Developer Apparatus Segmented Mixing for Toner Charging
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Solution Overview
Problem
Conventional image forming apparatuses face issues with recycle toner that has partially lost external additives or mixed with paper dust, leading to inefficient charging and potential scattering or attachment to the photosensitive drum, resulting in suboptimal image formation.
Innovation Solution
The apparatus includes a developer unit with a first, second, and third mixer chamber, along with fresh and recycled toner supply portions, where the recycled toner is stirred and mixed with fresh toner to ensure proper charging, using a specific conveying and stirring mechanism to maintain charge levels and prevent scattering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If recycle toner is directly returned into the developer unit without additional mixing, then the structure is simple, but the charge amount is insufficient and toner scattering occurs
Solution Approach 1:
The developer unit is divided into multiple chambers (first chamber, second chamber, third chamber) with separate mixers for fresh toner and recycled toner. This segmentation allows independent processing and mixing of different toner types, ensuring proper charging while maintaining a manageable structure through modular design
Solution Approach 2:
Recycled toner is mixed with fresh toner in advance in the third chamber before being supplied to the first chamber. This preliminary mixing action ensures that recycled toner acquires sufficient charge through contact with fresh toner, preventing scattering issues before they occur during image formation
2Reliability
If recycled toner is mixed with fresh toner in advance, then the charge amount is sufficient, but the mixing process becomes more complex
Solution Approach 1:
The mixing process is segmented into separate stages: first mixing recycled toner with fresh toner in the third chamber, then mixing the result with more fresh toner in the first chamber. This segmentation distributes the mixing complexity across multiple independent chambers rather than requiring a single complex mixing system
Solution Approach 2:
The third chamber acts as an intermediary mixing zone between the recycled toner supply and the main developer unit. It serves as a buffer where recycled toner is preliminarily mixed with fresh toner before entering the main development area, simplifying the overall process by creating a dedicated intermediate mixing stage
3Device complexity
If recycled toner is not properly charged, then the structure remains simple, but toner attaches to wrong areas or scatters
Solution Approach 1:
Recycled toner undergoes preliminary charging action in the third chamber where it is mixed with fresh toner before being supplied to the first chamber. This preliminary action ensures proper charge accumulation, preventing toner from attaching to wrong areas or scattering during the actual image formation process
Solution Approach 2:
The mixing and charging process continues throughout the toner circulation cycle, with mixers operating continuously to maintain charge levels. This continuous action ensures that recycled toner consistently achieves proper charging, eliminating precision issues related to toner placement
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution ensures consistent toner charging and distribution, minimizing toner scattering and attachment issues, thereby improving image quality and extending toner life by maintaining charge levels and optimizing toner usage.
Implementation Method 1
charging by friction (triboelectrification) caused by stirring
Implementation Method 2
charging by friction (triboelectrification) caused by stirring
Implementation Method 3
charging by friction (triboelectrification) caused by stirring
Data Source
AI summary
An image forming apparatus includes a first mixer 24a that conveys developer in the first direction while stirring the developer. Recycled toner delivered from a delivery opening 116b of a photosensitive drum cleaner 116 is supplied to an upstream side of the first chamber that contains the toner that is to be supplied to a developing position on a photosensitive drum 103 to which a predetermined potential is applied by a developing roller 27 formed rotatable.