Method for toner discharge from a developing cartridge and method for reusing a developing cartridge

Abstract

This invention provides a toner discharge method that reduces the amount of toner remaining inside the casing. [Solution] The toner discharge method of the developing cartridge 1 involves opening a hole 12 in the housing 10 for discharging toner, and discharging the toner from the hole 12 while rotating the developing roller 20. The developing cartridge 1 comprises a developing roller 20 and a housing 10 that houses the toner. The housing 10 has an opening 11 that exposes the developing roller 20.

Description

[Technical Field]

[0001] The present disclosure relates to a toner discharge method for a developing cartridge and a reuse method for a developing cartridge. [Background Art]

[0002] Patent Document 1 discloses a method for removing toner from a container. Patent Document 1 discloses a method in which a cleaning medium is put into the container and the cleaning media with toner adsorbed thereon is discharged. [Prior Art Document] [Patent Document]

[0003] [Patent Document 1] Japanese Unexamined Patent Publication No. 2005-164813 [Summary of the Invention] [Problem to be Solved by the Invention]

[0004] When reusing a developing cartridge, residual toner remaining in the housing of the developing cartridge is discharged, and then new toner is filled. In this case, in order to prevent mixing of residual toner and new toner, it is required to reduce the amount of toner remaining in the housing of the developing cartridge as much as possible.

[0005] Accordingly, an object of the present disclosure is to provide a toner discharge method that reduces toner remaining in a housing, and a reuse method for a developing cartridge. [Means for Solving the Problem]

[0006] A toner discharge method for a developing cartridge that solves the above problem includes forming a hole for discharging toner from a housing, and discharging toner through the hole while rotating a developing roller. The developing cartridge includes a developing roller, and a housing that has an opening exposing the developing roller and accommodates toner.

[0007] By discharging toner while the developing roller is rotating, less toner remains inside the casing.

[0008] Furthermore, the toner discharge method may involve determining whether or not the amount of toner inside the casing exceeds a predetermined amount. If the printer determines that the amount of toner inside the casing exceeds a predetermined level, the developing roller rotates while the toner is ejected through the holes. If the printer determines that the amount of toner inside the casing is below a predetermined level, the printer will discharge the toner through the hole without rotating the developing roller.

[0009] If the printer determines that the amount of toner inside the casing exceeds a certain level, the developing roller rotates while the toner is discharged, thus reducing the amount of toner remaining inside the casing. If the toner level inside the casing is determined to be below a predetermined amount, the toner is discharged without rotating the developing roller, thus reducing the rotation of the developing roller and suppressing its wear.

[0010] Furthermore, the developing cartridge may have a memory capable of storing information regarding the usage history of the developing cartridge. The toner discharge method of the developing cartridge may determine whether or not the amount of toner in the casing is above a predetermined amount based on the information stored in the memory.

[0011] Furthermore, the toner discharge method for the developing cartridge may be determined based on the weight of the developing cartridge to determine whether or not the amount of toner inside the casing is above a predetermined amount.

[0012] Furthermore, the toner discharge method for the developing cartridge may involve inspecting the surface of the developing roller when it is rotated, and stopping the discharge of toner from the hole if any abnormality is found on the surface of the developing roller.

[0013] By inspecting the surface of the developing roller and detecting any abnormalities, the developing roller is not reused, thus stopping the toner discharge process and preventing unnecessary work.

[0014] Furthermore, when inspecting the surface of the developing roller, the roller may be rotated at least once before the surface of the developing roller is inspected.

[0015] By rotating the developing roller at least once and inspecting its surface, the entire surface of the developing roller can be inspected.

[0016] Furthermore, the toner discharge method for the developing cartridge may involve introducing air into the housing through a hole while simultaneously sucking out the toner from inside the housing through the same hole.

[0017] When toner is ejected from the casing, air is introduced into the casing through the holes, and toner inside the casing is also sucked out through the holes, resulting in less toner remaining inside the casing.

[0018] Furthermore, the developing cartridge may also have a supply roller that supplies toner from within the housing to the developing roller. The toner discharge method of the developing cartridge may involve discharging the toner from the hole while rotating the supply roller.

[0019] Because the toner is discharged while the supply roller rotates, less toner remains inside the casing.

[0020] Furthermore, the developing cartridge may also have an agitator for stirring the toner inside the casing. The toner discharge method of the developing cartridge may involve discharging the toner through the holes while rotating the agitator.

[0021] Because the toner is discharged while the agitator is rotating, less toner remains inside the casing.

[0022] Furthermore, the developing roller may be rotatable around a rotation axis extending in the axial direction. The housing may have a hole in one of its axial walls. The toner discharge method for the developing cartridge may involve discharging the toner through the hole with the hole facing downwards.

[0023] Since the toner is discharged with the hole facing downward, less toner remains inside the housing.

[0024] In a reuse method for a developing cartridge for solving the above problem, new toner may be filled through the hole after executing the above-described toner discharging method for a developing cartridge. [Advantageous Effects of Invention]

[0025] According to the present disclosure, there can be provided a toner discharging method that reduces toner remaining in a housing, and a reuse method for a developing cartridge. [Brief Description of the Drawings]

[0026] [Figure 1] It is a cross-sectional view of the developing cartridge. [Figure 2] It is a perspective view of the developing cartridge. [Figure 3] It is a perspective view showing a part of the developing cartridge in a state where a cap and a memory holder are removed. [Figure 4] It is a diagram showing a developing roller, a supply roller, an agitator, and a gear train. [Figure 5] It is a diagram showing a toner discharging device for a developing cartridge. [Figure 6] It is a flowchart showing a reuse method for a developing cartridge. [Figure 7] It is a flowchart showing a toner discharging method for a developing cartridge. [Figure 8] It is a flowchart showing a toner discharging method for a developing cartridge according to a modified example. [Mode for Carrying Out the Invention]

[0027] Next, embodiments of the present disclosure will be described with appropriate reference to the drawings. In the following description, a direction in which the rotation shaft of the developing roller 20 extends is referred to as an "axial direction". In addition, arrows in the drawings indicate one side in the axial direction.

[0028] As shown in Figure 1, the developing cartridge 1 is used in an electrophotographic image forming apparatus such as a laser printer. The developing cartridge 1 is detachably mounted in the image forming apparatus.

[0029] The developing cartridge 1 comprises a housing 10, a developing roller 20, a supply roller 30, a layer thickness regulating blade 40, an agitator 50, and a cap 60.

[0030] The housing 10 houses the toner inside. The housing 10 supports the developing roller 20, the supply roller 30, the layer thickness regulating blade 40, and the agitator 50. The housing 10 is made of, for example, plastic. The housing 10 has an opening 11 and a hole 12. The opening 11 exposes the developing roller 20. The hole 12 is located on one axial wall of the housing 10. The hole 12 is capable of filling and ejecting toner.

[0031] The developing roller 20 is a roller having a surface for carrying toner. The developing roller 20 is rotatable around a rotation axis 20X that extends in the axial direction.

[0032] The supply roller 30 supplies toner from the housing 10 to the developing roller 20. The supply roller 30 is rotatable about the supply roller axis 30X which extends in the axial direction.

[0033] The layer thickness regulating blade 40 is a component that restricts the toner supplied to the developing roller 20 to a thin layer of a certain thickness. The layer thickness regulating blade 40 is in contact with the developing roller 20.

[0034] The agitator 50 stirs the toner inside the housing 10. The agitator 50 is rotatable around an agitator shaft 50X that extends in the axial direction.

[0035] The cap 60 is a component that closes the hole 12.

[0036] As shown in Figures 2 and 3, the hole 12 is formed on one side of the housing 10 in the axial direction. In this embodiment, the hole 12 is a circular hole. The housing 10 can be supplied with toner through the hole 12.

[0037] The cap 60 is removable from the housing 10. When the cap 60 is removed, toner can be replenished through the hole 12. When the cap 60 is put back on, toner will not leak out of the housing 10 through the hole 12.

[0038] The cap 60 is made of a flexible material such as polyethylene resin. The cap 60 can be attached and detached multiple times without damaging the housing 10.

[0039] The developing cartridge 1 further comprises a memory ME, a memory holder 70, a first guide 80, a second guide 90, and a seal ST. The memory ME, memory holder 70, first guide 80, second guide 90, and seal ST are arranged on one side in the axial direction of the housing 10.

[0040] Memory ME can store information regarding the usage history of developing cartridge 1. Information regarding the usage history of the developing cartridge 1 includes, for example, at least one of the cumulative number of printed pages, the cumulative dot count, and the cumulative number of rotations of the developing roller 20 when the developing cartridge 1 was used. The memory ME is, for example, an IC chip.

[0041] The memory holder 70 is a holder that holds the memory ME. The memory holder 70 holds the memory ME such that the electrical contact surface of the memory ME is movable relative to the housing 10. The first guide 80 and the second guide 90 hold the memory holder 70 in a movable position. The first guide 80 and the second guide 90 allow the memory holder 70 to move in a direction perpendicular to the axial direction.

[0042] The seal ST is attached across the housing 10 and the cap 60. The seal ST is there to confirm that the cap 60 has not been removed. Since the seal ST must be peeled off when removing the cap 60, if the seal ST is not peeled off, it can be confirmed that the cap 60 has not been removed.

[0043] As shown in Figure 4, the developing cartridge 1 further comprises a coupling CP, a developing gear 20G, a supply gear 30G, an agitator gear 50G, an intermediate gear 60G, and a gear cover GC. The coupling CP, developing gear 20G, supply gear 30G, agitator gear 50G, intermediate gear 60G, and gear cover GC are located on the other axial side of the housing 10.

[0044] The coupling CP receives the driving force that drives the developing roller 20, the supply roller 30, and the agitator 50. The coupling CP has a large-diameter gear and a small-diameter gear. The developing gear 20G meshes with the large-diameter gear of the coupling CP. The developing roller 20 rotates as the coupling CP receives the driving force. The supply gear 30G meshes with the small-diameter gear of the coupling CP. The supply roller 30 rotates as the coupling CP receives the driving force. The agitator gear 50G meshes with the large-diameter gear of the coupling CP via an intermediate gear 60G. The developing roller 20 rotates as the coupling CP receives the driving force. The gear cover GC covers the coupling CP, the developing gear 20G, the supply gear 30G, the agitator gear 50G, and the intermediate gear 60G. The gear cover GC is mounted on the housing 10.

[0045] Next, we will explain how to reuse the developing cartridge 1. Reusing the developing cartridge 1 means collecting the used developing cartridge 1 and making it usable again.

[0046] When reusing the developer cartridge 1, a hole 12 is made in the housing 10 to discharge the toner. In this embodiment, as shown in Figure 3, the cap 60 is removed from the housing 10 in order to make the hole 12 for discharging the toner.

[0047] Next, the toner discharge process is performed. The toner discharge process is the process of discharging the remaining toner from the developer cartridge 1. For example, the toner discharge device 100 shown in Figure 5 is used for the toner discharge process. As shown in Figure 5, in the toner discharge process, the developer cartridge 1 to be reused is set in the toner discharge device 100. The toner discharge device 100 is a device for discharging toner from the developer cartridge 1. The toner discharge device 100 includes a drive unit 110, a camera 120, a toner suction device 130, and a memory ME reading device (not shown).

[0048] During the toner discharge process, the operator uses a reader to read the information in the memory ME of the developer cartridge 1. The operator obtains information regarding the usage history of the developer cartridge 1.

[0049] The operator determines whether the amount of toner in the housing 10 is equal to or greater than a predetermined amount. In this embodiment, the operator determines whether the amount of toner in the housing 10 is equal to or greater than a predetermined amount based on the information stored in the memory ME.

[0050] If the operator determines that the amount of toner in the housing 10 is less than a predetermined amount, the operator will discharge the toner from the hole 12 without rotating the developing roller 20.

[0051] When the operator determines that the amount of toner in the housing 10 is greater than a predetermined amount, the operator rotates the developing roller 20, the supply roller 30, and the agitator 50 while discharging toner from the hole 12. To rotate the developing roller 20, the supply roller 30, and the agitator 50, the drive unit 110 is rotated. By rotating the drive unit 110, the coupling CP rotates, and the driving force is transmitted to the developing roller 20, the supply roller 30, and the agitator 50 via the developing gear 20G, the supply gear 30G, the agitator gear 50G, and the intermediate gear 60G.

[0052] When the operator discharges toner from the hole 12 while rotating the developing roller 20, the operator inspects the surface of the developing roller 20 as it rotates. The surface of the developing roller 20 is photographed using the camera 120 of the toner discharge device 100. The camera 120 is capable of capturing an image of the surface of the developing roller 20. The image captured by the camera 120 can be used to determine whether or not there is an abnormality on the surface of the developing roller 20. When inspecting the surface of the developing roller 20, the operator inspects the surface of the developing roller 20 by rotating it at least once. If there is an abnormality on the surface of the developing roller 20, the operator stops the toner discharge process. If there is no abnormality on the surface of the developing roller 20, the operator continues the toner discharge process.

[0053] The operator discharges toner from hole 12 with hole 12 facing downwards. That is, the developer cartridge 1 is set in the toner discharge device 100 with hole 12 facing downwards. Then, the toner is discharged from the housing 10 using the toner suction device 130.

[0054] The toner suction device 130 comprises a collection container 131, a suction machine 132, and a blower 133. The collection container 131 is a container for collecting the suctioned toner. The suction machine 132 sucks up the toner from inside the housing 10 and sends it to the collection container 131. The blower 133 blows air into the housing 10. In other words, when the toner suction device 130 discharges toner from the housing 10, it introduces air into the housing 10 through the hole 12 and simultaneously sucks up the toner from inside the housing 10 through the hole 12.

[0055] After the toner discharge process, the operator performs the toner refilling process. The toner refilling process is the process of filling the housing 10 of the developer cartridge 1 with new toner. After filling with new toner in the toner refilling process, the hole 12 is sealed with the cap 60.

[0056] Next, an example of how to reuse the developing cartridge 1 will be explained with reference to the flowchart in Figure 6.

[0057] When reusing the developer cartridge 1, open a hole 12 in the housing 10 to allow toner to be ejected (S10). To open the toner ejection hole 12, remove the cap 60 from the housing 10.

[0058] After step S10, the toner discharge process is performed (S20). In the toner discharge process, any toner remaining in the housing 10 of the developer cartridge 1 is discharged through the hole 12.

[0059] After step S20, the toner filling process is performed (S30). In the toner filling process, new toner is filled into the housing 10 of the developer cartridge 1 through the hole 12.

[0060] After step S30, close hole 12. After filling with new toner, seal hole 12 with cap 60.

[0061] Next, an example of the toner ejection process will be explained with reference to the flowchart in Figure 7.

[0062] In the toner ejection process (S20), information is read from the memory ME of the developer cartridge 1 (S21).

[0063] After step S21, based on the information regarding the usage history of the developing cartridge 1 read from memory ME, it is determined whether or not the amount of toner in the housing 10 is greater than or equal to a predetermined amount (S22).

[0064] If, in step S22, it is not determined that the amount of toner is equal to or greater than a predetermined amount (S22, No), then, because the amount of toner is less than a predetermined amount, the toner is sucked up without rotating the developing roller 20 (S23), and the toner discharge process is terminated.

[0065] On the other hand, if it is determined in step S22 that the amount of toner is greater than or equal to a predetermined amount (S22, Yes), the developing roller 20 is rotated (S24).

[0066] After step S24, the surface of the developing roller 20 is photographed (S25).

[0067] After step S25, it is determined (S26) whether there is any abnormality on the surface of the developing roller 20 based on the captured image.

[0068] In step S26, if it is determined that there is an abnormality on the surface of the developing roller 20 (S26, Yes), the developing cartridge 1 will not be reused, so the rotation of the developing roller 20 is stopped (S29) and the toner discharge process is terminated.

[0069] On the other hand, if it is not determined in step S26 that there is an abnormality on the surface of the developing roller 20 (S26, No), then toner suction is started (S27).

[0070] After step S27, wait until toner suction is complete (S28, No). Once toner suction is complete (S28, Yes), stop the rotation of the developing roller 20 (S29) and end the toner discharge process (S20).

[0071] Based on the above, the following effects can be obtained in this embodiment.

[0072] In this embodiment, the toner discharge method for the developing cartridge 1 involves discharging toner while rotating the developing roller 20. By rotating the developing roller 20, toner that has entered gaps in the movable parts of the developing roller 20 can also be discharged. Therefore, the amount of toner remaining inside the housing 10 of the developing cartridge 1 can be reduced.

[0073] Furthermore, if it is determined that the amount of toner in the housing 10 exceeds a predetermined amount, the developing roller 20 is rotated while the toner is discharged. This reduces the amount of toner remaining in the housing 10. On the other hand, if the remaining amount of toner in the housing 10 is determined to be less than a predetermined amount, the toner is discharged without rotating the developing roller 20. As a result, the rotation of the developing roller 20 is reduced, and wear on the developing roller 20 can be suppressed.

[0074] Furthermore, when toner is discharged from the hole 12 while the developing roller 20 is rotating, the surface of the developing roller 20 is inspected. In this case, if there is an abnormality on the surface of the developing roller 20, the developing roller 20 is not reused. In this way, if there is an abnormality on the surface of the developing roller 20, the toner discharge process is stopped, thereby reducing unnecessary work.

[0075] Furthermore, when inspecting the surface of the developing roller 20, the developing roller 20 is rotated at least once. This allows the entire surface of the developing roller 20 to be inspected.

[0076] Furthermore, when toner is discharged from the casing 10, air is introduced into the casing 10 through the hole 12, and the toner inside the casing 10 is also sucked out through the hole 12. As a result, the air pushes out the toner inside the casing 10, reducing the amount of toner remaining inside the casing 10.

[0077] Furthermore, by discharging toner while rotating the supply roller 30, toner that has gotten into gaps in the movable parts of the supply roller 30 can also be discharged. This reduces the amount of toner remaining inside the housing 10.

[0078] Furthermore, by discharging toner while rotating the agitator 50, toner that has gotten into gaps in the movable parts of the agitator 50 can also be discharged. This reduces the amount of toner remaining inside the casing 10.

[0079] Furthermore, with the hole 12 of the developing cartridge 1 facing downwards, toner is discharged from the hole 12. By facing downwards, gravity causes the toner to fall towards the hole 12. This reduces the amount of toner remaining inside the housing 10.

[0080] Next, a modified example S120 of the toner discharge process S20 will be explained with reference to the flowchart in Figure 8. In this configuration as well as in Figure 7, toner can be discharged efficiently. In Figure 8, only the parts that differ from Figure 7 will be explained, and the parts that are the same will not be explained.

[0081] In the toner discharge process S120 shown in Figure 8, toner suction is started after step S24 (S127).

[0082] After step S127, the surface of the developing roller 20 is photographed (S25).

[0083] After step S25, it is determined whether there is any abnormality on the surface of the developing roller 20 (S26).

[0084] In step S26, if it is determined that there is an abnormality on the surface of the developing roller 20 (S26, Yes), the rotation of the developing roller 20 is stopped (S29) and the toner discharge process S120 is terminated.

[0085] In step S26, if it is determined that there is an abnormality on the surface of the developing roller 20 (S26, No), wait until the toner suction is complete (S28, No). Then, once the toner suction is complete (S28, Yes), stop the rotation of the developing roller 20 (S29) and end the toner discharge. If it is determined that there is an abnormality on the surface of the developing roller 20, either perform maintenance on the developing roller 20 or replace the developing roller 20. In addition, if it is determined that there is an abnormality on the surface of the developing roller 20, the developing cartridge 1 may be discarded without being reused.

[0086] Although embodiments have been described above, this disclosure is not limited to the embodiments described above and can be implemented with appropriate modifications as illustrated below.

[0087] In the above-described embodiment, the amount of toner in the housing 10 was determined based on information stored in memory ME. However, the amount of toner in the housing 10 may also be determined based on the weight of the developing cartridge 1. In this configuration, the amount of toner remaining is determined by weighing the developing cartridge 1, so there is no need to read the information in memory ME. Therefore, it is easier to determine whether the amount of toner in the housing 10 is above a predetermined level.

[0088] In the above embodiment, the operator removed the cap 60 from the housing 10 in order to create a hole for toner discharge. However, the operator may also create a new hole for toner discharge. For example, the operator may drill a hole in the housing 10, fill it with toner, and then seal the hole with a cap or filler.

[0089] In the above embodiment, the reuse of the developing cartridge 1 was performed by an operator, but each process may be performed by an automated machine such as a robot or other machine. If each process is performed by an automated machine, the judgment process will also be performed by the automated machine.

[0090] In the above embodiment, the memory ME was an IC chip, but it may be a storage medium other than an IC chip.

[0091] The elements described in the above embodiments and modifications may be implemented in any combination. [Explanation of Symbols]

[0092] 1. Developing cartridge 10 cabinets 11 Aperture 12 holes 20 Developing roller

Claims

1. A method for discharging toner from a developing cartridge having a developing roller and a housing having an opening for exposing the developing roller and for housing toner, A hole is made in the aforementioned housing for ejecting toner, A method for discharging toner from a developing cartridge, characterized by discharging toner from the hole while rotating the developing roller.

2. Determine whether the amount of toner in the aforementioned enclosure is greater than or equal to a predetermined amount. If it is determined that the amount of toner in the housing exceeds a predetermined amount, the developing roller is rotated while the toner is discharged from the hole. The toner discharge method for a developing cartridge according to claim 1, characterized in that, when it is determined that the amount of toner in the housing is less than a predetermined amount, the developing roller is not rotated and the toner is discharged from the hole.

3. The developing cartridge further has memory capable of storing information regarding the usage history of the developing cartridge, The toner discharge method for a developing cartridge according to claim 2, characterized in that it determines whether or not the amount of toner in the housing is greater than or equal to a predetermined amount based on the information stored in the memory.

4. The method for discharging toner from a developing cartridge according to claim 2, characterized in that it is determined whether or not the amount of toner in the housing is greater than or equal to a predetermined amount based on the weight of the developing cartridge.

5. The toner discharge method for a developing cartridge according to claim 1, characterized in that when the developing roller is rotated, the surface of the developing roller is inspected, and if there is an abnormality on the surface of the developing roller, the discharge of toner from the hole is stopped.

6. The method for discharging toner from a developing cartridge according to claim 1, characterized in that the developing roller is rotated at least once to inspect the surface of the developing roller.

7. The toner discharge method for a developing cartridge according to claim 1, characterized in that when discharging toner from the housing, air is introduced into the housing through the hole and toner inside the housing is sucked out through the hole.

8. The developing cartridge further includes a supply roller that supplies toner from the housing to the developing roller, The method for discharging toner from a developing cartridge according to claim 1, characterized in that toner is discharged from the hole while the supply roller is rotated.

9. The developing cartridge further includes an agitator for stirring the toner inside the housing, The method for discharging toner from a developing cartridge according to claim 1, characterized in that toner is discharged from the hole while the agitator is rotated.

10. The developing roller is rotatable around a rotation axis that extends in the axial direction. The housing has the hole in one of the axial walls, The toner discharge method for a developing cartridge according to claim 1, characterized in that the toner is discharged from the hole while the hole is facing downwards.

11. A method for reusing a developer cartridge, characterized in that, after performing the toner discharge method for the developer cartridge according to any one of claims 1 to 10, new toner is filled through the hole.

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