Abstract:
An image forming apparatus includes a developing unit which supplies toner to an image carrier for developing a latent image. A toner cartridge is normally mounted on the developing unit and covers an opening thereof. In order to minimize toner spillage, a lug on the developing unit can cooperate with a stationary projection on the apparatus body to permit installation of the developing unit into the apparatus body only when the toner cartridge is mounted on the developing unit. Alternatively, a lug on the developing unit can cooperate with a stationary projection on the apparatus body for prohibiting mounting or removal of the toner cartridge only when the developing unit is installed in the apparatus. Alternatively, guide ribs are formed on both the developing unit and the toner cartridge for guiding the developing unit and toner cartridge for installation in the apparatus body only when the toner cartridge is mounted on the developing unit. Alternatively, a removal blocking member permits removal of the toner cartridge from the developing unit only when the developing unit is installed in the apparatus body. In a final alternative, a prohibiting member prohibits the removal of the developing unit from the apparatus body when the toner cartridge is not mounted to the developing unit, while a pivotal member and a projection member cooperate to permit the toner cartridge to be mounted on or removed from the developing unit only when the developing unit is installed in the apparatus body.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to an image forming apparatus such as a copying machine, a printer, a facsimile machine, etc., which records images on a sheet of paper using an electrophotographic process. The invention particularly relates to an improvement in the installation and removal structure of a developing unit, or an image forming process kit including a developing unit, and a toner cartridge in the image forming apparatus. 
     2. Discussion of the Background 
     In an image forming apparatus such as a copying machine, a printer, a facsimile machine, etc., using an electrophotographic process, a latent image formed on a photoconductive member is developed by applying toner from a developing unit onto the photoconductive member. The developed image is then transferred and fixed onto a sheet of paper. It is common that a removable toner cartridge is used to supply toner to the developing unit. 
     In conventional apparatuses in which a toner cartridge is exchanged while in the developing unit, or an image forming process kit, including the developing unit, is positioned inside the apparatus, or where the toner cartridge is exchanged while the developing unit or the image forming process kit is removed from the apparatus, if the developing unit or the image forming process kit can be inserted or removed without the toner cartridge being mounted thereon, a large amount of toner can be spilled and spread inside the image forming apparatus due to installation or removal shock, or due to turbulent air. As a result, the spread toner adheres to optical devices or a corona discharge wire, and printing quality is deteriorated. 
     Moreover, in conventional apparatuses in which the toner cartridge is exchanged while the developing unit or the image forming process kit is removed from the apparatus, if the toner cartridge can be removed from the developing unit or the image forming process kit while the developing unit or the image forming process kit remains inside the apparatus, the problem described above can occur because an entrance for supplying toner in the developing unit becomes open inside the apparatus. 
     Finally, in conventional apparatuses in which the toner cartridge is exchanged while the developing unit, or the image forming process kit including a developing unit, is installed inside the apparatus, if the toner cartridge can be installed and removed while the developing unit or the image forming process kit is removed from the apparatus, and if the cartridge is in fact removed from the developing unit or the image forming process kit, the developing unit or the image forming process kit can be overturned and the toner in the developing unit spilled and spread. Also, when the entrance for supplying toner in the developing unit is opened outside of the apparatus, foreign substances can enter the developing unit and cause serious damage. 
     SUMMARY OF THE INVENTION 
     It is a first object of the present invention to provide an image forming apparatus with an installation and removal structure of a developing unit, etc., and a toner cartridge which prevents accidental spillage or spreading of the toner. 
     It is another object of the present invention to provide an image forming apparatus with an installation or removal structure of a developing unit, etc., and a toner cartridge which prevents the toner from spreading inside the apparatus and reducing print quality. 
     It is another object of the present invention to provide an image forming apparatus with an installation and removal structure of a developing unit, etc., and a toner cartridge which prevents toner from spreading outside of the apparatus. 
     It is yet a further object of the present invention to provide an image forming apparatus with an installation and removal structure of a developing unit, etc., and a toner cartridge which prevents foreign substances from entering into an open entrance for supplying toner to the developing unit. 
     According to one feature of the invention, an image forming apparatus comprises an image carrier on which a latent image is formed. A developing unit has means for supplying toner to the image carrier for developing the latent image when the developing unit is installed in a body of the image forming apparatus. The developing unit has an opening through which the toner from a toner cartridge can be introduced thereinto. A toner cartridge is mountable on the developing unit and covers the opening. Means are provided on at least one of the developing unit and the toner cartridge for permitting installation of the developing unit into the image forming apparatus body only when the toner cartridge is mounted on the developing unit. 
     According to another feature of the invention, there are provided means on at least one of the developing unit and the apparatus body for prohibiting mounting or removal of the toner cartridge on the developing unit only when the developing unit is installed in the image forming apparatus body. 
     According to yet another feature of the invention, guide means are formed on both the developing unit and the toner cartridge for guiding the developing unit and the toner cartridge for installation in the image forming apparatus body only when the toner cartridge is mounted on the developing unit. 
     According to yet a further feature of the invention, means are provided on at least one of the developing unit and the toner cartridge for permitting removal of the toner cartridge from the developing unit only when the developing unit is installed in the image forming apparatus body. 
     According to yet a further feature of the invention, means are provided on at least one of the developing unit, the toner cartridge and the image forming apparatus body for prohibiting the removal of the developing unit from the image forming apparatus body when the toner cartridge is not mounted to the developing unit, and also for permitting the toner cartridge to be mounted on or removed from the developing unit only when the developing unit is installed in the image forming apparatus body. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein: 
     FIG. 1 is a sectional elevation view of a developing unit and toner cartridge according to one embodiment of the invention; 
     FIGS. 2(a) and 2(b) are front and side elevation details of the insertion prohibiting members of the embodiment of FIG. 1; 
     FIGS. 2(c) and 2(d) correspond to FIGS. 2(a) and 2(b), but show the insertion prohibiting member being folded by a rib of the toner cartridge; 
     FIG. 3(a) is a detail of a plan view of a second embodiment, showing another removal prohibiting member; 
     FIG. 3(b) corresponds to FIG. 3(a) but shows the removal prohibiting member moved to an active state; 
     FIG. 4(a) is a schematic elevation of an image forming process kit and toner cartridge of another embodiment, installed in an image forming apparatus; 
     FIG. 4(b) shows the image forming process kit and toner cartridge of FIG. 4(a) independent of the image forming apparatus; 
     FIG. 5(a) is a sectional elevation view of another embodiment of the invention; 
     FIG. 5(b) is a perspective detail of the embodiment of FIG. 5(a); 
     FIG. 6(a) is a sectional elevation view of yet another embodiment of the invention; and 
     FIG. 6(b) is a detail in plan of the embodiment of FIG. 6(a). 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the figures, embodiments of the invention will be described. 
     FIG. 1 shows a first embodiment in which the present invention is applied to a two component developing unit. 
     The structure of the developing unit 1 is as follows. In FIG. 1, a photoconductive member 4 is installed close to a developing roller 3. Magnets P1-P5 are installed within the developing roller 3. A doctor member 9 is installed close to the circumference of the developing roller 3. A paddle wheel 11 is installed below and to the left side of the developing roller 3 and close to it. A unit including a screw member 12, an inclined fin 13, a guide 14 and etc. is installed above the paddle wheel 11. A wing roller is installed in the unit. The developing roller 3, the doctor member 9, the paddle wheel 11, the screw member 12, the inclined fin 13, the guide 14, the wing roller 15 and etc. are enclosed in a casing 2 and developing material circulates while being stirred by them. The toner adheres to the photoconductive member 4 and is consumed. It is also supplied, while being stirred by a stirring member 16, from the toner cartridge 5 toward the wing roller 15. 
     This developing unit is operated as follows. The developer is carried in the clockwise direction by the paddle wheel 11 and then is carried up in the clockwise direction by the developing roller 3, with its thickness being controlled by the doctor member 9. It is thus put in contact with the photoconductive member 4 for development. Developer remaining on the developing roller after contacting with the photoconductive member 4 is removed from the developing roller 3 by the magnetic field of the magnets P2, P3 and is carried, while being stirred, by the wheel 11. On the other hand, the developer removed by the doctor member 9 is guided by the inclined fin 13 as it falls down the guide 14. The inclined fin 13 moves the developer in the horizontal direction toward one edge of the guide 14 having a hole 14a. The developer falls through the hole and onto a member 18 having the screw member 12. The developer is carried horizontally to the opposite edge of the member 18 by the screw member 12 and is dropped from the opposite edge. The developer which is dropped from the guide 14 and the member 18 is stirred by the wing roller 15 and conveyed to the paddle wheel 11. 
     The upper end of the toner tank 2 has an opening 8 through which toner can be introduced into the toner tank. The opening is normally closed by a toner cartridge 5. The toner cartridge 5 has flanges 5a which fit within guide rails 6 attached to the developing unit at opposite sides of the opening 8. As a result, the toner cartridge 5 can slide relative to the developing unit in a direction perpendicular to the plane of FIG. 1 for installing or removing the toner cartridge on the developing unit 1. 
     Although not shown in FIG. 1, the developing unit 1 can be installed or removed from the image forming apparatus by movement in a direction perpendicular to the plane of FIG. 1. Means are provided for permitting installation of the developing unit 1 in the body of the image forming apparatus only when the toner cartridge 5 is mounted on the developing unit 1. In for example, element 10 of FIGS. 2(a)-2(d) represents a blocking projection stationarily mounted in the image forming apparatus body. The projection 10 cooperates with an insertion prohibiting member described below to prevent installation of the developing unit into the image forming apparatus unless the toner cartridge is mounted thereon. 
     Referring to FIGS. 2(a) and 2(b), the insertion prohibiting member comprises a lug 7 pivotally mounted to the guide rail 6 for rotation in the direction of arrow A from the standing position of FIGS. 2(a) and 2(b). A spring (not shown) normally biases the lug in the standing or prohibiting position. When in the standing position, the lug 7 abuts the projection 10 of the image forming apparatus body as the developing unit is being inserted within the image forming apparatus, and prevents such insertion. 
     Referring to FIGS. 2(c) and 2(d), the toner cartridge 5 has a means for moving the lug 7 to a folded position, for example, a rib 5b. When the toner cartridge is fully installed on the developing unit 1 by sliding the flanges 5a within the guide rails 6, the rib 5b abuts the lug 7 and pivots the lug 7 to the folded position, as seen in FIG. 2(d), so that the lug 7 can no longer act to prevent insertion of the developing unit into the apparatus. Therefore, the insertion prohibiting apparatus assures that the developing unit will be inserted in the image forming apparatus body only when the toner cartridge is fully installed thereon, thereby preventing the danger of spillage and spread of toner due to shock or air turbulence. 
     Referring to the embodiment of FIGS. 3(a) and 3(b), FIG. 3(a) shows a partial plan view of a developing unit 1 having the toner cartridge 5 installed thereon, in which the toner cartridge can be removed from the developing unit by relative movement in the direction of the arrow. 
     Means are provided for prohibiting mounting or removal of the toner cartridge on the developing unit only when it is installed on the apparatus body. For example, a removal prohibiting member is comprised by a generally L shaped lug 20 which is pivotally mounted to the developing unit 1 for rotation about center C. It includes both a first projection part 20a and a second projection part 20b. A spring (not shown) biases the lug 20 normally in the free position shown in FIG. 3(a) in which it does not interfere with the movement of the toner cartridge 5 relative to the developing unit 1. Therefore, the toner cartridge can be installed or removed for exchange. 
     However, as the developing unit 1 is being installed in an image forming apparatus, the image forming apparatus body includes a projection 25 (FIG. 3(b)) mounted at a fixed position. As the developing unit approaches the fully installed position of FIG. 3(b), the projection 25 abuts the first projection part 20a and causes the lug 20 to pivot to the position of FIG. 3(b), at which time the second projection part 20b enters the concavity 23 in the toner cartridge and prevents the toner cartridge from moving in the direction of the arrow, relative to the developing unit 1. Therefore, the toner cartridge cannot be installed or removed from the developing unit while the developing unit is installed within the image forming apparatus, thereby assuring that toner cannot be spilled and spread within the image forming apparatus due to shock or air turbulence. 
     It should also be noted that the structure of FIG. 3(a) and 3(b) prevents the developing unit from being installed within the image forming apparatus when the toner cartridge 5 is only partly, and not fully, installed on the developing unit 1. In the case of partial installation of the toner cartridge on the developing unit, the concavity 23 will not be aligned with the lug 20, and the toner cartridge will prevent the removal prohibiting member from pivoting to the position of FIG. 3(b), thereby preventing installation of the toner cartridge 1. 
     Referring to the embodiment of FIGS. 4(a) and 4(b), in this embodiment, an image forming process kit 34 includes a developing unit 35, a photosensitive body 36, a corona charger 37 and a cleaning unit 38. A pair of guide rails 39a and 39b cooperate with flanges of the toner cartridge 40 to permit the toner cartridge to be installed or removed from the image forming process kit by sliding in a direction perpendicular to the plane of the figures. The toner cartridge 40 also includes a rib 41, while the image forming process kit includes a rib 42. 
     Referring to FIG. 4(a), the image forming apparatus 30 has a pivoting cover 32 including a pair of guide rails 32a and 32b. The ribs 41 and 42 can cooperate with the guide rails 32a and 32b for installation or removal of the image forming process kit on the cover 32. Therefore, since one of the support ribs is on the toner cartridge while the other is on the image forming process kit, it is only when the two are first united via the guide rails 39a  and 39b that the entire assembly can be installed on the cover 32. Neither the image forming process kit 34 nor the toner cartridge 40 can be installed separately from the other. 
     Therefore, there cannot exist an open entrance for supplying toner to the developing unit 35 and the spillage and spread of the toner within the apparatus can be minimized. 
     FIGS. 5(a) and 5(b) show a further embodiment incorporated into a one component developing unit. In the embodiment of FIG. 5(a), the developing unit 50 is installed in the image forming apparatus body (not shown). This type of image forming apparatus body is of the &#34;clamshell&#34; type in which an upper structure is pivotally mounted on a lower structure to open and close like a clamshell. In this case, the developing unit is mounted in the lower structure, while a photoconductor belt 51 and a cover 52 are together mounted on the upper structure. FIG. 5(a) shows the photoconductor belt 51 and the upper cover 52 in the closed position wherein the upper cover rests on part 57 of the developing unit and forms a sealed closure via the grommet 52A. 
     The toner is supplied from the toner cartridge 53 into the toner tank 56 and is carried in the direction of the developing roller 55 by a toner mixing plate 59. A toner supply bar 61 is installed near the developing roller 55 and works to steadily supply the toner to the developing roller. On the surface of the developing roller 55 is formed a rubber magnet layer having poles spaced at intervals of 1 mm in the circumferential direction. 
     The magnet captures the magnetic one component toner by its magnetic field. Then the developing roller rotates in the counterclockwise direction and the thickness of the toner is controlled by a metal toner metering blade 57 whose edge touches slightly the surface of the developing roller 55 and at the same time it is charged by the friction of the blade 54. Then when the toner reaches the photoconductor belt 51 which has a latent image, the toner adheres to the photoconductor 51 and the development is done. After the development, the surface of the developing roller 55 is discharged by a conductive bias brush 62. 
     The developing unit includes a toner tank 56 and a developing roller 55 which engages the photoconductor 51 when the cover 52 is closed, so as to transfer toner onto the photoconductor 51 for developing a latent image thereon. The developing unit is otherwise conventional, except as noted below. 
     A toner cartridge 53 is used to supply toner to the developing unit 50. It normally contains toner and has an opening normally closed by a seal (not shown). The seal is torn away after installation, at which time the toner cartridge is installed on the opening 56a of the toner tank of the developing unit 50 from above. 
     It is desirable in this embodiment that the toner cartridge can be installed or removed from the developing unit only when the developing unit is inside the image forming apparatus body, and fixed thereto. Therefore, the toner cannot be spread inside the apparatus and foreign substances cannot be put into the developing unit because the opening of the developing unit 50 is covered by other units inside the image forming apparatus. 
     In order to assure that the toner cartridge 53 can only be installed or removed from the developing unit 50 when the developing unit is installed in the image forming apparatus body. The developing unit includes means for permitting removal of the toner cartridge from the developing unit only when the developing unit is installed on the image forming apparatus body. For example, an installation part 57 is formed around the edge of the opening 56a of the toner tank 56, and a removal blocking member 58 is mounted to the installation part 57. The removal blocking member 58 includes a rotation part 58a pivotally mounted to the installation part 57 and rotatable in either direction shown by the arrows &#34;C&#34; in FIG. 5(b). A spring (not shown) biases the rotation part 58a in the counterclockwise direction, as seen in FIG. 5(b). A member 58b, which has a &#34;L&#34; shape, is mounted on the rotation part 58a, and so is biased by the spring into the blocking position shown in FIG. 5(b) in which it latches onto a flange of the toner cartridge 53, and prevents the toner cartridge from being removed from the developing unit. 
     A stationary projection 60 is formed inside the image forming apparatus body at such a location that it can extend through the opening 57a in the installation part 57 as the developing unit 50 is moved downward and into its installed position. Once the developing unit has moved fully downward to its installed position, which is below the position shown in FIG. 5(b), the projection 60 abuts a member 58c which extends laterally from the rotation part 58a and into the opening 57a. Projection 60 thus pivots the blocking member 58 in the clockwise direction, and against the biasing force of the spring, to the unblocking position shown by solid lines in FIG. 5(a), when the developing unit is in the fully installed position. Therefore, the toner cartridge 53 can be removed from the developing unit only when the blocking member 58 has been pivoted by the projection 60 and the developing unit is in its fully installed position within the image forming apparatus body. Toner therefore cannot be spread outside of the apparatus and foreign substances cannot be put into the developing unit 50 because the toner cartridge 53 maintains its opening 56a closed when the developing unit is not fully installed within the image forming apparatus. 
     The embodiment of FIGS. 6(a) and 6(b) includes means for preventing the toner cartridge from being installed on or removed from the developing unit when the developing unit is not installed within the image forming apparatus body, and also for preventing the developing unit from being removed from the image forming apparatus body when the toner cartridge is not installed thereon. 
     Referring to FIG. 6(a), a developing unit shown therein is similar to that shown in FIG. 1, except with respect to the error operation preventing structure 65 described below. 
     Referring to FIG. 6(b) which is a plan detail of the developing unit 1, the error operation preventing structure 65 includes a projection member 66 and an installation and removal member 67. The projection member 66 is slidably mounted on the developing unit by a pin 71 which fits in the elongate slot 66a of the projection member 66. The installation and removal member 67 is rotatably mounted on the developing unit 1 via a pin 73. It includes a concavity 67a and a projection 67b. Springs, not shown, normally keep the installation and removal member rotationally oriented in the position shown in FIG. 6(b) wherein the projection 67b projects inwardly while the concavity 67a faces a projection 66c of the projection member 66. While not illustrated in FIG. 6(b), the spring 70 normally biases the projection member 66 fully to the left so that the projection 66c fits in the concavity 67a, thereby preventing rotation of the installation and removal member 67 from the orientation shown in the figures. 
     The projection member 66 also includes a projection 66b which projects into engagement with the stationary projection 69 of the image forming apparatus body when the developing unit is fully installed in the image forming apparatus body, as is shown in FIG. 6(b). 
     An error operation preventing member 68 is rotatably mounted on the developing unit 1 and has two radially projecting nails 68a and 68b. A spring normally rotates the error operation preventing member 68 in the counterclockwise direction until limited by the first rotation preventing member 75. 
     FIG. 6(b) shows the developing unit 1 fully installed in the image forming apparatus. In this position, the projection member 66 is retracted by the engagement of the projection 66b with the stationary projection 69, and so the installation and removal member 67 is free to rotate. Therefore, as the toner cartridge 5 is moved to the left (as seen in the figure) during its mounting on the developing unit, its leading edge first rotates the installation and removal member 67 in the clockwise direction, and then rotates the error operation preventing member 68 in the clockwise direction. When the toner cartridge 5 has reached the fully installed position, the installation and removal member 67 is able to pivot counterclockwise so that the projection 67b fits into the concavity 5b of the toner cartridge 5, while the error operation preventing member 68 remains pivoted in a clockwise direction so that the nail 68a no longer projects into the path of the stationary projection 69. Therefore, the toner cartridge can be fully installed and the developing unit can be removed from the image forming apparatus without interference from the error operation preventing member 68. However, when the toner cartridge is not installed, the nail 68a abuts the stationary projection 69 to prevent removal of the developing unit 1. 
     Once the developing unit is removed from the image forming apparatus, however, the projection member 66 is able to slide under the biasing action of the spring 70 until it mates with the concavity 67a, thereby preventing pivoting of the installation and removal member 67, and so preventing removal of the toner cartridge 5 from the developing unit. 
     Therefore, according to this embodiment the toner cartridge 5 cannot be installed to or removed from the developing unit 1 outside of the image forming apparatus, although this can be done when the developing unit is within the image forming apparatus. Therefore, the toner cannot be spread outside of the apparatus and foreign substances cannot be put into the developing unit. Moreover, since the developing unit cannot be removed from the image forming apparatus without the toner cartridge mounted thereon, there can be no removal shock which will cause the spread of toner in the apparatus. 
     While the invention has so far been described with reference to embodiments having a developing unit, it may be appreciated that it is equally applicable to an image forming apparatus which uses an image forming process kit in which case the installation permitting means, the mounting or removal prohibiting means, the guide means, the removal permitting means and the removal prohibiting means will be associated with the image forming process kit in the same way that they are associated with the developing unit in the above embodiments. 
     Obviously, numerous modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described herein.