JP2018087967A - Method for manufacturing developer container, developer container, development device, and process cartridge - Google Patents

Abstract

PROBLEM TO BE SOLVED: To precisely detect an amount of developer.SOLUTION: There are a first resin sheet to be a first electrode and a second resin sheet having a recess and to be a second electrode. A manufacturing method is provided that has a holding process in which the first resin sheet and the second resin sheet are held in a metal mold such that the recess is situated at a position opposing to an end portion of the first resin sheet, and a forming process in which a developer container is formed. Meanwhile, in the forming process, the recess is disposed on a region where a confluent section is formed where the first resin injected from a first inlet port joins the second resin injected from a second inlet port.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a developer container manufacturing method, a developer container, a developing device, a process cartridge, and an image forming apparatus.

  Here, the image forming apparatus refers to an apparatus that forms an image on a recording material. The process cartridge means a cartridge having at least an image carrier. In many cases, the charging unit, the developing unit, the cleaning unit, and the image carrier are integrally formed into a cartridge, which is a cartridge that can be attached to and detached from the main body of the image forming apparatus. Further, the developing device means a device having at least a developer carrying member. In many cases, a developer carrying body and a developing frame that supports the developer carrying body are integrated and detachable from the apparatus main body of the image forming apparatus. The developer container refers to a container for containing the developer.

  Examples of the electrophotographic image forming apparatus include a copying machine, an LED printer, a laser printer, and a facsimile.

  In an electrophotographic image forming apparatus (hereinafter, also referred to as “image forming apparatus”), an electrophotographic photosensitive member that is generally a drum type as an image carrier, that is, a photosensitive drum is uniformly charged.

  Next, an electrostatic latent image (electrostatic image) is formed on the photosensitive drum by selectively exposing the charged photosensitive drum. Next, the electrostatic latent image formed on the photosensitive drum is developed as a toner image with toner as a developer.

  Then, the toner image formed on the photosensitive drum is transferred to a recording material such as recording paper or plastic sheet, and the toner image is applied to the recording material by applying heat or pressure to the toner image transferred onto the recording material. Image recording is performed by fixing.

  Such an image forming apparatus generally requires toner replenishment and maintenance of various process means. In order to facilitate this toner replenishment and maintenance, a photosensitive cartridge, a charging unit, a developing unit, a cleaning unit, and the like are combined into a cartridge into a cartridge, and a process cartridge that can be attached to and detached from the image forming apparatus main body has been put into practical use. ing.

  According to this process cartridge system, since the user can perform maintenance of the apparatus himself, the operability can be remarkably improved, and an image forming apparatus excellent in usability can be provided. For this reason, this process cartridge system is widely used in image forming apparatuses.

  In the process cartridge type image forming apparatus described above, the user replaces the process cartridge. For this reason, in many cases, there is provided a means for detecting when the toner is consumed and notifying the user of the replacement time, that is, a toner remaining amount detecting means. Such toner remaining amount detecting means includes a method for detecting the amount of toner using a change in capacitance that changes when the amount of toner occupied between a pair of input / output electrodes changes (Patent Document). 1 and 2).

  Patent Document 1 proposes a plate antenna system that includes a pair of input side and output side electrodes and detects the amount of toner by measuring the capacitance between both electrodes. Patent Document 2 proposes using a styrene resin in which carbon black is dispersed for an electrode serving as an antenna.

JP 2001-117346 A (page 14, FIG. 13) JP 2006-142881 A

  When manufacturing a developer container like patent document 2, there exists a possibility that the subject shown in FIG. 19 and 20 may arise. 19 and 20 are explanatory diagrams for explaining the flow of resin inside the mold.

  As shown in FIG. 19, the resin J injected from the gates 92r and 92l spreads concentrically (FIG. 19A).

  Further, the resin is injected, and when the molding proceeds, the resins injected from both gates join together (joining portion G) (FIG. 19B).

  And it turned out that the linear trace (weld line) W generate | occur | produces from the junction G (FIG.19 (c)).

  When a conductive resin sheet containing a resin is used for an electrode that is an antenna, the resin sheet is deformed or stretched by the injected resin. When the resin is injected in a state where the resin sheet is installed in the mold at the position of the joining portion G in FIG. 19B, the resin sheet is deformed or stretched. Then, when the resin injection is in the state shown in FIG. 19C, the deformation and elongation of the resin sheet greatly increase along with the weld line W.

  As a result, when the developer container is manufactured, the resin sheet on the developer container frame is formed with an extension N protruding from the end 30b located downstream in the resin movement direction as shown in FIG. End up. If the elongation N is too close to the other electrode, there is a risk of causing a problem in the developer amount detection function.

Therefore, the present invention provides
A manufacturing method for manufacturing a developer container capable of detecting a developer amount using a change in capacitance between a first electrode and a second electrode,
There is a first resin sheet to be the first electrode and a second resin sheet to be the second electrode having a recess, so that the recess is located at a position facing the end of the first resin sheet, A holding step of holding the first resin sheet and the second resin sheet in a mold;
A molding step of injecting a resin from a first injection port and a second injection port for injecting a resin, and molding a developer container including the first resin sheet and the second resin sheet,
In the molding step, the recess is disposed on a region that forms a junction where the first resin injected from the first injection port and the second resin injected from the second injection port merge. A method for producing a developer container is provided.

  The present invention also provides a developer container, a developing device, a process cartridge, and an image forming apparatus.

  As described above, according to the present invention, it is possible to provide a developer container or the like that does not have a defect in capacitance detection.

3 is a schematic diagram illustrating a bottom member that is a part of a developer container according to Embodiment 1. FIG. 2 is a cross-sectional view of an apparatus main body and a process cartridge of the electrophotographic image forming apparatus. FIG. 2 is a cross-sectional view of a process cartridge according to Embodiment 1. FIG. It is sectional drawing inside the cleaning container of a process cartridge. FIG. 2 is a perspective view of the image forming apparatus main body in a state where an opening / closing door of the electrophotographic image forming apparatus is opened. FIG. 2 is a perspective view of the apparatus main body in a state where an opening / closing door of the electrophotographic image forming apparatus is opened and a tray is pulled out. FIG. 3 is a perspective view of the apparatus main body and the process cartridge when the process cartridge is attached to and detached from the tray with the open / close door of the electrophotographic image forming apparatus opened and the tray pulled out. FIG. 6 is a perspective view of the process cartridge and the drive side positioning portion of the apparatus main body in a state where the process cartridge is mounted on the apparatus main body. FIG. 3 is a perspective view of a process cartridge and a non-driving side positioning portion of the image forming apparatus main body in a state where the process cartridge is mounted on the apparatus main body. It is an exploded view of a process cartridge. It is an exploded view of a process cartridge. It is an exploded view of a process cartridge. It is an exploded view of a process cartridge. FIG. 3 is a cross-sectional view of the developing device for explaining the developer amount detecting means according to the first embodiment. 1 is a circuit configuration diagram of a developer amount detection device according to Embodiment 1. FIG. 6 is a perspective view illustrating a method for manufacturing a developer container according to Embodiment 1. FIG. 6 is a cross-sectional view of a mold illustrating a method for manufacturing a bottom member that is a part of the developer container according to Embodiment 1. FIG. 6 is a schematic diagram illustrating a bottom member that is a part of a developer container according to Embodiment 2. FIG. It is a schematic diagram explaining the flow of the resin inside a metal mold | die explaining the manufacturing method of the bottom member which is a part of developer container. It is a schematic diagram explaining the flow of the resin inside a metal mold | die explaining the manufacturing method of the bottom member which is a part of developer container.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments for carrying out the present invention will be exemplarily described in detail with reference to the drawings. However, the dimensions, materials, shapes, and relative arrangements of the components described in this embodiment should be appropriately changed according to the configuration of the apparatus to which the invention is applied and various conditions. That is, it is not intended to limit the scope of the present invention to the following embodiments.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

  In this specification, the longitudinal axis direction of the electrophotographic photosensitive drum as the image carrier, the developing roller as the developer carrier, and the developing sleeve is the longitudinal direction.

  In the longitudinal direction of the electrophotographic photosensitive drum as an image carrier, the side on which the electrophotographic photosensitive drum receives driving force from the image forming apparatus main body is defined as a driving side, and the opposite side is defined as a non-driving side.

  The overall configuration and the image forming process will be described with reference to FIGS.

  FIG. 2 is a cross-sectional view of an apparatus main body (hereinafter referred to as apparatus main body A) and a process cartridge (hereinafter referred to as cartridge B) of an electrophotographic image forming apparatus (hereinafter referred to as image forming apparatus).

  FIG. 3 is a cross-sectional view of the cartridge B. Here, the apparatus main body A is a portion obtained by removing the cartridge B from the electrophotographic image forming apparatus. In the case where the developing device can be detachably attached to the apparatus main body, the apparatus constituent portion excluding the developing apparatus from the configuration of the image forming apparatus is used as the apparatus main body.

<Overall configuration of image forming apparatus>
The image forming apparatus shown in FIG. 2 is a laser beam printer using an electrophotographic technique in which a cartridge B is detachable from the apparatus main body A. When the cartridge B is mounted on the apparatus main body A, an exposure device 3 (laser scanner unit) for forming a latent image on the electrophotographic photosensitive drum 62 of the cartridge B is disposed. In addition, a sheet tray 4 that stores a recording material (hereinafter referred to as a sheet material P) that is an image forming target is disposed below the cartridge B.

  Further, the apparatus main body A includes a pickup roller 5a, a feeding roller pair 5b, a conveyance roller pair 5c, a transfer guide 6, a transfer roller 7, a conveyance guide 8, a fixing device 9, along the conveyance direction D of the sheet material P. A pair of discharge rollers 10, a discharge tray 11, and the like are sequentially arranged. The fixing device 9 includes a heating roller 9a and a pressure roller 9b.

<Image formation process>
Next, an outline of the image forming process will be described. Based on the print start signal, the electrophotographic photosensitive drum (hereinafter referred to as drum 62) is rotationally driven in the direction of arrow R with a predetermined peripheral speed (process speed).

  A charging roller 66, which is a charging member to which a bias voltage is applied, contacts the outer peripheral surface of the drum 62, and uniformly charges the outer peripheral surface of the drum 62.

  The exposure device 3 outputs a laser beam L corresponding to the image information. The laser light L passes through a laser opening 71 h provided in the cleaning frame 71 of the cartridge B, and scans and exposes the outer peripheral surface of the drum 62. Thereby, an electrostatic image or an electrostatic latent image corresponding to the image information is formed on the outer peripheral surface of the drum 62.

  On the other hand, as shown in FIG. 3, in the developing unit 20 as a developing device, the toner T in the developer container (toner chamber) 29 is transferred to the first conveying member 43, the second conveying member 44, and the third conveying member 50. It is agitated and conveyed by rotation, and sent to the toner supply chamber 28. The conveying member has at least a rotatable shaft part 43a and a sheet-like conveying part 43b.

  The toner T as the developer is carried on the surface of the developing roller 32 which is a developer carrying member and a developing sleeve by the magnetic force of the magnet roller 34 (fixed magnet).

  The layer thickness of the toner T on the circumferential surface of the developing roller 32 is regulated while being frictionally charged by the developing blade 42 which is a developer layer regulating member.

  The toner T is developed on the drum 62 in accordance with the electrostatic latent image, and is visualized as a toner image which is a developer image.

  Further, as shown in FIG. 2, the sheet material P stored in the lower part of the apparatus main body A is moved to the sheet tray by the pickup roller 5a, the feeding roller pair 5b, and the conveying roller pair 5c in accordance with the output timing of the laser beam L. 4 is sent out. Then, the sheet material P is conveyed to the transfer position between the drum 62 and the transfer roller 7 via the transfer guide 6. At this transfer position, the toner images are sequentially transferred from the drum 62 to the sheet material P.

  The sheet material P to which the toner image has been transferred is separated from the drum 62 and conveyed to the fixing device 9 along the conveyance guide 8. The sheet material P passes through the nip portion between the heating roller 9a and the pressure roller 9b constituting the fixing device 9. A pressure / heat fixing process is performed in the nip portion, and the toner image is fixed on the sheet material P. The sheet material P that has undergone the toner image fixing process is conveyed to the discharge roller pair 10 and discharged to the discharge tray 11.

  On the other hand, as shown in FIG. 3, the drum 62 after transfer is used again in the image forming process after the residual toner on the outer peripheral surface is removed by a cleaning blade 77 as a cleaning member. The toner removed from the drum 62 is stored in the waste toner chamber 71 b of the cleaning unit 60.

  In this embodiment, a charging roller 66 that is a charging member, a developing roller 32 that is a developer carrier, a transfer roller 7 that is a transfer member, and a cleaning blade 77 that is a cleaning member act on a drum 62 that is an image carrier. Process means.

<Removal of cartridge>
Next, attachment / detachment of the cartridge B with respect to the apparatus main body A will be described with reference to FIGS.

  FIG. 5 is a perspective view of the apparatus main body A with the open / close door 13 opened in order to attach and detach the cartridge B. FIG. FIG. 6 is a perspective view of the apparatus main body A and the cartridge B in a state in which the opening / closing door 13 is opened to detach the cartridge B and the tray 18 as a moving member is pulled out. FIG. 7 is a perspective view of the apparatus main body A and the cartridge B when the cartridge B is attached and detached with the opening / closing door 13 opened and the tray 18 as a drawer member pulled out. The cartridge B can be attached to and detached from the tray 18 along the attaching / detaching direction E.

  An opening / closing door 13 is rotatably attached to the apparatus main body A, and a cartridge insertion opening 17 is provided when the opening / closing door 13 is opened. A tray 18 for mounting the cartridge B to the apparatus main body A is provided in the cartridge insertion opening 17. When the tray 18 is pulled out to a predetermined position, the cartridge B can be attached and detached. The cartridge B is mounted in the apparatus main body A along a guide rail (not shown) in the direction of arrow C in the figure while being placed on the tray 18.

  In addition, a first drive shaft 14 and a second drive shaft 19 for transmitting drive to the first coupling 70 and the second coupling 21 (FIG. 8) provided in the cartridge B are provided. The first drive shaft 14 and the second drive shaft 19 are driven by a motor (not shown) of the apparatus main body A. As a result, the drum 62 connected to the first coupling 70 is rotated by receiving a driving force from the apparatus main body A. Further, the driving force is transmitted from the second coupling 21, and the developing roller 32 rotates. Further, the charging roller 66 and the developing roller 32 are supplied with power from a power supply unit (not shown) of the apparatus main body A.

<Cartridge support>
As shown in FIG. 5, the apparatus main body A is provided with a driving side plate 15 and a non-driving side plate 16 for supporting the cartridge B. As shown in FIGS. 8 and 9, the drive side plate 15 is provided with a drive side first support portion 15a, a drive side second support portion 15b, and a rotation support portion 15c of the cartridge B. The non-driving side plate 16 is provided with a non-driving side first support portion 16a, a non-driving side second support portion 16b, and a rotation support portion 16c.

  On the other hand, as supported portions of the cartridge B, a supported portion 73b and a supported portion 73d of the drum bearing 73, a driving side boss 71a of the cleaning frame 71, a non-driving side protrusion 71f, and a non-driving side boss 71g are provided. ing. The supported portion 73b is supported by the drive side first support portion 15a, the supported portion 73d is supported by the drive side second support portion 15b, and the drive side boss 71a is supported by the rotation support portion 15c. Further, the non-driving side protrusion 71f is supported by the non-driving side first support portion 16a and the non-driving side second support portion 16b, and the non-driving side boss 71g is supported by the rotation support portion 16c, whereby the cartridge B is It is positioned in the apparatus main body A.

<Configuration of the entire cartridge>
Next, the entire configuration of the cartridge B will be described with reference to FIGS. 3, 4, 10, 11, 12, and 13. 3 is a cross-sectional view of the cartridge B, and FIGS. 10, 11, 12, and 13 are perspective views illustrating the configuration of the cartridge B. FIG. FIGS. 11 and 13 are partial enlarged views in which portions within the dotted line portions of FIGS. 10 and 12 are enlarged at different angles. In the present embodiment, the screws for connecting the parts will be omitted.

  The cartridge B is a process cartridge having a cleaning unit 60 and a developing unit 20. In general, a process cartridge is an image carrier and an electrophotographic photosensitive member, and a process unit that acts on the photosensitive drum is integrally formed into a cartridge so that the process cartridge is attached to the main body of the electrophotographic image forming apparatus. Detachable. The process means includes a charging means, a developing means, and a cleaning means.

  As shown in FIG. 3, the cleaning unit 60 includes a drum 62, a charging roller 66, a cleaning member 77, a cleaning frame body 71 that supports them, and a lid member 72 fixed to the cleaning frame body 71 by welding or the like. Have In the cleaning unit 60, the charging roller 66 and the cleaning member 77 are disposed in contact with the outer peripheral surface of the drum 62.

  The cleaning member 77 includes a rubber blade 77a that is a blade-like elastic member formed of rubber as an elastic material, and a support member 77b that supports the rubber blade. The rubber blade 77 a is in contact with the drum 62 in the counter direction with respect to the rotation direction of the drum 62. That is, the rubber blade 77 a is in contact with the drum 62 so that the tip end portion thereof faces the upstream side in the rotation direction of the drum 62.

  FIG. 4 is a cross-sectional view of the cleaning frame 71. As shown in FIGS. 3 and 4, the waste toner removed from the surface of the drum 62 by the cleaning member 77 is transported by the waste toner transport member. Waste toner is transported by a first screw 86, a second screw 87, and a third screw 88 as waste toner transport members, and is stored in a waste toner chamber 71b formed by a cleaning frame 71 and a lid member 72. Further, the first screw 86 is rotated by a drive transmitted from the coupling 21 shown in FIG. 13 by a gear (not shown). The second screw 87 receives the driving force from the first screw 86 and the third screw 88 rotates from the second screw 87, respectively. The first screw 86 is disposed in the vicinity of the drum 62, the second screw 87 is disposed at the longitudinal end of the cleaning frame 71, and the third screw 88 is disposed in the waste toner chamber 71b. Here, the rotation axes of the first screw 86 and the third screw 88 are parallel to the rotation axis of the drum 62, and the rotation axis of the second screw 87 is orthogonal to the rotation axis of the drum 62.

  Further, as shown in FIG. 3, a squeeze sheet 65 for preventing waste toner from leaking from the cleaning frame 71 is provided at the edge of the cleaning frame 71 so as to contact the drum 62.

  The drum 62 is rotationally driven in the direction of arrow R in the drawing according to an image forming operation by receiving a driving force from a main body driving motor (not shown) as a driving source.

  The charging roller 66 is rotatably attached to the cleaning unit 60 via a charging roller bearing 67 at both ends in the longitudinal direction of the cleaning frame 71 (substantially parallel to the rotation axis direction of the drum 62). The charging roller 66 is in pressure contact with the drum 62 by the charging roller bearing 67 being pressed toward the drum 62 by the biasing member 68. The charging roller 66 rotates following the rotation of the drum 62.

  As shown in FIG. 3, the developing unit 20 includes a developing roller 32, a developing container 23 that supports the developing roller 32, a developing blade 42, and the like. A magnet roller 34 is provided in the developing roller 32 which is a developing sleeve. In the developing unit 20, a developing blade 42 for restricting the developer layer on the developing roller 32 is disposed. As shown in FIGS. 10 and 12, a spacing member 38 is attached to the developing roller 32 at both ends of the developing roller 32, and the spacing roller 38 and the drum 62 abut so that the developing roller 32 is a drum. 62 and a slight gap. Further, as shown in FIG. 3, a blowout prevention sheet 33 for preventing the toner from leaking from the developing unit 20 is provided at the edge of the bottom member 22 so as to contact the developing roller 32. Further, the toner chamber 29 formed by the developing container 23 and the bottom member 22 is provided with a first transport member 43, a second transport member 44, and a third transport member 50. The first conveyance member 43, the second conveyance member 44, and the third conveyance member 50 agitate the toner stored in the toner chamber 29 and convey the toner to the toner supply chamber 28.

  As shown in FIGS. 10 and 12, the cartridge B is configured by combining the cleaning unit 60 and the developing unit 20.

  The cleaning unit 60 is provided with a cleaning frame 71, a lid member 72, a drum 62, and a drum bearing 73 and a drum shaft 78 for rotatably supporting the drum 62. As shown in FIG. 13, on the driving side, the driving side drum flange 63 of the drum 62 provided on the driving side is rotatably supported by the hole 73 a of the drum bearing 73. On the other hand, as shown in FIG. 11, on the non-driving side, the drum shaft 78 press-fitted into the hole 71c provided in the cleaning frame 71 can rotate the hole (not shown) of the non-driving side drum flange 64. It is the structure which supports to.

  As shown in FIGS. 3, 10, and 12, the developing unit 20 includes a bottom member 22, a developing container 23, a driving side developing side member 26, a developing blade 42, a developing roller 32, and the like. The developing roller 32 is rotatably attached to the developing container 23 by bearing members 27 and 37 provided at both ends.

  Then, as shown in FIGS. 11 and 13, the cartridge B is configured by coupling the cleaning unit 60 and the developing unit 20 so as to be rotatable with a coupling pin 69.

  Specifically, the development container 23 is provided with a development first support hole 23 a and a development second support hole 23 b at both ends in the longitudinal direction of the development unit 20. In addition, a first suspension hole 71 i and a second suspension hole 71 j are provided in the cleaning frame 71 at both longitudinal ends of the cleaning unit 60. The coupling unit 69 press-fitted and fixed in the first suspension hole 71i and the second suspension hole 71j is fitted with the development first support hole 23a and the development second support hole 23b, so that the cleaning unit 60 and the development unit 20 are rotated with each other. It is linked movably.

  The first hole 46Ra of the driving side biasing member 46R is hooked on the boss 73c of the drum bearing 73, and the second hole 46Rb is hooked on the boss 26a of the driving side developing side member 26.

  Further, the first hole 46Fa of the non-driving side urging member 46F is hooked on the boss 71k of the cleaning frame 71, and the second hole 46Fb is hooked on the boss 37a of the bearing member 37.

  In this embodiment, the driving side urging member 46R and the non-driving side urging member 46F are formed by tension springs. The developing unit 20 is urged toward the cleaning unit 60 by the urging force of the spring so that the developing roller 32 is surely pressed toward the drum 62. The developing roller 32 is held at a predetermined interval from the drum 62 by a spacing holding member 38 attached to both ends of the developing roller 32.

<Developer amount detection means>
The developer amount detection will be described with reference to FIGS.

  FIG. 14 is a cross-sectional view of the developing device for explaining the developer amount detecting means.

  As shown in FIG. 14, the first electrode 30 as one electrode and the other electrode are provided on the bottom surface of the toner chamber 29 inside the toner chamber 29 as a detection unit for detecting the toner amount as the developer amount. A second electrode 31 is provided.

  When a voltage in which an AC voltage and a DC voltage are superimposed is applied from the developing bias power source 51 to the developing roller 32, the electrostatic force between the developing roller 32 and the second electrode 31 is between the developing roller 32 and the second electrode 31. A current corresponding to the capacitance is induced.

  Further, when a voltage in which an AC voltage and a DC voltage are superimposed is applied from the developing bias power source 51 to the first electrode 30, the first electrode 30 and the second electrode are interposed between the first electrode 30 and the second electrode 31. A current corresponding to the capacitance between 31 is induced. Here, the electrostatic capacity between the developing roller 32 and the second electrode 31 changes according to the amount of toner between the developing roller 32 and the second electrode 31, and the electrostatic capacity between the first electrode 30 and the second electrode 31. The electric capacity changes according to the amount of toner between the first electrode 30 and the second electrode 31.

  The change in the value of the current flowing through the second electrode 31 is measured by the developer amount detection device in the apparatus main body A via the contact provided on the cartridge B and the main body contact of the apparatus main body.

  The first electrode 30 and the second electrode 31 are arranged below the first conveying member 43 so as to be along the bottom surface of the toner chamber 29 with a distance L2. The distance L <b> 2 is located at the lowest position in the toner chamber 29. The shaft portion 43a of the first transport member is disposed immediately above the distance L2.

  The first conveying member 43 includes a shaft portion 43a and a flexible sheet-like member conveying portion 43b. The shaft portion is rotatably supported, and the conveying portion is driven by the rotation of the shaft portion. Transports the toner on the bottom surface. Therefore, the toner to be conveyed passes through a distance L2 portion on the bottom surface of the toner chamber 29.

  By providing the distance L2 between the first electrode 30 and the second electrode 31 at the above position, the toner amount can be accurately detected even when the toner in the toner chamber 29 is low.

  FIG. 15 is a circuit configuration diagram of the developer amount detection device. In this embodiment, when a voltage in which an AC voltage and a DC voltage are superimposed is output from the developing bias applying means 51, it is applied to the reference capacitor 54, the developing sleeve 32, and the first electrode 30.

  As a result, a voltage V1 is generated in the reference capacitor 54, and a voltage V2 is generated in the first electrode 30 with a current corresponding to the combined capacitance.

  The detection circuit 55 generates a voltage V3 from the voltage difference between V1 and V2, and outputs the voltage V3 to the AD converter 56.

  The AD conversion unit 56 outputs the result of digital conversion of the analog voltage V3 to the control unit 57. The control unit 57 determines the remaining toner level as the developer amount from this result, and stores the result in the storage medium 58. The display unit 59 displays the remaining amount.

<Method for producing developer container>
Production of the developer container will be described with reference to FIGS.

  FIG. 16 is a perspective view of a developer container for explaining a developer container manufacturing method.

  FIG. 17 is a cross-sectional view of a mold for explaining a method for producing a developer container.

  As shown in FIG. 16, the developer container 29 in this embodiment includes a developing container 23 that is a first frame and a bottom member 22 that is a second frame.

  In the present embodiment, the first electrode 30 and the second electrode 31 are formed integrally with the bottom member 22.

  As will be described later, the first electrode 30 and the second electrode 31 are formed of a resin sheet having conductivity.

  FIG. 17 shows an example of a sectional view of the entire mold for molding the bottom member 22, FIG. 17 (a) shows a state where the mold is open, and FIG. 17 (b) shows the mold. It is the figure which showed the state which the type | mold has closed.

  There are a first mold 90 and a second mold 91, and a shape that becomes the surface shape of the bottom member 22 is formed when transferred to each of them.

  The first mold 90 has an injection port (gate) 92 for injecting resin into a void portion (cavity) 93 in the mold.

  First, when the mold shown in FIG. 17A is in an open state, conductive resin sheets to be the first electrode 30 and the second electrode 31 are inserted (inserted) into the mold at positions facing each other.

  A fine air hole is provided in a mold corresponding to the S portion of the first electrode 30 and the second electrode 31, and the air hole is connected to a suction device (not shown) so that the first electrode 30 and the second electrode are connected. 31 is held (or fixed) by the second mold 91 (holding step).

  In the present embodiment, the first electrode 30 and the second electrode 31 are held (or fixed) in the second mold 91, but it is not always necessary to hold (or fix) in the second mold 91. The mold 90 may be held (or fixed). In addition to these methods, it is possible to hold (or fix) using a known method.

  Next, as shown in FIG. 17B, the first mold 90 and the second mold 91 are matched (mold closing).

  The bottom member 22 is formed by pouring molten resin from the gate 92 into a cavity 93 formed by matching the molds.

  By pouring resin into the cavity (cavity) 93, the bottom member 22 is formed, and the first electrode 30 and the second electrode 31 are attached to the molded product and molded integrally.

  The resin is injected from a plurality of injection ports. Therefore, a joining portion where the flow of the resin injected from the first injection port and the flow of the resin injected from the second injection port different from the first injection port in the gap (cavity) 93 is formed. When the resin is further injected after the joining portion is formed, the joining portion spreads. This widened junction is also called a weld line W. This joining portion melts or pulls a part of the electrode which is a resin, and makes the electrode stretch.

  When the first mold 90 and the second mold 91 are combined, the first mold 90 and the second mold 91 are opposed to each other with a distance M therebetween. It is formed as a wall thickness M of 22.

  In the above description, two resin sheets of the first electrode 30 and the second electrode 31 are inserted (inserted) into the mold, but how many resin sheets are inserted (inserted) in the same manner as necessary. You may do it.

  A developer container is formed by welding a bottom member, which is a second frame body formed by bonding the first electrode 30 and the second electrode 31, and a developing container, which is a first frame body, by ultrasonic welding. Mold.

  The molding process and the present specification are carried out until the bottom member as the second frame body is molded in this way, and the developer container as the first frame body and the bottom member as the second frame body are welded to mold the developer container. In the book.

<Electrode as developer amount detector>
The 1st electrode 30 and the 2nd electrode 31 are formed with the resin sheet which has electroconductivity.

  In this example, a resin sheet having a thickness of 0.1 mm was used. In addition, having the electrical conductivity described in the present embodiment means that the surface resistivity by the measuring method defined in JIS K 7194 is 10 kΩ / sq or less, and that having no electrical conductivity is from 10 kΩ / sq. It has a large surface resistivity.

  As a material for the resin sheet having conductivity, an ethylene-vinyl acetate copolymer (EVA) resin in which carbon black is dispersed was used.

  In the present embodiment, the resin sheet having conductivity is obtained by bonding the EVA resin to the PS resin by the heat and pressure at the time of molding the bottom member 22 using the molding method described above. The first electrode 30, the second electrode 31, and the bottom member 22 are integrally formed.

  However, the present invention is not limited to this, and other resin sheet thicknesses or combinations of resin materials may be used.

  More specifically, in this example, a 0.1 mm resin sheet was selected from the viewpoints of the influence on the deformation of the frame, the transferability to the frame shape, and the conductivity. You can choose. Further, as the material of the resin sheet, an EVA-based resin that is adhesive to the material of the bottom member 22 is selected. However, the resin and the resin of the bottom member 22 are melted and compatible resins that can be integrated without an interface. You may use as a material of a resin sheet.

  The heat deformation temperature (glass transition temperature) of the resin used in this example is about 90 ° C. for the resin used for the bottom member 22 and ethylene used for the developer amount detection member which is a conductive resin sheet. The vinyl acetate copolymer (EVA) resin was about 80 ° C.

  In addition, the heat deformation temperature of the bottom member 22, the 1st electrode 30, and the 2nd electrode 31 is an illustration, Comprising: It is not limited to this.

  It is sufficient that the thermal deformation temperature of the resin forming the conductive sheet member is lower than the thermal deformation temperature of the resin forming the frame.

<Bottom member that is part of developer container>
The bottom member 22 will be described with reference to FIG.

  FIG. 1 is a view of the inside of the bottom member 22 as viewed from the front in the direction of the gate 92 described above.

  Since the number of gates 92 varies depending on the size of the frame to be molded, there may be a plurality of gates. In this embodiment, description will be made using a two-point gate. One gate of the gate 92 of the bottom member 22 is 92r, and the other gate is 92l.

  The resin in the gap 93 at the time of molding described above flows from one gate 92r and the other gate 92l toward the end of the shape to be molded. For this reason, one gate 92r and the other gate 92l are defined as the most upstream, and the end of the shape (bottom member) to be molded is defined as the downstream. In FIG. 1, with respect to the direction from top to bottom, the gate is upstream and one end of the bottom member is downstream.

  The shape of the bottom member 22 is molded by the resin injected from the gates 92r and 92l flowing from upstream to downstream during molding.

  The first electrode 30 will be described with reference to FIG. 1. The first electrode 30 is disposed upstream of the second electrode 31. In the present embodiment, the first electrode 30 has a recess, and this recess is in a position facing the upstream end of the second electrode.

  Further, when viewed from the axial direction of the developing roller as shown in FIG. 14, the first electrode 30 is disposed at the lowermost position of the toner chamber 29 along the bottom surface of the toner chamber 29. Similarly, the second electrode 31 is arranged along the bottom surface of the toner chamber 29. In the present embodiment, the distance between the first electrode 30 and the second electrode 31 (FIG. 14) is the distance L between the downstream end 30b of the first electrode 30 and the upstream end 31a of the second electrode 31. The distance between the downstream end 30b of the longitudinal end of the first electrode 30 and the upstream end 31a of the second electrode 31 (for example, the longitudinal end of the corresponding position of the second electrode 31) is set to L2. On the other hand, a notch 30 c having a recessed shape is provided in a part of the downstream end 30 b of the first electrode 30. The notch 30c, which is a recess, is provided in the longitudinal center of the first electrode 30 in the longitudinal direction in this embodiment. In the present embodiment, the bottom portion 30d of the concave portion is provided at the longitudinal center of the first electrode 30, and the distance from the bottom portion 30d of the concave portion to the upstream end 31a at the longitudinal center at the corresponding position of the second electrode is the distance L1. It is provided to become. However, the present invention is not limited to this, and it may be designed such that the distance from the position near the bottom in the recess to the upstream end 31a at the longitudinal center at the corresponding position of the second electrode is the distance L1. This is because, depending on the manufacturing process, there is a possibility that an extension portion is formed from the bottom portion and the distance may change.

  In the present embodiment, the relationship between the distance L2 and the distance L1 is L2 <L1.

  A portion where the distance between the first electrode 30 and the second electrode 31 is L1 due to the provision of the notch 30c is provided between one gate 92r and the other gate 92l. More specifically, a thin line (weld line) generated at a joining portion where the resin injected from the gate 92r and the other gate 92l joins at a gap portion (cavity) 93 in the mold and at a joined portion and fused. ). That is, the merge portion is formed by the injected resin. When the resin is further injected after the joining portion is formed, the weld lines W are formed above and below in FIG. 1 so as to include the joining portion. The weld line W is a portion where the joining portion is initially formed with a point, but then spreads up and down, and is referred to as a joining portion in this specification. In FIG. 1, the conductive sheet on the region overlapping with the weld line W that is the joining portion is pulled by the resin flow, and an elongation N as shown in FIG. 20 occurs. However, in the present embodiment, the distance between the conductive sheets arranged in the region on the merge portion is previously set longer than the distance between other portions (for example, between the longitudinal end portions) in consideration of the elongation N. Thus, even when the elongation N occurs, the contact between the conductive sheets as electrodes due to the elongation N is reduced.

  A distance L1 between the downstream end 30d of the first electrode 30 and the upstream end of the second electrode 31 at the cutout portion of the first electrode 30 is secured. This is to prevent the second electrode 31 from approaching or contacting even if the elongation N occurs in the portion corresponding to the weld line W of the first electrode 30 in FIG. The first electrode 30 is cut away to ensure a distance L1 between the downstream end 30d of the first electrode 30 and the upstream end of the second electrode 31.

  The concave portion of the first electrode is located at an intermediate point between the gate 92r and the gate 92l. Therefore, the lower end portion 30d of the concave portion of the first electrode of the present embodiment is provided at an equal distance from the gate 92r and the gate 92l. In the manufactured developer container or the like, since the injection port trace injected from the gate which is the injection port is formed of resin, the distance between the injection port trace and the electrode, the distance between the injection port trace and the bottom of the recess, etc. Judgment can also be made from the manufactured one.

  The functions, materials, shapes, and relative arrangements of the components described in the present embodiment are not intended to limit the scope of the present invention only to those unless otherwise specified.

  Next, the form of Example 2 of this invention is demonstrated based on drawing.

  In the present embodiment, parts different from the above-described embodiment will be described in detail. Unless otherwise noted, the material, shape, etc. are the same as in the previous embodiment. Such parts are given the same numbers and will not be described in detail.

  The bottom member 22 which is a part of the developer container will be described with reference to FIG.

  FIG. 18 is a view of the bottom member 22 as viewed from the front in the direction of the gate 92 described above.

  The first electrode 30 will be described with reference to FIG. 18. The first electrode 30 is disposed upstream of the second electrode 31.

  The distance (FIG. 14) between the first electrode 30 and the second electrode 31 located at the lowermost position of the toner chamber 29 along the bottom surface of the toner chamber 29 is the second end of the first electrode 30 and the second end 30b. It is formed by the distance of the upstream end 31a of the electrode 31.

  The distance between the downstream end 30b of the first electrode 30 and the upstream end 31a of the second electrode 31 is L4. By providing a notch 31c having a recessed shape in a part of the upstream end 31a of the second electrode 31, A portion where the distance is the distance L3 is provided. In the present embodiment, the distance from the notch that is the recess of the second electrode 31 to the corresponding longitudinal center (longitudinal center) of the first electrode 30 is the distance L3.

  The relationship between the distance L4 and the distance L3 is L4 <L3.

  As described above, by providing the notch 31c in the second electrode 30, it is possible to obtain the same effect as in the first embodiment described above.

  In addition, since the notch 31c which is a recessed part should just be arrange | positioned in the area | region on the joining part which can be inject | poured with resin, it is not necessarily necessary to provide a recessed part in a longitudinal center. For example, the structure which provided the recessed part in the edge part of the longitudinal direction of an electrode may be sufficient.

  Various modifications will be described.

  In the first and second embodiments, the recess has a triangular shape, but is not limited thereto, and may be a quadrangular shape, a rectangular shape, a trapezoidal shape, or a semicircular shape. The cartridge is not limited to the process cartridge configuration described in the first and second embodiments. For example, there is a developer container (for example, a toner cartridge) that contains a developer, and a developing device (for example, a developing cartridge) that has at least a developer carrying member.

  Here, the developing device has a form in which the developing device itself has a frame for storing the developer, and when the stored developer is used up, the developing device itself is replaced. Further, the developing device may have a configuration in which a developer container for containing the developer is detachable from the developing device. In this case, the developing device is configured such that the developer can be replenished from the developer container into a space that can accommodate the developer of the frame that supports the developer carrying member.

  The apparatus main body of the image forming apparatus may be configured such that only the process cartridge is detachably mounted, or may be configured such that the developing cartridge and the drum cartridge are detachable. Further, in the case of two units, a configuration in which the developing cartridge is attached to the drum cartridge and then attached to the main body of the image forming apparatus, or a configuration in which each can be attached to the main body of the apparatus regardless of the mounting state of other cartridges. Good.

  So far, the configuration in which one cartridge can be attached / detached has been exemplified, but a configuration in which a plurality of cartridges can be attached / detached may be used. For example, in the case of a color machine, an image forming apparatus in which four cartridges of the same type of YMCK can be attached and detached can be considered.

22 Bottom member 23 Developer container 30 First electrode 31 Second electrode

Claims (11)

A manufacturing method for manufacturing a developer container capable of detecting a developer amount using a change in capacitance between a first electrode and a second electrode,
There is a first resin sheet to be the first electrode and a second resin sheet to be the second electrode having a recess, so that the recess is located at a position facing the end of the first resin sheet, A holding step of holding the first resin sheet and the second resin sheet in a mold;
A molding step of injecting a resin from a first injection port and a second injection port for injecting a resin, and molding a developer container including the first resin sheet and the second resin sheet,
In the molding step, the recess is disposed on a region that forms a junction where the first resin injected from the first injection port and the second resin injected from the second injection port merge. A method for producing a developer container.   The distance from the longitudinal end of the first resin sheet to the second resin sheet at the end of the first resin sheet close to the second resin sheet is from the bottom of the recess of the first resin sheet to the second resin. The method for producing a developer container according to claim 1, wherein the developer container is shorter than a distance to the sheet.   In the molding step, resin is injected from a first inlet and a second inlet for injecting resin, a first frame including the first resin sheet and the second resin sheet is molded, and the first frame is formed. 3. The method of manufacturing a developer container according to claim 1, wherein the developer container is molded by welding a second frame and the second frame body. 4.   The development according to any one of claims 1 to 3, wherein a glass transition temperature of a resin constituting the first resin sheet is lower than a glass transition temperature of the first resin and the second resin. A method for producing an agent container.   5. The method of manufacturing a developer container according to claim 1, wherein the concave portion is any one of a triangular shape, a quadrangular shape, a trapezoidal shape, a rectangular shape, and a semicircular shape. The developer container has a transport member having a sheet-shaped transport unit for transporting the developer,
The second resin sheet is located on the downstream side of the first injection port and the second injection port and on the upstream side of the first resin sheet in the rotation direction of the conveying member. Item 6. The method for producing a developer container according to any one of Items 1 to 5. A developer container capable of detecting a developer amount using a change in capacitance between the first electrode and the second electrode;
A first resin sheet to be the first electrode; a second resin sheet having a recess and the second electrode;
A rotatable conveyance member having a sheet-shaped conveyance unit for conveying the developer,
In the first resin sheet and the second resin sheet, the recess is located at a position facing an end of the first resin sheet,
The distance from the longitudinal end of the first resin sheet to the second resin sheet at the end of the first resin sheet close to the second resin sheet is from the bottom of the recess of the first resin sheet to the second resin. A developer container characterized by being shorter than the distance to the sheet. A first injection port trace and a second injection port trace for injecting resin;
The second resin sheet is located on the downstream side of the first injection port trace and the second injection port trace and on the upstream side of the first resin sheet in the rotation direction of the conveying member. Item 8. The developer container according to Item 7. A developer container according to claim 7 or 8,
And a developer carrying member for carrying the developer. At least one of the developer container according to claim 7 or 8, and the developing device according to claim 9,
A process cartridge having an image carrier for carrying a developer image. At least one of the developer container according to claim 7 or 8, the developing device according to claim 9, and the process cartridge according to claim 10,
An image forming apparatus for forming an image on a recording material.

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