Abstract:
A developer amount regulation blade structure that effectively reduces assembly cost and improves image quality configured to form a layer of a developer on a developer bearer includes a regulation blade configured to regulate a thickness of the developer on the developer bearer, a first supporting member configured to support the regulation blade maintaining a gap between the regulation blade and the developer bearer, and a second supporting member configured to sandwich the regulation blade tightly with the first supporting member, wherein at least one of the first supporting member and the second supporting member is made of a plastically deformable material, and the second supporting member and the first supporting member sandwich the regulation blade by at least two plastically deformed portions separated from each other in a longitudinal direction of the first supporting member and connecting the first supporting member and the second supporting member.

Description:
PRIORITY STATEMENT 
   The present patent application claims priority under 35 U.S.C. §119 from Japanese Patent Application No. 2006-242338, filed in the Japan Patent Office on Sep. 7, 2006, the content and disclosure of which are hereby incorporated by reference herein in their entirety. 
   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present disclosure generally relates to a developer amount regulation blade structure used in an image forming apparatus, for example, printers, facsimiles, copiers, and multifunctional machines including functions of printer, facsimile, and copier. 
   2. Discussion of the Related Art 
   A conventional image forming apparatus has a developing apparatus which includes a developer bearer (a developing roller) and a developer amount regulation blade structure. The developer bearer (developing roller) attracts a two-component developer including a toner and a magnetic carrier or a one-component developer including a toner by magnetic force of a magnet roller and supplies the developer to a latent image bearer. The developer amount regulation blade structure faces the developer bearer and supplies the developer to the latent image bearer. A regulation blade, which is a thin board member, is provided on the developer amount regulation blade structure. 
   The regulation blade regulates the amount of the developer supported on the surface of the developer bearer. In a one-component type developer, for example, the regulation blade such as blade springs is pressed against the surface of the developer bearer. Therefore, the amount of the developer on the surface of the developer bearer is regulated by the regulation blade. 
   As with the developing apparatus, in order to make the developer bearer be supplied uniformly with the developer in a longitudinal direction of the developer bearer, it is necessary that the regulation blade be pressed with a uniform force in the longitudinal direction. Therefore, uniform flatness is required of the regulation blade. 
     FIG. 1  is a cross-sectional diagram illustrating an exemplary configuration of a developer amount regulation blade structure of a conventional image forming apparatus. As shown in  FIG. 1 , a supporting member  2  faces a developer bearer  1 . Screws  4  located along a regulation blade  3  fix the regulation blade  3  on the supporting member  2 . The regulation blade  3  is in touch with the surface of the developer bearer  1  by a given pressing force F. 
   However, this type of the regulation blade  3  has a waveform in the longitudinal direction, and therefore fails to achieve the straight edge intended by design. As a result, a gap between the developer bearer  1  and the regulation blade  3  is uneven and consequently good frictional electrification is not obtained, resulting in production of defective images in image formation. 
   For the straightness of the edge of the regulation blade  3 , it is considered that it is good to increase the pressing force F. However, the increase of the pressing force F may cause the regulation blade  3  to scratch the developer bearer  1 , in which case a lifetime of the development bearer  1  may decrease. 
   To fix this problem, a developer amount regulation blade structure in which a bolting torque gradually decreases toward a center of the regulation blade  3  from the both ends thereof when the regulation blade  3  is fixed on the supporting member  2  is proposed. 
   In addition, a developer amount regulation blade structure in which a thin regulation blade is fixed on the supporting member  2  by welding is also proposed. 
   SUMMARY OF THE INVENTION 
   An embodiment of the present invention is directed to a developer amount regulation blade structure. The developer amount regulation blade structure effectively reduces assembly cost and improves image quality. In the embodiment, the developer amount regulation blade structure configured to form a layer of a developer on a developer bearer includes a regulation blade configured to regulate a thickness of the developer on the developer bearer, a first supporting member configured to support the regulation blade maintaining a gap between the regulation blade and the developer bearer, and a second supporting member configured to sandwich the regulation blade tightly with the first supporting member, wherein at least one of the first supporting member and the second supporting member is made of a plastically deformable material, and the second supporting member and the first supporting member sandwich the regulation blade by at least two plastically deformed portions separated from each other in a longitudinal direction of the first supporting member and connecting the first supporting member and the second supporting member. 
   Additional features and advantages of the present invention will be more fully apparent from the following detailed description of embodiments, the accompanying drawings, and the appended claims. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete appreciation of the disclosure 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 cross-sectional diagram showing a configuration of a developer amount regulation blade structure of a conventional image forming apparatus; 
       FIG. 2  is a perspective diagram showing a developer amount regulation blade structure of an image forming apparatus according to an embodiment of the present invention; 
       FIG. 3  is a cross-sectional diagram showing a configuration of the developer amount regulation blade structure of  FIG. 2 ; 
       FIG. 4  is a front view showing a configuration of the developer amount regulation blade structure of  FIG. 2 ; 
       FIG. 5  is a fragmentary sectional view along a line A-A of the developer amount regulation blade structure of  FIG. 4 ; 
       FIG. 6  is an exploded perspective view of the developer amount regulation blade structure of  FIG. 2 ; 
       FIG. 7  is a fragmentary sectional view along a line B-B of the developer amount regulation blade structure of  FIG. 4 ; 
       FIG. 8  is a fragmentary sectional view of the developer amount regulation blade structure of  FIG. 4  before plastic deformation of cylindrical projections; 
       FIG. 9  is a fragmentary sectional view of the developer amount regulation blade structure of  FIG. 4  after plastic deformation of the cylindrical projections; 
       FIG. 10  is a fragmentary sectional view of another example of the developer amount regulation blade structure of  FIG. 4 ; 
       FIG. 11  is a fragmentary sectional view of another example of the developer amount regulation blade structure of  FIG. 4 ; and 
       FIG. 12  is a fragmentary sectional view of another example of the developer amount regulation blade structure of  FIG. 4 . 
   

   DETAILED DESCRIPTION OF THE EMBODIMENTS 
   Referring now to the drawings, wherein like reference numerals designate identical or corresponding parts throughout the several views, embodiments of the present disclosure, which are applied to a developer amount regulation blade structure, are described below. 
   In the following description, it is to be understood that if an element or layer is referred to as being “on,” “against,” “connected to” or “coupled to” another element or layer, then it may be either directly on, against, connected or coupled to that other element or layer or intervening elements or layers may be present. By contrast, if an element is referred to as being “directly on”, “directly connected to” or “directly coupled to” another element or layer, then there are no intervening elements or layers present. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. 
   Spatially relative terms, such as “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, a term such as “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
   Although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers and/or sections, it should be understood that these elements, components, regions, layers and/or sections should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer or section from another region, layer or section. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the present invention. 
   The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including”, when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. 
   In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this patent specification is not intended to be limited to the specific terminology so selected and it is to be understood that each specific element includes all technical equivalents that operate in a similar manner. 
   Referring now to the drawings, particularly to  FIG. 2 , an example of a developer amount regulation blade structure of an image forming apparatus according to embodiments is described. 
   EXAMPLE 1 
     FIG. 2  is a perspective diagram of a developer amount regulation blade structure of an image forming apparatus according to an example embodiment of the present invention.  FIG. 3  is a cross-sectional diagram illustrating an exemplary configuration of the developer amount regulation blade structure of  FIG. 2 .  FIG. 4  is a front view illustrating an exemplary configuration of the developer amount regulation blade structure of  FIG. 2 .  FIG. 5  is a fragmentary sectional view along a line A-A of the developer amount regulation blade structure of  FIG. 4 .  FIG. 6  is an exploded perspective view of the developer amount regulation blade structure of  FIG. 2 . 
   In  FIG. 2 , reference numeral  10  shows the developer amount regulation blade structure. The developer amount regulation blade structure  10  includes a first supporting member  11 , a second supporting member  12 , and a thin regulation blade  13 . The first supporting member  11 , the second supporting member  12 , and the thin regulation blade  13  are constituted of materials which can plastically deform, and they extend along a developer bearer (not shown). 
   As shown in  FIG. 4 , screw holes  11 A are formed at both ends of the first supporting member  11  for fixing the developer amount regulation blade structure  10  in the main body of the image forming apparatus (not shown). 
   Half die cutting cylindrical projections  11 B shown in  FIG. 5  are formed on the first supporting member  11  having a given interval in a longitudinal direction. These cylindrical projections  11 B are formed on the first supporting member  11  using, for example, a press metal mold (not shown). It is desirable that the cylindrical projections  11 B be spaced regular intervals apart. 
   Penetration holes  13 A having a diameter greater than an outer diameter of the cylindrical projections  11 B are formed in the regulation blade  13  at positions corresponding to the cylindrical projections  11 B. Penetration holes  12 A having a diameter smaller than the outer diameter of the cylindrical projections  11 B are formed in the second supporting member  12  at positions corresponding to the cylindrical projections  11 B. The regulation blade  13  is arranged between the first supporting member  11  and the second supporting member  12 , as shown in  FIG. 6 . The regulation blade  13  is tightened between the first supporting member  11  and the second supporting member  12  by pressing the cylindrical projections  11 B into the penetration holes  12 A, as shown in  FIG. 5 . 
   In this example 1, the developer amount regulation blade structure  10  has a structure such that the regulation blade  13  is tightened between the first supporting member  11  and the second supporting member  12  by pressing the cylindrical projections  11 B into the penetration holes  12 A. Therefore, it is inexpensive to assemble the developer amount regulation blade structure  10  and its working efficiency is improved. Further, it is not easily susceptible to the influence of changes in environment even if different materials are used in assembly, and it has a good flatness. 
   When the regulation blade  13  has a thickness of 0.1 mm or smaller, the regulation blade  13  is pressed against the first supporting member  11  with the second supporting member  12  by plastic deformation of heads  11 C of the cylindrical projections  11 B due to applied external force. Since the peripheral wall of the penetration holes  12 A of the second supporting member  12  deforms by the plastic deformation of the cylindrical projections  11 B, the portions of the regulation blade  13  corresponding to the peripheral wall of the penetration holes  12 A may deform to have a waveform. However, in this example 1, the heads  11 C of the cylindrical projections  11 B do not plastically deform, thus assuring that the regulation blade  13  is flat. 
   When the regulation blade  13 , the first supporting member  11 , and the second supporting member  12  are made of different materials, coefficients of linear expansion thereof are different. However, a gap G exists between the penetration holes  13 A of the regulation blade  13  and the cylindrical projections  11 B to accommodate differences in the coefficients of linear expansion of such different materials. Since the gap G prevents growth and shrinkage of the first supporting member  11  brought about by temperature change from being transmitted to the regulation blade  13 , waveform of the regulation blade  13  due to such temperature change is reduced. 
   In this example 1, the first supporting member  11  has  12  cylindrical projections  11 B. However, at least 2 cylindrical projections  11 B are enough to assemble the developer amount regulation blade structure  10 . 
   In this example 1, the first supporting member  11  has the cylindrical projections  11 B and the penetration holes  12 A are formed in the second supporting member  12 . Alternatively, however, the second supporting member  12  may have the cylindrical projections, with the penetration holes formed in the first supporting member  11 . 
   EXAMPLE 2 
     FIG. 7  is a fragmentary sectional view along a line B-B of the developer amount regulation blade structure of  FIG. 4 . In this example 2, cylindrical projections  11 B′ are provided at both ends of the cylindrical projections  11 B of the example 1. The heads  11 C of the cylindrical projections  11 B′ are plastically deformed by a punch member (not shown) as shown in  FIG. 7 . In this example 2, the heads  11 C of the cylindrical projections  11 B′ has plastic deformation and they are fitted in the second supporting member  12 . Therefore, the second supporting member  12  is hard to be separated from the first supporting member  11 . 
   Even if the heads  11 C of the cylindrical projections  11 B′ plastically deform and they are fitted into the second supporting member  12 , and the regulation blade  13  is pressed against the first supporting member  11  with the second supporting member  12  by such plastic deformation, the flatness of the regulation blade  13  is not affected because the cylindrical projections  11 B′ are located at both end portions. 
   In this example 2, the first supporting member  11  has  12  cylindrical projections  11 B. However, at least 3 cylindrical projections  11 B are enough to assemble the developer amount regulation blade structure  10 , and the cylindrical projections  11 B at both end portions have enough plastic deformation to enable them to be attached. 
   EXAMPLE 3 
     FIG. 8  is a fragmentary sectional view of the developer amount regulation blade structure of  FIG. 4  before plastic deformation of cylindrical projections.  FIG. 9  is a fragmentary sectional view of the developer amount regulation blade structure of  FIG. 4  after plastic deformation of cylindrical projections. In example 3, as shown in  FIG. 8 , the penetration holes  12 A′ having a diameter greater than an outer diameter of the cylindrical projections  11 B′ are formed in the second supporting member  12  at positions corresponding to the cylindrical projections  11 B′. Further, a beveling portion  12 B is formed in the penetration hole  12 A′. As shown in  FIG. 9 , the heads  11 C corresponding to the cylindrical projections  11 B′ deform so as to extrude outside and pressing in the second supporting member  12 . Therefore, compared to example 2, the regulation blade  13  is firmly fixed to the first supporting member  11  without affecting the flatness of the regulation blade  13 . Because the cylindrical projections  11 B′ are located at both ends of the developer amount regulation blade structure they do not affect the flatness of the regulation blade  13  even though they deform. 
   In this example 3, the first supporting member  11  has the cylindrical projections  11 B and the penetration holes  12 A are formed in the second supporting member  12 . Alternatively, however, the second supporting member  12  may have the cylindrical projections and the penetration holes may be formed in the first supporting member  11 . 
   Moreover, although in this example 3 the beveling part  12 B is provided in the penetration hole  12 A′, it is not necessary that such beveling part  12 B be provided in the penetration hole  12 A′. 
   EXAMPLE 4 
     FIG. 10  is a fragmentary sectional view of another example of the developer amount regulation blade structure of  FIG. 4 .  FIG. 11  is a fragmentary sectional view of another example of the developer amount regulation blade structure of  FIG. 4 .  FIG. 12  is a fragmentary sectional view of another example of the developer amount regulation blade structure of  FIG. 4 . 
   In example 3 described above, the cylindrical projections  11 B are formed by press processing. On the other hand, as shown in  FIG. 10 , the cylindrical projections  11 B are formed by emboss processing. In example 4, the cylindrical projections  11 B are formed by burring processing. Mild steel plate, e.g., galvanized sheet iron is used for forming the first supporting member  11  and the second supporting member  12 . A SUS may be used for forming the second supporting member  12 . The penetration holes  12 A having a diameter greater than an outer diameter of the cylindrical projections  11 B and having a diameter smaller than a diameter of the penetration holes  13 A are formed in the second supporting member  12  at positions corresponding to the cylindrical projections  11 B. The penetration holes  13 A having a diameter greater than the outer diameter of the cylindrical projections  11 B are formed in the regulation blade  13  at the positions corresponding to the cylindrical projections  11 B. 
   The regulation blade  13  is located between the first supporting member  11  and the second supporting member  12 . As shown in  FIG. 12 , the heads  11 C of the cylindrical projections  11 B deforms to extrude outside by punch processing (not shown). Therefore, the regulation blade  13  is tightened between the first supporting member  11  and the second supporting member  12 . Openings of the cylindrical projections  11 B are covered with a strip of tape to prevent attachment of toner. 
   In this example 4, the first supporting member  11  has the cylindrical projections  11 B and the penetration holes  12 A are formed in the second supporting member  12 . Alternatively, however, the second supporting member  12  may have the cylindrical projections  11 B and the penetration holes  12 A may be formed in the first supporting member  11 . 
   It should be noted that, in the above-described embodiments, descriptions are provided using examples in which the subject matter of the present disclosure is applied to the electrophotographic image forming apparatus. However, it is to be understood that the subject matter of the present disclosure may be applied to other image forming apparatuses such as printers, facsimiles and so forth, and also to a multi-functional image forming apparatus. 
   The embodiments being thus described, it should be apparent to one skilled in the art after reading this patent specification that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, and all such modifications as would be apparent to one skilled in the art are intended to be included within the scope of the following claims.