Process cartridge mountable in an image forming system and a method for assembling a cleaning device

BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a process cartridge, an image forming system on which the a process cartridge can be mounted, and a method for assembling a cleaning device. Such an image forming system may be embodied, for example, as an electrophotographic copying machine, a laser beam printer, a facsimile, a word processor or the like.
2. Description of the Related Art
In image forming systems such as copying machines, a latent image is formed by selectively exposing an image bearing member uniformly charged, the latent image is then visualized with toner, and then the toner image is transferred onto a recording sheet, thereby forming an image on the recording sheet. In such image forming systems, whenever the toner is used up, new toner must be replenished. The toner replenishing operation not only is troublesome, but also often causes the contamination of the surroundings. Further, since the maintenance of various elements or members can be performed only by an expert in the art, most of the users feel inconvenient.
In order to eliminate such drawbacks and inconvenience, an image forming system wherein parts such as a developing device which toner therein was used up or an image bearing member which a service life thereof was expired can easily be exchanged, thereby facilitating the maintenance, by assembling the image bearing member, a charger, the developing device and a cleaning device integrally as a process cartridge which can be removably mounted within the image forming system has been proposed and put into practical use, for example, as disclosed U.S. Pat. Nos. 3,985,436, 4,500,195, 4,540,268 and 4,627,701.
In such a process cartridge, it is considered that a frame of the process cartridge can be divided into an upper frame and a lower frame in order to improve the assembling ability (Japanese Patent Application No. 2-301779; U.S. Pat. Ser. No.785,401 (filed Jun. 4, 1992 and pending in Group Art Unit 2105); EP-A 91402953.3; Chinese Patent Application No. 91111554.4; and Korean Patent Application No. 91-19663). Further, it is considered that the upper frame and the lower frame are interconnected by screws. Alternatively, it is considered that the upper frame and the lower frame are interlocked by fitting locking pawls formed on one of the frames into corresponding locking openings formed in the other frame.
However, such connecting techniques may have the following disadvantages:
When the upper and lower frames are interconnected only by the screws, in order to eliminate the clearance or gap between the interconnected frames, a large number of screws must be used, thereby worsening the assembling ability, which results in cost increases.
On the other hand, in the interconnection by means of the locking pawls and locking openings, when the upper and lower frames have the adequate rigidity there is no problem; however, if the rigidity of the frames is insufficient, the upper and lower frames are apt to be displaced relatively. Further, when an operator grips to hold the upper and lower frames together, the gap is likely to be created between the frames and it is feared that the pawls may be damaged.
Further, when the number of re-cycles of the same process cartridge is increased, the locking force between the locking pawl and the locking opening will be reduced or will be null.
In addition, if the parts are attached to the process cartridge by press-fit, when the number of re-cycles of the same process cartridge is increased, play will arise between the interfitted portions.
Particularly, in view of the protection of the earth-environment, it has been strongly required to re-cycle the process cartridge. Thus, it is desired to provide a process cartridge which can be re-cycled more easily. Now, the "re-cycle" of the process cartridge means the fact that the used-up process cartridge is collected from the market and is then disassembled to exchange only the waste and/or damaged (worn) parts to new ones (the other parts are re-used), and then the process cartridge is re-assembled as a new cartridge.
Incidentally, in the above U.S. Pat. No. 3,985,436, although the fact that a unit used for a predetermined term is collected for re-use was described (refer to lines 38-62, column 16), there is no suggestion regarding the re-cycle.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, which are suitable to re-cycle.
Another object of the present invention is to provide a process cartridge mountable in an image forming system, mountable such a process cartridge therein, and a method for assembling a cleaning device, which can cope with even a large number of re-cycle operations.
A further object of the present invention is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, which can remarkably improve the assembling ability.
A still further object of the present invention is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, which can remarkably improve the disassembling ability.
A further object of the present invention is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, wherein a used-up process cartridge collected from the market can be disassembled efficiently and which are suitable to re-cycle.
A further object of the present invention is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, which can easily be assembled and which can sufficiently cope with even a large number of re-cycles.
A still further object of the present invention is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, which can surely interlock an upper frame and a lower frame repeatedly.
One other object of the present invention among others, is to provide a process cartridge mountable in an image forming system, and a method for assembling a cleaning device, wherein parts can surely be attached repeatedly.

BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a process cartridge according to an embodiment of the present invention;
FIGS. 2A, 2B and 2C are sectional views taken along lines 2A--2A, 2B--2B and 2C--2C, respectively, of FIG. 1;
FIG. 3 is a sectional view of an image forming apparatus to which the process cartridge according to the present invention is detachably mountable;
FIG. 4 is a sectional view of a process cartridge according to another embodiment of the present invention;
FIG. 5 is a sectional view of a process cartridge according to a further embodiment of the present invention;
FIG. 6A is a perspective view of an upper body;
FIG. 6B is a perspective view of a lower body;
FIG. 7 illustrates disassembling of the process cartridge;
FIG. 8 is a sectional view of a process cartridge to which the present invention is applicable;
FIG. 9 is a perspective view of the process cartridge when liquid elastomer is injected to a joint in a cartridge frame;
FIG. 10 is a perspective view of a cartridge after liquid elastomer is injected to the joint surface of the toner container;
FIG. 11 is a sectional view after the liquid elastomer is injected;
FIG. 12 is a sectional view of a process cartridge according to an embodiment of the present invention;
FIG. 13 is a sectional view when the process cartridge is divided into an upper body and a lower body;
FIG. 14 is a perspective view when liquid elastomer is injected to the joint of the upper body;
FIG. 15 schematically illustrates an injection system for the liquid elastomer;
FIG. 16 is a schematic view of a liquid elastomer injection system;
FIG. 17 is a sectional view of a conventional process cartridge;
FIG. 18 is an elevational sectional view of a copying machine within which a process cartridge according to a preferred embodiment of the present invention is mounted;
FIG. 19 is a perspective view of the copying machine in a condition that a tray is opened;
FIG. 20 is a perspective view of the copying machine in a condition that a tray is closed;
FIG. 21 is an elevational sectional view of the process cartridge;
FIG. 22 is a perspective view of the process cartridge;
FIG. 23 is a perspective view of the process cartridge in an inverted condition;
FIG. 24A and 24B are views of an upper frame and a lower frame, respectively, of the process cartridge in a condition that an upper frame and a lower frame are separated;
FIG. 25 is a perspective view of the lower frame showing an internal structure thereof;
FIG. 26 is a perspective view of the upper frame showing an internal structure thereof;
FIG. 27 is a longitudinal sectional view of a photosensitive drum of the process cartridge;
FIG. 28 is a schematic view for explaining the measurement of the charging noise;
FIG. 29A and 29B are, respectively, a graph showing the result of the measurement of the charging noise regarding a position of a filler, and a photosensitive drum showing a filler position;
FIG. 30 is a perspective view of an earthing contact for the photosensitive drum;
FIG. 31 is a perspective view of an earthing contact for the photosensitive drum, according to another embodiment;
FIG. 32 is a perspective view showing an embodiment wherein an earthing contact which is not bifurcated is used with the photosensitive drum;
FIG. 33 is a sectional view of the non-bifurcated earthing contact used with the photosensitive drum;
FIG. 34 is an elevational view showing an attachment structure for a charger roller;
FIG. 35A is a perspective view of an exposure shutter, and FIG. 35B is a partial sectional view of the exposure shutter;
FIG. 36 is a sectional view showing a non-magnetic toner feeding mechanism having an agitating vane;
FIG. 37 is a longitudinal sectional view showing a positional relation between the photosensitive drum (9) and a developing sleeve (12d) and a structure for pressurizing the developing sleeve;
FIG. 38A is a sectional view taken along the line 38A--38A of FIG. 37, and FIG. 38B is a sectional view taken along the line 38B--38B of FIG. 37;
FIG. 39 is a sectional view for explaining the pressurizing force acting on the developing sleeve;
FIG. 40 is a perspective view of a squeegee sheet in a condition that an upper edge of the sheet is tortuous;
FIG. 41A is a perspective view showing a condition that a both-sided adhesive tape is protruded from a lower end of the squeegee sheet, and FIGS. 41B and 41C are views showing a condition that a sticking tool is adhered to the protruded both-sided adhesive tape;
FIG. 42A is a perspective view showing a condition that the squeegee sheet is stuck to a curved attachment surface with a lower end portion of the sheet being curved, and FIG. 42B is a perspective view showing a condition that an upper end portion of the squeegee sheet is tensioned by releasing the curvature of the attachment surface;
FIG. 43 is a perspective view of a squeegee sheet according to another embodiment wherein a width of the sheet is widened straightly and gradually from both ends to a central portion thereof;
FIG. 44 is a perspective view for explaining the formation of the curvature of the squeegee sheet attachment surface by pressing the surface;
FIGS. 45A-45C are views showing conditions that a recording medium is being guided by a lower surface of the lower frame;
FIG. 46 is a sectional view showing a condition that the photosensitive drum is finally assembled;
FIG. 47 is a sectional view showing a condition that a developing blade and a cleaning blade are stuck;
FIGS. 48A and 48B are views of an upper frame and a lower frame, respectively, for explaining the assembling of the process cartridge;
FIG. 49 is a view for explaining a position of guide members when the photosensitive drum of the process cartridge is assembled;
FIG. 50 is a sectional view of a structure wherein drum guides are arranged at ends of blade supporting members;
FIG. 51 is a perspective view for explaining the attachment of bearing members for the photosensitive drum and the developing sleeve;
FIG. 52 is a sectional view of the photosensitive drum and the developing sleeve with the bearing members attached thereto;
FIG. 53 is a perspective view for explaining a cover film and a tear tape;
FIG. 54 is a perspective view showing a condition that the tear tape is protruded from a gripper;
FIG. 55 is a schematic view showing a condition that the process cartridge is gripped by an operator's hand;
FIG. 56A is a flow chart showing the assembling and shipping line for the process cartridge, and FIG. 56B is a flow chart showing the disassembling and cleaning line for the process cartridge;
FIG. 57 is a perspective view showing a condition that the process cartridge is being mounted within the image forming system;
FIG. 58 is a perspective view showing a condition that the process cartridge of FIG. 24 is being mounted within the image forming system;
FIG. 59 is a perspective view showing the arrangement of three contacts provided on the image forming system;
FIG. 60 is a sectional view showing the construction of the three contacts;
FIG. 61 is a sectional view for explaining the positioning of the relative position between the lower frame and a lens unit;
FIG. 62 is a sectional view for explaining the positioning of the relative position between the lower frame and an original glass support;
FIG. 63 is a perspective view showing the attachment positions of positioning pegs;
FIG. 64 is a schematic elevational view showing the relation between rotary shafts of the drum and of the sleeve and shaft supporting members therefore, and a transmitting direction of a driving force from a drive gear to a flange gear of the photosensitive drum;
FIG. 65 is an exploded perspective view of a developing sleeve according to an embodiment wherein it can easily be slid;
FIG. 66 is a schematic elevational view of the developing sleeve of FIG. 65;
FIG. 67 is an elevational sectional view showing a condition that the upper frame and the lower frame are released;
FIG. 68 is a view showing gears and contacts attached to the photosensitive drum;
FIG. 69A is an elevational view of a developing sleeve receiving member according to another embodiment, and FIG. 69B is an end view of the receiving member of FIG. 69A;
FIG. 70 is an elevational view showing an arrangement wherein the developing blade and the cleaning blade can be attached to the interior of the image forming system by pins;
FIG. 71 is an elevational view showing a condition that the photosensitive drum is being finally assembled, according to another embodiment;
FIG. 72 is an elevational sectional view of bearing members for supporting the photosensitive drum and the developing sleeve, according to another embodiment;
FIG. 73 is a schematic view of a transmission mechanism for transmitting a driving force from a drive motor of the image forming system to various elements;
FIGS. 74 and 75 are perspective views showing a condition that the flange gear of the photosensitive drum and a gear integral with the flange gear are protruded from the lower frame;
FIG. 76 is a view showing a gear train for transmitting a driving force from the drive gear of the image forming system to the photosensitive drum and the transfer roller;
FIGS. 77A and 77B are views showing different drive transmitting mechanisms to developing sleeves, wherein magnetic toner is used and non-magnetic toner is used.
FIG. 78 is an exploded perspective view for explaining the attachment of the cleaning blade;
FIG. 79 is a partial plan view of the cleaning blade before attachment;
FIG. 80 is a partial plan view of the cleaning blade after attachment;
FIGS. 81, 82, and 83 are plan views for explaining the assembling of the cleaning blade;
FIG. 84 is a partial plan view of a cleaning blade according to another embodiment wherein a fitting projection of the cleaning blade has a round end;
FIG. 85 is a partial perspective view of a cleaning blade according to a further embodiment wherein a fitting projection of the cleaning blade is rounded by chamferring a tapered portion thereof;
FIG. 86 is a partial plan view of a cleaning blade according to a still further embodiment wherein a tape is stuck to a tapered portion; and
FIG. 87 is a partial plan view of a cleaning blade according to the other embodiment wherein oil is coated on a tapered portion.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the accompanying drawings, the embodiments of the present invention will be described.
Referring to FIG. 3, there is shown an image forming apparatus usable with a process cartridge according to an embodiment of the present invention. Designated by a reference numeral 10 is an image bearing member in the form of a photosensitive drum, for example. Around the photosensitive drum 10, there are disposed image formation process means such as a developing device 11, a charger 12 or a cleaning device 13. The photosensitive drum 10 and such process means are constituted into a unit on process cartridge frames 14a and 14b of plastic material. The process cartridge 14 thus constituted is detachably mountable to the main assembly 1 of the apparatus. Thus, the maintenance or servicing operation is made easier. The structure of the process cartridge casing will be described in detail hereinafter. When the process cartridge 14 is mounted in the main assembly, a transfer charger 15 is below the photosensitive drum 10. At the sheet supply side of the transfer charger 15, there are a sheet feeding tray 16, a pick-up roller 17 and registration rollers 18. On the other hand, at the sheet discharge side thereof, there are a sheet guide 19, an image fixing device 20, sheet discharging rollers 21 and a sheet discharge tray 22.
Above the process cartridge 14, there is disposed a short focus optical element array 24 for imaging on the photosensitive drum 10 the light which is emitted from an original illumination lamp 23 and is reflected by the original 0. At the top of the main assembly 1, there is an original carriage 25 reciprocable in the directions indicated by arrow A. Designated by a reference numeral 26 is an original cover.
The photosensitive drum 10 is uniformly charged by a charger and is exposed to the light from the original 0 through the optical element array 24, so that an electrostatic latent image is formed on the photosensitive drum 10 in accordance with the information of the original. The electrostatic latent image is carried by the rotation of the photosensitive drum 10 to the developing device 11 where the latent image is developed with toner t into a toner image. Then, the transfer sheet P is fed to the registration rollers 18 from the sheet tray 16 through the sheet feeding roller 17. Then, it is fed to between the photosensitive drum 10 and the transfer charger 15 in timed relation with the latent image by the registration roller 18. The toner image is transferred from the photosensitive drum 10 onto the transfer sheet P by the transfer charger 15. The transfer sheet P carrying the transferred toner image is fed to the fixing device 20 where the toner image is fixed into a permanent image. Then, the transfer sheet P is discharged onto the tray 22 by the discharging rollers 21. The photosensitive drum 10, after the completion of the image transfer, is cleaned by the cleaning device 13 for removing the residual toner, so that the photosensitive drum 1 is now prepared for the next image forming operation. Designated by reference numerals 30a and 30b are mounting means in the form of guides for facilitating mounting of the process cartridge 14 to the main assembly of the image forming apparatus.
Referring to FIGS. 1, 2A, 2B and 2C, the process cartridge 14 of this embodiment will be described in detail. The casing of the process cartridge 14 in this embodiment comprises upper casing A (14a) and a lower casing B (14b). The casings A and B can be joined or disjoined to each other.
The casings A and B are of molded plastic material having elasticity. At the right side of the casing A, a toner container 110 functioning as the developer container is integrally formed. A plug 111 is fused to seal the container. The opening 111a of the toner container 110 which communicates with the developing device 11 is closed by a bonded sealing member 113, as shown in FIG. 2C. An end of the sealing member 113 is folded and is projected to the outside of the casing A. A grip 114 is connected to the end. When the operator pulls the grip 114, the sealing member 113 is removed from the opening 111a so as to permit supply of the toner t to the developing sleeve 112. Below the toner container 110, there is a pawl 27 for coupling the casings A and B. By the engagement between the pawl 27 integrally formed on the casing A and an opening formed in the casing B, the upper and lower casings A and B can be coupled with a simple structure. Four of such pawls 24 and corresponding openings 28 are arranged in a direction perpendicular to the sheet of the drawing. More particularly, the opening 23 is engaged by the pawl 27 at the inclined surface 27a, and an end 28a of the opening 28 is locked by the bottom surface 27b of the pawl 27. Since the pawl 27 has such an elasticity that the engagement with the opening 28 and the disengagement therefrom can be smoothly carried out, the coupling by the opening 28 is assured. At the left side of the casing A, as shown in the FIG. 3, a residual toner container 130 (developer container) 130 is formed. An end of the casing A is folded to form a part 14a1 of the bottom surface of the container 130. The bottom casing B is extended to the position overlapping with the bottom surface 14a1, where they are threaded at the overlapped portion by screws 29. Therefore, the bottom surface of the container 130 is constituted by the parts of the casings A and B. A part of the casing A facing the upper part of the photosensitive drum 10, is provided with an opening 141 for permitting passage of light for the image exposure. Around the openings in the toner container and the cleaner container, there are sealing members 26a and 26b made of foamed polyurethane material to prevent leakage of the toner from the container.
As shown in FIG. 2A, the casing B covers the bottom part of the process cartridge 14, and from the side surface, walls 102a and 102b are raised and are extended to the bottom surface of the casing A. To the walls 102a and 102b of the casing B, supporting shafts 103a and 103b for rotatably supporting the photosensitive drum 10 are securedly mounted by screws 106a and 106b below the photosensitive drum 10, the casing B is provided with an opening 101 for permitting transfer of the toner image from the photosensitive drum 10 to the transfer sheet P and for receiving an unshown driving device of the main assembly of the image forming apparatus. Above the side wall 102a of the casing B, a charger case 122 is supported by a fixing pin 125. At the other end of the charger casing 122, a pin 128 is integrally formed and is engaged in and supported by a hole 129 formed in the side wall 102b of the casing B. In the charger casing 122, bearings 123a and 123b, which support a shaft 130 of the charging roller 121 while urging the charging roller 121 to the photosensitive drum 10. An end of the charger case 122 extends to the outside of the casing B and contains electrode plate 126 for supplying electric power to the charging roller 121. The electrode plates 126 are connectable with power supply contacts (not shown) of the main assembly of the image forming apparatus.
Referring to FIGS. 1 and 2B, the cleaning device 13 and the developing device 12 will be described in detail. The casing B is provided with seats 133a and 133b for mounting the cleaning blade 131 for contacting to the photosensitive drum 10 to scrape the residual toner off the peripheral surface of the photosensitive drum 10. The cleaning blade 131 is fixedly mounted on the seats 133a and 133b by screws 135. Adjacent a longitudinal end of the opening 101 formed at the lower side of the casing B, a receiving sheet 132 is bonded. The side wall of the casing B is bent toward the inside adjacent the toner container 110. The bent portion functions to support through springs 118a and 118b sleeve bearings 117a and 117b for supporting the developing sleeve 112. The developing sleeve 112 has spacers 116a and 116b for maintaining a constant clearance between the surface of the developing sleeve 112 and the photosensitive drum 10. The spacers 116a and 116b are urged to the photosensitive drum by the springs 118a and 118b. To one of the ends of the developing sleeve 112, a gear 119 is mounted which meshes with a drum gear 104 mounted to the drum 10. With the rotation of the photosensitive drum 10, the gear 119, and therefore, the developing sleeve 112 is rotated in the direction indicated by an arrow in FIG. 1. In the developing sleeve 112, a cylindrical magnet roller 115 is disposed. It is provided with plural magnetic poles. The end pins thereof are supported by the casing B. Above the developing sleeve 112, a blade 120 is mounted on an unshown seat projected from the side walls 102a and 102b of the casing B.
The lower casing B contains the photosensitive drum 10, the cleaning blade 131, the receiving sheet 132, the charger 12, the developing sleeve 112 and the blade 120 for the developing sleeve 112. Therefore, the positional accuracies of various elements relative to the photosensitive drum 10 are assured by the accuracy of the casing B, and therefore, the correct positioning is made easier.
In addition, the process cartridge 14 of this embodiment can be disassembled into the upper casing A and the lower casing B. The process cartridges 14 from which the toner has been used up, are collected. The collected cartridge 14 is disassembled into the casings A and B. Then, the casing A is., cleaned, and a fresh sealing member 113 is bonded. An unshown toner cap is removed from a filling opening, and the toner is supplied through the opening. Thereafter, the opening is plugged by the toner cap, again. In addition, worn parts and creeped rubber elements or the like which are not reusable, are replaced with new ones. Then, the casings are joined together. The process cartridge 14 is now distributed from the factory.
Casing B containing the process means may be joined with another casing 14c which has the shape as shown in FIG. 1 and which has a larger toner capacity and a larger residual toner capacity than those of the casing B. Then, another process cartridge having a longer service life and usable with a different type main assembly, can be easily manufactured.
FIG. 4 shows a process cartridge according to another embodiment of the present invention. A pipe 138 is provided for permitting discharge of the residual toner from the process cartridge 14. The pipe is connected to an unshown residual toner bottle (not shown) in the main assembly of the image forming apparatus. The residual toner container 113 is provided therein with a helical residual toner convener 139 for supplying the residual toner to the discharge pipe 138. An end of the residual toner convener 139 is coupled with a driving gear (not shown). The driving gear is meshed with the drum gear 104. In this example, it will suffice if the upper casing A is provided only with the toner container 110. The residual toner container is not necessary. Then, it is not necessary that the residual toner capacity is dependent on the toner capacity. In this embodiment, the residual toner container is formed by the coupling between the casing A and the casing B.
A phantom line 14c illustrates a configuration of another example of the casing A. In the case of the casing 14c, the toner container 110 is disposed at a lower side. The toner container 110 is provided therein with toner convener means (not shown). To both sides of the toner container 110, the casing B is extended and is engaged with coupling pawl 27 formed on the ends of the toner container 110 of the casing A.
In the foregoing embodiments, the process cartridge has the developing means. However, the present invention is applicable to the process cartridge not having the developing means. In this case, the present invention is applied to the residual toner container for the cleaning means.
Referring to FIGS. 5, 6A and 6B, a further embodiment of the present invention will be described. FIG. 5 is a side sectional view of a process cartridge according to this embodiment, FIG. 6A is a perspective view of an upper casing, and FIG. 6B is a perspective view of a lower casing.
In the foregoing embodiments, the upper and lower casings A and B are joined not only by the engagement between pawls and openings but also by screws. In the present embodiment, however, the casings A and B can be joined merely by using engagement between pawls and openings. In the description of this embodiment, the same reference numerals as in the foregoing embodiments are assigned to the elements having the corresponding functions, and the detailed description thereof is omitted for simplicity.
Sectional views taken along lines 2A--2A, 2B--2B and 2C--2C in FIG. 5 are as shown in FIGS. 2A, 2B and 2C, respectively, which have been described hereinbefore. The process cartridge of this embodiment is also detachably mountable to the main assembly of the image forming apparatus, as shown in FIG. 3.
In this embodiment, the casing A and the casing B are securedly joined by engagement between pawls 27b and the openings 29 in place of the screws 29 in the above-described embodiment. In the present embodiment, four pawl 27b are formed on the bottom outside surface 14a1 of the residual toner container 130 formed at the left side of the casing A. Correspondingly, the casing B is provided with four openings 29 in the wall overlapped with the bottom surface 14a1 of the casing A. Similarly to the toner container 110 side, the pawls 27b of the casing A and the openings 29 of the casing B are engaged with each other at the residual toner container 130 side, so that the casings A and B are joined together. Designated by a reference 27c is an inclined surface of the pawl 27b, and 29a is an engaging end of the opening 29. In this embodiment, the pawls 27 at the toner container 110 side and the pawls 27b at the residual toner container 130 side are inclined outwardly, in other words, they are inclined away from each other. By doing so, the elasticity of the casings A and B of plastic material, more particularly, the elasticity of the pawls 27 and 20b cooperates to enhance the fastening engagement when they are engaged with the associated openings 28 and 29.
In this embodiment, the process cartridge can be easily disjoined. As described above, the upper and lower casings A and B are joined by the pawls 27 and 27b. When the process cartridge is to be disjoined, the process cartridge 14 is put on a disjoining device 200. Then, rods 201 and 202 are pushed to push the pawls 27 and 27b. Thus, the upper casing A can be easily disjoined from the lower casing B.
Without use of the device 200, the casings A and B can be disjoined from each other by properly pushing the pawls 27 and 27b. However, in this case, it is preferable to push the plural pawls simultaneously, and therefore, it is easier if the device 200 is used.
A further embodiment of the process cartridge will be described. In this embodiment, additional sealing members are employed to further prevent the leakage of the developer to the outside of the cartridge.
Referring to FIGS. 8, 9, 10 and 11, the description will be made as to the cartridge of this embodiment having the sealing members. FIG. 8 is a sectional view of the process cartridge according to this embodiment. The process cartridge 201 contains an image bearing member in the form of a photosensitive drum 202 and process means disposed therearound. The process means include a cleaning device 203, a developing device 204 and a charger 205 supported on a cartridge frame 201a. They constitute a unit which is detachably mountable to a main assembly of the image forming apparatus, as a unit. When the photosensitive drum 202 and/or the developing device 204 comes to an end of the service life, when the cleaning device 203 is filled with the residual toner or when the toner in the developing device 204 is used up, the entirety of the process cartridge 201 is replaced with a new process cartridge. Thus, the maintenance or servicing operations are easy. In this embodiment, the charger 205 is in the form of a well-known corona charger, but it may be replaced with a contact type charger as disclosed in U.S. Pat. No. 4,851,960.
The cleaning device 203 comprises a cleaning blade 230 for removing the residual toner (residual developer) from the surface of the photosensitive drum 202, a toner receiving sheet 231 for preventing leakage of the residual toner to an outside, and a residual toner container 232 for containing the residual toner. The residual toner container 232 is constituted by connecting through sealing members 213 the cleaning container 203a, the blade holder 230a and the cartridge frame 201a. The sealing members 213 are effective to prevent leakage of the toner through the joint portions.
The developing device 204 comprises a developing sleeve 240 rotatable in a constant direction and effective to supply the toner (developer) from its outer periphery to the photosensitive drum 202, a regulating blade 241 for regulating a thickness of a layer of the developer on the developing sleeve 240, and a toner container 242 for containing the toner and for supplying the developer to the developing sleeve 240. The toner container 242 is constituted by the toner container 212 and the developer container 204 which are coupled by screws or the like with a sealing member 214 therebetween so that they can be disjoined and cleaned. The sealing member 214 is effective to prevent leakage of the toner through the joint portion.
In the process cartridge having the structure described above, the photosensitive drum 202 is uniformly charged by a charger 205 and is exposed to image light, so that an electrostatic latent image is formed on the photosensitive drum 202. With the rotation of the photosensitive drum 202, the electrostatic latent image reaches the developing device 204, where the latent image is supplied with the toner from the developing sleeve 240 of the developing device 204 so as to be developed into a toner image. The toner image is transferred onto the transfer sheet through an unshown transfer charger or the like. After the completion of the image transfer action, the photosensitive drum 202 is cleaned by the cleaning blade 230 so that the residual toner is removed from the photosensitive drum 202. Then, the photosensitive drum 202 is prepared for the next image forming operation. The residual toner removed by the cleaning blade 230 is collected into the residual toner container 232 of the cleaning device 203 by way of the receiving sheet 231 contacted to the photosensitive drum 202.
Referring to FIGS. 9 and 10, the description will be further made as to the sealing members 213 and 214. The sealing members of this embodiment are provided by injecting from a nozzle 215 two-liquid urethane rubber material R to a coupling surface 201b (FIG. 9) of the cartridge frame 201a and to a coupling surface 212a (FIG. 10) of the toner container 212. The material R is a foaming material, and therefore, it is foamed and solidified into elastomer on the coupling surfaces 201b and 212a approximately 20 sec.-10 min. after the injection.
In FIG. 9, the material R extends from point (a) along arrows 216 and 217 and returns to the point (a), thus constituting a closed loop. As regards the sealing member 214 shown in FIG. 10, the injection starts at point (b) and proceeds along the direction of arrows 218 and 219 and returns to the original point (b). The coupling surfaces 201b and 212a are provided beforehand with grooves 211 as shown in FIG. 11. Therefore, the material R ultimately becoming the sealing member flows into the groove and then is solidified into an elastic elastomer. Therefore, the sealing member is not easily removed or easily deviated.
With the solidified sealing members 213 and 214 an the cartridge frame 210a and the toner container 212, the cartridge frame 201a and the toner container 212 are coupled with the cleaning container 203a and the developing container 204a, respectively, by which the toner leakage through the connecting portions can be properly prevented. The height h (FIG. 11) of the elastomer members 213 and 214, after solidification, is larger than the clearance C (FIG. 8) after the containers are coupled, and therefore, the sealing members are pressed down to the height which is equal to the clearance C, thus filling the clearance.
In this embodiment, the material R dispensing from the injection nozzle, nozzel 215, the injection speed, the injection rate, can be completely and automatically controlled, so that the sealing members can be formed along the connecting surface with certainty. Therefore, the system conveniently accounts for the complicated shape as shown in FIG. 9.
In the foregoing description, the foaming polyurethane rubber is used as the sealing member material R. However, the material is not limited to this, and another material such as soft rubber or plastic material such as silicone rubber or another elastomer (elastic high polymer material) may be used with the same advantageous effects.
Thus, the sealing members are provided by solidifying liquid elastomer such as foaming polyurethane rubber or the like to seal the coupling portion of plural members such as the developing device 204 in the process cartridge, the toner container of the cleaning device 203 and the residual toner container. Therefore, the toner seal can be easily accomplished in the coupling portions of the containers having a complicated structure. In addition, the closed loop can be easily formed, and therefore, the toner leakage through a sealing member connecting portion can be prevented.
Referring to FIGS. 12, 13 and 14, there is shown a process cartridge according to a further embodiment of the present invention. As shown in FIG. 12, the process cartridge is constituted by an upper frame A and a lower frame B in this Figure, the same reference numerals as in FIG. 8 are added to the elements having the corresponding functions.
As shown in FIG. 13, the process cartridge of FIG. 12 has the upper and lower frames A and B which are coupled by pawls 250 and screws 251. The pawls 250 of the upper frame A are elastically engaged with associated openings 251 formed in the lower frame B, by which the upper frame A and the lower frame B are coupled. The upper and lower frames A and B sandwich sealing members 213b and 214b. The toner container 242 is constituted by coupling the upper and lower frames A and B and by coupling the upper frame A and a blade holder 241a for supporting a regulating blade 241. The coupling portions are provided with a sealing member 214a to prevent leakage of the toner. The residual toner container 232 of the cleaning device 203 is constituted by coupling the upper and lower frames A and B and by coupling the upper frame A and a cleaning holder 230a for supporting a cleaning blade 230. The coupling portion is provided with a sealing member 213a to prevent the toner leakage.
FIG. 14 shows the view in the direction I in FIG. 13. In this embodiment, as shown in FIG. 14, the two-liquid urethane rubber material R is dispensed from the nozzle 215 to the coupling surfaces between the upper and lower frame portions of the toner container and the residual toner container. Since the material is of a foaming nature, it foams and becomes elastomer on the coupling surfaces 201b and 212a in approximately 30 sec.-10 min. after injection or dispensing. The injection path starts at (a) and extends in the directions of arrows 216 and 217 to return the position (a), so that a closed loop is formed. The surfaces receiving the material R (coupling surfaces 201b and 212a) are formed into grooves beforehand, and therefore, the material R easily flows into the grooves, and then solidified into an elastomer. Therefore, the sealing member is not easily removed or deviated. In this manner, with the solidified sealing members 213 and 214 on the upper frame A, it is coupled with the lower frame B, so that the sealing members 213 and 214 function to prevent leakage of the toner from the toner container and from the residual toner container. The height h (FIG. 11) of the sealing members 213 and 214, after solidification, is higher than the clearances C1, C2, C3 and C4 (FIG. 12) after the frames are coupled, and therefore, the elastomer is pressed to the heights equal to the clearances Cl-C4, thus filling the clearances.
Similarly to the foregoing embodiment, in the present embodiment, the injecting path, speed and rate can be completely automatically controlled, so that the sealing member can be provided along the coupling surfaces with certainty. In addition, the injecting portions are concentrated on one of the frames, and therefore, the injecting or dispensing operation can be completed after only one positioning of the frames. This is advantageous in that the number of manufacturing steps can be significantly reduced.
Similarly to the foregoing embodiment, the material R may be soft rubber of soft plastic or the like.
In this embodiment, the liquid elastomer is dispensed to the coupling surface. Referring to FIG. 15, the description will be made as to the system for mixing the two-liquid-active material (liquid elastomer) and ejecting it through a nozzle 215.
In FIG. 15, liquid A and liquid B are contained in containers 260 and 261. They are metered by precise metering pumps 262 and 263 to a mixing and stirring station 264 so that the mixture ratio thereof is proper for the two-liquid reaction. In the mixing and stirring station 264, the liquid A and liquid B are uniformly mixed by the motor. It requires at least 30 sec approximately for the mixed liquid to solidify into an elastic elastomer, and therefore, the mixed liquid is ejected through a nozzle 215 of the ejector 265 in the middle of the reaction. The mixing and stirring station 264, the ejector 265 and an injection head including a nozzle 215 are moved along X-, Y-, and Z-axes to meet the configuration of the containers or the like, while the liquid elastomer is being ejected.
The metering by the metering pumps 262 and 263, the mixing and stirring speeds, movement of the ejecting head along the three axes, the ejecting speed or the like, are properly controlled in accordance with program set in a controller of an unshown industrial robot. Therefore, the injecting operation is carried out automatically.
The materials used are as follows.
TABLE 1______________________________________ Foaming RateLiquid A Liquid B (Vol.) Solidified Elastomer______________________________________Ex. 1 Polyol Isocyanate 2-5 Foaming PolyurethaneMix.ratio: 10:2-3 (ISOACK Corporation)Ex. 2 (--OH) (--H) 2-10 Foaming Silicone Silicone Silicone (TORAY SILICONE)Mix.ratio: 1:1______________________________________
Referring to FIG. 16, the description will be made as to a system in which single-liquid reaction type liquid is used. A N.sub.2 gas is injected into the liquid to foam it, and it is ejected through a nozzle 16
In FIG. 16, a liquid elastomer mainly comprising polyurethane material is heated by a heater to 70.degree. C.-100.degree. C. in a container 266. It is supplied by a pump to a foam mixing machine 268. In the foam mixing machine 268, the liquid supplied from the container 266 is mixed with N.sub.2 gas so as to be foamed. Before the liquid elastomer is solidified, it is ejected to the member such as the toner container or the like through the nozzle 215 of the ejector 270.
Similarly to the case of the two-liquid type material, an unshown industrial robot is used, so that the controller thereof properly controls the mixture of the N.sub.2 gas, the supply of the material, the movement in the three axes directions of the injecting head and the injection speed or the like. Therefore, the injecting or dispensing operations are automatic.
The elastomer in this embodiment preferably has an elongation of 100-200%, a hardness (Asker C) of 4-15, compression-restoration of not less than 90%.
In the foregoing, the description has been made as to the case of the process cartridge having both of the residual toner container for the cleaning means and the toner container for the developing means. The present invention is not limited to this, and the present invention is applicable to the process cartridge comprising at least one of the containers.
As described in the foregoing, according to the embodiments of the present invention, the sealing member is constituted by solidifying the dispensed liquid elastomers for the plural connecting portions of the process cartridge developer container, and therefore, the leakage of the developer can be prevented more positively than conventionally, and in addition, the present invention is advantageous in that the sealing can accommodate complicated connecting portions.
In addition, the automatic control for the liquid elastomer injection is possible, and therefore, the assembling operation of the process cartridge is made easier.
The process cartridge described in the foregoing may contain an image bearing member and at least one of process means actable directly or indirectly on the image bearing member. More particularly, the process cartridge may contain as a unit an electrophotographic photosensitive member and a charging means, developing means and/or cleaning means. The cartridge thus constituted is detachably mountable to an image forming apparatus such as a copying machine or a laser beam printer.
As described in the foregoing, according to the embodiments of the present invention, the process cartridge is divisible into frames, one of which contains an image bearing member and process means actable thereon, and the other of which contains a toner container having toner particles and/or residual toner container. They are assembled by putting them together, and thereafter, they may be disassembled.
Therefore, the present invention provides the following advantageous effects:
1. By selecting the frame containing the toner container (developer container), process cartridges having different service lives and cross-sections can be easily produced:
2. The frame containing the image bearing member and the process means can be made the same so that the manufacturing management is made simpler: and
3. The process cartridge can be reused by collecting the used process cartridge (empty toner container), disassembling the frames, replacing worn parts and coupling the toner container refilled with the fresh toner.
According to the present invention, the process cartridge having the nature of easy assembling and an image forming apparatus usable therewith, can be provided.
The Whole Construction of a Process Cartridge and an Image Forming System Mounting the Process Cartridge thereon
First of all, the whole construction of the image forming system will briefly be described. Incidentally, FIG. 18 is an elevational sectional view of a copying machine as an example of the image forming system, within which the process cartridge is mounted, FIG. 19 is a perspective view of the copying machine with a tray opened, FIG. 20 is a perspective view of the copying machine with the tray closed, FIG. 21 is an elevational sectional view of the process cartridge, FIG. 22 is a perspective view of the process cartridge, and FIG. 23 is a perspective view of the process cartridge is an inverted condition.
As shown in FIG. 18, the image forming system A operates to optically read image information on an original or document 2 by an original reading means 1. A recording medium rested on a sheet supply tray 3 or manually inserted from the sheet supply tray 3 is fed, by a feeding means 5, to an image forming station of the process cartridge B, where a developer (referred to as "toner" hereinafter) image formed in response to the image information is transferred onto the recording medium 4 by a transfer means 6. Thereafter, the recording medium 4 is sent to a fixing means 7 where the transferred toner image is permanently fixed to the recording medium 4. Then, the recording medium is ejected onto an ejection tray 8.
The process cartridge B defining the image forming station operates to uniformly charge a surface of a rotating photosensitive drum (image bearing member) 9 by a charger means 10, then to form a latent image on the photosensitive drum 9 by illuminating a light image read by the reading means 1 on the photosensitive drum by means of an exposure means 11, and then to visualize the latent image as a toner image by a developing means 12. After the toner image is transferred onto the recording medium 4 by the transfer means 6, the residual toner remaining on the photosensitive drum 9 is removed by a cleaning means 13.
Incidentally, the process cartridge B is formed as a cartridge unit by housing the photosensitive drum 9 and the like within frames which include a first or upper frame 14 and a second or lower frame 15. Further, in the illustrated embodiment, the frames 14, 15 are made of high impact styrol resin (HIPS), and a thickness of the upper frame 14 is about 2 mm and a thickness of the lower frame 15 is about 2.5 mm. However, material and thickness of the frames are not limited to the above, but may be selected appropriately.
Next, various parts of the image forming system A and the process cartridge B mountable within the image forming system will be fully described.
Image Forming System
First of all, various parts of the image forming system A will be explained.
(Original Reading Means)
The original reading means 1 serves to optically read the information written on the original, and, as shown in FIG. 18, includes an original glass support 1a which is disposed at an upper portion of a body 16 of the image forming system and on which the original 2 is to be rested. An original hold-down plate 1b having a sponge layer 1b1 on its inner surface is attached to the original glass support 1a for opening and closing movement. The original glass support 1a and the original hold-down plate 1b are mounted on the system body 16 for reciprocal sliding movement in the left and right directions in FIG. 18. On the other hand, a lens unit 1c is disposed below the original glass support 1a at the upper portion of the system body 16 and includes a light source 1c1 and a short focus focusing lens array 1c2 therein.
With this arrangement, when the original 2 is rested on the original glass support 1a with an image surface thereof faced downside and the light source 1c1 is activated and the original glass support 1a is slid in the left and right direction in FIG. 18, the photosensitive drum 9 of the process cartridge B is exposed by reflection light from the original 2 via the lens array 1c2.
(Recording Medium Feeding Means)
The feeding means 5 serves to feed the recording medium 4 rested on the sheet supply tray 3 to the image forming station and to feed the recording medium to the fixing means 7. More particularly, after a plurality of recording media 4 are stacked on the sheet supply tray 3 or a single recording medium 4 is manually inserted on the sheet supply tray 3, and leading end(s) of the recording media or medium are abutted against a nip between a sheet supply roller 5a and a friction pad 5b urged against the roller, when a copy start button A3 is depressed, the sheet supply roller 5a is rotated to separate and feed the recording medium 4 to a pair of regist rollers 5c1, 5c2 which, in turn, feed the recording medium in registration with the image forming operation. After the image forming operation, the recording medium 4 is fed to the fixing means 7 by a convey belt 5d and a guide member 5e, and then is ejected onto the ejection tray 8 by a pair of ejector rollers 5f1, 5f2.
(Transfer Means)
The transfer means 6 serves to transfer the toner image formed on the photosensitive drum 9 onto the recording medium 4 and, in the illustrated embodiment, as shown in FIG. 18, it comprises a transfer roller 6. More particularly, by urging the recording medium 4 against the photosensitive drum 9 in the process cartridge B mounted within the image forming system by means of the transfer roller 6 provided in the image forming system and by applying to the transfer roller 6 a voltage having the polarity opposite to that of the toner image formed on the photosensitive drum 9, the toner image on the photosensitive drum 9 is transferred onto the recording medium 4.
(Fixing Means)
The fixing means 7 serves to the toner image transferred to the recording medium 4 by applying the voltage to the transfer roller 6 and, as shown in FIG. 18, comprises a heat-resistive fixing film 7e wound around and extending between a driving roller 7a, a heating body 7c held by a holder 7b and a tension plate 7d. Incidentally, the tension plate 7d is biased by a tension spring 7f to apply a tension force to the film 7e. A pressure roller 7g is urged against the heating body 7c with the interposition of the film 7e so that the fixing film 7e is pressurized against the heating body 7c with a predetermined force required for the fixing operation.
The heating body 7c is made of heat-resistive material such as alumina and has a heat generating surface comprised of a wire-shaped or plate-shaped members having a width of about 160 .mu.m and a length (dimension perpendicular to a plane of FIG. 18) of about 216 mm and made of Ta.sub.2 N for example arranged on an under surface of the holder 7b made of insulation material or composite material including insulation, and a protection layer made of Ta.sub.2 O for example and covering the heat generating surface. The lower surface of the heating body 7c is flat, and front and rear ends of the heating body are rounded to permit the sliding movement of the fixing film 7e. The fixing film 7e is made of heat-treated polyester and has a thickness of about 9 .mu.m. The film can be rotated in a clockwise direction by the rotation of the driving roller 7a. When the recording medium 4 to which the toner image was transferred passes through the area between the fixing film 7e and the pressure roller 7g, the toner image is fixed to the recording medium 4 by heat and pressure.
Incidentally, in order to escape or discharge the heat generated by the fixing means 7 out of the image forming system, a cooling fan 17 is provided within the body 16 of the image forming system. The fan 17 is rotated, for example when the copy start button A3 (FIG. 19) is depressed, so as to generate air flows (FIG. 18) flowing into the image forming system from the recording medium supply inlet and flow out from the recording medium ejecting outlet. The various parts including the process cartridge B are cooled by the air flows so that the heat does not remain in the image forming system.
(Recording Medium Supply and Ejection Trays)
As shown in FIGS. 18 to 20, the sheet supply tray 3 and the ejection tray 8 are mounted on shafts 3a, 8a, respectively within the system body 16 for pivotal movements in directions b in FIG. 19, and for pivotal movements around shafts 3b, 8b in directions c in FIG. 19. Locking projections 3c, 8c are formed on free ends of the trays 3, 8 at both sides thereof, respectively. These projections can be fitted into locking recesses 1b2 formed in an upper surface of the original hold-down plate 1b. Thus, as shown in FIG. 20, when the trays 3, 8 are folded inwardly to fit the locking projections 3c, 8c into the corresponding recesses 1b2, the original glass support 1a and the original hold-down plate 1b are prevented from sliding in the left and right directions. As a result, an operator can easily lift the image forming system A via grippers 16a and transport it.
(Setting Buttons for Density and the like)
Incidentally, setting buttons for setting the density and the like are provided on the image forming system A. Briefly explaining, in FIG. 19, a power switch A1 is provided to turn ON and OFF the image forming system. A density adjusting dial A2 is used to adjust the fundamental density (of the copied image) of the image forming system. The copy start button A3, when depressed, starts the copying operation of the image forming system. A copy clear button A4, when depressed, interrupts the copying operation and clears the various setting conditions (for example, the set density condition). A copy number counter button A5 serves to set the number of copies when depressed. An automatic density setting button A6, when depressed, automatically sets the density in the copying operation. A density setting dial A7 is provided so that the operator can adjust the copy density by rotating this dial as needed.
Process Cartridge
Next, various parts of the process cartridge B which can be mounted within the image forming system A will be explained.
The process cartridge B includes an image bearing member and at least one process means. For example, the process means may comprise a charge means for charging a surface of the image bearing member, a developing means for forming a toner image on the image bearing member and/or a cleaning means for removing the residual toner remaining on the image bearing member. As shown in FIGS. 18 and 21, in the illustrated embodiment, the process cartridge B is constituted as a cartridge unit which can be removably mounted within the body 16 of the image forming system, by enclosing the charger means 10, the developing means 12 containing the toner (developer) and the cleaning means 13 which are arranged around the photosensitive drum 9 as the image bearing member by a housing comprising the upper and lower frames 14, 15. The charger means 10, exposure means 11 (opening 11a) and toner reservoir 12a of the developing means 12 are disposed within the upper frame 14, and the photosensitive drum 9, developing sleeve 12d of the developing means 12 and cleaning means 13 are disposed within the lower frame 15.
Now, the various parts of the process cartridge B will be fully described regarding the charger means 11, exposure means 11, developing means 12 and cleaning means 13 in order. Incidentally, FIG. 24 is a sectional view of the process cartridge with the upper and lower frames separated from each other, FIG. 25 is a perspective view showing the internal construction of the lower frame, and FIG. 26 is a perspective view showing the internal construction of the upper frame.
(Photosensitive Drum) In the illustrated embodiment, the photosensitive drum 9 comprises a cylindrical drum core 9a having a thickness of about 1 mm and made of aluminum, and an organic photosensitive layer 9b disposed on an outer peripheral surface of the drum core, so that an outer diameter of the photosensitive drum 9 becomes 24 mm. The photosensitive drum 9 is rotated in a direction shown by the arrow in response to the image forming operation, by transmitting a driving force of a drive motor 54 (FIG. 73) of the image forming system to a flange gear 9c (FIG. 15) secured to one end of the photosensitive drum 9.
During the image forming operation, when the photosensitive drum 9 is being rotated, the surface of the photosensitive drum 9 is uniformly charged by applying to the charger roller 10 (contacting with the drum 9) a vibrating voltage obtained by overlapping a DC voltage with an AC voltage. In this case, in order to uniformly charge the surface of the photosensitive drum 9, the frequency of the AC voltage applied to the charger roller 10 must be increased. However, if the frequency exceeds about 2000 Hz, the photosensitive drum 9 and the charger roller 10 will be vibrated, thus generating the so-called "charging noise".
That is to say, when the AC voltage is applied to the charger roller 10, an electrostatic attraction force is generated between the photosensitive drum 9 and the charger roller 10, so that the attraction force becomes maximum at the maximum and minimum values of the AC voltage, thus attracting the charger roller 10 against the photosensitive drum 9 while elastically deforming the charger roller. On the other hand, at an intermediate value of the AC voltage, the attraction force becomes minimum, with the result that the elastical deformation of the charger roller 10 is restored to tray to separate the charger roller 10 from the photosensitive drum 9. Consequently, the photosensitive drum 9 and the charger roller 10 are vibrated at the frequency substantially twice that of the applied AC voltage. Further, when the charger roller 10 is attracted against the photosensitive drum 9, the rotations of the drum and the roller are braked, thus causing vibration due to the stick slip, which also results in the charging noise.
In order to reduce the vibration of the photosensitive drum 9, in the illustrated embodiment, as shown in FIG. 27 (sectional view of the drum), a rigid or elastic filler 9d is disposed within the photosensitive drum 9. The filler 9d may be made of metal such as aluminum, brass or the like, cement, ceramics such as gypsum, or rubber material such as natural rubber, in consideration of the productivity, workability, effect of weight and cost. The filler 9d has a solid cylindrical shape or a hollow cylindrical shape, and has an outer diameter smaller than an inner diameter of the photosensitive drum 9 by about 100 .mu.m, and is inserted into the drum core 9a. That is to say, a gap between the drum core 9a and the filler 9d is set to have a value of 100 .mu.m at the maximum, and an adhesive (for example, cyanoacrylate resin, epoxy resin or the like) 9e is applied on the outer surface of the filler 9d or on the inner surface of the drum core 9a, and the filler 9d is inserted into the drum core 9a, thus adhering them to each other.
Now, the test results performed by the inventors, wherein the relation between the position of the filler 9d and the noise pressure (noise level) was checked by varying the position of the filler 9d in the photosensitive drum 9 will be explained. As shown in FIG. 28, the noise pressure was measured by a microphone M arranged at a distance of 30 cm from the front surface of the process cartridge B disposed in a room having the background noise of 43 dB. As result, as shown in FIG. 29, when the filler having a weight of 80 grams was arranged, at a central position in the longitudinal direction of the photosensitive drum 9, the noise pressure was 54.5-54.8 dB. Whereas, when the filler having a weight of 40 grams was arranged at a position offset from the central position toward the flange gear 9c by 30 mm, the noise pressure was minimum. From this result, it was found that it was more effective to arrange the filler 9d in the photosensitive drum 9 offset from the central position toward the gear flange 9c. The reason seems that one end of the photosensitive drum 9 is supported via the flange gear 9c while the other end of the drum 9 is supported by a bearing member 26 having no flange, so that the construction of the photosensitive drum 9 is not symmetrical with respect the central position in the longitudinal direction of the drum.
Thus, in the illustrated embodiment, as shown in FIG. 27, the filler 9d is arranged in the photosensitive drum 9 offset from the central position c (in the longitudinal direction of the drum) toward the flange gear 9c, i.e., toward the drive transmission mechanism to the photosensitive drum 9. Incidentally, in the illustrated embodiment, a filler 9d comprising a hollow aluminum member having a length L3 of 40 mm and a weight of about 20-60 grams, preferably 35-45 grams (most preferably about 40 grams) is positioned within the photosensitive drum 9 having a longitudinal length L1 of 257 mm at a position offset from the central position c toward the flange gear 9c by a distance L2 of 9 mm. By arranging the filler 9d within the photosensitive drum 9, the latter can be rotated stably, thus suppressing the vibration due to the rotation of the photosensitive drum 9 in the image forming operation. Therefore, even when the frequency of the AC voltage applied to the charger roller 10 is increased, it is possible to reduce the charging noise.
Further, in the illustrated embodiment, as shown in FIG. 27, an earthing contact 18a is contacted with the inner surface of the photosensitive drum 9 and the other end of the earthing contact is abutted against a drum earth contact pin 35a, thereby electrically earthing the photosensitive drum 9. The earthing contact 18a is arranged at the end of the photosensitive drum opposite to the end adjacent to the flange gear 9c.
The earthing contact 18a is made of spring stainless steel, spring bronze phosphate or the like and is attached to the bearing member 26. More particularly, as shown in FIG. 30, the earthing contact comprises a base portion 18a1 having a locking opening 18a2 into which a boss formed on the bearing member 26 can be fitted, and two arm portions 18a3 extending from the base portion 18a1, each arm portion being provided at its free end with a semi-circular projection 18a4 protruding downwardly. When the bearing member 26 is attached to the photosensitive drum 9, the projections 18a4 of the earthing contact 18a are urged against the inner surface of the photosensitive drum 9 by the elastic force of the arm portions 18a3. In this case, since the earthing contact 18a is contacted with the photosensitive drum at plural points (two points), the reliability of the contact is improved, and, since the earthing contact 18a is contacted with the photosensitive drum via the semi-circular projections 18a4, the contact between the earthing contact and the photosensitive drum 9 is stabilized.
Incidentally, as shown in FIG. 31, lengths of the arm portions 18a3 of the earthing contact 18a may be differentiated from each other. With this arrangement, since positions where the semi-circular projections 18a4 are contacted with the photosensitive drum 9 are offset from each other in the circumferential direction of the drum, even if there is a crack portion extending in the axial direction in the inner surface of the photosensitive drum 9, both projections 18a4 do not contact with such crack portion simultaneously, thereby maintaining the earthing contact (between the contact and the drum) without fail. Incidentally, when the lengths of the arm portions 18a3 are differentiated, the contacting pressure between one of the arm portions 18a3 and the photosensitive drum is differentiated from the contacting pressure between the other arm portion and the drum. However, such difference can be compensated, for example, by changing the bending angles of the arm portions 18a3.
In the illustrated embodiment, while the earthing contact 18a had two arm portions 18a3 as mentioned above, three or more arm portions may be provided, or, when the earthing contact is contacted with the inner surface of the photosensitive drum 9 without fail, a single arm portion 18a3 (not bifurcated) having no projection may be used, as shown in FIGS. 32 and 33.
Now, if the contacting pressure between the earthing contact 18a and the inner surface of the photosensitive drum 9 is too weak, the semi-circular projections 18a4 cannot follow the unevenness of the inner surface of the photosensitive drum, thus causing the poor contact between the earthing contact and the photosensitive drum and generating the noise due to the vibration of the arm portions 18a3. In order to prevent such poor contact and noise, the contacting pressure must be increased. However, if the contacting pressure is too strong, when the image forming system is used for a long time, the inner surface of the photosensitive drum will be damaged by the high pressure of the semi-circular projections 18a4. Consequently, when the semi-circular projections 18a4 pass through such a damaged portion, vibration occurs, thus causing the poor contact and the vibration noise. In consideration of the above affairs, it is preferable that the contacting pressure between the earthing contact 18a and the inner surface of the photosensitive drum is set in a range between about 10 grams and about 200 grams. That is to say, according to the test result effected by the inventors, when the contacting pressure was smaller than about 10 grams, it was feared that the poor contact was likely to occur in response to the rotation of the photosensitive drum, thus causing the radio wave jamming regarding other electronic equipments. On the other hand, when the contacting pressure was greater than about 200 grams, it was feared that the inner surface of the photosensitive drum 9 was damaged due to the sliding contact between the drum inner surface and the earthing contact 18a for a long time, thus causing the abnormal noise and/or poor contact.
Incidentally, although the generation of the above noise and the like sometimes cannot be eliminated completely because of the inner surface condition of the photosensitive drum, it is possible to reduce the vibration of the photosensitive drum 9 by arranging the filler 9d within the drum 9, and it is also possible to prevent the damage of the drum and the poor contact more effectively by disposing the conductive grease on the contacting area between the earthing contact 18a and the inner surface of the photosensitive drum 9. Further, since the earthing contact 18a positioned on the bearing member 26 is situated remote from the filler 9d offset toward the flange gear 9c, the earthing contact can easily be attached to the bearing member.
(Charger Means)
The charger means serves to charge the surface of the photosensitive drum 9. In the illustrated embodiment, the charger means is of a so-called contact charging type as disclosed in the Japanese Patent Laid-open Appln. No. 63-149669. More specifically, as shown in FIG. 21, the charger roller 10 is rotatably mounted on the inner surface of the upper frame 14 via a slide bearing 10c. The charger roller 10 comprises a metallic roller shaft 10b (for example, a conductive metal core made of iron, SUS or the like), an elastic rubber layer made of EPDM, NBR or the like and arranged around the roller shaft, and an urethane rubber layer dispersing carbon therein and arranged around the elastic rubber layer, or comprise a metallic roller shaft and a foam urethane rubber layer dispersing carbon therein. The roller shaft 10b of the charger roller 10 is held by bearing slide guide pawls 10d of the upper frame 14 via the slide bearing 10c so that it cannot be detached from the upper frame and it can slightly be moved toward the photosensitive drum 9. The roller shaft 10b is biased by a spring 10a so that the charger roller 10 is urged against the surface of the photosensitive drum 9. Thus, the charger means is constituted by the charger roller 10 incorporated into the upper frame 14 via the bearing 10c. In the image forming operation, when the charger roller 10 is driven by the rotation of the photosensitive drum 9, the surface of the photosensitive drum 9 is uniformly charged by applying the overlapped DC and AC voltage to the charger roller 10 as mentioned above.
Now, the voltage applied to the charger roller 10 will be described. Although the voltage applied to the charger roller 10 may be the DC voltage alone, in order to achieve the uniform charging, the vibration voltage obtained by overlapping the DC voltage and the AC voltage as mentioned above should be applied to the charger roller. Preferably, the vibration voltage obtained by overlapping the DC voltage having the peak-to-peak voltage value greater, by twice or more, than the charging start voltage when the DC voltage along is used, and the AC voltage is applied to the charger roller 10 to improve the uniform charging (refer to the Japanese Patent Laid-open Appln. No. 63-149669). The "vibration voltage" described herein means a voltage that the voltage value is periodically changed as a function of time and that preferably has the peak-to-peak voltage greater, by twice or more, than the charging start voltage when the surface of the photosensitive drum is charged only by the DC voltage. Further, the wave form of the vibration voltage is not limited to the sinusoidal wave, but may be rectangular wave, triangular wave or pulse wave. However, the sinusoidal wave not including the higher harmonic component is preferable in view of the reduction of the charging noise. The DC voltage may include a voltage having the rectangular wave obtained by periodically turning ON/OFF a DC voltage source, for example.
As shown in FIG. 34, the application of the voltage to the charger roller 10 is accomplished by urging one end 18c1 of a charging bias contact 18c against a charging bias contact pin of the image forming system as will be described later, and the other end 18c2 of the charging bias contact 18c is urged against the metallic roller shaft 10b, thereby applying the voltage to the charger roller 10. Incidentally, since the charger roller 10 is biased by the elastic contact 18c toward the right in FIG. 34, the charger roller bearing 10c disposed remote from the contact 18c has a hooked stopper portion 10c1. Further, a stopper portion 10e depending from the upper frame 14 is arranged near the contact 18c in order to prevent the excessive axial movement of the charger roller 10 when the process cartridge B is dropped or vibrated.
In the illustrated embodiment, with the arrangement as mentioned above, the voltage of 1.6-2.4 KVVpp,-600 VVDC (sinusoidal wave) is applied to the charger roller 10.
When the charger roller 10 is incorporated into the upper frame 14, first of all, the bearing 10c is supported by the guide pawls 10d of the upper frame 14 and then the roller shaft 10b of the charger roller 10 is fitted into the bearing 10c. And, when the upper frame 14 is assembled with the lower frame 15, the charger roller 10 is urged against the photosensitive drum 9, as shown in FIG. 21.
Incidentally, the bearing 10c for the charger roller 10 is made of conductive bearing material including a great amount of carbon filler, and the voltage is applied to the charger roller 10 from the charging bias contact 18c via the metallic spring 10a so that the stable charging bias can be supplied.
(Exposure Means)
The exposure means 11 serves to expose the surface of the photosensitive drum 9 uniformly charged by the charger roller 10 with a light image from the reading means 1. As shown in FIGS. 18 and 21, the upper frame 14 is provided with an opening 11a through which the light from the lens array 1c2 of the image forming system is illuminated onto the photosensitive drum 9. Incidentally, when the process cartridge B is removed from the image forming system A, if the photosensitive drum 9 is exposed by the ambient light through the opening 11a, it is feared that the photosensitive drum is deteriorated. To avoid this, a shutter member 11b is attached to the opening 11a so that when the process cartridge B is removed from the image forming system A the opening 11a is closed by the shutter member 11b and when the process cartridge is mounted within the image forming system the shutter member opens the opening 11a.
As shown in FIGS. 35A and 35B, the shutter member 11b has an L-shaped cross-section having a convex portion directing toward the outside of the cartridge, and is pivotally mounted on the upper frame 14 via pins 11b1. A torsion coil spring 11c is mounted around one of the pins 11b1 so that the shutter member 11b is biased by the coil spring 11c to close the opening Ha in a condition that the process cartridge B is dismounted from the image forming system A.
As shown in FIG. 35A, abutment portions 11b2 are formed on the outer surface of the shutter member 11b so that, when the process cartridge B is mounted within the image forming system A and an upper opening/closing cover 19 (FIG. 18) openable with respect to the body 16 of the image forming system is closed, a projection 19a formed on the cover 19 is abutted against the abutment portions 11b2, thereby rotating the shutter member 11b in a direction shown by the arrow e (FIG. 35B) to open the opening 11a.
In the opening and closing operation of the shutter member 11b, since the shutter member 11b has the L-shaped cross-section and the abutment portions 11b2 are disposed outwardly of the contour of the cartridge B and near the pivot pins 11b1, as shown in Figs. 21 and 35B, the shutter member 11b is abutted against the projection 19a of the cover 19 outwardly of the contour of the process cartridge B. As a result, even when the opening and closing angle of the shutter member 11b is small, a leading end of the rotating shutter member 11b is surely opened, thereby surely illuminating the light from the lens array 1c2 disposed above the shutter member onto the photosensitive drum to form the good electrostatic latent image on the surface of the photosensitive drum 9. By constituting the shutter member 11b as mentioned above, when the process cartridge B is inserted into the image forming system, it is not necessary to retard the cartridge B from the shutter opening projection 19a of the cover 19 of the image forming system, with the result that it is possible to shorten the stroke of the projection, thereby making the process cartridge B and the image forming system A small-sized.
(Developing Means)
Next, the developing means 12 will be explained. The developing means 12 serves to visualize the electrostatic latent image formed on the photosensitive drum 9 by the exposure means with toner as a toner image. Incidentally, in this image forming system A, although magnetic toner or non-magnetic toner can be used, in the illustrated embodiment, the developing means in the process cartridge B includes the magnetic toner as one-component magnetic developer.
Binder resin of the one-component magnetic toner used in the developing operation may be the following or a mixture of the following polymer of styrene and substitute thereof such as polystyrene and polyvinyltoluene; styrene copolymer such as styrene-propylene copolymer, styrene-vinyltoluene copolymer, styrene-vinylnaphthalene copolymer, styrene-acrylic acid ethyl copolymer or styrene-acrylic acid butyl copolymer; polymetylmethacrylate, polybuthymethacrylate, polyvinylacetate, polyethylene, polypropylene, polyvinylbutyral, polycrylic acid resin, rosin, modified rosin, turpentine resin, phenolic resin, aliphatic hydrocarbon resin, alicyclic hydrocarbon resin, aromatic petroleum resin, paraffin wax, carnauba wax or the like.
As for the coloring material added to the magnetic toner it may be known carbon black, copper phthalocyanine, iron black or the like. The magnetic fine particles contained in the magnetic toner may be of the material magnetizable when placed in the magnetic field, such as ferromagnetic powder of metal such as iron, cobalt, and nickel, powder of metal alloy or powder of compound such as magnetite or ferrite.
As shown in FIG. 21, the developing means 12 for forming the toner image with the magnetic toner has a toner reservoir 12a for containing the toner, and a toner feed mechanism 12b disposed within the toner reservoir 12a and adapted to feed out the toner. Further, the developing means is so designed that the developing sleeve 12d having a magnet 12c therein is rotated to form a thin toner layer on a surface of the developing sleeve. When the toner layer is being formed on the developing sleeve 12d, the developable frictional charging charges are applied to the electrostatic latent image on the photosensitive drum 9 by the friction between the toner and the developing sleeve 12d. Further, in order to regulate a thickness of the toner layer, a developing blade 12e is urged against the surface of the developing sleeve 12d. The developing sleeve 12d is disposed in a confronting relation to the surface of the photosensitive drum 9 with a gap of about 100-400 .mu.m therebetween.
As shown in FIG. 21, the magnetic toner feed mechanism 12b has feed members 12b1 made of polypropylene (PP), acrylobutadienestyrol (ABS), high-impact styrol (HIPS) or the like and reciprocally shiftable in a direction shown by the arrows f along a bottom surface of the toner reservoir 12a. Each feed member 12b1 has a substantial triangular cross-section and is provided with a plurality of long rod members extending along the rotation axis of the photosensitive drum (direction perpendicular to the plane of FIG. 21) for scraping the whole bottom surface of the toner reservoir 12a. The rod members are interconnected at both their ends to constitute an integral structure. Further, there are three feed members 12b1, and the shifting range of the feed members are selected to be greater than a bottom width of the triangular cross-section so that all of the toner on the bottom surface of the toner reservoir can be scraped. In addition, an arm member 12b2 is provided at its free end with a projection 12b6, thereby preventing the feed members 12b1 from floating and being disordered.
The feed member 12b1 has a lock projection 12b4 at its one longitudinal end, which projection is rotatably fitted into a slot 12b5 formed in the arm member 12b2. The arm member 12b2 is rotatably mounted on the upper frame 14 via a shaft 12b3 and is connected to an arm (not shown) disposed outside the toner reservoir 12a. Further, a drive transmitting means is connected to the feed members 12b1 so that, when the process cartridge B is mounted within the image forming system A, the driving force from the image forming system is transmitted to the feed members to swing the arm member 12b2 around the shaft 12b3 by a predetermined angle. Incidentally, as shown in FIG. 24 and the like, the feed members 12b1 and the arm member 12b2 may be integrally formed from resin such as polypropylene, polyamide or the like so that they can be folded at a connecting portion therebetween.
Accordingly, in the image forming operation, when the arm member 12b2 is rocked by the predetermined angle, the feed members 12b1 are reciprocally shifted along the bottom surface of the toner reservoir 12a in directions f between a condition shown by the solid lines and a condition shown by the broken lines. Consequently, the toner situated near the bottom surface of the toner reservoir 12a is fed toward the developing sleeve 12d by the feed members 12b1. In this case, since each feed member 12b1 has the triangular cross-section, the toner is scraped by the feed members and is gently fed along inclined surfaces of the feed members 12b1. Thus, the toner near the developing sleeve 12d is hard to be agitated, and, therefore, the toner layer formed on the surface of the developing sleeve 12d is hard to be deteriorated.
Further, as shown in FIG. 21, a lid member 12f of the toner reservoir 12a is provided with a depending member 12f1. A distance between a lower end of the depending member 12f1 and the bottom surface of the toner reservoir is selected so as to be slightly greater than a height of the triangular cross-section of each toner feed member 12b1. Accordingly, the toner feed member 12b1 is reciprocally shifted between the bottom surface of the toner reservoir and the depending member 12f1, with the result that, if the feed member 12b1 tries to float from the bottom surface of the toner reservoir, such floating is limited or regulated, thus preventing the floating of the feed members 12b1.
Incidentally, the image forming system A according to the illustrated embodiment can also receive a process cartridge including the non-magnetic toner. In this case, the toner feed mechanism is driven to agitate the non-magnetic toner near the developing sleeve 12d.
That is to say, when the non-magnetic toner is used, as shown in FIG. 36, an elastic roller 12g rotated in a direction same as that of the developing sleeve 12d feeds the non-magnetic toner fed from the toner reservoir 12a by the toner feed mechanism 12h toward the developing sleeve 12d. In this case, at a nip between the developing sleeve 12d and the elastic roller 12g, the toner on the elastic roller 12g is frictionally charged by the sliding contact between the toner and the developing sleeve 12d to be adhered onto the developing sleeve 12d electrostatically. Thereafter, during the rotation of the developing sleeve 12d, the non-magnetic toner adhered to the developing sleeve 12d enters into an abutment area between the developing blade 12e and the developing sleeve 12d to form the thin toner layer on the developing sleeve, and the toner is frictionally charged by the sliding contact between the toner and the developing sleeve with the polarity sufficiently to develop the electrostatic latent image. However, when the toner remains on the developing sleeve 12d, the remaining toner is mixed with the new toner fed to the developing sleeve 12d and is fed to the abutment area between the developing sleeve and the developing blade 12e. The remaining toner and the new toner are frictionally charged by the sliding contact between the toner and the developing sleeve 12d. In this case, however, although the new toner is charged with the proper charge, since the remaining toner is further charged from the condition that it has already been charged with the proper charge, it is over-charged. The over-charged or excessively charged toner has the adhesion force (to the developing sleeve 12d) stronger than that of the properly charged toner, thus becoming harder to use in the developing operation.
To avoid this, in the illustrated embodiment, regarding the process cartridge containing the non-magnetic toner, as shown in FIG. 36, the non-magnetic toner feed mechanism 12h comprises a rotary member 12h1 disposed in the toner reservoir 12a, which rotary member 12h1 has an elastic agitating vane 12h2. When the non-magnetic toner cartridge is mounted within the image forming system A, the drive transmitting means is connected to the rotary member 12h1 so that the latter is rotated by the image forming system in the image forming operation. In this way, when the image is formed by using the cartridge containing the non-magnetic toner and mounted within the image forming system, the toner in the toner reservoir 12a is greatly agitated by the agitating vane 12h2. As a result, the toner near the developing sleeve 12d is also agitated to be mixed with the toner in the toner reservoir 12a, thereby dispersing the charging charges removed from the developing sleeve 12d in the toner within the toner reservoir to prevent the deterioration of the toner.
By the way, the developing sleeve 12d on which the toner layer is formed is arranged in a confronting relation to the photosensitive drum 9 with a small gap therebetween (about 300 .mu.m regarding the process cartridge containing the magnetic toner, or about 200 .mu.m regarding the process cartridge containing the non-magnetic toner). Accordingly, in the illustrated embodiment, abutment rings each having an outer diameter greater than that of the developing sleeve by an amount corresponding to the small gap are arranged in the vicinity of both axial ends of the developing sleeve 12d and outside the toner layer forming area so that these rings are abutted against the photosensitive drum 9 at zones outside the latent image forming area.
Now, the positional relation between the photosensitive drum 9 and the developing sleeve 12d will be explained. FIG. 37 is a longitudinal sectional view showing a positional relation between the photosensitive drum 9 and the developing sleeve 12d and a structure for pressurizing the developing sleeve, FIG. 38A is a sectional view taken along the line 38A--38A of FIG. 37, and FIG. 38B is a sectional view taken along the line 38B--38B of FIG. 37.
As shown in FIG. 37, the developing sleeve 12d on which the toner layer is formed is arranged in a confronting relation to the photosensitive drum 9 with the small gap therebetween (about 200-300 .mu.m). In this case, the photosensitive drum 9 is rotatably mounted on the lower frame 15 by rotatably supporting a rotary shaft 9f of the flange gear 9c at the one end of the drum via a supporting member 33. The other end of the photosensitive drum 9 is also rotatably mounted on the lower frame 15 via a bearing portion 26a of the bearing member 26 secured to the lower frame. The developing sleeve 12d has the above-mentioned abutment rings 12d1 each having the outer diameter greater than that of the developing sleeve by the amount corresponding to the small gap and arranged in the vicinity of both axial ends of the developing sleeve and outside the toner layer forming area so that these rings are abutted against the photosensitive drum 9 at the zones outside the latent image forming area.
Further, the developing 12d is rotatably supported by sleeve bearings 12i disposed between the abutment rings 12d1 in the vicinity of both axial ends of the developing sleeve and outside the toner layer forming area, which sleeve bearings 12i are mounted on the lower frame 15 in such a manner that they can be slightly shifted in directions shown by the arrow g in FIG. 37. Each sleeve bearing 12i has a rearwardly extending projection around which an urging spring 12j having one end abutted against the lower frame 15 is mounted. Consequently, the developing sleeve 12d is always biased toward the photosensitive drum 9 by these urging springs. With this arrangement, the abutment rings 12da are always abutted against the photosensitive drum 9, with the result that the predetermined gap between the developing sleeve 12d and the photosensitive drum 9 is always maintained, thereby transmitting the driving force to the flange gear 9c of the photosensitive drum 9 and a sleeve gear 12k of the developing sleeve 12d meshed with the flange gear 9c.
The sleeve gear 12k also constitutes a flange portion of the developing sleeve 12d. That is to say, according to the illustrated embodiment, the sleeve gear 12k and the flange portion are integrally formed from resin material (for example, polyacetylene resin). Further, a metallic pin 12d2 having a small diameter (for example, made of stainless steel) and having one end rotatably supported by the lower frame 15 is press-fitted and secured to the sleeve gear 12k (flange portion) at its center. This metallic pin 12d2 acts as a rotary shaft at one end of the developing sleeve 12d. According to the illustrated embodiment, since the sleeve gear and the flange portion can be integrally formed from resin, it is possible to facilitate the manufacturing of the developing sleeve and to make the developing sleeve 12d and the process cartridge B light-weight.
Now, the sliding directions of the sleeve bearings 12i will be explained with reference to FIG. 39. First of all, the driving of the developing sleeve 12d will be described. When the driving force is transmitted from the drive source (drive motor 54) of the image forming system to the flange gear 9c and then is transmitted from the flange gear 9c to the sleeve gear 12k, the meshing force between the gears is directed to a direction inclined or offset from a tangential line contacting a meshing pitch circle of the flange gear 9c and a meshing pitch circle of the sleeve gear 12k by a pressure angle (20.degree. in the illustrated embodiment). Thus, the meshing force is directed to a direction shown by the arrow P in FIG. 39 (.theta..congruent.20.degree.). In this case, if the sleeve bearings 12i are slid in a direction parallel to a line connecting the center of rotation of the photosensitive drum 9 and the center of rotation of the developing sleeve 12d, when the meshing force P is divided into a force component Ps of a horizontal direction parallel with the sliding direction and a force component Ph of a vertical direction perpendicular to the sliding direction, as shown in FIG. 39, the force component of the horizontal direction parallel with the sliding direction is directed away from the photosensitive drum 9. As a result, regarding the driving of the developing sleeve 12d, the distance between the photosensitive drum 9 and the developing sleeve 12d is easily varied in accordance with the meshing force between the flange gear 9c and the sleeve gear 12k, with the result that the toner on the developing sleeve 12d cannot be moved to the photosensitive drum 9 properly, thus worsening the developing ability.
To avoid this, in the illustrated embodiment, as shown in FIG. 38A, in consideration of the transmission of the driving force from the flange gear 9c to the sleeve gear 12k, the sliding direction of the sleeve bearing 12i at the driving side (side where the sleeve gear 12k is disposed) is coincided with directions shown by the arrow Q. That is to say, an angle .phi. formed between the direction of the meshing force P (between the flange gear 9c and the sleeve gear 12k) and the sliding direction is set to have a value of about 90.degree. (92.degree. in the illustrated embodiment). With this arrangement, the force component Ps of the horizontal direction parallel with the sliding direction is negligible, and, in the illustrated embodiment, the force component Ps acts to slightly bias the developing sleeve 12d toward the photosensitive drum 9. In such a case, the developing sleeve 12d is pressurized by an amount corresponding to spring pressure a of the urging springs 12j to maintain the distance between the photosensitive drum 9 and the developing sleeve 12d constant, thereby ensuring the proper development.
Next, the sliding direction of the slide bearing 12i at the non-driving side (side where the sleeve gear 12k is not arranged) will be explained. At the non-driving side, unlike the above-mentioned driving side, since the slide bearing 12i does not receive a driving force, as shown in FIG. 38B, the sliding direction of the slide bearing 12i is selected to be substantially parallel with a line connecting a center of the photosensitive drum 9 and a center of the developing sleeve 12d.
In this way, when the developing sleeve 12d is pressurized toward the photosensitive drum 9, by changing the urging angle for urging the developing sleeve 12d at the driving side from that at the non-driving side, the positional relation between the developing sleeve 12d and the photosensitive drum 9 is always maintained properly, thus permitting the proper development.
Incidentally, the sliding direction of the slide bearing 12i at the driving side may be set to be substantially parallel with the line connecting the center of the photosensitive drum 9 and the center of the developing sleeve 12d as in the case of the non-driving side. That is to say, as described in the above-mentioned embodiment, at the driving side, since the developing sleeve 12d is urged away from the photosensitive drum 9 by the force component Ps (of the meshing force between the flange gear 9c and the sleeve gear 12k) directing toward the sliding direction of the slide bearing 12i, in this embodiment, the urging force of the urging spring 12j at the driving side may be set to have a value greater than that at the non-driving side by an amount corresponding to the force component Ps. That is, when the urging force of the urging spring 12j to the developing sleeve 12d at the non-driving side is P, the urging force P2 of the urging spring 12j at the driving side is set to have a relation P2=P1+Ps, with the result that the developing sleeve 12d is always subjected to the proper urging force, thus ensuring the constant distance between the developing sleeve and the photosensitive drum 9.
(Cleaning Means)
The cleaning means 13 serves to remove the residual toner remaining on the photosensitive drum 9 after the toner image on the photosensitive drum 9 has been transferred to the recording medium 4 by the transfer means 6. As shown in FIG. 21, the cleaning means 13 comprises an elastic cleaning blade 13a contacting with the surface of the photosensitive drum 9 and adapted to remove or scrape off the residual toner remaining on the photosensitive drum 9, a squeegee sheet 13b slightly contacting with the surface of the photosensitive drum 9 and disposed below the cleaning blade 13a to receive the removed toner, and a waste toner reservoir 13c for collecting the waste toner received by the sheet 13b. Incidentally, the squeegee sheet 13b is slightly contacted with the surface of the photosensitive drum 9 and the serves to permit the passing of the residual toner remaining on the photosensitive drum, but to direct the toner removed from the photosensitive drum 9 by the cleaning blade 13a to a direction away from the surface of the photosensitive drum 9.
Now, a method for attaching the squeegee sheet 13b will be described. The squeegee sheet 13b is adhered to an attachment surface 13d of the waste toner reservoir 13c via both-side adhesive tape 13e. In this case, the waste toner reservoir 13c is made of resin material (for example, high-impact styrol (HIPS) or the like) and has a slightly uneven surface. Thus, as shown in FIG. 40, if the both-sided adhesive tape 13e is merely stuck to the attachment surface 13d and the squeegee sheet 13b is merely attached to the adhesive tape 13e, it is feared that a free edge of the squeegee sheet 13b (to be contacted with the photosensitive drum 9) becomes tortuous as shown by x. If such a tortuous edge x of the squeegee sheet 13b is generated, the squeegee sheet 13b does not closely contact with the surface of the photosensitive drum 9, so that it cannot surely receive the toner removed by the cleaning blade 13a.
In order to avoid this, it is considered that, when the squeegee sheet 13b is attached to the attachment surface, as shown in FIG. 41A, the attachment surface 13d at a lower portion of the waste toner reservoir is pulled downwardly by a pulling tool 20 to elastically deform the attachment surface to a curvature and then the squeegee sheet 13b is stuck to the curved attachment surface, and, thereafter the curvature of the attachment surface is released to apply the tension to the free edge of the squeegee sheet 13b, thereby preventing the free edge from becoming tortuous. However, in the recent small-sized process cartridges B, since the dimension of the attachment surface 13d is small, if the squeegee sheet 13b is stuck to the curved attachment surface 13d, as shown in FIG. 41A, both lower ends or corners 13b1 of the squeegee sheet 13b will be protruded from the attachment surface 13d downwardly. And, when the squeegee sheet 13b is protruded downwardly from the attachment surface 13d, as apparent from the sectional view of FIG. 18, it is feared that the recording medium 4 is interfered with by the protruded squeegee sheet 13b.
Further, if the squeegee sheet 13b is attached to the curved attachment surface 13d, as shown in FIG. 41A, the both-sided adhesive tape 13e will be protruded from the lower end of the squeegee sheet 13b. Thus, in this condition, when the squeegee sheet 13b is urged against the both-sided adhesive tape 13e by a sticking tool 21, as shown in FIG. 41B, the protruded portion of the both-sided adhesive tape 13e is stuck to the sticking tool 21, with the result that, when the sticking tool 21 is removed, as shown in FIG. 41C, the both-sided adhesive tape 13e is peeled from the attachment surface 13d, thus causing the poor attachment of the squeegee sheet 13b.
To avoid this, in the illustrated embodiment, as shown in FIG. 42A, the configuration of the lower end of the squeegee sheet 13b becomes substantially the same as the curvature configuration of the attachment surface 13d which has been curved by the pulling tool 20. That is to say, a width of the squeegee sheet 13b is varied from both longitudinal ends to a central portion so that the latter becomes greater than the former (for example, width at the central portion is about 7.9 mm, and width at both ends is about 7.4 mm). In this way, when the squeegee sheet 13b is attached to the attachment surface, the curved both-sided adhesive tape 13e does not protrude from the squeegee sheet 13b. Further, when the pulling tool 20 is removed to release the curvature of the attachment surface 13d thereby to apply the tension to the upper edge of the squeegee sheet 13b as shown in FIG. 42B, the lower end of the squeegee sheet does not protrude from the attachment surface 13d downwardly. Therefore, the above-mentioned interference between the recording medium 4 and the squeegee sheet 13b and the poor attachment of the squeegee sheet 13b can be prevented.
Incidentally, in view of the workability and the service life of a working tool, it is desirable that the lower edge of the squeegee sheet 13b is straight. Thus, as shown in FIG. 43, the width of the squeegee sheet 13b may be varied straightly so that the width at the central portion becomes greater than those at both longitudinal ends in correspondence to the amount of the curvature of the attachment surface 13d. In the above-mentioned embodiment, while the attachment surface 13d was curved by pulling it by the pulling tool 20, it is to be understood that, as shown in FIG. 44, the attachment surface 13d may be curved by pushing toner reservoir partition plates 13c1 integrally formed with the attachment surface 13d by pushing tools 20a.
Further, in the illustrated embodiment, while the squeegee sheet attachment surface 13d was formed on the lower portion of the waste toner reservoir 13c, the squeegee sheet 13b may be stuck to a metallic plate attachment surface independently formed from the waste toner reservoir 13c and then metallic plate may be incorporated into the waste toner reservoir 13c.
Incidentally, in the illustrated embodiment, the squeegee sheet 13b is made of polyethylene terephthalate (PET) and has a thickness of about 38 .mu.m, a length of about 241.3 mm, a central width of about 7.9 mm, end widths of about 7.4 mm and an appropriate radius of curvature of about 14556.7 mm.
(Upper and Lower Frames)
Next, the upper and lower frames 14, 15 constituting the housing of the process cartridge B will be explained. As shown in FIGS. 24 and 25, the photosensitive drum 9, the developing sleeve 12d and developing blade 12e of the developing means 12, the cleaning means 13 are provided in the lower frame 15. On the other hand, as shown in FIGS. 24 and 26, the charger roller 10, the toner reservoir 12a of the developing means 12 and the toner feed mechanism 12b are provided in the upper frame 14.
In order to assemble the upper and lower frames 14, 15 together, four pairs of locking pawls 14a are integrally formed with the upper frame 14 and are spaced apart from each other equidistantly in a longitudinal direction of the upper frame. Similarly, locking openings 15a and locking projections 15b for engaging by the locking pawls 14a are integrally formed on the lower frame 15. Accordingly, when the upper and lower frames 14, 15 are forcibly urged against each other to engage the locking pawls 14a by the corresponding locking openings 15a and locking projections 15b, the upper and lower frames 14, 15 are interconnected. Incidentally, in order to ensure the interconnection between the upper and lower frames, as shown in FIG. 25, a locking pawl 15c and a locking opening 15d are formed near both longitudinal ends of the lower frame 15, respectively, whereas, as shown in FIG. 26, a locking opening 14b (to be engaged by the locking pawl 15c) and a locking pawl 14c (to be engaged by the locking opening 15d) are formed near both longitudinal ends of the upper frame 14, respectively.
When the parts constituting the process cartridge B are separately contained within the upper and lower frames 14, 15 as mentioned above, by arranging the parts which should be positioned with respect to the photosensitive drum 9 (for example, developing sleeve 12d, developing blade 12e and cleaning blade 13a) within the same frame (lower frame 15 in the illustrated embodiment), it is possible to ensure the excellent positioning accuracy of each part and to facilitate the assembling of the process cartridge B. Further, as shown in FIG. 25, fitting recesses 15n are formed in the lower frame 15 in the vicinity of one lateral edge thereof. On the other hand, as shown in FIG. 26, fitting projections 14h (to be fitted into the corresponding fitting recesses 15n) are formed on the upper frame 14 in the vicinity of one lateral edge thereof at intermediate locations between the adjacent locking pawls 14a.
Further, in the illustrated embodiment, as shown in FIG. 25, fitting projections 15e are formed on the lower frame 15 near two corners thereof, whereas fitting recesses 15f are formed in the lower frame near the other two corners. On the other hand, as shown in FIG. 26, fitting recesses 14d (to be engaged by the corresponding fitting projections 15e) are formed in the upper frame 14 near two corners thereof, whereas fitting projections 14e (to be fitted into the corresponding fitting recesses 15f) are formed in the lower frame near the other two corners. Accordingly, when the upper and lower frames 14, 15 are interconnected, by fitting the fitting projections 14h, 14e, 15e (of the upper and lower frames 14, 15) into the corresponding fitting recesses 15n, 15f, 14d, the upper and lower frames 14, 15 are firmly interconnected to each other so that, even if a torsion force is applied to the interconnected upper and lower frames 14, 15, they are not disassembled.
Incidentally, the positions of the above-mentioned fitting projections and fitting recesses may be changed so long as the interconnected upper and lower frames 14, 15 are not disassembled by any torsion force applied thereto.
Further, as shown in FIG. 26, a protection cover 22 is rotatably mounted on the upper frame 14 via pivot pins 22a. The protection cover 22 is biased toward a direction shown by the arrow h in FIG. 26 by torsion coil springs (not shown) arranged around the pivot pins 22a, so that the projection cover 22 closes or covers the photosensitive drum 9 in the condition that the process cartridge B is removed from the image forming system A as shown in FIG. 21.
More specifically, as shown in FIG. 1, the photosensitive drum 9 is so designed that it is exposed from an opening 15g formed in the lower frame 15 to be opposed to the transfer roller 6 in order to permit the transferring of the toner image from the photosensitive drum onto the recording medium 4. However, in the condition that the process cartridge B is removed from the image forming system A, if the photosensitive drum 9 is exposed to the atmosphere, it will be deteriorated by the ambient light and the dirt and the like will be adhered to the photosensitive drum 9. To avoid this, when the process cartridge B is dismounted from the image forming system A, the opening 15g is closed by the protection cover 22, thereby protecting the photosensitive drum 9 from the ambient light and dirt. Incidentally, when the process cartridge B is mounted within the image forming system A, the protection cover 22 is rotated by a rocking mechanism (not shown) to expose the photosensitive drum 9 from the opening 15g.
Further, as apparent from FIG. 18, in the illustrated embodiment, the lower surface of the lower frame 15 also acts as a guide for conveying the recording medium 4. The lower surface of the lower frame is formed as both side guide portions 15h1 and a stepped central guide portion 15h2 (FIG. 23). The longitudinal length (i.e., distance between the steps) of the central guide portion 15h2 is about 102-120 mm (107 mm in the illustrated embodiment) which is slightly greater than a width (about 100 mm), and the depth of the step is selected to have a value of about 0.8-2 mm. With this arrangement, the central guide portion 15h2 increases the conveying space for the recording medium 4, with the result that, even when a thicker and resilient sheet such as a post card, visiting card or envelope is used as the recording medium 4, such thicker sheet does not interfere with the guide surface of the lower frame 15, thereby preventing the recording medium from jamming. On the other hand, when a thin sheet having a greater width than that of the post card such as a plain sheet is used as the recording medium, since such sheet (recording medium) is guided by the both side guide portions 15h1, it is possible to convey the sheet without floating.
Now, the lower surface of the lower frame 15 acting as the convey guide for the recording medium will be described more concretely. As shown in FIG. 45, both side guide portions 15h1 can be flexed by an amount La (=5-7 mm) with respect to a tangential direction X regarding a nip N between the photosensitive drum 9 and the transfer roller 6. Since the both side guide portions 15h1 are formed on the lower surface of the lower frame 15 designed to provide the required space between the lower frame and the developing sleeve 12d and the required space for sufficiently supplying the toner to the developing sleeve, such guide portions are determined by the position of the developing sleeve 12d selected to obtain the optimum developing condition. If the lower surfaces of the side guide portions are approached to the tangential line X, the thickness of the lower portion of the lower frame 15 is decreased, thus causing a problem regarding the strength of the process cartridge B.
Further, the position of a lower end 13f of the cleaning means 13 is determined by the positions of the cleaning blade 13a, the squeegee sheet 13b and the like constituting the cleaning means 13 as described later, and is so selected to provide a distance Lb (=3-5 mm) preventing the interference with the recording medium 4 being fed. Incidentally, in the illustrated embodiment, as angle .beta. between a vertical line passing through the rotational center of the photosensitive drum 9 shown in FIG. 45, and a line connecting the rotational center of the photosensitive drum and the rotational center of the transfer roller 6 is selected to have a value of 5-20 degrees.
In consideration of the above affairs, by providing the recess or step having a depth Lc (=1-2 mm) only in the central guide portion 15h2 to approach this guide portion to the tangential line X, it is possible to feed the thicker and resilient recording medium 4 smoothly without reducing the strength of the lower frame 15. Incidentally, in most cases, since the thicker and resilient recording medium 4 such as the visiting card, envelope or the like which is narrower than the post card under the general specification of the image forming system, so long as the width of the stepped or recessed central guide portion 15h2 is selected to be slightly greater than that of the post card, there is no problem in practical use.
Further, regulating projections 15i protruding downwardly are formed on the outer surface of the lower frame 15 in areas outside of the recording medium guiding zone. The regulating projections 15i each protrudes from the guide surface of the lower frame for the recording medium 4 by about 1 mm. With this arrangement, even if the process cartridge B is slightly lowered for some reason during the image forming operation, since the regulating projections 15i are abutted against a lower guide member 23 (FIG. 18) of the body 16 of the image forming system, the further lowering of the process cartridge can be prevented. Accordingly, a space of at least 1 mm is maintained between the lower guide member 23 and the lower guide surface of the lower frame 15 to provide a convey path for the recording medium 4, thereby conveying the recording medium without jamming. Further, as shown in FIG. 18, a recess 15j is formed in the lower surface of the lower frame 15 so as not to interfere with the regist roller 5c2. Thus, when the process cartridge B is mounted within the image forming system A, since it can be mounted near the regist roller 5c2, the whole image forming system can be small-sized.
(Assembling of Process Cartridge)
Next, the assembling of the process cartridge having the above-mentioned construction will be explained. In FIG. 46, toner leak preventing seals S having a regular shape and made of Moltopren (flexible polyurethane, manufactured by INOAC Incorp.) rubber for preventing the leakage of toner are stuck on ends of the developing means 12 and of the cleaning means 13 and on the lower frame 15. Incidentally, the toner leak preventing seals S each may not have a regular shape. Alternatively, toner leak preventing seals may be attached by forming recesses in portions (to be attached) of the seals and by pouring liquid material which becomes elastomer when solidified into the recesses.
A blade support member 12e1 to which the developing sleeve 12e is attached and a blade support member 13a1 to which the cleaning blade 13a is attached are attached to the lower frame 15 by pins 24a, 24b, respectively. According to the illustrated embodiment, as shown by the phantom lines in FIG. 46, the attachment surfaces of the blade support members 12e1, 13a1 may be substantially parallel to each other so that the pins 24a, 24b can be driven from the same direction. Thus, when a large number of process cartridges B are manufactured, the developing blades 12e and the cleaning blades 13a can be continuously attached by the pins by using an automatic device. Further, the assembling ability for the blades 12e, 13a can be improved by providing a space for a screw driver, and the shape of a mold can be simplified by aligning the housing removing direction from the mold, thereby achieving cost reduction.
Incidentally, the developing blade 12e and the cleaning blade 13a may not be attached by the pins (screws), but may be attached to the lower frame 15 by adhesives 24c, 24d as shown in FIG. 47. Also in this case, when the adhesives can be applied from the same direction, the attachment of the developing blade 12e and the cleaning blade 13a can be automatically and continuously performed by using an automatic device.
After the blades 12e, 13a have been attached as mentioned above, the developing sleeve 12d is attached to the lower frame 15. Then, the photosensitive drum 9 is attached to the lower frame 15. To this end, in the illustrated embodiment, guide members 25a, 25b are attached to surfaces (opposed to the photosensitive drum) of the blade support members 12e1, 13a1, respectively, at zones outside of the longitudinal image forming area C (FIG. 49) of the photosensitive drum 9. (Incidentally, in the illustrated embodiment, the guide members 25a, 25b are integrally formed with the lower frame 15). A distance between the guide members 25a and 25b is set to be greater than the outer diameter D of the photosensitive drum 9. Thus, after the various parts such as the developing blade 12e, cleaning blade 13a and the like have been attached to the lower frame 15, as shown in FIG. 48, the photosensitive drum 9 can be finally attached to the lower frame while guiding both longitudinal ends (outside of the image forming area) of the photosensitive drum by the guide members 25a, 25b. That is to say, the photosensitive drum 9 is attached to the lower frame 15 while slightly flexing the cleaning blade 13a and/or slightly retarding and rotating the developing sleeve 12d.
If the photosensitive drum 9 is firstly attached to the lower frame 15 and then the blades 12e, 13a and the like are attached to the lower frame, it is feared that the surface of the photosensitive drum 9 is damaged during the attachment of the blades 12e, 13a and the like. Further, during the assembling operation, it is difficult or impossible to check the attachment positions of the developing blade 12e and the cleaning blade 13a and to measure the contacting pressures between the blades and the photosensitive drum. In addition, although lubricant must be applied to the blades 12e, 13a to prevent the increase in torque and/or the blade turn-up due to the close contact between the initial blades 12e, 13a (at the non-toner condition) and the photosensitive drum 9 and the developing sleeve 12d before the blades 12e, 13a are attached to the lower frame 15, such lubricant is likely to drop off from the blades during the assembling of the blades. However, according to the illustrated embodiment, since the photosensitive drum 9 is finally attached to the lower frame, the above-mentioned drawbacks and problems can be eliminated.
As mentioned above, according to the illustrated embodiment, it is possible to check the attachment positions of the developing means 12 and the cleaning means 13 in the condition that these means 12, 13 are attached to the frames, and to prevent the image forming area of the photosensitive drum from being damaged or scratched during the assembling of the drum. Further, since it is possible to apply the lubricant to the blades in the condition that these means 12, 13 are attached to the frames, the dropping of the lubricant can be prevented, thereby preventing the occurrence of the increase in torque and/or the blade turn-up due to the close contact between the developing blade 12e and the developing sleeve 12d, and the cleaning blade 13a and the photosensitive drum 9.
Incidentally, in the illustrated embodiment, while the guide members 25a, 25b were integrally formed with the lower frame 15, as shown in FIG. 50, projections 12e2, 13a2 may be integrally formed on the blade support members 12e1, 13a1 or other guide members may be attached to the blade support members at both longitudinal end zones of the blade support members outside of the image forming area of the photosensitive drum 9, so that the photosensitive drum 9 is guided by these projections or other guide members during the assembling of the drum.
After the developing sleeve 12d, developing blade 12e, cleaning blade 13a and photosensitive drum 9 have been attached to the lower frame 15 as mentioned above, as shown in FIG. 51 (perspective view) and FIG. 52 (sectional view), the bearing member 26 is incorporated to rotatably support one of the ends of the photosensitive drum 9 and of the developing sleeve 12d. The bearing member 26 is made of anti-wear material such as polyacetal and comprises a drum bearing portion 26a to be fitted on the photosensitive drum 9, a sleeve bearing portion 26b to be fitted on the outer surface of the developing sleeve 12d, and a D-cut hole portion 26c to be fitted on an end of a D-cut magnet 12c. Alternatively, the sleeve bearing portion 26b may be fitted on the outer surface of the sleeve bearing 12i supporting the outer surface of the developing sleeve 12d or may be fitted between slide surfaces 15Q of the lower frame 15 which are fitted on the outer surface of the slide bearing 12i.
Accordingly, when the drum bearing portion 26a is fitted on the end of the photosensitive drum 9 and the end of the magnet 12c is inserted into the D-cut hole portion 26c and the developing sleeve 12d is inserted between into the sleeve bearing portion 26b and the bearing member 26 is fitted into the side of the lower frame 15 while sliding it in the longitudinal direction of the drum, the photosensitive drum 9 and the developing sleeve 12d are rotatably supported. Incidentally, as shown in FIG. 51, the earthing contact 18a is attached to the bearing member 26, and, when the bearing member 26 is fitted into the side of the lower frame, the earthing contact 18a is contacted with the aluminum drum core 9a of the photosensitive drum 9 (see FIG. 27). Further, the developing bias contact 18b is also attached to the bearing member 26, and, when the bearing member 26 is attached to the developing sleeve 12d, the bias contact 18b is contacted with a conductive member 18d contacting the inner surface of the developing sleeve 12d.
In this way, by rotatably supporting the photosensitive drum 9 and the developing sleeve 12d by the single bearing member 26, it is possible to improve the positional accuracy of the elements 9, 12d, and to reduce the number of parts, thereby facilitating the assembling operation and achieving cost reduction. Further, since the positioning of the photosensitive drum 9 and the positioning of the developing sleeve 12d and the magnet 12c can be performed by using the single member, it is possible to determine the positional relation between the photosensitive drum 9 and the magnet 12c with high accuracy, with the result that it is possible to maintain a magnetic force regarding the surface of the photosensitive drum 9 constant, thus obtaining a high quality image. In addition, since the earthing contact 18a for earthing the photosensitive drum 9 and the developing bias contact 18b for applying the developing bias to the developing sleeve 12d are attached to the bearing member 26, the compactness of the parts can be achieved effectively, thus making the process cartridge B small-sized effectively.
Further, by providing (on the bearing member 26) supported portions for positioning the process cartridge B within the image forming system when the process cartridge is mounted within the image forming system, the positioning of the process cartridge B regarding the image forming system can be effected accurately. Furthermore, as apparent from Figs.22 and 23, an outwardly protruding U-shaped projection, i.,e, drum shaft portion 26d (FIG. 37) is also formed on the bearing member 26. When the process cartridge B is mounted within the body 16 of the image forming system, the drum shaft portion 26d is supported by a shaft support member 34 as will be described later, thereby positioning the process cartridge B. In this way, since the process cartridge B is positioned by the bearing member 26 for directly supporting the photosensitive drum 9 when the cartridge is mounted within the system body 16, the photosensitive drum 9 can be accurately positioned regardless of the manufacturing and/or assembling errors of other parts.
Further, as shown in FIG. 52, the other end of the magnet 12c is received in an inner cavity formed in the sleeve gear 12k, and an outer diameter of the magnet 12c is so selected as to be slightly smaller than an inner diameter of the cavity. Thus, at the sleeve gear 12k, the magnet 12c is held in the cavity without any play and is maintained in a lower position in the cavity by its own weight or is biased toward the blade support member 12e1 made of magnetic metal such as ZINKOTE (zinc plated steel plate, manufactured by shin Nippon Steel Incorp.) by a magnetic force of the magnet 12c. In this way, since the sleeve gear 12k and the magnet 12c are associated with each other without any play, the friction torque between the magnet 12c and the rotating sleeve gear 12k can be reduced, thereby reducing the torque regarding the process cartridge.
On the other hand, as shown in FIG. 48, the charger roller 10 is rotatably mounted within the upper frame 14, and the shutter member 11b, the protection cover 22 and the toner feed mechanism 12b are also attached to the upper frame 15. The opening 12a1 for feeding out the toner from the toner reservoir 12a to the developing sleeve 12d is closed by a cover film 28 (FIG. 53) having a tear tape 27. Further, the lid member 12f is secured to the upper frame, and, thereafter, the toner is supplied to the toner reservoir 12a through the filling opening 12a3 and then the filling opening 12a3 is closed by the lid 12a2, thus sealing the toner reservoir 12a.
Incidentally, as shown in FIG. 53, the tear tape 27 of the cover film 28 stuck around the opening 12a1 extends from one longitudinal end (right end in FIG. 53) of the opening 12a1 to the other longitudinal end (left end in FIG. 53) and is bent at the other end and further extends along a gripper portion 14f formed on the upper frame 14 and protrudes therefrom outwardly.
Next, the process cartridge B is assembled by interconnecting the upper and lower frames 14, 15 via the above-mentioned locking pawls and locking openings or recesses. In this case, as shown in FIG. 54, the tear tape 27 is exposed between the gripper portion 14f of the upper frame 14 and a gripper portion 15k of the lower frame 15. Therefore, when a new process cartridge B is used, the operator pulls a protruded portion of the tear tape 27 exposed between the gripper portions 14f, 15k to peel the tear tape 27 from the cover film 28 so as to open the opening 12a1, thus permitting the movement of the toner in the toner reservoir 12a toward the developing sleeve 12d. Thereafter, the process cartridge is mounted within the image forming system A.
As mentioned above, by exposing the tear tape 27 between the gripper portions 14f, 15k of the upper and lower frames 14, 15, the tear tape 27 can easily be exposed from the process cartridge in assembling the upper and lower frames 14, 15. The gripper portions 14f, 15k are utilized when the process cartridge B is mounted within the image forming system. Thus, if the operator forgets to remove the tear tape 27 before the process cartridge is mounted within the image forming system, since he must grip the gripper portions in mounting the process cartridge, he will know the existence of the non-removed tear tape 27. Further, when the color of the tear tape 27 is clearly differentiated from the color of the frames 14, 15 (for example, if the frames are black, a white or yellow tear tape 27 is used), the noticeability is improved, thus reducing missing of the removal of the tear tape.
Further, for example, when a U-shaped guide rib for temporarily holding the tear tape 27 is provided on the gripper portion 14f of the upper frame 14, it is possible to surely and easily expose the tear tape 27 at a predetermined position during the interconnection between the upper and lower frames 14, 15. Incidentally, when the process cartridge B is assembled by interconnecting the upper and lower frames 14, 15, since the recess 15j for receiving the regist roller 5c2 is formed in the outer surface of the lower frame 15, as shown in FIG. 55, the operator can surely grip the process cartridge B by inserting his fingers into the recess 15j. Further, in the illustrated embodiment, as shown in FIG. 23, slip preventing ribs 14i are formed on the process cartridge B so that, when the operator can easily grip the process cartridge by hooking his fingers against the ribs. Incidentally, since the recess for receiving (preventing the contact with) the regist roller 5c2 is formed in the lower frame 15 of the process cartridge B, it is possible to make the image forming system more small-sized.
Further, as shown in FIG. 23 since the recess 15j is formed along and in the vicinity of the locking pawls 14aand the locking openings 15b through which the upper and lower frames 14, 15 are interconnected, when the operator grips the process cartridge B by hooking his fingers against the recess 15j, the gripping force from the operator acts toward the locking direction, thus surely interlocking the locking pawls 14a and the locking openings 15b.
Now, the assembling and shipping line for the process cartridge B will be explained with reference to FIG. 56A. As shown, the various parts are assembled in the lower frame 15, and then, the lower frame into which the various parts are incorporated is checked (for example, the positional relation between the photosensitive drum 9 and the developing sleeve 12d is checked). Then, the lower frame 15 is interconnected to the upper frame 14 within which the parts such as the charger roller 10 are assembled, thereby forming the process cartridge B. Thereafter, the total check of the process cartridge B is effected, and then the process cartridge is shipped. Thus, the assembling and shipping line is very simple.
(Mounting of Cartridge)
Next, the construction for mounting the process cartridge B within the image forming system A will be explained.
As shown in FIG. 57, a loading member 29 having a fitting window 29a matched to the contour of the process cartridge B is provided on the upper opening/closing cover 19 of the image forming system A. The process cartridge B is inserted into the image forming system through the fitting window 29a by gripping the gripper portions 14f, 15k. In this case, a guide ridge 31 formed on the process cartridge B is guided by a guide groove (not numbered) formed in the cover 19 and the lower portion of the process cartridge is guided a guide plate 32 having a hook at its free end.
Incidentally, as shown in FIG. 57, a miss-mount preventing projection 30 is formed on the process cartridge B and the fitting window 29a has a recess 29b for receiving the projection 30. As shown in FIGS. 57 and 58, the configuration or position of the projection 30 is differentiated depending upon a particular process cartridge containing the toner having the developing sensitivity suitable to a particular image forming system A (i.e. differentiated for each process cartridge), so that, even when a process cartridge containing the toner having the different developing sensitivity is tried to be mounted within the particular image forming system, since the projection 30 does not match with the fitting window 29a of that image forming system, it cannot be mounted within that image forming system. Accordingly, the miss-mounting of the process cartridge B can be prevented, thus preventing the formation of the obscure image due to the different developing sensitive toner. Incidentally, it is also possible to prevent the miss-mounting of a process cartridge including a different kind of photosensitive drum, as well as the different developing sensitivity. Further, since the recess 29b and the projection 30 are situated at this side when the process cartridge is mounted, if the operator tries to erroneously mount the process cartridge within the image forming system, he can easily ascertain with his eyes the fact that the projection 30 is blocked by the filling member 29. Thus, the possibility that the operator may forcibly push the process cartridge into the image forming system to damage the process cartridge B and/or the image forming system A as in the conventional case can be avoided.
After the process cartridge B is inserted into the fitting window 29a of the opening/closing cover 19, when the cover 19 is closed, the rotary shaft 9f of the photosensitive drum 9 which is protruded from one side of the upper and lower frames 14, 15 is supported by a shaft support member 33 (FIG. 57) via a bearing 46a, and the rotary shaft 12d2 of the developing sleeve 12d which is protruded from one side of the upper and lower frames 14, 15 is supported by the shaft support member 33 via a slide bearing 46b and a bearing 46c (FIG. 52). On the other hand, the drum shaft portion 26d (FIG. 52) of the bearing member 26 attached to the other end of the photosensitive drum 9 is supported by a shaft support member 34 shown in FIG. 59.
In this case, the protection cover 22 is rotated to expose the photosensitive drum 9, with the result that the photosensitive drum 9 is contacted with the transfer roller 6 of the image forming system A. Further, the drum earthing contact 18a contacting the photosensitive drum 9, the developing bias contact 18b contacting the developing sleeve 12d and the charging bias contact 18c contacting the charger roller 10 are provided on the process cartridge B so that these contacts protrude from the lower surface of the lower frame 15, and these contacts 18a, 18b, 18c are urgingly contacted with the drum earthing contact pin 35a, developing bias contact pin 35b and charging bias contact pin 35c (FIG. 59), respectively.
As shown in FIG. 59, these contact pins 35a, 35b, 35c are arranged so that the drum earthing contact pin 35a and the charging bias contact pin 35c are disposed at a downstream side of the transfer roller 6 in the recording medium feeding direction and the developing bias contact pin 35b is disposed at an upstream side of the transfer roller 6 in the recording medium feeding direction. Accordingly, as shown in FIG. 60, the contacts 18a, 18b, 18c provided on the process cartridge B are similarly arranged so that the drum earthing contact 18a and the charging bias contact 18c are disposed at a downstream side of the photosensitive drum 9 in the recording medium feeding direction and the developing bias contact 18b is disposed at an upstream side of the photosensitive drum 9 in the recording medium feeding direction.
Now, the disposition of the electric contacts of the process cartridge B will be explained with reference to FIG. 68. Incidentally, FIG. 68 is a schematic plan view showing the positional relation between the photosensitive drum 9 and the electric contacts 18a, 18b, 18c.
As shown in FIG. 68, the contacts 18a, 18b, 18c are disposed at the end of the photosensitive drum 9 opposite to the end where the flange gear 9c is arranged in the longitudinal direction of the drum. The developing bias contact 18b is disposed at one side of the photosensitive drum 9 (i.e. side where the developing means 12 is arranged), and the drum earthing contact 18a and the charging bias contact 18c are disposed at the other side of the photosensitive drum (where the cleaning means 13 is arranged). The drum earthing contact 18a and the charging bias contact 18c are substantially arranged on a straight line. Further, the developing bias contact 18b is arranged slightly outwardly of the positions of the drum earthing contact 18a and the charging bias contact 18c in the longitudinal direction of the photosensitive drum 9. The drum earthing contact 18a, the developing bias contact 18b and the charging bias contact 18c are spaced apart from the outer peripheral surface of the photosensitive drum 9 gradually in order (i.e. a distance between the contact 18a and the drum is smallest, and a distance between the contact 18c and the drum is greatest). Further, an area of the developing bias contact 18b is greater than an area of the drum earthing contact 18a and an area of the charging bias contact 18c. Furthermore, the developing bias contact 18b, the drum earthing contact 18a and the charging bias contact 18c are disposed outwardly of a position where the arm portions 18a3 of the drum earthing contact 18a are contacted with the inner surface of the photosensitive drum 9, in the longitudinal direction of the photosensitive drum 9.
As mentioned above, by arranging the electric contacts between the process cartridge (which can be mounted within the image forming system) and the image forming system at the positioning and abutting side of the process cartridge, it is possible to improve the positional accuracy between the contacts of the process cartridge and the contact pins of the image forming system, thereby preventing a poor electrical connection, and, by arranging the contacts at the non-driving side of the process cartridge, it is possible to make the configurations of the contact pins of the image forming system simple and small-sized.
Further, since the contacts of the process cartridge are disposed inside of the contour of the frames of the process cartridge, it is possible to prevent foreign matter from adhering to the contacts, and, thus, to prevent the corrosion of the contacts; and, further to prevent the deformation of the contacts due to the external force. Further, since the developing bias contact 18b is arranged at the side of the developing means 12 and the drum earthing contact 18a and the charging bias contact 18c are arranged at the side of the cleaning means 13, the arrangement of electrodes in the process cartridge can be simplified, thus making the process cartridge small-sized.
Now, dimensions of various parts in the illustrated embodiment will be listed herein below. However, it should be noted that these dimensions are merely an example, and the present invention is not limited to this example:
(1) Distance (X1) between the photosensitive drum 9 and the drum earthing contact 18a about 6.0 mm;
(2) Distance (X2) between the photosensitive drum 9 and the charging bias contact 18c about 18.9 mm;
(3) Distance (X3) between the photosensitive drum 9 and the developing bias contact 18b about 13.5 mm;
(4) Width (Y1) of the charging bias contact 18c about 4.9 mm;
(5) Length (Y2) of the charging bias contact 18c about 6.5 mm;
(6) Width (Y3) of the drum earthing contact 18a about 5.2 mm;
(7) Length (Y4) of the drum earthing contact 18a about 5.0 mm;
(8) Width (Y5) of the developing bias contact 18a about 7.2 mm;
(9) Length (Y6) of the developing bias contact 18a about 8.0 mm
(10) Diameter (Z1) of the flange gear 9c about 28.6 mm;
(11) Diameter (Z2) of the gear 9i about 26.1 mm;
(12) Width (Z3) of the flange gear 9c about 6.7 mm;
(13) Width (Z3) of the gear 9i about 4.3 mm;
(14) Number of teeth of the flange gear 9c 33; and
(15) Number of teeth of the gear 9i 30.
Now, the flange gear 9c and the gear 9i will be explained. The gears 9c, 9i comprise helical gears. When the driving force is transmitted from the image forming system to the flange gear 9c, the photosensitive drum 9 mounted in the lower frame 15 with play is subjected to the thrust force to be shifted toward the flange gear 9c, thereby positioning the drum at the side of the lower frame 15.
The gear 9c is used with a process cartridge containing the magnetic toner for forming a black image. When the black image forming cartridge is mounted within the image forming system, the gear 9c is meshed with a gear of the image forming system to receive the driving force for rotating the photosensitive drum 9 and is meshed with a gear of the developing sleeve 12d to rotate the latter. The gear 9i is meshed with a gear connected to the transfer roller 6 of the image forming system to rotate the transfer roller. In this case, the rotational load does not almost act on the transfer roller 6.
Incidentally, the gear 9i is used with a color image forming cartridge containing the non-magnetic toner. When the color image forming cartridge is mounted within the image forming system, the gear 9c is meshed with the gear of the image forming system to receive the driving force for rotating the photosensitive drum 9. On the other hand, the gear 9i is meshed with the gear connected to the transfer roller 6 of the image forming system to rotate the transfer roller and is meshed with the gear of the developing sleeve 12d for the non-magnetic toner to rotate the latter. The flange gear 9c has a diameter greater than that of the gear 9i, a width greater than that of the gear 9i and a number of teeth greater than that of the gear 9i. Thus, even when the greater load is applied to the gear 9c, the gear 9c can receive the driving force to rotate the photosensitive drum 9 more surely, and can transmit the greater driving force to the developing sleeve 12d for the magnetic toner to rotate the latter more surely.
Incidentally, as shown in FIG. 60, each of the contact pins 35a-35c is held in a corresponding holder cover 36 in such a manner that it can be shifted in the holder cover but cannot be detached from the holder cover. Each contact pin 35a-35c is electrically connected to a wiring pattern printed on an electric substrate 37 to which the holder covers 36 are attached, via a corresponding conductive compression spring 38. Incidentally, the charging bias contact 18c to be abutted against the contact pin 35c has the arcuated curvature in the vicinity of the pivot axis 19b of the upper opening/closing cover 19 so that, the opening/closing cover 19 mounting the process cartridge B thereon is rotated around the pivot axis 19b in a direction shown by the arrow R to close the cover, the charging bias contact 18c nearest to the pivot axis 19b (i.e. having the minimum stroke) can contact with the contact pin 35c effectively.
(Positioning)
When the process cartridge B is mounted and the opening/closing cover 19 is closed, the positioning is established so that a distance between the photosensitive drum 9 and the lens unit 1c and a distance between the photosensitive drum 9 and the original glass support 1a are kept constant. Such positioning will now be explained.
In shown in FIG. 25, positioning projections 15m are formed on the lower frame 15 to which the photosensitive drum 9 is attached, in the vicinity of both longitudinal ends of the frame. As shown in FIG. 22, when the upper and lower frames 14, 15 are interconnected, these projections 15m protrude upwardly through holes 14g formed in the upper frame 14.
Further, as shown in FIG. 61, the lens unit 1c containing therein the lens array 1c2 for reading the original 2 is attached to the upper opening/closing cover 19 (on which the process cartridge B is mounted) via a pivot pin 1c3 for slight pivotal movement around the pivot pin and is biased downwardly (FIG. 61) by an urging spring 39. Thus, when the process cartridge B is mounted on the upper cover 19 and the latter is closed, as shown in FIG. 61, the lower surface of the lens unit 1c is abutted against the positioning projections 15m of the process cartridge B. As a result, when the process cartridge B is mounted within the image forming system A, the distance between the lens array 1c2 in the lens unit 1c and the photosensitive drum 9 mounted on the lower frame 15 is accurately determined, so that the light image optically read from the original 2 can be accurately illuminated onto the photosensitive drum 9 via the lens array 1c2.
Further, as shown in FIG. 62, positioning pegs 40 are provided in the lens unit 1c, which positioning pegs can be protruded slightly from the upper cover 19 upwardly through holes 19c formed in the upper cover. As shown in FIG. 63, the positioning pegs 40 are protruded slightly at both longitudinal sides of an original reading slit Z (FIGS. 18 and 63). Thus, when the process cartridge B is mounted on the upper cover 19 and the latter is closed and then the image forming operation is started, as mentioned above, since the lower surface of the lens unit 1c is abutted against the positioning projections 15m, the original glass support 1a is shifted while riding on the positioning pegs 40. As a result, a distance between the original 2 rested on the original glass support 1a and the photosensitive drum 9 mounted on the lower frame 15 is always kept constant, thus illuminating the light reflected from the original 2 onto the photosensitive drum 9 accurately. Therefore, since the information written on the original 2 can be optically read accurately and the exposure to the photosensitive drum 9 can be effected accurately, it is possible to obtain the high quality image.
(Drive Transmission)
Next, the driving force transmission to the photosensitive drum 9 in the process cartridge B mounted within the image forming system A will be explained.
When the process cartridge B is mounted within the image forming system A, the rotary shaft 9f of the photosensitive drum 9 is supported by the shaft support member 33 of the image forming system as mentioned above. As shown in FIG. 64, the shaft support member 33 comprises a supporting portion 33a for the drum rotary shaft 9f, and an abutment portion 33b for the rotary shaft 12d2 of the developing sleeve 12d. An overlap portion 33c having a predetermined overhanging amount L (1.8 mm in the illustrated embodiment) is formed on the supporting portion 33a, thus preventing the drum rotary shaft 9f from floating upwardly. Further, when the drum rotary shaft 9f is supported by the supporting portion 33a, the rotary shaft 12d2 of the developing sleeve is abutted against the abutment portion 33b, thus preventing the rotary shaft 12d2 from dropping downwardly. Further, when the upper opening/closing cover 19 is closed, positioning projections 15p of the lower frame 15 protruding from the upper frame 14 of the process cartridge B are abutted against an abutment portion 19c of the opening/closing cover 19.
Accordingly, when the driving force is transmitted to the flange gear 9c of the photosensitive drum 9 by driving the drive gear 41 of the image forming system meshed with the flange gear, the process cartridge B is subjected to a reaction force tending to rotate the process cartridge around the drum rotary shaft 9f in a direction shown by the arrow i in FIG. 64. However, since the rotary shaft 12d2 of the developing sleeve is abutted against the abutment portion 33b and the positioning projections 15p of the lower frame 15 protruding from the upper frame 14 are abutted against the abutment portion 19c of the upper cover, the rotation of the process cartridge B is prevented.
As mentioned above, although the lower surface of the lower frame 15 acts as the guide for the recording medium 4, since the lower frame is positioned by abutting it against the body of the image forming system as mentioned above, the positional relation between the photosensitive drum 9, the transfer roller 6 and the guide portions 15h1, 15h2 for the recording medium 4 is maintained with high accuracy, thus performing the feeding of the recording medium and the image transfer with high accuracy.
During the driving force transmission, the developing sleeve 12d is biased downwardly not only by the rotational reaction force acting on the process cartridge B but also by a reaction force generated when the driving force is transmitted from the flange gear 9c to the sleeve gear 12j. In this case, if the rotary shaft 12d2 of the developing sleeve is not abutted against the abutment portion 33b, the developing sleeve 12d will be always biased downwardly during the image forming operation. As a result, it is feared that the developing sleeve 12d is displaced downwardly and/or the lower frame 15 on which the developing sleeve 12d is mounted is deformed. However, in the illustrated embodiment, since the rotary shaft 12d2 of the developing sleeve is abutted against the aboutment portion 33b without fail, the above-mentioned inconvenience does not occur.
Incidentally, as shown in FIG. 37 the developing sleeve 12d is biased against the photosensitive drum 9 by the springs 12j via the sleeve bearings 12i. In this case, the arrangement as shown in FIG. 65 may be adopted to facilitate the sliding movement of sleeve bearings 12i. That is to say, a bearing 12m for supporting the rotary shaft 12d2 of the developing sleeve is held in a bearing holder 12n in such a manner that the bearing 12m can slide along a slot 12n1 formed in the bearing holder. With this arrangement, as shown in FIG. 66, the bearing holder 12n is abutted against the abutment portion 33b of the shaft support member 33 and is supported thereby; in this condition, the bearing 12m can be slide along the slot 12n1 in directions shown by the arrow. Incidentally, in the illustrated embodiment, an inclined angle .theta. (FIG. 64) of the abutment portion 33b is selected to have a value of about 40 degrees.
Further, the developing sleeve 12d may be supported, not via the sleeve rotary shaft. For example, as shown in FIGS. 69A and 69B, it may be supported at its both ends portions by sleeve bearings 52 lower ends of which are supported by the lower frame 15 which is in turn supported by receiving portions 53 formed on the image forming system.
Further, in the illustrated embodiment, the flange gear 9c of the photosensitive drum 9 is meshed with the drive gear 41 for transmitting the driving force to the flange gear in such a manner that, as shown in FIG. 64, a line connecting a rotational center of the flange gear 9c and a rotational center of the drive gear 41 is offset from a vertical line passing through the rotational center of the flange gear 9c in an anti-clockwise direction by a small angle .alpha. (about 1.degree. in the illustrated embodiment), whereby a direction F of the driving force transmission from the drive gear 41 to the flange gear 9c directs upwardly. In general, although the floating of the process cartridge can be prevented by a downwardly directing force generated by setting the angle .alpha. to a value of 20.degree. or more, in the illustrated embodiment, such angle .alpha. is set to about 1.degree..
By setting the above-mentioned angle .alpha. to about 1.degree., when the upper opening/closing cover 19 is opened in a direction shown by the arrow j to remove the process cartridge B, the flange gear 9c is not blocked by the drive gear 41 and, thus, can be smoothly disengaged from the drive gear 41. Further, when the direction F of the driving force transmission is directed upwardly as mentioned above, the rotary shaft 9f of the photosensitive drum is pushed upwardly and, therefore, tends to be disengaged from the drum supporting portion 33a. However, in the illustrated embodiment, since the overlap portion 33c is formed on the supporting portion 33a, the drum rotary shaft 9f is not disengaged from the drum supporting portion 33a. (Re-cycle)
The process cartridge having the above-mentioned construction permits the re-cycle. That is to say, the used-up process cartridge(s) can be collected from the market and the parts thereof can be re-used to form a new process cartridge. Such a re-cycle operation will now be explained. Generally, the used-up process cartridge was disposed or dumped in the past. However, the process cartridge B according to the illustrated embodiment can be collected from the market after the toner in the toner reservoir has been used up, to protect the resources on the earth and the natural environment. Then, the collected process cartridge is disassembled into the upper and lower frames 14, 15 which are in turn cleaned. Thereafter, reusable parts and new parts are mounted on the upper frame 14 or the lower frame 15 at need, and then new toner is supplied into the toner reservoir 12a again. In this way, a new process cartridge is obtained.
More particularly, by releasing the connections between the locking pawls 14a and the locking openings 15a, the locking pawls 14a and the locking projection 15b, the locking pawl 14c and the locking opening 15d, and the locking pawl 15c and the locking opening 14b (FIGS. 21, 22 and 23) which interconnect the upper and lower frames 14, 15, the upper and lower frames 14, 15 can easily be disassembled from each other. Such disassembling operation can easily be performed, for example, by resting the used-up process cartridge B on a disassembling tool 42 and by pushing the locking pawl 14a by means of a pusher rod 42a, as shown in FIG. 67. Even when the disassembling tool is not used, the process cartridge can be disassembled by pushing the locking pawls 14a, 14c, 15c.
After the upper frame 14 and the lower frame 15 are disconnected from each other as mentioned above (FIGS. 25 and 26), the frames are cleaned by removing the waste toner adhered to or remaining in the cartridge by an air blow technique. In this case, a relatively large amount of waste toner is adhered to the photosensitive drum 9, developing sleeve 12d and/or cleaning means 13 since they are directly contacted with the toner. On the other hand, the waste toner is not or almost not adhered to the charger roller 10 since it is not directly contacted with the toner. Accordingly, the charger roller 10 can be cleaned more easily than the photosensitive drum 9, developing sleeve 12d and the like. In this regard, according to the illustrated embodiment, since the charger roller 10 is mounted on the upper frame 14 other than the lower frame 15 on which the photosensitive drum 9, developing sleeve 12d and cleaning means 13 are mounted, the upper frame 14 separated from the lower frame 15 can easily be cleaned.
In the disassembling and cleaning line as shown in FIG. 56B, first of all, the upper and lower frames 14, 15 are separated from each other as mentioned above. Then, the upper frame 14 and the lower frame 15 are disassembled and cleaned independently. Thereafter, as to the upper frame 14, the charger roller 10 is separated from the upper frame and is cleaned; and as to the lower frame 15, the photosensitive drum 9, developing sleeve 12d, developing blade 12e, cleaning blade 13a and the like are separated from the lower frame and are cleaned. Thus, the disassembling and cleaning line is very simple.
After the toner is cleared, as shown in FIG. 26, the opening 12a1 is sealed by a new cover film 28 again, and new toner is supplied into the toner reservoir 12a through the toner filling opening 12a3 formed in the side surface of the toner reservoir 12a, and then the filling opening 12a3 is closed by the lid 12a2. Then, the upper frame 14 and the lower frame 15 are interconnected again by achieving the connections between the locking pawls 14a and the locking openings 15a, the locking pawls 14a and the locking projection 15b, the locking pawl 14c and the locking opening 15d, and the locking pawl 15c and the locking opening 14b, thus assembling a process cartridge again in a usable condition.
Incidentally, when the upper and lower frames 14, 15 are interconnected, although the locking pawls 14a and the locking openings 15a, the locking pawls 14a and the locking projection 15b and the like are interlocked, when the same process cartridge is frequently re-cycled, it is feared that the locking forces between the locking pawls and the locking openings become weaker. To cope with this, in the illustrated embodiment, threaded holes are formed in the frames in the vicinity of four corners thereof. That is to say, threaded-through holes are formed in the fitting recesses 14d and the fitting projections 14e of the upper frame 14 (FIG. 25) and in the fitting projections 15e (to be fitted into the recesses 14d) and the fitting recesses 15f (to be fitted onto the projections 14e) of the lower frame 15, respectively. Thus, even when the locking force due to the locking pawls become weaker, after the upper and lower frames 14, 15 are interconnected and the fitting projections and fitting recesses are interfitted, by screwing screws in the mated threaded holes, the upper and lower frames 14, 15 can be firmly interconnected.
Image forming Operation
Next, the image forming operation effected by the image forming system A within which the process cartridge B is mounted will be explained.
First of all, the original 2 is rested on the original glass support 1a shown in FIG. 18. Then, when the copy start button A3 is depressed, the light source 1c1 is turned ON and the original glass support 1a is reciprocally shifted on the image forming system in the left and right directions in FIG. 18 to read the information written on the original optically. On the other hand, in registration with the reading of the original, the sheet supply roller 5a and the pair of register rollers 5c1, 5c2 are rotated to feed the recording medium 4 to the image forming station. The photosensitive drum 9 is rotated in the direction d in FIG. 18 in registration of the feeding timing of the regist roller 5c1, 5c2 pair, and is uniformly charged by the charger means 10. Then, the light image read by the reading means 1 is illuminated onto the photosensitive drum 9 via the exposure means 11, thereby forming the latent image on the photosensitive drum 9.
At the same time when the latent image is formed, the developing means 12 of the process cartridge B is activated to drive the toner feed mechanism 12b, thereby feeding out the toner from the toner reservoir 12a toward the developing sleeve 12d and forming the toner layer on the rotating developing sleeve 12d. Then, by applying to the developing sleeve 12d a voltage having the same charging polarity and same potential as that of the photosensitive drum 9, the latent image on the photosensitive drum 9 is visualized as the toner image. In the illustrated embodiment, the voltage of about 1.2 KVVpp, 1590 Hz (rectangular wave) is applied to the developing sleeve 12d. The recording medium 4 is fed between the photosensitive drum 9 and the transfer roller 6. By applying to the transfer roller 6 a voltage having the polarity opposite to that of the toner, the toner image on the photosensitive drum 9 is transferred onto the recording medium 4. In the illustrated embodiment, the transfer roller 6 is made of foam EPDM having the volume resistance of about 10.sup.9 .OMEGA.cm and has an outer diameter of about 20 mm, and the voltage of -3.5 KV is applied to the transfer roller as the transfer voltage.
After the toner image was transferred to the recording medium, the photosensitive drum 9 continues to rotate in the direction d. Meanwhile, the residual toner remaining on the photosensitive drum 9 is removed by the cleaning blade 13a, and the removed toner is collected into the waste toner reservoir 13c via the squeegee sheet 13b. On the other hand, the recording medium 4 on which the toner image was transferred is sent, by the convey belt 5d, to the fixing means 7 where the toner image is permanently fixed to the recording medium 4 with heat and pressure. Then, the recording medium is ejected by the pair of ejector rollers 5f1, 5f2. In this way, the information on the original is recorded on the recording medium.
Next, other embodiments will be explained.
In the above-mentioned first embodiment, while an example that the developing blade 12e and the cleaning blade 13a are attached to the frame by pins 24a, 24b was explained, as shown in FIG. 70, when the developing blade 12e and the cleaning blade 13a are attached to the lower frame 15 by forcibly inserting fitting projections 43a, 43b formed on both longitudinal ends of the developing blade 12e and the cleaning blade 13e into corresponding fitting recesses 44a, 44b formed in the body 16 of the image forming system, pin holes 45 for receiving the pins for attaching the blades 12e, 13a may be formed in the vicinity of the fitting projections 43a, 43b, and corresponding pin holes 45 may be formed in the body 16 of the image forming system (Incidentally, in place of the fitting projections 43a, 43b, half punches or circular bosses may be used).
With this arrangement, when the fitting connections between the blades 12e, 13a and the lower frame are loosened by the repeated re-cycle of the process cartridge B, the blades 12e, 13a can be firmly attached to the lower frame by pins.
Further, in the first embodiment, as shown in FIG. 46, while an example that the outer diameter D of the photosensitive drum 9 is smaller than the distance L between the drum guide members 25a, 25b to permit the final attachment of the photosensitive drum 9 to the lower frame 15 was explained, as shown in FIG. 71, even when the photosensitive drum 9 is incorporated into the upper frame 14, the outer diameter D of the photosensitive drum 9 may be smaller than the distance L between the drum guide members 25a, 25b so that the photosensitive drum can be lastly incorporated into the upper frame, thereby preventing the surface of the photosensitive drum 9 from damage, as in the first embodiment. Incidentally, in FIG. 71, elements or parts having the same function as those in the first embodiment are designated by the same reference numerals. Further, the upper and lower frames 14, 15 are interconnected by interlocking locking projections 47a and locking openings 47b and by securing them by pins 48.
Further, as shown in FIG. 52, in the first embodiment, while the photosensitive drum 9 and the developing sleeve 12d were supported by the bearing member 26, when the flange gear 9c is provided at one end of the photosensitive drum 9 and the transfer roller gear 49 is provided at the other end of the photosensitive drum, a structure as shown in FIG. 72 may be adopted. Incidentally, also in FIG. 72, elements having the same function as those in the first embodiment are designated by the same reference numerals. More particularly, in FIG. 72, the flange gear 9c and the transfer roller gear 49 are secured to both ends of the photosensitive drum 9 by adhesive, press-fit or the like, respectively, the positioning of the drum is effected by rotatably supporting a central boss 49a of the transfer roller gear 49 by the bearing portion 33a of the bearing member 26. In this case, in order to earth the photosensitive drum 9, a drum earthing plate 50 having a central L-shaped contact portion is secured to and contacted with the inner surface of the drum, and a drum earthing shaft 51 passing through a central bore in the transfer roller gear 49 is always contacted with the drum earthing plate 50. The drum earthing shaft 51 is made of conductive metal such as stainless steel, and the drum earthing plate 50 is also made of conductive metal such as bronze phosphate, stainless steel or the like. When the process cartridge B is mounted within the image forming system A, a head 51a of the drum earthing shaft 51 is supported by the bearing member 26. In this case, the head 51a of the drum earthing shaft 51 is contacted with the drum earthing contact pin of the image forming system, the earthing the photosensitive drum. Also in this case, as in the first embodiment, the positional accuracy between the photosensitive drum 9 and the developing sleeve 12d can be improved by using the single bearing member 26.
Further, the process cartridge B according to the present invention can be used to not only form a mono-color image as mentioned above, but also form a multi-color image (two color image, three color image or full-color image) by providing a plurality of developing means 12. Furthermore, the developing method may be of known two-component magnetic brush developing type, cascade developing type, touch-down developing type or cloud developing type. In addition, in the first embodiment, while the charger means was of the so-called contact-charging type, for example, another conventional charging technique wherein three walls are formed by tungsten wires and metallic shields made of aluminum are provided on the three walls, and positive or negative ions generated by applying a high voltage to the tungsten wires are shifted onto the surface of the photosensitive drum 9, thereby uniformly charging the surface of the photosensitive drum 9 may be adopted.
Incidentally, the contact-charging may be, for example, of blade (charging blade) type, pad type, block type, rod type or wire type, as well as the aforementioned roller type. Further, the cleaning means for removing the residual toner remaining on the photosensitive drum 9 may be of fur brush type or magnetic brush type, as well as blade type.
Furthermore, the process cartridge B comprises an image bearing member (for example, an electrophotographic photosensitive member) and at least one process means. Therefore, as well as the above-mentioned construction, the process cartridge may incorporate integrally therein the image bearing member and the charger means as a unit which can be removably mounted within the image forming system; or may incorporate integrally therein the image bearing member and the developing means as a unit which can be removably mounted within the image forming system; or may incorporate integrally therein the image bearing member and the cleaning means as a unit which can be removably mounted within the image forming system; or may incorporate integrally therein the image bearing member and two or more process means as a unit which can be removable mounted within the image forming system. That is to say, the process cartridge incorporates integrally therein the charger means, developing means or cleaning means and the electrophotographic photosensitive member as a unit which can be removably mounted within the image forming system; or incorporates integrally therein at least one of the charger means, developing means and cleaning means, and the electrophotographic photosensitive member as a unit which can be removably mounted within the image forming system; or incorporates integrally therein the developing means and the electrophotographic photosensitive member as a unit which can be removably mounted within the image forming system.
Further, in the illustrated embodiment, while the image forming system was the electrophotographic copying machine, the present invention is not limited to the copying machine, but may be adapted to other various image forming system such as a laser beam printer, a facsimile, a word processor and the like.
Now, the above-mentioned driving force transmission to the photosensitive drum 9 will further explained with more detail. As shown in FIG. 73, the driving force is transmitted from the drive motor 54 attached to the body 16 of the image forming system to a drive gear G6 via a gear train G1-G5, and from the drive gear G6 to the flange gear 9c meshed with the drive gear, thereby rotating the photosensitive drum 9. Further, the driving force of the drive motor 54 is transmitted from the gear G4 to a gear train G7-G11, thereby rotating the sheet supply roller 5a. Furthermore, the driving force of the drive motor 54 is transmitted from the gear G1 to the driving roller 7a of the fixing means 7 via gears G12, G13.
Further, as shown in FIGS. 74 and 75, the flange gear (first gear) 9c and the gear (second gear) 9i are integrally formed and portions of the gears 9c, 9i are exposed from an opening 15g formed in the lower frame 15. When the process cartridge B is mounted within the image forming system A, as shown in FIG. 76, the drive gear G6 is meshed with the flange gear 9c of the photosensitive drum 9 and the gear 9i integral with the gear 9c is meshed with the gear 55 of the transfer roller 6. Incidentally, in FIG. 76, the parts of the image forming system are shown by the solid line, and the parts of the process cartridge are shown by the phantom line.
The number of teeth of the gear 9c is different from that of the gear 9i, so that the rotational speed of the developing sleeve 12d when the black image forming cartridge containing the magnetic toner is used is differentiated from the rotational speed of the developing sleeve when the color image forming cartridge containing the non-magnetic toner is used. That is to say, when the black image forming cartridge containing the magnetic toner is mounted within the image forming system, as shown in FIG. 77A, the flange gear 9c is meshed with the sleeve gear 12k of the developing sleeve 12d. On the other hand, when the color image forming cartridge containing the non-magnetic toner is mounted within the image forming system, as shown in FIG. 77B, the gear 9i is meshed with the sleeve gear 12k of the developing sleeve 12d to rotate the developing sleeve.
As mentioned above, since the gear 9c has the greater diameter and wider width than those of the gear 9i and has the number of teeth greater than that of the gear 9i, even when the greater load is applied to the gear 9c, the gear 9c can surely receive the driving force to rotate the photosensitive drum 9 surely and transmits the greater driving force to the developing sleeve 12d for the magnetic toner, thereby surely rotating the developing sleeve 12d.
Next, when the developing blade 12e and the cleaning blade 13a are forcibly fitted into the fitting portions 44a, 44b of the body 16 of the image forming system as shown in FIG. 53, preferred embodiments of a cleaning blade will be explained. Incidentally, hereinbelow, although the cleaning blade 13a will be described, the developing blade 12e can be considered similarly.
FIG. 78 is a perspective view showing a cleaning blade 13a and a fitting portion 44b, and FIGS. 79 and 80 are plan views thereof. As shown in FIGS. 78 to 80, a tapered portion 43b1 is formed by obliquely cutting a lower portion of a fitting projection 43b formed on a longitudinal end of the blade supporting member 13a1, and a tapered portion 44b1 is formed by obliquely cutting an upper portion of the fitting portion 44b of the body 16 of the image forming system. Thus, when the fitting projection 43b is being fitted into the fitting portion 44b, by engaging the tapered portions 43b1, 44b1 with each other, the projection 43b can smoothly be inserted into the fitting portion 44b.
Incidentally, as shown in FIG. 80, when the fitting projection 43b is fitted into the fitting portion 44b, a lower end 43b2 of the projection 43b is abutted against a lower end 44b2 of the fitting portion 43b, thereby regulating an inserting amount of the cleaning blade 13a. Thus, when the tapered portion 43b1 is formed on the fitting projection 43b, it is preferable that the lower end 43b2 is left.
Further, although the fitting projection 43b is forcibly fitted into the fitting portion 44b as mentioned above when the blade supporting member 13a1 is fitted, in case of the automatic assembling operation, as shown in FIG. 81, the lower frame 15is pulled by a suitable tool (not shown) in a direction shown by the arrow to elastically deform it so as to increase the distance between the fitting portions 44b, and then, as shown in FIG. 82, the blade supporting member 13a1 is fitted between the fitting portions 44b. In this case, as mentioned above, the fitting operation can be performed smoothly because of the existence of the tapered portions 43b1, 44b1. Then, when the tool is released, as shown in FIG. 66, the deformation of the lower frame 15 is elastically restored, thus fitting the fitting projections 43b into the fitting portions 44b. Further, the fitting portions 44b are pushed in directions shown by the arrows in FIG. 83, thereby interlocking the fitting projections 43b and the fitting portions 44b without fail. In this way, the cleaning blade can easily be assembled.
Further, in place of the inclined tapered portion 43b1 formed on the fitting projection 43b, as shown in FIG. 84, the lower portion of the fitting projection may be rounded to have a certain curvature of radius. Also in this case, the same technical effect can be obtained.
Further, as shown in FIG. 85, the tapered portion 43b1 formed on the fitting projection 43b may be rounded by chamferring a lower portion of the tapered portion 43b1. In this case, the fitting projection can be fitted into the fitting portion 44b more smoothly. Further, even if the tapered portion 43b1 is not formed, when the lower portion of the fitting projection 43b is merely rounded as mentioned above, the fitting smoothness is improved to some extent.
In addition, FIG. 86 shows an embodiment wherein a PTFE tape 13a3 and the like is adhered to the tapered portion 43b1 of the blade supporting member 13a1, thereby permitting the smooth fitting of the projection into the fitting portion of the system body. Furthermore, FIG. 87 shows another embodiment wherein lubricant 13a4 such as silicone oil, grease and the like is coated on the tapered portion 13b1 to lubricate the tapered portion, thereby improving the smooth fitting of the fitting projection into the fitting portion of the system body.
Incidentally, when the tape 13a3 is adhered to the tapered portion or when the lubricant is coated on the tapered portion, although it is not necessary to form the tapered portion 43b1 in the fitting portion 43b, the tape or lubricant should not be provided on the lower end 43b2 which serves as the positioning reference, in order to maintain the attachment accuracy.
As mentioned above, according to the present invention, the first and second frames can be surely interconnected, and it is possible to provide a process cartridge, and an image forming system, which can sufficiently cope even when the number of re-uses (re-cycles) is increased.
Further, according to the present invention, it is possible to provide a process cartridge, an image forming system, and a method for assembling a cleaning device, which parts can surely be attached repeatedly and which can sufficiently cope even when the number of re-uses (re-cycles) is increased.

Number	Date	Country
2-110613	Apr 1990	JPX
2-301779	Nov 1990	JPX
3-054446	Mar 1991	JPX
4-194660	Jun 1992	JPX
4-217423	Jul 1992	JPX

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4500195	Hosono	Feb 1985
4540268	Toyono et al.	Sep 1985
4563074	Tsutsui et al.	Jan 1986
4575221	Onoda et al.	Mar 1986
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5223893	Ikemoto et al.	Jun 1993

Number	Date	Country
0153824A3	Sep 1985	EPX
0276910	Aug 1988	EPX
0314140A3	May 1989	EPX
0368346	May 1990	EPX
0485271	May 1991	EPX
0453963A3	Oct 1991	EPX
0473180A3	Mar 1992	EPX
0572048	Dec 1993	EPX
2611930	Sep 1988	FRX
8907136	Jun 1989	DEX
4003695	Aug 1990	DEX
58-63961	Apr 1983	JPX
59-155877	Sep 1984	JPX
61-192768	Aug 1986	JPX
63-149669	Jun 1988	JPX
2301779	May 1989	JPX
2-123376	May 1990	JPX
2-163769	Jun 1990	JPX
2-168277	Jun 1990	JPX
4-9869	Jan 1992	JPX
2074095	Oct 1981	GBX

Process cartridge mountable in an image forming system and a method for assembling a cleaning device

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

US Classifications

Field of Search

US

International Classifications

Abstract

Description

Claims

Priority Claims (5)

CROSS REFERENCE TO RELATED APPLICATIONS

US Referenced Citations (36)

Foreign Referenced Citations (21)

Non-Patent Literature Citations (3)

Related Publications (1)

Continuations (1)

Continuation in Parts (1)

Entry
Patent Abstracts of Japan, vol. 5, No. 154, (P-82), Sep. 29, 1981.
"Gaskets for Xerographic Developer", IBM Technical Bulletin, vol. 28, No. 8, Jan. 1986.
"Developer Unit Incorporating Liquid Sealant," IBM Technical Bulletin, Buckley, et al., Feb. 1974.