Toner conveyance roller and method for manufacturing toner conveyance roller

Abstract

A toner conveyance roller for an image forming apparatus including a toner image forming mechanism including a developing roller and the toner conveyance roller which is arranged opposite to the developing roller and used for supplying and scraping toner, wherein the toner conveyance roller has a roller part and a shaft part, the roller part includes a substantially cylindrical elastic layer composed of an elastic foaming body on a surface of the roller part, and a density of the elastic layer is higher in a longitudinal center part of the roller part than in both longitudinal end parts thereof, and a method for manufacturing the toner conveyance roller including a step of heat-pressing the crown-shaped elastic foaming body, and thereby, forming the elastic layer.

Claims

1. A toner conveyance roller for an image forming apparatus including a toner image forming mechanism including a developing roller and the toner conveyance roller which is arranged opposite to the developing roller and used for supplying and scraping toner, wherein the toner conveyance roller has a roller part and a shaft part, the roller part includes a substantially cylindrical elastic layer composed of an elastic foaming body on a surface of the roller part, the elastic layer is formed by heat-pressing the elastic foaming body after foam curing such that the compression rate of the elastic foaming body in the longitudinal center part of the roller part is made higher than the compression rate thereof in both the longitudinal end parts, a density of the elastic layer is higher in a longitudinal center part of the roller part than in both longitudinal end parts thereof, and the ratio of the pressing force of the elastic layer in the longitudinal center part of the roller part relative to the pressing force of the elastic layer in the longitudinal end part thereof is within a range of 89% to 99.2%.

2. The toner conveyance roller according to claim 1, wherein a density ratio (D.sub.c/D.sub.e) of a density (D.sub.c) of the elastic layer in the longitudinal center part of the roller part relative to a density (D.sub.e) of the elastic layer in both the longitudinal end parts thereof is within a range of 104% to 119.4%.

3. The toner conveyance roller according to claim 2, wherein the density (D.sub.e) is an average density of the elastic layer in each of 50 mm segments, each of which are included in respective longitudinal end parts of the roller part, and the density (D.sub.c) is an average density of the elastic layer in another 50 mm segment which includes the longitudinal center part of the roller part.

4. The toner conveyance roller according to claim 1, wherein the elastic layer is a layer composed of polyurethane foam.

5. A method for manufacturing the toner conveyance roller according to claim 1, the method comprising: a step of processing an elastic foaming body for forming the elastic layer of the roller part into a crown shape in which an outer diameter in the longitudinal center part is larger than an outer diameter in both the longitudinal end parts; and a step of press-fitting the crown-shaped elastic foaming body into a substantially cylindrical tubular body, and after heating the tubular body, taking out the elastic foaming body to form the elastic layer.

6. The method for manufacturing the toner conveyance roller according to claim 5, wherein a crown amount of the crown shape of the elastic foaming body (difference between the outer diameter of the elastic foaming body in both the longitudinal ends and the outer diameter thereof in the longitudinal center) is in a range of 0.2 to 0.8 mm.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a schematic perspective view showing a representative example of a toner conveyance roller of the present invention.

(2) FIGS. 2A, 2B, 2C and 2D present schematic cross-sectional views showing a representative example of a method for manufacturing the toner conveyance roller of the present invention.

(3) FIGS. 3A and 3B present schematic cross-sectional views for explaining a method for measuring pressing force in evaluation of the toner conveyance roller of the present invention.

(4) FIG. 4 is a schematic cross-sectional view explaining an example of a developing mechanism using a toner conveyance roller in a process of an image forming apparatus.

MODE FOR CARRYING OUT THE INVENTION

(5) The present invention is the invention of a toner conveyance roller for an image forming apparatus including a toner image forming mechanism including a developing roller and the toner conveyance roller which is arranged opposite to the developing roller and used for supplying and scraping toner as shown in FIG. 4.

(6) Hereafter, an embodiment of the toner conveyance roller of the present invention is described with reference to the drawings. FIG. 1 is a schematic perspective view showing a representative example of the toner conveyance roller of the present invention. As shown in the figure, a toner conveyance roller 30 of the present invention includes a shaft part 11 and a roller part 20, and the roller part 20 has an elastic layer 21 composed of an elastic foaming body on the surface. The shaft part 11 and the roller part 20 may be adhesively fixed together with an adhesive layer (not shown). Moreover, the roller part 20 is sufficient to have the elastic layer 21 on the surface, and may have another layer such as a rubber layer inside (not shown). Further, the density of the elastic layer 21 is higher in a longitudinal center part of the roller part 20 (region c near the longitudinal center C) than in both longitudinal end parts thereof (regions e and e near both longitudinal ends E and E). As mentioned above, in the case where the density of the elastic layer is the same over the whole area of the roller part, when the toner conveyance roller is pressed onto the developing roller, the shaft part of the toner conveyance roller bends, and pressing force with respect to the longitudinal center part of the developing roller tends to be smaller than pressing force with respect to the longitudinal end part thereof. According to the toner conveyance roller 30 of the present invention, as represented by Examples mentioned later, when the toner conveyance roller 30 is pressed onto the developing roller, even in the case where the shaft part 11 bends, the difference between the pressing force with respect to the longitudinal end part of the developing roller and the pressing force with respect to the longitudinal center part thereof can be made small. This is considered as that the difference in pressing force is made small since the modulus of elasticity of the center part becomes relatively high by making the density of the elastic layer 21 higher in the center part of the roller part 20 as compared with the longitudinal end part thereof. As the difference in pressing force of the elastic layer 21, as represented by Examples mentioned later, the ratio of the pressing force in the longitudinal center part relative to the pressing force in the longitudinal end part is preferably 89 to 103%. Thereby, image quality can be further improved. The ratio of the pressing force in the longitudinal center part relative to the pressing force in the longitudinal end part is further preferably 89 to 100%, particularly preferably 96 to 100%. Notably, the density of the elastic layer 21 preferably gradually becomes higher from both the longitudinal end parts of the roller part 20 toward the longitudinal center part thereof.

(7) In the toner conveyance roller 30 of the present invention, the shape of the elastic layer 21 is not needed to be a crown shape in which its maximum diameter is largely increased, but space-saving can be achieved. Notably, while the shape of the elastic layer 21 is preferably a cylindrical shape as shown in FIG. 1 with which space-saving can be most achieved, it is not specially limited as long as the effects of the present invention can be obtained, but formation into a crown shape with a small crown amount, a reverse crown shape, or the like is possible (in the present invention, each of such shapes and a cylindrical shape is referred to as substantially cylindrical shape).

(8) Notably, according to the toner conveyance roller of the present invention, as represented by Examples mentioned later, since the volume of the elastic layer can be made small by not setting a crown shape in which its maximum diameter is largely increased, an amount of toner remaining on the toner conveyance roller after the usage can be reduced, which enables loss of toner to be reduced.

(9) In the toner conveyance roller 30 of the present invention, the density ratio (D.sub.c/D.sub.e) of the density (D.sub.c) of the elastic layer 21 in the longitudinal center part of the roller part 20 relative to the density (D.sub.e) of the elastic layer 21 in both the longitudinal end parts thereof is preferably 104 to 126%. With the density ratio (D.sub.c/D.sub.e) within this range, as represented by Examples mentioned later, the difference between the pressing force with respect to the longitudinal end part of the developing roller and the pressing force with respect to the longitudinal center part thereof in the toner conveyance roller can be made further small, which enables image quality to be further improved. The density ratio (D.sub.c/D.sub.e) is further preferably 104 to 120%, particularly preferably 113 to 120%. The density (D.sub.e) of the elastic layer 21 in both the longitudinal end parts is the average density of the elastic layer 21 in the regions e and e near both the longitudinal ends E and E. The regions e and e are preferably in ranges of 50 mm from both the longitudinal ends E and E (in 50 mm of both the longitudinal end parts), respectively. Moreover, the density (D.sub.c) of the elastic layer 21 in the longitudinal center part is the average density of the elastic layer 21 in the region c near the longitudinal center C, and the region c is preferably in a range of 50 mm around the longitudinal center C (in 50 mm of the longitudinal center part).

(10) The elastic foaming body used for the elastic layer 21 of the toner conveyance roller 30 of the present invention is not specially limited. For example, examples thereof can include polyurethane foam, silicone rubber foam, ethylene-propylene rubber foam, acrylonitrile-butadiene rubber foam and the like. Above all, the polyurethane foam is preferable. The foaming body structure may have any of an open-cell property and a closed-cell property.

(11) The polyurethane material for forming the polyurethane foam is not specially limited as long as the resin contains a urethane bond. A known polyol component can be used, and, for example, polyether polyol, polytetramethylene ether glycol, polyol of THF-alkylene oxide copolymer, polyester polyol, acryl polyol, polyolefin polyol, a partially saponified compound of ethylene-vinyl acetate copolymer, phosphate-based polyol, halogen-containing polyol and the like can be preferably used. A known isocyanate component can be used, and TDI, MDI, crude MDI (polymeric MDI), modified MDI and the like, which are for general use, can be used.

(12) In addition to these polyurethane raw materials, to the polyurethane material, a crosslinking agent, a foaming agent (water, low-boiling point substances, gas bodies and the like), a surfactant, a catalyst and the like can be added as needed, and thereby, a desired structure can be made. Moreover, a known additive such as a flame retardant, a filler material and a crosslinking agent can be properly used. Moreover, in order to give the toner conveyance roller conductivity, a known conductive agent such as an ion conductive agent and an electron conductive agent is desired to be blended. Examples of the ion conductive agent can include ammonium salts such as a perchlorate salt, a chlorate salt, a hydrochloride salt, a bromate salt, an iodate salt, a fluoroborate acid salt, a sulfate salt, an ethylsulfate salt, a carboxylate salt and a sulfonate salt, for example, tetraethylammonium, tetrabutylammonium, dodecyltrimethylammonium (for example, lauryltrimethylammonium), hexadecyltrimethylammonium, octadecyltrimethylammonium (for example, stearyltrimethylammonium), benzyltrimethylammonium, (modified-fatty-acid)dimethylethylammonium and the like, a perchlorate salt, a chlorate salt, a hydrochloride salt, a bromate salt, an iodate salt, a fluoroborate acid salt, a trifluoromethylsulfonate salt, a sulfonate salt and the like of alkali metal and alkali earth metal such as lithium, sodium, potassium, calcium and magnesium. Moreover, examples of the electron conductive agent can include: conductive carbon such as Ketjen black and acetylene black; carbon for rubber such as SAF, ISAF, HAF, FEF, GPF, SRF, FT and MT; carbon for ink, pyrolytic carbon, natural graphite and artificial graphite which undergo oxidation processing; conductive metal oxide such as tin oxide, titanium oxide and zinc oxide; and metal such as nickel, copper, silver and germanium.

(13) A method for obtaining a foaming body constituting the roller using the above-mentioned polyurethane material is not limited, but a known method such as a method for chemical foaming using the above-mentioned foaming agent, and a method for foaming by mechanically sucking air into a vortex in molding can be properly selected and used.

(14) The material of the shaft part in the toner conveyance roller of the present invention is not specially limited. For example, a shaft material which is solid or hollow and composed of metal such as iron, stainless steel and aluminum, a resin such as rigid plastics, or the like can be used. In particular, a shaft material composed of conductive metal or conductive plastics is preferable.

(15) A method for manufacturing the toner conveyance roller of the present invention is not specially limited as long as it can give the elastic layer the above-mentioned characteristics. In order to easily manufacture the toner conveyance roller of the present invention, for example, the method shown below can be used.

(16) FIGS. 2A, 2B, 2C and 2D present schematic cross-sectional views showing a representative example of the method for manufacturing the toner conveyance roller of the present invention. First, as shown in FIG. 2A, an elastic foaming body 40 for forming the elastic layer 21 of the roller part 20 is processed into a crown shape in which the outer diameter of the longitudinal center part is larger than the outer diameter of both the longitudinal end parts.

(17) As to the processing into the crown shape, an elastic foaming body in a prismatic shape or the like may be processed by grinding processing, or an elastic foaming body may be prepared in a crown-shaped metal mold. Typically, the shaft part 11 is inserted into the elastic foaming body 40 before the processing by a usual method. Between the shaft part 11 and the elastic foaming body 40, an adhesive layer for adhesively fixing the same to the elastic foaming body 40 may be formed, and another layer such as a rubber layer (not shown) may be inside the elastic foaming body 40. Next, as shown in FIG. 2B, the elastic foaming body 40 is press-fitted into a substantially cylindrical tubular body 50 to compress the elastic foaming body 40 into a substantially cylindrical shape. The material of the tubular body 50 is not specially limited, but a pipe made of metal and/or a resin, and the like can be cited. As mentioned later, since it is heated in the next step, it is preferable a pipe made of metal such as aluminum, copper and iron, which are excellent in thermal conductivity, and its inner surface may be coated with a fluorine resin or the like such that the elastic foaming body 40 is easily press-fitted thereinto. Moreover, the inner diameter of the tubular body 50 is not specially limited as long as it is smaller than the maximum outer diameter of the elastic foaming body 40, but it can be designed in relation to the desired density and hardness of the elastic layer 21. It is preferably the same as or smaller than the minimum outer diameter of the elastic foaming body 40 such that the elastic foaming body 40 is molded into the shape of the tubular body 50. While the shape of the tubular body 50 is cylindrical in FIG. 2B, the shape of the interior thereof can be designed as a crown shape with a small crown amount, a reverse crown shape or the like (that is, a substantially cylindrical shape) to meet the desired shape of the elastic layer 21.

(18) Next, as shown in FIG. 2C, in the state where the elastic foaming body 40 is press-fitted into the tubular body 50, the tubular body 50 is heated from its outer circumference. The heating method is not specially limited, but a known method can be used. The heating temperature can be properly adjusted depending on the material of the elastic foaming body 40. In the case of polyurethane foam, 150 to 250 C. is preferable. By doing so, the elastic foaming body 40 is heat-pressed and molded into the shape of the interior of the tubular body 50. After the heating, as shown in FIG. 2D, the elastic foaming body 40 is taken out of the tubular body 50 to obtain the toner conveyance roller 30 having the roller part 20 in which the elastic layer 21 is formed. According to this method, the crown-shaped elastic foaming body 40 is heat-pressed into a substantially cylindrical shape, thereby, the compression rate of the elastic foaming body in the longitudinal center part is made higher than the compression rate thereof in both the longitudinal end parts, and thus, the toner conveyance roller of the present invention in which the density of the elastic layer is higher in the longitudinal center part of the roller part than in both the longitudinal end parts thereof can be easily manufactured.

(19) In the manufacturing method of the present invention, the crown amount of the crown shape of the elastic foaming body 40 is not specially limited, but can be properly configured. In order to set the difference between the density of the elastic layer 21 in both the longitudinal end parts of the roller part 20 and the density in the longitudinal center part thereof to fall within the preferable range, the crown amount of the crown shape of the elastic foaming body 40 is preferably 0.2 to 1.0 mm, further preferably 0.2 to 0.8 mm, particularly preferably 0.6 to 0.8 mm. Notably, in the present invention, the crown amount is set as the difference between the outer diameter at the positions of both the longitudinal ends E and E of the elastic foaming body 40 and the outer diameter at the position of the longitudinal center C thereof in FIG. 2A.

EXAMPLES

(20) Hereafter, the present invention is described on the basis of Examples.

(21) (I) Evaluation of Image Quality

(22) (1) Preparation of Rollers

(23) By the method presented in FIGS. 2A, 2B, 2C and 2D, using a cylindrical tubular body with 13 mm of inner diameter, toner conveyance rollers in Examples 1 to 7 and Comparative Example 1 each of which has a roller part with 13 mm of outer diameter and 220 mm of length and a shaft part with 5 mm of outer diameter were prepared from the respective elastic foaming bodies (polyurethane foam) with the crown amounts presented in Table 1. Table 1 presents the density of the elastic layer of each roller in both the longitudinal end parts (average density in each 50 mm of both the longitudinal end parts), the density thereof in the longitudinal center part (average density in 50 mm of the longitudinal center part), and the density ratio between these.

(24) (2) Evaluation Method

(25) (i) Ratio of Pressing Force of Elastic Layer in Longitudinal Center Part Relative to That in Both Longitudinal End Parts

(26) Evaluation of the pressing force of the toner conveyance roller was performed as follows. FIGS. 3A and 3B present schematic cross-sectional views for explaining a method for measuring the pressing force in the evaluation of the toner conveyance roller. As shown in the figure, the toner conveyance roller 30 was supported at both the end portions of the shaft part 11, and pressing bodies 60 and 61 each of which had 50 mm of length (in the longitudinal direction of the roller), 10 mm of width and 10 mm of thickness were disposed at the positions opposite to the region e in one end part of both the longitudinal end parts of the elastic layer 21 and the region c in the longitudinal center part thereof, to be parallel to the axis direction of the toner conveyance roller (FIG. 3A). Next, the pressing bodies 60 and 61 were moved at the speed of 10 mm/min in the cross-sectional direction of the roller part of the toner conveyance roller, and the pressing was performed until the pressing body 60 compressed the longitudinal end part of the roller part of the elastic layer 21 by 1 mm in the cross-sectional direction of the roller part (FIG. 3B). The pressing force in the longitudinal end part of the roller part of the elastic layer 21 was measured as the load exerted on the pressing body 60 in compressing. Moreover, the pressing force in the longitudinal center part of the elastic layer 21 was measured as the load exerted on the pressing body 61 at the time when the pressing body 61 compressed the longitudinal center part such that its pressing position in the cross-sectional direction of the roller part became the same as that of the pressing body 60 as shown in FIG. 3B (there was a case where the compressing distance became shorter due to bending of the shaft part 11 as shown in the figure). Table 1 presents the ratio of the pressing force in the longitudinal center part of the elastic layer 21 relative to the pressing force in the longitudinal end part thereof.

(27) (ii) Image Quality

(28) Each toner conveyance roller was attached to a corresponding image forming apparatus (printer), an image outputting test was performed, and a solid image that suffered blur caused by the poor property of scratching in the printed images was visually detected. One through which a solid image that suffered blur was not detected until reaching a predefined number of sheets was regarded as , one through which although a solid image that suffered blur had been detected at the time point of reaching the predefined number of sheets, it was not at a problematic level was regarded as , one through which although a solid image that suffered blur was detected in the early stage of the test, it was not at a problematic level was regarded as , and one through which a problematic solid image that suffered blur was detected was regarded as X. Table 1 presents the results.

(29) TABLE-US-00001 TABLE 1 Comparative Example 1 Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Crown Amount of Elastic Foaming 0 0.2 0.3 0.4 0.6 0.7 0.8 1.0 Body (mm) Density of Elastic End Part (De) 107 109 110 111 111 112 113 114 Layer Center Part (Dc) 107 113 117 122 126 130 135 143 (kg/m3) Density Ratio of Elastic Layer (Dc/De) 100.0 104.0 106.8 110.4 113.5 116.0 119.4 125.4 (%) Pressing Force Ratio of Elastic Layer 88.6 89.1 91.9 92.4 96.2 97.7 99.2 102.7 (Center Part/End Part) (%) Image Quality X

(30) (3) Evaluation Results

(31) As presented in Table 1, as compared with the toner conveyance roller in Comparative Example 1 in which the density of the elastic layer was uniform over the whole area, it can be indicated that for the toner conveyance rollers in Examples 1 to 7 in each of which the density of the elastic layer was higher in the longitudinal center part than in both the longitudinal end parts, the ratio of the pressing force in the longitudinal center part relative to the pressing force in both the longitudinal end parts becomes close to 100%, and the difference between the pressing force with respect to the longitudinal end part of the developing roller and the pressing force with respect to the longitudinal center part thereof can be made small when the toner conveyance roller is pressed onto the developing roller. It is indicated that image quality in each of Examples 1 to 7 is improved as compared with that in Comparative Example 1, and it is indicated that the density ratio of the density of the elastic layer in the longitudinal center part relative to the density thereof in both the longitudinal end parts is preferably 104 to 126%. Moreover, likewise, it is indicated that the ratio of the pressing force in the longitudinal center part relative to the pressing force in both the longitudinal end parts is preferably 89 to 103%.

(32) (II) Evaluation of Amount of Remaining Toner

(33) (1) Preparation of Rollers

(34) According to a usual method, a roller for conveying toner in Comparative Example 2 which was in a crown shape with 13 mm of outer diameter of both the longitudinal end parts and 1 mm of crown amount and had a roller part having an elastic layer which had 220 mm of length and a shaft part with 5 mm of outer diameter was prepared.

(35) (2) Evaluation Method

(36) Each of the toner conveyance rollers in Example 5 which is mentioned above and Comparative Example 2 was attached and used to a corresponding image forming apparatus (printer), the weights of each toner conveyance roller before and after the usage were measured, and the amount of remaining toner in the elastic layer was obtained on the basis of the difference between those. Notably, the ratio of the pressing force of the elastic layer in the longitudinal center part relative to that in both the longitudinal end parts was measured similarly to the above. Table 2 presents the results.

(37) TABLE-US-00002 TABLE 2 Compar- ative Example 5 Example 2 Density of Elastic Layer End Part (De) 112 107 (kg/m3) Center Part (Dc) 130 107 Outer Diameter of Elastic End Part 13.0 13.0 Layer (mm) Center Part 13.0 14.0 Pressing Force Ratio of Elastic Layer (Center 97.7 98.2 Part/End Part) (%) Volume of Elastic Layer (cm3) 22.6 24.5 Amount of Toner Remaining in Elastic Layer (g) 10.3 10.8

(38) (3) Evaluation Results

(39) As presented in Table 2, while the ratios of the pressing force in Example 5 and Comparative Example 2 are approximately the same, the amount of remaining toner is less in Example 5, and it is indicated that the toner conveyance roller of the present invention can reduce loss of toner more as compared with the crown-shaped roller.

(40) Notably, the present invention is not limited to the configuration of the embodiment and Examples mentioned above, but it can be variously modified without departing from the spirit of the present invention.

INDUSTRIAL APPLICABILITY

(41) According to the present invention, a toner conveyance roller can be provided which can be used for an image forming apparatus such as a copying machine and a printer and with which image quality can be improved and space-saving designing is enabled.

REFERENCE SIGNS LIST

(42) 11 Shaft part 20 Roller part 21 Elastic layer 30 Toner conveyance roller 40 Elastic foaming body 50 Tubular body