Developer filling method Number:7,163,032 from the United States Patent and Trademark Office (PTO) owispatent The developer cartridge 24 is mounted in the holder 101 of the toner filling device 100 with the toner injecting through-hole 70 of the developer cartridge 24 on top. At this time, the axis of the developer roller 31 is vertical. The slide nozzle 110 is inserted into the toner injecting through-hole 70, such that the nozzle tip is positioned near the bottom of the toner accommodating chamber 34, and the toner expulsion device 120 injects toner into the developer cartridge 24. The toner is introduced with pressure, while the nozzle tip is gradually raised to match the amount of toner introduced.<H Developer, filling, Developer, filli, 7163032.html, Patent, pto, 7163032

Title: Developer filling method

Abstract: The developer cartridge 24 is mounted in the holder 101 of the toner filling device 100 with the toner injecting through-hole 70 of the developer cartridge 24 on top. At this time, the axis of the developer roller 31 is vertical. The slide nozzle 110 is inserted into the toner injecting through-hole 70, such that the nozzle tip is positioned near the bottom of the toner accommodating chamber 34, and the toner expulsion device 120 injects toner into the developer cartridge 24. The toner is introduced with pressure, while the nozzle tip is gradually raised to match the amount of toner introduced.

Patent Number: 7,163,032 Issued on 01/16/2007 to Itabashi

Inventors: Itabashi; Nao (Nagoya, JP)
Assignee: Brother Kogyo Kabushiki Kaisha (Nagoya, JP)

Appl. No.: 10/610,876

Filed: July 2, 2003

Foreign Application Priority Data


Jul 02, 2002 [JP]			P2002-193908
Jul 26, 2002 [JP]			P2002-218669
Sep 27, 2002 [JP]			P2002-284277

Current U.S. Class: 141/12 ; 141/286; 141/366; 141/71; 399/258

Current International Class: B65B 1/20 (20060101)

Field of Search: 141/2,12,18,69-74,285,286,291,292,319,346,363,366 347/85,86 222/99,100 399/99-101,258,359

References Cited [Referenced By]

U.S. Patent Documents


5144382	September 1992	Funayama et al.
5215845	June 1993	Yusa et al.
5287150	February 1994	Kinoshita et al.
5426492	June 1995	Diehl
5701563	December 1997	Fukuda et al.
5719610	February 1998	Scheffelin
5745137	April 1998	Scheffelin et al.
5887227	March 1999	Kawai et al.
5960246	September 1999	Kasahara et al.
6056025	May 2000	Wegman
6201941	March 2001	Kasahara et al.
6331053	December 2001	Seccombe et al.
6337956	January 2002	Sato et al.
6628913	September 2003	Matsumoto et al.
6871033	March 2005	Sato et al.

Foreign Patent Documents


55-55914	Apr., 1980	JP
A 1-222277	Sep., 1989	JP
A-1-222277	Sep., 1989	JP
A-3-87866	Apr., 1991	JP
U-3-35002	Apr., 1991	JP
A-3-144471	Jun., 1991	JP
A 3-176308	Jul., 1991	JP
3-210582	Sep., 1991	JP
4-162049	Jun., 1992	JP
4-351397	Dec., 1992	JP
A-5-46022	Feb., 1993	JP
5-88541	Apr., 1993	JP
U-5-29060	Apr., 1993	JP
U-5-43164	Jun., 1993	JP
A 5-232810	Sep., 1993	JP
A-6-11958	Jan., 1994	JP
A 6-110304	Apr., 1994	JP
A 8-72821	Mar., 1996	JP
A-8-220883	Aug., 1996	JP
8-305152	Nov., 1996	JP
9-311553	Dec., 1997	JP
11-184228	Jul., 1999	JP
A-2000-47466	Feb., 2000	JP
A-2000-066501	Mar., 2000	JP
A 2000-81778	Mar., 2000	JP
A-2000-258984	Sep., 2000	JP
A-2000-267411	Sep., 2000	JP
A 2001-34008	Feb., 2001	JP
2001-278342	Oct., 2001	JP

Primary Examiner: Maust; Timothy L.
Attorney, Agent or Firm: Oliff & Berridge, PLC

Claims

What is claimed is:

1. A developer accommodating vessel comprising: a casing, the casing having a first casing section and a second casing section, the first and second casing sections defining a developer accommodating chamber that accommodates the developer therein, the first and second casing sections being made of a rigid material; a developer supply through-hole formed in the casing for filling the casing with developer, the first and second casing sections being movable relative to one another, allowing the developer to be compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole; and the developer being a powdered developer.

2. A developer accommodating vessel as claimed in claim 1, wherein the casing is capable of being compressed to reduce a width defined along a direction different from the filling direction while maintaining fixed a length defined along the filling direction, thereby reducing the volume of the casing.

3. A developer accommodating vessel as claimed in claim 1, wherein the casing is capable of being compressed to reduce a width defined along a direction substantially orthogonal to the filling direction while maintaining fixed a length defined along the filling direction.

4. A developer accommodating vessel as claimed in claim 1, wherein the developer supply through-hole is formed in the casing such that the filling direction for introducing developer is aligned with a lengthwise direction of the casing.

5. A developer accommodating vessel as claimed in claim 1, wherein the casing is capable of being compressed in a direction substantially orthogonal to a lengthwise direction of the casing.

6. A developer accommodating vessel as claimed in claim 1, wherein the casing is capable of being fixed in its compressed state with its volume being maintained fixed.

7. A developer accommodating vessel as claimed in claim 1, further comprising an agitating member provided inside the casing for agitating the developer, wherein the agitating member is disposed such that an axial direction of the agitating member is aligned with a lengthwise direction of the casing.

8. A developer accommodating vessel as claimed in claim 7, wherein the casing has a top portion facing upward along the gravitational direction while the developer supply through-hole faces horizontally and the axial direction of the agitating member is aligned horizontally, the top portion being movable to compress the casing to reduce the volume thereof.

9. A developer accommodating vessel as claimed in claim 1, further comprising a filter provided on the casing for allowing the passage of air while preventing the passage of developer.

10. A developer accommodating vessel as claimed in claim 1, wherein the developer is a toner having substantially spherically shaped particles.

11. A developer accommodating vessel as claimed in claim 1, wherein the developer is filled in the casing at a density equal to or higher than an apparent loose density when the casing is in a compressed state.

12. A developer accommodating vessel as claimed in claim 1, wherein the casing includes a first casing section having a first sponge member and a second casing section having a second sponge member, the first and second casing sections being movable relatively with each other with the first and second sponge members sliding against each other.

13. A developer cartridge comprising: a developer accommodating vessel including: a casing, the casing having a first casing section and a second casing section, the first and second casing sections defining a developer accommodating chamber that accommodates the developer therein, the first and second casing sections being made of a rigid material; a developer supply through-hole formed in the casing for filling the casing with developer, the first and second casing sections being movable relative to one another, allowing the developer to be compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole; and a developer carrying member for receiving the developer supplied from the casing; wherein the developer is a powdered developer.

14. A developer cartridge as claimed in claim 13, wherein the casing includes: a wall formed with the developer supply through-hole; and another wall moved to compress the casing.

15. A developer cartridge as claimed in claim 13, wherein the developer carrying member is disposed such that an axis of the developer carrying member is aligned with a lengthwise direction of the casing.

16. A developer cartridge as claimed in claim 13, further comprising a developer leakage preventing member contacting the developer carrying member for preventing developer from leaking out of the developer cartridge, wherein the developer leakage preventing member is pressed against the developer carrying member by a pressure of the developer when the developer is introduced into the casing through the developer supply through-hole.

17. A developer cartridge as claimed in claim 13, further comprising a blade provided in contact with the developer carrying member for forming a thin layer of developer on the developer carrying member, wherein the blade is pressed against the developer carrying member by a pressure of the developer when the developer is introduced into the casing through the developer supply through-hole.

18. A developer cartridge as claimed in claim 13, wherein the developer is filled in the casing at a density equal to or higher than an apparent loose density when the casing is in a compressed state.

19. A developer cartridge as claimed in claim 13, wherein the casing includes: a first casing section having a first sponge member and defining an accommodating chamber accommodating the developer; and a second casing section having a second sponge member, the second casing section moving in contact with the first casing section with opposing surfaces of the first sponge member and the second sponge member sliding against each other.

20. A developer cartridge as claimed in claim 13, wherein the developer accommodating vessel further includes a filter provided on the casing for allowing the passage of air while preventing the passage of developer.

21. A processing device comprising: a developer cartridge including: a developer accommodating vessel having: a casing, the casing having a first casing section and a second casing section, the first and second casing sections defining a developer accommodating chamber that accommodates the developer therein, the first and second casing sections being made of a rigid material; a developer supply through-hole formed in the casing for filling the casing with developer, the first and second casing sections being movable relative to one another, allowing the developer to be compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole; and a developer carrying member for receiving the developer supplied from the casing; and an electrostatic latent image bearing member for forming an electrostatic latent image thereon and for receiving the developer from the developer carrying member; wherein the developer is a powdered developer.

22. A processing device as claimed in claim 21, wherein the developer is filled in the casing at a density equal to or higher than an apparent loose density when the casing is in a compressed state.

23. A processing device as claimed in claim 21, wherein the casing includes: a first casing section having a first sponge member and defining an accommodating chamber accommodating the developer; and a second casing section having a second sponge member, the second casing section moving in contact with the first casing section with opposing surfaces of the first sponge member and the second sponge member sliding against each other.

24. A processing device as claimed in claim 21, wherein the developer accommodating vessel further includes a filter provided on the casing for allowing the passage of air while preventing the passage of developer.

25. An image forming device comprising: a developer cartridge including: a developer accommodating vessel having: a casing, the casing having a first casing section and a second casing section, the first and second casing sections defining a developer accommodating chamber that accommodates the developer therein, the first and second casing sections being made of a rigid material; and a developer supply through-hole formed in the casing for filling the casing with developer, the first and second casing sections being movable relative to one another, allowing the developer to be compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole; and a developer carrying member for receiving the developer supplied from the casing; and an electrostatic latent image bearing member for forming an electrostatic latent image thereon and for receiving the developer from the developer carrying member; wherein the developer is a powdered developer.

26. An image forming device as claimed in claim 25, wherein the developer is filled in the casing at a density equal to or higher than an apparent loose density when the casing is in a compressed state.

27. An image forming device as claimed in claim 25, wherein the casing includes: a first casing section having a first sponge member and defining an accommodating chamber accommodating the developer; and a second casing section having a second sponge member, the second casing section moving in contact with the first casing section with opposing surfaces of the first sponge member and the second sponge member sliding against each other.

28. An image forming device comprising: a processing device including: a developer cartridge having: a developer accommodating vessel having: a casing, the casing having a first casing section and a second casing section, the first and second casing sections defining a developer accommodating chamber that accommodates the developer therein, the first and second casing sections being made of a rigid material; a developer supply through-hole formed in the casing for filling the casing with developer, the first and second casing sections being movable relative to one another, allowing the developer to be compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole; and a developer carrying member for receiving the developer supplied from the casing; and an electrostatic latent image bearing member for forming an electrostatic latent image thereon and for receiving the developer from the developer carrying member; wherein the developer is a powdered developer.

29. An image forming device as claimed in claim 28, wherein the developer is filled in the casing at a density equal to or higher than an apparent loose density when the casing is in a compressed state.

30. An image forming device as claimed in claim 28, wherein the casing includes: a first casing section having a first sponge member and defining an accommodating chamber accommodating the developer; and a second casing section having a second sponge member, the second casing section moving in contact with the first casing section with opposing surfaces of the first sponge member and the second sponge member sliding against each other.

31. A developer accommodating vessel comprising: a casing accommodating developer therein; a developer supply through-hole formed in the casing for filling the casing with developer, the casing capable of being compressed in a direction different from a filling direction in which the developer is introduced through the developer supply through-hole; a developer discharge through-hole formed in the casing for discharging the developer to the outside of the casing, the developer discharge through-hole being provided separately from the developer supply through-hole; and a filter provided on the casing for allowing the passage of air while preventing the passage of developer.

32. A developer filling method comprising: filling a casing with a predetermined amount of developer, the casing having a first casing section and a second casing section, the first and second casing sections defining a developer accommodating chamber that accommodates the developer therein, the first and second casing sections being made of a rigid material; and compressing the predetermined amount of developer in and the casing in a direction different from a direction in which developer is introduced into the; wherein the developer is a powdered developer.

33. A developer filling method as claimed in claim 32, wherein developer is introduced into the casing in a lengthwise direction of the casing during the filling step.

34. A developer filling method as claimed in claim 32, wherein the casing is compressed in a direction substantially orthogonal to the lengthwise direction of the casing during the compressing step.

35. A developer filling method as claimed in claim 32, further comprising: fixing the casing after the compressing step.

36. A developer filling method as claimed in claim 32, wherein the developer is filled in the casing at a density equal to or higher than an apparent loose density when the casing is in a compressed state.

37. A developer filling method as claimed in claim 32, wherein the casing includes: a first casing section having a first sponge member and defining an accommodating chamber accommodating developer; and a second casing section having a second sponge member; wherein, in the compressing step, the second casing section moves in contact with the first casing section with opposing surfaces of the first sponge member and the second sponge member sliding against each other.

38. A developer filing method as claimed in claim 32, wherein the casing is provided with a filter for allowing the passage of air while preventing the passage of developer in the filling step and in the compressing step.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a developer filling method for supplying developer to a developer cartridge used in such image forming devices as a printer, a photocopy machine, a facsimile device, or a multifunction device providing a combination of these functions; a developer cartridge; and a developer accommodating vessel.

2. Description of Related Art

Image forming device well known in the art including laser printers, photocopiers, facsimile devices, multifunction devices, and the like employ detachable developer cartridges for accommodating developer. These developer cartridges include a toner accommodating chamber for accommodating developer integrally formed with a developer roller for supplying the developer to a photosensitive drum in the image forming device. When the developer cartridge is mounted in the image forming device, a driving force from the image forming device is transferred to a developing roller to rotate the same, while developer is electrostatically attracted to the surface of the developing roller to form a thin layer thereon. This thin layer of developer is supplied to the photosensitive drum.

Powders, such as ground toner and polymer toner, are used as the developer. The particle size in the toner is approximately several to several tens of .mu.m. When filling the developer cartridge with developer, the developer is dropped by gravity force from a hopper in a developer filling device into the developer cartridge. The operation needs to be done carefully so that the developer does not leak through a gap between the developer roller and a casing of the developer cartridge.

However when employing the method described above to fill the developer cartridge with developer, it is not possible to fill the developer cartridge with developer at a density greater than an apparent loose density, that is, the density of the developer compressed by its own weight. Hence, the volume of the developer cartridge must be greater than the volume of developer being introduced. This problem has been a detriment to attempts to reduce the size of the developer cartridge as well as the size of the image forming device.

On the other hand, one method for filling a vessel with toner is disclosed in Japanese patent application publication No. HEI-5-232810. This vessel includes an upper vessel cylinder having an open bottom end and a toner injection inlet formed in a suitable location, a lower vessel cylinder having an open top end, and a contracting cylinder for integrally coupling the lower edge on the open bottom end of the upper vessel cylinder with the upper edge on the open top end of the lower vessel cylinder in a watertight and airtight construction. The toner vessel includes at least one air escape through-hole at an appropriate location to allow air to escape when the contracting cylinder is contracted to compress the overall toner vessel. After filling the toner vessel with toner, the toner vessel can be compressed by moving the upper vessel cylinder toward the lower vessel cylinder to contract the contracting cylinder. In this way, the toner vessel can be made smaller, even when air enters the cylinder during the toner filling operation.

However, when filling the vessel with toner, the toner mixes with air when poured into the vessel into the vessel. Therefore, the vessel must be configured sufficiently long in the direction that the toner is introduced.

However, in the toner filling method disclosed in Japanese patent application publication No. HEI-5-232810, the direction for introducing toner is the same as the direction in which the toner vessel is compressed. In other words, the vessel is shortened in the filling direction. Therefore, by securing sufficient length of the vessel in the direction in which toner is introduced, the distance in which the vessel is compressed becomes longer, leading to various problems including a need to increase the length of the contracting cylinder, a need to increase the compressing distance, and an increased complexity in the filling operation.

SUMMARY OF THE INVENTION

In view of the foregoing, it is an object of the present invention to provide a developer filling method for filling a developer cartridge with developer, allowing the casing of the developer cartridge to be reduced in size, as well as a developer cartridge, a developer accommodating vessel, and an image forming device employed for the developer filling method.

It is another object of the present invention to provide a developer filling method capable of filling efficiently a developer cartridge with developer and capable of increasing the efficiency of the filling operation, as well as a developer accommodating vessel, a developer cartridge, a processing device, and an image forming device employed for the developer filling method.

In order to attain the above and other objects, the present invention provides a developer filling method for filling an accommodating chamber in a casing with developer. The developer filling method includes preparing a casing defining an accommodating chamber, the casing being formed with a developer supply through-hole for introducing developer into the accommodating chamber and an opening for supplying the developer out of the accommodating chamber, and filling the accommodating chamber with the developer at a density equal to or higher than an apparent loose density.

The present invention also provides a developer filling method for filling an accommodating chamber in a casing with developer. The developer filling method includes inserting a tip of a developer supplying nozzle of a developer filling device into a developer supply through-hole which is formed in a top of a casing and which is communicated with an accommodating chamber in the casing, and pressurizing the developer in the developer filling device and filling the accommodating chamber with the developer by forcing the developer out of the developer supplying nozzle with pressure through the tip of the developer supplying nozzle inserted into the developer supply through-hole.

The present invention also provides a developer filling method for filling an accommodating chamber in a developer cartridge with developer. The developer cartridge includes a casing defining the accommodating chamber for accommodating developer, a developer carrying member for supplying developer accommodated in the accommodating chamber to an electrostatic latent image bearing member on which an electrostatic latent image is formed, the casing having an end wall on one end thereof along an axial direction of the developer carrying member, an opposite end wall on the other end of the axial direction, and a lengthwise wall extending along the axial direction, a developer supply through-hole formed in the end wall of the casing for introducing developer into the accommodating chamber, and an opening formed in the lengthwise wall of the casing for exposing the developer carrying member to an area outside the casing. The method includes arranging the developer cartridge such that the axial direction of the developer carrying member is substantially aligned with the direction of gravitational force, with the opening being positioned to face horizontally and the developer supply through-hole being positioned to face upward, inserting a tip of a developer supplying nozzle of a developer filling device into the developer supply through-hole of the developer cartridge, and pressurizing the developer in the developer filling device and filling the accommodating chamber with the developer by forcing the developer out with pressure through the tip of the developer supplying nozzle inserted into the developer supply through-hole.

The present invention also provides a developer filling method for filling a developer cartridge with developer. The developer cartridge includes a casing defining an accommodating chamber for accommodating developer, and a developer carrying member for supplying developer accommodated in the accommodating chamber to an electrostatic latent image bearing member on which an electrostatic latent image is formed, the casing having an end wall on one end thereof along an axial direction of the developer carrying member, an opposite end wall on the other end of the axial direction, and a lengthwise wall extending along the axial direction. The method includes filling the accommodating chamber with developer, and applying vibrations to the developer cartridge.

The present invention also provides a developer filling method. The developer filling method includes filling a casing with developer, and compressing the casing in a direction different from a direction in which developer is introduced into the casing.

The present invention also provides a developer accommodating vessel. The developer accommodating vessel includes a casing defining an accommodating chamber, and developer accommodated in the casing, the accommodating chamber being filled with the developer at a density equal to or higher than an apparent loose density.

The present invention also provides a developer accommodating vessel. The developer accommodating vessel includes a casing defining an accommodating chamber, developer accommodated in the casing, a developer supply through-hole formed with the casing for filling the accommodating chamber with the developer, and an opening formed with the casing for supplying the developer out of the accommodating chamber, wherein the developer is introduced into the accommodating chamber such that the opening is positioned to face horizontally and the developer supply through-hole is positioned to fate upward, and pressurized developer is introduced into the accommodating chamber via a developer supplying nozzle of a developer filling device inserted into the developer supply through-hole.

The present invention also provides a developer accommodating vessel. The developer accommodating vessel includes a casing defining an accommodating chamber, and developer accommodated in the casing, vibrations being applied to the casing when or after the developer is introduced into the accommodating chamber.

The present invention also provides a developer cartridge. The developer cartridge includes a casing defining an accommodating chamber for accommodating developer, a developer carrying member for supplying developer accommodated in the accommodating chamber to an electrostatic latent image bearing member on which an electrostatic latent image is formed, the casing having an end wall on one end thereof along an axial direction of the developer carrying member, an opposite end wall on the other end of the axial direction, and a lengthwise wall extending along the axial direction, a developer supply through-hole formed in the end wall of the casing for introducing developer into the accommodating chamber, and an opening formed in the lengthwise wall of the casing for exposing the developer carrying member to an area outside the casing, wherein the casing is disposed such that the axial direction of the developer carrying member is substantially aligned with the direction of gravitational force, with the opening positioned on the side thereof and the developer supply through-hole on the top, and pressurized developer is introduced into the accommodating chamber via a developer supplying nozzle of a developer filling device inserted into the developer supply through-hole.

The present invention also provides a developer cartridge. The developer cartridge includes a casing defining an accommodating chamber for accommodating developer, a developer carrying member for supplying developer to an electrostatic latent image bearing member on which an electrostatic latent image is formed, a developer supply through-hole formed in the casing for introducing developer into the accommodating chamber so that the accommodating chamber is filled with the developer through the developer supply through-hole at a density higher than an apparent loose density, and an opening formed in the casing along an axial direction of the developer carrying member, the opening exposing the developer carrying member to an area outside the casing.

The present invention also provides an image forming device. The image forming device includes a developer cartridge including a casing defining an accommodating chamber for accommodating developer, a developer carrying member for supplying developer accommodated in the accommodating chamber to an electrostatic latent image bearing member on which an electrostatic latent image is formed, the casing having an end wall on one end thereof along an axial direction of the developer carrying member, an opposite end wall on the other end of the axial direction, and a lengthwise wall extending along the axial direction, a developer supply through-hole formed in the end wall of the casing for introducing developer into the accommodating chamber, and an opening formed in the lengthwise wall of the casing for exposing the developer carrying member to an area outside the casing, wherein the casing is disposed such that the axial direction of the developer carrying member is substantially aligned with the direction of gravitational force, with the opening positioned on the side thereof and the developer supply through-hole on the top, and pressurized developer is introduced into the accommodating chamber via a developer supplying nozzle of a developer filling device inserted into the developer supply through-hole, and the electrostatic latent image bearing member for forming an electrostatic latent image thereon.

The present invention also provides a developer cartridge. The developer cartridge includes a developer carrying member supplying developer to an electrostatic latent image bearing member on which an electrostatic latent image is formed, and a casing defining an accommodating chamber that is filled with developer and that has been applied with vibrations.

The present invention also provides a developer cartridge. The developer cartridge includes a developer carrying member supplying developer to an electrostatic latent image bearing member on which an electrostatic latent image is formed, and a casing defining an accommodating chamber that is filled with developer at a density higher than an apparent loose density.

The present invention also provides an image forming device. The image forming device includes an electrostatic latent image bearing member forming an electrostatic latent image thereon, and a developer cartridge including a developer carrying member supplying developer to the electrostatic latent image bearing member, and a casing defining an accommodating chamber that is filled with developer and that has been applied with vibrations.

The present invention also provides a developer accommodating vessel. The developer accommodating vessel includes a casing accommodating developer therein, and a developer supply through-hole formed in the casing for filling the casing with developers the casing being capable of being compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole.

The present invention also provides a developer accommodating vessel for accommodating developer. The developer accommodating vessel includes a first casing section having a first sponge member and defining an accommodating chamber accommodating developer, and a second casing section having a second sponge member, the second casing section moving in contact with the first casing section with opposing surfaces of the first sponge member and the second sponge member sliding against each other.

The present invention also provides a developer cartridge. The developer cartridge includes a developer accommodating vessel including a casing accommodating developer therein, and a developer supply through-hole formed in the casing for filling the casing with developer, the casing being capable of being compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole, and a developer carrying member for receiving the developer supplied from the casing.

The present invention also provides a processing device. The processing device includes a developer cartridge including a developer accommodating vessel having a casing accommodating developer therein, and a developer supply through-hole formed in the casing for filling the casing with developer, the casing being capable of being compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole, and a developer carrying member for receiving the developer supplied from the casing, and an electrostatic latent image bearing member for forming an electrostatic latent image thereon and for receiving the developer from the developer carrying member.

The present invention also provides an image forming device. The image forming device includes a developer cartridge including a developer accommodating vessel having a casing accommodating developer therein, and a developer supply through-hole formed in the casing for filling the casing with developer, the casing being capable of being compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole, and a developer carrying member for receiving the developer supplied from the casing, and an electrostatic latent image bearing member for forming an electrostatic latent image thereon and for receiving the developer from the developer carrying member.

The present invention also provides an image forming device. The image forming device includes a processing device including a developer cartridge having a developer accommodating vessel having a casing accommodating developer therein, and a developer supply through-hole formed in the casing for filling the casing with developer, the casing being capable of being compressed in a direction different from a filling direction in which developer is introduced through the developer supply through-hole, and a developer carrying member for receiving the developer supplied from the casing, and an electrostatic latent image bearing member for forming an electrostatic latent image thereon and for receiving the developer from the developer carrying member.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the invention will become more apparent from reading the following description of the preferred embodiments taken in connection with the accompanying drawings in which:

FIG. 1 is a center cross-sectional view showing a laser printer according to first and second embodiments of the present invention;

FIG. 2 is a side cross-sectional view showing a processing cartridge according to the first and second embodiments,

FIG. 3 is a perspective view showing a developer cartridge according to the first embodiment;

FIG. 4 is a left side view showing the developer cartridge according to the first embodiment;

FIG. 5 is a right side view showing the developer cartridge according to the first embodiment;

FIG. 6 is a cross-sectional view showing relevant parts of a toner filling device according to the first embodiment;

FIG. 7 is an explanatory diagram showing the toner filling device according to the first embodiment;

FIG. 8 is a perspective view showing a modification of a slide nozzle of the first embodiment;

FIG. 9 is a perspective view showing a modification of the developer cartridge of the first embodiment;

FIG. 10 is a perspective view showing another modification of the developer cartridge of the first embodiment;

FIG. 11 is a perspective view showing another modification of the slide nozzle of the first embodiment;

FIG. 12 is a front view showing a toner cartridge;

FIG. 13 is a perspective view showing a developer cartridge according to a second embodiment of the present invention;

FIG. 14 is a left side view showing the developer cartridge according to the second embodiment;

FIG. 15 is a right side view showing the developer cartridge according to the second embodiment;

FIG. 16 is an enlarged plan view showing a shaft guiding groove, a support unit, and the like according to the second embodiment;

FIG. 17 is a cross-sectional view along a single-dot chain line B B' in FIG. 16;

FIG. 18 is an explanatory diagram showing the construction of a toner filling device according to the second embodiment;

FIG. 19 is a side cross-sectional view showing a laser printer according to a third embodiment of the present invention;

FIG. 20 is a side cross-sectional view showing a processing unit according to the third embodiment;

FIG. 21 is a perspective view showing a developer cartridge according to the third embodiment;

FIG. 22 is a left side view showing the developer cartridge of FIG. 21;

FIG. 23 is a right side view showing the developer cartridge of FIG. 21;

FIG. 24 is a side cross-sectional view showing the developer cartridge before the top cover section is compressed;

FIG. 25 is a side view showing the developer cartridge during a toner filling process according to the third embodiment; and

FIG. 26 is a side cross-sectional view showing the developer cartridge after the top cover section is compressed.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A developer filling method, a developer cartridge, and an image forming device employing the developer cartridge according to a first embodiment will be described while referring to the accompanying drawings.

First, the constructions of a developer cartridge 24 and a laser printer 1 will be described with reference to FIGS. 1 through 5.

As shown in the cross-sectional view of FIG. 1, the laser printer 1 includes a main case 2 and, within the main case 2, a feeder unit 4 for feeding sheets of paper 3 as the recording medium, a scanning unit 16 including an image forming unit for printing images on the supplied paper 3, a processing cartridge 17, a fixing unit 18, and the like. The right side in the drawing denotes the front surface of the laser printer 1.

A discharge tray 46 is formed as a depression in the top of the main case 2 from the top center of the main case 2 to the front side, the slope of the depression lessening toward the front side of the main case 2 for maintaining printed paper 3 in a stacked state. A open space is formed in a section in the front surface of the main case 2 near the top for inserting the processing cartridge 17. A space for inserting or removing the processing cartridge 17 can be created by rotating a cover 54 provided on the front side (the right side in the FIG. 1) of the main case 2 downward.

A paper discharge path 44 is provided in the back of the main case 2 (the left side in the drawing), forming an arc from top to bottom along the back surface of the main case 2. The paper discharge path 44 serves to guide the paper 3 discharged from the fixing unit 18 that is disposed in the lower back section of the main case 2 to the discharge tray 46 provided on the top of the main case 2. Discharge rollers 45 are provided along the paper discharge path 44 to convey the paper 3.

The feeder unit 4 includes a feed roller 8 provided in the bottom section of the main case 2; a feed cassette 6 detachably mounted in the front surface of the laser printer 1 and capable of being mounted or removed in the front-to-back direction; a paper pressing plate 7 disposed in the feed cassette 6 for retaining the stacked paper 3 and pressing the paper 3 into contact with the feed roller 8; a separating pad 9 provided in the top of the feed cassette 6 on one end, which applies pressure toward the feed roller 8 and works in cooperation with the feed roller 8 during a paper feed operation to separate the paper 3 one sheet at a time; and register rollers 12 disposed downstream from the feed roller 8 in the conveying direction of the paper 3 for adjusting the timing in which the paper 3 is fed for printing.

Sheets of the paper 3 can be stacked on the paper pressing plate 7. A support shaft 7a provided on the end of the paper pressing plate 7 farthest from the feed roller 8 maintains the paper pressing plate 7 on the bottom surface of the feed cassette 6, enabling the end of the paper pressing plate 7 nearest the feed roller 8 to move up and down while rotating around the support shaft 7a. A spring 7b disposed on the underside of the paper pressing plate 7 urges the paper pressing plate 7 toward the feed roller 8. As more sheets of paper 3 are stacked on the paper pressing plate 7, the paper pressing plate 7 resists the urging force of the spring 7b and pivots downward about the support shaft 7a. The feed roller 8 and separating pad 9 are disposed in confrontation with each other. A spring 13 provided on the underside of the separating pad 9 presses the separating pad 9 toward the feed roller 8.

The scanning unit 16 of the image forming unit is disposed directly beneath the discharge tray 46 in the main case 2. The scanning unit 16 includes a laser light emitting unit (not shown in the drawing) for emitting laser light, a polygon mirror 19 that is driven to rotate in order to scan the laser light emitted by the laser light emitting unit in a main scanning direction, an f.theta. lens 20 for fixing the scanning speed of the laser light scanned by the polygon mirror 19, reflecting mirrors 21a and 21b for reflecting the scanned laser light, a relay lens 22 for adjusting the focal point of laser light reflected by the reflecting mirrors 21a in order to form an image on a photosensitive drum 27 via the reflecting mirror 21b, and the like. Hence, the surface of the photosensitive drum 27 in the processing cartridge 17 is exposed to laser light scanned by the scanning unit 16 based on print data. The laser light is emitted from the laser light emitting unit and passes through or is reflected by the polygon mirror 19, f.theta. lens 20, reflecting mirrors 21a, relay lens 22, and reflecting mirror 21b in the order given.

The fixing unit 18 is disposed to the side of and downstream of the processing cartridge 17. The fixing unit 18 includes a heat roller 41, a pressure roller 42 applying pressure to the heat roller 41, and a pair of conveying rollers 43 disposed downstream of the heat roller 41 and pressure roller 42. The heat roller 41 includes a halogen lamp 41a for heating the interior of the cylindrical roller. The toner that is transferred to the surface of the paper 3 in the processing cartridge 17 is fixed to the paper 3 by heat, as the paper 3 passes between the heat roller 41 and pressure roller 42. Subsequently, the conveying rollers 43 convey the paper 3 along the paper discharge path 44.

As shown in FIG. 2, the processing cartridge 17 in the image forming unit includes a drum cartridge 23 and the developer cartridge 24 detachably mounted on the drum cartridge 23. The drum cartridge 23 includes the photosensitive drum 27, a Scorotron type charging device 29, a transfer roller 30, and the like. The developer cartridge 24 includes a casing 50 and an inside wall 51 defining a developing chamber 37 and a toner accommodating chamber 34. The developer cartridge 24 further includes a developer roller 31, a supply roller 33, a thickness regulating blade 32, a sealing member 40, and the like, provided in the developing chamber 37.

The photosensitive drum 27 of the drum cartridge 23 is disposed to the side of the developer roller 31 with the rotating shaft of the photosensitive drum 27 parallel to the rotating shaft of the developer roller 31. The photosensitive drum 27 is capable of rotating in the direction indicated by the arrow (clockwise in the drawing) while in contact with the developer roller 31. The photosensitive drum 27 includes a conductive base on which are layered a charge generating layer in which a positively-charged organic light conductor, such as an azo pigment or a phthalocynanine pigment, as the charge generating material is dispersed in a binder resin; a charge transporting layer in which such compounds as hydrazones or arylamines are mixed in a polycarbonate or other resin; and the like. When the photosensitive drum 27 is exposed to laser light or the like, a charge is generated in the charge generating layer from the absorbed light. This charge is transported to the conductive base and the surface of the photosensitive drum 27 via the charge transporting layer, negating the potential on this surface that has been applied by the charging device 29. In this way, a potential differential can be achieved between areas that have been exposed to light and areas that have not. Electrostatic latent images are formed on the photosensitive drum 27 by exposing the surface of the photosensitive drum 27 to a laser light scanned according to print data.

The charging device 29 is disposed above the photosensitive drum 27 and separated a predetermined distance therefrom so as not to contact the photosensitive drum 27. The charging device 29 is a positive charging scorotron charger having a charging wire formed of tungsten or the like from which a corona discharge is generated. By switching on and off a charging bias circuit (not shown), the charging device 29 applies a uniform charge of positive polarity across the entire surface of the photosensitive drum 27.

When the developer cartridge 24 is mounted on the drum cartridge 23, the developer roller 31 is positioned downstream of the charging device 29 in the rotating direction of the photosensitive drum 27 (clockwise in the drawing) and is capable of rotating in the direction indicated by the arrow (counterclockwise in the drawing). The developer roller 31 includes a metal roller shaft covered by a roller formed of a conductive rubber material. A developer bias circuit (not shown) applies a developer bias to the developer roller 31.

The supply roller 33 is rotatably disposed on the side of the developer roller 31 opposite the side of the photosensitive drum 27 and contacts the developer roller 31 while applying pressure to the same. The supply roller 33 includes a metal roller shaft covered by a roller formed of a conductive foam material and is configured to tribocharge toner supplied to the developer roller 31.

The toner accommodating chamber 34 is positioned to the side of the supply roller 33 and is filled with developer to be supplied to the developer roller 31 via the supply roller 33. In the present embodiment, the developer is a positively charged nonmagnetic single-component toner. The developer is a polymerized toner obtained by copolymerizing a polymerized monomer using a well-known polymerization method such as suspension polymerization. The polymerized monomer may be, for example, a styrene monomer such as styrene or an acrylic monomer such as acrylic acid, alkyl (C1 C4) acrylate, or alkyl (C1 C4) meta acrylate. The polymerized toner is formed as particles substantially spherical in shape in order to have excellent fluidity. The toner is compounded with a coloring agent such as carbon black or wax, as well as an additive such as silica to improve fluidity. The diameter of the toner particles is about 6 10 .mu.m.

An agitator 36 has a coarse mesh-like plate shape formed substantially rectangular. A film member 36a functioning to scrape the inner wall of the toner accommodating chamber 34 is provided on the end of the agitator 36. A rotating shaft 35 is formed along one lengthwise edge of the agitator 36, supporting the agitator 36 on both lengthwise ends of the toner accommodating chamber 34. The agitator 36 rotates in the direction of the arrow (clockwise in the drawing) to stir toner in the toner accommodating chamber 34.

The thickness regulating blade 32 is a blade formed of a thin metal leaf spring extending along the axial direction of the developer roller 31. One end of the thickness regulating blade 32 is fixed on the inner wall of the casing 50 near the developer roller 31, which is a fixed end 32c. The other end is a free end 32d, on which a pressing member 32b is provided along the axial direction of the developer roller 31. The pressing member 32b has a semicircular shaped cross-section and is formed of an insulating silicon rubber. The pressing member 32b is configured to pressingly contact the developer roller 31 by the elastic force of the blade member.

The sealing member 40 is provided to prevent toner from leaking out through gaps between the developer roller 31 and the inner wall of the casing 50. The sealing member 40 is a thin plastic film extending in the axial direction of the developer roller 31. One end of the sealing member 40 (fixed end) is fixed to the inner wall of the casing 50 on the opposite side of the developer roller 31 from the thickness regulating blade 32. The other end of the sealing member 40 (free end) elastically contacts the outer surface of the developer roller 31 at a position closer to the toner accommodating chamber 34 than the fixing position.

The transfer roller 30 is provided below the photosensitive drum 27 and downstream of the developer roller 31 in the rotating direction of the photosensitive drum 27. The transfer roller 30 is supported to be able to rotate in the direction of the arrow (counterclockwise in the drawing). The transfer roller 30 includes a metal roller shaft covered by a roller formed of an ion-conducting rubber material. During a transfer process, a transfer bias circuit (not shown) applies a transfer bias to the transfer roller 30. A transfer bias is a bias applied to the transfer roller 30 to generate a potential difference that causes toner electrostatically deposited on the surface of the photosensitive drum 27 to be electrically attracted toward the surface of the transfer roller 30.

In this laser printer 1, the transfer roller 30 transfers toner from the photosensitive drum 27 to the paper 3. Subsequently, the developer roller 31 recovers toner remaining on the surface of the photosensitive drum 27, employing what is known as a cleanerless developing system. The use of this type of cleanerless system to recover residual toner on the photosensitive drum 27 can aid in the simplification of the device construction and reduce costs by eliminating the need for a blade or other cleaning device and a reservoir for recovering waste toner.

When removing the developer cartridge 24 from the processing cartridge 17, first a stopper (not shown) fixing the drum cartridge 23 to the developer cartridge 24 is disengaged. Next, the developer cartridge 24 is rotated about a shaft 31a of the developer roller 31 in a direction that separates the developer roller 31 from the photosensitive drum 27, as indicated by a two-dot chain line A in FIG. 2.

The inside space of the developer cartridge 24 is separated by the inside wall 51, forming the toner accommodating chamber 34 and the developing chamber 37. As described above, a rectangular opening 28 is formed in the developer cartridge 24 along the axial direction of the developer roller 31, such that the developer roller 31 is exposed from the developing chamber 37 and contacts the photosensitive drum 27. The supply roller 33 is also provided in the developing chamber 37. A toner supply through-hole 47 having a width smaller than a diameter of the developer roller 31 is formed in the inside wall 51 between the developing chamber 37 and toner accommodating chamber 34 along the axial direction of the developer roller 31. Since the toner supply through-hole 47 regulates the amount of toner supplied from the toner accommodating chamber 34 to the developing chamber 37, the pressure of toner applied to the developing chamber 37 is alleviated.

Hereinafter, the front direction in which the processing cartridge 17 is mounted in the laser printer 1 is denoted as the front direction, as shown in FIG. 3. The rear, right and left directions are denoted in the same way. As shown in FIGS. 3 through 5, hearing through-holes for the shaft 31a of the developer roller 31, a shaft 33a of the supply roller 33, and the shaft 35 of the agitator 36 accommodated in the developer cartridge 24 penetrate through a left side surface 24a in the lengthwise direction of the developer cartridge 24 (the side surface on the left side). Gears rotating about the shaft 31a, shaft 33a, and rotating shaft 35 are disposed on and exposed from the left side surface 24a outside the casing of the developer cartridge 24. A gear train 71 is configured of these gears and linking gears that link adjacent gears. A gear provided in a drive input unit 72 is engaged with the gear train 71. When the processing cartridge 17 is mounted in the laser printer 1, a driving force generated by the laser printer 1 is transferred to the gear train 71 via the drive input unit 72, driving each of the developer roller 31, supply roller 33, and agitator 36 to rotate.

Windows 38a and 38b for detecting the amount of remaining toner are provided in the left side surface 24a and a right side surface 24b (the side surface on the right side) of the developer cartridge 24. The amount of remaining toner is detected by, for example, projecting an LED light through the window 38a into the developer cartridge 24 and determining whether a photosensor (not shown) can detect the LED light through the window 38b of the right side surface 24h. Accordingly, cleaners 39 (see FIG. 2) formed of urethane rubber or the like are provided one on either end of the rotating shaft 35 and positioned axisymmetrically to the agitator 36 in relation to the rotating shaft 35.

A toner injecting through-hole 70 in fluid commun