Seal member, toner carrier equipped with seal member, and image forming apparatus

Abstract

A drum unit 8 can be applied to this image forming apparatus 500 and comprises: a photosensitive drum 4 that is rotatable and is configured to carry toner; a cleaning container 15 that rotatably supports the photosensitive drum 4; and an end seal 300 that seals a gap between an end of the photosensitive drum 4 in a longitudinal direction of the photosensitive drum 4 and the cleaning container 15. A fiber surface layer 401 that rubs against the end seal 300 and the photosensitive drum 4 is included. The fiber surface layer 401 includes a lubricant-containing fiber yarn 404 to which particles of a solid lubricant are fixed.

Description

SEALING MEMBER, TONER CARRYING DEVICE AND IMAGE FORMING APPARATUS EQUIPPED WITH SEALING MEMBER - Patent application

[0001] The present invention relates to a seal member, a toner carrier device including the seal member, and an image forming apparatus, for example, a seal member used in an electrophotographic image forming apparatus such as a copying machine or a printer that employs an electrophotographic system, and a toner carrier device including the seal member.

[0002] Conventional electrophotographic image forming apparatuses require toner replenishment and maintenance of various process means. To facilitate this, a photosensitive drum, charging means, developing means, cleaning means, and other components are packaged within a frame to form a cartridge. This cartridge is commercially available as a process cartridge that can be detachably attached to the image forming apparatus. The cartridge system allows users to perform device maintenance themselves, improving operability and providing an image forming apparatus with excellent usability. For this reason, this cartridge system is widely used in image forming apparatuses. A process cartridge generally consists of a drum unit having a photosensitive drum and a developing unit that supplies developer to the photosensitive drum.

[0003] The drum unit includes a photosensitive drum, a charging roller for charging the photosensitive drum, a cleaning member for scraping and collecting toner (waste toner) remaining on the photosensitive drum from the photosensitive drum, and a cleaning container for supporting the photosensitive drum, the charging roller, and the cleaning member. The drum unit is configured to be sealed with multiple sealing members to prevent the toner stored in the cleaning container from leaking out of the drum unit. For example, cleaning-side end seals are used as sealing members at both longitudinal ends of the photosensitive drum in the gaps between the cleaning container, the photosensitive drum, and the cleaning member (see JP 2014-081620 A).

[0004] SUMMARY OF THE INVENTION An object of the present invention is to provide a development device having a new type of end seal.

[0005] In order to solve the above-mentioned problems, the present invention has the following configuration.

[0006] (1) A toner carrier device used in an image forming apparatus, comprising: a rotating member configured to be rotatable and to carry toner; a frame body that rotatably supports the rotating member; and a sealing member that seals a gap between an end of the rotating member in the longitudinal direction of the rotating member and the frame body, wherein the sealing member has a surface layer that contacts the rotating member, and the surface layer includes fiber threads to which particles of solid lubricant are fixed.

[0007] (2) An image forming apparatus including the toner carrier device described in (1) above.

[0008] (3) A sealing member used in an image forming device to seal a gap between a rotating body that carries toner and a frame that rotatably supports the rotating body, the sealing member having a surface layer that includes fiber threads to which particles of solid lubricant are fixed.

[0009] According to the present invention, a development device having an end seal of a new type can be provided.

[0010] FIG. 1 is a schematic cross-sectional view of an image forming apparatus according to a first embodiment.

[0011] FIG. 2 is a cross-sectional view of the process cartridge of the first embodiment.

[0012] FIG. 3 is an assembled perspective view of the process cartridge of the first embodiment.

[0013] FIG. 4 is an exploded view of a part of the developing unit of the first embodiment.

[0014] FIG. 5 is an assembled perspective view of a part of the developing unit of the first embodiment.

[0015] FIG. 6 is an enlarged assembly view of a part of the developing unit of the first embodiment.

[0016] FIG. 7 is a perspective view of the end seal of the first embodiment.

[0017] FIG. 8 is an exploded view of a part of the drum unit of the first embodiment.

[0018] FIG. 9 is an assembled perspective view of a part of the drum unit of the first embodiment.

[0019] FIG. 10 is an enlarged assembly view of a part of the drum unit of the first embodiment.

[0020] FIG. 11 is an enlarged view of the surface layer of the end seal of the first embodiment.

[0021] FIG. 12 is an enlarged schematic view of the fiber yarn produced by the production method of Example 1.

[0022] FIG. 13 is a diagram showing a state in which a lubricant is applied to an end seal in a modified example of the first embodiment.

[0023] The following examples will exemplarily illustrate embodiments of the present invention. However, the configurations disclosed in the following examples, such as the functions, materials, shapes, and relative positions of components, are merely examples of embodiments related to the claims, and are not intended to limit the scope of the claims to the configurations disclosed in these examples. Furthermore, the problems solved by the configurations disclosed in the following examples or the actions and effects obtained from the configurations are not intended to limit the scope of the claims.

[0024] An electrophotographic image forming apparatus (image forming apparatus) is an apparatus that forms an image on a sheet-like recording medium such as paper using an electrophotographic image forming method. Examples of image forming apparatuses include copiers, facsimile machines, printers (laser beam printers, LED printers, etc.), and combination machines (multifunction printers) of these. A cartridge is a unit that can be attached to and detached from the image forming apparatus and includes a photosensitive member and process means that act on the photosensitive member (e.g., a charging member, a developing member, a cleaning member, etc.).

[0025] Example 1 will be described below with reference to Figures 1 to 13. In the following embodiment, an image forming apparatus to which four cartridges (hereinafter referred to as process cartridges) can be detachably attached is exemplified. Note that the number of process cartridges attached to the image forming apparatus is not limited to this, and may be set appropriately as needed. In the embodiment described below, a laser beam printer is exemplified as one aspect of the image forming apparatus. [General Configuration of Image Forming Apparatus]

[0026] Fig. 1 is a schematic cross-sectional view of an image forming apparatus 500 according to the first embodiment. Fig. 2 is a cross-sectional view of a process cartridge P according to the first embodiment. Fig. 3 is an assembled perspective view of the process cartridge P according to the first embodiment, seen from the drive side, which is one end side in the axial direction (also the longitudinal direction) of a photosensitive drum (rotating member) 4.

[0027] The image forming apparatus 500 is a four-color full-color laser printer using an electrophotographic process, and forms a color image on a recording medium S. The image forming apparatus 500 is of a process cartridge type, and a process cartridge P is detachably mounted in a main body 502 of the image forming apparatus 500. When the process cartridge P is mounted in the main body 502, a color image is formed on the recording medium S.

[0028] Here, with respect to the image forming apparatus 500, the side where the front door 111 is provided is referred to as the front (front face), and the side opposite the front is referred to as the back (rear face). These directions are referred to as the X2 and X1 directions (see FIG. 1). Furthermore, when viewing the image forming apparatus 500 from the front, the right side is referred to as the drive side, and the left side is referred to as the non-drive side. These directions are referred to as the Y1 and Y2 directions (see FIG. 3). The longitudinal direction is the Y1 and Y2 directions. Furthermore, when viewing the image forming apparatus 500 from the front, the upper side is referred to as the top face, and the lower side is referred to as the bottom face. These directions are referred to as the Z1 and Z2 directions (see FIG. 1). FIG. 1 is a cross-sectional view of the image forming apparatus 500 as viewed from the non-drive side.

[0029] Four process cartridges P (PY, PM, PC, PK) - a first process cartridge PY, a second process cartridge PM, a third process cartridge PC, and a fourth process cartridge PK - are arranged in a substantially horizontal direction in the main body 502. Each of the first to fourth process cartridges P (PY, PM, PC, PK) has a similar electrophotographic process mechanism, but uses a different color developer (toner). A rotational driving force is transmitted to the first to fourth process cartridges P (PY, PM, PC, PK) from a drive output unit (not shown) of the main body 502. In addition, various voltages (charging voltage, developing voltage, etc.) are supplied from the main body 502 to each of the first to fourth process cartridges P (PY, PM, PC, PK) (not shown).

[0030] As shown in FIG. 2, the frame of each of the first to fourth process cartridges P (PY, PM, PC, PK) of Example 1 rotatably supports a photosensitive drum 4. Each process cartridge P has a drum unit 8 equipped with a charging roller 5 as charging means and a cleaning blade 7 as cleaning means, which serve as process means acting on the photosensitive drum 4. Furthermore, each of the first to fourth process cartridges P (PY, PM, PC, PK) shown in FIG. 1 has a development unit 9 equipped with a development roller (rotating member) 6 as developing means for developing an electrostatic latent image (toner image) on the photosensitive drum 4. The drum unit 8 and the development unit 9 are coupled to each other. A more specific configuration of the process cartridge P will be described later.

[0031] The first process cartridge PY contains yellow (Y) toner in a developer container 25 serving as a toner storage section, and forms a yellow toner image on the surface of the photosensitive drum 4. The second process cartridge PM contains magenta (M) toner in the developer container 25, and forms a magenta toner image on the surface of the photosensitive drum 4. The third process cartridge PC contains cyan (C) toner in the developer container 25, and forms a cyan toner image on the surface of the photosensitive drum 4. The fourth process cartridge PK contains black (K) toner in the developer container 25, and forms a black toner image on the surface of the photosensitive drum 4.

[0032] A laser scanner unit 114 serving as an exposure means is provided above the first to fourth process cartridges P (PY, PM, PC, PK). The laser scanner unit 114 outputs a laser beam U corresponding to image information. The laser beam U passes through an exposure window 10 of the process cartridge P and scans and exposes the surface of the photosensitive drum 4.

[0033] An intermediate transfer belt unit 112 serving as a transfer member is provided below the first to fourth process cartridges P (PY, PM, PC, PK). The intermediate transfer belt unit 112 includes a drive roller 112e, a turn roller 112c, and a tension roller 112b, and a transfer belt 112a serving as a flexible transfer-receiving member is wound around the intermediate transfer belt unit 112. The lower surfaces of the photosensitive drums 4 (4Y, 4M, 4C, 4K) of the first to fourth process cartridges P (PY, PM, PC, PK) contact the upper surface of the transfer belt 112a. This contact area is the primary transfer area. A primary transfer roller 112d is provided inside the transfer belt 112a, facing the photosensitive drum 4. A secondary transfer roller 106a is in contact with the turn roller 112c via the transfer belt 112a. The contact area between the transfer belt 112a and the secondary transfer roller 106a is the secondary transfer area.

[0034] A feeding unit 104 is provided below the intermediate transfer belt unit 112. The feeding unit 104 has a paper feed tray 104a that holds a stack of recording media S, and a paper feed roller 104b. A fixing device 107 and a discharge device 108 are provided in the upper left of the main body 502 in FIG. 1. The top surface of the main body 502 serves as a discharge tray 113. The unfixed toner image on the recording medium S is fixed by the fixing device 107 as a fixing means, and the recording medium S is discharged to the discharge tray 113. [Image Forming Operation]

[0035] The operation for forming a full-color image is as follows: The photosensitive drums 4 of the first to fourth process cartridges P (PY, PM, PC, PK) are rotated at a predetermined speed (in the direction of arrow A in FIG. 2). The transfer belt 112a is also rotated in the forward direction (in the direction of arrow C in FIG. 1) relative to the rotation of the photosensitive drums 4 at a speed corresponding to the speed of the photosensitive drums 4.

[0036] The laser scanner unit 114 is also driven. In synchronization with the driving of the laser scanner unit 114, the charging roller 5 in each process cartridge P uniformly charges the surface of the photosensitive drum 4 to a predetermined polarity and potential. The laser scanner unit 114 scans and exposes the surface of each photosensitive drum 4 with laser light U in accordance with an image signal for each color. As a result, an electrostatic latent image in accordance with the image signal for the corresponding color is formed on the surface of each photosensitive drum 4. The formed electrostatic latent image is developed by the developing rollers 6 (6Y, 6M, 6C, 6K) which are rotationally driven at a predetermined speed (in the direction of arrow D in Figure 2).

[0037] Through the above-described electrophotographic image forming process, a yellow toner image corresponding to the yellow component of the full-color image is formed on the photosensitive drum 4 (4Y) of the first process cartridge PY. This toner image is then primarily transferred onto the transfer belt 112a. Similarly, a magenta toner image corresponding to the magenta component of the full-color image is formed on the photosensitive drum 4 (4M) of the second process cartridge PM. This toner image is then primarily transferred onto the transfer belt 112a, superimposed on the yellow toner image already transferred onto the transfer belt 112a. Similarly, a cyan toner image corresponding to the cyan component of the full-color image is formed on the photosensitive drum 4 (4C) of the third process cartridge PC. This toner image is then primarily transferred onto the transfer belt 112a, superimposed on the yellow and magenta toner images already transferred onto the transfer belt 112a. Similarly, a black toner image corresponding to the black component of the full-color image is formed on the photosensitive drum 4 (4K) of the fourth process cartridge PK. This toner image is then primarily transferred onto the transfer belt 112a, superimposed on the yellow, magenta, and cyan toner images already transferred onto the transfer belt 112a, forming a full-color unfixed toner image of four colors, yellow, magenta, cyan, and black, on the transfer belt 112a.

[0038] Meanwhile, the recording medium S is separated and fed one by one at a predetermined control timing. The recording medium S is introduced into a secondary transfer section, which is the contact point between the secondary transfer roller 106a and the transfer belt 112a, at a predetermined control timing. As a result, as the recording medium S is transported to the secondary transfer section, the four-color superimposed toner image on the transfer belt 112a is transferred all at once onto the surface of the recording medium S. Thereafter, the toner image is fixed onto the surface of the recording medium S by a fixing device 107, and the recording medium S is discharged by a discharge device 108. Note that the image forming apparatus to which the present invention is applied is not limited to the configuration shown in FIG. 1, and may be configured to include, for example, a carrier belt that supports the recording medium S, or may be a monochrome image forming apparatus. In this case, the recording medium S corresponds to the transferred member. [Overall Configuration of Process Cartridge]

[0039] In the first embodiment, the first to fourth process cartridges P (PY, PM, PC, PK) have the same electrophotographic process mechanism, but differ in the color of the toner contained therein and the amount of toner filled therein.

[0040] The process cartridge P shown in Figure 2 is equipped with a photosensitive drum 4 and process means acting on the photosensitive drum 4. The process means includes a charging roller 5 as charging means for charging the photosensitive drum 4, and a developing roller 6 as developing means for developing a latent image formed by adhering toner to the photosensitive drum 4. The process means also includes a cleaning blade 7 as cleaning means for removing residual toner remaining on the surface of the photosensitive drum 4. The process cartridge P is divided into a drum unit 8 and a developing unit 9. Note that a unit or device equipped with a sealing member, which will be described later, may be referred to as a toner carrying unit or toner carrying device. [Configuration of the Drum Unit]

[0041] As shown in FIGS. 2 and 3 , the drum unit 8 is composed of the photosensitive drum 4, the charging roller 5, the cleaning blade 7, the cleaning container 15, the waste toner storage compartment 15a, a drive-side cartridge cover member 520, and a non-drive-side cartridge cover member 521. The photosensitive drum 4 is rotatably supported by the drive-side cartridge cover member 520 and the non-drive-side cartridge cover member 521, which are provided at both ends of the process cartridge P in the longitudinal direction. Also, as shown in FIG. 3 , a coupling member 43 for the photosensitive drum 4 is provided at one end of the photosensitive drum 4 in the longitudinal direction, to which a driving force for rotating the photosensitive drum 4 is input. The coupling member 43 engages with a coupling (not shown) serving as a drive output portion of the main body 502, and the driving force of a drive motor (not shown) of the main body 502 is transmitted to the photosensitive drum 4. The charging roller 5 is rotatably supported in the cleaning container 15 so as to be in contact with the photosensitive drum 4 and to be rotated by the photosensitive drum 4. The cleaning blade 7 is supported by a cleaning container 15 so as to contact the peripheral surface of the photosensitive drum 4 with a predetermined pressure. The toner (also called transfer residual toner) removed from the peripheral surface of the photosensitive drum 4 by the cleaning blade 7 is stored in a waste toner storage section 15a in the cleaning container 15. The drum unit 8 is provided with a waste toner sealing structure to prevent the waste toner in the waste toner storage section 15a from leaking out. The waste toner sealing structure of the drum unit 8 will be described in detail later. [Configuration of the Development Unit]

[0042] As shown in Figures 2 and 3, the development unit 9 is composed of a development roller 6, a development blade 30, a development container 25, and other components. The development container 25 has a toner storage section 29 that stores toner to be supplied to the development roller 6, and a development blade 30 that regulates the thickness of the toner layer on the circumferential surface of the development roller 6. The development blade 30 is formed by attaching an elastic member 30b, a sheet metal approximately 0.1 mm thick, to a support member 30a, a metal material with an L-shaped cross section, by welding or other means. The development blade 30 is attached to the development container 25 at two locations, one end and the other end, in the longitudinal direction with fixing screws 30c. The development roller 6 is composed of a metal core 6c and a rubber portion 6d. The development roller 6 is rotatably supported by a drive-side bearing 526 and a non-drive-side bearing 27, which are attached to both ends of the development container 25 in the longitudinal direction.

[0043] As shown in FIG. 3 , one longitudinal end of the developing unit 9 is provided with a coupling member 74 for the developing roller 6, which receives the driving force for rotating the developing roller 6. The coupling member 74 engages with a coupling (not shown) serving as a drive output unit of the main body 502, and the driving force of a drive motor (not shown) of the main body 502 is input to the developing unit 9. The driving force input to the developing unit 9 is transmitted through a drive train (not shown) provided within the developing unit 9, thereby rotating the developing roller 6 in the direction of arrow D in FIG. 2 . One longitudinal end of the developing unit 9 is provided with a developing unit cover member 533 that supports and covers the coupling member 74 and the drive train (not shown). The developing unit 9 is provided with a toner sealing structure (160, 210, etc., described below) to prevent toner from leaking from the toner storage section 29 to the outside. The toner sealing structure of the developing unit 9 will be described in detail later. [Assembly of the Drum Unit and the Developing Unit]

[0044] Assembly of the drum unit 8 and the developing unit 9 will be described with reference to Figure 3. The drum unit 8 and the developing unit 9 are held by a drive-side cartridge cover member 520 and a non-drive-side cartridge cover member 521, which are provided at both ends of the process cartridge P in the longitudinal direction. The drive-side cartridge cover member 520, which is provided at one end of the process cartridge P in the longitudinal direction, is provided with a support hole 520a for supporting the developing unit 9 so that it can swing (move). The non-drive-side cartridge cover member 521, which is provided at the other end of the process cartridge P in the longitudinal direction, is provided with a cylindrical support portion 521a for supporting the developing unit 9 so that it can swing. Furthermore, the drive-side cartridge cover member 520 and the non-drive-side cartridge cover member 521 are provided with support holes 520b, 521b, respectively, for rotatably supporting the photosensitive drum 4.

[0045] Here, at one end, the outer diameter portion of the cylindrical portion 533b of the developing device cover member 533 is fitted into the support hole 520a of the drive-side cartridge cover member 520. At the other end, the support portion 521a of the non-drive-side cartridge cover member 521 is fitted into the hole of the non-drive-side bearing 27. Furthermore, both ends in the longitudinal direction of the photosensitive drum 4 are fitted into the support hole portion 520b of the drive-side cartridge cover member 520 and the support hole portion 521b of the non-drive-side cartridge cover member 521. Then, the drive-side cartridge cover member 520 and the non-drive-side cartridge cover member 521 are fixed to the cleaning container 15 with screws, adhesive, or the like (not shown).

[0046] Therefore, the drive side cartridge cover member 520 and the non-drive side cartridge cover member 521 are integrated with the cleaning container 15 to form the drum unit 8. Furthermore, the developing unit 9 is supported by the drive side cartridge cover member 520 and the non-drive side cartridge cover member 521 so as to be swingable (movable) relative to the drum unit 8 (photosensitive drum 4), and is assembled as a single unit into the process cartridge P. [Toner seal configuration of the developing unit]

[0047] Next, the toner seal configuration of the developing unit 9 will be described with reference to FIGS. 4 to 7. FIG. 4 is an assembled perspective view, seen from the drive side, of the developing blade 30, the lower seal 160 of the developing blade 30, and the developing-side sheet member 210 being assembled into the developing container 25. FIG. 5 is an assembled perspective view, seen from the drive side, of the developing unit 9 after the developing blade 30, the lower seal 160 of the developing blade 30, and the developing-side sheet member 210 have been assembled into the developing container 25. FIG. 6 is an assembled enlarged front view of a portion of the driving side of the developing unit 9 after the developing blade 30, the lower seal 160 of the developing blade 30, and the developing-side sheet member 210 have been assembled into the developing container 25. FIG. 7 is a perspective view of the developing-side drive end seal 400g.

[0048] 4 to 6, the toner seal configuration for sealing the toner in the developer container 25 includes an end seal 400 as a developer-side sealing member, a lower seal 160 of the developer blade 30, and a developer-side sheet member 210 arranged in the developer container 25. The developer-side end seals 400 include a drive end seal 400g and a non-drive end seal 400ng. The end seals 400 seal the gap between the developer roller 6 and the developer container 25 at the longitudinal ends of the developer roller 6.

[0049] The developer-side end seal 400 is curved and positioned on the developer container 25 so as to closely contact the circumferential surface of the developing roller 6. FIG. 7 is a perspective view of the developer-side drive end seal 400g. The developer-side drive end seal 400g is composed of a fiber surface layer 401, an intermediate adhesive layer 406, an intermediate layer 407, and a container adhesive layer 408. When the developing roller 6 is driven, the fiber surface layer 401 of the developer-side end seal 400 that contacts the developing roller 6 is in a state of sliding friction. In addition, the developer-side end seal 400 has a container adhesive layer 408 on the developer container 25 side, which adheres and fixes it to the developer container 25. The developer-side end seal 400 will be described in detail below.

[0050] 4 to 6, a flexible developer-side sheet member 210 is disposed on the upstream side of the developer-side end seal 400 in the direction of rotation (DK direction) of the developer roller 6 on the side of the surface that rubs against the developer roller 6. On the other hand, the elastic member 30b of the developer blade 30 is disposed on the downstream side of the developer roller 6 in the direction of rotation (DK direction).

[0051] The developing blade 30 is composed of a support member 30a and an elastic member 30b. The elastic member 30b is made of a thin plate of stainless steel or phosphor bronze with a thickness of approximately 0.1 mm. The support member 30a is made of a steel plate with a thickness of 1 to 2 mm. The support member 30a and the elastic member 30b are positioned by a positioning mechanism (not shown) and joined by laser spot welding or the like. The support member 30a is also provided with a first notch 131 for positioning in the developing container 25, which fits into a positioning portion 225 of the developing container 25 to determine the longitudinal position of the process cartridge P. The support member 30a is fixed by screws 118 (118R, 118L) while abutting against the blade mounting surface 121b (121bR, 121bL) of the developing container 25. In addition, the side of the elastic member 30b opposite to the side joined to the support member 30a in the short direction is a free end, and a part of this free end comes into contact with the circumferential surface of the developing roller 6, thereby regulating the amount of toner held by the developing roller 6.

[0052] Here, the developing-side sheet member 210 is configured to be sandwiched between the developing-side end seal 400 and the developing roller 6. This results in a range where the developing-side sheet member 210 and the developing-side end seal 400 come into contact, a range where the developing-side end seal 400 and the developing roller 6 come into contact, and a range where the developing roller 6 and the developing-side sheet member 210 come into contact.

[0053] Furthermore, the elastic member 30b of the developing blade 30 is sandwiched between the developer-side end seal 400 and the developing roller 6, and the elastic member 30b and the developer-side end seal 400, the developer-side end seal 400 and the developing roller 6, and the developing roller 6 and the elastic member 30b are in contact with each other. This fills the gaps at the longitudinal ends of the developing container 25, sealing the toner on the developer-side end seal 400.

[0054] The lower seal 160 of the developing blade 30 has a double-sided tape 160a and an elastic foam member 160b, and is attached to the developing container 25 by the double-sided tape 160a. Thereafter, when the developing blade 30 is assembled to the developing container 25, the gap between the support member 30a and the developing container 25 is filled.

[0055] As shown in FIG. 6 , the hot melt resin HM is injected into the minute gaps formed when the end seal 400, the developing blade 30, and the lower seal 160 of the developing blade 30 are attached to the developing container 25, ensuring their tight adhesion. The non-drive side has a similar configuration, so only the drive side will be described. As shown in FIG. 7 , the hot melt resin HM is injected into the notches 409 and 410 for hot melt adhesion in the developing side end seal 400g. This allows for tight sealing of the minute gaps formed when the developing side end seal 400g, the developing blade 30, and the lower seal 160 are attached to the developing container 25. The hot melt resin HM used in Example 1 is a mixture of thermoplastic rubber, tackifier resin, etc., and is characterized by being liquefied when heated and hardened into an elastic solid when cooled.

[0056] The developer-side sheet member 210 is a flexible resin sheet made of resin such as PPS and approximately 0.1 mm thick. It is attached and fixed to the developer container 25 with double-sided tape attached to the developer frame 25a. The developer-side sheet member 210 is disposed downstream of the developer blade 30 in the direction of rotation of the developer roller 6 and across the entire longitudinal area of ​​the developer container 25. The side of the developer-side sheet member 210 facing the developer roller 6 in the short direction is a free end, and a portion of the free end is configured to abut against the circumferential surface of the developer roller 6 over the entire longitudinal area. Furthermore, the longitudinal end of the developer-side sheet member 210 is configured to at least partially contact and overlap the fiber surface layer 401 of the developer-side end seal 400 described above.

[0057] 6, the device is configured to ensure close contact by injecting hot melt resin HM into the minute gap that forms when the developer-side end seal 400 and the developer-side sheet member 210 are attached to the developer container 25. Also, as shown in FIG. 7, by injecting hot melt resin HM into the notch 411 of the developer-side drive end seal 400g, it is possible to tightly seal the minute gap between the end seal 400 attached to the developer container 25 and the sheet member 210.

[0058] As described above, after the end seals 400, the developing blade 30, the lower seal 160, and the hot melt resin HM are attached to the developing container 25, the developing roller 6 is assembled to form the developing unit 9. This seals the toner from the toner storage section 29 in the developing container 25 so that it does not leak out of the developing unit 9. [Toner Sealing Configuration of the Drum Unit]

[0059] Fig. 8 is a diagram showing the state before the cleaning side sheet member 310, cleaning blade 7, and charging roller 5 are assembled in the cleaning container 15. Fig. 9 is an enlarged assembled view of a part of the drum unit 8 with the photosensitive drum 4 removed from the drum unit 8. Fig. 10 is an enlarged view of the drive side of Fig. 9.

[0060] As shown in Figures 2 and 8 to 10, the configuration for sealing the toner in the waste toner storage section 15a inside the cleaning container 15 is as follows. The cleaning container 15 is provided with the cleaning blade 7, a cleaning-side end seal 300, a bottom seal 260 for the cleaning blade 7, and a cleaning-side sheet member 310. The cleaning-side end seal 300 specifically includes a drive end seal 300g and a non-drive end seal 300ng. The end seal 300, which is a sealing member, seals the gap between the photosensitive drum 4 and the waste toner storage section 15a at the longitudinal end of the photosensitive drum 4. The cleaning-side end seal 300 will be described in detail below.

[0061] Furthermore, a flexible sheet member 310 is disposed on the upstream side in the rotation direction of the photosensitive drum 4 on the side of the sliding surface between the cleaning-side end seal 300 and the photosensitive drum 4. On the other hand, an elastic member 7b of the cleaning blade 7 is disposed on the downstream side in the rotation direction of the photosensitive drum 4.

[0062] Here, the sheet member 310 that contacts the photosensitive drum 4 is sandwiched between the cleaning-side end seal 300 and a part of the photosensitive drum 4. There is a range where the cleaning-side sheet member 310 and the cleaning-side end seal 300 contact each other, a range where the cleaning-side end seal 300 and the photosensitive drum 4 contact each other, and a range where the photosensitive drum 4 and the cleaning-side sheet member 310 contact each other.

[0063] The cleaning blade 7 is composed of a support portion 7a fixed to the cleaning container 15 and an elastic member 7b that comes into contact with the photosensitive drum 4 and rubs against it to clean residual toner that has not been completely transferred. The support portion 7a is an iron plate with a thickness of about 1 mm and is fixed to the cleaning container 15 with screws 318. The elastic member 7b is made of rubber or the like with a thickness of about 1 mm and comes into contact with the photosensitive drum 4.

[0064] 10 , the end seal 300 is L-shaped. At the longitudinal end of the elastic member 7b of the cleaning blade 7, the parallel end surface 300a and the perpendicular end surface 300b of the L-shaped portion of the end seal 300 are disposed so as to abut against the L-shaped end portion (corner) of the elastic member 7b of the cleaning blade 7. This fills the gap at the longitudinal end of the cleaning container 15, sealing off the toner at the longitudinal end of the elastic member 7b of the cleaning blade 7.

[0065] The lower seal 260 of the cleaning blade 7 is made of an elastic foam material such as urethane foam, and is attached to the cleaning container 15 with double-sided tape 260a of the lower seal 260. Thereafter, when the cleaning blade 7 is assembled to the cleaning container 15, the seal 260 is configured to fill the longitudinal gap between the cleaning blade 7 and the cleaning container 15. The material of the lower seal 260 need only be capable of filling the gap, and therefore the seal 260 may be configured to fill the gap with a hot melt material, an elastomer material, a silicone bond coating, or the like.

[0066] The end seal 300 includes a layer made of an elastic foam material such as urethane foam, and is attached to the cleaning container 15 with double-sided tape. It is configured to fill the gap at the end in the longitudinal direction between the cleaning blade 130 and the cleaning container 121 when the cleaning blade 130 is then assembled to the cleaning container 121. The end seal 300 only needs to be able to fill the gap, and may be configured to fill the gap in the same way as the end seal 400, using a hot melt material, an elastomer material, a silicone bond coating, or the like.

[0067] The cleaning-side sheet member 310 is a flexible resin sheet made of resin such as PPS and approximately 0.1 mm thick, and is attached and fixed to the cleaning container 15 with double-sided tape attached to the cleaning container 121. The cleaning-side sheet member 310 is disposed upstream of the cleaning blade 7 in the rotation direction of the photosensitive drum 4 and across the entire longitudinal length of the cleaning container 15. The side of the cleaning-side sheet member 310 in the short direction facing the photosensitive drum 4 is a free end, and a portion of the free end is configured to abut against the circumferential surface of the photosensitive drum 4 over the entire longitudinal length. Furthermore, the longitudinal end of the cleaning-side sheet member 310 is configured to at least partially contact and overlap the fiber surface layer 401 of the end seal 300.

[0068] As described above, after the end seal 300, cleaning blade 7, and bottom seal 260 are attached to the cleaning container 15, the charging roller 5 and photosensitive drum 4 are assembled, and then the side cover is attached to complete the drum unit 8. This seals the waste toner storage section 15a in the cleaning container 15 so that waste toner does not leak out of the drum unit 8. [Detailed Configuration of the Toner Seal (End Seal)]

[0069] 7 is a perspective view of the drive end seal 400g on the development side of the development unit 9. The non-drive end seal 400ng on the development side of the development unit 9 has a similar configuration, so the drive end seal 400g will also be described. The end seals 300 (drive end seal 300g, non-drive end seal 300ng) on ​​the cleaning side of the drum unit 8 have a different shape but a similar configuration, so only the drive end seal 400g will be described. The drive end seal 400g is composed of a fiber surface layer 401, an intermediate adhesive layer 406, an intermediate layer 407, and a container adhesive layer 408.

[0070] 11 is a cross-sectional view of DT1 in FIG. 7 and is an enlarged view of the fiber surface layer 401 on one side of the end seal 400. As shown in FIG. 11 , the fiber surface layer 401 as the first layer is composed of a base fabric portion (substrate) 402 formed by weaving warp yarns 402a and weft yarns 402b approximately perpendicular to each other, and a fiber portion 403 as a fiber portion (surface layer) woven into the base fabric portion 402 using a pile weave to raise the fabric. When the fiber surface layer 401 contacts the developing roller 6 or the photosensitive drum 4, the rotation of the developing roller 6 or the photosensitive drum 4 causes the fiber portion 403 to rub against it. An example of contact with the developing roller 6 will be described below.

[0071] Here, the fiber portion 403 is a pile fabric composed of fiber threads of multiple different materials, woven so that the different fiber threads are arranged in stripes when the surface is viewed from the side opposite the developing roller 6. Here, pile fiber portions of lubricant-containing fiber threads 404, which contain lubricant, and lubricant-free fiber threads 405, which do not contain lubricant, are arranged in stripes at regular intervals along the longitudinal direction of the end seal 400. It is sufficient that the lubricant-containing fiber threads 404 are used in at least a portion of the fiber surface layer 401, and the spacing between the stripes and the ratio of the lubricant-containing fiber threads 404 to the lubricant-free fiber threads 405 do not have to be 1:1. Furthermore, the end seals 300 and 400 are required to have at least one type of lubricant-containing fiber thread, and may have multiple types of lubricant-containing fiber threads.

[0072] The lubricant used in Example 1 is a type of lubricant used for the purposes of reducing sliding friction, suppressing temperature rise due to sliding friction, and suppressing abrasion of the fiber surface layer 401 due to sliding friction. The fiber material of the lubricant-containing fiber yarn (first fiber yarn) 404 containing the lubricant is, for example, polyester, nylon, acrylic, rayon, polyolefin, or the like. However, the materials are not limited to these. The fiber material of the lubricant-free fiber yarn (second fiber yarn) 405 not containing the lubricant is the same material as the lubricant-containing fiber yarn 404, or a fluorine-based material such as PTFE (polytetrafluoroethylene), PFA (perfluoroalkoxyalkane), or ETFE (ethylene-tetrafluoroethylene). However, the materials are not limited to these.

[0073] The purpose of using multiple types of fiber yarns, lubricant-containing fiber yarn 404 and lubricant-free fiber yarn 405, is to selectively use fiber yarns according to different functions and costs. Each fiber generally has various advantages and disadvantages. For example, a fiber yarn with high sliding properties and temperature rise suppression performance may not achieve the desired functions in terms of fiber strength, electrostatic properties, manufacturing cost, etc. To compensate for this, by using two or more types of fiber yarns, lubricant-containing fiber yarn 404 and lubricant-free fiber yarn 405 as in Example 1, fiber yarns can be selected according to function, cost, etc.

[0074] In Example 1, by using the lubricant-containing fiber yarn 404 in at least a portion of the fiber surface layer 401, it is possible to use a fiber yarn for the end seal that is inexpensive to produce while compensating for the sliding properties and temperature rise suppression performance compared to an end seal that uses only the non-lubricant-containing fiber yarn 405. The non-lubricant-containing fiber yarn 405 can be made of a fiber material selected selectively. Alternatively, the end seal may be made of only the lubricant-containing fiber yarn 404 without using the non-lubricant-containing fiber yarn 405.

[0075] 11, the lubricant-containing fiber yarn 404 and the lubricant-free fiber yarn 405 are preheated to tilt the fibers at an angle θS2. Here, the angle is set to 10° to 90°, with the untilted state being 0°. This allows the direction of each fiber to be regulated even when the developing roller 6 rotates, enabling stable contact. However, it is not necessary to specifically tilt the fibers.

[0076] 7, the lubricant-containing fiber threads 404 and the lubricant-free fiber threads 405 are arranged in a stripe pattern in the longitudinal direction of the end seal 400, i.e., in the rotational direction (DK direction) of the developing roller 6. As a result, when the developing roller 6 rotates, the lubricant-containing fiber threads 404 and the lubricant-free fiber threads 405 alternately rub against each other. The stripe-like arrangement depends on the diameter of the rotating body, the length of the fiber portion 403, and the ratio of contact between the fibers, so the angle θS2 can be set based on the toner sealing ability, production costs, etc.

[0077] As shown in FIG. 7 , each fiber thread in the fiber portion 403 is tilted toward the inside of the developer container 25 at an angle θS1 relative to the rotational direction (DK) of the developing roller 6. This is to address the possibility that toner carried on the developing roller 6 may partially penetrate into the fiber surface layer 401 as the rotation time of the developing roller 6 increases with repeated image formation. It is also to address the possibility that toner scattered by the airflow from the air fan installed in the image forming apparatus may adhere to the surface of the fiber surface layer 401. The angle θS1 is set to facilitate the return of toner to the inside of each container by the rotational friction of the developing roller 6. Here, the angle is set at a center angle θS1 = 45° toward the longitudinal direction inside each container, with a tolerance of 30° to 60°. The angle θS1 may also be set based on factors such as toner sealing properties and production costs. Note that the angle θS1 does not necessarily have to be set to the rotational direction of the developing roller 6.

[0078] 11 , the length of the fiber threads used for the fiber portion 403 is set to a length that prevents contact between the developing roller 6 and the base fabric portion 402 when the fiber surface layer 401 contacts the developing roller 6. Here, the performance of the fiber portion 403 and the base fabric portion 402 are differentiated to prevent contact between the developing roller 6 and the base fabric portion 402. When the raised fiber portion 403 contacts the developing roller 6, it collapses and folds over, preventing contact between the developing roller 6 and the base fabric portion 402. The base fabric portion 402 is required to have a fiber diameter that allows it to be woven at a density that prevents toner from penetrating near the base of the fiber portion 403. Furthermore, the base fabric portion 402 is required to have durability, flexibility, heat resistance, and other properties that prevent the fiber portion 403 from coming loose due to the sliding resistance between the fiber portion 403 and the developing roller 6. Since the base fabric portion 402 does not come into contact with the developing roller 6, it is possible to use, for example, inexpensive fiber threads that do not have sliding properties in order to reduce costs. Note that the fibers used in the fiber surface layer 401 may also be used.

[0079] To prevent the fiber portion 403 from falling off the base fabric portion 402, the following measures are taken: Here, the base portion of the fiber portion 403 is fixed to the base fabric portion 402 by a method such as permeating, applying, or thermally fusing hot melt or a hardening coating agent made of synthetic resin, a thermoplastic resin sheet, or a thermoplastic fiber into the base fabric portion 402. However, the fixing method is not limited to this.

[0080] In this way, by using different fiber threads for the fiber portion 403 that rubs against the developing roller 6 and the base fabric portion 402 that does not rub against the developing roller 6, the cost of the fiber used in the base fabric portion 402 can be reduced, resulting in a low-cost end seal 400. In addition, by changing the density and weaving method of the fiber portion 403, it is possible to create a surface layer configuration aimed at improving the toner sealing performance. These can be changed as appropriate in accordance with the target lifespan of the process cartridge P.

[0081] The fiber surface layer 401 of the end seal 400 is a pile-woven fiber surface layer 401 with a raised fiber portion 403, taking into consideration factors such as adhesion to the developing roller 6, a configuration in which the fibers are slanted toward the inside of the developing container 25, and toner capture and heat dissipation. However, the fiber surface layer 401 may be made of any fiber yarn. For example, other than a pile weave, the fiber surface layer 401 may be sealed using only the warp and weft yarns of the base fabric portion 402, a knitted fabric, a nonwoven fabric-like intertwined fiber yarn, or a crimped fiber yarn. In this case, the lubricant-containing fiber yarn 404 may be provided in at least a portion of the fiber surface layer 401 to achieve the aforementioned lubricant-containing effect. The base fabric portion 402 itself may also contain the lubricant-containing fiber yarn 404. This applies to pile weave, knitted fabric, and nonwoven fabric. In this case, the surface may be subjected to a nap raising process to raise fibers from the base fabric portion 402 to form the fiber portion (surface layer) 403. Alternatively, an electrostatic flocking process may be used in which adhesive is applied to the base fabric portion 402 using a spray gun or the like, and a high voltage of 30,000 to 80,000 volts is applied, utilizing the force of static electricity to implant lubricant-containing fiber yarns into the substrate.

[0082] The second intermediate layer 407 is an elastic layer made of an elastic material (elastic body) that fills the gap between the developer container 25 and the developing roller 6 while bringing the fiber surface layer 401 into contact with the developing roller 6 at a predetermined pressure. For example, foamed polyurethane is used. It has a thickness that is sufficient to fill the gap even if the gap between the developing frame 25a and the developing roller 6 varies due to dimensional tolerances and assembly tolerances of each component. Here, a synthetic resin foam made by adding heat-dissipating carbon to foamed polyurethane is used. Other materials, such as polystyrene, polypropylene, elastomer, and rubber materials such as natural rubber, may also be used. When electrostatic flocking is used, the lubricant-containing fiber threads 404 may be planted directly into the intermediate layer 407 (substrate).

[0083] The third layer, intermediate adhesive layer 406, is an adhesive layer that bonds and fixes base fabric portion 402 and intermediate layer 407 together. It is sufficient if the fixing is performed without impairing the sealing performance of base fabric portion 402 or the repulsive force performance of intermediate layer 407. Here, fixing is performed using double-sided tape, hot melt, a curable coating agent made of synthetic resin, a thermoplastic resin sheet, thermoplastic fiber, or the like. However, the fixing method is not limited to these.

[0084] The container adhesive layer 408 as the fourth layer is an adhesive layer for fixing the end seal 400 to the developing container 25 to which it is to be assembled. In the case of the end seal 300, the container adhesive layer 408 is a layer for fixing the end seal 400 to the waste toner storage section 15a to which it is to be assembled. In this case, it is sufficient to fix the end seal 400 to the developing container 25 without impairing the repulsive force performance of the intermediate layer 407, and the end seal 400 is fixed with double-sided tape, hot melt, or the like. However, the fixing method is not limited to this. [Detailed configuration of the lubricant and lubricant-containing fiber yarn]

[0085] As mentioned above, toner may adhere to the end seal due to the influence of the rotation of the developing roller 6 and photosensitive drum 4 during image formation, the airflow from the main body fan, etc. For this reason, the end seal is required to have various improved performances to address the various influences on the toner sealing performance. For example, further improvements are required in the toner wiping performance, the toner collection performance inside the fiber portion, the sliding performance to improve the toner fluidity so that the toner is returned toward the inside of the container, the temperature rise suppression performance to prevent toner melting due to frictional heat, the heat dissipation performance, etc.

[0086] In the first embodiment, the purpose of including a lubricant in the fiber threads of the end seals 300 and 400 is to improve the sliding performance and the temperature rise suppression performance related to the toner sealing performance.

[0087] Furthermore, one method for improving the sliding performance, temperature rise suppression performance, heat dissipation performance, etc. of the seal surface of an end seal is to apply a powder or granular material to the seal surface. However, the powder or granular material is not directly fixed to the fibers. Therefore, there is a risk that the powder or granular material will gradually come off or scatter from the seal surface as the process cartridge increases in speed and lifespan. Therefore, by using fibers containing a lubricant, the lubricant is fixed to the fibers, making it easier to maintain the functionality of the seal surface than with a powder or granular material application method. It is also possible to use a powder or granular material on the seal surface in combination.

[0088] The lubricants used in the present invention include liquid lubricants and solid lubricants. Liquid lubricants include hydrocarbon-based liquids and silicone-based liquids. Solid lubricants include molybdenum disulfide, tungsten disulfide, graphite, graphite fluoride, hexagonal boron nitride (h-BN), organic fluorines (PTFE, PVDF, etc.), melamine cyanurate, dimethyl silicone oil, etc.

[0089] In the present invention, a solid lubricant is preferred as the lubricant to be contained in the fiber yarn of the end seals 300 and 400. The toner used in electrophotography is composed of fine particles and is composed of relatively low-molecular-weight resin components. If a liquid lubricant is used, the toner particles may aggregate, causing problems. Furthermore, some liquid lubricants may attack the toner, potentially causing phenomena such as toner blocking. In contrast, the solid lubricant particles used in the present invention reduce the occurrence of the aforementioned phenomena, such as the formation of toner aggregates and toner blocking. Therefore, a solid lubricant is preferred.

[0090] Among these, in the present invention, hexagonal boron nitride (boron nitride) is particularly preferred as the solid lubricant. Hexagonal boron nitride is insulating, and when used in electrophotography applications, it reduces the occurrence of the above-mentioned phenomenon. In addition, since hexagonal boron nitride has high thermal conductivity, it is expected to have an effect of diffusing heat (heat dissipation performance) when used in sliding parts such as the end seals 300 and 400.

[0091] Furthermore, the particle diameter of the solid lubricant preferably has an average primary particle diameter of 50 μm or less, more preferably 30 μm or less, and even more preferably 10 μm or less. The filament (fiber) diameter used for the fiber yarns in the surface layer of the end seals 300 and 400 is often 50 μm or less. When segmented fibers or the like are used, the diameter is often 10 μm or less. Therefore, the particle diameter of the solid lubricant is preferably equal to or smaller than the diameter of the fiber yarn. If the particle diameter of the solid lubricant is larger than the diameter of the fiber yarn, this may lead to a decrease in fiber strength. Furthermore, even if the solid lubricant particles detach from the fiber yarn, a smaller particle diameter is preferable because it remains between the fiber yarns in the surface layer of the end seals 300 and 400, thereby maintaining the effects of the present invention. In Example 1, boron nitride is used as an example of a solid lubricant particle material. The number-average diameter of the boron nitride is 0.1 μm or more and 20 μm or less. [Method for Manufacturing Lubricant-Containing Fiber Yarn]

[0092] One method for incorporating and fixing solid lubricant particles into a fiber yarn is to melt and knead a premix of resin pellets and solid lubricant particles and then spin the mixture. Another method involves melting and spinning a resin that already contains solid lubricant particles, which also includes using a diluted masterbatch containing a high concentration of solid lubricant particles. Another method involves adding solid lubricant particles midway through the resin melt-kneading process and spinning the mixture. Another method involves extruding a resin and solid lubricant molten in an organic solvent into a filament in a high-temperature environment and spinning the filament into a fiber. Another method involves heating the spun fiber yarn to soften it, then contacting it with a solid lubricant and then cooling it to fix it. Another method involves contacting the spun fiber yarn with a softening solvent to soften it, then contacting it with solid lubricant particles and fixing it. Another method involves contacting the fiber yarn with a liquid in which the solid lubricant particles are dispersed, thereby fixing the solid lubricant to the particles. In this case, from the viewpoint of the stability of fixing the solid lubricant to the fiber thread, it is preferable that the liquid is viscous or sticky. ■ Example of manufacturing fiber thread (yarn) kneaded with solid lubricant ○ Example of manufacturing

[0093] Polyester resin pellets (first resin pellets) and boron nitride having an average particle size of 0.6 μm were mixed thoroughly in a weight ratio of 100:5, and the mixture was melt-kneaded in a kneader to prepare resin pellets (second resin pellets) containing boron nitride in polyester resin. These resin pellets were then spun to produce threads with a diameter of approximately 15 μm.

[0094] Polyester resin pellets (first resin pellets) and boron nitride having an average particle size of 7 μm were mixed thoroughly in advance at a weight ratio of 100:8, and then melt-kneaded in a kneader to prepare resin pellets (second resin pellets) containing boron nitride in polyester resin. These resin pellets were then spun to produce threads with a diameter of approximately 25 μm.

[0095] Polyester resin pellets (first resin pellets) and melamine cyanurate having an average particle size of 2 μm were mixed thoroughly in advance at a weight ratio of 100:8, and the mixture was melt-kneaded in a kneader to prepare resin pellets (second resin pellets) containing melamine cyanurate in polyester resin. These resin pellets were spun to produce threads with a diameter of approximately 25 μm. ○ Manufacturing Example

[0096] Nylon resin pellets (first resin pellets) and boron nitride having an average particle size of 0.6 μm were mixed thoroughly in a weight ratio of 100:5, and the mixture was melted and kneaded in a kneader to prepare resin pellets (second resin pellets) containing boron nitride in nylon resin. These resin pellets were then spun to produce threads with a diameter of approximately 15 μm. ○ Manufacturing Example

[0097] Polyester resin pellets (first resin pellets) and dimethyl silicone oil were mixed in a weight ratio of 100:3 and then melted and kneaded in a kneader to prepare resin pellets (second resin pellets) containing dimethyl silicone oil in polyester resin. These resin pellets were spun to produce threads with a diameter of approximately 15 μm. ■ Example of the production of threads containing solid lubricant by the solvent method ○ Example of the production

[0098] Acrylic resin and boron nitride with an average particle size of 0.6 μm were dissolved in acrylonitrile at a weight ratio of 100:5, and the solution was formed into threads in a high-temperature environment, and the solvent was evaporated to produce threads with a diameter of approximately 15 μm containing boron nitride in acrylic resin. ■ Example of manufacturing threads with solid lubricant fixed to the surface of the thread ○ Example of manufacturing

[0099] A thread made of polyester resin and having a diameter of about 15 μm was passed through an oven at 280° C. to soften the surface, and then passed through a container containing boron nitride with an average particle size of 0.6 μm to produce a thread with boron nitride fixed to the surface of the thread.

[0100] A thread made of polyester resin and having a diameter of about 15 μm was passed through an oven at 280° C. to soften the surface, and then passed through a container containing melamine cyanurate with an average particle size of 2 μm to produce a thread with melamine cyanurate fixed to the surface of the thread.

[0101] A thread made of acrylic resin and having a diameter of approximately 15 μm was passed through an oven at 250° C. to soften the surface, and then passed through a container containing boron nitride with an average particle size of 0.6 μm to produce a thread with boron nitride fixed to the surface of the thread.

[0102] A nylon resin thread with a diameter of approximately 15 μm was passed through an oven at 250°C to soften the surface, and then passed through a container containing boron nitride with an average particle size of 0.6 μm to produce a thread with boron nitride fixed to the surface. ■ Example of manufacturing a thread with a solid lubricant fixed to the surface (using a liquid) ○ Example of manufacturing

[0103] A thread made of polyester resin and having a diameter of approximately 15 μm was passed through a silicone oil solution in which boron nitride with an average particle size of 0.6 μm was dispersed, to produce a thread with boron nitride fixed to the surface of the thread. Note that the resin material of the fiber, the type and particle size of the solid lubricant, and the manufacturing method are not limited to the above example. <Fiber thread kneaded with solid lubricant>

[0104] FIG. 12(a) shows a fiber yarn manufactured by the above-described manufacturing example of a fiber yarn (yarn) incorporating a solid lubricant. Components similar to those in FIG. 11 are designated by the same reference numerals. When a lubricant-containing fiber yarn 404 is manufactured by incorporating a solid lubricant, the solid lubricant 404a creates an uneven surface on the lubricant-containing fiber yarn 404, as indicated by the solid circle DTA in FIG. 12(a). In this case, approximately 10% to 50% of the average particle volume of the solid lubricant is exposed on the fiber surface. The percentage of exposure can be measured by electron microscope observation, such as SEM or TEM. During measurement, an image is captured, analyzed, and converted based on the magnification to measure particle diameter and other dimensions. Based on the results of multiple measurements, the average particle volume of the exposed particle portion is calculated. Instead of capturing an image, a photograph may be printed and measured with a ruler, and the particle diameter and other dimensions may be calculated based on the magnification used during measurement. <Fiber yarn incorporating solid lubricant by a solvent method>

[0105] FIG. 12(b) shows a fiber yarn manufactured by the above-described manufacturing example of a fiber yarn (yarn) containing a solid lubricant by the solvent method. The same reference numerals are used for components similar to those in FIG. 11 . When a lubricant-containing fiber yarn 404 is manufactured by incorporating a solid lubricant by the solvent method, the solid lubricant 404b creates an uneven surface on the lubricant-containing fiber yarn 404, as shown by the solid circle DTB in FIG. 12(b). As shown in FIG. 12, the degree of protrusion of the solid lubricant is greater when the solvent method is used than when the lubricant is kneaded into the fiber. In this case, approximately 40% to 80% of the average particle volume of the solid lubricant is exposed on the fiber surface. This can also be measured in the same way as for fiber yarns containing a solid lubricant.

[0106] In addition, in the manufacturing examples of yarn in which solid lubricant was fixed to the surface of the yarn and yarn in which boron nitride was fixed to the surface of the yarn (using a liquid), lubricant-containing fiber yarn 404 as shown in Figure 12 (b) was produced.

[0107] By kneading the solid lubricant or incorporating it by the solvent method in this way, about 10% to 80% of the average particle volume of the solid lubricant is exposed on the fiber surface. When the solid lubricant is kneaded, about 10% to 50% of the average particle volume is exposed on the fiber surface, and when it is incorporated by the solvent method, about 40% to 80% of the average particle volume is exposed on the fiber surface. [Application of lubricant to fiber yarn containing solid lubricant]

[0108] In the first embodiment, the fiber surface layer is described as using fiber yarns containing a solid lubricant for the purpose of improving the sliding performance and temperature rise suppression performance related to the toner sealing performance of the end seals 300 and 400. However, an additional lubricant may be applied. When the solid lubricant contained in the fiber yarn is used as the first solid lubricant, a second solid lubricant is further applied to the fiber surface layer. Figure 13 is an explanatory diagram showing the end seal 400 of Figure 11 further coated with a lubricant, and the same components as in Figure 11 are designated by the same reference numerals. The same applies to the end seal 300.

[0109] As described above, the surface layer of the end seal 400 rubs against the photosensitive drum 4 and the developing roller 6. Therefore, there is a risk that the fibers of the surface layer will gradually be worn away, and the abrasion of the lubricant-containing fiber threads 404 may result in a decrease in sliding performance and temperature rise suppression performance. Therefore, by further applying the lubricant particles 600, it is possible to extend the life of the process cartridge P even if the effectiveness of the lubricant-containing fiber threads 404 decreases.

[0110] It is also possible to apply lubricant particles 600 to the surface layer of the end seal 400 made only of the lubricant-free fiber thread 405. However, there is a risk that the lubricant particles 600 will not move from the end seal 400 along with the inside of each toner storage section or the transferred toner due to the rotation of the photosensitive drum 4 and the developing roller 6. For this reason, it is preferable to use the lubricant-containing fiber thread 404 and also apply the lubricant particles 600.

[0111] Here, the lubricant particles 600 are applied to the lubricant-containing fiber yarn 404 using the above-mentioned solid lubricants such as boron nitride, zinc stearate, and silicone resin particles such as Tospearl. The application method involves applying a liquid in which powder particles are dispersed in isopropyl alcohol to the surface of the end seal 400, and then volatilizing the isopropyl alcohol to apply the lubricant to the surface of the end seal 400. The lubricant to be applied may be other solid lubricants, liquid lubricants, or other particles.

[0112] The solid lubricant to be applied is preferably of the same type and particle size as the solid lubricant contained in the lubricant-containing fiber yarn 404. However, other materials and particle sizes may also be used. The timing of application may be during the assembly of the drum unit 8 and the developing unit 9, or after pre-applied end seals have been prepared.

[0113] As image forming devices become faster and their lifespans increase, the surfaces of the cleaning-side end seals and the developing-side end seals (collectively referred to as toner seals or end seals) can be worn away due to friction between the seal surfaces and each component. One method for preventing this wear and developer penetration is to apply a powder to the seal surface. Simply applying a powder may result in the powder gradually coming off the seal surface or scattering as the device becomes faster and longer-lasting. This can result in the end seals losing their ability to seal toner, potentially leading to toner leakage. Furthermore, if the toner melts and adheres to the surface of the end seal due to a low melting point, the end seals may lose their ability to seal toner, potentially leading to toner leakage. However, the above-described configuration can improve cartridge durability.

[0114] As described above, according to the first embodiment, it is possible to improve the sealing performance of the toner at the longitudinal ends of the cartridge, and thus improve durability. According to the first embodiment, it is possible to provide a developing device having an end seal of a new type.

[0115] According to the present invention, there are provided a seal member, a toner carrier device including the seal member, and an image forming apparatus.

[0116] The present invention is not limited to the above-described embodiments, and various modifications and variations can be made without departing from the spirit and scope of the present invention. Therefore, the following claims are appended to apprise the public of the scope of the present invention.

[0117] This application claims priority based on Japanese Patent Application No. 2023-166834, filed on September 28, 2023, the entire contents of which are incorporated herein by reference.

Claims

1. A toner carrier device for use in an image forming apparatus, comprising: a rotating member configured to be rotatable and to carry toner; a frame that rotatably supports the rotating member; and a sealing member that seals a gap between an end of the rotating member in the longitudinal direction of the rotating member and the frame, wherein the sealing member has a surface layer that contacts the rotating member, and the surface layer includes fiber yarns to which particles of a solid lubricant are fixed.

2. The toner carrying device according to claim 1, wherein said particles are embedded inside said fiber yarn so that a portion of said particles is exposed from the surface of said fiber yarn.

3. The toner carrying device according to claim 1, wherein the surface portion includes a base material, and a plurality of the fiber threads are provided on the base material.

4. The toner carrying device according to claim 1, wherein said rotating member is a photosensitive drum configured to carry a toner image, and said frame is a toner storage section that stores toner recovered from said photosensitive drum.

5. A toner carrying device according to claim 1, wherein said rotating member is a developing roller for supplying toner to a photosensitive drum, and said frame includes a toner containing section for containing the toner to be carried by said developing roller.

6. The toner carrying device according to claim 1, wherein said solid lubricant is boron nitride.

7. The toner carrying device according to claim 6, wherein said boron nitride has a number average particle diameter of 0.1 μm or more and 20 μm or less.

8. The toner carrying device according to claim 2, wherein a portion of said particles corresponding to 10% or more and 80% or less of the average volume thereof is exposed from the surface of said fiber yarn.

9. A toner carrying device according to claim 2, wherein said fiber thread is a fiber thread spun from a second resin pellet formed by melting and kneading a mixture of a first resin pellet and said particles.

10. A toner carrying device according to claim 2, wherein the fiber yarn is a fiber yarn made of polyester resin and passed through silicone oil in which the particles are dispersed, so that the particles are fixed to the surface of the fiber yarn.

11. The toner carrying device according to claim 9, wherein a portion of said particles corresponding to 10% to 50% of the average volume of said particles is exposed from the surface of said fiber yarn.

12. The toner carrying device according to claim 10, wherein a portion of said particles corresponding to 40% or more and 80% or less of the average volume thereof is exposed from the surface of said fiber yarn.

13. A toner carrier device according to claim 3, wherein when the solid lubricant is a first solid lubricant, the surface layer is coated with a powder of a second solid lubricant different from the first solid lubricant.

14. The toner carrying device according to claim 13, wherein the second solid lubricant includes zinc stearate or a silicone resin.

15. A toner carrier device as described in claim 1, wherein when the surface layer is a first layer, the sealing member has the first layer, a second layer made of an elastomer, a third layer bonding the first layer and the second layer together, and a fourth layer bonding the second layer and the frame body.

16. The toner carrier device according to claim 3, wherein the base material is made of the fiber thread.

17. The toner carrier device according to claim 8, wherein the surface layer is made of a knitted fabric made of the fiber yarn or a nonwoven fabric containing the fiber yarn.

18. The toner carrier device according to claim 8, wherein the surface portion is made of a base material on which the fiber threads are planted by electrostatic flocking.

19. The toner carrier device according to claim 1, wherein the material of said fiber threads is any one of polyester, nylon, acrylic, rayon, and polyolefin.

20. A toner carrying device according to claim 1, wherein when the fiber yarn is a first fiber yarn, the surface layer further includes a second fiber yarn to which the particles are not fixed.

21. A toner carrier device as described in claim 20, wherein the material of the first fiber yarn is any one of polyester, nylon, acrylic, rayon, and polyolefin, and the material of the second fiber yarn is any one of polytetrafluoroethylene, perfluoroalkoxyalkane, and ethylene-tetrafluoroethylene.

22. An image forming apparatus comprising the toner carrying device according to any one of claims 1 to 21.

23. A sealing member used in an image forming device to seal a gap between a rotating body that carries toner and a frame that rotatably supports the rotating body, the sealing member having a surface layer including fiber yarns to which particles of a solid lubricant are fixed.

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