Japanese patent application No. 2022-103628 filed on Jun. 28, 2022 including description, claims, drawings, and abstract the entire disclosure is incorporated herein by reference in its entirety.
The present invention relates to a toner container, a manufacturing method, and an image forming apparatus.
There are image forming apparatuses that form an image on a sheet such as printing paper by an electrophotographic method. The image forming apparatus includes a toner container that contains toner. The toner container includes a stirring member for stirring and conveying the toner therein. The stirring member includes a shaft portion in which a screw is formed. One end of a shaft portion of the stirring member is inserted into a through hole formed in the toner container. The stirring member is attached to a drive transmission member outside the toner container via the through hole (for example, JP2002-62735A).
The toner container having the above configuration is attached to an image forming apparatus. When the toner container is attached to the image forming apparatus, the toner container is coupled to a drive unit in which a drive transmission member is rotationally driven by a motor. The motor rotates the drive unit. The drive unit rotates the stirring member inside the toner container via the drive transmission member. Thus, the toner container can convey toner in a predetermined direction while stirring the toner.
When the number of rotations of the stirring member is high, there is a possibility that the bearing portion generates heat due to friction caused by the rotation of the stirring member. When the temperature of the bearing portion becomes high, toner contained in a surrounding area of the bearing portion is melted. When the toner is melted, there is a possibility that the torque for rotating the stirring member is increased. In order to prevent this, it is preferable to keep the number of rotations of the stirring member low. A structure is conventionally adopted in which a reduction ratio is increased by making a radius of the drive transmission member greater than a radius of the drive unit. Therefore, the size of the drive transmission member attached to one end of the stirring member is increased.
The toner container generally includes a container body and a cover member welded to the container body. The toner container is formed as a container whose inside is sealed by welding of a cover member. For example, vibration welding is adopted for the welding of the container body and the cover member. In the vibration welding, each of the container body and the cover member is installed in a jig. The jig holds the container body and the cover member in a state of being joined to each other. Vibration is applied to the container body and the cover member in a state of being held by the jig, and thus joining portions of the container body and the cover member are welded.
In a conventional toner container, it is assumed that a drive transmission member is attached to one end of a stirring member prior to welding of a container body and a cover member. In this case, since the size of the drive transmission member is large, the jig cannot be appropriately installed during vibration welding. Therefore, in the conventional toner container, a problem occurs during welding, and it is difficult to ensure the hermeticity of the toner container. Conventionally, after the stirring member is installed inside the container body, the container body and the cover member are welded to each other in a state where the drive transmission member is not mounted. Further, conventionally, after the container body and the cover member are welded to each other, a method of fitting and attaching the drive transmission member to one end of the stirring member inserted into the through hole of the container body has been employed.
However, in the conventional method, the shaft portion of the stirring member in the container body cannot be held when the drive transmission member is fitted to one end of the stirring member. Therefore, there has been a problem that a stress at the time of the fitting acts on the shaft portion of the stirring member, the shaft portion is deformed inside the toner container, and in the worst case, the shaft portion is broken.
The present invention is intended to solve the above-described conventional problems. Thus, the present invention is intended to provide a toner container in which a stirring member is prevented from being deformed or broken when a drive transmission member is attached to one end of the stirring member. The present invention is also intended to provide a method of manufacturing such a toner container, and an image forming apparatus including such a toner container.
First, the present invention is directed to a toner container.
In order to achieve at least one of the aforementioned objects, according to one aspect of the present invention, the toner container comprises: a container for containing toner; a stirring member provided inside the container and configured to stir the toner by rotating around an axis; an engaging member attached to one end of the stirring member and configured to engage with a peripheral edge portion of an opening formed in the container; and a drive transmission member attached to the engaging member and configured to rotate the stirring member around the axis.
Second, the present invention is also directed to a method of manufacturing a toner container that comprises: a container formed by a container body and a cover member; a stirring member that is provided inside the container and rotates around an axis to stir the toner; an engaging member attached to one end of the stirring member and configured to engage with a peripheral edge portion of an opening formed in the container body; and a drive transmission member mounted on the engaging member and configured to rotate the stirring member about the axis.
In order to achieve at least one of the aforementioned objects, according to one aspect of the present invention, the method comprises the steps of: installing the stirring member inside of the container body and attaching the engaging member to one end of the stirring member to bring the engaging member into engagement with the peripheral edge portion of the opening; forming the container by welding the container body and the cover member to each other after the engaging member is attached to one end of the stirring member; and attaching the drive transmission member to the engagement member after the container is formed.
Third, the present invention is directed to an image forming apparatus.
In order to achieve at least one of the aforementioned objects, according to one aspect of the present invention, the image forming apparatus comprises: a toner container. The toner container comprises: a container for containing toner; a stirring member provided inside the container and configured to stir the toner by rotating around an axis; an engaging member attached to one end of the stirring member and configured to engage with a peripheral edge portion of an opening formed in the container; and a drive transmission member attached to the engaging member and configured to rotate the stirring member around the axis.
The advantages and features provided by one or more embodiments of the invention will become more fully understood from the detailed description given herein below and the appended drawings which are given by way of illustration only, and thus are not intended as a definition of the limits of the present invention.
Hereinafter, one or more embodiments of the present invention will be described with reference to the drawings. However, the scope of the invention is not limited to the disclosed embodiments.
The conveyance mechanism 10 conveys the sheet 9 along a conveyance path 11 formed inside the image forming apparatus 1. The conveyance direction of the sheet 9 is a direction indicated by arrow F1. The conveyance mechanism 10 includes a pickup roller 12, a paper feed roller 13, a registration roller 14, a secondary transfer roller 15, a fixing section 16, and a discharge roller 17. The conveying mechanism 10 conveys the sheet 9 one by one by rotationally driving those rollers.
The image forming mechanism 20 forms an image by transferring a toner image onto one surface of the sheet 9 conveyed by the conveying mechanism 10. The image forming mechanism 20 includes an intermediate transfer belt 21. The intermediate transfer belt 21 is an endless belt. The intermediate transfer belt 21 is stretched between a driving roller 22 and a driven roller 23, and circularly moves in a direction of an arrow F2. The image forming mechanism 20 includes image forming units 24Y, 24M, 24C, and 24K that form toner images of respective colors of Y (yellow), M (magenta), C (cyan), and K (black) below the intermediate transfer belt 21. The image forming mechanism 20 includes primary transfer rollers 25Y, 25M, 25C, and 25K provided at positions facing the respective image forming units 24Y, 24M, 24C, and 24K with the intermediate transfer belt 21 interposed therebetween.
The charging device 32 charges the surface of the rotating photoreceptor 31 to a predetermined charge. The exposure device 33 exposes the surface of the photoreceptor 31 charged to a predetermined charge based on image data to be printed. The exposure device 33 forms an electrostatic latent image corresponding to image data on the surface of the photoreceptor 31 by exposure. The developing device 34 applies a developer containing toner to the surface of the photoreceptor 31. The developing device 34 visualizes and develops the electrostatic latent image with toner by providing a developer. Thus, a toner image is formed on the surface of the photoreceptor 31. When the toner images contact the intermediate transfer belt 21, the toner images are primarily transferred to the intermediate transfer belt 21 by transfer voltages applied from the primary transfer rollers 25Y, 25M, 25C, and 25K. The image forming units 24Y, 24M, 24C, and 24K sequentially transfer toner images of respective colors of Y, M, C, and K to the intermediate transfer belt 21. Thus, a color image is formed on the intermediate transfer belt 21. When the color image formed on the intermediate transfer belt 21 passes through the position of the secondary transfer roller 15, the color image is secondarily transferred onto one surface of the sheet 9 conveyed by the conveyance mechanism 10. The sheet 9 to which the toner image has been transferred by the secondary transfer roller 15 is subjected to a heating process and a pressing process when passing through the fixing section 16. As a result, the toner image is fixed to the sheet 9.
Toner may remain on the surfaces of the photoreceptor 31 that have passed through the positions of the primary transfer rollers 25Y, 25M, 25C, and 25K. The cleaner 35 removes the residual toner from the surface of the photoreceptor 31. The cleaner 35 includes a blade-like cleaning member 36 that comes into contact with the surface of the photoreceptor 31. The cleaning member 36 collects residual toner as waste toner inside the cleaner 35 by scraping off the residual toner from the surface of the photoreceptor 31. Furthermore, a conveyance member 37 for conveying the collected waste toner is provided inside the cleaner 35. For example, the conveying member 37 is constituted by a screw member extending in a direction parallel to the rotation axis of the photoreceptor 31.
Furthermore, toner may also remain on the surface of the intermediate transfer belt 21 that has passed through the position of the secondary transfer roller 15. In order to collect the residual toner of the surface of the intermediate transfer belt 21, a cleaner 26 is provided near the driven roller 23 as shown in
The container 41 is integrally formed by welding the container body 42 and the cover member 43. The container body 42 is open on the front surface side, and the open peripheral edge part is formed as a joining part 50 to which the cover member 43 is joined.
Toner collection portions 51, 52, 53, 54, and 55 that protrude upward are provided in the upper portion of the container main body 42. The toner collection portions 51, 52, 53, and 54 collect waste toner ejected from the cleaners 35 of the image forming units 24Y, 24M, 24C, and 24K. Openings 51a, 52a, 53a, and 54a for receiving the waste toner transported by the conveyance member 37 provided in each cleaner 35 are formed on the rear surface side of the toner collection portions 51, 52, 53, and 54. Furthermore, the toner collection portion 55 collects waste toner ejected from the cleaner 26 that collects residual toner on the intermediate transfer belt 21. An opening 55a for receiving the toner discharged from the cleaner 26 is provided on the upper surface of the toner collecting portion 55. The opening 55a can be opened and closed by a shutter member 56. The shutter member 56 is urged by an elastic body such as a spring so as to close the opening 55a. As the toner container 40 is attached to the image forming apparatus 1, the shutter member 56 slides on the upper surface of the toner collection portion 55 against the biasing force of the elastic body to open the opening 55a.
As illustrated in
The cover member 43 covers the open front surface side of the container body 42 and is welded to the joining part 50. By being welded to the front surface side of the container body 42, the cover member 43 is integrated with the container body 42 to form the container 41 in which the inside is sealed. For example, the container body 42 and the cover member 43 in the present embodiment are formed of a resin, and are welded and fixed in a uniform state over the entire region of the joining part 50 by vibration welding. As a result, the container body 42 and the cover member 43 can form the container 41 in which the toner leakage does not occur.
The stirring member 60 is for stirring and leveling the toner carried into the container 41 from the toner collecting portions 51, 52, 53, 54, and 55. The stirring member 60 includes a shaft portion 61, a first stirring portion 62, and a second stirring portion 63. Further, the stirring member has a flange portion 64 and a locking portion 65 at one end of the shaft portion 61. In the stirring member 60, inside the container body 42, one end of the shaft portion 61 having the locking portion 65 is inserted into the opening 46 of the container body 42, and the other end 68 is supported by the bearing portion 44 of the container body 42.
The first stirring portion 62 is provided on one end side with respect to the center of the shaft portion 61, and conveys the toner in the container 41 toward the center of the container 41 while stirring the toner as the shaft portion 61 rotates in a predetermined direction. The second stirring section 63 is provided closer to the other end than the center of the shaft portion 61, and conveys the toner in the container 41 toward the center of the container 41 while stirring the toner by rotation of the shaft portion 61 in the predetermined direction. For example, the first stirring section 62 and the second stirring section 63 include screw vanes having different directions. Therefore, when the shaft portion 61 rotates in the predetermined direction, the first stirring portion 62 and the second stirring portion 63 can collect and level the toner in the container 41 at the center while stirring the toner.
The engaging member 70 is formed to be smaller in size than the drive transmission member 80. The engaging member 70 is attached from the outside of the container 41 while being locked to a locking portion 65 provided at one end of the stirring member 60. The engagement member 70 is a member for attaching the drive transmission member 80 to one end of the stirring member 60.
The drive transmission member 80 is a disk-shaped member having a gear formed on an outer peripheral surface 81 thereof. An engaging hole 82 that engages with the engaging member is formed at the center of the drive transmission member 80. By fitting the engaging member 70 into the engaging hole 82, the drive transmission member 80 is attached to one end of the stirring member 60 outside the container 41.
When the toner container 40 is mounted in the space 8 on the front surface side of the image forming apparatus 1, the outer peripheral surface 81 of the drive transmission member 80 is coupled to a gear of a drive section (not shown) provided inside the image forming apparatus 1. The drive section is rotationally driven by a motor provided inside the image forming apparatus 1. Therefore, when the drive section is rotationally driven, the drive transmission member 80 causes the stirring member 60 in the container 41 to rotate in the predetermined direction via the engaging member 70. Thus, the toner in the container 41 is stirred, and the state of accumulation of the toner in the container 41 can be made uniform. For example, a radius of the drive transmission member is formed to be larger than a radius of the drive section, and the stirring member 60 is configured to be rotationally driven at a predetermined number of rotations or less. Here, there is another method in which a deceleration mechanism is provided in a drive mechanism mounted on the apparatus body 1a of the image forming apparatus 1 so that the number of rotations of the stirring member 60 is suppressed low on the side of the apparatus body 1a. However, it is difficult to reduce the size of the apparatus body 1a when the reduction mechanism is provided in the apparatus body 1a. Therefore, in the image forming apparatus 1 of the present embodiment, by increasing the size of the drive transmission member 80, the number of rotations of the stirring member 60 is suppressed to be low, and the miniaturization of the apparatus body 1a is realized. As described above, the toner container 40 of the present embodiment employs a configuration in which the engaging member 70 is attached to one end of the stirring member 60, and the drive transmission member 80 is attached to the engaging member 70. By employing such a configuration, when the drive transmission member 80 is attached to one end of the stirring member 60, the stirring member 60 is not deformed or broken. Hereinafter, a method for manufacturing the toner container 40 and constituent members of the toner container 40 will be described in detail.
Next, as illustrated in
Here, it is preferable that the locking portion 65 is provided with a projection portion (not shown) which is fitted into the gap 75 between the engagement portion 72 and the locking piece 73 when the engaging member 70 is fitted. By fitting the projection portion into the gap 75, the locking portion 65 is integrated with the engaging member 70 in the rotating direction. Therefore, when the engaging member 70 rotates, the stirring member 60 also rotates together with the engaging member 70.
When the engaging member 70 is engaged with the locking portion 65, stress acts on the shaft portion 61 of the stirring member 60. This stress acts as a compressive force that compresses the shaft portion 61 in the axial direction. Therefore, in a case where the shaft portion 61 is not fixed, the shaft portion 61 may be deformed inside the container body 42, and the shaft portion 61 may be bent in the worst case. To avoid it, as shown in
When the pair of locking pieces 66 and 66 are accommodated on the inner side of the ring portion 71 and the engaging member 70 is fitted on the outer side of the locking portion 65, the locking claws 66a and 66a of the pair of locking pieces 66 and 66 are brought into a state of being locked to the pair of engagement portions 72 and 72 of the engaging member 70. Accordingly, the engaging member 70 is not separated from the locking portion 65.
Further, the pair of engagement portions 72 and 72 of the engaging member 70 extends outward longer than the radius of the sleeve 45. Therefore, when the engaging member 70 is fitted to the outside of the locking portion 65, the distal ends of the engagement portions 72 and 72 protrude to the outside of the sleeve 45 and are in contact with the end surface of the sleeve 45 (see
Next, as shown in
At this time, the toner container 40 is in a state where the drive transmission member 80 having a relatively large size is not mounted. Therefore, the drive transmission member 80 does not interfere with installation of the container body 42 in a jig, thereby enabling appropriate installation of the jig in the container body 42. Therefore, no problem occurs during vibration welding, and the hermeticity of the container 41 can be ensured.
When the cover member 43 is welded to the container body 42, next, as illustrated in
As shown in
Further, when the drive transmission member 80 is attached to the engaging member 70, the locking claws 74 and 74 provided at the distal ends of the locking pieces 73 and 73 of the engaging member 70 are engaged with the peripheral edge portion of the circular hole 83. Accordingly, the drive transmission member 80 is fixed so as not to separate from the engaging member 70. However, when the pair of locking claws 74 and 74 are pinched by fingertips and the interval between the locking claws 74 and 74 is reduced, the engagement state by the locking claws 74 and 74 is easily released. Therefore, it is also possible to easily remove the drive transmission member 80 from the engaging member 70.
The process of attaching the drive transmission member 80 to the engaging member 70 may be performed at a factory. Further, the process of attaching the drive transmission member 80 to the engagement member 70 may be performed at a site where the image forming apparatus 1 is installed.
In particular, in the toner container 40 of the present embodiment, even when a user or a service person attaches the drive transmission member 80 to the engaging member 70 at a site where the image forming apparatus 1 is installed, there is no possibility that the stirring member 60 inside the container 41 is damaged at the time of attaching the drive transmission member 80. Therefore, a user or a service person can appropriately mount the drive transmission member 80 at the installation site of the image forming apparatus 1.
As described above, the toner container 40 of the present embodiment includes the container 41 that contains the toner, the stirring member 60 that is provided inside the container 41 and rotates around the axis to stir the toner, the engaging member 70 that is attached to one end of the stirring member 60 and engages with the peripheral edge of the opening 46 formed in the container 41, and the drive transmission member 80 that is attached to the engaging member 70 and rotates the stirring member 60 around the axis. According to such a configuration, when the drive transmission member 80 is attached to one end of the stirring member 60, the stirring member 60 is not deformed or broken, and the toner container 40 can be stably completed.
Several preferred embodiments of the present invention have been described above. However, the present invention is not limited to the content described in the above embodiments, and various modifications can be applied.
For example, in the above-described embodiment, an example in which the seal member 49 provided inside the sleeve 45 is disposed between the wall portion 48 and the engaging member has been described. That is, in the example illustrated in
Further, in the above-described embodiment, the case where the toner container 40 is a container for collecting the waste toner is exemplified. However, a container to which the above-described configuration of the toner container 40 is applicable is not limited to a container that collects waste toner. For example, the above-described configuration can be applied to the developing device 34, and can also be applied to the cleaners 26 and 35.
In addition, in the above-described embodiment, the case where the image forming apparatus 1 is a color machine capable of forming a color image using toners of four colors of Y, M, C, and K has been exemplified. However, the image forming apparatus 1 is not limited to a color machine, and may be a monochrome machine capable of forming only a monochrome image.
Further, in the above-described embodiment, the case where the container 41 is formed by welding two components of the container body 42 and the cover member 43 has been exemplified. However, the number of components forming the container 41 is not limited to two, and may be three or more.
Number | Date | Country | Kind |
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2022-103628 | Jun 2022 | JP | national |