JP2005215272A - Process cartridge and image forming apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a process cartridge which a user, etc. can easily and individually replace a latent image carrier and process means independently for the latent image carrier and each process means even when the latent image carrier and the process means are integrally formed and makes effective use of a sensor means possible, and provide an image forming apparatus using the same. <P>SOLUTION: In the process cartridge which is formed by integrating a photoreceptor 3 and at least one of more process means and is attachable/detachable to/from the image forming apparatus main body, it includes the sensor means 21, 22, 23, process cartridge frames 2a, 2b which support the photoreceptor 3 and the process means, the photoreceptor 3 and the process means are replaceable, respectively in a state that the process cartridge is detached from the image forming apparatus and the sensor means 21, 22, 23 are arranged in the process cartridge frames 2a, 2b. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a process cartridge used for image formation by an electrostatic copying process, such as a copying machine, a facsimile machine, and a printer, and an image forming apparatus including the process cartridge.

  The image forming apparatus needs to be replenished because the toner in the developing device is consumed by image formation. In the case of a two-component developer, the magnetic carrier needs to be replaced. In addition, other members in the image forming apparatus, for example, a photoconductor that has been worn out or deteriorated by long-term use, a charging device that is contaminated with toner that has floated or scattered in the image forming apparatus, or a contact with the photoconductor Therefore, if the worn craning blade or the like is not replaced, an image of characters such as dust and ground fog is generated. To prevent this, these members and devices must be replaced. Therefore, when a character dust or the like is generated, the service person goes to the user and replaces each member or device. However, each member or apparatus of the image forming apparatus has become highly durable, and further, the need for maintenance that a service person visits has been reduced due to the extended life of the developer and the like used in the image forming apparatus. Further, even when the service person actually replaces, it takes a lot of time to take out each member or device in the image forming apparatus and attach a new member. Therefore, the photosensitive member and processes necessary for image formation are performed. For example, a process unit such as a charging unit, a developing unit, and a cleaning unit and a sensor unit that acquires information on the latent image carrier are integrally supported to form an image. By replacing the process cartridge itself with the process cartridge that can be attached to and detached from the main body of the device, the service person can shorten the work time under the user. Users can now easily exchange without having to go out. Also, as a member or device, the photoconductor is 10,000 to 80,000 prints, the magnetic carrier in the developing device is 50,000 to 100,000 prints, and the charging device is 30,000 to 80,000 prints. Yes. Conventionally, a user or a service person has exchanged the entire integrated process cartridge regardless of the lifetime of each member. This contributes to the convenience of replacement, but since the parts that can be used must be replaced at the same time, it leads to waste of resources, and there has been dissatisfaction from consumers.

  Therefore, for example, Patent Document 1 includes a cleaning member that removes toner remaining on the photosensitive member and a waste toner storage unit that stores the removed toner, and the waste toner storage unit faces the photosensitive member. A container-shaped cleaning frame having an opening, a second opening at a position away from the first opening, a cleaning member that substantially closes the first opening, and a lid provided around the second opening There is disclosed a process cartridge comprising a part frame and having an elastic seal member 15 disposed between a support part of a cleaning member and a lid part frame. As a result, it is possible to reduce the size of the waste toner container and the process cartridge while accommodating as much toner as possible and further improving the amount of waste toner stored.

  Further, in Patent Document 2, a process cartridge incorporating a latent image carrier and at least one process unit is provided, and a developer supply box and a waste developer collection box are connected to a development housing in which the developer is accommodated. A process in which the developer replenishment box is disposed on the upstream side of the latent image writing position on the latent image carrier, and the waste developer recovery box is disposed on the downstream side of the latent image writing position. A cartridge is disclosed. In Patent Document 3, at least a developing device and at least one of a charging device, an electrophotographic photosensitive member, and an electrophotographic photosensitive member cleaning device are integrally configured, and are detachably attached to an image forming apparatus main body. Among the existing process cartridges, there is disclosed a process cartridge configured to be easily held and swung.

JP 2003-177651 A JP 2003-186305 A JP 2001-331082 A

However, in each of the process cartridges described in Patent Documents 1 to 3, consideration is given to miniaturization and long life, but expensive components such as sensor means for acquiring information on the latent image carrier are provided. There was a problem of exchanging as a unit.
Therefore, the present invention has been made in view of the above problems, and the problem can be easily exchanged for each latent image carrier and each process means by a user or a service person, The present invention also provides a process cartridge in which sensor means is disposed in a process cartridge frame and an image forming apparatus using the process cartridge.
It is another object of the present invention to provide a process cartridge and an image forming apparatus using the process cartridge that can accurately position image forming conditions even if the latent image carrier and each process means are independently replaced.
It is another object of the present invention to provide a process cartridge and an image forming apparatus using the process cartridge, in which members that are consumed and worn by each process means can be replaced independently.
It is another object of the present invention to provide a process cartridge capable of cleaning even a toner having a small particle size and a substantially spherical shape, and an image forming apparatus using the process cartridge.

In order to achieve the above object, the present invention has the following features.
The process cartridge according to the present invention includes a latent image carrier and at least one or more process means, and is a process cartridge that can be attached to and detached from the main body of the image forming apparatus, and at least one sensor that acquires information on the latent image carrier. , A latent image carrier and a process cartridge frame for supporting the process means, and the latent image carrier and the process means can be exchanged with the process cartridge removed from the image forming apparatus, and the sensor means. Is arranged on the process cartridge frame.
The process cartridge of the present invention is further characterized in that the latent image carrier or at least one selected process means can be replaced without removing other process means.
The process cartridge according to the present invention is further characterized in that the latent image carrier is removed from the process cartridge frame without removing the process means.
The process cartridge according to the present invention is characterized in that the process means is a cleaning means, and the latent image carrier is removed from the process cartridge frame after rotating the cleaning means. .

The process cartridge according to the present invention is further characterized in that the process means is a cleaning means, and the cleaning means is fixed to the process cartridge frame by positioning members of the cleaning means provided on both sides.
In the process cartridge of the present invention, the process means is a cleaning means, and the cleaning means has a coating mechanism including a coating roller and a lubricant molded body, and the latent image carrier is formed by the coating mechanism. A lubricant is applied.
The process cartridge of the present invention is further characterized in that the cleaning means can be replaced with a cleaning blade and a molded lubricant.
The process cartridge according to the present invention is further characterized in that the process means is a charging means, and the charging means is inserted into a recess of the process cartridge frame.
The process cartridge according to the present invention is further characterized in that the process means is a developing means, and the developing means is fixed to the process cartridge frame by developing means positioning members provided on both sides.

The process cartridge according to the present invention is further characterized in that the developing means has a drive bearing hole of the process cartridge frame fixed to a developing reference shaft disposed in the developing means by a developing means positioning member. .
The process cartridge according to the present invention is further characterized in that a drive shaft disposed in the image forming apparatus main body is inserted into the latent image carrier.
The process cartridge of the present invention is further characterized in that a drive shaft disposed in the image forming apparatus main body is inserted into a drive bearing hole provided in the process cartridge frame.
The process cartridge according to the present invention is further characterized in that the frame of the process cartridge includes a charge eliminating unit.
The process cartridge of the present invention is further characterized in that the charge eliminating means is EL.
In the process cartridge of the present invention, the sensor means further includes a potential sensor for the latent image carrier, a density sensor for detecting the amount of toner on the latent image carrier, and a temperature and humidity sensor for detecting the temperature and humidity in the process cartridge. It is characterized by being.
The process cartridge according to the present invention is further characterized in that the process cartridge is connected to the outside from one place of the process cartridge.

The process cartridge of the present invention is further characterized in that the developing means uses toner having an average circularity in the range of 0.93 to 1.00.
The process cartridge of the present invention is further characterized in that the toner has a ratio of the weight average particle diameter to the number average particle diameter in the range of 1.05 to 1.40.
Further, in the process cartridge of the present invention, the toner has a substantially spherical appearance, and the ratio of the major axis to the minor axis (r2 / r1) is in the range of 0.5 to 1.0. The ratio between the thickness and the minor axis (r3 / r2) is in the range of 0.7 to 1.0, and the relationship of major axis r1 ≧ minor axis r2 ≧ thickness r3 is satisfied.
The process cartridge of the present invention further includes a toner composition containing at least a polyester prepolymer having a functional group containing a nitrogen atom, a polyester, a colorant, and a release agent. Crosslinking and / or extension reaction is carried out in the presence.
In addition, the process cartridge of the present invention is further characterized in that the process cartridge further comprises a storage unit for storing toner or newly supplied toner.
The process cartridge according to the present invention is further characterized in that the process cartridge can be replenished with toner.
The process cartridge according to the present invention is further characterized in that the process cartridge further comprises a storage portion for storing the replenished toner.

The image forming apparatus of the present invention is an image forming apparatus that visualizes an electrostatic latent image formed on a latent image carrier with toner, and the latent image carrier and process means can be integrally attached and detached. In the image forming apparatus including a process cartridge, the process cartridge is characterized in that the latent image carrier and the process means can be individually replaced.
The image forming apparatus of the present invention is an image forming apparatus for visualizing an electrostatic latent image formed on a latent image carrier with toner, and the latent image carrier and at least two process means are integrated. In the image forming apparatus including the removable process cartridge, the process cartridge is characterized in that the latent image carrier and the two process units can be individually replaced.
The image forming apparatus of the present invention is an image forming apparatus that visualizes an electrostatic latent image formed on a latent image carrier with toner, and the latent image carrier and three process units are integrated. In the image forming apparatus including a detachable process cartridge, the process cartridge is characterized in that the latent image carrier and three process means can be individually replaced.

The image forming apparatus of the present invention is an image forming apparatus that visualizes an electrostatic latent image formed on a latent image carrier with toner, and includes a latent image carrier, a charging unit, a developing unit, and a cleaning unit. In an image forming apparatus comprising a process cartridge integrated with at least one selected means, the process cartridge supports a latent image carrier on a process cartridge frame, and at least one process means is processed. The latent image carrier and the selected at least one process means supported on the cartridge frame can be individually replaced.
The image forming apparatus according to the present invention further includes a process cartridge including a storage unit that stores toner and newly supplied toner.
The image forming apparatus according to the present invention further includes a process cartridge that can be replenished with toner and reused.
The image forming apparatus according to the present invention further includes a storage unit that stores the replenished toner.
An image forming apparatus according to the present invention includes the process cartridge according to any one of claims 1 to 23.

As described above, according to the present invention, in the process cartridge and the image forming apparatus of the present invention, the process cartridge itself can be replaced by the means for solving the above, and the image carrier and each process means can be easily used. The sensor means can be exchanged, and the sensor means can be effectively used by leaving the sensor means in the process cartridge frame.
Further, the process cartridge and the image forming apparatus of the present invention can be assembled with high accuracy by a positioning member to be assembled with a guide serving as a reference at the time of assembly.
Furthermore, in the process cartridge and the image forming apparatus of the present invention, consumable members having different lifetimes can be replaced separately.

  The best mode for carrying out the present invention will be described below with reference to the drawings. The following description is an example of the best mode of the present invention, and it is easy for those skilled in the art to make other embodiments within the scope of the claims by making changes and modifications within the scope of the claims. However, this does not limit the scope of the claims.

FIG. 1 is a schematic view showing the structure of a process cartridge according to an embodiment of the present invention. FIG. 2 is a schematic sectional view showing the structure of a process cartridge according to an embodiment of the present invention.
As shown in FIGS. 1 and 2, the process cartridge 1 is charged as a process cartridge frame (hereinafter, referred to as “frame”) 2 as a latent image carrier 3 and a process means. A charging module 4 as a means, a developing module 5 as a developing means, and a cleaning module 6 as a cleaning means can be provided. The process cartridge 1 itself can also be replaced. With the process cartridge 1 removed from the main body of the image forming apparatus 100, the photosensitive member 3, the charging module 4, the developing module 5, and the cleaning module 6 can be replaced with new modules. It is exchangeable. Each module can be handled by a serviceman and a user.

3 is a schematic view showing the structure of the process cartridge frame, FIG. 3 (a) is a view as seen from the front side of the image forming apparatus, and FIG. 3 (b) is a view as seen from the back side of the image forming apparatus. It is a figure.
The process cartridge frame 2 includes a first process cartridge frame (hereinafter referred to as “first frame”) 2 a and a second process cartridge frame (hereinafter referred to as “second frame”). 2b is engaged with the engagement portion 2c as an axis so as to be rotatable between an open position and a closed position. In the closed position, the frames 2a and 2b are enclosed so that the photoconductor 3 cannot be removed. The engaging portion 2c is provided with a projection and a hole (not shown) in each frame 2a and 2b. The projection is inserted into the hole and engaged, and the projection is held by a ring so as not to come off. To do. Further, two pins planted in the frame positioning member 74 with respect to the hole provided at the place where the first and second process cartridge frame bodies 2a and 2b overlap at the closed position. The first or second frame bodies 2a and 2b are positioned and fixed at the same time. As a result, the process cartridge frame 2 can be assembled without integrally forming the first or second frame 2a, 2b, and can be easily separated. As a result, the process means 4 and the like described below and the photoreceptor 3 can be replaced separately and independently.

The frame 2 is provided with sensor means as shown in FIG. The sensor means includes a temperature / humidity sensor 21 for detecting the temperature / humidity in the process cartridge 1, a potential sensor 22 for detecting the potential of the photosensitive member 3, and the amount of toner developed on the photosensitive member 3 after development. A toner density sensor 23 is provided.
The temperature / humidity sensor 21 is disposed in the second process cartridge frame 2b and has a positive temperature characteristic, for example, platinum, tungsten, nichrome, Kanthal, or a negative temperature coefficient, for example, SiC (silicon carbide). It is detected by a detection element such as a fine wire such as TaN (tantalum nitride) or a thin thermosensitive element such as a thin film or thermistor. As shown in FIG. 2, the temperature / humidity sensor 21 is disposed on the upper portion of the second frame 2b. However, the temperature / humidity sensor 21 is not limited to this position as long as it is on the frame.

  The potential sensor 22 is disposed on the second process cartridge frame 2b and includes a potential detection unit and a control unit. The potential sensor 22 is spaced from the surface of the photoconductor 3 of the object to be measured by 1 to 3 mm. By disposing, the surface potential of the photoreceptor 3 can be detected. As shown in FIG. 2, the potential sensor 22 is disposed above the first frame 2a, between the charging module 4 and the developing module 5, and downstream of the laser light to be exposed. At this position, the potential of the photoreceptor 3 on which a latent image that becomes a patch-like solid black portion is formed is detected, and the detected signal is transmitted to the main body of the image forming apparatus 100 through a signal line (harness) 24 and developed by this control unit. The magnitude of the developing bias applied by the module 5 is determined, and the voltage is applied by controlling the power source. The potential sensor 22 is not limited to the position, and may detect the potential of the photoconductor 3 serving as a white background portion, and control the light amount and exposure time of the laser beam forming the solid black portion.

A toner density detection sensor (hereinafter referred to as a “P sensor”) 23 is disposed on the first process cartridge frame 2a, and a latent image of a solid black portion formed outside the image forming area on the photoreceptor 3 is formed with toner. A visible image is formed, the toner adhesion amount of the solid black portion is optically detected as an image density, and the detection result is transmitted as a signal to the control unit. The P sensor 23 is composed of a light emitting element (for example, LED) and a light receiving element (not shown), and the light receiving element captures the amount of light reflected from the solid black portion to obtain the amount of toner on the photoreceptor 3. The toner amount on the photosensitive member 3 is detected, and the toner concentration of the developer contained in the developing module 5 is determined from the table recorded in the control unit. The P sensor is provided on the downstream side of the developing module 5.
By arranging the sensors related to the photosensitive member 3 in the cartridge frames 2a and 2b in this way, the sensor means can be used effectively without wasting expensive sensors, and the process means can be replaced individually. Can be easily. In addition, each replaceable process means can be made inexpensive.

In addition, signal line harnesses (not shown) are gathered on the back side of the process cartridge 1 and are collectively connected to a connector part 2d provided on the back side of the process cartridge 1, and are connected to the main body connector part of the image forming apparatus 100 from the connector part 2d. . A connector portion 2d is formed on the back side of the process cartridge 1, and is connected to an electric circuit on the image forming apparatus 100 main body side. A harness extending from the above-described sensor is attached to the connector portion 2d. Each harness has a rotating shaft 2c. With this configuration, the process cartridge frame 2 can be freely rotated and the exchangeability of the photosensitive member 3 and each process means can be improved.
In addition to this, for example, a pre-transfer neutralization device 25 and a pre-cleaning neutralization device 26 may be provided. The pre-transfer neutralization 25 is provided upstream of the transfer region, and the pre-cleaning neutralization device 26 is provided downstream of the transfer region and upstream of the cleaning module 6 to attenuate the charge on the photosensitive member 3 to perform transfer or cleaning. Make it easier. In particular, the pre-cleaning static elimination device 26 facilitates cleaning of residual toner that has not been transferred onto the photoreceptor 3. These light emitting diodes (LD), LEDs, electroluminescence (EL), fluorescent lamps and the like are disposed as light emitting means, and any of them can expose the photoreceptor 3 to attenuate the charge on the photoreceptor 3. . The light emitting means is preferably EL or LD, and the structure is simple, and it is more preferable to use EL. Moreover, you may provide static elimination before a charge upstream of a charging device. The residual potential of the photoconductor 3 can be erased to uniformly charge the photoconductor.

FIG. 4 is a schematic view showing the structure of the photoreceptor.
FIG. 5 is a schematic view showing a state of the back side of the process cartridge incorporated in the image forming apparatus. FIG. 6 is a schematic view showing a state of the front side of the process cartridge incorporated in the image forming apparatus.
As shown in FIG. 4, the photoreceptor 3 is provided with a photosensitive layer 36 on a cylindrical aluminum substrate 35. In the case of the cylindrical photoreceptor 3, flanges 31 and 32 are provided at both ends inside the cylinder.
As shown in FIG. 5, the flange 32 on the back side of the process cartridge is formed with a bearing 33 through which the drive shaft 101 provided in the main body of the image forming apparatus 100 passes. A gear 34 is formed on the inner surface of the bearing 33 and is fitted to a gear 102 provided on the drive shaft 101.
Further, as shown in FIG. 6, the flange 31 on the front side of the process cartridge 1 is formed with a fitting portion 37f at the center. The fitting portion 37f is fitted to the positioning portion 2e attached to the process cartridge frame 2a when the photosensitive member 3 is attached to the process cartridge 1. The positioning portion 2e is urged by a spring (not shown) in a direction in which the photosensitive member 3 is pushed back. The photosensitive member 3 is attached to the process cartridge 1 by attaching the photosensitive member 3 to the process cartridge frame while pressing the fitting portion 37r of the flange 32 against the positioning portion 2e, and vice versa at the time of removal. The photosensitive member 3 is not positioned with high accuracy so that image formation can be performed only by being supported by the support portion 12 provided on the side plate 11 of the process cartridge frame 2. The image forming apparatus 100 includes a bearing 103 that is aligned with a hole 13 provided in the frame rear plate 11r of the process cartridge 1 on the back plate 111r of the image forming apparatus 100 main body. The drive shaft 101 is inserted into the hole 13 of the process cartridge 1 to position the image forming apparatus 100 and the process cartridge 1.

  Further, the drive shaft 101 is inserted into a bearing 33 in the flange 31 of the photosensitive member 3 and is fitted to a gear 102 of the drive shaft 101 and a gear 34 provided on the flange 31. When the drive shaft 101 disposed in the main body of the image forming apparatus 100 is rotated, the gear 102 of the drive shaft 101 rotates the photoconductor 3 via the gear 34 of the photoconductor 3. Further, the photosensitive member 3 is not fixed to the support portion 11 of the process cartridge 1 but is supported, and the drive shaft 101 provided in the main body of the image forming apparatus 100 is inserted into the photosensitive member 3, whereby the photosensitive member 3. Positioning. The positioning of the process cartridge 1 and the photosensitive member 3 is simultaneously performed by the drive shaft 101 provided in the main body of the image forming apparatus 100. In order to drive the photoconductor 3 with high accuracy as in this configuration, it is effective to have the rotating shaft of the photoconductor 3, but in this embodiment, the drive shaft 101 is placed on the image forming apparatus 100 main body side. By providing and positioning while penetrating the process cartridge 1, the photosensitive member 3 and the process cartridge 1 can be made inexpensive and can be rotationally driven with high accuracy.

FIG. 7 is a schematic view showing the structure of the photosensitive layer of the photoreceptor.
The substrate 35 of the photoconductor 3 is formed by, for example, extruding a metal such as aluminum, copper, iron, or an alloy of these metals, drawing it, etc. to form a cylindrical blank, then cutting, superfinishing, polishing or the like surface Formed into a treated cylindrical drum.
The structure of the photosensitive layer 36 includes a charge generation layer 36a that is a layer mainly composed of a charge generation material and a charge transport layer 36b that transports the generated charges to the surface of the photoreceptor or the substrate 35. In the charge generation layer 36a, a charge generation material is dispersed in a suitable solvent together with a binder resin as necessary using a ball mill, an attritor, a sand mill, an ultrasonic wave, etc., and this is applied onto a conductive support. It is formed by drying. A known charge generation material can be used for the charge generation layer 36a, and representative examples thereof include monoazo pigments, disazo pigments, trisazo pigments, perylene pigments, perinone pigments, quinacridone pigments, quinone condensation polymers. Examples thereof include ring compounds, squalic acid dyes, phthalocyanine pigments, naphthalocyanine pigments, and azulenium salt dyes. Of these, azo pigments and / or phthalocyanine pigments are effectively used.

The charge transport layer 36b can be formed by dissolving or dispersing a charge transport material and a binder resin in an appropriate solvent, and applying and drying the solution on the charge generation layer. Moreover, a plasticizer, a leveling agent, antioxidant, etc. can also be added as needed. Charge transport materials include hole transport materials and electron transport materials. Examples of the charge transporting material include chloroanil, bromineyl, tetracyanoethylene, and examples of the hole transporting material include poly-N-vinylcarbazole and derivatives thereof, poly-γ-carbazolylethyl glutamate and derivatives thereof, and pyrene-formaldehyde condensates. And derivatives thereof, polyvinylpyrene, and polyvinylphenanthrene.
Further, a protective layer 36 c may be provided on the photosensitive layer 36 in order to protect the photosensitive layer 36. In addition, a filler can be added to the protective layer 36c for the purpose of improving wear resistance. In particular, it is advantageous to use an inorganic material among them from the viewpoint of the hardness of the filler. In particular, silica, titanium oxide, and alumina can be used effectively.

FIG. 8A is a schematic diagram showing an external appearance of the charging module, and FIG. 8B is a schematic diagram showing a side surface thereof. FIG. 9 is a schematic diagram showing the configuration of the charging module.
As shown in FIGS. 8 and 9, the charging module 4 prevents the charging member 42 disposed opposite to the photoreceptor 3 and the charging member 42 from vibrating, and the spring material 43 and the charging member 42 are contaminated. And a spacer member 45, a spring support member 46, and a housing 41 for housing them. The charging member 42 and the charging cleaning roller 44 are rotatably supported by the spring support member 46. The spring support member 46 is pressed by the spring material 43 in a direction away from the housing 41 (a direction toward the drum shaft of the photosensitive member), and movement of the spring support member 46 is restricted by a restriction member formed on the housing 41. With this configuration, when the charging module 4 is mounted on the process cartridge 1, the charging member 42 maintains an appropriate distance from the photoreceptor 3 by the spacer member 45 and prevents the charging member 42 from vibrating. Further, when the charging module 4 is removed, the charging module 4 itself can be handled.

FIG. 10 is a schematic view showing a state in which the charging module is mounted on the process cartridge.
As shown in FIG. 10, the charging module 4 has charging fitting portions 15 f provided on both side plates 11 f and 11 r (“f” represents the front side and “r” represents the back side. The same applies hereinafter) of the process cartridge 1. , 15r, and are fitted and positioned to be fixed to the second process cartridge frame 2b.

FIG. 11 is a schematic view showing the structure of the charging member. In this charging module 4, the charging member 42 can be configured in an appropriate form, but a roller shape is preferable. The charging roller 42 has a structure including a main body portion 42b having a shaft portion 42a made of a metal core at the center, an intermediate resistance layer 42c on the outer side, and a surface layer 42d on the outermost layer. The shaft portion 42a is made of, for example, stainless steel having a diameter of 8 to 20 mm, aluminum having high rigidity and conductivity, or 1 × 10 ³ Ω · cm or less, preferably 1 × 10 ² Ω · cm or less. It is made of conductive resin having high rigidity. The medium resistance layer 42c preferably has a volume resistivity of 1 × 10 ⁵ Ω · cm to 1 × 10 ⁹ Ω · cm and a thickness of about 1 to 2 mm. The surface layer 42d has a volume resistivity of 1 × 10 ⁶ Ω · cm to 1 × 10 ¹² Ω · cm, and preferably has a thickness of about 10 μm. The volume resistivity of the surface layer 42d is preferably higher than the electrical resistivity of the middle resistance layer 42c. Here, the main body portion 42b is shown as a two-layer structure of the middle resistance layer 42c and the surface layer 42d, but is not particularly limited to this structure, and may be a single layer or three layers.

  The gap between the charging roller 42 and the photoreceptor 3 is set to 100 μm or less, particularly 20 to 50 μm, by the spacer member 45. Thereby, formation of an abnormal image at the time of operation of the charging module 4 can be suppressed. The gap may be adjusted by a charging fitting portion 15 that fits the process cartridge 1 and the charging device 4. The charging roller 42 is pressed toward the surface of the photoreceptor 3 by a spring material 43 provided on a bearing made of a resin having a low friction coefficient. As a result, a constant gap can be formed even if there is mechanical vibration or deviation of the cored bar. Further, the charging module 4 includes a charging cleaning roller 44 for removing contamination of the charging roller 42. As shown in FIG. 10, the charging cleaning roller 44 is fitted into a bearing 47 provided on a side plate of the housing 41 (not shown) of the charging module 4 and is rotatably supported. The charging cleaning roller 44 contacts the charging roller 42 to clean the outer peripheral surface. If foreign matter such as toner, paper powder, or a damaged member adheres to the surface of the charging roller 42, abnormal discharge is prevented. The charging cleaning roller 44 is preferably in the form of a resin fiber brush, and a plurality of charging cleaning rollers 44 can be provided.

FIG. 12 is a schematic view showing the appearance of the developing module.
As shown in FIG. 1, the developing module 5 is mounted on the first frame 2a. Further, the developing module 5 includes a developing sleeve 51 that is a developer carrying member disposed so as to be close to the photosensitive member 3, a replenishing port 58 that replenishes toner from a replenishing toner container that is provided separately from the developing module, replenishment A mixing screw 55 that mixes and stirs the toner that has been mixed, a supply roller 56 that supplies the mixed developer to the developing sleeve, and the like, and allows the developer to be supplied to the photoreceptor 3.
FIG. 13 shows another example of the developing module and is a cross-sectional view showing the structure thereof. In the developing module 5, a toner hopper 52 for storing supply toner, a supply roller 54 for supplying toner from the toner hopper to the developer storage unit 53, a mixing screw 55 for mixing and stirring the supplied toner with a magnetic carrier, and mixing A supply roller 56 that supplies the developed developer to the developing sleeve and a regulating member 57 that regulates the amount of the developer supplied to the developing sleeve 51 are disposed.
In the developing sleeve, a developing sleeve formed of a non-magnetic material such as aluminum, brass, stainless steel, or conductive resin in a cylindrical shape is rotated by a rotation driving mechanism. The height of the developer chain spike, that is, the amount of developer on the developing sleeve 51 is regulated by a regulating member 57 arranged in the upstream portion of the developing area in the developer transport direction. The distance between the regulating member 57 and the developing sleeve 51 in the developing region is accurately positioned to obtain a high-quality image.

14 and 15 are schematic views showing a state in which the developing module is mounted.
As shown in FIGS. 14 and 15, the developing module 5 is mounted along the guide groove 2e provided in the first frame 2a and once held, and then the hole 71b of the positioning member 71 which is a developing means face plate. Thus, the shaft portion of the photosensitive drum is penetrated by the second protrusion-shaped (D-type) guide 59b coaxial with the developing sleeve and the hole portion 71d, and is used as a main reference for positioning. At the same time, the first protruding guide 59a of the developing module 5 is inserted into the guide portion 2f of the first frame 2a, and the protruding guide 28 of the first frame 2a is inserted into the third hole-shaped guide 71c of the positioning member 71. Determine the subordinate standard.
After positioning by the positioning member 71, the sleeve angle determining member 72 (name changed from the fixed member) is inserted into the second protrusion-shaped (D-type) guide 59b after the D-shaped hole 71e is inserted, and then the direction of the lines of magnetic force is changed to the photosensitive drum. It fixes to the 1st frame 2a with the hole 71e according to an axial direction. In this way, the developing module 5 can be easily and accurately positioned on the process cartridge.
On the contrary, by removing the sleeve angle determination member 72 and the development positioning member 71, the development module 5 can be easily separated from the process cartridge.
The developing module of the present invention has been described with respect to the developing module using a dry two-component developer. However, even in a developing module using a dry two-component developer and using recycled toner, a one-component magnetic developer, one A developing module using a component nonmagnetic developer may be used.
Further, the developing module 5 of the present invention can be provided with a supply port 58 for supplying toner. The process cartridge 1 of the present invention is shipped with the replenishment port 58 sealed with a seal, a lid or the like, and is opened when first used. After opening, the process cartridge 1 that has been used and the toner has been emptied can be used again by refilling the toner. Further, the process cartridge 1 can store newly supplied toner in a storage unit 53 that stores toner. This toner may be a refilled toner or a toner that is collected and reused. At this time, a storage unit (not shown) for storing toner for replenishment may be provided in the image forming apparatus main body. Further, the storage portion may be provided in the process cartridge 1. In these cases, the developing module 5 can be used repeatedly without replacing the developing module 5 by supplying toner to the developing module 5 and placing the highest priority on the toner.

FIG. 16 is a schematic cross-sectional view showing the configuration of the cleaning module.
As shown in FIG. 16, the cleaning module 6 includes a cleaning mechanism 6a and an application mechanism 6b. As shown in FIG. 16, the cleaning mechanism 6 a includes a cleaning blade 61 that removes residual toner on the surface of the photoreceptor 3, a support member 62 that biases the cleaning blade 61 toward the photoreceptor, and a bias that controls the charge amount of the residual toner. A roller 64, a collection roller 66 for collecting the toner attached to the cleaning blade, a flicker 63a for scraping off the residual toner attached to the bias roller, and a flicker 63b for sweeping out the residual toner attached to the collection roller. I do. The residual toner cleaned by the cleaning blade 61 and the residual toner swept off by the flicker 63 fall downward due to its own weight, and are transported to the outside of the process cartridge 1 by the transport auger 65 formed coaxially with the rotating shaft 2c of the frame. And collected in the waste toner container.

  The application mechanism 6 b includes a lubricant molded body 67 and an application roller 66 that contacts the lubricant molded body 67 and scrapes off the lubricant and supplies it to the surface of the photoreceptor 5. Here, the application roller 66 also serves as the above-described collection roller 66 (hereinafter referred to as “collection / application roller”). In addition, although not shown, a pressure spring that presses the lubricant molded body 67 against the recovery / application roller 66 with a predetermined pressure may be provided. The lubricant molded body 67 is formed in a rectangular parallelepiped shape, is held by the cleaning module 6, and is pressed by a pressure spring to be brought into contact with the collection / application roller 66. As a result, the collection / application roller 66 simultaneously collects the residual toner accumulated on the cleaning blade and applies the lubricant. Here, the lubricant application mechanism 6b is provided in the cleaning module 6. However, the lubricant application mechanism 6b is provided separately from the cleaning mechanism 6a and can be independently replaced independently of the cleaning mechanism 6b. May be. The collection / application roller 66 has a shape extending in the axial direction of the photoreceptor 3. The pressure spring is biased against the collection / application roller 66 so that almost all of the lubricant molded body 67 is used up. Since the lubricant molded body 67 is a consumable product, its thickness decreases with time, but since it is pressurized by the pressure spring, the lubricant is scraped off by constantly contacting the recovery / application roller 66, Thereafter, the photosensitive member 3 is supplied and applied. Examples of the lubricant of the lubricant molded body 67 include lead oleate, zinc oleate, copper oleate, zinc stearate, cobalt stearate, iron stearate, copper stearate, zinc palmitate, copper palmitate, linolene. Fatty acid metal salts such as zinc acid, polytetrafluoroethylene, polychlorotrifluoroethylene, polyvinylidene fluoride, polytrifluorochloroethylene, dichlorodifluoroethylene, tetrafluoroethylene-ethylene copolymer, tetrafluoroethylene-oxafluoropolo Fluorine-based resins such as pyrene copolymers are exemplified. In particular, a metal stearate having a large effect of reducing the friction of the photoreceptor 5 and further zinc stearate are more preferable.

FIG. 17 is a schematic view showing a state where the cleaning module is mounted.
The cleaning module 6 can be mounted and removed from the lateral direction of the process cartridge 1 independently from other process means. The cleaning module 6 is engaged with the process cartridge 1, and the first and second holes 25 a and 25 b provided in the second frame 2 b are passed through the first and second protruding guides provided in the cleaning module 6. It is fixed and mounted by a cleaning positioning member 73 having a cylindrical guide 73a that can be used. Here, when the cleaning module 6 is fixed to the second frame 2 b with the cleaning positioning member 73, the cleaning module 6 adjusts the contact condition for contacting the photosensitive member 3 such as the cleaning blade 61. Further, the transport auger 65 may be inserted into the frame engaging portion 2c and fixed.
FIG. 18 is a schematic view showing a state where the cleaning cartridge is opened by rotating the process cartridge second frame 2b. As shown, the cleaning module 6 can be pivoted open. Although the cleaning module 6 includes the cleaning blade 61, those that can still be used, such as the support member 62 that holds the cleaning blade 61, are replaced, resulting in waste. In order to avoid this, in the cleaning module 6, the cleaning blade 61 and the support member 62 are fixed to the side plate of the frame 2b by a blade positioning member 76. Since the frame 2b is open, only the cleaning blade 61 can be easily replaced by removing the blade positioning member 76. In particular, since the wear of the cleaning blade 61 greatly affects the cleaning performance, the long-term cleaning performance of the image forming apparatus 100 can be easily ensured.
Here, by removing the cleaning positioning member 75, it is possible to replace the members provided in the cleaning module 6 that are easily worn by rotation, such as the bias roller 64 and the collection / application roller 66, respectively. Also, the lubricant molded body 67 can be easily removed and replenished by removing the cleaning positioning member 75. This facilitates replacement of the collection / application roller 66 and the like of the cleaning module 6 without replacing the entire cleaning module 6.

FIG. 19 shows a casing (hereinafter referred to as “cleaning sub-module”) composed of a plurality of parts having the same lifetime in the cleaning means in a different embodiment from the cleaning module shown in FIGS. FIG. 3 is a schematic configuration diagram of a cleaning submodule that is supported by the main body.
The cleaning sub-module 6c can easily replace the cleaning module 6 by using members such as the bias roller 64, the collection / application roller 66, and the lubricant molding 67 as one replacement unit. Here, as shown in FIG. 19, the bias roller 64 for controlling the charge amount of the residual toner, the lubricant collection / application roller 66, the lubricant molding 67, and the residual toner attached to the recovery roller and the bias roller are swept away. The members, such as first and second flickers (not shown) that are frequently exchanged, are integrated as a cleaning sub-module 6c, and can be replaced independently by being modularized separately from the cleaning module 6.
FIG. 20 is a schematic view showing a state in which the cleaning submodule 6c is opened by rotating the process cartridge second frame 2b. As a result, the cleaning submodule 6c can be easily replaced. The cleaning submodule 6c is fixed by inserting two pins planted on the cleaning positioning member 75 into the second frame 2b. The cleaning submodule 6c can be removed by removing the cleaning positioning member 75 after rotating the frame 2b by 90 ° so that the cleaning submodule 6c faces upward.

In the process cartridge 1 of the present invention, any of the mounted photoconductor 3, charging module 4, developing module 5, and cleaning module 6 can be removed, separated, and replaced. In particular, any of the charging module 4, the developing module 5, the cleaning module 6, and the cleaning sub-module 6c can be detached and attached independently of the other modules.
The charging module 4 can be removed by pulling upward from the charging fitting portion 15 of the process cartridge 1. As can be seen from FIG. 10, the developing module 5 can be removed from the frame 2 by removing the sleeve angle positioning member 72 and further removing the developing positioning member 71. The cleaning module 6 can be removed laterally by removing the cleaning positioning member 73.

  In the cleaning module 6, as shown in FIGS. 18 and 20, by removing the frame positioning member 74, the frame 2b can be rotated about 90 ° to open the inside. When the cleaning blade 61 contacts the photoreceptor 3 to clean the toner, the tip is worn and must be replaced. Further, since the lubricant molded body 67 is also consumed by being applied to the photoreceptor 3, the lubricant molded body 67 must be replaced. Therefore, the cleaning blade 61 and the collection / application roller 66 can be easily replaced individually at the open position of the frame 2b, and the collection / application roller 66, which is easily worn and consumed in the cleaning submodule 6c, The lubricant molded body 67 can be integrated and removed.

  21 and 22 are schematic views showing a state when the photosensitive member is detached from the process cartridge and separated. Further, the photoreceptor 3 can be separated as follows. As shown in FIG. 21, the positioning member 74 that fixes the second frame 2b is removed and rotated by the engaging portion 2c of the frame 2b to open the upper portion of the process cartridge 1. Furthermore, as shown in FIG. 22, the photosensitive member 3 that is only supported by the support portion 13 of the frame 2 of the process cartridge 1 and is not fixed is pressed against the positioning portion 75 side of the process cartridge frame 2. By pulling upward, it can be easily separated.

FIG. 23 is a schematic diagram illustrating a configuration of an image forming apparatus according to an embodiment of the present invention. Here, an embodiment applied to the electrophotographic image forming apparatus 100 will be described. The image forming apparatus 100 is an image forming apparatus (hereinafter referred to as a “tandem type”) 100 that forms a color image by arranging four process cartridges 1 in parallel in the moving direction of the photoreceptor 3. Further, the conveying belt 106a in the transfer device 106 is configured to endlessly move by being stretched around four support rollers 106b, 106c, 106d, and 106e. The toner images on the process cartridges 1Y, 1C, 1M, and 1K using four color toners are transferred onto the transfer paper conveyed on the conveying belt 106a so as to overlap each other by the electrostatic transfer method. The electrostatic transfer method employs a configuration using a transfer roller 106f. Specifically, the transfer rollers 106fY, 106fC, 106fM, and 106fK as the transfer devices 106 are arranged on the back surface of the portion of the conveyance belt 106a that contacts the process cartridges 1Y, 1C, 1M, and 1K, respectively. Here, a transfer region is formed by the portion of the conveyor belt 106a pressed by the transfer roller 106f and the photosensitive member 3. When the toner images on the process cartridges 1Y, 1C, 1M, and 1K are transferred onto the transfer paper on the conveyance belt 106a, a positive polarity bias is applied to the transfer roller 106e. As a result, a transfer electric field is formed in each primary transfer region, and the toner image on the photosensitive member 3 of each process cartridge 1 is electrostatically attached to the transfer paper that is sent at a predetermined timing. Transcribed. A belt cleaning device for removing toner remaining on the surface of the conveyor belt 106a may be provided.
This transfer paper is accommodated in a paper feed cassette 109 and is conveyed to a registration roller pair 109b by a pickup roller 109a and the like. The toner image superimposed on the transfer paper on the conveyance belt 106a is conveyed to the fixing device 108 and fixed by heat and pressure, and is discharged out of the image forming apparatus 100 by the discharge roller 120 and discharged. It is placed on the paper tray 125.
Further, the process cartridge 1 of the present invention can replenish toner. The process cartridge 1 is shipped with a supply port 58 sealed with a seal, a lid, and the like, and is opened when first used. Normally, the process cartridge 1 that has been used and has run out of toner is replaced, but the process cartridge 1 provided in the image forming apparatus 100 of the present invention can be used again by refilling the toner. Further, the process cartridge 1 can store newly supplied toner in a storage unit 53 that stores toner. This toner may be a refilled toner or a toner that is collected and reused. At this time, a storage unit (not shown) that stores the supply toner may be provided in the main body of the image forming apparatus 100. Further, the storage portion may be provided in the process cartridge 1. In these cases, the developing module 5 can be used repeatedly without replacing the developing module 5 by supplying toner to the developing module 5 and placing the highest priority on the toner.

  At this time, in the image forming apparatus 100 of the present invention, it is preferable to use toner having an average circularity of 0.93 or more. This degree of circularity is thermally or mechanically spheroidized with toner produced by dry grinding. Thermally, for example, the spheroidizing treatment can be performed by spraying toner particles together with a hot air stream on an atomizer or the like. In addition, a spheroidizing treatment can be performed by mechanically charging the mixture into a mixer such as a ball mill together with a mixed medium such as glass having a low specific gravity and stirring. However, in the thermal spheronization process, toner particles that are aggregated and have a large particle diameter or in the mechanical spheronization process generate fine powder, so that a classification process is required again. In addition, in a toner manufactured in an aqueous solvent, the shape can be controlled by applying strong stirring in the process of removing the solvent.

  The circularity is defined as circularity SR = (peripheral length of a circle having the same area as the particle projection area / perimeter length of the particle projection image) × 100%. The closer the toner is to a true sphere, the closer to 100%. The toner having a high degree of circularity is easily affected by the electric force lines on the carrier or the developing sleeve 5a, and is faithfully developed along the electric force lines of the electrostatic latent image. When reproducing minute latent image dots, fine line reproducibility is enhanced because it is easy to obtain a dense and uniform toner arrangement. In addition, a toner with a high degree of circularity has a smooth surface and a suitable fluidity, so it is easily affected by the lines of electric force and easily transfers faithfully along the lines of electric force. A quality image can be obtained. Further, even when the intermediate transfer belt 6a is pressed against the photosensitive member 3, toner having a high degree of circularity uniformly contacts the intermediate transfer belt 6a, and the contact area of the toner becomes uniform, contributing to an improvement in transfer rate. To do. However, if the average circularity of the toner is less than 0.93, faithful development and transfer with a high transfer rate cannot be performed. This is because when the toner is irregularly shaped, the toner surface is non-uniformly charged, and the center of gravity and the center of the charge are shifted, making it difficult to move faithfully to the electric field.

  Here, the image forming operation of the image forming apparatus 100 of the present invention will be described with one process cartridge 1. When the image forming operation is started, first, the charging module 4 uniformly charges the photosensitive member 3 to the negative polarity. Next, the exposure device 104 irradiates the surface of the photoconductor 3 with a laser beam based on the image data to form a latent image. A toner image is formed from the latent image by the developing module 5. At this time, the photosensitive member 3 on which the toner image is formed rotates to enter the transfer region, and is moved from the photosensitive member 3 to the intermediate transfer belt 106a that has moved at the same time by the bias from the transfer roller 106b in the transfer region. The toner image is transferred to the transfer belt 106a. In the transfer area, the toner image developed on the photoreceptor 3 is subjected to the action of a transfer electric field and nip pressure. In the tandem type in which the photosensitive member 3 has a plurality of color toners, a color toner image is formed on the intermediate transfer belt 106a by repeating this transfer a plurality of times. After that, the transfer paper that has started to be fed by the pickup roller 109a from the paper feeding unit 109 is conveyed to the registration roller 109b, and is conveyed to the secondary transfer area in synchronization with the timing of the intermediate transfer belt. In the secondary transfer area, the toner image is transferred from the intermediate transfer belt 106a to the transfer paper by the bias of the secondary transfer roller 106f. Thereafter, the toner is melted and fixed by the fixing device and fixed onto the transfer paper, and is stacked on a paper discharge tray outside the image forming apparatus 100 by the paper discharge roller 101.

  After the image is formed on the photosensitive member 3, the lubricant application mechanism 6b scrapes off the zinc stearate, which is the lubricant, from the lubricant molded body 67 by the recovery / application roller 66 and attaches it to the roller. This is applied to the surface of the photoreceptor 3 by rubbing. Next, the lubricant is pressed by the cleaning blade 61 in contact with the photosensitive member 3 to form a thin film. By forming a thin layer of this lubricant, the toner on the photoreceptor 3 is easily cleaned, and even residual toner with a high degree of circularity can be cleaned.

Further, the photosensitive member 3 coated with the lubricant is pressed onto the photosensitive member 3 by the cleaning blade 61 of the cleaning module 6 to form a thin film. This thin film reduces the coefficient of friction of the photoreceptor 3. At this time, the friction coefficient μ of the photosensitive member 3 is preferably set to 0.4 or less. The friction coefficient μ is controlled by the setting conditions of the coating mechanism 6b such as the pressure depending on the strength of the pressure spring against the lubricant molding 67, the brush density of the recovery / application roller 66, the brush diameter, the rotation speed of the roller, and the rotation direction. be able to.
By setting the coefficient of friction of the photosensitive member 3 to 0.4 or less, the friction with the cleaning blade 61 is suppressed, the deformation or turning of the cleaning blade 61 is suppressed, and the toner is prevented from slipping through the cleaning blade 61. Thus, the occurrence of cleaning failure can be suppressed. Furthermore, 0.4 or less, and further 0.3 or less are more preferable. The coefficient of friction of the photosensitive member 3 varies from the value of the coefficient of friction immediately after the image formation because it is affected by other devices provided in the image forming apparatus 100. However, the value of the friction coefficient becomes a substantially constant value by forming about 1,000 images on A4 size recording paper. Therefore, the coefficient of friction referred to here means the coefficient of friction when it becomes constant in the steady state.

Further, since the toner having a smaller volume average particle diameter Dv can improve the reproducibility of fine lines, a toner having a maximum particle size of 8 μm or less is used. However, since the developing property and the cleaning property are lowered when the particle size is small, at least 3 μm is preferable. Further, if the particle diameter is less than 3 μm, the toner having a small particle diameter that is difficult to be developed on the surface of the carrier or the developing roller 5a increases. This is not preferable because an abnormal image such as a ground cover is formed.
Moreover, it is preferable that the particle size distribution represented by ratio (Dv / Dn) of volume average particle diameter Dv and number average particle diameter Dn is the range of 1.05-1.40. By sharpening the particle size distribution, the toner charge amount distribution can be made uniform. When Dv / Dn exceeds 1.40, the toner charge amount distribution is wide and the amount of reversely charged toner increases, making it difficult to obtain a high-quality image. If Dv / Dn is less than 1.05, it is difficult to produce and it is not practical. The particle size of the toner is 50,000 by using a Coulter Counter Multisizer (manufactured by Coulter Co., Ltd.) and selecting an aperture having a measurement hole size of 50 μm corresponding to the particle size of the toner to be measured. It is obtained by measuring the average particle size of the particles.

The toner preferably has a shape factor SF-1 in the range of 100 or more and 180 or less and a shape factor SF-2 in the range of 100 or more and 180 or less in the circularity. 24A and 24B are diagrams schematically illustrating the shape of the toner. FIG. 24A is a diagram for explaining the shape factor SF-1, and FIG. 24B is a diagram for explaining the shape factor SF-2. The shape factor SF-1 indicates the ratio of the roundness of the toner shape and is represented by the following formula (1). This is a value obtained by dividing the square of the maximum length MXLNG of the shape formed by projecting the toner on a two-dimensional plane by the figure area AREA and multiplying by 100π / 4.
SF-1 = {(MXLNG) ² / AREA} × (100π / 4) (1)
When the value of SF-1 is 100, the shape of the toner becomes a true sphere, and becomes larger as the value of SF-1 increases.
The shape factor SF-2 indicates the ratio of the unevenness of the toner shape, and is represented by the following formula (2). A value obtained by dividing the square of the perimeter PERI of the figure formed by projecting the toner on the two-dimensional plane by the figure area AREA and multiplying by 100π / 4.
SF-2 = {(PERI) ² / AREA} × (100π / 4) …… Equation (2)
When the value of SF-2 is 100, there is no unevenness on the toner surface, and as the value of SF-2 increases, the unevenness of the toner surface becomes more prominent.
Specifically, the shape factor is measured by taking a photograph of the toner with a scanning electron microscope (S-800: manufactured by Hitachi, Ltd.), introducing it into an image analyzer (LUSEX 3: manufactured by Nireco) and analyzing it. Calculated.

When the shape of the toner is close to a spherical shape, the contact with the toner becomes a point contact, so that the attractive force between the toners is weakened. As a result, the fluidity is increased, and the attractive force between the toner and the photoreceptor 3 is increased. It becomes weaker, the transfer rate becomes higher, and the residual toner on the photoreceptor 3 can be easily cleaned.
The shape factors SF-1 and SF-2 of the toner are preferably 100 or more. Further, when SF-1 and SF-2 are increased, the shape becomes indeterminate, the toner charge amount distribution becomes wide, development is not faithful to the latent image, and transfer is not faithful to the transfer electric field. Image quality deteriorates. Furthermore, the transfer rate is reduced, the amount of residual toner is increased, and a large cleaning module 6 is required, which is disadvantageous in designing the image forming apparatus 100. For this reason, SF-1 preferably does not exceed 180, and SF-2 preferably does not exceed 180.

Further, the toner used in the image forming apparatus 100 may be substantially spherical. FIG. 25 is a schematic view showing the outer shape of the toner, FIG. 25A is an appearance of the toner, and FIG. 25B is a cross-sectional view of the toner. In FIG. 25 (a), the X axis represents the longest axis r1 of the longest axis of the toner, the Y axis represents the shortest axis r2 of the next longest axis, and the Z axis represents the thickness r3 of the shortest axis. ≧ Short axis r2 ≧ Thickness r3
The toner has a major axis / minor axis ratio (r2 / r1) of 0.5 to 1.0 and a thickness / minor axis ratio (r3 / r2) of 0.7 to 1.0. It has a substantially spherical shape. When the ratio of the major axis to the minor axis (r2 / r1) is less than 0.5, the charge amount distribution becomes wide because it approaches an indefinite shape.
When the ratio of the thickness to the short axis (r3 / r2) is less than 0.7, the charge amount distribution becomes wide because the shape approaches an indefinite shape. In particular, when the ratio of the thickness to the short axis (r3 / r2) is 1.0, the charge amount distribution becomes narrow because of the substantially spherical shape.
The size of the toner so far was measured with a scanning electron microscope (SEM) while changing the angle of the field of view and observing in situ.
The shape of the toner can be controlled by the manufacturing method. For example, the toner by the dry pulverization method has an irregular shape in which the toner surface is uneven and the toner shape is not constant. Even this dry pulverized toner can be made into a nearly spherical toner by applying mechanical or thermal treatment. In many cases, a toner produced by forming droplets by a suspension polymerization method or an emulsion polymerization method has a smooth surface and a nearly spherical shape. Moreover, it can be made into an ellipse by stirring in the middle of the reaction in a solvent and applying a shearing force.

In addition, as such a substantially spherical toner, a toner composition containing a polyester prepolymer having a functional group containing a nitrogen atom, a polyester, a colorant, and a release agent in an aqueous medium in the presence of fine resin particles. A toner that undergoes crosslinking and / or elongation reaction is preferred.
Hereinafter, the constituent material of the toner and a suitable manufacturing method will be described.
(polyester)
The polyester is obtained by a polycondensation reaction between a polyhydric alcohol compound and a polycarboxylic acid compound.
Examples of the polyhydric alcohol compound (PO) include dihydric alcohol (DIO) and trihydric or higher polyhydric alcohol (TO). (DIO) alone or a mixture of (DIO) and a small amount of (TO) preferable. Examples of the dihydric alcohol (DIO) include alkylene glycol (ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 1,4-butanediol, 1,6-hexanediol, etc.); alkylene ether glycol (diethylene glycol) , Triethylene glycol, dipropylene glycol, polyethylene glycol, polypropylene glycol, polytetramethylene ether glycol, etc.); alicyclic diols (1,4-cyclohexanedimethanol, hydrogenated bisphenol A, etc.); bisphenols (bisphenol A, bisphenol) F, bisphenol S, etc.); alkylene oxide (ethylene oxide, propylene oxide, butylene oxide, etc.) adduct of the above alicyclic diol; Alkylene oxide bisphenol (ethylene oxide, propylene oxide, butylene oxide, etc.), etc. adducts. Among them, preferred are alkylene glycols having 2 to 12 carbon atoms and alkylene oxide adducts of bisphenols, and particularly preferred are alkylene oxide adducts of bisphenols and alkylene glycols having 2 to 12 carbon atoms. It is a combined use. The trihydric or higher polyhydric alcohol (TO) includes 3 to 8 or higher polyhydric aliphatic alcohols (glycerin, trimethylolethane, trimethylolpropane, pentaerythritol, sorbitol, etc.); trihydric or higher phenols (Trisphenol PA, phenol novolak, cresol novolak, etc.); and alkylene oxide adducts of the above trivalent or higher polyphenols.

  Examples of the polyvalent carboxylic acid (PC) include divalent carboxylic acid (DIC) and trivalent or higher polyvalent carboxylic acid (TC). (DIC) alone and (DIC) with a small amount of (TC) Mixtures are preferred. Divalent carboxylic acids (DIC) include alkylene dicarboxylic acids (succinic acid, adipic acid, sebacic acid, etc.); alkenylene dicarboxylic acids (maleic acid, fumaric acid, etc.); aromatic dicarboxylic acids (phthalic acid, isophthalic acid, terephthalic acid) And naphthalenedicarboxylic acid). Of these, preferred are alkenylene dicarboxylic acids having 4 to 20 carbon atoms and aromatic dicarboxylic acids having 8 to 20 carbon atoms. Examples of the trivalent or higher polyvalent carboxylic acid (TC) include aromatic polycarboxylic acids having 9 to 20 carbon atoms (such as trimellitic acid and pyromellitic acid). In addition, as polyhydric carboxylic acid (PC), you may make it react with polyhydric alcohol (PO) using the above-mentioned acid anhydride or lower alkyl ester (Methyl ester, ethyl ester, isopropyl ester, etc.).

The ratio of the polyhydric alcohol (PO) to the polycarboxylic acid (PC) is usually 2/1 to 1/1, preferably as the equivalent ratio [OH] / [COOH] of the hydroxyl group [OH] and the carboxyl group [COOH]. Is 1.5 / 1 to 1/1, more preferably 1.3 / 1 to 1.02 / 1.
The polycondensation reaction between a polyhydric alcohol (PO) and a polycarboxylic acid (PC) is carried out in the presence of a known esterification catalyst such as tetrabutoxytitanate or dibutyltin oxide, and heated to 150 to 280 ° C. while reducing the pressure as necessary. The produced water is distilled off to obtain a polyester having a hydroxyl group. The hydroxyl value of the polyester is preferably 5 or more, and the acid value of the polyester is usually 1 to 30, preferably 5 to 20. By giving an acid value, it tends to be negatively charged, and furthermore, when fixing to a recording paper, the affinity between the recording paper and the toner is good and the low-temperature fixability is improved. However, when the acid value exceeds 30, there is a tendency to deteriorate with respect to the stability of charging, particularly environmental fluctuation.
The weight average molecular weight is 10,000 to 400,000, preferably 20,000 to 200,000. A weight average molecular weight of less than 10,000 is not preferable because offset resistance deteriorates. On the other hand, if it exceeds 400,000, the low-temperature fixability is deteriorated.

In addition to the unmodified polyester obtained by the above polycondensation reaction, the polyester preferably contains a urea-modified polyester. The urea-modified polyester is obtained by reacting a terminal carboxyl group or hydroxyl group of the polyester obtained by the above polycondensation reaction with a polyvalent isocyanate compound (PIC) to obtain a polyester prepolymer (A) having an isocyanate group. It is obtained by cross-linking and / or extending the molecular chain by the reaction of the amine with amines.
Examples of the polyvalent isocyanate compound (PIC) include aliphatic polyisocyanates (tetramethylene diisocyanate, hexamethylene diisocyanate, 2,6-diisocyanatomethylcaproate, etc.); alicyclic polyisocyanates (isophorone diisocyanate, cyclohexylmethane diisocyanate, etc.) Aromatic diisocyanates (tolylene diisocyanate, diphenylmethane diisocyanate, etc.); araliphatic diisocyanates (α, α, α ′, α′-tetramethylxylylene diisocyanate, etc.); isocyanates; Those blocked with caprolactam or the like; and combinations of two or more of these.
The ratio of the polyvalent isocyanate compound (PIC) is usually 5/1 to 1/1, preferably as an equivalent ratio [NCO] / [OH] of the isocyanate group [NCO] and the hydroxyl group [OH] of the polyester having a hydroxyl group. 4/1 to 1.2 / 1, more preferably 2.5 / 1 to 1.5 / 1. When [NCO] / [OH] exceeds 5, low-temperature fixability deteriorates. When the molar ratio of [NCO] is less than 1, when a urea-modified polyester is used, the urea content in the ester is lowered and hot offset resistance is deteriorated.

The content of the polyvalent isocyanate compound (PIC) component in the polyester prepolymer (A) having an isocyanate group is usually 0.5 to 40 wt%, preferably 1 to 30 wt%, more preferably 2 to 20 wt%. . If it is less than 0.5 wt%, the hot offset resistance deteriorates, and it is disadvantageous in terms of both heat-resistant storage stability and low-temperature fixability. On the other hand, if it exceeds 40 wt%, the low-temperature fixability deteriorates.
The number of isocyanate groups contained per molecule in the polyester prepolymer (A) having an isocyanate group is usually 1 or more, preferably 1.5 to 3 on average, more preferably 1.8 to 2 on average. Five. If it is less than 1 per molecule, the molecular weight of the urea-modified polyester will be low, and the hot offset resistance will deteriorate.

Next, as amines (B) to be reacted with the polyester prepolymer (A), a divalent amine compound (B1), a trivalent or higher polyvalent amine compound (B2), an amino alcohol (B3), an amino mercaptan (B4) ), Amino acid (B5), and amino acid block of B1 to B5 (B6).
Examples of the divalent amine compound (B1) include aromatic diamines (phenylenediamine, diethyltoluenediamine, 4,4′-diaminodiphenylmethane, etc.); alicyclic diamines (4,4′-diamino-3,3′-dimethyldicyclohexyl). Methane, diamine cyclohexane, isophorone diamine, etc.); and aliphatic diamines (ethylene diamine, tetramethylene diamine, hexamethylene diamine, etc.) and the like. Examples of the trivalent or higher polyvalent amine compound (B2) include diethylenetriamine and triethylenetetramine. Examples of amino alcohol (B3) include ethanolamine and hydroxyethylaniline. Examples of amino mercaptan (B4) include aminoethyl mercaptan and aminopropyl mercaptan. Examples of the amino acid (B5) include aminopropionic acid and aminocaproic acid. Examples of the compound (B6) obtained by blocking the amino group of B1 to B5 include ketimine compounds and oxazolidine compounds obtained from the amines of B1 to B5 and ketones (acetone, methyl ethyl ketone, methyl isobutyl ketone, etc.). Among these amines (B), preferred are B1 and a mixture of B1 and a small amount of B2.

The ratio of amines (B) is equivalent to the equivalent ratio [NCO] / [NHx] of isocyanate groups [NCO] in the polyester prepolymer (A) having isocyanate groups and amino groups [NHx] in amines (B). Is usually 1/2 to 2/1, preferably 1.5 / 1 to 1 / 1.5, more preferably 1.2 / 1 to 1 / 1.2. When [NCO] / [NHx] is more than 2 or less than 1/2, the molecular weight of the urea-modified polyester is lowered, and the hot offset resistance is deteriorated.
The urea-modified polyester may contain a urethane bond together with a urea bond. The molar ratio of the urea bond content to the urethane bond content is usually 100/0 to 10/90, preferably 80/20 to 20/80, and more preferably 60/40 to 30/70. When the molar ratio of the urea bond is less than 10%, the hot offset resistance is deteriorated.

The urea-modified polyester is produced by a one-shot method or the like. Polyhydric alcohol (PO) and polyvalent carboxylic acid (PC) are heated to 150-280 ° C. in the presence of a known esterification catalyst such as tetrabutoxytitanate, dibutyltin oxide, etc., and water generated while reducing the pressure as necessary. Distill off to obtain a polyester having a hydroxyl group. Subsequently, at 40-140 degreeC, this is made to react with polyvalent isocyanate (PIC), and the polyester prepolymer (A) which has an isocyanate group is obtained. Further, this (A) is reacted with amines (B) at 0 to 140 ° C. to obtain a urea-modified polyester.
When reacting (PIC) and when reacting (A) and (B), a solvent may be used if necessary. Usable solvents include aromatic solvents (toluene, xylene, etc.); ketones (acetone, methyl ethyl ketone, methyl isobutyl ketone, etc.); esters (ethyl acetate, etc.); amides (dimethylformamide, dimethylacetamide, etc.) and ethers And those inert to isocyanates (PIC), such as tetrahydrofuran (such as tetrahydrofuran).

In addition, in the crosslinking and / or extension reaction between the polyester prepolymer (A) and the amines (B), a reaction terminator can be used as necessary to adjust the molecular weight of the resulting urea-modified polyester. Examples of the reaction terminator include monoamines (diethylamine, dibutylamine, butylamine, laurylamine, etc.), and those obtained by blocking them (ketimine compounds).
The weight average molecular weight of the urea-modified polyester is usually 10,000 or more, preferably 20,000 to 10,000,000, and more preferably 30,000 to 1,000,000. If it is less than 10,000, the hot offset resistance deteriorates. The number average molecular weight of the urea-modified polyester or the like is not particularly limited when the above-mentioned unmodified polyester is used, and may be a number average molecular weight that can be easily obtained to obtain the weight average molecular weight. When the urea-modified polyester is used alone, its number average molecular weight is usually 2000-15000, preferably 2000-10000, more preferably 2000-8000. When it exceeds 20000, the low-temperature fixability and the glossiness when used in a full-color apparatus are deteriorated.

By using the unmodified polyester and the urea-modified polyester in combination, the low-temperature fixability and the gloss when used in the full-color image forming apparatus 100 are improved. Therefore, it is preferable to use the urea-modified polyester alone. The unmodified polyester may include a polyester modified with a chemical bond other than a urea bond.
The unmodified polyester and the urea-modified polyester are preferably at least partially compatible with each other in terms of low-temperature fixability and hot offset resistance. Therefore, it is preferable that the unmodified polyester and the urea-modified polyester have a similar composition.
The weight ratio of unmodified polyester to urea-modified polyester is usually 20/80 to 95/5, preferably 70/30 to 95/5, more preferably 75/25 to 95/5, and particularly preferably 80 /. 20-93 / 7. When the weight ratio of the urea-modified polyester is less than 5%, the hot offset resistance is deteriorated, and it is disadvantageous in terms of both heat-resistant storage stability and low-temperature fixability.
The glass transition point (Tg) of the binder resin containing unmodified polyester and urea-modified polyester is usually 45 to 65 ° C, preferably 45 to 60 ° C. If it is less than 45 ° C., the heat resistance of the toner deteriorates, and if it exceeds 65 ° C., the low-temperature fixability becomes insufficient.
In addition, since the urea-modified polyester is likely to be present on the surface of the obtained toner base particles, the heat-resistant storage stability tends to be good even when the glass transition point is low as compared with known polyester-based toners.

  Here, existing materials can be used for the colorant, charge control agent, release agent and the like.

Next, a toner manufacturing method will be described. Here, although a preferable manufacturing method is shown, it is not limited to this.
(Toner production method)
1) A toner material solution is prepared by dispersing a colorant, unmodified polyester, a polyester prepolymer having an isocyanate group, and a release agent in an organic solvent.
The organic solvent is preferably volatile with a boiling point of less than 100 ° C. from the viewpoint of easy removal after toner base particle formation. Specifically, toluene, xylene, benzene, carbon tetrachloride, methylene chloride, 1,2-dichloroethane, 1,1,2-trichloroethane, trichloroethylene, chloroform, monochlorobenzene, dichloroethylidene, methyl acetate, ethyl acetate, methyl ethyl ketone, Methyl isobutyl ketone and the like can be used alone or in combination of two or more. In particular, aromatic solvents such as toluene and xylene and halogenated hydrocarbons such as methylene chloride, 1,2-dichloroethane, chloroform, and carbon tetrachloride are preferable. The usage-amount of an organic solvent is 1-300 weight part normally with respect to 100 weight part of polyester prepolymers, Preferably it is 1-100 weight part, More preferably, it is 25-70 weight part.

2) The toner material liquid is emulsified in an aqueous medium in the presence of a surfactant and resin fine particles.
The aqueous medium may be water alone or an organic solvent such as alcohol (methanol, isopropyl alcohol, ethylene glycol, etc.), dimethylformamide, tetrahydrofuran, cellosolves (methyl cellosolve, etc.), lower ketones (acetone, methyl ethyl ketone, etc.). It may be included.
The amount of the aqueous medium used relative to 100 parts by weight of the toner material liquid is usually 50 to 2000 parts by weight, preferably 100 to 1000 parts by weight. If the amount is less than 50 parts by weight, the dispersion state of the toner material liquid is poor, and toner particles having a predetermined particle diameter cannot be obtained. If it exceeds 20000 parts by weight, it is not economical.
Further, in order to improve the dispersion in the aqueous medium, a dispersant such as a surfactant and resin fine particles is appropriately added.
As surfactants, anionic surfactants such as alkylbenzene sulfonates, α-olefin sulfonates, phosphate esters, alkylamine salts, amino alcohol fatty acid derivatives, polyamine fatty acid derivatives, amine salt types such as imidazoline, Quaternary ammonium salt type cationic surfactants such as alkyltrimethylammonium salt, dialkyldimethylammonium salt, alkyldimethylbenzylammonium salt, pyridinium salt, alkylisoquinolinium salt, benzethonium chloride, fatty acid amide derivative, polyhydric alcohol Nonionic surfactants such as derivatives, for example, amphoteric surfactants such as alanine, dodecyldi (aminoethyl) glycine, di (octylaminoethyl) glycine and N-alkyl-N, N-dimethylammonium betaine And the like.

Further, by using a surfactant having a fluoroalkyl group, the effect can be obtained in a very small amount. Preferred anionic surfactants having a fluoroalkyl group include fluoroalkyl carboxylic acids having 2 to 10 carbon atoms and metal salts thereof, disodium perfluorooctanesulfonyl glutamate, 3- [ω-fluoroalkyl (C6-C11 ) Oxy] -1-alkyl (C3-C4) sodium sulfonate, 3- [ω-fluoroalkanoyl (C6-C8) -N-ethylamino] -1-propanesulfonic acid sodium, fluoroalkyl (C11-C20) carvone Acids and metal salts, perfluoroalkylcarboxylic acids (C7 to C13) and metal salts thereof, perfluoroalkyl (C4 to C12) sulfonic acids and metal salts thereof, perfluorooctanesulfonic acid diethanolamide, N-propyl-N- ( 2-Hydroxyethyl) Perful Olooctanesulfonamide, perfluoroalkyl (C6-C10) sulfonamidopropyltrimethylammonium salt, perfluoroalkyl (C6-C10) -N-ethylsulfonylglycine salt, monoperfluoroalkyl (C6-C16) ethyl phosphate, etc. Can be mentioned.
Product names include Surflon S-111, S-112, S-113 (Asahi Glass Co., Ltd.), Florard FC-93, FC-95, FC-98, FC-129 (Sumitomo 3M Co., Ltd.), Unidyne DS-101. DS-102 (manufactured by Daikin Industries, Ltd.), Megafac F-110, F-120, F-113, F-191, F-812, F-833 (manufactured by Dainippon Ink, Inc.), Xtop EF-102, 103, 104, 105, 112, 123A, 123B, 306A, 501, 201, 204 (manufactured by Tochem Products), and Fgentent F-100, F150 (manufactured by Neos).

  Further, as the cationic surfactant, aliphatic quaternary ammonium salts such as aliphatic primary, secondary or secondary amine acids having a fluoroalkyl group, and perfluoroalkyl (C6-C10) sulfonamidopropyltrimethylammonium salts. , Benzalkonium salt, benzethonium chloride, pyridinium salt, imidazolinium salt, trade names include Surflon S-121 (manufactured by Asahi Glass), Florard FC-135 (manufactured by Sumitomo 3M), Unidyne DS-202 (Daikin Industries) Manufactured), MegaFuck F-150, F-824 (Dainippon Ink Co., Ltd.), Xtop EF-132 (Tochem Products), Footgent F-300 (Neos), and the like.

The resin fine particles are added to stabilize the toner base particles formed in the aqueous medium. For this reason, it is preferable to add so that the coverage existing on the surface of the toner base particles is in the range of 10 to 90%. For example, polymethyl methacrylate fine particles 1 μm and 3 μm, polystyrene fine particles 0.5 μm and 2 μm, poly (styrene-acrylonitrile) fine particles 1 μm, trade names are PB-200H (manufactured by Kao), SGP (manufactured by Soken), Techno Examples include polymer SB (manufactured by Sekisui Chemical Co., Ltd.), SGP-3G (manufactured by Sokensha), and micropearl (manufactured by Sekisui Fine Chemical Co., Ltd.).
In addition, inorganic compound dispersants such as tricalcium phosphate, calcium carbonate, titanium oxide, colloidal silica, and hydroxyapatite can also be used.
As a dispersant that can be used in combination with the above resin fine particles and inorganic compound dispersant, the dispersed droplets may be stabilized by a polymer protective colloid. For example, acrylic acid, methacrylic acid, α-cyanoacrylic acid, α-cyanomethacrylic acid, itaconic acid, crotonic acid, fumaric acid, maleic acid or maleic anhydride and other (meth) acrylic monomers containing hydroxyl groups Bodies such as acrylic acid-β-hydroxyethyl, methacrylic acid-β-hydroxyethyl, acrylic acid-β-hydroxypropyl, methacrylic acid-β-hydroxypropyl, acrylic acid-γ-hydroxypropyl, methacrylic acid-γ-hydroxy Propyl, acrylic acid-3-chloro-2-hydroxypropyl, methacrylic acid-3-chloro-2-hydroxypropyl, diethylene glycol monoacrylate, diethylene glycol monomethacrylate, glycerol monoacrylate, glycerol monomethacrylate Luric acid esters, N-methylol acrylamide, N-methylol methacrylamide, etc., vinyl alcohol or ethers with vinyl alcohol, such as vinyl methyl ether, vinyl ethyl ether, vinyl propyl ether, or compounds containing vinyl alcohol and a carboxyl group Esters such as vinyl acetate, vinyl propionate, vinyl butyrate, acrylamide, methacrylamide, diacetone acrylamide or their methylol compounds, acid chlorides such as acrylic acid chloride, methacrylic acid chloride, vinyl pyridine, vinyl pyrrolidone, vinyl Nitrogen compounds such as imidazole and ethyleneimine, or homopolymers or copolymers such as those having a heterocyclic ring thereof, polyoxyethylene, poly Xoxypropylene, polyoxyethylene alkylamine, polyoxypropylene alkylamine, polyoxyethylene alkylamide, polyoxypropylene alkylamide, polyoxyethylene nonylphenyl ether, polyoxyethylene lauryl phenyl ether, polyoxyethylene stearyl phenyl ester, polyoxy Polyoxyethylenes such as ethylene nonylphenyl ester, celluloses such as methyl cellulose, hydroxyethyl cellulose, and hydroxypropyl cellulose can be used.

  The dispersion method is not particularly limited, and known equipment such as a low-speed shear method, a high-speed shear method, a friction method, a high-pressure jet method, and an ultrasonic wave can be applied. Among these, the high-speed shearing method is preferable in order to make the particle size of the dispersion 2 to 20 μm. When a high-speed shearing disperser is used, the rotational speed is not particularly limited, but is usually 1000 to 30000 rpm, preferably 5000 to 20000 rpm. The dispersion time is not particularly limited, but in the case of a batch method, it is usually 0.1 to 5 minutes. The temperature during dispersion is usually 0 to 150 ° C. (under pressure), preferably 40 to 98 ° C.

3) At the same time as the preparation of the emulsion, the amines (B) are added to cause a reaction with the polyester prepolymer (A) having an isocyanate group.
This reaction involves molecular chain crosslinking and / or elongation. The reaction time is selected depending on the reactivity between the isocyanate group structure of the polyester prepolymer (A) and the amines (B), but is usually 10 minutes to 40 hours, preferably 2 to 24 hours. The reaction temperature is generally 0 to 150 ° C, preferably 40 to 98 ° C. Moreover, a well-known catalyst can be used as needed. Specific examples include dibutyltin laurate and dioctyltin laurate.

4) After completion of the reaction, the organic solvent is removed from the emulsified dispersion (reactant), washed and dried to obtain toner base particles.
In order to remove the organic solvent, the temperature of the entire system is gradually raised in a laminar stirring state, and after giving strong stirring in a certain temperature range, the solvent base is removed to produce spindle-shaped toner base particles. . Further, when an acid such as calcium phosphate salt or an alkali-soluble material is used as the dispersion stabilizer, the calcium phosphate salt is dissolved from the toner base particles by a method such as dissolving the calcium phosphate salt with an acid such as hydrochloric acid and washing with water. Remove. It can also be removed by operations such as enzymatic degradation.

5) A charge control agent is injected into the toner base particles obtained above, and then inorganic fine particles such as silica fine particles and titanium oxide fine particles are externally added to obtain a toner.
When preparing a developer by adding external additives and lubricants, these may be added simultaneously or separately and mixed. For mixing external additives and the like, a general powder mixer is used, but it is preferable to equip a jacket or the like to adjust the internal temperature. Examples of the mixing equipment that can be used include a V-type mixer, a rocking mixer, a Ladige mixer, a Nauter mixer, a Henschel mixer, and the like. It is preferable to prevent the embedding of the external additive and the formation of a thin film on the toner surface of the lubricant by changing the mixing conditions such as the rotation speed, rolling speed, time, and temperature.
Thereby, a toner having a small particle size and a sharp particle size distribution can be easily obtained. Furthermore, by giving strong agitation in the process of removing the organic solvent, the shape between the spherical shape and the spindle shape can be controlled, and the surface morphology is also controlled between the smooth shape and the umeboshi shape. Can do.

As an external additive for assisting fluidity, developability and chargeability, inorganic fine particles can be preferably used. In particular, hydrophobic silica and / or hydrophobic titanium oxide are preferred. The primary particle diameter of the inorganic fine particles is preferably 5 μm to 2 μm, and particularly preferably 5 μm to 500 μm. Moreover, it is preferable that the specific surface area by BET method is 20-500 m < ² > / g. The proportion of the inorganic fine particles used is preferably 0.01 to 5% by weight of the toner, and particularly preferably 0.01 to 2.0% by weight.
Specific examples of other inorganic fine particles include, for example, alumina, barium titanate, magnesium titanate, calcium titanate, strontium titanate, zinc oxide, tin oxide, silica sand, clay, mica, wollastonite, diatomaceous earth, Examples thereof include chromium oxide, cerium oxide, pengala, antimony trioxide, magnesium oxide, zirconium oxide, barium sulfate, barium carbonate, calcium carbonate, silicon carbide, and silicon nitride. Other polymer fine particles such as polystyrene obtained by soap-free emulsion polymerization, suspension polymerization and dispersion polymerization, methacrylic acid ester and acrylic acid ester copolymer, polycondensation system such as silicone, benzoguanamine and nylon, and thermosetting resin Examples include polymer particles.
Such a fluidizing agent can be surface-treated to increase hydrophobicity and prevent deterioration of flow characteristics and charging characteristics even under high humidity. For example, silane coupling agents, silylating agents, silane coupling agents having an alkyl fluoride group, organic titanate coupling agents, aluminum coupling agents, silicone oils, modified silicone oils and the like are preferable surface treatment agents. .

  The toner of the present invention can be mixed with a magnetic carrier and used as a two-component developer. In this case, the toner concentration of the carrier and the toner in the developer is preferably 1 to 10 parts by weight of the toner with respect to 100 parts by weight of the carrier. The toner of the present invention can also be used as a one-component magnetic toner or non-magnetic toner that does not use a carrier.

It is the schematic which shows the structure of the process cartridge which is one Embodiment of this invention. It is a schematic sectional drawing which shows the structure of the process cartridge which is one Embodiment of this invention. FIG. 3A is a schematic view showing the structure of a process cartridge frame, FIG. 3A is a view from the front side of the image forming apparatus, and FIG. 3B is a view from the back side of the image forming apparatus. . It is the schematic which shows the structure of a photoreceptor. FIG. 2 is a schematic diagram illustrating a state on the back side of a process cartridge incorporated in the image forming apparatus. FIG. 2 is a schematic diagram illustrating a state on the front side of a process cartridge incorporated in the image forming apparatus. It is the schematic which shows the structure of the photosensitive layer of a photoreceptor. (A) is the schematic which shows the external appearance of a charging module, (b) is a schematic diagram which shows the side surface. It is the schematic which shows the structure of a charging module typically. It is the schematic which shows the state which mounts a charging module in a process cartridge. It is the schematic which shows the structure of a charging member. It is the schematic which shows the external appearance of a developing module. It is sectional drawing which shows the other example of the image development module, and shows the structure. FIG. 6 is a schematic view showing a state where the developing module 5 is mounted. FIG. 6 is a schematic view showing a state where the developing module 5 is mounted. It is a schematic sectional drawing which shows the structure of a cleaning module. It is the schematic which shows the state which has mounted | wore the cleaning module. It is the schematic which shows the state which rotated the process cartridge 2nd frame and opened the cleaning module. It is the schematic which shows the structure of a cleaning submodule. It is the schematic which shows the state which rotated the process cartridge 2nd frame and opened the cleaning submodule. FIG. 3 is a schematic view showing a state when a photoconductor is removed from a process cartridge and separated. FIG. 3 is a schematic view showing a state when a photoconductor is removed from a process cartridge and separated. 1 is a schematic diagram illustrating a configuration of an image forming apparatus according to an embodiment of the present invention. FIG. 6 is a diagram schematically illustrating the shape of a toner, where (a) illustrates a shape factor SF-1, and (b) illustrates a shape factor SF-2. 2A and 2B are schematic diagrams illustrating an outer shape of a toner, where FIG. 1A is an appearance of the toner, and FIG. 2B is a cross-sectional view of the toner.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Process cartridge 11 Side plate 12 Support part 13 Hole part 15 Charge fitting part 2 Process cartridge frame 2a 1st process cartridge frame 2b 2nd process cartridge frame 2c Engagement part 2d Holding member 2e Guide part 21 Temperature / humidity Sensor 22 Potential sensor 23 Toner concentration sensor 24 Signal line harness 25 Pre-transfer neutralization device 26 Pre-cleaning neutralization device 3 Photoconductor 31, 32 Flange 33 Bearing 34 Gear 35 Substrate 36 Photosensitive layer 36a Charge generation layer 36b Charge transport layer 36c Protective layer 37 Fitting unit 4 Charging module 41 Housing 42 Charging roller 42a Substrate 42b Main body 42c Middle resistance layer 42d Surface layer 43 Spring material 44 Charging cleaning roller 45 Spacer member 46 Spring support member 5 Development module 51 Development sleeve 52 G -Hopper 53 Developer storage part 54 Supply roller 55 Mixing screw 56 Supply roller 57 Restriction member 58 Toner supply port 59 Guide 6 Cleaning module 6a Cleaning mechanism 6b Coating mechanism 6c Cleaning submodule 61 Cleaning blade 62 Support member 64 Bias roller 65 Conveyor auger 66 Application roller 67 Lubricant molding 68a First projection guide 68b First projection guide 71 Development positioning member 72 Sleeve angle positioning member 73 Cleaning positioning member 74 Frame positioning member 75 Process cartridge positioning member 76 Blade positioning member 100 Image Forming device 101 Drive shaft 102 Drive gear 111 Side plate 112, 113, 114 Bearing 104 Exposure device 106 Transfer device 106a Intermediate transfer base DOO 106b 1 primary transfer rollers 106c, 106d supporting roller 106f 2 transfer roller 106g conveyor belt 108 the fixing device 108a heating roller 108b pressure roller 109 the sheet feeding unit 109a pickup roller 109b registration rollers 110 discharge roller

Claims (31)

In the process cartridge in which the latent image carrier and at least one process means are integrated and detachable from the main body of the image forming apparatus,
At least one sensor means for acquiring information on the latent image carrier, and a process cartridge frame for supporting the latent image carrier and the process means, with the process cartridge removed from the image forming apparatus, A process cartridge, wherein the carrier and the process means are exchangeable, and the sensor means is disposed on the process cartridge frame. The process cartridge according to claim 1,
The process cartridge, wherein the latent image carrier or at least one selected process means is replaceable without removing other process means. The process cartridge according to claim 1 or 2,
The process cartridge, wherein the latent image carrier is removed from the process cartridge frame without removing the process means. The process cartridge according to any one of claims 1 to 3,
The process means is a cleaning means,
The latent image carrier is removed from the process cartridge frame after rotating the cleaning means. The process cartridge according to any one of claims 1 to 4,
The process means is a cleaning means,
The process cartridge, wherein the cleaning means is fixed to the process cartridge frame by positioning members of the cleaning means provided on both sides. The process cartridge according to any one of claims 1 to 5,
The process means is a cleaning means,
The cleaning means has an application mechanism including an application roller and a lubricant molded body,
A process cartridge in which a lubricant is applied to a latent image carrier by an application mechanism. The process cartridge according to claim 6,
A cleaning cartridge and a lubricant molded body can be replaced in the cleaning unit. A process cartridge. The process cartridge according to claim 1 or 2,
The process means is a charging means,
The process cartridge, wherein the charging means is inserted into the recess of the process cartridge frame. The process cartridge according to claim 1 or 2,
The process means is a developing means,
The process cartridge, wherein the developing means is fixed to the process cartridge frame by developing means positioning members provided on both sides. The process cartridge according to claim 9, wherein
The process cartridge is characterized in that a drive bearing hole of a process cartridge frame and a development reference shaft disposed in the development means are fixed by a development means positioning member. The process cartridge according to any one of claims 1 to 10,
A process cartridge in which the latent image carrier is inserted with a drive shaft disposed in an image forming apparatus main body. The process cartridge according to claim 11, wherein
The process cartridge is characterized in that a drive shaft provided in an image forming apparatus main body is inserted into a drive bearing hole provided in a process cartridge frame. The process cartridge according to any one of claims 1 to 12,
A process cartridge, wherein a frame of the process cartridge includes a charge eliminating unit. The process cartridge according to claim 13, wherein
The process cartridge, wherein the charge eliminating means is EL. The process cartridge according to any one of claims 1 to 14,
A process cartridge, wherein the sensor means is a potential sensor of a latent image carrier, a density sensor that detects the amount of toner on the latent image carrier, and a temperature and humidity sensor that detects temperature and humidity in the process cartridge. The process cartridge according to any one of claims 1 to 15,
The process cartridge is characterized in that electrical wiring is connected to the outside from one place of the process cartridge. The process cartridge according to any one of claims 1 to 16,
The process cartridge according to claim 1, wherein the developing means uses toner having an average circularity in a range of 0.93 to 1.00. The process cartridge according to claim 17,
The process cartridge according to claim 1, wherein the toner has a ratio of a weight average particle diameter to a number average particle diameter in a range of 1.05 to 1.40. The process cartridge according to claim 17 or 18,
The toner has a substantially spherical appearance,
The ratio of the major axis to the minor axis (r2 / r1) is in the range of 0.5 to 1.0, and the ratio of the thickness to the minor axis (r3 / r2) is in the range of 0.7 to 1.0. A process cartridge characterized by satisfying the relationship of major axis r1 ≧ minor axis r2 ≧ thickness r3. The process cartridge according to any one of claims 17 to 19,
In the toner, a toner composition containing at least a polyester prepolymer having a functional group containing a nitrogen atom, a polyester, a colorant, and a release agent is crosslinked and / or extended in an aqueous medium in the presence of resin fine particles. Process cartridge characterized by. The process cartridge according to any one of claims 1 to 20,
The process cartridge includes a storage unit that stores toner or newly supplied toner. The process cartridge according to any one of claims 1 to 21,
The process cartridge can be reused by replenishing toner. The process cartridge according to claim 22, wherein
The process cartridge includes a storage unit that stores the replenished toner. An image forming apparatus for visualizing an electrostatic latent image formed on a latent image carrier with toner, the image forming apparatus including a process cartridge in which the latent image carrier and the process unit are detachably attached.
In the process cartridge, the latent image carrier and the process means can be individually replaced. An image forming apparatus for visualizing an electrostatic latent image formed on a latent image carrier with toner, comprising: an image forming apparatus including a removable process cartridge integrally formed with a latent image carrier and at least two process means; In the device
In the process cartridge, the latent image carrier and the two process units can be individually replaced, respectively. An image forming apparatus for visualizing an electrostatic latent image formed on a latent image carrier with toner, comprising: a process cartridge in which the latent image carrier and three process units are integrated and removable. In
In the process cartridge, the latent image carrier and the three process units can be individually replaced, respectively. An image forming apparatus for visualizing an electrostatic latent image formed on a latent image carrier with toner, comprising: a latent image carrier; at least one means selected from a charging means, a developing means, and a cleaning means. In an image forming apparatus including an integrated process cartridge,
The process cartridge has a latent image carrier supported on the process cartridge frame, and at least one process means supported on the process cartridge frame,
An image forming apparatus, wherein the latent image carrier and at least one or more selected process means are individually replaceable. The image forming apparatus according to any one of claims 24 to 27.
The image forming apparatus includes a process cartridge including a storage unit that stores toner and newly supplied toner. The image forming apparatus according to any one of claims 24 to 28.
The image forming apparatus includes a process cartridge that can be replenished by replenishing toner. 30. The image forming apparatus according to claim 29, wherein
The image forming apparatus includes a storage unit that stores replenished toner. The image forming apparatus according to any one of claims 24 to 30, wherein
An image forming apparatus comprising the process cartridge according to claim 1.

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