on the rear side.
In other words, as shown in
As is shown in
The recycle toner supply mechanism 28 has an axis in a direction B that is preset, e.g. in relation to the axial direction A of the photosensitive drum 103. The recycle toner supply mechanism 28 is a mixer that is provided with helical blades and is able to convey recycle toner by rotational motion.
The recycle toner from the recycle toner supply mechanism 28 is fed to a recycle toner supply section 29 that is located on the front side of the third chamber 26.
A fresh toner supply section 30 is provided on the front side of the second chamber 25, that is, on the same side as the recycle toner supply section 29. Fresh toner from the fresh toner supply device 115 is brought to the fresh toner supply section 30. As is shown in
The first mixer 24a is rotated to stir and convey the developer in the first chamber 24 at a first speed in a first direction A4 from the rear side to the front side. In other words, the first mixer 24a stirs and conveys the developer, which is received from the second mixer 25a and third mixer 26a, and delivers it to the developing roller 27. In addition, the first mixer 24a receives developer, which is removed from the developing roller 27 after development, and conveys it.
The second mixer 25a is rotated to stir and convey the developer in the second chamber 25 at a second speed in a second direction A5 from the front side to the rear side. The second speed may be equal to the first speed. In other words, the second mixer 25a has a function of stirring and conveying the developer that is received from the first mixer 24a, and a function of stirring and conveying the fresh toner received from the fresh toner supply device 115, along with the developer, and delivering it to the first mixer 24a.
The third mixer 26a is rotated to stir and convey the developer in the third chamber 26 at a third speed in the second direction A5 from the front side to the rear side. It should suffice if the third speed is such a speed that a sufficient frictional charge can be applied to the recycle toner. In other words, the third mixer 26a stirs and conveys the recycle toner that is received from the recycle toner supply mechanism 28, along with the developer, and delivers it to the second mixer 25a.
Specifically, the recycle toner supply section 29 is located on the upstream side of the developer (comprising toner and carrier) that is moved in the second direction A5 in the third chamber 26 by the rotation of the third mixer 26a. In other words, the recycle toner supply section 29 is located on the front side of the rotational axis α of the third mixer 26a, that is, at a lowest position in the direction of axis α.
The fresh toner supply section 30 is located on the upstream side of the developer (comprising toner and carrier) that is moved in the second direction A5 in the second chamber 25 by the rotation of the second mixer 25a, and on the upstream side of the communicating part between the second chamber 25 and third chamber 26.
The third mixer 26a may be configured like a mixer 40 shown in
As is shown in
Thus, the third speed is lower than the first or second seed. For example, the third speed is ½, ⅓ or ⅙ of the first or second speed. The degree of stirring of developer in the third chamber can be made greater than that of the stirring of developer in the first or second chamber. Hence, the degree of stirring of recycle toner that is conveyed in the third chamber can be made greater than the degree of stirring of fresh toner. Therefore, the difference in charge level between the fresh toner and recycle toner can be minimized.
It should suffice if the height H1 is determined such that the recycle toner that is supplied to the recycle toner supply section 29 is prevented from being conveyed to the adjacent second chamber 25.
A gear G5 is coupled to one end portion of a center shaft of the recycle toner supply mechanism 28. The gear G5 is engaged with a gear G1, which is coupled to the rear-end portion of the third mixer 26a in the axis α, via a gear G2 that is meshed with the gear G1 as well as gears G3 and G4. The recycle toner supply mechanism 28 is rotated by a torque that is transmitted from a main motor 55 (see
Hence, the photosensitive drum 103, recycle toner convey roller 116a, first to third mixers 24a to 26a and recycle toner supply mechanism 28, which are coupled by the gears G1 to G5, can be rotated at the same time by the rotation of the main motor.
In the second chamber 25, the magnetic sensor 21 is disposed on the downstream side of the fresh toner supply section 30 in the direction of movement of the developer.
In the case where both the recycle toner supply section 29 and fresh toner supply section 30 are disposed on the front side, as in the present embodiment, the length of the front-side part of the second chamber 25 in the axial direction A may be made greater than that of the third chamber 26 so that the front-side part of the second chamber 25 projects to the front side. This can prevent overlapping of the recycle toner supply mechanism 28 and fresh toner supply section 30.
As is shown in
The control panel 54 includes a display section 54a, through which a user instructs predetermined operations. For example, the user instructs image scan by the scanner 101, image formation by the image forming section 102, or both of image scan and image formation.
The magnetic sensor 21 detects, as a toner concentration, the ratio of toner (e.g. resin) to carrier (e.g. iron or ferrite), which are contained in the developer container 20 of the developer unit 106. The magnetic sensor 21 outputs a detection value to the CPU 50. The CPU 50 compares the detection value of toner concentration from the magnetic sensor 21 with a predetermined reference value. If the detection value is lower, the CPU 50 outputs a toner supply signal to the toner concentration control circuit 53. To be more specific, the CPU 50 outputs to the toner concentration control circuit 53 such a toner supply signal as to supply toner for a predetermined time period in accordance with the level of a voltage that is input from the magnetic sensor 21. This level of voltage is representative of the toner concentration.
The main motor driver 51 is connected to the main motor 55. Upon receiving an image formation instruction from the control panel 54, the main motor driver 51 outputs to a drive signal to the main motor 55.
The main motor 55 is coupled to the first to third mixers 24a to 26a and developing roller 27 of the developer unit 106, the photosensitive drum 103, the recycle toner convey roller 116a and the recycle toner supply mechanism 28. Upon receiving the drive signal from the main motor driver 51, the main motor 55 applies a predetermined drive force.
The power supply unit 52 is connected to the charger 104 and a transfer separation charger 56. Upon receiving an image scan instruction from the control panel 54, the power supply unit 52 produces a predetermined voltage after a predetermined elapsed time or immediately.
The charger 104 is supplied with a predetermined voltage from the power supply unit 52 and applies a predetermined charge to the surface of the photosensitive drum 103.
The toner concentration control circuit 53 is connected to the fresh toner motor 57. Upon receiving a toner supply signal from the CPU 50, the fresh toner motor 57 operates only for a predetermined time period.
The fresh toner motor 57 drives the supply roller 115b, which is controlled by the toner concentration control circuit 53, thereby supplying a predetermined amount of fresh toner to the fresh toner supply section 30.
In short, the supply amount of fresh toner can be determined in accordance with the level of toner concentration in the developer container 20. For example, if the toner concentration considerably decreases, the supply time of fresh toner becomes longer.
The operation of the image forming apparatus 100 will now be described. In this embodiment, image formation is performed using a reverse development method.
Assume that both image scan and image formation have been instructed through the control panel 54. In this case, the scanner 101 starts image scan. In the image forming section 102, the power supply unit 52 outputs a predetermined voltage and causes the charger 104 to apply charge. Since the image formation is instructed at the same time, the main motor driver 51 outputs a drive signal to the main motor 55.
The scanner 101 includes, for instance, a light source, a lens and a charge-coupled device (CCD). Reflective light from a to-be-copied object is focused on a light-receiving surface of the CCD via the lens. The CCD photoelectrically converts the reflective light to an image signal. The obtained image signal is output to the exposing device 105 and converted to a laser beam LB with a predetermined light intensity.
The laser beam LB is applied to the surface of the photosensitive drum 103, which has been uniformly electrified with a negative charge by the charger 104. The potential of that part of the surface of the photosensitive drum 103, which has been illuminated with the laser beam LB, decreases close to zero. Hence, an electrostatic latent image is formed on the surface of the photosensitive drum 103.
Negatively charged toner in the developer unit 106 is attracted to the latent image on the surface of the photosensitive drum 103, which has been illuminated with the laser beam LB so as to have a predetermined potential level. Thus, a toner image is formed on the surface of the photosensitive drum 103.
The toner image is transferred to a paper sheet Q that is conveyed by the aligning roller 110 to the position for transfer and is positively charged by the transfer device 111.
The toner image that is transferred to the paper sheet Q is fused and fixed by the fuser 112. In short, an image is formed on the paper sheet Q.
The paper sheet Q, on which the image is formed by the fuser 112, is discharged to the output tray 114 by the output roller 113.
On the other hand, the toner, which has not been transferred from the surface of the photosensitive drum 103 and has moved to the photosensitive drum cleaner 116, is recovered by the photosensitive drum cleaner 116.
The recovered recycle toner is collected to the front side by the recycle toner convey roller 116a. The collected recycle toner is brought to the recycle toner supply section 29 via the recycle toner supply mechanism 28. Thus, the recycle toner is reused. On the other hand, if a decrease in toner concentration within the developer container 20 is detected by the magnetic sensor 21, the toner density control circuit 53 drives the fresh toner motor 57 for a predetermined time period (i.e. by a predetermined number of rotations), thereby supplying fresh toner to the fresh toner supply section 30.
If the toner concentration that is detected by the magnetic sensor 21 does not increase even if the toner concentration control circuit 53 outputs the drive signal for a predetermined time period or more and drives the supply roller 115b, the display section 54a displays such indication that the fresh toner within the fresh toner cartridge 115a has been consumed, thus notifying the user of the runout of toner.
Next, referring to
If image formation (or image formation involving image scan) is instructed through the control panel 54, the main motor driver 51 of the image forming section 102 outputs a drive signal to the main motor 55.
Upon receiving the drive signal, the main motor 55 operates to rotate the first to third mixers 24a to 26a and developing roller 27 of the developer unit 106 in predetermined directions at substantially equal speeds.
The recycle toner supplied from the recycle toner supply section 29 is stirred and conveyed in the second direction A5 in the third chamber 26, along with the developer that is already present in the third chamber 26 and the developer coming from the upstream side (front side) of the second chamber 25. The developer stirred in the third chamber 26 on the downstream side is conveyed into the downstream-side part of the second chamber 25.
The fresh toner supplied to the fresh toner supply section 30 is conveyed and stirred in the second direction A5 in the second chamber 25, along with the developer coming from the first chamber 24. The developer stirred in the second chamber 25 on the downstream side is conveyed into the upstream side of the first chamber 24.
The developer conveyed to the upstream side of the first chamber 24 is further conveyed in the first direction A4, while being stirred. The developer is then guided to the surface of the photosensitive drum 103 by the developing roller 27.
Since the recycle toner is stirred and conveyed in the third chamber 26 at the third speed, it is sufficiently charged by friction. When the developer reaches the upstream side of the first chamber 24, the difference in charge level between the fresh toner and recycle toner can be minimized.
The upstream side of the third mixer 26a of the third chamber 26 is lower than the upstream side of the second chamber 25 in the height direction H. Thus, even when the developer unit 116 is inclined, it is possible to prevent the recycle toner from reversely flowing to the second chamber 25 and entering the third chamber 26. Hence, it is possible to prevent the recycle toner from entering the second chamber 25 and being conveyed to the first chamber 24 in the state in which the recycle toner is not sufficiently stirred. Therefore, problems such as fogging of image can be prevented.
Moreover, since the downstream side of the third mixer 26a is higher than the downstream side of the second chamber 25 in the height direction H, the developer can smoothly be conveyed to the second chamber 25.
In the present embodiment, it is preferable that the ratio between carrier and toner of the two-component developer in the developer container 20 be set at about 95% (% by mass):5% (% by mass). The ratio between carrier and toner is detected by the magnetic sensor 21. Based on the detection result, toner is supplied from the fresh toner supply device 115.
In the present embodiment, the second and third mixers 25a and 26a have a phase displacement in the height direction on the front and rear sides, as described in the aforementioned feature (1). Alternatively, (2) the axis α may cross the imaginary axis A3 on the rear side, with a phase displacement on the front side and without a phase displacement on the rear side, or (3) the axis α may cross the imaginary axis A3 on the front side, with a phase displacement on the rear side and without a phase displacement on the front side.
