Waste toner collecting apparatus and image forming apparatus Number:7,426,365 from the United States Patent and Trademark Office (PTO) owispatent

Title: Waste toner collecting apparatus and image forming apparatus

Abstract: A toner-collecting apparatus collects waste toner therein. A toner collecting chamber holds the waste toner therein. The toner is directed into the toner collecting chamber through an inlet of the toner collecting chamber. A toner transporting member is located in the toner collecting chamber. The toner transporting member transports the toner received through the inlet into the toner collecting chamber. The toner transporting member includes a plurality of toner transporting sections. A first one of the plurality of toner transporting sections has a toner-transporting ability that changes in accordance with a condition of the toner held in the toner collecting chamber. The ability of the toner transporting member to transport the toner decreases with increasing a load exerted on the toner transporting member by the toner. The toner transporting member includes a shaft that extends toner collecting chamber and rotates about a longitudinal axis.

Patent Number: 7,426,365 Issued on 09/16/2008 to Uchihashi

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Inventors:	Uchihashi; Satoru (Tokyo, JP)
Assignee:	Oki Data Corporation (Tokyo, JP)
Appl. No.:	11/294,040
Filed:	December 5, 2005

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Foreign Application Priority Data

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Dec 07, 2004 [JP]			2004-353915

Current U.S. Class:	399/358
Current International Class:	G03G 21/00 (20060101)
Field of Search:	399/358

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References Cited [Referenced By]

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U.S. Patent Documents

5021825	June 1991	Niki
6937838	August 2005	Ishii et al.
2002/0114651	August 2002	Wang

Foreign Patent Documents

	60103366		Jun., 1985		JP
	01316785		Dec., 1989		JP
	04-127186		Apr., 1992		JP
	2005-316351		Nov., 2005		JP

Primary Examiner: Grainger; Quana M
Attorney, Agent or Firm: Panitch Schwarze Belisario & Nadel LLP

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Claims

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What is claimed is:

1. A toner-collecting apparatus comprising: a toner collecting chamber that holds toner therein; an inlet through which said toner collecting chamber receives the toner; and a toner transporting member located in said toner collecting chamber and transporting the toner in said toner collecting chamber, said toner transporting member including a first transporting section and a second transporting section; and a force transmitting section positioned between the first and second transporting sections transmitting a drive force from the first transporting section to the second transporting section; wherein the ability of said toner transporting member to transport the toner decreases with increasing load on said toner transporting member exerted by the toner.

2. The toner-collecting apparatus according to claim 1, wherein said toner transporting member extends in said toner collecting chamber from upstream to downstream with respect to a direction in which the toner is transported in said toner collecting chamber, wherein the second transporting section extends from a substantially downstream end of said toner transporting member to an upstream portion of said toner transporting member.

3. The toner-collecting apparatus according to claim 1, wherein said force transmitting section ceases to transmit the drive force to the second transporting section from the first transporting section when a sufficient force is exerted on the second transporting section by the toner.

4. The toner-collecting apparatus according to claim 1, wherein said toner transporting member includes a shaft that extends in said toner collecting chamber and rotates about a longitudinal axis.

5. The toner-collecting apparatus according to claim 4, wherein said toner transporting member includes an engagement portion fixed on the shaft, and the second transporting section is in frictional contact with the engagement portion so that rotation of the shaft is transmitted to the second transporting section through a frictional force.

6. The toner-collecting apparatus according to claim 5, wherein the second transporting section is a coil spring through which the shaft extends, the coil spring urges against the engagement portion to create the frictional force.

7. The toner-collecting apparatus according to claim 4, wherein the second transporting section is coupled to the first transporting section via a ratcheting mechanism provided at the boundary between the first transporting section and the second transporting section; wherein rotation of the first transporting section is transmitted to the second transporting section through the ratcheting mechanism.

8. The toner-collecting apparatus according to claim 7, wherein the second transporting section is a coil spring through which the shaft extends, the coil spring urges the ratcheting mechanism into an engagement state in which rotation of the first transporting section is transmitted to the second transporting section.

9. The toner-collecting apparatus according to claim 4, wherein the first transporting section includes a spiral screw that spirals on the shaft.

10. The toner-collecting apparatus according to claim 4, wherein the force transmitting section has a portion having a smaller mechanical strength than any of the first transporting section and the second transporting section, wherein the first transporting section and the second transporting section are broken apart at the force transmitting section when the second transporting section receives a torque load greater than a certain value during rotation of said toner transporting member.

11. The toner-collecting apparatus according to claim 4, wherein said toner transporting member includes an engagement portion fixed on the shaft, wherein the second transporting sections is a coil spring having one end connected to the engagement portion so that the coil spring is rotatable together with the shaft, wherein the coil spring is compressed as a torque load exerted by the toner increases.

12. The toner-collecting apparatus according to claim 1, wherein the force transmitting section includes a coil spring that is in friction engagement with the first transporting section and the second transporting section such that rotation of the first transporting section is transmitted to the second transporting section through the coil spring, wherein with increasing load on the second transporting section exerted on the second transporting section by the toner, continued rotation of the first transporting section causes the coil spring to unwind.

13. A toner-collecting apparatus comprising: a toner collecting chamber that holds toner therein; an inlet through which said toner collecting chamber receives the toner; a toner transporting member located in said toner collecting chamber, said toner transporting member transporting the toner received through said inlet into said toner collecting chamber; and a direction switching section that switches a direction in which toner transporting member transports the toner in the toner collecting chamber, the direction being switched in accordance with an amount of toner in said toner collecting chamber based on a load exerted on the toner transporting member by the toner so that the toner is transported either in a first direction or in a second direction opposite to the first direction.

14. The toner-collecting apparatus according to claim 13, wherein said toner transporting member has a toner-transporting ability that changes in accordance with a condition of the toner held in said toner collecting chamber.

15. The toner-collecting apparatus according to claim 14, wherein the toner-transporting ability is constrained in a specific direction.

16. The toner-collecting apparatus according to claim 13, wherein said toner transporting member includes a shaft that extends in the toner collecting chamber and rotates about a longitudinal axis; and a toner transporting element formed about the shaft, said toner transporting element transporting the toner when the shaft rotates.

17. The toner-collecting apparatus according to claim 16, wherein said direction switching section includes a drive motor that drives the shaft in rotation; a load detecting section that detects a torque load exerted on the shaft; wherein said direction switching section switches a direction in which the drive motor rotates, the direction being switched depending on the torque load detected by said load detecting section.

18. The toner-collecting apparatus according to claim 17, wherein said load detecting section detects the torque load based on a rotational speed of the shaft.

19. The toner-collecting apparatus according to claim 17, wherein said toner transporting member includes a transporting section provided at least in the vicinity of the inlet.

20. An image forming apparatus incorporating said toner collecting apparatus according to claim 1, the image apparatus comprising: a toner transporting mechanism that collects toner scraped off from a photoconductor on which a toner image is formed; wherein said toner collecting apparatus receives the toner discharged from said toner transporting mechanism, the toner being received through an inlet of said toner collecting apparatus.

21. An image forming apparatus incorporating said toner collecting apparatus according to claim 4, the image apparatus comprising: a toner transporting mechanism that collects toner scraped off from a photoconductor on which a toner image is formed; wherein said toner collecting apparatus receives the toner discharged from said toner transporting mechanism, the toner being received through an inlet of said toner collecting apparatus.

22. The toner-collecting apparatus according to claim 1, wherein the drive force is a torque exerted on the toner transmitting member.

23. The toner-collecting apparatus according to claim 12, wherein when the coil spring unwinds, a diameter of the coil spring increases allowing the first transporting section to rotate relative to the second transporting section.

24. The toner-collecting apparatus according to claim 19, wherein the transporting section in the vicinity of the inlet ceases to transport toner toward the inlet when the toner transporting member is rotated in the second direction and a sufficient force is exerted on the toner transporting member by the toner in the vicinity of the inlet.

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Description

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BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a waste toner collecting apparatus and an image forming apparatus, and more particularly to a transporting mechanism that transports waste toner in a toner collecting chamber.

2. Description of the Related Art

Among image forming apparatuses are laser printers, facsimile machines, copiers, and the like that use an electrophotographic image forming process. An electrophotographic image forming process employs toner to develop an electrostatic latent image into a visible image or a toner image. After the toner image is transferred onto a print medium, some toner remains on the surface of a photoconductive drum. This residual toner is removed from the photoconductive drum and is collected into a toner collecting chamber provided within the electrophotographic image forming apparatus. One way of collecting waste toner is to allow the residual toner to fall by gravity into a toner collecting chamber. However, this way of collecting waste toner requires a toner chamber to extend vertically so that the toner chamber has a sufficient volume to accommodate the residual toner. This often places some limitations on efficient utilization of space in the image forming apparatus. Another way of collecting the waste toner is to transport the collected residual toner in a horizontal toner chamber. This requires a waste toner transporting mechanism (e.g., a spiral) in the horizontal chamber.

However, if the waste toner transporting mechanism has the ability to transport the toner across its length in the toner chamber, the waste toner tends to pile up at a downstream space with respect to the direction of travel of the waste toner while an upstream space is still capable of holding the waste toner. Thus, the waste toner at the downstream space is over packed to exert an extremely large load on the waste toner transporting mechanism, failing to hold any more waste toner in the chamber.

Likewise, if the waste toner transporting mechanism has the ability to transport the toner only part of its length along the toner chamber, the waste toner will not reach the downstream space, so that the downstream space is not effectively used to hold the waste toner.

SUMMARY OF THE INVENTION

An object of the invention is to solve the problem that non-uniform density distribution in a waste toner holding chamber deteriorates the ability of toner holding chamber to accommodate toner.

Another object of the invention is to provide a toner collecting apparatus that can accommodate as large an amount of waste toner as the toner collecting apparatus is designed, and an image forming apparatus that employs the toner collecting apparatus.

A toner-collecting apparatus is used to collect waste toner. A toner collecting chamber holds toner therein. The chamber receives the waste toner through an inlet. A toner transporting member is located in the toner collecting chamber. The toner transporting member transports the toner in the toner collecting chamber. The toner transporting member includes a plurality of toner transporting sections. A first one of the plurality of toner transporting sections has a toner-transporting ability that changes in accordance with a condition of the toner held in the toner collecting chamber.

The toner transporting member extends in the toner collecting chamber from upstream to downstream with respect to a direction in which the toner is transported in the toner collecting chamber. The first one of the plurality of toner transporting sections extends from a substantially downstream end of the toner transporting member to an upstream portion of the toner transporting member.

The ability of the toner transporting member to transport the toner decreases with increasing load on the toner transporting member exerted by the toner.

The toner transporting member includes a shaft that extends in the toner collecting chamber and rotates about a longitudinal axis.

The toner transporting member includes an engagement portion fixed on the shaft. The first one of the plurality of toner transporting sections includes a toner transporting element that is in frictional contact with the engagement portion so that rotation of the shaft is transmitted to the toner transporting element through a frictional force.

The toner transporting element is a coil spring through which the shaft extends, the coil spring urges against the engagement portion to create the frictional force.

The toner transporting element is coupled to a second one of the plurality of transporting sections via a ratcheting mechanism provided between the boundary of the first one of the plurality of transporting sections and the second one of the plurality of transporting sections. Rotation of the second one of the plurality of transporting sections is transmitted to the first one of the plurality of transporting sections through the ratcheting mechanism.

The toner transporting element is a coil spring through which the shaft extends, the coil spring urges the ratcheting mechanism into an engagement state in which rotation of the second one (54c) of the plurality of transporting sections is transmitted to the first one of the plurality of transporting sections.

The first one of the plurality of transporting sections includes a spiral screw that spirals on the shaft.

The first one of the plurality of transporting sections is connected to a second one of the plurality of transporting sections via a portion having a smaller mechanical strength than any of the first one of the plurality of transporting sections and the second one of the plurality of transporting sections. The portion fractures when the first one of the plurality of transporting sections receives a torque load greater than a certain value during rotation of the toner transporting member.

The toner transporting member includes an engagement portion fixed on the shaft. The first one of the plurality of toner transporting sections includes a coil spring having one end connected to the engagement portion so that the coil spring is rotatable together with the shaft. The coil spring is compressed as a torque load exerted by the toner increases.

The first one of the plurality of transporting sections and a second one of the plurality of transporting sections are coupled through a coil spring that is in friction engagement with the first one of the plurality of transporting sections and the second one of the plurality of transporting sections such that rotation of the second one of the plurality of transporting sections is transmitted to the first one of the plurality of transporting sections through the coil spring. When the second one of the plurality of transporting sections rotates, the rotation is transmitted to the first one of the plurality of transporting sections so that a force acts on the coil spring in such a direction as to unwind the coil spring.

A toner-collecting apparatus is used to collect waste toner. A toner collecting chamber holds toner therein. The toner collecting chamber receives the waste toner through an inlet. A toner transporting member is located in the toner collecting chamber. The toner transporting member transports the toner received through the inlet into the toner collecting chamber. A direction switching section switches a direction in which toner transporting member transports the toner in the toner collecting chamber.

The toner transporting member has a toner-transporting ability that changes in accordance with a condition of the toner held in the toner collecting chamber.

The toner-transporting ability is constrained in a specific direction.

The toner transporting member includes a shaft that extends in the toner collecting chamber and rotates about a longitudinal axis. A toner transporting element is formed about the shaft, the toner transporting element transporting the toner when the shaft rotates.

The direction switching section includes a drive motor that drives the shaft in rotation. A load detecting section detects a torque load exerted on the shaft. The direction switching section switches a direction in which the drive motor rotates, the direction being switched depending on the torque load detected by the load detecting section.

The load detecting section detects the torque load based on a rotational speed of the shaft.

The toner transporting member includes a toner transporting section provided at least in the vicinity of the inlet.

An image forming apparatus incorporates the aforementioned toner collecting apparatus. The image apparatus includes a toner transporting mechanism that collects toner scraped off from a photoconductor on which a toner image is formed. The toner collecting apparatus receives the toner discharged from the toner transporting mechanism, the toner being received through an inlet of the toner collecting apparatus.

Further scope of applicability of the present invention will become apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus are not limiting the present invention, and wherein:

FIG. 1 is a schematic diagram illustrating an electrophotographic image forming apparatus having a waste toner collecting apparatus according to a first embodiment;

FIG. 2 is an exploded perspective view illustrating the configuration of the waste toner collecting apparatus;

FIG. 3 is a fragmentary enlarged cross-sectional view of the vicinity of a collecting section;

FIGS. 4A and 4B are fragmentary enlarged views of a coupling relation between a toner guide of a toner transporting mechanism and an inlet of the waste toner collecting apparatus;

FIG. 5 is a perspective view illustrating a fixed cap and a movable cap;

FIG. 6 is a fragmentary enlarged view of a spiral;

FIGS. 7A-7C are front views illustrating the waste toner collecting apparatus at different levels of the toner;

FIG. 8 is a fragmentary side view of a pertinent portion of a spiral for use in a waste toner collecting apparatus according to a second embodiment;

FIGS. 9A-9C are front views illustrating the toner collecting apparatus;

FIG. 10 is a fragmentary side view of a pertinent portion of a spiral for use in a waste toner collecting apparatus according to a third embodiment.

FIG. 11A is a fragmentary enlarged view of a flange, a coil spring, and another flange;

FIG. 11B is a fragmentary view illustrating the positional relation between the flange and another flange with the coil spring omitted;

FIG. 12A is a fragmentary side view of a pertinent portion of a spiral for use in a waste toner collecting apparatus according to a fourth embodiment;

FIG. 12B illustrates the operation of the spiral;

FIG. 13 is a fragmentary side view of a pertinent portion of a spiral for use in a waste toner collecting apparatus according to a fifth embodiment;

FIG. 13A is a fragmentary side view of the pertinent portion of the spiral shown in FIG. 13 with a fractured small diameter portion;

FIG. 14 is a graph of the amount of waste toner versus torque load on the spiral;

FIG. 15A is a cross-sectional side view of a waste toner collecting apparatus according to a sixth embodiment;

FIG. 15B is a block diagram illustrating the configuration of a control of a drive motor that drives a spiral for use in the waste toner collecting apparatus;

FIG. 16 is a graph of elapsed time versus rotation of the drive motor under control of the drive controller; and

FIG. 17 is a fragmentary side view illustrating a pertinent portion of a spiral for use in a waste toner collecting apparatus according to a seventh embodiment.

DETAILED DESCRIPTION OF THE INVENTION

First Embodiment

FIG. 1 is a schematic diagram illustrating an electrophotographic image forming apparatus having a waste toner collecting apparatus according to a first embodiment.

Referring to FIG. 1, an image forming apparatus 200 includes process units 201-204 that form yellow (Y), magenta (M), cyan (C), and black (K) images. The process units 201-204 are detachably attached to the image forming apparatus 200, and are aligned in this order from upstream to downstream along the transport path of a recording medium. Each of the process units 201-204 may be substantially identical; for simplicity only the operation of the process unit 201 for forming yellow images will be described, it being understood that the other cartridges 20 may work in a similar fashion.

The process unit 201 includes a photoconductive drum 11 that is rotatable in a direction shown by an arrow A. Disposed around the photoconductive drum 11 are a charging roller 12, an exposing unit 13, a developing roller 14, a cleaning blade 15, and a neutralizing device 16, which are aligned in this order from upstream to downstream with respect to the rotation of the photoconductive drum 11. The charging roller 12 rotates in contact with the photoconductive drum 11 to charge the surface of the photoconductive drum 11. In accordance with print data, the exposing unit 13 illuminates the charged surface of the photoconductive drum 11 to form an electrostatic latent image. The developing roller 14 deposits a yellow toner to the electrostatic latent image formed on the photoconductive drum 11 to develop the electrostatic latent image into a toner image. The cleaning blade 15 removes residual toner that remains on the surface of the photoconductive drum 11 after transferring the toner image. The neutralizing device 16 removes residual charges from the photoconductive drum 11. The aforementioned drum and rollers are driven in rotation through gears by a drive source, not shown.

The image forming apparatus 200 includes a paper cassette 206 at a lower portion of the image forming apparatus 200, the paper cassette 206 holding a stack of recording medium 205 such as paper. A hopping roller 207 is disposed over the paper cassette 206 and feeds the recording medium 205 on a page-by-page basis. A transport roller 210 is disposed downstream of the hopping roller 207 with respect to the transport path of the recording medium to the process unit 201, and cooperates with a pinch roller 208 to transport the recording medium 205 while holding the recording medium 205 in a sandwiched relation between the transport roller 210 and the pinch roller 208. A registration roller 211 cooperates with a pinch roller 209 to remove skew of the recording medium 205 with the transport path immediately before the recording medium 205 is fed into the process unit 201. The hopping roller 207, transport roller 210, and registration roller 211 are driven in rotation through gears by a drive source, not shown.

Transfer rollers 212 are made of, for example, an electrically conductive rubber and are disposed to oppose the photoconductive drums 11 of the process units 201-204. The transfer rollers 212 receive a high voltage to create a potential difference between each of the transfer rollers 212 and corresponding photoconductive drums 11 when the toner image is transferred onto the recording medium 205.

A fixing unit 213 includes a heat roller and a backup roller, which cooperate with each other to apply heat and pressure to the toner image on the recording medium 205, thereby forming a permanent image on the recording medium 205. Discharge rollers 214 and 215 cooperate with pinch rollers 216 and 217, respectively, to hold the recording medium 205 in a sandwiched relation and transport the recording medium 205 to a stacker 218. The fixing unit 213, discharge rollers 214 and 215, and pinch rollers 216 and 217 are driven in rotation through gears by a drive source, not shown. A belt unit 219 forms a transport path through which the recording medium 205 passes through the process units 201-204. A belt 220 is sandwiched between the photoconductive drums 11 and corresponding transfer rollers 212, and transports the recording medium 205 to the fixing unit 203.

The operation of the image forming apparatus 200 will be described.

The hopping roller 207 separates a top page of the recording medium 205 from the stack of the recording medium 205, and feeds the top page into the transport path. The recording medium 205 is then transported to an entrance of the belt unit 219 while being held by the transport roller 210, registration roller 211, and pinch rollers 208 and 209. Then, the recording medium 205 is transported by the belt unit 219 to the process unit 201 where a yellow toner image is transferred from the photoconductive drum 11 onto the recording medium 205.

Likewise, the recording medium 205 passes through the process units 202-204 in sequence so that toner images of the respective colors are transferred onto the recording medium 205 one over the other in registration. The toner images of the respective colors carried on the recording medium 205 are fixed into a full color permanent image. Then, the recording medium 205 is discharged by the discharge rollers 214 and 215 and the pinch rollers 216 and 217 onto the stacker 218.

Referring to FIG. 1, an X-axis is parallel to a direction in which the recording medium 205 is transported through the process units 201-204, a Y-axis is perpendicular to the X-axis, and a Z-axis is perpendicular to the X-axis and Y-axis.

The configuration and operation of the image forming apparatus for collecting waste toner will be described.

Disposed below the cleaning blade 15 of the process unit 201 is a toner collecting section 101 through which the waste toner is directed to a toner transporting mechanism 105. The collecting section 101 for each of the process units 201-204 may be substantially identical; for simplicity only the operation of the collecting section 101 for the process unit 201 for forming yellow images will be described, it being understood that the other collecting sections may work in a similar fashion.

FIG. 3 is a fragmentary enlarged cross-sectional view of the vicinity of the collecting section 101. Referring to FIG. 3, the cleaning blade 15 extends across substantially the entire length of the photoconductive drum 11 that extends in the Y-axis. The cleaning blade 15 engages the surface of the photoconductive drum 11 to scrape off the residual toner in such a way that the residual toner falls by gravity into the collecting space 101a. A screw conveyer 102 has a rotational shaft that extends in the Y-axis in the collecting space 101a, and extends substantially across the length of the cleaning blade 15. The screw conveyer 102 is driven in rotation by a drive source, not shown. A toner exit 101b is formed below the end portion of the collecting section 101 in the Y-axis.

The waste toner 19 scraped off by the cleaning blade 15 falls by gravity into the collecting space 101a and is transported in the collecting space 101a by the screw conveyer 102 in a direction parallel to the Y-axis (toward the reader). Then, the waste toner 19 reaches the toner exit 101b through which the waste toner falls into a toner guide 105a.

Referring to FIG. 1, the toner transporting mechanism 105 is disposed at one end portion of the Y-axis (on the reader's side of FIG. 3). The toner transporting mechanism 105 includes toner guides 105a-105d and a toner transporting path 105e. The toner guides 105a-105d communicate with corresponding toner exits 101b (FIG. 3), and receive the waste toner 19 that falls by gravity from the toner collecting section 101. The toner guides 105a-105d extends in the Y-axis. The toner transporting path 105e communicates with the toner guides 105a-105d, and extends in the X-axis. A spiral 106 extends in the transporting path 105e, and is rotated about its longitudinal axis by a drive source, not shown, so as to transport the waste toner 19 in the X-axis (rightward in FIG. 1).

The toner transport mechanism 105 includes a toner discharging port 105f provided at its one longitudinal end portion, and a toner guide 105g. The toner discharging port 105f communicates with the toner guide 105g such that the waste toner 19 falls by gravity into the toner guide 105g through the discharging port 105f. The toner guide 105g guides the waste toner 19 into a chamber 52 of a waste toner collecting apparatus 51. The waste toner collecting apparatus 51 is detachably attached to the image forming apparatus 200.

The toner transporting mechanism 105 includes a belt-cleaning member 110 that scrapes the waste toner from the transfer belt 220, and a spiral 112 that transports the waste toner scraped off by the belt-cleaning member 110 into the toner guide 105g.

As described above, the waste toner 19 gathered into the toner guide 105g is then accommodated into the chamber 52 of the waste toner collecting apparatus 51.

The configuration and operation of the waste toner collecting apparatus 51 will be described. FIG. 2 is an exploded perspective view illustrating the configuration of the waste toner collecting apparatus 51.

Referring to FIGS. 1 and 2, the waste toner collecting apparatus 51 includes the chamber 52, an inlet 53, a spiral 54, a gear train 55 that drives the spiral 54 in rotation, and a coupling 56 that transmits the drive force from a drive motor to the gear train 55. The chamber 52 includes a half shell 52a and a half shell 52b as shown in FIG. 2. The half shelves 52a and 52b are fitted together through fitting portions, not shown, formed at lower portions of the half shelves 52a and 52b. The half shelves 52a and 52b also engage each other through tongues 81 formed on the half shell 52a and recesses 82 formed in the half shell 52b. The half shelves 52a and 52b are fitted together to define a toner holding space 63 therein. A sealing member 83 is sandwiched between the half shelves 52a and 52b to improve sealing effect of the toner holding space 63 against the environment.

The chamber 52 includes bearings 84 formed on the half shelves 52a and 52b such that when the half shelves 52a and 52b are assembled together, the bearings 84 oppose each other to cooperate with each other to rotatably support the spiral 54 at two locations in the toner holding space 63.

The inlet 53 is fitted to an opening 85 in the half shell 52a with its cylindrical sleeve 53a receiving a guide portion 54a of the spiral 54. At this moment, a projection 53 of the inlet 53 projects outwardly of the chamber 52, so that when the waste toner collecting apparatus 51 has been fitted to the image forming apparatus 200, the projection 53b abuts the toner guide 105g of the toner transporting mechanism 105. A toner receiving port 53c is an opening formed in the projection 53b, and communicates with the cylinder 53a.

When the waste toner collecting apparatus 51 has been attached into the image forming apparatus 200, the spiral 54 extends in the X-axis so that one end portion of the spiral 54 projects outwardly of the chamber 52. This end portion has a gear 57 that is in mesh with the gear train 55. The toner transporting member or spiral 54 also includes the guide portion 54a, a spiral portion 54b, a first toner transporting section or spiral portion 54c, and a free end portion 54d.

A description will now be given of the coupling between the toner transporting mechanism 105 and the waste toner collecting apparatus 51 when the waste toner collecting apparatus 51 is attached to or detached from the image forming apparatus 200.

FIGS. 4A and 4B are fragmentary enlarged views of a coupling relation between the toner guide 105g of the toner transporting mechanism 105 and the inlet 53 of the waste toner collecting apparatus 51. FIG. 4A is a fragmentary cross-sectional view illustrating the coupling relation when the waste toner collecting apparatus 51 has been attached into the image forming apparatus 200. FIG. 4B is a fragmentary cross-sectional view illustrating the coupling relation when the waste toner collecting apparatus 51 has been detached from the image forming apparatus 200.

The toner guide 105g includes a fixed cap 120 that engages a movable cap 121 in such a way that the movable cap 121 fits over the fixed cap and is slidable relative to the fixed cap 120.

FIG. 5 is a perspective view illustrating the fixed cap 120 and the movable cap 121. The movable cap 121 is supported so that the movable cap 121 loosely fits over the fixed cap 120 and is slidable in the Y-axis. The movable cap 121 is biased by a compressed coil spring 122 such that the movable cap 121 is movable relative to the fixed cap 120.

Referring back to FIG. 4A, the fixed cap 120 and the movable cap 121 are formed with an opening 124 and an opening 123, respectively, such that when the waste toner collecting apparatus 51 has been attached to the image forming apparatus 200, the openings 123 and 124 are in line with each other. The movable cap 121 is formed with a projection 121a. As shown in FIG. 4B, the toner guide 105g is formed with a stopper 105h. When the waste toner collecting apparatus 51 has been detached from the image forming apparatus 200, the stopper 105h engages the projection 121a at a position where the fixed cap 120 closes the opening 123 and the movable cap 121 closes the opening 124.

With the aforementioned coupling relation between the waste toner collecting apparatus 51 and toner transporting mechanism 105, when the waste toner collecting apparatus has been attached to the image forming apparatus 200, the waste toner 19 falls through the toner discharging port 105f of the toner transporting mechanism 105. Then, the waste toner 19 passes through the openings 123 and 124 as shown by arrows B1-B3 (FIG. 4A), and then through the toner receiving port 53c of the inlet 53 into the cylindrical sleeve 53a (FIG. 1) of the inlet 53.

When the waste toner collecting apparatus 51 has been detached from the image forming apparatus 200, the movable cap 121 slides in the Y-axis to a position where the movable cap 121 is stopped by the stopper 105h. At this moment, the movable cap 121 is at a position where the fixed cap 120 closes the opening 123 and the movable cap 121 closes the opening 124. Therefore, the toner guide 105g of the toner transporting mechanism 105 is sealed, so that the waste toner 19 stays within the toner guide 105g and will not leak into the inner space of the image forming apparatus 200.

Although the coil spring 122 in the above example has been described as merely urging the movable cap 121, the coil spring may be configured such that the coil spring rotates about its longitudinal axis (Y-axis) to transport the waste toner 19 toward the openings 123 and 124.

The spiral 54 in FIG. 2 includes the guide portion 54a, the spiral portion 54b, the spiral portion 54c, and a shaft 54e of the free end portion 54d, which are molded from a plastic material.

FIG. 6 is a fragmentary enlarged view of the spiral 54. Referring to FIG. 6, the free end portion 54d includes a force transmitting section that is comprised of a flange 54f formed in one piece with the shaft 54e and a washer 59. The free end portion 54d also includes a second toner transporting section or a coil spring 58, a fixed stopper 61, and an engagement piece 60 slidably mounted on the shaft 54e. The shaft 54e extends through the coil spring 58. The coil spring 58 has one end secured to the engagement piece 60 and another end abuts the fixed stopper 61 such that the coil spring 58 is slidable on the surface of the stopper 61. The stopper 61 is secured to the shaft 54e at a position somewhat away from an end 54g by means of a knock pin 62. In other words, the coil spring 58 and engagement piece 60 are integral with each other, and are positioned between the flange 54f and stopper 61 with the coil spring 58 compressed.

The operation of the waste toner collecting apparatus 51 of the aforementioned configuration will be described.

FIGS. 7A-7C are front views illustrating the waste toner collecting apparatus 51 at different levels of the waste toner 19.

Referring to FIG. 7A, the waste toner 19 is discharged from the toner transporting mechanism 105 (FIG. 1), and falls into the cylindrical sleeve 53a. At this stage, the spiral 54 is driven by a drive source, not shown, to rotate in a direction shown by arrow C (FIGS. 6 and 7A) to transport the waste toner 19 into the toner holding space 63.

Thus, the waste toner 19 is transported in the cylindrical sleeve 53a to be discharged to the outside. Referring to FIG. 7A, when the toner holding space 63 is nearly empty, the waste toner 19 discharged from the cylindrical sleeve 53a falls toward the bottom of the toner holding space 63 and will pile up at the bottom gradually.

When the top of the pile of the waste toner 19 reaches the spiral 54, the spiral 54 moves the top portion of the pile of the waste toner 19 little by little toward the back end portion of the toner holding space 63. Then, the waste toner 19 will eventually reach the free end portion 54d of the spiral 54. The coil spring 58 on the free end portion 54d rotates to move the waste toner 19 further toward the back end of the toner holding space 63.

The waste toner 19 will eventually reaches the back end of the toner holding space 63 as shown in FIG. 7C, and therefore the density of the waste toner 19 will increase gradually in the vicinity of the back end of the toner holding space 63. As the density of the waste toner 19 increases, the torque load on the coil spring 58 (FIG. 6) will increase. When the torque load exerted on the coil spring 58 exceeds a certain value, the second toner transporting section of the free end portion 54d of the spiral 54 stops transporting the waste toner 19.

In other words, when the density of the waste toner at the back end portion of the toner holding space 63 exceeds a certain value, the waste toner 19 exerts a torque load on the coil spring 58 larger than the friction force between the flange 54f and the washer 59 or the friction force between the engagement piece 60 and the washer 59. As a result, the spring 58 stops rotating, so that the waste toner 19 is no longer transported to the back end portion of the toner holding space 63.

Although the first embodiment has been described with respect to the coil spring 58 mounted only on the free end portion 54d of the spiral 54, a similar coil spring may also be mounted on the spiral portion 54b and/or the spiral portion 54c.

While the spiral portions 54b and 54c have been described as being made of a plastic material with screws formed around the shaft 54e, the spiral portions 54b and 54c may also be implemented by using a coil spring integrally mounted on the shaft 54e so that the coil spring rotates together with the shaft 54e.

According to the aforementioned waste toner collecting apparatus 51, when the density of the waste toner 19 at the back end portion of the toner holding space 63 exceeds a certain value, the spiral portion 54d stops transporting the waste toner 19. This prevents the drive sources such as a drive motor from being overloaded, thereby preventing the failure of the toner holding space 63 to accommodate the waste toner 19 which would otherwise occur if the spiral 54 is stopped due to overload.

The friction force between the flange 54f and the washer 59 and/or the friction between the engagement piece 60 and the washer 59 causes the coil spring 58 to rotate, and the coil spring 58 rotates to transport the waste toner 19. Thus, this simple configuration minimizes the number of necessary components.

Second Embodiment

FIG. 8 is a fragmentary side view of a pertinent portion of a spiral 151 for use in a waste toner collecting apparatus 150 according to a second embodiment.

The waste toner collecting apparatus 150 that employs the spiral 151 differs from the waste toner collecting apparatus 51 in the configuration of a free end portion 151d of the spiral 151 and a method for driving the spiral 151 to rotate. Like components have been given like reference numerals and the description thereof is omitted. The second embodiment will be described primarily with reference to the difference between the first embodiment and second embodiment.

Referring to FIG. 8, the free end portion 151d includes a force transmitting section that is comprised of a ratchet pawl 151f formed in one piece with a shaft 151e and a ratchet wheel 152. The free end portion 151d also includes a second toner transporting section or coil spring 58 and fixed stopper 61. The ratchet wheel 152 is slidably mounted on the shaft 151e. The coil spring 58 has one end secured to the ratchet wheel 152 and another end abutting the stopper 61 such that the coil spring 58 is slidable on the surface of stopper 61. The stopper 61 is secured to the shaft 151e at a position somewhat away from an end 151h by means of a knock pin 62. In other words, the coil spring 58 and ratchet wheel 152 are integral with each other, and are positioned between the ratchet pawl 151f and stopper 61 with the coil spring 58 is in a compressed state. The ratchet pawl 151f has a projection 151g while the ratchet wheel 152 has a recess 152a, the projection 151g and recess 152a forming a ratcheting mechanism.

A waste toner collecting apparatus 150 according to the second embodiment has the aforementioned configuration. The operation of the waste toner collecting apparatus 150 will be described. FIGS. 9A-9C are front views illustrating the waste toner collecting apparatus 150.

The waste toner collecting apparatus 150 operates in the same way as the waste toner collecting apparatus 51 according to the first embodiment from the beginning of introducing the waste toner until the density of the waste toner in the toner holding space 63 increases gradually. An increase in the density of the waste toner causes the torque load exerted on the coil spring 58 to increase. At this moment, a drive force transmitted from a drive motor, not shown, is driving the spiral 151 to rotate about the X-axis in a direction shown by arrow D (FIG. 8).

When the torque load on the coil spring 58 exceeds a certain value, the ratcheting mechanism begins to operate so that the ratchet wheel 152 climbs over an inclined surface formed on the projection 151g of the ratchet pawl 151f to allow the coil spring 58 to rotate relative to the shaft 151e with no load exerted on the coil spring 58. After the engagement piece 52 has climbed over the inclined surface of the projection 151g of the ratchet pawl 151f, the recess 152a will move again into a fitting engagement with the projection 151g. Thus, as the spiral 151 rotates, the engagement piece 52 and ratchet pawl 151f cycle to move into and out of fitting engagement with each other. This causes the coil spring 58 to be more compressed and less compressed alternately, but the coil spring 58 does not rotate so that the waste toner is not transported by the spiral 151 toward the back end of the toner holding space 63.

When the torque load exerted on the coil spring 58 has not exceeded a certain value yet, the coil spring 58 continues to rotate together with the shaft 151e.

If the spiral 151 is rotated about the X-axis in a direction opposite to arrow D, the ratchet mechanism prevents the ratchet wheel 152 from climbing the ratchet pawl 151f but causes the ratchet wheel 152 to rotate together with the shaft 151e so that the coil spring 58 transports the waste toner away from the stopper 61.

FIG. 9B illustrates the distribution of the waste toner 19 when the spiral 151 in FIG. 9A rotates in the direction opposite to the arrow A for a certain length of time after the density of the waste toner in the toner holding space 63 had reached a certain value.

Because the spiral 151 now rotates in the opposite direction, the spiral 151 will operate to transport the waste toner 19 in the opposite direction, i.e., away from the back end portion of the toner holding space 63. This reduces the torque load exerted on the spiral 151. Thus, if the spiral 151 is rotated in the D direction (FIG. 8) again, the coil spring 58 will again transport the waste toner 19 toward the back end portion of the toner holding space 63. As a result, the waste toner 19 becomes distributed substantially uniformly across the full length of the spiral 151. It is desirable that the spiral 151 is rotated in the opposite direction to the D direction at predetermined rotation intervals.

According to the second embodiment, because the toner transporting operation of the free end portion 151d is stopped when the density of the waste toner at the back end portion of the toner holding space 63 exceeds a certain value, the drive motor for the spiral 151 is prevented from being overloaded. This allows the waste toner to be accommodated in a space at a lower density after the density of the waste toner at the back end portion of the toner holding space 63 has exceeded a certain value.

When the spiral 151 rotates in the D direction, if the density of the waste toner at the back end portion of the toner holding space 63 exceeds a certain value, the coil spring 58 will rotate relative to the shaft 151e without a load exerted on the coil spring 58. When the spiral 151 rotates in the opposite direction to the D direction, the coil spring 58 will rotate together with the shaft 151 to transport the waste toner away from the back end portion of the toner holding space 63.

Third Embodiment

FIG. 10 is a fragmentary side view of a pertinent portion of a spiral 155 for use in a waste toner collecting apparatus according to a third embodiment.

The toner collecting apparatus that employs the spiral 155 differs from the waste toner collecting apparatus 51 in the configuration of a free end portion 156 and a spiral portion 155c and a method for driving the spiral 155 to rotate. Like components have been given like reference numerals and the description thereof is omitted. The third embodiment will be described primarily with reference to a portion different from the first embodiment (FIG. 2).

Referring to FIG. 10, unlike the spiral 54 (FIGS. 6) and the spiral 151 (FIG. 8), the spiral 155 is not in one piece construction. In other words, the free end portion 156 is a member separate from the rest of the spiral 151. The free end portion 156 is a one-piece molded plastic structure including a shaft 156a and a second toner transporting section or screw 156b. One longitudinal end of the screw 156 is somewhat away from an end 156h. A flange 156c is formed on the side of the screw 156 remote from a free end 156h of the shaft 156a. The free end portion 156 is coupled to a spiral portion 155c via a coil spring 157 mounted between the flange 156c and a flange 155m.

FIG. 11A is a fragmentary enlarged view of the force transmitting section that includes flange 156c, coil spring 157, and flange 155m. FIG. 11B is a fragmentary view illustrating the positional relation between the flange 156c and flange 155m with the coil spring 157 omitted.

Referring to FIG. 11B, the free end portion 156 has an engagement shaft 156d and an engagement recess 156e formed in the engagement portion 156d. The free end portion 156 has an engagement shaft 155f and an engagement projection 155g that projects from the engagement shaft 155f. The engagement recess 156e receives the engagement projection 155g loosely therein.

The coil spring 157 has an inner diameter, which is the same as or slightly smaller than the outer diameter of the engagement shafts 155f and 156d. The coil spring 157 is mounted on the engagement shafts 155f and 156d in a press-fitting manner, so that the torque is transmitted from the spiral portion 155c to the free end portion 156d via the coil spring 157 that holds both the engagement shafts 155f and 156d through friction. The engagement recess 156e receives the engagement projection 155g loosely such that the engagement shafts 155f and 156d are in line with each other. The coil spring 157 spirals in a direction opposite to the direction in which the screw 156b spirals.

The operation of a waste toner collecting apparatus of the aforementioned configuration will be described. This waste toner collecting apparatus differs from that of the second embodiment (FIG. 9) in that the spiral 155 is used in place of the spiral 151. A description will be given with reference to FIG. 9, assuming that the spiral 155 is assembled to the waste toner collecting apparatus 150 in FIG. 9.

When the density of the waste toner is low and therefore the load on the spiral 156b is small, the spiral 155 rotates in a direction shown by arrow E (FIG. 10). As the density of the waste toner at the back end portion of the toner holding space 63 increases, the load on the spiral 156b (FIG. 10) increases gradually. Thus, the coil spring 157 receives a large force that acts in such a direction as to unwind the coil spring 157 to loosen the frictional engagement between the coil spring 157 and the engagement shafts 155g and 156d.

When the density of waste toner increases further, the inner diameter of the coil spring 157 becomes larger, so that the friction between the coil spring 157 and the engagement shaft 155f and 156d decreases. When the load on the spiral 156b exceeds a certain value, the force to rotate the free end portion 156 is no longer transmitted to the free end portion 156. As a result, the free end portion 156 stops rotating so that the free end portion 156 stops its toner-transporting operation.

The third embodiment has been described in terms of the coil spring 157 not secured to any of the flange 155m and the flange 156c. Instead, the coil spring 157 may be secured at least its one end to the flange 155m or flange 156c, in which case a flange to which the coil spring 157 is not secured is not required.

When the spiral 155 stops rotating, the force that acts in such a direction as to unwind the coil spring 157 no longer acts on the coil spring 157, so that the friction between the coil spring 157 and the engagement shafts 155f and 156d is developed again. This friction allows transmission of the rotational force from the engagement shaft 155f to the engagement shaft 156d. If the spiral 155 is rotated in a direction opposite to the arrow E (FIG. 10), the coil spring 157 tends to further wind to firmly hold the engagement shafts 155f and 156d, allowing the rotational force to be transmitted from the engagement shaft 155f to the engagement shaft 156d.

As described above, because the toner-transporting operation of the free end portion 156 is stopped when the density of the waste toner at the back end portion of the toner holding space 63 exceeds a certain value, the drive motor for the spiral 151 is prevented from being overloaded. This allows the waste toner to be accommodated in a space at a lower density after the density of the waste toner at the back end portion of the toner holding space 63 has exceeded a certain value.

When the spiral rotates in the E direction, the coil spring 157 will not transmit the rotational force to the free end portion 156 so that no waste toner is transported toward the back end portion of the toner holding space 63. When the spiral rotates in the opposite direction to the E direction, the coil spring 157 will transmit the rotational force to the free end portion 156 so that the waste toner can be transported away from the back end portion of the toner holding space 63 for uniform distribution of waste toner within the toner holding space 63.

The spiral 155 may be a one-piece molded structure of a plastic material and the coil spring 157 may be assembled to the spiral 155. This is a simple structure and leads to cost reduction and improvement of reliability of operation.

Fourth Embodiment

FIG. 12A is a fragmentary side view of a pertinent portion of a spiral 160 for use in a waste toner collecting apparatus according to a fourth embodiment. FIG. 12B illustrates the operation of the spiral 160.

The toner collecting apparatus that employs the spiral 160 differs from the waste toner collecting apparatus 51 (FIG. 2) only in the configuration of a free end portion 160d. Like components have been given like reference numerals and the description thereof is omitted. The fourth embodiment will be described primarily with reference to a portion different from the first embodiment.

Referring to FIG. 12A, a free end portion 160d includes a second toner transporting section or coil spring 161a, stopper 61, and flange 160f formed in one piece construction with a shaft 160e. The stopper 61 is secured to the shaft 160e near a free end 160h by means of a knock pin 62. The stopper 61 is mounted at a position somewhat away from an end 160h. The coil spring 161 is mounted on the shaft 160e between the flange 160f and the stopper 61, and is prevented from moving toward the free end 160h of the shaft 160e. The coil spring 161 has one end secured to the flange 160f and another end that slides on the surface of the stopper 61. The coil spring 161 has a smaller spring constant than the coil spring 58 in the first embodiment.

The operation of the waste toner collecting apparatus that employs the spiral 160 of the aforementioned configuration will be described. This waste toner collecting apparatus differs from that of the first embodiment (FIG. 7) in that the spiral 160 is used in place of the spiral 54. A description will be given with reference to FIG. 7, assuming that the spiral 160 is assembled to the waste toner collecting apparatus 51 in FIG. 7.

When the density of the waste toner 19 is low and therefore the load on the spiral 161 (FIG. 12A) is small, the spiral 161 rotates in a direction shown by arrow F. As the density of the waste toner at the back end portion of the toner holding space 63 increases, the torque load on the spiral 161 (FIG. 12A) increases gradually. Thus, the coil spring 161 receives a large force that tends to push back the coil spring 161 toward the flange 160f. Because the coil spring 161 has a small spring constant, the coil spring 161 is compressed gradually as the density of the waste toner at the back end portion of the toner holding space 63 increases, so that the coil spring 161 finally becomes as short as is shown in FIG. 12B. At this stage, the coil spring 161 no longer has the ability to transport the waste toner 19.

As described above, because the toner-transporting operation of the free end portion 160d is stopped when the density of the waste toner at the back end portion of the toner holding space 63 exceeds a certain value, the drive motor for the spiral 160 is prevented from being overloaded. This allows the waste toner to be accommodated in a space at a lower toner density after the density of the waste toner at the back end portion of the toner holding space 63 has exceeded a certain value.

The spiral 160 may be a one-piece molded structure of a plastic material and the coil spring 161 may be assembled to the spiral 160. This simple structure requires a small number of components, and leads to cost reduction and improvement of reliability of operation.

Fifth Embodiment

FIG. 13 is a fragmentary side view of a pertinent portion of a spiral 165 for use in a waste toner collecting apparatus according to a fifth embodiment.

The waste toner collecting apparatus that employs the spiral 165 differs from the waste toner collecting apparatus 51 (FIG. 2) only in the configuration of a spiral portion 165c and a free end portion 165d. Like components have been given like reference numerals and the description thereof is omitted. The fifth embodiment will be described primarily with reference to the difference between the first embodiment and fifth embodiment.

Referring to FIG. 13, the free end portion 165d has a flange 165f, a shaft 165e, and a second toner transporting section or screw 165g, which are all formed in one piece construction. The spiral portion 165c has a force transmitting section comprised of a small diameter portion 166 formed in its shaft near the flange 165f. The spiral 165 differs from the spiral 54 (FIG. 2) in that the small diameter portion 166 is formed near the flange 165f.

The operation of the waste toner collecting apparatus of the aforementioned configuration will be described. This waste toner collecting apparatus differs from that of the first embodiment (FIG. 7) in that the spiral 165 is used in place of the spiral 54. A description will be given with reference to FIG. 7, assuming that the spiral 165 has been assembled to the waste toner collecting apparatus 51 in FIG. 7.

When the density of the waste toner 19 is low and therefore the load on the screw 165g (FIG. 13) is small, the spiral 165 rotates in a direction shown by arrow G to transport the waste toner 19 toward the back end of the toner holding space 63. As the density of the waste toner 19 at the back end portion of the toner holding space 63 increases, the load on the screw 165g (FIG. 13) increases. When the torque load exceeds a certain value, an increased torsional stress causes the small diameter portion 166 to fracture (see FIG. 13A). As a result, the free end portion 165d and the spiral portion 165c are broken apart, thereby stopping the operation of the free end portion 165d to transport the waste toner 19 into the back end portion of the toner holding space 63 any further.

FIG. 14 is a graph of the amount of waste toner versus the torque load on the spiral 165. As is clear from FIG. 14, the torque load exerted on the free end portion 165d increases as the amount of the waste toner increases. Once the small diameter portion 166 fractures, the torque load exerted on the free end portion 165d drops to zero. This allows the drive source to drive the spiral 165 to transport the waste toner to a space in the toner collecting space 613 where the density of the waste toner is low.

As described above, because the toner-transporting operation of the free end portion 165d is stopped when the density of the waste toner at the back end portion of the toner holding space 63 exceeds a cer