Developer bearing member, method for producing developer bearing member, developing device, image-forming apparatus, and computer system

A developer bearing member for bearing toner, the developer bearing member having a multitude of depressions on its surface, and each of the depressions has a multitude of protrusions on its surface. A method for forming the developer bearing member where a surface of the developer bearing member is treated by a blasting treatment, an etching treatment, and electroless plating. Alternatively, the surface of the developer bearing member can be treated with a blasting treatment using particles having a multitude of depressions.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority upon Japanese Patent Application No. 2002-62329 filed Mar. 7, 2002, Japanese Patent Application No. 2002-62330 filed Mar. 7, 2002, and Japanese Patent Application No. 2002-62331 filed Mar. 7, 2002, which are herein incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a developer bearing member, a method for producing a developer bearing member, a developing device, an image-forming apparatus, and a computer system.

2. Description of the Related Art

As one type of an image-forming apparatus, there is known an apparatus comprising a rotary-type developing unit. This rotary-type developing unit comprises a plurality of developing devices arranged radially about its axis of rotation. The developing devices are capable of developing a latent image formed on a photoconductor using developer, such as toner. When an image signal is transmitted from an external device such as a host computer, the image-forming apparatus makes the developing unit rotate about its axis of rotation in order to locate one of the plurality of developing devices in a developing position opposing the photoconductor. A toner image is formed by developing the latent image formed on the photoconductor, and the image is transferred to an intermediate medium. A color image is formed by superimposing the plurality of toner images, by sequentially changing the plurality of developing devices and repeating the above-mentioned developing and transferring processes.

(1) In order to realize such functions as to develop a latent image formed on a photoconductor as mentioned above, a developing device comprises, for example: a developing roller, which serves as a developer bearing member for bearing toner; a toner reservoir; a toner supplying roller; and a restriction blade. In order to enhance performance for bearing and/or delivering toner, a multitude of depressions are formed on the surface of the developing roller. These depressions can be formed by, for example, blasting using spherical particles, such as glass beads, and the like.

If the surface roughness of the depressions formed by blasting or other methods is small (in other words, if the surface of each depression is not so rough), a situation may occur in which the “tumbling property” of the toner bore by the depressions deteriorates (in other words, the toner will not tumble sufficiently in the depressions). Such a situation occurs because the area of contact between the toner and the surface of the depression is large due to the fact that the surface roughness of the depressions is not sufficient.

The deterioration of the tumbling property may bring about various problems. For example, when the toner carried (bore) by the developing roller is charged by a developer charging member, such as the restriction blade, there is a problem that the toner charge is not sufficient due to the deterioration in the tumbling property. Another example may be that, when the toner remaining on the developing roller after development of the latent image is to be stripped off by a developer stripping member, such as the toner supplying roller, the toner cannot be stripped off sufficiently due to the deterioration in the tumbling property.

Therefore, a way of improving the tumbling property of the toner has been desired.

(2) Further, as explained later, a multitude of protrusions may be provided on the surface of the depressions as a method of avoiding deterioration of the tumbling property of toner. By providing these protrusions, the surface of the depressions will become coarse, and since the area of contact between the toner and the surface of the depression will become smaller, it becomes possible to improve the tumbling property of the toner.

Among the toner particles, there exist so-called “pulverized toners”. A “pulverized toner” is smaller than toners having a particle size sufficient for developing the latent image formed on an image bearing member. These pulverized toners tend to be produced particularly when manufacturing toner according to the grinding method. Pulverized toners will increasingly be produced if a lubricant is mixed to the toner, since the toner becomes susceptible to cracking.

When toner is bore by the developing roller, there is a possibility that the toner (and mainly the pulverized toner) gets trapped between the protrusions. In this case, there is a possibility that the toner will keep accumulating at the same position on the surface of the developing roller, and degradation of toner will proceed, causing problems such as the so-called “filming phenomenon”.

In order to avoid such a situation, a way of preventing the toner (mainly the pulverized toner) from getting trapped in the developing roller has been desired.

(3) Meanwhile, in order to realize functions such as to develop a latent image formed on a photoconductor as mentioned above, another type of developing device comprises, for example, a developing roller, which serves as a developer bearing member for bearing toner, and a toner supplying roller and a restriction blade, which serve as an abutting member that abuts against (or contacts) the developing roller. In order to enhance performance for bearing and/or delivering toner, a multitude of depressions are formed on the surface of the developing roller. These depressions can be formed according to, for example, a blasting treatment using spherical particles, such as glass beads, and the like.

If the surface roughness of the depressions formed by blasting or other methods is small (in other words, if the surface of each depression is not so rough), a situation may occur in which the “tumbling property” of the toner, which is bore by the developing roller, at the abutting section where the abutting member and the developing roller abut against each other deteriorates (in other words, the toner will not tumble sufficiently in the depressions). Such a situation occurs because the area of contact between the toner and the surface of the depression is large due to the fact that the surface roughness of the depressions is not sufficient.

The deterioration of the tumbling property may bring about various problems. For example, when the toner bore by the developing roller is charged by a developer charging member (which also serves as the above-mentioned abutting member) at the abutting section where the developer charging member and the developing roller abut against each other, there is a problem that the toner charge is not sufficient due to the deterioration in the tumbling property. Another example may be that, when the toner remaining on the developing roller after development of the latent image is to be stripped off by a developer stripping member (which also serves as the above-mentioned abutting member) at the abutting section where the developer stripping member and the developing roller abut against each other, the toner cannot be stripped off sufficiently due to the deterioration in the tumbling property.

Therefore, a way of improving the tumbling property of the toner has been desired.

SUMMARY OF THE INVENTION

The present invention has been contrived in view of the above and other problems, and an object thereof is to provide a developer bearing member, a method for producing a developer bearing member, a developing device, an image-forming apparatus, and a computer system, which improve the tumbling property of a developer as well as prevent the developer from getting trapped in the developer bearing member.

According to an aspect of the present invention, in a developer bearing member for bearing toner, the developer bearing member has a multitude of depressions on its surface, and each of the depressions has a multitude of protrusions on its surface.

According to another aspect of the present invention, a developing device comprises: toner having at least two peaks in particle-size distribution in which particle-number distribution is adopted as a distribution reference, and in which a particle size of the toner that constitutes a largest peak among the peaks is larger than a particle size of the toner that constitutes a second largest peak among the peaks; and a movable developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface, the developing device being capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member, each of the depressions having a multitude of protrusions on its surface, and a diameter of the protrusions of the developer bearing member in its moving direction being smaller than the particle size of the toner that constitutes the second largest peak.

According to another aspect of the present invention, a developing device comprises: toner; a developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface; and an abutting member capable of abutting against the developer bearing member, the developing device being capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member, and each of the depressions having a multitude of protrusions on its surface.

Features of the present invention other than the above will become clear by the description of the present specification with reference to the accompanying drawings.

DETAILED DESCRIPTION OF THE INVENTION

At least the following matters will be made clear by the explanation in the present specification and the description of the accompanying drawings.

One aspect of the present invention is a developer bearing member for bearing toner, wherein the developer bearing member has a multitude of depressions on its surface, and each of the depressions has a multitude of protrusions on its surface.

Since the depressions each have a multitude of protrusions on its surface, it becomes possible to improve the tumbling property of the toner.

It is further preferable if a diameter of the depressions is 80 μm or less, and more preferably, 20 μm to 30 m.

In this way, it becomes possible to make the depression sufficiently exert its ability to carry the developer (toner).

It is further preferable if a diameter of the protrusions is 7 μm or less, and more preferably, 0.5 μm to 1.5 μm.

In this way, it becomes possible to provide an ideal contact area between the developer (toner) and the surface of the depressions.

The depressions may be formed by treating the surface of the developer bearing member with a blasting treatment.

In this way, it becomes possible to form a rough surface having a smooth sectional form with only a few cracks in the developer bearing member surface.

The protrusions may be formed by using particles having a multitude of depressions for the blasting treatment.

In this way, it becomes possible to significantly lessen the number of post-treatments carried out after the blasting treatment of the developer bearing member surface, thereby reducing the manufacturing cost of the developer bearing member.

The multitude of depressions of the particles may be formed by treating the surface of the particles with an etching treatment.

In this way, it becomes possible to easily form a multitude of depressions of the particles.

The protrusions may be formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating.

In this way, since it becomes possible to fill the cracks, which have been formed by the blasting treatment of the developer bearing member surface, with the plating, it becomes possible to avoid problems such as the “filming phenomenon” caused by the developer (toner) being trapped (or buried) in the cracks, and also form fine protrusions in the depressions, which have been formed by the blasting, due to the growth of the plating in the protruding direction.

The protrusions may be formed by, after treating the surface of the developer bearing member with the blasting treatment, allowing particles that are smaller than the particles used for the blasting treatment to adhere to the surface of the depressions formed by the blasting treatment.

In this way, it becomes possible to easily adjust the size of the protrusions simply by appropriately selecting the particles that are made to adhere to the surface of the depressions formed by the blasting treatment.

The material for the developer bearing member may be aluminum alloy.

In this way, it becomes possible to reduce manufacturing cost of the developer bearing member because of the inexpensiveness of the material as well as make a developing equipment light in weight.

The material for the developer bearing member may be iron alloy.

In this way, it becomes possible to reduce wear of the protrusions and depressions on the developer bearing member surface through long-term use due to the high hardness characteristic of the material.

Another aspect of the present invention is a developer bearing member for bearing toner, wherein: the developer bearing member has a multitude of depressions on its surface; each of the depressions has a multitude of protrusions on its surface; a diameter of the depressions is 80 μm or less; a diameter of the protrusions is 7 μm or less; the depressions are formed by treating the surface of the developer bearing member with a blasting treatment; the protrusions are formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating; and the material for the developer bearing member is iron alloy.

In this way, since almost all of the above-mentioned effects can be achieved, an object of the present invention can further effectively be achieved.

Another aspect of the present invention is a method for producing a developer bearing member comprising: treating the surface of the developer bearing member with a blasting treatment using particles having a multitude of depressions.

According to such a method, it becomes possible to significantly lessen the number of post-treatments carried out after the blasting treatment of the developer bearing member surface, thereby reducing the manufacturing cost of the developer bearing member.

Another aspect of the present invention is a method for producing a developer bearing member comprising: treating the surface of the developer bearing member with a blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating.

According to such a method, since it becomes possible to fill the cracks, which have been formed by the blasting treatment of the developer bearing member surface, with the plating, it becomes possible to avoid problems such as the “filming phenomenon” caused by the developer (toner) being trapped (or buried) in the cracks, and also form fine protrusions in the depressions, which have been formed by the blasting, due to the growth of the plating in the protruding direction.

Another aspect of the present invention is a method for producing a developer bearing member comprising: treating the surface of the developer bearing member with a blasting treatment, and allowing particles that are smaller than particles used for the blasting treatment to adhere to the surface of the depressions formed by the blasting treatment.

According to such a method, it becomes possible to easily adjust the size of the protrusions simply by appropriately selecting the particles that are made to adhere to the surface of the depressions formed by the blasting treatment.

Another aspect of the present invention is a developing device comprising a developer bearing member for bearing toner, wherein the developer bearing member has a multitude of depressions on its surface, and each of the depressions has a multitude of protrusions on its surface.

According to such a developing device, since the depressions each have a multitude of protrusions on its surface, it becomes possible to improve the tumbling property of the developer (toner).

Another aspect of the present invention is an image-forming apparatus comprising a developer bearing member for bearing toner, wherein the developer bearing member has a multitude of depressions on its surface, and each of the depressions has a multitude of protrusions on its surface.

According to such an image-forming apparatus, since the depressions each have a multitude of protrusions on its surface, it becomes possible to improve the tumbling property of the developer (toner).

Another aspect of the present invention is a computer system comprising: a computer; a display device that can be connected to the computer; and an image-forming apparatus that can be connected to the computer and that comprises a developer bearing member for bearing toner, wherein the developer bearing member has a multitude of depressions on its surface, and each of the depressions has a multitude of protrusions on its surface.

In a computer system realized as above, the system, as a whole, will be superior to a usual system.

Another aspect of the present invention is a developing device comprising: toner having at least two peaks in particle-size distribution in which particle-number distribution is adopted as a distribution reference, and in which a particle size of the toner that constitutes a largest peak among the peaks is larger than a particle size of the toner that constitutes a second largest peak among the peaks; and a movable developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface, the developing device being capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member, each of the depressions having a multitude of protrusions on its surface, and a diameter of the protrusions of the developer bearing member in its moving direction being smaller than the particle size of the toner that constitutes the second largest peak.

Since the depressions each have a multitude of protrusions on its surface and the diameter of the protrusions of the developer bearing member in its moving direction is smaller than the particle size of the developer (toner) that constitutes the second largest peak, it becomes possible to reduce occurrence of a situation in which the developer (toner) gets trapped by the developer bearing member.

It is further preferable if the diameter of the protrusions is 7 μm or less, and more preferably, 0.5 μm to 1.5 μm.

In this way, it becomes possible to provide an ideal contact surface between the developer (toner) and the surface of the depressions.

A diameter of the depressions of the developer bearing member in its moving direction may be larger than the particle size of the toner that constitutes the largest peak.

In this way, it becomes possible to provide a sufficient interval for the developer (toner), which has the size suitable for developing a latent image formed on an image bearing member, to tumble in the depressions.

It is further preferable if the diameter of the depressions is 80 μm or less, and more preferably, 20 μm to 30 μm.

In this way, it becomes possible to make the depression sufficiently exert its ability to carry the developer (toner).

The toner may be produced according to a grinding method.

In this way, since there is a tendency that so-called pulverized developer (toner) is easily produced, the above-mentioned effect of reducing occurrence of a situation in which the developer (toner) gets trapped by the developer bearing member becomes further noticeable and effective.

The toner may comprise a lubricant.

In this way, since the developer (toner) tends to break (chip) and there is a tendency that so-called pulverized developer (toner) is easily produced when the toner comprises a lubricant, the above-mentioned effect of reducing occurrence of a situation in which the developer (toner) gets trapped by the developer bearing member becomes further noticeable and effective.

The lubricant may have non-miscibility to the toner.

In this way, since there is a tendency that so-called pulverized developer (toner) is easily produced due to strengthening of the property of the developer (toner) of tending to break (chip), the above-mentioned effect of reducing occurrence of a situation in which the developer (toner) gets trapped by the developer bearing member becomes further noticeable and effective.

The depressions may be formed by treating the surface of the developer bearing member with a blasting treatment.

In this way, it becomes possible to form a rough surface having a smooth sectional form with only a few cracks in the developer bearing member surface.

The protrusions may be formed by using particles having a multitude of depressions for the blasting treatment.

In this way, it becomes possible to significantly lessen the number of post-treatments carried out after the blasting treatment of the developer bearing member surface, thereby reducing the manufacturing cost of the developer bearing member.

The multitude of depressions of the particles may be formed by treating the surface of the particles with an etching treatment.

In this way, it becomes possible to easily form a multitude of depressions of the particles.

The protrusions may be formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating.

In this way, since it becomes possible to fill the cracks, which have been formed by the blasting treatment of the developer bearing member surface, with the plating, it becomes possible to avoid problems such as the “filming phenomenon” caused by the developer (toner) being trapped (or buried) in the cracks, and also form fine protrusions in the depressions, which have been formed by the blasting, due to the growth of the plating in the protruding direction.

The protrusions may be formed by, after treating the surface of the developer bearing member with the blasting treatment, allowing particles that are smaller than the particles used for the blasting treatment to adhere to the surface of the depressions formed by the blasting treatment.

In this way, it becomes possible to easily adjust the size of the protrusions simply by appropriately selecting the particles that are made to adhere to the surface of the depressions formed by the blasting treatment.

The material for the developer bearing member may be aluminum alloy.

In this way, it becomes possible to reduce manufacturing cost of the developer bearing member due to inexpensiveness of the material as well as make a developing equipment light in weight.

The material for the developer bearing member may be iron alloy.

In this way, it becomes possible to reduce wear of the protrusions and depressions on the developer bearing member surface through long-term use due to the high hardness characteristic of the material.

Another aspect of the present invention is a developing device, wherein: the developing device comprises toner having at least two peaks in particle-size distribution in which particle-number distribution is adopted as a distribution reference, and in which a particle size of the toner that constitutes a largest peak among the peaks is larger than a particle size of the toner that constitutes a second largest peak among the peaks, and a movable developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface; the developing device is capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member; each of the depressions has a multitude of protrusions on its surface; a diameter of the protrusions of the developer bearing member in its moving direction is smaller than the particle size of the toner that constitutes the second largest peak; the diameter of the protrusions is 7 μm or less; a diameter of the depressions of the developer bearing member in its moving direction is larger than the particle size of the toner that constitutes the largest peak; the diameter of the depressions is 80 μm or less; the toner is produced according to a grinding method and comprises a lubricant; the lubricant has non-miscibility to the toner; the depressions are formed by treating the surface of the developer bearing member with a blasting treatment; the protrusions are formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating; and the material for the developer bearing member is iron alloy.

In this way, since almost all of the above-mentioned effects can be achieved, an object of the present invention can further effectively be achieved.

Another aspect of the present invention is an image-forming apparatus comprising a developing device, wherein: the developing device comprises toner having at least two peaks in particle-size distribution in which particle-number distribution is adopted as a distribution reference, and in which a particle size of the toner that constitutes a largest peak among the peaks is larger than a particle size of the toner that constitutes a second largest peak among the peaks, and a movable developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface; the developing device is capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member; each of the depressions has a multitude of protrusions on its surface; and a diameter of the protrusions of the developer bearing member in its moving direction is smaller than the particle size of the toner that constitutes the second largest peak.

Since the depressions each have a multitude of protrusions on its surface and the diameter of the protrusions of the developer bearing member in its moving direction is smaller than the particle size of the developer (toner) that constitutes the second largest peak, it becomes possible to reduce occurrence of a situation in which the developer (toner) gets trapped by the developer bearing member.

Another aspect of the present invention is a computer system comprising: a computer; a display device that can be connected to the computer; and an image-forming apparatus that can be connected to the computer and that comprises a developing device, wherein the developing device comprises: toner having at least two peaks in particle-size distribution in which particle-number distribution is adopted as a distribution reference, and in which a particle size of the toner that constitutes a largest peak among the peaks is larger than a particle size of the toner that constitutes a second largest peak among the peaks; and a movable developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface, the developing device is capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member, each of the depressions has a multitude of protrusions on its surface, and a diameter of the protrusions of the developer bearing member in its moving direction is smaller than the particle size of the toner that constitutes the second largest peak.

In a computer system realized as above, the system, as a whole, will be superior to a usual system.

Another aspect of the present invention is a developing device comprising: toner; a developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface; and an abutting member capable of abutting against the developer bearing member, the developing device being capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member, and each of the depressions having a multitude of protrusions on its surface.

Since the depressions each have a multitude of protrusions on its surface, it becomes possible to improve the tumbling property of the developer (toner).

The abutting member may be a developer charging member for charging the toner bore by the developer bearing member.

In this way, it becomes possible to solve the problem that the developer (toner) charge is insufficient due to deterioration of the tumbling property of the developer (toner).

The developer bearing member may be movable, and a ten-points average roughness of the developer bearing member in its moving direction may be larger than a ten-points average roughness of the developer charging member on a side used for charging and in a direction towards a tip end of the developer charging member.

In this way, it becomes possible for the developer bearing member to sufficiently exert its ability to carry the developer (toner).

The developer charging member may be capable of restricting the thickness of the toner bore by the developer bearing member.

In this way, it becomes possible to appropriately restrict the thickness of the developer (toner) that has been sufficiently charged.

The abutting member may be a developer stripping member for stripping the toner bore by the developer bearing member off.

In this way, it becomes possible to solve the problem that the developer (toner) cannot sufficiently be stripped off due to deterioration of the tumbling property of the developer (toner).

The developer stripping member may have a foamed elastic body on its surface, the developer bearing member may be movable, and a diameter size of the depressions of the developer bearing member in its moving direction may be equal to or smaller than a size of a cell diameter of the foamed elastic body.

In this way, since it is possible to strip the developer (toner) bore by the developer bearing member of f by securely catch the developer (toner) with the cells provided on the formed elastic body, it becomes possible to further appropriately solve the problem that the developer (toner) cannot sufficiently be stripped off due to deterioration of the tumbling property of the developer (toner).

The developer stripping member may be capable of supplying the toner to the developer bearing member.

In this way, since it is possible to repeat developer (toner) supplying and developer (toner) stripping with the stripping member in an ideal manner, the developer (toner) bore by the developer bearing member and the developer (toner) contained in a developer reservoir will be circulated appropriately, thereby enabling effective prevention of problems such as the so-called “hysteresis”.

The developer stripping member and the developer bearing member may be rotatable, and the rotating direction of the developer stripping member may be in the opposite direction of the rotating direction of the developer bearing member.

In this way, the above-mentioned effect (that is, the effect of being able to solve the problem that the developer (toner) stripping is insufficient) becomes further noticeable and effective.

The toner may be produced according to a grinding method.

In this way, since spherical developer (toner) particles are difficult to make and the tumbling performance of the developer (toner) therefore becomes insufficient if the developer (toner) is produced according to the grinding method, the above-mentioned effect (that is, the effect of being able to improve the tumbling property of the developer (toner)) becomes further noticeable and effective.

The toner may comprise a lubricant.

In this way, since the tumbling property of the developer (toner) will become insufficient if the developer (toner) comprises a lubricant, the above-mentioned effect (that is, the effect of being able to improve the tumbling property of the developer (toner)) becomes further noticeable and effective.

A latent image bore by the image bearing member may be developed with the toner according to the projection development system.

In this way, the above-mentioned effect (that is, the effect of being able to improve the tumbling property of the toner) becomes further noticeable and effective. The reason to this will be explained later.

It is further preferable if a diameter of the depressions is 80 μm or less, and more preferably, 20 μm to 30 μm.

In this way, it becomes possible to make the depression sufficiently exert its ability to carry the developer (toner).

The depressions may be formed by treating the surface of the developer bearing member with a blasting treatment.

In this way, it becomes possible to form a rough surface having a smooth sectional form with only a few cracks in the developer bearing member surface.

The protrusions may be formed by using particles having a multitude of depressions for the blasting treatment.

In this way, it becomes possible to significantly lessen the number of post-treatments carried out after the blasting treatment of the developer bearing member surface, thereby reducing the manufacturing cost of the developer bearing member.

The multitude of depressions of the particles may be formed by treating the surface of the particles with an etching treatment.

In this way, it becomes possible to easily form a multitude of depressions of the particles.

The protrusions may be formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating.

In this way, since it becomes possible to fill the cracks, which have been formed by the blasting treatment of the developer bearing member surface, with the plating, it becomes possible to avoid problems such as the “filming phenomenon” caused by the developer (toner) being trapped (or buried) in the cracks, and also form fine protrusions in the depressions, which have been formed by the blasting, due to the growth of the plating in the protruding direction.

The protrusions may be formed by, after treating the surface of the developer bearing member with the blasting treatment, allowing particles that are smaller than the particles used for the blasting treatment to adhere to the surface of the depressions formed by the blasting treatment.

In this way, it becomes possible to easily adjust the size of the protrusions simply by appropriately selecting the particles that are made to adhere to the surface of the depressions formed by the blasting treatment.

The material for the developer bearing member may be aluminum alloy.

In this way, it becomes possible to reduce manufacturing cost of the developer bearing member due to inexpensiveness of the material as well as make a developing equipment light in weight.

The material for the developer bearing member may be iron alloy.

In this way, it becomes possible to reduce wear of the protrusions and depressions on the developer bearing member surface through long-term use due to the high hardness characteristic of the material.

Another aspect of the present invention is a developing device, wherein: the developing device comprises toner, a developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface, and an abutting member capable of abutting against the developer bearing member; the developing device is capable of developing a latent image with the toner bore by the developer bearing member according to the projection development system, the latent image being bore by an image bearing member; each of the depressions has a multitude of protrusions on its surface; the abutting member is a developer charging member for charging the toner bore by the developer bearing member; the developer bearing member is rotatable; a ten-points average roughness of the developer bearing member in its rotating direction is larger than a ten-points average roughness of the developer charging member on a side used for charging and in a direction towards a tip end of the developer charging member; the developer charging member is capable of restricting the thickness of the toner bore by the developer bearing member; the abutting member is a developer stripping member for stripping the toner bore by the developer bearing member off; the developer stripping member has a foamed elastic body on its surface; a diameter size of the depressions of the developer bearing member in its rotating direction is equal to or smaller than a size of a cell diameter of the foamed elastic body; the developer stripping member is capable of supplying the toner to the developer bearing member; the developer stripping member is rotatable; the rotating direction of the developer stripping member is in the opposite direction of the rotating direction of the developer bearing member; the toner is produced according to a grinding method and comprises a lubricant; a diameter of the depressions is 80 μm or less; a diameter of the protrusions is 7 μm or less; the depressions are formed by treating the surface of the developer bearing member with a blasting treatment; the protrusions are formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating; and the material for the developer bearing member is iron alloy.

In this way, since almost all of the above-mentioned effects can be achieved, an object of the present invention can further effectively be achieved.

Another aspect of the present invention is an image-forming apparatus comprising a developing device, wherein: the developing device comprises toner, a developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface, and an abutting member capable of abutting against the developer bearing member; the developing device is capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member; and each of the depressions has a multitude of protrusions on its surface.

According to such an image-forming apparatus, since the depressions each have a multitude of protrusions on its surface, it becomes possible to improve the tumbling property of the developer (toner).

Another aspect of the present invention is a computer system comprising: a computer; a display device that can be connected to the computer; and an image-forming apparatus that can be connected to the computer and that comprises a developing device, wherein the developing device comprises: toner; a developer bearing member for bearing the toner, the developer bearing member having a multitude of depressions on its surface; and an abutting member capable of abutting against the developer bearing member, the developing device is capable of developing a latent image with the toner bore by the developer bearing member, the latent image being bore by an image bearing member, and each of the depressions has a multitude of protrusions on its surface.

In a computer system realized as above, the system, as a whole, will be superior to a usual system.

===Example of Overall Configuration of Image-Forming Apparatus===

Next, with reference toFIG. 1, explanation will be made of an outline of an image-forming apparatus, taking a laser-beam printer10(hereinafter referred to also as “printer”) as an example.FIG. 1is a diagram showing some main structural components constructing the printer10. InFIG. 1, the vertical direction is shown by the arrow; for example, a paper-feed tray92is arranged at a lower section of the printer10, and a fusing unit90is arranged at an upper section of the printer10.

As shown inFIG. 1, the printer10according to the present embodiment comprises the following components in the circumferential (rotating) direction of a photoconductor20, which is an example of an image bearing member carrying a latent image: a charging unit30; an exposing unit40; a YMCK developing unit50; a first transferring unit60; an intermediate transferring element70; and a cleaning head75. The printer10further comprises: a second transferring unit80; a fusing unit90; a displaying unit95comprising a liquid-crystal display and serving as notifying means to a user; and a controlling unit (FIG. 2) for controlling these units and the like and managing the operations as a printer.

The photoconductor20comprises a cylindrical, conductive base and a photoconductive layer formed on its outer peripheral surface, and is rotatable about a central axis. In the present embodiment, the photoconductor20rotates clockwise, as shown by the arrow in FIG.1.

The charging unit30is a device for charging the photoconductor20. The exposing unit40is a device for forming a latent image on the charged photoconductor20by radiation of laser. The exposing unit40comprises, for example, a semiconductor laser, a polygon mirror, an F-θ lens, and the like, and radiates modulated laser onto the charged photoconductor20according to the image signal having been input from the host computer (not shown) such as a personal computer, a word processor, and the like.

The YMCK developing unit50is a device for developing the latent image formed on the photoconductor20using toner (as an example of developer) contained in each of the developing devices, that is, yellow (Y) toner, magenta (M) toner, cyan (C) toner, and black (K) toner. The black (K) toner is contained in a black developing device51, the magenta (M) toner is contained in a magenta developing device52, the cyan (C) toner is contained in a cyan developing device53, and the yellow (Y) toner is contained in a yellow developing device54.

In the present embodiment, the YMCK developing unit50can move the positions of the four developing devices51,52,53,54through rotation. More specifically, the YMCK developing unit50holds the four developing devices51,52,53,54with four holders, or holding sections,55a,55b,55c,55d. The four developing devices51,52,53,54can be rotated about a rotating shaft50a, which is an axis of rotation, while maintaining their relative positions. The photoconductor20rotates several times, and every time the photoconductor20finishes forming an image for 1 page, the developing devices51,52,53,54selectively oppose the photoconductor20. Accordingly, the latent image formed on the photoconductor20is developed by the toner contained respectively in the developing devices51,52,53,54.

The first transferring unit60is a device for transferring a single-color toner image formed on the photoconductor20onto the intermediate transferring element70. When the toners of all four colors are sequentially transferred in a superimposing manner, a full-color toner image will be formed on the intermediate transferring element70. The intermediate transferring element70is an endless (annular) belt, and is rotatingly driven at substantially the same circumferential speed as the photoconductor20. The second transferring unit80is a device for transferring the single-color toner image or the full-color toner image formed on the intermediate transferring element70onto a recording medium, such as paper, film, cloth, and the like.

The fusing unit90is a device for fusing, to the recording medium such as paper, the single-color toner image or the full-color toner image which has been transferred onto the recording medium, to make it into a permanent image.

The cleaning unit75is a device which is provided between the first transferring unit60and the charging unit30, has a rubber cleaning blade76placed in contact with (or, abutting against) the surface of the photoconductor20, and can remove the toner remaining on the photoconductor20by scraping it off with the cleaning blade76after the toner image has been transferred onto the intermediate transferring element70by the first transferring unit60.

The controlling unit100comprises a main controller101and a unit controller102as shown in FIG.2. An image signal is input to the main controller101; according to instructions based on the image signal, the unit controller102controls each of the above-mentioned units and the like, to form an image.

Next, explanation will be made of operations of the printer10structured as above, with reference to other structural components.

First, when an image signal is input from the host computer (not shown) to the main controller101of the printer10through an interface (I/F)112, the photoconductor20, a developing roller provided on the developing device as an example of a “developer bearing member”, and the intermediate transferring element70rotate under the control of the unit controller102based on the instructions from the main controller101. While rotated, the photoconductor20is sequentially charged by the charging unit30at a charging position.

With the rotation of the photoconductor20, the charged area of the photoconductor20reaches an exposure position. A latent image in accordance with image information about the first color, such as yellow Y, is formed in the charged area by the exposing unit40. The YMCK developing unit50locates the yellow developing device54containing yellow (Y) toner in a developing position opposing the photoconductor20.

With the rotation of the photoconductor20, the latent image formed on the photoconductor20reaches the developing position, and is developed with the yellow toner by the yellow developing device54. Thus, a yellow toner image is formed on the photoconductor20.

With the rotation of the photoconductor20, the yellow toner image formed on the photoconductor20reaches a first transferring position, and is transferred onto the intermediate transferring element70by the first transferring unit60.

Here, a first transferring voltage, having an opposite polarity from the charge polarity of the toner, is applied to the first transferring unit60. During the above, the second transferring unit80is kept apart from the intermediate transferring element70.

By repeating the above-mentioned process for the second, the third, and the fourth colors, toner images in four colors corresponding to the respective image signals are transferred to the intermediate transferring element70in a superimposed manner. As a result, a full-color toner image is formed on the intermediate transferring element70.

With the rotation of the intermediate transferring element70, the full-color toner image formed on the intermediate transferring element70reaches a second transferring position, and is transferred onto a recording medium by the second transferring unit80. The recording medium is carried from the paper-feed tray92to the second transferring unit80through the paper-feed roller94and resisting rollers96. While the image is being transferred, a second transferring voltage is applied to the second transferring unit80as the unit80is pressed against the intermediate transferring element70.

The full-color toner image transferred onto the recording medium is heated and pressurized by the fusing unit90and fused to the recording medium.

On the other hand, after the photoconductor20passes the first transferring position, the toner attaching to the surface of the photoconductor20is scraped off by the cleaning blade76that is supported to the cleaning unit75, and the photoconductor20is prepared for charging for forming a next latent image. The scraped-off toner is collected in a remaining-toner collector that the cleaning unit75comprises.

===Configuration Example of Developing Device===

Next, with reference toFIG. 3, explanation will be made of an example of a configuration of the developing device.FIG. 3is a section view showing some main structural components of the developing device. As inFIG. 1, inFIG. 3, the arrow indicates the vertical directions; for example, the central axis of the developing roller510(which is an example of a “developer bearing member”) is located below the central axis of the photoconductor20. Further,FIG. 3shows a state in which the yellow developing device54is located in the developing position opposing the photoconductor20.

The YMCK developing unit50comprises: the black developing device51containing black (K) toner; the magenta developing device52containing magenta (M) toner; the cyan developing device53containing cyan (C) toner; and the yellow developing device54containing yellow (Y) toner. Since the configuration of each of the developing devices is the same, explanation will be made only of the yellow developing device54.

The yellow developing device54comprises: the developing roller510, which serves as a “developer bearing member”; a sealing member520; a toner reservoir530; a frame540; a toner-supplying roller550, which serves as a “developer stripping member”; a restriction blade560, which serves as a “developer charging member”; and a blade-backing member570for impelling the restriction blade560.

The developing roller510carries toner T, which is an example of a “developer”, and delivers it to a developing position opposing the photoconductor20. The developing roller510is made from, for example, aluminum alloy such as aluminum alloy5056or aluminum alloy6063, and iron alloy such as STKM, and the roller510is plated with, for example, nickel plating, chromium plating and the like, as necessary. Further, the developing roller510is rotatable about a central axis. As shown inFIG. 3, the roller510rotates in the opposite direction (counterclockwise inFIG. 3) of the rotating direction of the photoconductor20(clockwise in FIG.3). The central axis of the roller510is located below the central axis of the photoconductor20. As shown inFIG. 3, in the state where the yellow developing device54opposes the photoconductor20, there exists a gap between the developing roller510and the photoconductor20. That is, the yellow developing device54develops the latent image formed on the photoconductor20in a non-contacting state.

Note that an alternating field is generated between the developing roller510and the photoconductor20upon developing the latent image formed on the photoconductor20. That is, in the present embodiment, the latent image bore by the photoconductor20is developed with the toner T according to projection development (sometimes called the “Jumping Development Method”).

The sealing member520prevents the toner T in the yellow developing device54from escaping out therefrom, and also collects the toner T, which is on the developing roller510that has passed the developing position, into the developing device without scraping. The sealing member520is a seal made from, for example, polyethylene film and the like. The sealing member520is supported by a seal-supporting metal plate522, and is attached to the frame540through the seal-supporting metal plate522. On the opposite side of the side of the developing roller510, the sealing member520is provided with a seal-impelling member524made from, for example, Moltoprene and the like. The sealing member520is pressed against the developing roller510by the elastic force of the seal-impelling member524. Note that an abutting position at which the sealing member520abuts against the developing roller510is above the central axis of the developing roller510.

The toner reservoir530is a section for receiving (containing) the toner T; a portion of the frame540structures the reservoir530. A stirring member for stirring the toner T contained in the toner reservoir530may be provided. However, in the present embodiment, each of the developing devices (the black developing device51, the magenta developing device52, the cyan developing device53, and the yellow developing device54) rotate with the rotation of the YMCK developing unit50, and the toner T contained in each developing device is stirred therewith; thus, the toner reservoir530does not comprise a stirring member.

The toner-supplying roller550has functions to supply the toner T contained in the toner reservoir530(described later) to the developing roller510and to strip the toner remaining on the developing roller510after development off from the developing roller510. The toner-supplying roller550is made from, for example, polyurethane foam and the like, and is in contact with the developing roller510in an elastically-deformed state. The toner-supplying roller550is arranged at a lower section of the toner reservoir530. The toner T contained in the toner reservoir530is supplied to the developing roller510by the toner-supplying roller550at the lower section of the toner reservoir530. The toner-supplying roller550is rotatable about a central axis. The central axis is situated below the central axis of rotation of the developing roller510. Further, the toner-supplying roller550rotates in the opposite direction (clockwise inFIG. 3) of the rotating direction of the developing roller510(counterclockwise in FIG.3).

As mentioned above, the toner supplying roller550is made from foamed elastic body such as polyurethane foam. The foamed elastic body has a multitude of cells (“foam pores”), which are not shown in the drawings. These cells serve to enhance the performance related to carrying and/or delivering of toner T. In the present embodiment, the toner supplying roller550is structured so that the size of the depressions of the developing roller510in its moving direction is equal to or smaller than the “cell diameter” of the foamed elastic body. In the present specification, the term “cell diameter” indicates an average value of the diameters of cells obtained by, for example: photographing the surface of the toner supplying roller550with, for example, a scanning electron microscope (SEM); measuring the diameter of ten cells that have been randomly selected from the photograph; and, calculating the average of the diameters for eight of the cells, omitting the cell having the largest diameter and the cell having the smallest diameter, to obtain the above-mentioned average value.

The restriction blade560gives charge to the toner T bore by the developing roller510and also restricts the thickness of the layer of the toner T bore by the developing roller510. The restriction blade560comprises a rubber portion560aand a rubber-supporting portion560b. The rubber portion560ais made from, for example, silicone rubber, urethane rubber, and the like. The rubber-supporting portion560bis a thin plate made from, for example, phosphor bronze, stainless steel, and the like having a springy characteristic. The rubber portion560ais supported by the rubber-supporting portion560b. The rubber-supporting portion560bis attached to the frame540through a pair of blade-supporting metal plates562, in a way such that one end of the rubber-supporting portion560bis pinched between the blade-supporting metal plates562. On the opposite side from the side of the developing roller510, the restriction blade560is provided with a blade-backing member570made from Moltoprene and the like.

The rubber portion560ais pressed against the developing roller510by the elastic force caused by bending of the rubber-supporting portion560b. Further, the blade-backing member570prevents toner from entering between the rubber-supporting portion560band the frame540so as to stabilize the elastic force caused by bending of the rubber-supporting portion560b, and also impels the rubber portion560afrom the back thereof towards the developing roller510to press the rubber portion560aagainst the developing roller510. Thus, the blade-backing member570can make the rubber portion560aabut against the developing roller510more evenly.

The other end of the restricting blade560that is not being supported by the blade-supporting metal plates562(i.e., the tip end of the restriction blade560) does not contact the developing roller510; rather, a section at a predetermined distance from the tip end contacts, with some breadth, the developing roller510. In other words, the restriction blade560does not abut against the developing roller510with its end, but abuts against the roller510near its central portion. Further, the restriction blade560is arranged so that its tip end faces towards the upper stream of the rotating direction of the developing roller510, and thus, makes a so-called counter-contact with respect to the roller510. Note that a abutting position at which the restriction blade560abuts against the developing roller510is below the central axis of the developing roller510and also below the central axis of the toner-supplying roller550.

Further, the surface roughness of the developing roller510at, for example, the section where the restriction blade560and the developing roller510contact each other is larger than the surface roughness of the surface of the restriction blade560used for charging. (In other words, the surface of the developing roller510is rougher than the surface of the restriction blade560with which charging is performed). More specifically, the ten-points average roughness (according to JIS B 0610) of the developing roller510(in its moving direction) is larger than the ten-points average roughness (in the direction from the sandwiched end towards the tip end) of the surface of the restriction blade560on the side used for charging.

The frame540is manufactured by joining a plurality of integrally-molded frames (for example, an upper frame, a bottom frame, and the like). The frame540has an opening at its lower section. The developing roller510is arranged at the opening in a state in which a portion of the roller510is exposed.

In the yellow developing device54thus structured, the toner-supplying roller550supplies the toner T contained in the toner reservoir530to the developing roller510. Having been supplied to the developing roller510, with the rotation of the developing roller510, the toner T reaches the abutting position of the restriction blade560; and, as the toner T passes the abutting position, the toner is charged and its thickness is restricted. Having its thickness being restricted, with further rotation of the developing roller510, the toner T on the developing roller510reaches the developing position opposing the photoconductor20; and under the alternating field, the toner T is used for developing the latent image formed on the photoconductor20at the developing position. Having passed the developing position, with further rotation of the developing roller510, the toner T on the developing roller510passes the sealing member520and is collected into the developing device by the sealing member520without being scraped off. Then, the toner still remaining on the developing roller510can be stripped off by the toner supplying roller550.

Next, with reference toFIG. 2, explanation will be made of the configuration of the controlling unit100. The main controller101of the controlling unit100is connected to the host computer through an interface (I/F)112and comprises an image memory113for storing image signals input from the host computer. The unit controller102is electrically connected to each of the units of the printer apparatus (i.e., the charging unit30, the exposing unit40, the YMCK developing unit50, the first transferring unit60, the cleaning unit75, the second transferring unit80, the fusing unit90, and the displaying unit95). By receiving signals from sensors provided on each of the units, the unit controller102detects the state of each unit; the unit controller102also controls each unit according to the signals input from the main controller101.

Next, explanation will be made of an example of the toner T according to the present embodiment. The toner T comprises a core particle and external additives (fine particles on the toner surface). The core particle and external additives are made to adhere to each-other by dry mixing using, for example, mixers using mechanochemical methods or high-speed fluid mixers, such as a Henschel mixer and a Papenmeier mixer. The toner T may either have negative or positive polarity.

The core particle comprises materials such as coloring agents (pigments), charge control agents, lubricants (WAX), and resin. The core particle can be made according to grinding methods such as the kneading-and-grinding method, using the above materials. The core particle can instead be made according to methods such as the spray-dry method and polymerization method. Note that the core particle can further include, for example, dispersing agents, magnetic materials, and other additives.

It is possible to use, for example, one or more of the following materials listed below as charge control agents: electron acceptor organic complexes; chlorinated polyethers; nitrohumic acid; quaternary ammonium salts; and pyridinyl salts.

The following materials can preferably be used as the lubricants (WAX): low molecular-weight polypropylene; low molecular-weight polyethylene; ethylene bis-amide; microcrystalline wax; carnauba wax; and paraffin waxes such as bees wax. However, the material used for the lubricant is not limited to the above, and other materials can be used as long as it is not miscible to the core particle of the toner and stays separate therefrom. Note that, in the present embodiment, “not miscible” indicates a state in which the lubricant disperses in the core particle like islands without being taken into the resin chain when melted and mixed.

Further, note that, in order to prevent the toner T from adhering to the fusing roller during the fusing process, there are cases in which oil is coated on the fusing roller. However, in the present embodiment, the core particle is made to contain a large amount of the lubricant in order to omit oil coating. The content of the lubricant is 3-10 wt % to the amount of resin.

It is possible to use, for example, metallic soaps and polyethylene glycol as dispersing agents. As other additives, it is possible to use, for example, zinc stearate, zinc oxide, and ceric oxide.

It is possible to use, for example, one or more of the following materials listed below as magnetic materials: metal powder such as Fe, Co, Ni, Cr, Mn, and Zn; metal oxides such as Fe3O4, Fe2O3, Cr2O3, and ferrites; and alloys displaying ferromagnetism, such as alloys containing Mn and acid and being treated with heat. The magnetic material may be pretreated with, for example, a coupling agent.

It is possible to use, as the external additives, various materials whose surface has been treated to have hydrophobic characteristics. In the present embodiment, silica is used as the external additive of the toner T. However, other than silica, it is possible to use both inorganic particles and organic particles. The inorganic particles may be, for example, particles of metal oxides, such as aluminum oxide, titanium oxide, strontium titanate, ceric oxide, magnesium oxide, and chromium oxide; particles of nitrides, such as silicon nitride; particles of carbides, such as silicon carbide; particles of metal salts, such as calcium sulfate, barium sulfate, and calcium carbonate; and materials obtained by combining the above. The organic particles may be, for example, particles of acrylic resin. Further, it is possible to use, as surface treatment agents for treating the surface of the external additives, silane coupling agents, titanate coupling agents, fluorine-containing silane coupling agents, and silicone oil. It is preferable that the hydrophobic ratio of the external additives having been treated with the above-mentioned treatment agents is 60% or higher when the ratio is measured according to a conventional methanol method. If the ratio is lower than the above-mentioned value, deterioration in the charging characteristic and fluidity will easily occur in a hot and wet environment owning to adsorption of moisture. It is preferable that the particle size of the external additives is 0.001 μm to 1 μm from a viewpoint of improving a carrying and charging characteristics. Further, the number of kinds of the external additives is not limited to one, but two or more kinds of external additives may be used in combination.

Next, explanation will be made of a method for analyzing the toner with reference to FIG.4and FIG.5.

FIG. 4is a diagram explaining the toner analysis method according to the present embodiment.FIG. 5is a diagram showing the results of toner analysis according to the present embodiment.

Different from the well-known “pore passage” method, the toner analysis method according to the present embodiment enables analysis of toner particles having a particle size of equal to or smaller than 1 μm. Further, different from the Scanning Electron Microscope (SEM), the method according to the present embodiment enables quantitative analysis of, for example, physical properties of each of the toner particles. It can be stated that the toner analysis method according to the present embodiment is far more superior to the conventional methods.

The toner analysis method according to the present embodiment uses an aerosizer, which is a dry particle-size distribution analyzer, as an analyzer. Note that a “Model 3225 Aerosizer DSP” from TSI Incorporated can be used as the aerosizer.

According to this toner analysis method, the speed at which the particles fly through a supersonic flow is measured, and the particle-size distribution is analyzed based on the results of the measurement.

As shown inFIG. 4, when two sections having different pressures are connected with a nozzle, the air flows from the section having high pressure to the section having low pressure. If the pressure ratio between the high-pressure section and the low-pressure section is high, a supersonic area is created in the shock wave, which is called “barrel shock”, due to expansion of air at the nozzle outlet. This supersonic area ends as a planar shock wave known as the “Mach disk”.

Being carried on the sheath-air flow, the toner particles that have entered the nozzle are ejected, one by one, from the nozzle to the ultraspeed area. The toner particles having a small diameter accelerate approximately to the air flow speed due to the attraction between air and the toner particles; on the other hand, acceleration of the large toner particles decreases because their volumes are large (“aerodynamic separation”).

At the ultraspeed area at the nozzle tip, two laser beams (first laser beam, second laser beam) are arranged at a 1 mm interval. The toner particles ejected into the ultraspeed area first pass across the first laser beam and then across the second laser beam.

According to the analysis method of the present embodiment, measurement is made of the “time of flight”, that is, the time it takes for a toner particle to first fly across the first laser beam and then across the second laser beam, or in other words, the time it takes for a toner particle to fly between the two laser beams according to the correlation method, and then the particle size of the toner is analyzed according to the density of the toner particle and from a calibration curve indicating the “time of flight” in relation to the particle size.

FIG. 5shows the analysis results for the toner according to the present embodiment analyzed according to the method explained above.FIG. 5shows a particle-size distribution of the toner, in which particle number distribution is adopted as the distribution reference. The lateral axis (abscissa) indicates “particle size” and the vertical axis (ordinate) indicates the particle number frequency for each of the particle sizes. Note that details on the particle-size distribution of the toner, in which particle-number distribution is adopted as a distribution reference as shown inFIG. 5, will be explained in detail later.

===First Embodiment of Surface Structure of Developing Roller and Method for Producing the Same===

Next, with reference toFIG. 6, FIG.7A throughFIG. 7E, and FIG.8A andFIG. 8B, explanation will be made of an embodiment of the surface structure of a developing roller and a method for producing the same.FIG. 6is a diagram schematically showing the structure of the surface of the developing roller510according to the present embodiment. FIG.7A throughFIG. 7Eare diagrams schematically showing an example of how the surface structure of the developing roller510, according to the present embodiment, changes during production of the surface structure of the roller. Explanation of FIG.8A andFIG. 8Bwill be made later.

First, reference is made to FIG.6. As it is apparent from the figure, the developing roller510according to the present embodiment has a multitude of depressions on its surface. (Note that, in order to make it easy to understand, only five depressions are shown inFIG. 6.) Further, each of the depressions has a multitude of protrusions on its surface.

From the viewpoint of making the depression sufficiently exert its ability to carry toner, it is preferable that the diameter of the depressions is 80 μm or less, and more preferably, 20 μm to 30 μm.

Further, from the viewpoint of providing an ideal contact area between the toner and the surface of the depressions, it is preferable that the diameter of the protrusions is 7 μm or less, and more preferably, 0.5 μm to 1.5 μm. It is preferable to provide the diameter of the protrusions in the above-mentioned size because if the diameter of the protrusions is too large, the “tumbling property” (as explained above) of the toner located between the adjacent protrusions will deteriorate.

Such a surface structure of the developing roller510can be produced according to the process explained below.

First, the surface of the developing roller510is subjected to a blasting treatment using spherical particles. More specifically, glass beads are used as the spherical particles, which are the material to be blasted, and these glass beads are sprayed from a blast nozzle to the surface of the developing roller510for a given amount of time at a given pressure. According to this treatment, a multitude of depressions are formed on the surface of the developing roller510as shown in FIG.7A and FIG.7B. (As inFIG. 6, only five of the depressions are shown in FIG.7B.) Note that in the present embodiment, depressions having a diameter of 20 μm to 30 μm are formed using glass beads having a particle size of 80 μm to 120 μm as the material to be blasted. (Depressions having a diameter of 20 μm and 30 μm are shown inFIG. 7B.) Note that the spherical particles are not limited to the glass beads used in the present embodiment.

Next, the surface of the developing roller510is cleaned and dried. Then, the surface of the roller510is subjected to etching. In the present embodiment, sulfuric acid is used as the reagent for etching. However, other reagent, such as nitric acid, phosphoric acid, and hydrofluoric acid, can be used. Further, in the present embodiment, the surface of the roller510is immersed into the reagent for 20 seconds. Note that, although the time for etching is not limited to a certain amount of time, it is preferable to treat the surface for 10 seconds to 50 seconds.

As shown in FIG.7C andFIG. 7D, as a result of the etching, the surface of the developing roller510is corroded, and a multitude of small pores are formed on the surface of the roller510. (Note that, in order to make it easy to understand, among the five depressions shown inFIG. 7B, only the depression on the left is shown inFIG. 7C.)

Then, a pretreatment is carried out on the surface of the roller510to form a zinc alloy film thereon. Next, the surface is subjected to electroless plating. Although electroless Ni—P plating is used in the present embodiment, it is also possible to use other kinds of plating, such as electroless Ni—B plating, electroless Pd—P plating, electroless Cr plating. Further, the plating thickness is approximately 4 μm in the present embodiment. Note that, although the plating thickness is not limited to a certain amount, it is preferable that the thickness is 3 μm to 5 μm.

As shown in FIG.7D andFIG. 7E, as a result of the electroless plating, the plating grows, taking the small pores formed by etching as cores, thereby forming a multitude of protrusions on the surface of the depressions. In other words, due to the difference in the size of the small pores formed in the depressions by the etching treatment, there will be a difference in the speed of growth of the plating on the surface of the depressions depending on the size of the small pores, thereby forming a multitude of protrusions on the depressions.

Note that the size of the protrusion depends on, for example, the size of the small pore formed in the depression. The size of the small pore depends on, for example, the amount of time for the etching treatment. As explained above, the surface of the developing roller510is immersed into the reagent for 20 seconds in the present embodiment. In this case, protrusions having a diameter of 0.5 μm to 1.5 μm will be formed. (InFIG. 7E, protrusions having diameters of 0.8 μm and 1 μm are shown.)

Next, reference is made to FIG.8. FIG.8A andFIG. 8Bare views showing results of observing the surface of the developing roller510, which has been subjected to the electroless plating, with a Scanning Electron Microscope (SEM). FIG.8A andFIG. 8Bshow views taken at different magnifications; more specifically,FIG. 8Bis an enlarged view showing a portion (mainly the depressions) of the surface shown in FIG.8A. As seen inFIG. 8A, on the surface of the developing roller510, there are a multitude of depressions formed by the above-mentioned blasting treatment. Note that the two depressions shown inFIG. 8Aaccompany their diameters (20 μm and 25 μm).

Further, note that the term “diameter” of the depression is used herein in two meanings: (1) if a depression of concern is specified, as the diameters of the two depressions shown inFIG. 8A, the term “diameter” will indicate the diameter of the specified depression; and (2) in other cases, the term “diameter” will indicate an average value of the diameters of depressions obtained by, for example: photographing the surface of the developing roller510, having a multitude of depressions, with a scanning electron microscope (SEM); measuring the diameter of ten depressions that have been randomly selected from the photograph; and, calculating the average of the diameters for eight of the depressions, omitting the depression having the largest diameter and the depression having the smallest diameter, to obtain the above-mentioned average value.

Further, as shown in FIG.8A andFIG. 8B, there are a multitude of protrusions on the surface of each of the depressions. InFIG. 8B, one of the protrusions accompanies its diameter.

Note that the term “diameter” of the protrusion is used herein in two meanings: (1) if a protrusion of concern is specified, as the diameter of the protrusion shown inFIG. 8B, the term “diameter” will indicate the diameter of the specified protrusion; and (2) in other cases, the term “diameter” will indicate an average value of the diameters of protrusions obtained by, for example: photographing the surface of the developing roller510, having a multitude of protrusions, with a scanning electron microscope (SEM); measuring the diameter of ten protrusions that have been randomly selected from the photograph; and, calculating the average of the diameters for eight of the protrusions, omitting the protrusion having the largest diameter and the protrusion having the smallest diameter, to obtain the above-mentioned average value.

<Another Embodiment for Producing the Surface Structure>

Next, explanation will be made of another method for producing the surface structure of the developing roller510.

In the embodiment explained above, the surface of the developing roller510was treated with a blasting treatment using spherical particles. In the present embodiment, the spherical particles used for the blasting treatment will be treated in advance. That is, the surface of each of the spherical particles, used for the blasting treatment, is treated with an etching treatment. As a result of the etching, the surface of each of the spherical particles is corroded, and a multitude of small pores, as depressions, are formed on the surface of the particles.

Then, the spherical particles with the small pores are sprayed from the blast nozzle to the surface of the developing roller510, as explained above. As a result of this treatment, a multitude of depressions will be formed in the surface of the developing roller510, and also, on each of the depressions, a multitude of protrusions will be formed. More specifically, the small pores formed in the surface of the spherical particles serve to form the protrusions on each of the depressions, which are formed in the surface of the developing roller510.

Note that, also in the present embodiment, it is possible to obtain depressions having a diameter of 20 μm to 30 μm by using, as the material to be blasted, spherical particles having a particle size of 80 μm to 120 μm. Further, by adjusting the amount of time for the etching treatment, it is possible to adjust the size of the small pores formed in the spherical particles and to obtain protrusions having a diameter of 0.5 μm to 1.5 μm.

<Another Embodiment for Producing Surface Structure>

Further, there are other methods for producing the surface structure of the developing roller510. For example, it is possible to first treat the surface of the roller510with the blasting treatment, and then allow particles, which are smaller than the particles used for the first blasting treatment, adhere to the surface of the depressions formed by the first blasting treatment.

For example, after treating the surface of the developing roller510with the blasting treatment, a coating treatment is carried out by spraying a coating agent, comprising fine particles, onto the surface of the roller510. Through these treatments, a multitude of depressions will be formed in the surface of the developing roller510, and also, on each of the depressions, a multitude of protrusions will be formed. More specifically, the fine particles contained in the coating agent will form the protrusions on the depressions of the surface of the developing roller510.

Note that, also in the present embodiment, it is possible to obtain depressions having a diameter of 20 μm to 30 μm by using, as the material to be blasted, spherical particles having a particle size of 80 μm to 120 μm. Further, by appropriately selecting the type of coating agent that comprises fine particles of the appropriate size, it is possible to obtain protrusions having a diameter of 0.5 μm to 1.5 μm.

By providing a multitude of protrusions on the surface of each of the depressions of the surface of the developing roller510as explained above, it becomes possible to improve the tumbling property of the toner.

More specifically, as explained in the “Description of the Related Art”, if the surface roughness of the depressions formed by blasting treatment etc., a situation in which the tumbling property of the toner carried by the depressions deteriorates may occur. Such a situation occurs because the area of contact between the toner and the surface of the depression is large due to the fact that the surface roughness of the depressions is not sufficient. The deterioration of the tumbling property may bring about various problems: for example, when the toner bore by the developing roller is charged by a developer charging member, such as the restriction blade, the toner charge is not sufficient due to the deterioration in the tumbling property, or, when the toner remaining on the developing roller after development of the latent image is to be stripped off by a developer stripping member, such as the toner supplying roller, the toner cannot be stripped off sufficiently due to the deterioration in the tumbling property.

In view of the above, by providing a multitude of protrusions on the surface of each of the depressions of the developing roller510, it becomes possible to increase the roughness of the surface of the depressions and decrease the area of contact between the toner and the surface of the depression. As a result, it becomes possible to enhance the tumbling property of the toner and solve the above-mentioned and other problems.

In other words, as explained in the “Description of the Related Art”, if the surface roughness of the depressions formed by blasting or other methods is small (in other words, if the surface of each depression is not so rough), a situation may occur in which the “tumbling property” of the toner, which is bore by the developing roller, at the abutting section where the abutting member and the developing roller abut against each other deteriorates (in other words, the toner will not tumble sufficiently in the depressions). Such a situation occurs because the area of contact between the toner and the surface of the depression is large due to the fact that the surface roughness of the depressions is not sufficient.

The deterioration of the tumbling property may bring about a problem that the toner charge will not be sufficient, if the above-mentioned abutting member serves as the developer charging member, such as the restriction blade560, or in other words, if the above-mentioned developer charging member is to charge the toner, bore by the developing roller, at the abutting section where the developer charging member and the developing roller510abut against each other. In other words, if the tumbling property of the toner is not sufficient, the position at which the toner contacts the developer charging member and/or the developing roller510will become fixed, and the charging of the toner caused by such a contact will be impeded.

Such an insufficient toner charge may cause problems such as toner scattering, fogging, and toner-fall-off.

Further, the deterioration of the tumbling property may bring about a problem that the toner will not be stripped off sufficiently, if the above-mentioned abutting member serves as the developer stripping member, such as the toner supplying roller550, or in other words, if the above-mentioned developer stripping member is to strip the toner, remaining on the developing roller, off at the abutting section, where the developer stripping member and the developing roller510abut against each other, after development.

Such an insufficient toner-stripping may give rise to a situation in which the toner keeps on accumulating at the same position on the developing roller surface and toner deterioration proceeds, which may cause problems such as the so-called “filming phenomenon”. Further, since the toner keeps on accumulating at the same position on the developing roller surface, the toner on the developing roller and the toner contained in the toner reservoir will not be circulated appropriately, and this may cause problems such as the so-called “hysteresis”.

In view of the above, by providing a multitude of protrusions on the surface of each of the depressions of the developing roller510, it becomes possible to increase the roughness of the surface of the depressions and decrease the area of contact between the toner and the surface of the depression. As a result, it becomes possible to enhance the tumbling property of the toner and solve the above-mentioned and other problems.

===Second Embodiment of Surface Structure of Developing Roller and Method for Producing the Same===

Next, with reference toFIG. 5,FIG. 6, FIG.7A throughFIG. 7E, FIG.8A andFIG. 8B, and FIG.9A andFIG. 9B, explanation will be made of another embodiment of the surface structure of a developing roller and a method for producing the same.

<Details on the Toner According to the Present Embodiment>

With reference toFIG. 5, explanation will be made of details on the toner according to the present embodiment.

The toner according to the present embodiment is produced according to a grinding method and comprises a lubricant. If the toner is produced with the grinding method, there is a tendency that so-called pulverized toner, which are smaller than the toner with a size suitable for developing a latent image formed on the photoconductor20, is produced. Further, the toner tends to break (chip) when it contains a lubricant. This will cause a further increase in the amount of the pulverized toner.

In view of the above, the toner according to the present embodiment is made so that it has at least two peaks (P1, P2in the figure) in particle-size distribution in which particle-number distribution is adopted as a distribution reference, and that a particle size of the toner that constitutes the largest peak (P1in the figure) is larger than a particle size of the toner that constitutes the second largest peak (P2in the figure). That is, the toner with the size suitable for developing a latent image formed on the photoconductor20will constitute the largest peak (P1in the figure), and the pulverized toner will constitute the second largest peak (P2in the figure).

As seen inFIG. 5, as regards the toner according to the present embodiment, the particle size of the toner that constitutes the largest peak (P1in the figure) is approximately 8.5 μm, and the particle size of the toner that constitutes the second largest peak (P2in the figure) is approximately 1.6 μm.

<Example of Surface Structure of Developing Roller and Method for Producing the Same>

Next, with reference toFIG. 6, FIG.7A throughFIG. 7E, and FIG.8A andFIG. 8B, explanation will be made of an embodiment of the surface structure of a developing roller and a method for producing the same.FIG. 6is a diagram schematically showing the structure of the surface of the developing roller510according to the present embodiment. FIG.7A throughFIG. 7Eare diagrams schematically showing an example of how the surface structure of the developing roller510, according to the present embodiment, changes during production of the surface structure of the roller. Explanation of FIG.8A andFIG. 8Bwill be made later.

First, reference is made to FIG.6. As it is apparent from the figure, the developing roller510according to the present embodiment has a multitude of depressions on its surface. (Note that, in order to make it easy to understand, only five depressions are shown inFIG. 6.) Further, each of the depressions has a multitude of protrusions on its surface.

From the viewpoint of making the depression sufficiently exert its ability to carry toner, it is preferable that the diameter of the depressions is 80 μm or less, and more preferably, 20 μm to 30 μm.

Further, the toner is made so that the diameter of the depressions of the developing roller510in its rotating direction is larger than the particle size of the toner that constitutes the largest peak.

Further, from the viewpoint of providing an ideal contact area between the toner and the surface of the depressions, it is preferable that the diameter of the protrusions is 7 μm or less, and more preferably, 0.5 μm to 1.5 μm. It is preferable to provide the diameter of the protrusions in the above-mentioned size because if the diameter of the protrusions is too large, the “tumbling property” (as explained above) of the toner located between the adjacent protrusions will deteriorate.

Further, the toner is made so that the diameter of the protrusions of the developing roller510in its rotating direction is smaller than the particle size of the toner that constitutes the second largest peak.

Note that the method for forming the depressions and protrusions having the above-mentioned diameter will be explained later.

Next, explanation will be made of the method for producing such a surface structure of the developing roller510.

First, the surface of the developing roller510is subjected to a blasting treatment using spherical particles. More specifically, glass beads are used as the spherical particles, which are the material to be blasted, and these glass beads are sprayed from a blast nozzle to the surface of the developing roller510for a given amount of time at a given pressure. According to this treatment, a multitude of depressions are formed on the surface of the developing roller510as shown in FIG.7A and FIG.7B. (As inFIG. 6, only five of the depressions are shown inFIG. 7B.)

Note that, it is possible to obtain depressions with a desired diameter by appropriately selecting the glass beads that have a particle size suiting the desired diameter of the depressions. In the present embodiment, depressions having a diameter of 20 μm to 30 μm are formed using glass beads having a particle size of 80 μm to 120 μm as the material to be blasted. (Depressions having a diameter of 20 μm and 30 μm are shown inFIG. 7B.) As explained above, as regards the toner according to the present embodiment, since the particle size of the toner that constitutes the largest peak (P1in the figure) is approximately 8.5 μm, the diameter of the depressions are larger than the particle size of the toner that constitutes the largest peak.

Note that the spherical particles are not limited to the glass beads used in the present embodiment.

Next, the surface of the developing roller510is cleaned and dried. Then, the surface of the roller510is subjected to etching. In the present embodiment, sulfuric acid is used as the reagent for etching. However, other reagent, such as nitric acid, phosphoric acid, and hydrofluoric acid, can be used. Further, in the present embodiment, the surface of the roller510is immersed into the reagent for 20 seconds. Note that, although the time for etching is not limited to a certain amount of time, it is preferable to treat the surface for 10 seconds to 50 seconds.

As shown in FIG.7C andFIG. 7D, as a result of the etching, the surface of the developing roller510is corroded, and a multitude of small pores are formed on the surface of the roller510. (Note that, in order to make it easy to understand, among the five depressions shown inFIG. 7B, only the depression on the left is shown inFIG. 7C.)

Then, a pretreatment is carried out on the surface of the roller510to form a zinc alloy film thereon. Next, the surface is subjected to electroless plating. Although electroless Ni—P plating is used in the present embodiment, it is also possible to use other kinds of plating, such as electroless Ni—B plating, electroless Pd—P plating, electroless Cr plating. Further, the plating thickness is approximately 4 μm in the present embodiment. Note that, although the plating thickness is not limited to a certain amount, it is preferable that the thickness is 3 μm to 5 μm.

As shown in FIG.7D andFIG. 7E, as a result of the electroless plating, the plating grows, taking the small pores formed by etching as cores, thereby forming a multitude of protrusions on the surface of the depressions. In other words, due to the difference in the size of the small pores formed in the depressions by the etching treatment, there will be a difference in the speed of growth of the plating on the surface of the depressions depending on the size of the small pores, thereby forming a multitude of protrusions on the depressions.

Note that the size of the protrusion depends on, for example, the size of the small pore formed in the depression. The size of the small pore depends on, for example, the amount of time for the etching treatment. As explained above, the surface of the developing roller510is immersed into the reagent for 20 seconds in the present embodiment. In this case, protrusions having a diameter of 0.5 μm to 1.5 μm will be formed. (InFIG. 7E, protrusions having diameters of 0.8 μm and 1 μm are shown.) As explained above, as regards the toner according to the present embodiment, since the particle size of the toner that constitutes the second largest peak (P2in the figure) is approximately 1.6 μm, the diameter of the protrusions are smaller than the particle size of the toner that constitutes the second largest peak.

Next, reference is made to FIG.8. FIG.8A andFIG. 8Bare views showing results of observing the surface of the developing roller510, which has been subjected to the electroless plating, with a Scanning Electron Microscope (SEM). FIG.8A andFIG. 8Bshow views taken at different magnifications; more specifically,FIG. 8Bis an enlarged view showing a portion (mainly the depressions) of the surface shown in FIG.8A. As seen inFIG. 8A, on the surface of the developing roller510, there are a multitude of depressions formed by the above-mentioned blasting treatment. Note that the two depressions shown inFIG. 8Aaccompany their diameters (20 μm and 25 μm).

Further, note that the term “diameter” of the depression is used herein in two meanings: (1) if a depression of concern is specified, as the diameters of the two depressions shown inFIG. 8A, the term “diameter” will indicate the diameter of the specified depression; and (2) in other cases, the term “diameter” will indicate an average value of the diameters of depressions obtained by, for example: photographing the surface of the developing roller510, having a multitude of depressions, with a scanning electron microscope (SEM); measuring the diameter of ten depressions that have been randomly selected from the photograph; and, calculating the average of the diameters for eight of the depressions, omitting the depression having the largest diameter and the depression having the smallest diameter, to obtain the above-mentioned average value.

Further, as shown in FIG.8A andFIG. 8B, there are a multitude of protrusions on the surface of each of the depressions. InFIG. 8B, one of the protrusions accompanies its diameter.

Note that the term “diameter” of the protrusion is used herein in two meanings: (1) if a protrusion of concern is specified, as the diameter of the protrusion shown inFIG. 8B, the term “diameter” will indicate the diameter of the specified protrusion; and (2) in other cases, the term “diameter” will indicate an average value of the diameters of protrusions obtained by, for example: photographing the surface of the developing roller510, having a multitude of protrusions, with a scanning electron microscope (SEM); measuring the diameter of ten protrusions that have been randomly selected from the photograph; and, calculating the average of the diameters for eight of the protrusions, omitting the protrusion having the largest diameter and the protrusion having the smallest diameter, to obtain the above-mentioned average value.

<Another Embodiment for Producing the Surface Structure>

Next, explanation will be made of another method for producing the surface structure of the developing roller510.

In the embodiment explained above, the surface of the developing roller510was treated with a blasting treatment using spherical particles. In the present embodiment, the spherical particles used for the blasting treatment will be treated in advance. That is, the surface of each of the spherical particles, used for the blasting treatment, is treated with an etching treatment. As a result of the etching, the surface of each of the spherical particles is corroded, and a multitude of small pores, as depressions, are formed on the surface of the particles.

Then, the spherical particles with the small pores are sprayed from the blast nozzle to the surface of the developing roller510, as explained above. As a result of this treatment, a multitude of depressions will be formed in the surface of the developing roller510, and also, on each of the depressions, a multitude of protrusions will be formed. More specifically, the small pores formed in the surface of the spherical particles serve to form the protrusions on each of the depressions, which are formed in the surface of the developing roller510.

Note that, also in the present embodiment, it is possible to obtain depressions having a diameter of 20 μm to 30 μm by using, as the material to be blasted, spherical particles having a particle size of 80 μm to 120 μm. Further, by adjusting the amount of time for the etching treatment, it is possible to adjust the size of the small pores formed in the spherical particles and to obtain protrusions having a diameter of 0.5 μm to 1.5 μm.

<Another Embodiment for Producing Surface Structure>

Further, there are other methods for producing the surface structure of the developing roller510. For example, it is possible to first treat the surface of the roller510with the blasting treatment, and then allow particles, which are smaller than the particles used for the first blasting treatment, adhere to the surface of the depressions formed by the first blasting treatment.

For example, after treating the surface of the developing roller510with the blasting treatment, a coating treatment is carried out by spraying a coating agent, comprising fine particles, onto the surface of the roller510. Through these treatments, a multitude of depressions will be formed in the surface of the developing roller510, and also, on each of the depressions, a multitude of protrusions will be formed. More specifically, the fine particles contained in the coating agent will form the protrusions on the depressions of the surface of the developing roller510.

Note that, also in the present embodiment, it is possible to obtain depressions having a diameter of 20 μm to 30 μm by using, as the material to be blasted, spherical particles having a particle size of 80 μm to 120 μm. Further, by appropriately selecting the type of coating agent that comprises fine particles of the appropriate size, it is possible to obtain protrusions having a diameter of 0.5 μm to 1.5 μm.

By forming a multitude of protrusions on the surface of the depressions and making the diameter of the protrusions of the developing roller510in its rotating direction smaller than the particle size of the toner that constitutes the second largest peak, it becomes possible to reduce occurrence of a situation in which the toner gets trapped by the developing roller510.

This will be explained in further detail with reference to FIG.9A and FIG.9B. FIG.9A andFIG. 9Bare schematic diagrams showing how the pulverized toner will be arranged on the surface of the depressions formed in the developing roller510.

As shown inFIG. 9A, if the diameter of the protrusions are larger than the particle size of the toner that constitutes the second largest peak, there is a possibility that the pulverized toner, which constitutes the second largest peak, will fit into (or get trapped between) the space between the adjacent protrusions. In such a situation, the toner will keep on accumulating at the same position on the developing roller surface and toner deterioration will proceed, which may cause problems such as the so-called “filming phenomenon”

On the contrary, if the diameter of the protrusions are smaller than the particle size of the toner that constitutes the second largest peak as in the present embodiment, the pulverized toner, which constitutes the second largest peak, will not fit into (or get trapped between) the space between the adjacent protrusions and will be in a state being carried on the protrusions, as shown in FIG.9B.

In this way, it becomes possible to reduce the number of the toner that gets trapped between the protrusions. In other words, it becomes possible to reduce occurrence of a situation in which the toner gets trapped by the developing roller510.

Above, explanation was made of a developing device, a developer bearing member, and so on, according to the present invention based on various embodiments. However, the above-mentioned embodiments of the invention are merely examples for facilitating understanding of the present invention, and are not to limit the scope of the present invention. It is without saying that the present invention may be altered and/or modified without departing from the scope thereof, and that the present invention includes its equivalents.

In the above-explained embodiment, explanation was made of a full-color laser-beam printer of the intermediate-transferring type as an example of an image-forming apparatus. However, the present invention is applicable to various image-forming apparatuses such as full-color laser-beam printers other than the intermediate-transferring type, single-color laser-beam printers, photocopiers, facsimile machines, and the like.

Further, the photoconductor is not limited to the so-called photoconductive roller structured by providing a photoconductive layer on the outer peripheral surface of a cylindrical, conductive base; it can be a so-called photoconductive belt structured by providing a photoconductive layer on a surface of a belt-like conductive base.

Further, in some of the above-mentioned embodiments, the diameter of the depressions of the developing roller in its rotating direction is larger than the particle size of the toner that constitutes the largest peak. However, the structure is not limited to the above.

However, according to such a structure, since it is possible to provide a sufficient interval for the toner, which has the size suitable for developing a latent image formed on the photoconductor, to tumble in the depressions, occurrence of problems, such as that the toner charge will be insufficient as explained in the “Description of the Related Art”, can be reduced. Further, since the possibility that the toner will get trapped by the depressions is low, occurrence of problems, such as the so-called filming phenomenon, can be reduced. The above-mentioned structure is therefore preferable.

Further, in some of the above-mentioned embodiments, the developer is produced according to a grinding method. However, the structure is not limited to the above. For example, the toner can be made according to a spray-dry method or a polymerization method.

However, note that the structure according to the above-mentioned embodiment is preferable because, since there is a tendency that so-called pulverized toner, which are smaller than the toner with a size suitable for developing a latent image formed on the photoconductor, is easily produced when the toner is produced according to the grinding method, the above-mentioned effect of reducing occurrence of a situation in which the toner gets trapped by the developing roller becomes further noticeable and effective.

Further, in some of the above-mentioned embodiments, the toner comprises a lubricant. However, the structure is not limited to the above.

However, since the toner tends to break (chip) and there is a tendency that so-called pulverized toner, which is smaller than the toner with a size suitable for developing a latent image formed on the photoconductor, is easily produced when the toner comprises a lubricant, the above-mentioned effect of reducing occurrence of a situation in which the toner gets trapped by the developing roller becomes further noticeable and effective.

Further, in some of the above-mentioned embodiments, the lubricant has non-miscibility to the toner. However, the structure is not limited to the above.

However, if the lubricant has non-miscibility to the toner, since there is a tendency that so-called pulverized toner, which is smaller than the toner with a size suitable for developing a latent image formed on the photoconductor, is easily produced due to strengthening of the property of the toner of tending to break (chip), the above-mentioned effect of reducing occurrence of a situation in which the toner gets trapped by the developing roller becomes further noticeable and effective.

Further, in some of the above-mentioned embodiments, the abutting member is the developer charging member for charging the toner bore by the developing roller. However, the structure is not limited to the above.

However, note that it is preferable to use the developer charging member as the abutting member because it becomes possible to solve the problem that the toner charge is insufficient due to deterioration of the tumbling property of the toner.

Further, in some of the above-mentioned embodiments, the developing roller is movable, and the ten-points average roughness (according to JIS B 0610) of the developing roller (in its moving direction) is larger than the ten-points average roughness (in the direction towards the tip end of the developer charging member) of the surface of the developer charging member on the side used for charging. However, the structure is not limited to the above.

However, note that the structure according to the above-mentioned embodiment is preferable because, since the toner can easily be bore by the developing roller rather than by the developer charging member by making the surface roughness of the developing roller larger than the surface roughness of the developer charging member, it becomes possible for the developing roller to sufficiently exert its ability to carry toner.

Further, in some of the above-mentioned embodiments, the developer charging member is capable of restricting the thickness of the toner bore by the developing roller. However, the structure is not limited to the above. For example, the developer charging member may be the above-mentioned toner supplying roller.

However, note that the structure according to the above-mentioned embodiment is preferable because it becomes possible to appropriately restrict the thickness of the toner that has been sufficiently charged.

Further, in some of the above-mentioned embodiments, the abutting member is the developer stripping member for stripping the toner bore by the developing roller off. However, the structure is not limited to the above.

However, note that the structure according to the above-mentioned embodiment is preferable because it becomes possible to solve the problem that the toner cannot sufficiently be stripped off due to deterioration of the tumbling property of the toner.

Further, in some of the above-mentioned embodiments, the developer stripping member has a foamed elastic body on its surface, the developing roller is movable, and the size of the diameter of the depressions of the developing roller in its moving direction is equal to or smaller than a cell diameter of the foamed elastic body. However, the structure is not limited to the above.

However, note that the structure according to the above-mentioned embodiment is preferable because, since it is possible to strip the toner bore by the developing roller off by securely catch the toner with the cells provided on the formed elastic body, it becomes possible to further appropriately solve the problem that the toner cannot sufficiently be stripped off due to deterioration of the tumbling property of the toner.

Further, in some of the above-mentioned embodiments, the developer stripping member is capable of supplying the toner to the developing roller. However, the structure is not limited to the above. For example, the developer stripping member can be the restriction blade explained above.

However, note that the structure according to the above-mentioned embodiment is preferable because, since it is possible to repeat toner supplying and toner stripping with the stripping member in an ideal manner, the toner bore by the developing roller and the toner contained in the toner reservoir will be circulated appropriately, thereby enabling effective prevention of problems such as the so-called “hysteresis”.

Further, in some of the above-mentioned embodiments, the developer stripping member and the developing roller are rotatable, and the rotating direction of the developer stripping member is in the opposite direction of the rotating direction of the developing roller. However, the structure is not limited to the above. For example, the rotating direction of the developer stripping member can be in the same direction as the rotating direction of the developing roller.

However, note that the structure according to the above-mentioned embodiment is preferable because, since the toner becomes difficult to strip off when the rotating direction of the developer stripping member is in the opposite direction of the rotating direction of the developing roller, compared with the case where the rotating directions are the same, the above-mentioned effect (that is, the effect of being able to solve the problem that the toner stripping is insufficient) becomes further noticeable and effective.

Further, in some of the above-mentioned embodiments, the toner is produced according to a grinding method. However, the structure is not limited to the above. For example, the toner can be made according to a spray-dry method or a polymerization method.

However, note that the structure according to the above-mentioned embodiment is preferable because, since spherical toner particles are difficult to make and the tumbling performance of the toner therefore becomes insufficient if the toner is produced according to the grinding method, the above-mentioned effect (that is, the effect of being able to improve the tumbling property of the toner) becomes further noticeable and effective.

Further, in some of the above-mentioned embodiments, the developer comprises a lubricant. However, the structure is not limited to the above.

However, note that the structure according to the above-mentioned embodiment is preferable because, since the tumbling property of the toner will become insufficient if the toner comprises a lubricant, the above-mentioned effect (that is, the effect of being able to improve the tumbling property of the toner) becomes further noticeable and effective.

Further, in some of the above-mentioned embodiments, a latent image bore by the photoconductor is developed with the toner according to the projection development system (sometimes called “jumping development method”). However, the method is not limited to the above.

However, note that the method according to the above-mentioned embodiment is preferable because the above-mentioned effect (that is, the effect of being able to improve the tumbling property of the toner) becomes further noticeable and effective. The reason to this is explained below.

If the tumbling property of the toner is not sufficient, it becomes difficult to tightly pack the toner on the developing roller and also to provide the toner in several layers on the developing roller. In such a situation, the absolute amount of toner to be transferred from the developing roller to the photoconductor will be insufficient. In order to solve this problem, it would be possible to increase the amount of toner supplied to the photoconductor by increasing the rotation speed of the developing roller. However, if the rotation speed of the developing roller is increased, the number of times that the toner jumps back and forth at the developing nip will not be sufficient in case the projection development system is adopted.

By improving the tumbling property of the toner, it will become unnecessary to increase the amount of toner supplied to the photoconductor by increasing the rotation speed of the developing roller. Therefore, the problem that the number of times the toner jumps back and forth at the developing nip is not sufficient will not occur, even when the projection development system is adopted.

Further, in some of the above-mentioned embodiments, the depressions are formed by treating the surface of the developing roller with a blasting treatment; however, the method of forming the depressions is not limited to the above.

However, note that the method according to the above-mentioned embodiment is preferable because, since it is possible to form a rough surface having a smooth sectional form with only a few cracks in the developing roller surface, it becomes possible to solve problems such as the “filming phenomenon” caused by the toner being trapped (or buried) in the cracks.

Further, in some of the above-mentioned embodiments, the protrusions are formed by using particles having a multitude of depressions (or small pores) for the blasting treatment; however, the method of forming the protrusions is not limited to the above.

However, note that the method according to the above-mentioned embodiment is preferable because, since it is possible to significantly lessen the number of post-treatments carried out after the blasting treatment of the developing roller surface, it becomes possible to reduce the manufacturing cost of the developing roller.

Further, in some of the above-mentioned embodiments, the multitude of depressions (small pores) in the particles are formed by treating the surface of the particles with an etching treatment; however, the method of forming the depressions is not limited to the above.

However, note that the method according to the above-mentioned embodiment is preferable because such a method will make it easy to form the multitude of depressions (small pores) in the particles.

Further, in some of the above-mentioned embodiments, the protrusions are formed by, after treating the surface of the developer bearing member with the blasting treatment, treating the surface of the developer bearing member with an etching treatment, and subjecting the surface of the developer bearing member to electroless plating. However, the method is not limited to the above.

However, note that the method according to the above-mentioned embodiment is preferable because, since it is possible to fill the cracks, which have been formed by the blasting treatment of the developer bearing member surface, with the plating, it becomes possible to avoid problems such as the “filming phenomenon” caused by the toner being trapped (or buried) in the cracks, and also form fine protrusions in the depressions, which have been formed by the blasting, due to the growth of the plating in the protruding direction.

Further, in some of the above-mentioned embodiments, the protrusions are formed by, after treating the surface of the developer bearing member with the blasting treatment, allowing particles that are smaller than the particles used for the blasting treatment to adhere to the surface of the depressions formed by the blasting treatment. However, the method is not limited to the above.

However, note that the method according to the above-mentioned embodiment is preferable because, since it is possible to form the protrusions without performing an etching treatment, it becomes possible to easily adjust the size of the protrusions simply by appropriately selecting the particles that are made to adhere to the surface of the depressions formed by the blasting treatment.

Further, in some of the above-mentioned embodiments, the material used for the developing roller is aluminum alloy or iron alloy. However, the material is not limited to the above.

However, note that the material according to the above-mentioned embodiment is preferable because: by using aluminum alloy as the material for the developing roller, it becomes possible to reduce manufacturing cost of the developing roller due to inexpensiveness of the material as well as make a developing equipment light in weight; and by using iron alloy as the material for the developing roller, it becomes possible to reduce wear of the protrusions and depressions on the developing roller surface through long-term use due to the high hardness characteristic of the material.

Further, in some of the above-mentioned embodiments, the particles used for the blasting treatment are spherical. However, the shape of the particles is not limited to the above, and, for example, elliptical particles can be used.

Further, it is possible to realize a computer system comprising, for example: a computer; a display device, such as a CRT, that can be connected to the computer; the image-forming apparatus, according to any of the above-explained embodiments, that can be connected to the computer; and an input device, such as a mouse or a keyboard, that are provided as necessary; a flexible disk drive; and a CD-ROM drive. In a computer system realized as above, the system, as a whole, will be superior to a usual system.

According to the present invention, it becomes possible to realize a developer bearing member, a method for producing a developer bearing member, a developing device, an image-forming apparatus, and a computer system, which improve the tumbling property of a developer as well as prevent the developer from getting trapped in the developer bearing member.