JP4284661B2 - Toner sensor assembly method - Google Patents

Description

  The present invention is used in, for example, a copying machine or a printer, detects the density and remaining amount of toner (or the presence or absence of toner), suppresses variation in characteristics, and maintains high sensitivity while reducing the size and thickness, and reducing the cost. The present invention relates to a method for assembling a toner sensor capable of achieving the above.

Conventionally, various toner sensors are used in copying machines, printers, and the like. For example, in a two-component development method using a two-component developer composed of a magnetic carrier and a toner, a magnetic component is used to detect the toner concentration in the developer or in a one-component development method using a developer composed of a magnetic toner. In order to detect the remaining amount of toner or the presence or absence of magnetic toner, a differential transformer type toner sensor has been frequently used.
In accordance with the demands for miniaturization and thinning of the above-described copying machines and laser printers, the miniaturization and thinning of the toner sensor mounted on the developing device has become an extremely important issue.

FIG. 10 is a cross-sectional view of a main part of a conventional toner sensor (see Patent Document 1).
In FIG. 10, the detection surface 84a is exposed from one surface of the mounting member 85 by inserting and fixing the tip end portion 84b of the toner sensor 84 into the fixing hole 85a of the mounting member 85, and the mounting member 85 has a plurality of mounting members 85. The developer is agitated by rotating it in the direction of the arrow when the detection surface 84a is exposed to the inner surface side of the case 81 by being fastened to the outer surface of the case 81 via a spacer 86 formed with a small thickness with a small screw 87. It is configured to face the stirring blade 82-1 provided in the paddle 82 with a certain gap. However, when the developing device of FIG. 10 is reduced in size and thickness, securing a mounting space for the toner sensor 84 becomes a problem.

FIG. 11 is a diagram for explaining the outline of the arrangement and size ratio of the toner sensor 84 and the stirring paddle 82 of the developing device.
In order to reduce the size and thickness of the developing device, it is important to reduce the width dimension (w) and the thickness dimension (t) of the toner sensor 84. That is, in a copying machine or a printer, the longitudinal dimension of the developing roll corresponds to a standardized paper size (for example, A4, A3, etc.), and the dimension in the longitudinal direction of the stirring paddle 82 in FIG. (L) Since [same as the longitudinal dimension of the developing roll] is limited by the paper size, the dimension (l) of the stirring paddle 82 is small even if the longitudinal dimension (l ′) of the toner sensor 84 is reduced. Can not. Therefore, there is a slight margin for the need to reduce the dimension (l ′).
Against this background, in order to achieve a reduction in the size and thickness of the developing device, it is necessary to reduce the size of the stirring paddle 82 in the radial direction, that is, to reduce the width (w) and thickness (t) of the toner sensor 84. is necessary.

Next, FIG. 12 shows an example of a toner sensor 84 attached to a developing device that is small and thin.
As shown in FIG. 12, the curvature radius (R) of the inner wall surface of the case 81 to which the toner sensor 84 is attached has become smaller due to the reduction in the size and thickness of the developing device. ) And its width dimension (w) is important. This is because, in order to maintain the toner sensor 84 with high sensitivity (a large amount of change in output voltage relative to the amount of change in permeability due to the developer), as shown in FIG. 10, the entire surface of the flat detection surface 84a. However, it is necessary to detect the developer which is exposed to the inner surface side of the case 81 and faces the stirring paddle 82 and is sufficiently stirred. However, a reduction in the size and thickness of the developing device ultimately leads to a decrease in the radius of curvature (R) of the inner surface of the case 81 of the developing device. This also means that the radius (r) of the stirring paddle 82 shown in FIG. Therefore, in FIG. 12, unless the thickness dimension (t ′) of the case 81 is appropriately selected, a part or the whole of the detection surface 84a is buried inside the case 81, and high sensitivity cannot be maintained. Alternatively, the detection surface 84a and the non-detection surface 84c are also exposed on the inner surface side of the case 81, and the smooth agitation and movement of the developer existing on the inner surface side of the case 81 is obstructed to maintain high sensitivity. There is a problem that you can not. In particular, under the condition of R ≦ 2D (approximately r ≦ 2D), for example, in the configuration of FIG. 10, the detection surface 84a exposed on the inner surface side of the case 81 often hits the stirring blade 82-1. However, if the stirring blade 82-1 is formed in a small size as a countermeasure, the space between the inner surface of the case 81 and the stirring blade 82-1 will be greatly opened. For this reason, the developer in the vicinity of the detection surface 84a of the toner sensor 84 is not sufficiently agitated, causing a problem that the measurement sensitivity of the toner sensor 84 is greatly reduced.
As described above, even if the developing device is intended to be small and thin, the mounting position of the toner sensor is limited to the flat portion or the large curvature radius portion on the inner surface of the case of the developing device. Since the dimensions (w) and (t) remain large, the conventional toner sensor will eventually protrude outside even if incorporated in the developing device, and it is difficult to make the developing device small and thin. is there.

Another example of the conventional toner sensor (Patent Document 2) is shown in FIGS. FIG. 7 is a plan view of a conventional toner sensor in which the cover 62 is omitted. 61 is a case, 63 is a mounting hole, 64 is a printed wiring board, 65 is a flat cable, 66 is a connector, 68 is a lead wire, 69. Is a connection line, 70 is a coil bobbin, 79 is a differential transformer, and (w) is a width dimension of the case 61. 8 is a cross-sectional view taken along the line XY of FIG. 7. In FIG. 8, 62 is a cover, 67 is a coil block constituting the differential transformer 79, and (t) is a thickness dimension of the toner sensor.
9 is a cross-sectional view of the head portion 57 of the toner sensor shown in FIGS. In FIG. 9, 51 is a sleeve, 52 is a flange portion of the coil bobbin 70, 73 is a soldering portion, and 55 is an insertion hole for a lead wire 68 provided in the printed wiring board 64 and the sleeve 51. Then, a screwdriver 71 (not shown) is inserted into the screw core 71 screwed into the shaft hole of the coil bobbin 70 via the driver insertion hole 74, the tip of the driver is inserted into the driver insertion groove 75 of the screw core 71, and the screw core 71 is attached to the coil bobbin. The output value of the toner sensor is set by rotating while being screwed along the axial direction of 70.

However, in the toner sensor disclosed in FIG. 9, since the sleeve 51 is disposed between the wiring board 64 and the coil block 67 constituting the differential transformer, it is difficult to reduce the thickness dimension (t) of the toner sensor. Have the problem. This problem has been studied by the present inventor, and it has been found that one factor is that the coil terminals of the differential transformer 79 are not configured to be surface-mountable.
Further, in the configuration of FIG. 8, it is necessary to attach a cover 62 in order to prevent electrical components mounted on the wiring board 64 from being contaminated with a developer or the like, and the thickness dimension (t) of the toner sensor is set. Making it smaller is even more difficult.

On the other hand, as shown in FIG. 13, when the outer diameter dimension (D) of the head portion of the toner sensor, that is, the winding outer diameter of the coil of the differential transformer constituting the detection head portion becomes smaller, the sensitivity (V) of the toner sensor. However, there is a problem that monotonously decreases. In order to obtain high detection accuracy, it is necessary to increase sensitivity (ratio of output voltage to change in toner density).
In addition, the toner sensor case and the coil bobbin of the differential transformer are usually formed of a resin such as PBT. The wall thickness is at least 0.4 mm in order to ensure mechanical strength and dimensional accuracy. It is a fact.
In addition, in the coil bobbin constituting the differential transformer, the coil bobbin is formed with a collar portion which is a partition portion of the coil winding and an insertion space for a screw-like magnetic body (screw core) for setting an output value. is required. Accordingly, in the conventional toner sensor, it is practically difficult to reduce the diameter of the coil wound around the coil bobbin, and the outer diameter (D) of the head portion of the toner sensor is about 10 mm or more. It has become mainstream. In the toner sensor, it is necessary to set the axial length (L) of the winding portion of the coil wound around the coil bobbin to a predetermined value corresponding to the outer diameter (D) dimension.
For the above reasons, it is difficult to reduce the above dimensions (w) and (t) with the conventional toner sensor.
SUMMARY OF THE INVENTION An object of the present invention is to provide a toner sensor assembling method that can achieve a reduction in size, thickness and cost while suppressing sensitivity variation and maintaining high sensitivity.
JP-A-5-35099 Japanese Utility Model Publication No. 3-75456

In order to achieve the above object, a toner sensor assembling method of the present invention is formed by integrally molding a resin toner sensor case having one surface open in the thickness direction and having a protrusion erected from the bottom. A wiring board on which a differential transformer in which a primary coil excited by alternating current and a secondary coil coupled to the primary coil are wound around a bobbin is surface-mounted is arranged on the open surface side of the case of the toner sensor. set to close this open face Runisaishi, wherein the tip of the projection of the toner sensor case is inserted into the through hole formed in the wiring substrate, a rivet shape by heating the projecting portion projecting through said wiring substrate In this case, the case of the toner sensor and the wiring board are fastened. According to the present invention, the toner sensor can be assembled thinly and firmly. In particular, since the fastening portion is caulked by heat fusion, a special fastener is not necessary, and the toner sensor structure is simplified and the cost is reduced.
In the method for assembling the toner sensor of the present invention, it is preferable that heating of the protruding portion protruding through the wiring substrate is performed by contacting a heating rod.

According to the present invention, the following effects can be obtained.
(1) Since the wiring board also serves as a cover (case lid) of the toner sensor and can be fixed integrally to the case, the number of parts can be omitted, which is extremely advantageous for cost reduction.
(2) Moreover, since the differential transformer is surface-mounted on the wiring board , high sensitivity can be maintained.

Hereinafter, the present invention will be described in detail with reference to the drawings.
FIG. 1 is a plan view of an essential part of a toner sensor according to the present invention viewed from the detection surface side, and FIG. 2 is a cross-sectional view taken along line AA of FIG. For ease of understanding, in FIG. 1, the toner sensor case 24 is shown in a removed state, and a portion where the case 24 engages with the wiring board 7 is indicated by a dotted line.
In both figures, 1 is a differential transformer, for example, four collar portions 3a, 3b, 3c, 3d are formed on the outer peripheral surface of a coil bobbin 2 made of PPS resin containing 40% by weight of glass beads, The primary coil 23 and the secondary coil, ie, the detection coil 21 and the reference coil 22 are wound around the collar portion as a partition portion. The flange 3d side at the tip of the differential transformer 1 is fitted into a recess 26 formed in the case 24 of the toner sensor, so that a detection unit (head unit) 17 of the toner sensor is configured.
In addition, the input / output terminals 8a and 8b of the primary coil 23 and the input / output terminals 9a, 9b, 10a and 10b of the secondary coils 21 and 22 are formed in the lower part of the pedestal portion 2b integrally molded with the coil bobbin 2. Each is attached. The differential transformer 1 is configured to be surface-mounted on the printed wiring board 7 by soldering these terminals to the printed wiring board 7.
In FIG. 1, 11 is an IC component, 12 is a Zener diode, 14 is a capacitor, 15 is a resistor, and 16 is a connector (however, these components are omitted in FIG. 2).

  As shown in FIG. 2, a space 5 in which a screw core 4 (for example, formed of soft ferrite) for setting an output value is inserted is provided in the central shaft portion of the coil bobbin 2. Is screwed so as to be movable in the axial direction of the coil bobbin 2. A concave groove 6 is provided in the screw core 4, and a tip end (not shown) of a driver inserted through a driver insertion hole 25 provided in the printed wiring board 7 is inserted into the concave groove 6 to insert the screw core 4. The output value can be set by rotating in the axial direction.

  13a and two portions 13b are boss pins integrally molded with a toner sensor case 24 (for example, formed of ABS resin containing 20% by weight of glass beads). These boss pins 13a, 13b , 13b firmly connects the wiring board 7 and the toner sensor case 24 to each other. As shown in FIG. 2, the bonding is achieved by heat-sealing the front end portion 13a of the boss pin 13 to form a rivet. That is, the boss pins 13a, 13b, and 13b pass through the through holes 18 provided in the printed wiring board 7 so that their tip portions protrude to the outside of the printed wiring board 7 and the resin that forms the protruding portions. A heating rod (not shown) held at a temperature higher than the melting temperature (for example, a temperature about 1 to 100 ° C. higher than the melting temperature of the resin to be used is preferable for efficiently performing the heat fusion operation while suppressing the deterioration of the resin). (The surface is coated with Teflon (registered trademark) to prevent adhesion of the molten resin.) The tip portions 13a, 13b, 13b are heated and melted to form a rivet, and then cooled. By solidifying, the case 24 and the printed wiring board 7 are integrally coupled. Therefore, according to this configuration, it is not necessary to use a special fastener, and the wiring board 7 also serves as a case of the toner sensor, so that the thickness dimension (t) of the toner sensor can be reduced and thinned. It is possible to prevent the developer from entering the space in which the transformer 1 is incorporated and causing electrical problems.

In the toner sensor, in order to obtain high sensitivity, it is advantageous that the gap G between the detection coil 21 and the detection surface 27 (that is, the gap G corresponds to the shortest distance between the developer and the detection coil 21) is small. . In the present invention, for example, the thickness (t _3d ) of the collar portion 3d shown in FIG. 2 can be formed to 0.35 mm by using the above PPS resin and selecting an appropriate injection molding condition. On the other hand, in the coil bobbin incorporated in the conventional toner sensor, the thickness (t _3d ) of the collar portion 3d is larger than 0.50 mm. Therefore, in the present embodiment, the gap (G) is narrowed by at least 0.15 mm compared to the conventional case, so that the sensitivity (V) can be increased accordingly.
In the present invention, the thickness of the collar portion (t _3d ) is preferably less than 0.50 mm from the viewpoint of improving the sensitivity, more preferably 0.35 mm or less, and particularly preferably 0.30 to 0.20 mm. is there. It should be noted that forming the brim thickness dimension (t _3d ) to less than 0.20 mm can reduce cost performance and mechanical strength of the coil bobbin as long as practical normal molding means (such as injection molding) are employed. It is not realistic considering it. Further, the thickness dimension (t ₂₄ ) of the toner sensor case 24 on the detection surface 27 can be set to 0.45 mm when an ABS resin is used. Further, it is needless to say that the flatness of the detection surface 27 needs to be kept good (for example, about 2/100) when the case 24 is molded.

In the present invention, as the resin forming the coil bobbin, for example, a known resin (preferably a resin having heat resistance) such as polyphenylene sulfide resin, polybutylene terephthalate resin, polyamide resin, polyimide resin, polyamideimide resin, or polyester resin is used. Can be used.
Among the resins mentioned above, those having a Young's modulus (measurement method: ASTM D638) of 0.5 × 10 ⁴ Kg / mm ² or more (preferably 10 × 10 ⁴ Kg / mm ² or more) are used when coiled on a coil bobbin. Alternatively, it is preferable because cracks, chips, and the like that occur during incorporation into the toner sensor can be suppressed.
In particular, it is preferable to use a liquid crystalline polyester resin (polyester having a rigid straight chain in the main chain) which is a kind of liquid crystal polymer (showing liquid crystallinity in a molten state).

  The liquid crystalline polyester resin has various basic compositions such as (a) a copolymer of parahydroxybenzoic acid and a polyethylene terephthalate resin, and (b) a copolymer of poly-p-hydroxybenzoate and naphthoic acid. However, the wholly aromatic (b) having a higher Young's modulus is preferable.

In the liquid crystal polymer, when the coil bobbin according to the present invention is molded at a liquid crystal state temperature lower than the complete melting temperature, for example, using a known injection molding means, the fluidity is high, and the coil bobbin is very thin as described above. Is preferable. PPS resin is also preferable because a very thin coil bobbin can be obtained.
In particular, a liquid crystal polymer having a Young's modulus of 16 × 10 ⁴ Kg / mm ² or more is preferably used. Specific examples of such a liquid crystal polymer include Vectra A130 (18 × 10 ⁴ (unit is Kg / mm ² , hereinafter the same), C130 (16 × 10 ⁴ ), A230, which are wholly aromatic thermotropic liquid crystalline polyesters. (30 × 10 ⁴ ), B230 (38 × 10 ⁴ ), A410 (21 × 10 ⁴ ), A422 (18 × 10 ⁴ ), C400 (17 × 10 ⁴ ), A540 (16 × 10 ⁴ ) (Celanese) ), XYDAR RC-210 (16.2 × 10 ⁴ ), G-43C (16.1 × 10 ⁴ ) (above Dartco).

Incidentally, the Young's modulus is steel: 220 × 10 ⁴ , aluminum: 68 × 10 ⁴ , methacrylic resin: 4.2 × 10 ⁴ , polystyrene resin: 3.2 to 3.6 × 10 ⁴ , polyphenylene sulfide resin: 10 Since it is × 10 ⁴ (both units are Kg / mm ² ), it is possible to obtain greater rigidity than using a general thermoplastic resin. Further, in the above resin, in order to improve mechanical properties, heat resistance, etc., one or more of glass fibers, carbon fibers, known whiskers, glass beads, known ceramic particles and the like are used as fillers. 10 to 50 weight% can be added with respect to a weight, More preferably, 20 to 40 weight% can be added.

In the toner sensor according to the present invention, a differential transformer is formed so as to satisfy D <7.0 mm and L / D = 0.5 to 3.0 in order to obtain a sensitivity that can withstand downsizing and thinning and practical use. It is preferable to do. The reason is that if the outer diameter of the head portion 17 of the toner sensor in FIG. 2 is D ≧ 7 mm, as described above, R ≦ 2D (roughly r ≦ 2D and / or R ′ ≦ 2D), and the sensitivity of the toner sensor 30 is greatly reduced, which is not preferable.
For example, in FIG. 2, the outer diameter of the coil bobbin 2 where the coils 20, 21, 22 are wound coaxially is formed to be 4.4 mm, and the flange portions 3a, 3b, 3c, 3d are formed. The outer diameter is 5.1 mm, the outer diameter (φ) of each coil winding 20, 21, 22 is 4.6mm, and the axial length (L) of the winding portion is 4.4mm. By setting the outer diameter (D) of the head portion 17 to 6.0 mm, L / D = 0.73 can be obtained.

FIG. 5 shows changes in sensitivity (V) when (L / D) is changed under the condition of D <7 mm in the toner sensor 30 of FIG.
FIG. 5 shows that L / D = 1 to 2.5 is preferable on the basis of sensitivity 1 (V), and L / D = 0.5 to 3.0 is preferable on the basis of 0.5 (V). Practically, if the sensitivity of the toner sensor is 0.5 (V) or more, it can be sufficiently put into practical use, and it is extremely important to set (L / D) to 0.5 to 3.0.

Next, FIG. 4A shows an example of the configuration of the differential transformer 1 incorporated in the toner sensor according to the present invention viewed from the terminal side disposed in the differential transformer 1. FIG. 4B is a sectional view taken along line BB in FIG.
4 (a) and 4 (b), a pedestal portion 2b positioned below the coil bobbin 2 has substantially L-shaped terminals 8a, 8b, 9a, 9b, 10a, and 10b, one end of which is embedded in the coil bobbin 2. Is provided. These terminals 8a, 8b, 9a, 9b, 10a and 10b are arranged in advance in the position shown in FIG. 4 in an injection mold (not shown) when the coil bobbin 2 is injection molded, and then in the mold. The molding resin is filled with the molten resin, and then the molten resin is cooled and solidified, and is integrally molded and fixed to the pedestal portion 2b as shown in FIG. All of these terminals extend downward from the pedestal 2b, and have an optimum structure for surface mounting on the wiring board 7. Further, projections 2c and 2c are provided at the lower end of the pedestal portion 2b, and these projections 2c and 2c are fitted into holes (not shown) provided in the printed wiring board 7 so that surface mounting is easier. It is configured. The pedestal 2b is provided with a groove 32 so that the mounting operation can be easily performed.

  The toner sensor according to the present invention may have a circuit configuration as shown in FIG. In FIG. 3, 4 indicates a screw core, and 29 indicates a developer to be detected. As shown in FIG. 3, the output waveform from the primary coil 23 excited by alternating current and the differential output waveforms of the detection coil 21 and the reference coil 22 coupled to the primary coil 23 and differentially connected are phased. The signal is input to a comparison circuit, where the phase difference between the two is compared, and then processed by a smoothing circuit. FIG. 3B shows an example of output data with respect to time t in each part a, b, c, and d in FIG.

FIG. 3 is a plan view illustrating an example of a toner sensor according to the present invention. It is the sectional view on the AA line of FIG. FIG. 4 is a block diagram (a) illustrating an example of a circuit configuration in the toner sensor according to the present invention, and a diagram (b) illustrating output characteristics of the sensor. 4A is a plan view showing an example of a terminal configuration of a differential transformer in the toner sensor according to the present invention, and FIG. FIG. 6 is a correlation diagram between sensitivity and (L / D) in the toner sensor according to the present invention. FIG. 6 is a plan view illustrating another example of a toner sensor according to the present invention. It is a top view which shows the conventional toner sensor. It is the XY sectional view taken on the line of FIG. It is sectional drawing of the head part of the conventional toner sensor. It is sectional drawing of the conventional image development apparatus. It is sectional drawing of the toner sensor attached to the conventional image development apparatus. It is the schematic explaining the arrangement | positioning relationship between the developing roll and toner sensor in the conventional developing device. It is a figure which shows the correlation with the sensitivity of a toner sensor, and the outer diameter size of a head part.

Explanation of symbols

1 differential transformer, 2 coil bobbin, 2b pedestal, 2c protrusion,
3, 3a, 3b, 3c, 3d collar part, 4 screw core, 5 holes, 6 concave groove,
7 Wiring board, 8a, 8b, 9a, 9b, 10a, 10b terminal,
11 IC parts, 12 Zener diodes,
13, 13a, 13b Bospin, 14 capacitors,
15 resistors, 16 connectors, 17 heads, 21 detection coils,
22 reference coil, 23 primary coil, 24 case, 25 through hole,
26 concave portion, 27 detection surface, 30, 31 toner sensor, 32 groove

Claims (2)

A case of a resin toner sensor that is open on one side in the thickness direction and has a protrusion standing from the bottom, is integrally molded,
A wiring board on which a differential transformer in which a primary coil excited by alternating current and a secondary coil coupled to the primary coil are wound around a bobbin is surface-mounted is mounted on the mounting surface of the wiring board. be disposed of in case the open side of the case of the toner sensor to face Runisaishi close this open face, and insert the tip of the projection of the toner sensor casing in a through hole formed in the wiring substrate A method of assembling a toner sensor, comprising: heating a protruding portion protruding through the wiring board to form a rivet to fasten the case of the toner sensor and the wiring board. 2. The toner sensor assembling method according to claim 1, wherein heating of the protruding portion protruding through the wiring board is performed by contacting a heating rod.

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