U.S. patent application number 09/742567 was filed with the patent office on 2001-09-06 for method of manufacturing an image forming apparatus.
Invention is credited to Hara, Yukinori, Narahara, Shuji.
Application Number | 20010019672 09/742567 |
Document ID | / |
Family ID | 18476469 |
Filed Date | 2001-09-06 |
United States Patent
Application |
20010019672 |
Kind Code |
A1 |
Narahara, Shuji ; et
al. |
September 6, 2001 |
Method of manufacturing an image forming apparatus
Abstract
When a photoreceptor unit and a developing unit are combined
with each other, the photoreceptor does not come into direct
contact with the developing unit. Accordingly, it is possible to
prevent generation of scratches on the surface of photoreceptor,
and lowering of electrostatic sensitivity due to scratches may be
prevented. As a result, an excellent image will be formed. It
improves the efficiency in the manufacture of image forming
apparatus. A method of manufacturing an image forming apparatus of
the present invention includes a process of applying a toner to the
surface of developing roller and a process of making the developing
roller with the toner applied thereto come into contact with the
photoreceptor to combine the developing unit and the photoreceptor
unit with each other. Preferably, the manufacturing method further
includes a process of performing functional tests of a finished
image forming apparatus.
Inventors: |
Narahara, Shuji; (Fukuoka,
JP) ; Hara, Yukinori; (Fukuoka, JP) |
Correspondence
Address: |
Lawrence E. Ashery
RATNER AND PRESTIA
One Westlakes, Berwyn, Suite 301
P.O. Box 980
Valley Forge
PA
19482-0980
US
|
Family ID: |
18476469 |
Appl. No.: |
09/742567 |
Filed: |
December 20, 2000 |
Current U.S.
Class: |
399/107 ;
399/111; 399/113; 399/130 |
Current CPC
Class: |
Y10T 29/49904 20150115;
G03G 21/1825 20130101; G03G 2221/1609 20130101 |
Class at
Publication: |
399/107 ;
399/111; 399/113; 399/130 |
International
Class: |
G03G 015/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 21, 1999 |
JP |
11-362286 |
Claims
What is claimed is:
1. A method of manufacturing an image forming apparatus, comprising
the steps of: (a) forming a photoreceptor unit having a
photoreceptor; (b) forming a developing unit having a developing
roller and a toner; (c) applying said toner to a surface of said
developing roller; and (d) setting up a combination of said
developing unit having said developing roller with said toner
applied and said photoreceptor unit.
2. The method of manufacturing an image forming apparatus as
defined in claim 1, further comprising a step of: (e) operating an
assembled image forming apparatus to perform functional tests of
said image forming apparatus.
3. The method of manufacturing an image forming apparatus as
defined in claim 1, wherein the step of setting up a combination of
said developing unit and said photoreceptor unit includes a process
of establishing contact between said developing roller with said
toner applied to the surface of said developing roller and said
photoreceptor with each other, and combining said photoreceptor
unit with said developing unit.
4. The method of manufacturing an image forming apparatus as
defined in claim 1, wherein the step of setting up a combination of
said developing unit and said photoreceptor unit includes a process
of establishing contact between said developing roller with said
toner applied to the surface of said developing roller and said
photoreceptor with each other, while said toner applied to the
surface of said developing roller is lain between said developing
roller and said photoreceptor, and combining said photoreceptor
unit and said developing unit with each other.
5. The method of manufacturing an image forming apparatus as
defined in claim 3, wherein said developing roller has a first
shape that is at least one of cylindrical and columnar; said
photoreceptor has a second shape that is at least one of
cylindrical and columnar; and said photoreceptor unit and said
developing unit are combined with each other in a manner such that
said developing roller having said first shape and said
photoreceptor unit having said second shape are parallel to each
other in the lengthwise direction.
6. The method of manufacturing an image forming apparatus as
defined in claim 3, wherein the step of applying said toner to the
surface of said developing roller includes a process of applying
said toner to the surface of said developing roller by rotating
said developing roller.
7. The method of manufacturing an image forming apparatus as
defined in claim 3, wherein said photoreceptor unit is capable of
forming an electrostatic latent image, and a toner image identical
with said electrostatic latent image of said photoreceptor may be
formed on the surface of said photoreceptor by using said
toner.
8. The method of manufacturing an image forming apparatus as
defined in claim 7, wherein said electrostatic latent image is
formed by application of a laser beam in accordance with image
data.
9. The method of manufacturing an image forming apparatus as
defined in claim 1, wherein said toner is non-magnetic, and said
image forming apparatus employs a single component developing
system.
10. The method of manufacturing an image forming apparatus as
defined in claim 1, wherein the step of applying said toner to the
surface of said developing roller includes a process of rotating
said developing roller until at least the area near the contact
between the developing roller and photoreceptor is completely
covered with said toner.
11. The method of manufacturing an image forming apparatus as
defined in claim 1, wherein the step of applying said toner to the
surface of said developing roller includes a process of rotating
said developing roller until the whole surface of said developing
roller is completely covered with said toner.
12. A method of manufacturing an image forming apparatus,
comprising the step of: (a) forming a photoreceptor unit having a
photoreceptor, wherein said photoreceptor unit has a function to
form an electrostatic latent image that appears with a laser beam
applied in accordance with image data, and said developing unit has
a function to develop said electrostatic latent image; (b) forming
a developing unit having a developing roller and a toner; (c)
applying said toner to a surface of said developing roller by
rotating said developing roller; (d) establishing contact between
said developing roller with said toner applied to the surface of
said developing roller said photoreceptor with each other, and
setting up a combination of said developing roller with said toner
applied and said photoreceptor unit; and (e) operating an assembled
image forming apparatus to perform functional tests of said image
forming apparatus.
13. A method of manufacturing an image forming apparatus,
comprising the steps of: (a) forming a photoreceptor unit having a
photoreceptor, wherein said photoreceptor unit has a function to
form an electrostatic latent image that appears with a laser beam
applied in accordance with image data, and said developing unit has
a function to develop said electrostatic latent image; (b) forming
a developing unit having a developing roller and a toner; (c)
applying said toner to a surface of said developing roller by
rotating said developing roller until at least the area near the
contact between the developing roller and photoreceptor is
completely covered with said toner; (d) establishing contact
between said developing roller with said toner applied to the
surface of said developing roller said photoreceptor with each
other, and setting up a combination of said developing roller with
said toner applied and said photoreceptor unit; and (e) operating
an assembled image forming apparatus to perform functional tests of
said image forming apparatus.
14. A method of manufacturing an image forming apparatus,
comprising the steps of: (a) forming a photoreceptor unit having a
photoreceptor, wherein said photoreceptor unit has a function to
form an electrostatic latent image that appears with a laser beam
applied in accordance with image data; said developing unit has a
function to develop said electrostatic latent image; (b) forming a
developing unit having a developing roller and a toner; (c)
applying said toner to a surface of said developing roller by
rotating said developing roller until the whole surface of said
developing roller is completely covered with said toner; (d)
establishing contact between said developing roller with said toner
applied to the surface of said developing roller said photoreceptor
with each other, and setting up a combination of said developing
roller with said toner applied and said photoreceptor unit; and (e)
operating an assembled image forming apparatus to perform
functional tests of said image forming apparatus.
15. A method of manufacturing an image forming apparatus,
comprising the steps of: (a) forming a plurality of photoreceptor
units, wherein each of said plurality of photoreceptor units has
each individual photoreceptor; (b) forming a plurality of
developing units, wherein each of said plurality of developing
units has each individual toner and developing roller, said
individual toners have color toners different in color from each
other, and said individual color toners are disposed in said
individual developing units; (c) applying individual color toner to
a surface of said individual developing roller; and (d) setting up
a combination of said individual developing unit having said
individual developing roller with said individual color toner
applied and said individual photoreceptor unit
16. The method of manufacturing an image forming apparatus as
defined in claim 15, wherein the step of setting up a combination
of said individual developing unit and said individual
photoreceptor unit includes a process of establishing contact
between said individual developing roller with said individual
toner applied to the surface of said individual developing roller
and said individual photoreceptor with each other, and combining
said individual photoreceptor unit and said individual developing
unit with each other.
17. The method of manufacturing an image forming apparatus as
defined in claim 15, wherein the step of setting up a combination
of said developing unit and said photoreceptor unit includes a
process of establishing contact between said developing roller with
said toner applied to the surface of said developing roller and
said photoreceptor with each other, while said toner applied to the
surface of said developing roller is lain between said developing
roller and said photoreceptor, and combining said photoreceptor
unit and said developing unit with each other.
18. The method of manufacturing an image forming apparatus as
defined in claim 16, wherein said individual developing roller has
a first shape that is at least one of cylindrical and columnar;
said individual photoreceptor has a second shape that is at least
one of cylindrical and columnar; and said individual photoreceptor
unit and said individual developing unit are combined with each
other in a manner such that said developing roller having said
first shape and said photoreceptor unit having said second shape
are parallel to each other in the lengthwise direction.
19. The method of manufacturing an image forming apparatus as
defined in claim 16, wherein the step of applying said individual
toner to the surface of said individual developing roller includes
a process of applying said individual toner to the surface of said
individual developing roller by rotating said individual developing
roller; said individual photoreceptor unit has a function to form
an electrostatic latent image formed by application of a laser beam
in accordance with image data; and said individual developing unit
has a function to develop said electrostatic latent image.
20. The method of manufacturing an image forming apparatus as
defined in claim 16, wherein the step of applying said individual
color toner to the surface of said individual developing roller
includes a process of rotating said individual developing roller
until at least the area near the contact between said individual
developing roller and said individual photoreceptor is completely
covered with said individual color toner.
21. The method of manufacturing an image forming apparatus as
defined in claim 16, wherein the step of applying said individual
color toner to the surface of said individual developing roller
includes a process of rotating said individual developing roller
until the whole surface of said individual developing roller is
completely covered with said individual color toner.
22. The method of manufacturing an image forming apparatus as
defined in claim 16, further comprising a step of: (e) operating an
assembled image forming apparatus to perform functional tests of
said image forming apparatus.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an image forming apparatus
which forms an image by placing image information on a transfer
material by using electrophotographic technology.
BACKGROUND OF THE INVENTION
[0002] A conventional method of manufacturing an image forming
apparatus will be described in the following. In FIG. 8 and FIG. 9
is shown a conventional method of manufacturing an image forming
apparatus, and FIG. 10 is an illustrative diagram showing a state
of contact between a photoreceptor unit and a developing roller in
a conventional method of manufacturing an image forming
apparatus.
[0003] FIG. 8, FIG. 9 and FIG. 10 show a method of manufacturing an
image forming apparatus in a single component developing system
using a non-magnetic toner. Firstly, a process unit 1 is described.
The process unit 1 comprises a photoreceptor unit 2 and a
developing unit 3. The process unit 1 is the control center of the
image forming apparatus.
[0004] In FIG. 8, the photoreceptor unit 2 comprises a
photoreceptor 4, a charged roller 5, a cleaning blade 6, and a
discharge lamp 7. The photoreceptor 4 has a surface coated with a
layer of organic photoconductive material. The charged roller 5,
cleaning blade 6 and discharge lamp 7 are disposed around the
photoreceptor 4.
[0005] In FIG. 8, the developing unit 3 includes a developing
roller 8 and a toner box 9. The toner box 9 has a function to feed
a toner 10 to the developing roller 8. A stirring member 11 is
fitted to the toner box 9. The stirring member 11 serves to stir
the toner 10. The toner 10 is non-magnetic.
[0006] In the first place, as shown in FIG. 8, the photoreceptor
unit 2 is assembled, followed by the developing unit 3. Secondly, a
pin 12 is inserted into a pin hole 2a of the photoreceptor unit 2
and a pin hole 3a of the developing unit 3, thereby combining the
photoreceptor unit 2 and developing unit 3 with each other.
Further, as shown in FIG. 9, a spring 13 is hooked over a
projection 2b of the photoreceptor unit 2 and a projection 3b of
the developing unit 3. The photoreceptor unit 2 and developing unit
3 are pulled to each other by the tensile force of the spring 13,
thereby causing the photoreceptor 4 and developing roller 8 to come
in contact with each other. The toner 10 is filled into the toner
box 9 of the developing unit 3. In this way, the process unit 1 of
a conventional image forming apparatus has been manufactured.
[0007] The mechanism of the process unit 1 will be briefly
described in the following with reference to FIG. 9. When the
photoreceptor 4 is rotated clockwise, the area coming in contact
with the charged roller 5 will be uniformly charged with
approximately -600V. Next, when a laser beam as shown by arrow 50
is applied by an exposure means (not shown) to the surface of
photoreceptor 4, the electric potential of the area exposed to the
laser beam will be increased to approximately -100V. An
electrostatic latent image having such different potentials is
formed on the surface of photoreceptor 4. When negatively charged
toner 10 is pressed against the electrostatic latent image by the
developing roller 8, the toner electrostatically sticks to the
photoreceptor 4, then the toner image is visualized and appears on
the photoreceptor 4 one after another. The toner image is
transferred by a transfer means (not shown) onto printing paper
(not shown). After that, the toner remaining on the surface of
photoreceptor 4 is removed by the cleaning blade 6, thereby
physically cleaning the surface of photoreceptor 4. Also, the
residual charge of the surface of photoreceptor 4 is eliminated by
the discharge lamp 7, thereby electrically cleaning the surface of
photoreceptor 4. These processes are repeated before going to the
next image forming process.
[0008] In such conventional method of manufacturing an image
forming apparatus, as shown in FIG. 10, when the developing unit 3
is combined with the photoreceptor unit 2, the surface of
photoreceptor 4 comes into direct contact with the surface of
developing roller 8. Accordingly, when the image forming apparatus
is operated in the functional test before delivery of the product,
a rubber portion 8a of developing roller 8 comes into direct
contact with the surface of photoreceptor 4. As a result, the
rubber portion 8a of developing roller 8 rubs against the surface
of photoreceptor 4. This may cause generation of scratches 14 on
the surface of photoreceptor 4 during only one turn of rotation
before the toner 10 sticks to the developing roller 8. In case
scratches 14 are generated on the surface of photoreceptor 4, the
electrostatic sensitivity of the area of scratches 14 will be
lowered, and consequently, the toner 10 will become hard to stick
to the scratched area of the photoreceptor. Excessive scratches
will cause generation of defective products. As a result, it will
lead to lowering of the product yield and the manufacturing
efficiency.
SUMMARY OF THE INVENTION
[0009] A method of manufacturing an image forming apparatus of the
present invention comprises the steps of:
[0010] (a) forming a photoreceptor unit having a photoreceptor;
[0011] (b) forming a developing unit having a developing roller and
a toner;
[0012] (c) applying the toner to the surface of the developing
roller; and
[0013] (d) setting up a combination of the developing unit having
the developing roller with the toner applied and the photoreceptor
unit.
[0014] Preferably, the step of setting up a combination of the
developing unit and the photoreceptor unit mentioned includes a
process of establishing contact between the developing roller with
the toner applied to the surface and the photoreceptor to set up a
combination of the photoreceptor unit and the developing unit.
[0015] Preferably, the method further comprises a step of
[0016] (e) operating an assembled image forming apparatus to
perform functional tests of the image forming apparatus.
[0017] In the above configuration, there exists a toner between the
photoreceptor surface and the developing unit surface. Accordingly,
when the photoreceptor unit and the developing unit are combined
with each other, the surface of developing roller itself does not
come into direct contact with the surface of photoreceptor. The
toner existing between the photoreceptor surface and the developing
unit surface serves to function as a lubricant. In this way,
generation of scratches on the surface of the photoreceptor, due to
the developing roller itself, may be prevented. As a result, an
excellent image will be formed. It gives rise to the improvement of
the manufacturing efficiency of the image forming apparatus.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a diagram showing a method of manufacturing an
image forming apparatus in accordance with one embodiment of the
present invention.
[0019] FIG. 2 is a diagram showing a state of toner application of
a developing roller in a method of manufacturing an image forming
apparatus in accordance with one embodiment of the present
invention.
[0020] FIG. 3 is a diagram showing a state of toner application of
a developing roller in a method of manufacturing an image forming
apparatus in accordance with one embodiment of the present
invention.
[0021] FIG. 4 is a diagram showing a method of manufacturing an
image forming apparatus in accordance with one embodiment of the
present invention.
[0022] FIG. 5 is an illustrative diagram showing a contact portion
between a photoreceptor and developing roller in a method of
manufacturing an image forming apparatus in accordance with one
embodiment of the present invention.
[0023] FIG. 6 is a diagram showing a configuration of a
photoreceptor unit in a method of manufacturing an image forming
apparatus in accordance with one embodiment of the present
invention.
[0024] FIG. 7 is a diagram showing a configuration of a developing
unit in a method of manufacturing an image forming apparatus in
accordance with one embodiment of the present invention.
[0025] FIG. 8 is a diagram showing a conventional method of
manufacturing an image forming apparatus.
[0026] FIG. 9 is a diagram showing a conventional method of
manufacturing an image forming apparatus.
[0027] FIG. 10 is an illustrative diagram showing a state of
contact between a photoreceptor and developing roller in a
conventional method of manufacturing an image forming
apparatus.
DESCRIPTION OF THE MARKS
[0028] 1 Process unit
[0029] 2 Photoreceptor unit
[0030] 2a Pin hole
[0031] 2b Projection
[0032] 3 Developing unit
[0033] 3a Pin hole
[0034] 3b Projection
[0035] 4 Photoreceptor
[0036] 5 Charged roller
[0037] 6 Cleaning blade
[0038] 7 Discharge lamp
[0039] 8 Developing roller
[0040] 8a Rubber portion
[0041] 9 Toner box
[0042] 10 Toner
[0043] 11 Stirring member
[0044] 12 Pin
[0045] 13 Spring
[0046] 14 Scratches
DETAILED DESCRIPTION OF THE INVENTION
[0047] A method of manufacturing an image forming apparatus of the
present invention comprises:
[0048] (a) a process of forming a photoreceptor unit having a
photoreceptor;
[0049] (b) a process of forming a developing unit having a
developing roller and a toner;
[0050] (c) a process of applying the toner to the surface of the
developing roller; and
[0051] (d) a process of setting up a combination of the developing
unit having the developing roller with the toner applied and the
photoreceptor unit.
[0052] Preferably, the method further comprises
[0053] (e) a process of operating an assembled image forming
apparatus to perform functional tests of the image forming
apparatus.
[0054] Preferably, a process of setting up a combination of the
developing unit and the photoreceptor unit mentioned in (d) above
includes a process of establishing contact between the developing
roller with the toner applied to the surface and the photoreceptor
to set up a combination of the photoreceptor unit and the
developing unit.
[0055] Preferably, the process (d) above includes a process of
combining the photoreceptor unit with the developing unit while
making the developing roller with the toner applied to the surface
come into contact with the photoreceptor.
[0056] Preferably, the developing roller has a first shape that is
either cylindrical or columnar, the photoreceptor has a second
shape that is either cylindrical or columnar, and the photoreceptor
unit and the developing unit are combined with each other in a
manner such that the lengthwise direction of the developing roller
having the first shape is parallel to the lengthwise direction of
the photoreceptor having the second shape.
[0057] Preferably, the process of applying the toner to the surface
of developing roller mentioned in (c) above includes a process of
applying the toner to the surface of the developing roller by
rotating the developing roller.
[0058] Preferably, the photoreceptor is able to form an
electrostatic latent image, and it is possible to form a toner
image identical with the electrostatic latent image of the
photoreceptor on the photoreceptor surface with use of the
toner.
[0059] Preferably, the electrostatic latent image is formed by
application of a laser beam in accordance with image data.
[0060] Preferably, the toner is non-magnetic, and the image forming
apparatus employs a single component developing system.
[0061] In the above configuration, there exists a toner between the
photoreceptor surface and the developing roller surface. The toner
existing between the photoreceptor surface and the developing
roller surface serves to function as a lubricant. Accordingly, when
the photoreceptor unit and the developing unit are combined with
each other, the surface of developing roller itself does not come
into direct contact with the surface of photoreceptor, and
therefore, generation of scratches on the surface of the
photoreceptor may be prevented. And, lowering of electrostatic
sensitivity due to scratches may be prevented. As a result, an
excellent image will be formed. Also, it gives rise to the
improvement of the product yield in the manufacturing process.
[0062] Further, when the functional test of an assembled image
forming apparatus is performed by operating the image forming
apparatus, the developing roller is prevented from scratching the
surface of the photoreceptor. Accordingly, it is possible to
improve the product yield in the manufacturing process.
[0063] An image forming apparatus in accordance with one embodiment
of the present invention comprises a photoreceptor unit and a
developing unit. The photoreceptor unit includes a photoreceptor,
and an electrostatic latent image is formed by application of a
laser beam in accordance with image data. The developing unit has a
function to develop the electrostatic latent image formed on the
photoreceptor. A method of manufacturing an image forming apparatus
in another embodiment of the present invention comprises (a) a
process of applying a toner to the surface of developing roller by
rotating the developing roller of the developing unit, (b) a
process of combining the photoreceptor unit with the developing
unit while making the photoreceptor come in contact with the
developing roller with the toner applied thereto, and (c) a process
of operating an assembled image forming apparatus to perform
functional tests of the image forming apparatus.
[0064] Due to this configuration, there exists a toner between the
developing roller and the photoreceptor. Accordingly, when the
photoreceptor unit and the developing unit are combined with each
other, it is possible to prevent direct contact between the surface
of developing roller itself and the surface of photoreceptor. In
this way, generation of scratches on the surface of the
photoreceptor and lowering of the electrostatic sensitivity due to
scratches may be prevented. As a result, an excellent image will be
formed. And it gives rise to the improvement of the manufacturing
efficiency of the image forming apparatus.
[0065] Preferably, the developing roller is rotated until at least
the area near the contact between the photoreceptor and the
developing roller is completely covered with the toner applied to
the developing roller, and after that, the photoreceptor unit is
combined with the developing unit while the photoreceptor is in
contact with the developing roller with the toner applied thereto.
This configuration will bring about an additional improvement.
[0066] Preferably, in particular, the developing roller is rotated
until the surface of the developing roller is completely covered
with the toner applied to the developing roller, and after that,
the photoreceptor unit is combined with the developing unit while
the photoreceptor is in contact with the developing roller with the
toner applied thereto. This configuration will bring about an
additional improvement.
[0067] A method of manufacturing an image forming apparatus in
accordance with another embodiment of the present invention
comprises:
[0068] (a) a process of forming a plurality of photoreceptor units,
wherein each of the plurality of photoreceptor units has each
individual photoreceptor;
[0069] (b) a process of forming a plurality of developing units,
wherein each of the plurality of developing units has each
individual toner and developing roller, the individual toners have
color toners different in color from each other, and the individual
color toners are arranged in the individual developing units;
[0070] (c) a process of applying individual color toner to the
surface of individual developing roller; and
[0071] (d) a process of setting up a combination of the individual
developing unit having the individual developing roller with the
individual color toner applied thereto and the individual
photoreceptor unit.
[0072] In this configuration, there exists the individual color
toner between the individual photoreceptor surface and the
individual developing roller surface. Accordingly, when the
individual photoreceptor unit and individual developing unit are
combined with each other, the surface of individual developing
roller itself does not come into direct contact with the surface of
individual photoreceptor. In this way, it is possible to prevent
generation of scratches on the surface of individual photoreceptor.
Thus, lowering of electrostatic sensitivity due to scratches may be
prevented. As a result, an excellent color image will be formed.
Further, it gives rise to the improvement of the product yield in
the manufacturing process.
[0073] Preferably, it further comprises
[0074] (e) a process of operating an assembled image forming
apparatus to perform functional tests of the image forming
apparatus.
[0075] Due to this configuration, when the functional test of an
assembled image forming apparatus is performed by operating the
image forming apparatus, it is possible to prevent the developing
roller from scratching the surface of the photoreceptor.
Accordingly, it gives rise to the improvement of the product yield
in the manufacturing process.
[0076] Preferably, a process of setting up a combination of the
individual developing unit and the individual photoreceptor unit
mentioned in (d) above includes a process of establishing contact
between the individual developing roller with the individual color
toner applied to the surface and the individual photoreceptor to
set up a combination of the individual photoreceptor unit and the
individual developing unit.
[0077] Preferably, the process of applying the individual color
toner to the surface of individual developing roller mentioned in
(c) above includes a process of applying the individual color toner
to the surface of individual developing roller by rotating the
individual developing roller.
[0078] The individual photoreceptor unit has a function to form an
electrostatic latent image formed by application of a laser beam in
accordance with image data. The individual developing unit has a
function to develop the electrostatic latent image.
[0079] An exemplary embodiment of the present invention will be
described in the following with reference to FIG. 1.about.FIG.
7.
[0080] Exemplary Embodiment 1:
[0081] In FIG. 1.about.FIG. 7 is shown a method of manufacturing an
image forming apparatus in an exemplary embodiment of the present
invention. FIG. 1 shows a method of manufacturing an image forming
apparatus, FIG. 2 and FIG. 3 show a state of toner application to a
developing roller in a method of manufacturing an image forming
apparatus, FIG. 4 shows a method of manufacturing an image forming
apparatus, and FIG. 5 is an illustrative diagram of a contact
portion between a photoreceptor and a developing roller in a method
of manufacturing an image forming apparatus. FIG. 6 shows a
configuration of a photoreceptor unit in a method of manufacturing
an image forming apparatus, and FIG. 7 shows a configuration of a
developing unit in a method of manufacturing an image forming
apparatus. FIG. 1.about.FIG. 7 illustrate a method of manufacturing
an image forming apparatus employing a single component developing
system with use of a non-magnetic toner.
[0082] Firstly, a process unit 1 is described. The process unit 1
comprises a photoreceptor unit 2 and a developing unit 3. The
process unit 1 is the control center of the image forming
apparatus.
[0083] In FIG. 6, the photoreceptor unit 2 comprises a
photoreceptor 4, a charged roller 5, a cleaning blade 6, and a
discharge lamp 7. The photoreceptor 4 has a surface coated with a
layer of organic photoconductive material. The charged roller 5,
cleaning blade 6 and discharge lamp 7 are disposed around the
photoreceptor 4. The photoreceptor 4 has a second shape that is
either cylindrical or columnar, and a sensitive material is
disposed on the surface of the photoreceptor 4.
[0084] In FIG. 7, the developing unit 3 has a developing roller 8
and a toner box 9. The developing roller 8 has a first shape that
is either cylindrical or columnar. The toner box 9 has a function
to feed a toner 10 to the developing roller 8. A stirring member 11
is fitted to the toner box 9. The stirring member 11 serves a
function to stir the toner 10. The toner 10 is non-magnetic. The
photoreceptor unit 2 shown in FIG. 6 and the developing unit 3
shown in FIG. 7 are identical in configuration with the
photoreceptor unit 2 and the developing unit 3 mentioned in the
description of the prior art.
[0085] Next, a method of manufacturing an image forming apparatus
in an exemplary embodiment of the present invention will be
described with reference to FIG. 1.about.FIG. 7.
[0086] First, a photoreceptor unit 2 is assembled as shown in FIG.
6, and then a developing unit 3 is assembled as shown in FIG.
7.
[0087] Next, as shown in FIG. 1, a toner 10 is filled into toner
box 9 of the assembled developing unit 3.
[0088] Next, the toner 10 is applied to a developing roller 8.
Preferably, as shown in FIG. 2, while the toner 10 is stirred by
rotation of a stirring member 11, the developing roller 8 is
rotated to apply the toner 10 to the surface of developing roller
8. In the process of applying the toner 10 to the surface of
developing roller 8, it is preferred to rotate the developing
roller 8 until at least the area near the contact between the
developing roller 8 and the photoreceptor of photoreceptor unit 2
is completely covered with the toner 10.
[0089] Preferably, as shown in FIG. 3, the developing roller 8 is
rotated until the whole of the developing roller 8 is completely
covered with the toner 10.
[0090] In this way, the toner 10 is applied to the surface of
developing roller 8 at the developing unit 3 in advance.
[0091] Next, with the toner 10 applied to the developing roller 8,
the photoreceptor unit 2 and the developing unit 3 are combined
with each other. Preferably, as shown in FIG. 1, a pin 12 is
inserted into pin hole 2a of the photoreceptor unit 2 and pin hole
3a of the developing unit 3, combining the photoreceptor unit 2 and
the developing unit 3 with each other.
[0092] Further, as shown in FIG. 4, a spring 13 is hooked over
projection 2b of the photoreceptor unit 2 and projection 3b of the
developing unit 3, and thereby the photoreceptor unit 2 and the
developing unit 3 are pulled to each other by the tensile force of
the spring 13.
[0093] Further, as shown in FIG. 5, the developing roller 8 with
the toner 10 applied to the surface comes into contact with the
photoreceptor 4. The developing unit 3 and the photoreceptor unit 2
are assembled in a manner such that the cylindrical developing
roller 8 and the cylindrical photoreceptor 4 come in contact with
each other in a parallel fashion in the lengthwise direction. In
this condition, there exists the toner 10 between the photoreceptor
surface and the developing roller surface. With the photoreceptor
unit 2 and the developing unit 3 assembled in this way, the toner
10 applied to the surface of developing roller 8 serves as a
lubricant. Accordingly, the developing roller 8 smoothly comes in
contact with the photoreceptor 4. That is, the photoreceptor 4 is
prevented from coming into direct contact with the surface of the
developing roller.
[0094] Before delivery of a finished image forming apparatus, the
image forming apparatus is subjected to functional tests. That is,
the image forming apparatus is operated for the first time. Also in
the before-delivery functional test, since toner 10 is applied to
the surface of developing roller 8, rubber portion 8a of the
developing roller 8 is prevented from scratching the surface of
photoreceptor 4. That is, generation of defectives in the
functional test of the finished image forming apparatus may be
prevented. Accordingly, it is possible to remarkably reduce the
percent defective of the image forming apparatus.
[0095] The mechanism of process unit 1 is briefly described in the
following with reference to FIG. 4.
[0096] Toner 10 is non-magnetic. The image forming apparatus
employs a single component developing system. When photoreceptor 4
is rotated clockwise, the area coming in contact with charged
roller 5 will be uniformly charged with approximately -600V. When a
laser beam as shown by arrow 50 is applied by an exposure means
(not shown) to the surface of photoreceptor 4 charged with
approximately -600V, the electric potential of the area exposed to
the laser beam will be increased to approximately -100V. Due to
such difference in electric potential, an electrostatic latent
image is formed on the surface of photoreceptor 4. When the toner
10 then negatively charged is pressed against the photoreceptor
with such electrostatic latent image formed thereon by the
developing roller 8, the toner 10 electrostatically sticks to the
predetermined area of the photoreceptor corresponding to the
electrostatic latent image, and thereby a toner image will be
formed. Then the toner image is visualized and formed on the
photoreceptor 4 one after another. That is, the developing unit 3
has a function to develop the electrostatic latent image. Next, the
toner image is transferred by a transfer means (not shown) onto
printing paper (not shown). After that, the toner remaining on the
surface of photoreceptor 4 is removed by cleaning blade 6. Thus,
the surface of photoreceptor 4 is physically cleaned. Also, the
residual charge of the surface of photoreceptor 4 is eliminated by
discharge lamp 7, thereby electrically cleaning the surface of
photoreceptor 4. These processes are repeated.
[0097] The present exemplary embodiment comprises a process of
combining the photoreceptor unit 2 with the developing unit 3 in a
manner such that the surface of developing roller 8 does not come
into direct contact with the photoreceptor 4. That is, a process of
assembling the developing unit and the photoreceptor unit while
protecting the surface of photoreceptor 4 is the difference from
the prior art described above.
[0098] Exemplary Embodiment 2:
[0099] A method of manufacturing an image forming apparatus in
another embodiment of the present invention is a method of
manufacturing an image forming apparatus for forming a color
image.
[0100] A method of manufacturing an image forming apparatus in the
present embodiment comprises:
[0101] (a) a process of forming a plurality of photoreceptor units,
wherein
[0102] each of the plurality of photoreceptor units has each
individual photoreceptor;
[0103] (b) a process of forming a plurality of developing
units,
[0104] wherein
[0105] each of the plurality of developing units has each
individual toner and developing roller;
[0106] the individual toners have color toners different in color
from each other;
[0107] the individual color toners are disposed in the individual
developing units;
[0108] (c) a process of applying individual color toner to the
surface of individual developing roller; and
[0109] (d) a process of combing the individual photoreceptor unit
with the individual developing unit while making the individual
developing roller with the individual color toner applied to the
surface come in contact with the individual photoreceptor.
[0110] Due to this configuration, it is possible to prevent
generation of scratches on the surface of individual photoreceptor.
Thus, lowering of electrostatic sensitivity due to scratches may be
prevented. As a result, an excellent color image will be formed.
Further, it gives rise to the improvement of the product yield in
the manufacturing process.
[0111] Preferably, the process of applying the individual color
toner to the surface of individual developing roller mentioned in
(c) above includes a process of applying the individual color toner
to the surface of the individual developing roller by rotating the
individual developing roller.
[0112] The individual photoreceptor unit has a function to form an
electrostatic latent image formed by application of a laser beam in
accordance with image data. The individual developing unit has a
function to develop the electrostatic latent image.
[0113] Preferably, the individual developing roller is rotated
until at least the area near the contact between the individual
photoreceptor and the individual developing roller is completely
covered with the color toner applied to the individual developing
roller, and after that, the individual photoreceptor unit is
combined with the developing unit while the individual
photoreceptor is in contact with the individual developing roller
with the toner applied thereto. This configuration will realize an
additional improvement.
[0114] Preferably, in particular, the developing roller is rotated
until the surface of the developing roller is completely covered
with the toner applied to the developing roller, and after that,
the photoreceptor unit is combined with the developing unit while
the photoreceptor is in contact with the developing roller with the
toner applied thereto. This configuration will bring about an
additional improvement.
[0115] In the present exemplary embodiment, each individual
photoreceptor unit of a plurality of photoreceptor units and each
individual developing unit of a plurality of developing units are
manufactured by the same method as in the exemplary embodiment 1
described above. In this case, the toners include individual color
toners disposed in individual process units. By such manufacturing
method, a color image formed with a plurality of colors can be
obtained. That is, the method of manufacturing an image forming
apparatus in the present exemplary embodiment is adapted to the
method of manufacturing an image forming apparatus corresponding to
the color image based on a tandem system. A tandem system stands
for a system wherein a plurality of sensitive drum process
mechanisms are arranged in a series fashion.
[0116] As described above, a method of manufacturing an image
forming apparatus of the present invention comprises a process of
applying a toner to a developing roller of a developing unit prior
to a process of combining a photoreceptor unit with a developing
unit. Thus, there exists a toner between the photoreceptor surface
and the developing roller surface. Accordingly, when the
photoreceptor unit is combined with the developing unit, the toner
applied to the developing roller serves as a lubricant, and the
developing roller is prevented from scratching the surface of the
photoreceptor. As a result, it gives rise to the improvement of the
product yield in the manufacturing process.
* * * * *