# Patent

## Title
Charge roller for noncontact charging across a charge gap, method for producing the same, and image-forming apparatus including the same

## Abstract

A charge roller includes a core, a resistive layer disposed on a circumferential surface of the core to charge an image-bearing member without contact, and gap members formed of tape-shaped films. These films are fixed to both ends of the charge roller by winding each of the films in a direction opposite a rotational direction of the charge roller in use and perpendicular to the axial direction thereof to form n layers (wherein n≧2) extending in the axial direction at every position in the circumferential direction of the charge roller. The gap members are pressed against a circumferential surface of an image-bearing member to define a charge gap between the image-bearing member and the charge roller.

## Background
BACKGROUND
1. Technical Field
The present invention relates to the technical field of a charge roller, a method for producing the charge roller, and an electrophotographic apparatus including the charge roller, such as an electrostatic copier, a printer, or a facsimile. The charge roller includes gap members formed of tape-shaped films fixed to the roller by winding them around both ends of the roller to define a predetermined charge gap for noncontact charging between the roller and an image-bearing member.
2. Related Art
JP-A-2001-296723, for example, discloses an image-forming apparatus that defines a predetermined charge gap between a charge roller and an image-bearing member to charge the image-bearing member without contact. Referring to FIG. 14A, a charge roller 14a included in the image-forming apparatus disclosed in this publication includes a core 14b, a resistive layer 14c disposed on the circumferential surface of the core 14b and formed of a conductive elastic material, and a pair of annular gap members 14d and 14e fixed to the resistive layer 14c by winding them around both ends of the circumferential surface of the resistive layer 14c and formed of insulating tape-shaped films. A predetermined charge gap G is defined by bringing the pair of gap members 14d and 14e into contact with the circumferential surface of a photosensitive drum 14f serving as an image-bearing member. Rotating shafts 14g and 14h protrude coaxially from end surfaces of the core 14b in the axial direction thereof. The rotating shafts 14g and 14h are supported by bearings 14i and 14j, respectively. Compression springs 14k and 14m urge the bearings 14i and 14j, respectively, against the photosensitive drum 14f to bring the gap members 14d and 14e into contact with the circumferential surface of the photosensitive drum 14f. 
When the charge roller 14a charges the photosensitive drum 14f without contact across the charge gap G, the charge gap G can prevent generation of ozone, adhesion of foreign matter such as toner from the photosensitive drum 14f to the charge roller 14a, and adhesion of substances contained in the resistive layer 14c to the photosensitive drum 14f. The charge roller 14a can thus charge the photosensitive drum 14f with higher charge performance.
When a tape-shaped film is wound around a charge roller, a seam is left between both ends of the film in the circumferential direction. The charge roller must be rotated with a uniform charge gap maintained at any position in the circumferential direction so that the roller can constantly perform stable, excellent charging. To meet the requirement, the film must be wound around the charge roller with no gap or overlapping portion (overlapping in the radial direction of the charge roller 14a) left at the seam between both ends of the film (in the circumferential direction of the charge roller). To wind the film around the charge roller in such a manner, however, the length of the film must be defined with high accuracy, and the film must also be wound around the charge roller with high accuracy. Consequently, the dimensions of the film must be extremely strictly controlled, and thus low productivity and high cost result.
If the dimensional accuracy and winding accuracy of the film are lowered for improved productivity and cost reduction, a gap or an overlapping portion inevitably occurs at the seam between both ends of a gap member formed by winding the film around the charge roller by substantially one turn. Such a condition can result in the absence of the gap member at the seam or a variation in the thickness thereof, and thus the charge gap can vary when the seam reaches the nip (contact position) between the gap member and an image-bearing member. In that case, the charge roller fails to constantly perform stable, excellent charging.
For the charge roller 14a disclosed in the publication above, as shown in FIGS. 14B and 14C, both ends 14d1 and 14d2 of the film of the gap member 14d are cut obliquely, and the film is wound around the charge roller 14a with a gap 14s left at the seam between the ends 14d1 and 14d2. The film can thus be wound around the charge roller 14a so that the gap member 14d extends in the axial direction at every position in the circumferential direction of the charge roller 14a. Even though the seam is left, accordingly, a constant charge gap G can be maintained without extremely strict control of the dimensions of the film. Although not illustrated, the film of the other gap member 14e is similar to the film of the gap member 14d. 
Referring to FIGS. 14D and 14E, the film of the gap member 14d may also be spirally wound around the charge roller 14a by a length that is larger than two turns by a predetermined length. The film is shifted for each turn in the axial direction of the charge roller 14a without overlapping in the radial direction thereof, and the end 14d2 is shifted from the end 14d1 in the axial direction. Thus, the gap member 14d extends in the axial direction at every position in the circumferential direction of the charge roller 14a. Such spiral winding leaves no seam between the ends 14d1 and 14d2 because the film is wound around the charge roller 14a by a length that is larger than two turns by a predetermined length such that the film is shifted in the axial direction for each turn. Accordingly, a constant charge gap G can be maintained without extremely strict control of the dimensions of the film. Although not illustrated, the film of the other gap member 14e is similar to the film of the gap member 14d. 
It should be noted that, although not described here, the publication above also discloses other methods for forming gap members extending in the axial direction at every position in the circumferential direction of the charge roller 14a. 
If, however, the film of the gap member 14d is simply wound around the circumferential surface of the charge roller 14a, the ends 14d1 and 14d2 of the film are exposed and come into contact with the photosensitive drum 14f either in the case of FIG. 14B or in the case of FIG. 14D. In FIGS. 14C and 14E, the ends 14d1 and 14d2 repeatedly come into contact with the photosensitive drum 14f when the charge roller 14a rotates clockwise. The photosensitive drum 14f then repeatedly exerts a force on the film at the nip between the charge roller 14a and the photosensitive drum 14f so as to peel the end of the film at which it starts entering the nip. This force undesirably peels the film off the charge roller 14a and curls it up. In particular, the gap member 14d can peel more frequently if the charge roller 14a is formed of an inelastic material.
In addition, foreign matter such as toner particles intrudes the gap 14s of the seam between the ends 14d1 and 14d2 of the film and adheres to the film during image-forming operation. Such foreign matter deteriorates the adhesion between the ends 14d1 and 14d2 of the film and the charge roller 14a, and thus promotes peeling of the film at the ends 14d1 and 14d2 thereof. The same holds true for the film of the other gap member 14e. 
If the ends of the gap members 14d and 14e are curled, the charge gap G varies when the charge roller 14a rotates, and thus the gap members 14d and 14e fail to maintain a constant charge gap G. This makes it difficult to perform uniform, stable, excellent charging of the photosensitive drum 14f. 
If the film is wound in layers to form the gap members 14d and 14e, the photosensitive drum 14f suffers from discharge during noncontact charging using a superimposed bias voltage containing DC and AC voltage components. The discharge undesirably decreases the thickness of a charged portion of the photosensitive drum 14f with increasing number of prints. The problem of decreased thickness makes it difficult to control the charge gap G to a predetermined width or less or successfully charge the photosensitive drum 14f. 
SUMMARY
An advantage of some aspects of the invention is that they provide a charge roller capable of preventing peeling of tape-shaped gap members fixed to both ends thereof over an extended period of time to perform stable, excellent noncontact charging across a predetermined charge gap defined by bringing the gap members into contact with an image-bearing member, and also provide a method for producing the charge roller and an image-forming apparatus including the charge roller.
Another advantage of some aspects of the invention is that they provide a charge roller capable of preventing peeling of seamed, tape-shaped gap members fixed to both ends thereof over an extended period of time and performing stable, excellent noncontact charging across a predetermined charge gap defined by bringing the gap members into contact with an image-bearing member even if the thickness of a charge portion of the image-bearing member is decreased, and also provide a method for producing the charge roller and an image-forming apparatus including the charge roller.
A charge roller according to an aspect of the invention includes a core, a resistive layer disposed on a circumferential surface of the core to charge an image-bearing member without contact, and gap members formed of tape-shaped films. These films are fixed to both ends of the charge roller by winding each of the films in a direction opposite a rotational direction of the charge roller in use and perpendicular to the axial direction thereof to form n layers (wherein n≧2) extending in the axial direction at every position in the circumferential direction of the charge roller. The gap members are pressed against a circumferential surface of an image-bearing member to define a charge gap between the image-bearing member and the charge roller.
The n layers of each film extend in the axial direction at every position in the circumferential direction of the charge roller so as to have a uniform thickness. An end of the film at which it starts entering a contact position (nip) between the charge roller and the image-bearing member is covered by the overlying layers of the film so as not to come into contact with the image-bearing member when entering the contact position. This prevents the peeling of the gap members off the charge roller after extended image-forming operation (printing operation). In particular, the peeling of the gap members can be prevented more effectively by forming the resistive layer with a material having a relatively low elastic coefficient, such as a conductive rubber, so that the resistive layer can readily be elastically deformed by a pressure applied at the contact position between the charge roller and the photosensitive member.
In addition, little foreign matter such as toner particles adheres to the ends of the gap members because they are seamless. In particular, the end of each film at which it starts entering the contact position can be covered and protected by the overlying layers of the film to prevent the peeling of the end of film more effectively. The gap members can therefore maintain a uniform, stable charge gap to perform excellent charging of the image-bearing member for high-quality image formation over an extended period of time.
Furthermore, a uniform, stable charge gap can readily be defined over an extended period of time without peeling of the films simply by winding them to form the n layers.
In the charge roller, both ends of each of the films may be cut in parallel obliquely with respect to the longitudinal direction thereof.
It is preferable that the core has annular grooves at both ends thereof, the resistive layer is disposed on a portion of the core between the annular grooves and in the annular grooves, and the gap members are fixed to portions of the circumferential surface of the core between the annular grooves and the ends of the core.
The annular grooves formed on the core can inhibit intrusion of toner into the bottom sides of the ends of the films to prevent the peeling of the ends of the films over an extended period of time.
Preferably, one side of each of the films protrudes to the adjacent annular groove, and the other side of the film protrudes outward beyond the adjacent end surface of the core.
These protrusions can prevent abnormal discharge (leakage of charge) between exposed portions of the core and the image-bearing member.
A method for producing the charge roller includes forming the annular grooves at both ends of the core; covering with masks the portions of the circumferential surface of the core between the annular grooves and the ends of the core; forming the resistive layer by applying a conductive coating material to the annular grooves and the portion of the core between the annular grooves while rotating the core; removing the masks from the portions of the circumferential surface of the core between the annular grooves and the ends of the core; and forming the gap members by winding the films around the portions of the circumferential surface of the core between the annular grooves and the ends of the core in the direction opposite the rotational direction of the charge roller in use and perpendicular to the axial direction of the charge roller to form the n layers.
According to the method for producing the charge roller, the portions of the core where the gap members are to be fixed are covered with the masks, and the conductive coating material is applied to the exposed portion of the circumferential surface of the core with the charge roller being rotated. The resistive layer can thus be uniformly formed on the circumferential surface of the core. Without the annular grooves, the boundaries (edges) of the resistive layer are difficult to reliably define by applying the conductive coating material. The annular grooves allow reliable definition of the boundaries of the resistive layer and more uniform application of the conductive coating material to the circumferential surface of the core.
It is preferable that the resistive layer includes thinner portions at both ends of the core and a thicker portion between the ends of the core, and the gap members are fixed to the thinner portions of the resistive layer.
A method for producing such a charge roller includes covering both end portions of the circumferential surface of the core with masks; forming the thicker portion of the resistive layer by applying a conductive coating material to a portion between the end portions of the circumferential surface of the core to a predetermined thickness while rotating the core; removing the masks from the end portions of the circumferential surface of the core; forming the thinner portions of the resistive layer by applying the conductive coating material to both ends of the core to a thickness smaller than that of the thicker portion; and forming the gap members by winding the films around the thinner portions of the resistive layer in the direction opposite the rotational direction of the charge roller in use and perpendicular to the axial direction of the charge roller to form the n layers.
It is also preferable that the core includes small-diameter portions at both ends thereof and a large-diameter portion between the ends thereof, the resistive layer is formed on circumferential surfaces of the small-diameter portions and the large-diameter portion so as to have a substantially uniform thickness, and the gap members are fixed to portions of the resistive layer which cover the small-diameter portions of the core.
A method for producing such a charge roller includes forming the resistive layer by applying a conductive coating material to the small-diameter and large-diameter portions of the core to a predetermined thickness while rotating the core; and forming the gap members by winding the films around the portions of the resistive layer which cover the small-diameter portions of the core in the direction opposite the rotational direction of the charge roller in use and perpendicular to the axial direction of the charge roller to form the n layers.
In such charge rollers, small-diameter portions are provided at the left and right ends of the charge rollers, and the gap members are fixed to the small-diameter portions. The diameter of the small-diameter portions can be appropriately adjusted so that commercially available films having a thickness corresponding to a desired charge gap can be used. Thus, the charge gap can easily be defined at low cost.
In one of the two methods for producing such charge rollers, the portions of the core where the gap members are to be fixed are covered with the masks, and the conductive coating material is applied to the exposed portion of the circumferential surface of the core with the charge roller being rotated. The masks are then removed from the core before the conductive coating material is applied to the portions of the core where the gap members are to be fixed with the charge roller being rotated. In the other method for producing such charge rollers, the core used includes the small-diameter portions at both ends thereof and the large-diameter portion between the ends thereof, and the conductive coating material is applied to the small-diameter and large-diameter portions with the charge roller being rotated. These methods allow formation of a resistive layer including a large-diameter portion serving as a charging portion and small-diameter portions serving as portions where the gap members are to be fixed.
An image-forming apparatus includes an image-bearing member on which an electrostatic latent image or a developer image is formed, the charge roller according to the aspect of the invention, which charges the image-bearing member without contact, a writing unit that writes an electrostatic latent image on the image-bearing member, a developing unit that develops the electrostatic latent image with a developer to form a developer image on the image-bearing member, and a transfer unit that transfers the developer image from the image-bearing member.
This image-forming apparatus can maintain a uniform, stable charge gap to perform excellent charging of the image-bearing member for high-quality image formation over an extended period of time.
The image-bearing member and the charge roller may be rotated at different circumferential speeds.
If the image-bearing member and the charge roller are rotated at different circumferential speeds, the thickness of the portions of the image-bearing member which come into contact the gap members is decreased by friction with the gap members as the thickness of the charged portion of the image-bearing member is decreased with increasing number of prints. This allows for a reduction in the difference in thickness between the contact portions and charged portion of the image-bearing member. The charge roller can therefore maintain the charge gap at a predetermined width or less to perform excellent charging over an extended period of time. The image-bearing member and the charge roller can thus be rotated at different circumferential speeds to prolong the life of the image-bearing member.



BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
FIG. 1 is a partial schematic diagram of an image-forming apparatus according to an embodiment of the invention.
FIG. 2 is a schematic diagram of a photosensitive member, a charge roller, and a cleaning member used in the image-forming apparatus shown in FIG. 1.
FIGS. 3A to 3C are schematic diagrams of the right end of the charge roller according to this embodiment. FIG. 3A is a partial front view of the charge roller. FIG. 3B is a right side view of the charge roller. FIG. 3C is a sectional view taken along line IIIC-IIIC of FIG. 3B.
FIGS. 4A to 4E are diagrams illustrating a method for producing the charge roller shown in FIGS. 3A to 3C.
FIGS. 5A to 5C are schematic diagrams of the right end of a charge roller according to another embodiment of the invention. FIG. 5A is a partial front view of the charge roller. FIG. 5B is a right side view of the charge roller. FIG. 5C is a sectional view taken along line VC-VC of FIG. 5B.
FIGS. 6A to 6C are schematic diagrams of the right end of a charge roller according to another embodiment of the invention. FIG. 6A is a partial front view of the charge roller. FIG. 6B is a right side view of the charge roller. FIG. 6C is a sectional view taken along line VIC-VIC of FIG. 6B.
FIGS. 7A to 7C are schematic diagrams of the right end of a charge roller according to another embodiment of the invention. FIG. 7A is a partial front view of the charge roller. FIG. 7B is a sectional view taken along line VIIB-VIIB of FIG. 7A. FIG. 7C is a sectional view taken along line VIIC-VIIC of FIG. 7B.
FIGS. 8A to 8C are schematic diagrams of the right end of a charge roller according to another embodiment of the invention. FIG. 8A is a partial front view of the charge roller. FIG. 8B is a right side view of the charge roller. FIG. 8C is a sectional view taken along line VIIIC-VIIIC of FIG. 8B.
FIGS. 9A to 9E are diagrams illustrating a method for producing the charge roller shown in FIGS. 8A to 8C.
FIGS. 10A to 10C are schematic diagrams of the right end of a charge roller according to another embodiment of the invention. FIG. 10A is a partial front view of the charge roller. FIG. 10B is a right side view of the charge roller. FIG. 10C is a sectional view taken along line XC-XC of FIG. 10B.
FIGS. 11A to 11C are diagrams illustrating a method for producing the charge roller shown in FIGS. 10A to 10C.
FIG. 12 is a schematic diagram of a photosensitive member, a charge roller, and a cleaning member used in an image-forming apparatus according to another embodiment of the invention.
FIGS. 13A to 13H are schematic diagrams of the right ends of charge rollers used in experiments.
FIG. 14A is a schematic diagram of a photosensitive member and a charge roller used in a known image-forming apparatus. FIG. 14B is a partial enlarged view of a known example of a gap member shown in FIG. 14A. FIG. 14C is a left side view of the gap member shown in FIG. 14B. FIG. 14D is a partial enlarged view of another known example of the gap member shown in FIG. 14A. FIG. 14E is a left side view of the gap member shown in FIG. 14D.



DESCRIPTION OF EXEMPLARY EMBODIMENTS
Exemplary embodiments of the invention will now be described with reference to the drawings.
FIG. 1 is a partial schematic diagram of an image-forming apparatus according to an embodiment of the invention. FIG. 2 is a schematic diagram of a photosensitive member and a charge unit of the apparatus shown in FIG. 1. In the description of each embodiment below, the same reference numerals as used in the previous embodiments indicate the same components, and detailed description thereof is omitted.
In FIGS. 1 and 2, an image-forming apparatus 1 includes a photosensitive member 2 serving as an image-bearing member on which an electrostatic latent image or a toner image (developer image) is formed. This photosensitive member 2 is surrounded by, in order from the upstream side in the rotational direction of the photosensitive member 2 (clockwise in FIG. 1), a charge unit 3 including a charge roller 3a that charges the photosensitive member 2 without contact, an optical writing unit 4 that writes an electrostatic latent image on the photosensitive member 2, a developing unit 5 that develops the electrostatic latent image with toner to form a toner image on the photosensitive member 2, a transfer unit 6 that transfers the toner image from the photosensitive member 2, and a cleaning unit 7 that cleans the photosensitive member 2. The photosensitive member 2 and the charge roller 3a, or the photosensitive member 2, the charge roller 3a, and the developing unit 5, may be integrated into a cartridge.
In this embodiment, the photosensitive member 2 is a photosensitive drum, similar to known photosensitive drums, formed of a metal pipe coated with a photosensitive layer having a predetermined thickness. The metal pipe used is a conductive pipe such as an aluminum pipe. The photosensitive layer is formed of a known organic photosensitive material. This photosensitive member 2 has rotating shafts 2a and 2b protruding coaxially from end surfaces thereof in the axial direction. These rotating shafts 2a and 2b are rotatably supported by the main body of the apparatus (not shown in FIG. 1) using bearings.
In FIG. 2, the charge roller 3a of the charge unit 3 includes a core 3b formed of a conductive shaft, such as a metal shaft, and a resistive layer 3c disposed on a circumferential surface 3g of the core 3b. The conductive shaft used for the core 3b may be, for example, a nickel-plated shaft formed of SUM22 (according to Japanese Industrial Standards (JIS). The resistive layer 3c is a conductive layer formed by, for example, coating the core 3b with a substantially inelastic conductive coating material using an appropriate method such as spraying.
FIGS. 3A to 3C are schematic diagrams of the right end of the charge roller 3a according to this embodiment. FIG. 3A is a partial front view of the charge roller 3a. FIG. 3B is a right side view of the charge roller 3a. FIG. 3C is a sectional view taken along line IIIC-IIIC of FIG. 3B.
In FIGS. 3A to 3C, the charge roller 3a according to this embodiment has an annular groove 3b1 on the circumferential surface 3g of the core 3b. This annular groove 3b1 is rectangular in axial cross section and is separated from the right end of the charge roller 3a toward the center thereof by a predetermined distance. Although not illustrated, another annular groove similar to the right annular groove 3b1 is formed at the left end of the circumferential surface 3g of the core 3b such that the two annular grooves are symmetrical with respect to the center of the core 3b. The shape of the annular grooves in axial cross section is not limited to a rectangular shape and may be any other shape such as an arc shape, a U-shape, or a V-shape.
The resistive layer 3c not only covers the circumferential surface 3g of the core 3b between the two annular grooves, but also covers the inner surfaces of the grooves, and thus has annular grooves formed over the grooves. In FIG. 3C, the resistive layer 3c does not cover a circumferential surface 3g1 of the core 3b on the right side of the right annular groove 3b1 and a right end surface 3b2. The right gap member 3e is directly fixed to the circumferential surface 3g1 of the core 3b without the resistive layer 3c disposed therebetween. The gap member 3e is formed of a tape-shaped film having ends 3e1 and 3e2 cut obliquely in parallel, as in the example of the known art shown in FIG. 14B. These ends 3e1 and 3e2 are cut in parallel obliquely down to the left in the example shown in FIG. 3A, although they may also be cut in parallel obliquely up to the left.
The end 3e1 of the film of the gap member 3e at which the film starts entering a contact position (nip) between the charge roller 3a and the photosensitive member 2 is fixed to the charge roller 3a by adhesion or bonding. The rest of the film is wound around the circumferential surface 3g1 of the charge roller 3a by one turn in a direction opposite a rotational direction α of the charge roller 3a in use, indicated by the arrow in FIGS. 1 and 3B, and perpendicular to the axial direction of the charge roller 3a without being shifted in the axial direction. The film is further wound around the first layer of the film by slightly less than one turn without being shifted in the axial direction and is fixed by adhesion or bonding. That is, the film is fixed to the charge roller 3a by winding the film in layers around the charge roller 3a by slightly less than two turns without shifting the film in the axial direction. In this embodiment, the film is wider than the circumferential surface 3g1 of the core 3b in the axial direction. The left side 3e3 of the film protrudes to the adjacent annular groove of the resistive layer 3c in the axial direction while the right side 3e4 of the film protrudes to the right beyond the right end surface 3b2 of the core 3b in the axial direction.
In the wound state, the end 3e1 of the gap member 3e faces the rotational direction a of the charge roller 3a while the other end 3e2, at which the film exits the contact position between the charge roller 3a and the photosensitive member 2, faces the opposite direction. The end 3e2 of the gap member 3e, indicated by the solid line, is located ahead of the end 3e1, indicated by the dotted line, in the circumferential direction of the charge roller 3a. That is, the ends 3e1 and 3e2 of the gap member 3e are separated from each other in the circumferential direction by a predetermined distance, as in the example of the known art shown in FIG. 14B. The obliquely cut portions of the ends 3e1 and 3e2 overlap each other in the axial direction. Thus, the film is wound by slightly less than two turns to form two layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. 
In addition, the end 3e1 of the gap member 3e is covered by the second layer of the film so as not to come into contact with the photosensitive member 2 when entering the contact position between the charge roller 3a and the photosensitive member 2. This prevents the photosensitive member 2 from exerting a force having such a direction as to peel the gap member 3e on the end 3e1 of the gap member 3e. 
Although not illustrated, the left gap member 3d is similarly wound around the charge roller 3a. That is, the film of the gap member 3d is wound by slightly less than two turns to form two layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. The ends of the gap member 3d may be cut in parallel in any oblique direction, for example, in the same direction as the end 3e1 and 3e2 or symmetrically therewith. One end of the gap member 3d is located at the same position (phase) as the end 3e1 of the gap member 3e in the circumferential direction of the charge roller 3a. That is, these ends overlap each other in the axial direction of the charge roller 3a. Also, these ends may be located at different positions (phases) in the circumferential direction of the charge roller 3a. 
The resistive layer 3c, which is formed on the circumferential surface 3g between the annular groove 3b1 of the core 3b, constitutes a charging portion 3f that charges the photosensitive member 2 without contact across the predetermined charge gap G. This charging portion 3f has a circumferential surface that is circular in cross section with a predetermined diameter along the axial direction of the charge roller 3a. 
The charge roller 3a has rotating shafts 3h and 3i protruding coaxially from end surfaces of the core 3b in the axial direction. These rotating shafts 3h and 3i are rotatably supported by bearings 3j and 3k, respectively. As in the example of the known art, compression springs 3m and 3n urge the bearings 3j and 3k, respectively, to push the charge roller 3a toward the photosensitive member 2, thereby bringing the gap members 3d and 3e into contact with the circumferential surface of the photosensitive member 2. The predetermined charge gap G is thus defined between the resistive layer 3c and the photosensitive member 2. The width of the charge gap G depends on the predetermined thickness of the films.
The width of the charge gap G is twice the thickness of the films of the gap members 3d and 3e. To define the desired charge gap G, therefore, the thickness of the films may be adjusted to half the width of the charge gap G. If no self-adhesive film having such a thickness is commercially available, films having a thickness that is most approximate to half the width of the charge gap G may be used. In this case, the charge gap G can easily be defined at low cost. The films used may be, for example, resin films such as polyester films and Kapton® films.
A method for producing the charge roller 3a according to this embodiment will be described.
FIGS. 4A to 4E are diagrams illustrating the method for producing the charge roller 3a. FIGS. 4A to 4E illustrate only the right side of the charge roller 3a, and the left side thereof is not illustrated. The description below focuses on the right side of the charge roller 3a, although the left side is similarly formed.
Referring to FIG. 4A, first, the core 3b is prepared. This core 3b has the rotating shaft 3i and is formed of a metal shaft having a predetermined length and a predetermined diameter. Referring to FIG. 4B, the annular groove 3b1 is formed at the right end of the circumferential surface 3g of the core 3b. Referring to FIG. 4C, a masking/bearing member 3q is provided so as to cover the circumferential surface 3g1of the core 3b, the right end surface 3b2, and part of the rotating shaft 3i adjacent to the core 3b and rotatably support the rotating shaft 3i. Referring to FIG. 4D, the resistive layer 3c is formed by applying a conductive coating material to the circumferential surface 3g of the core 3b, which is not covered by the masking/bearing member 3q, to a predetermined thickness while rotating the charge roller 3a in, for example, the β direction. The conductive coating material is also applied to the inner surface of the annular groove 3b1. The conductive coating material can be uniformly applied to the circumferential surface 3g of the core 3b by rotating the charge roller 3a. Without the annular groove 3b1, the boundary (edge) of the resistive layer 3c is difficult to reliably define by applying the conductive coating material. The annular groove 3b1 allows reliable definition of the boundary of the resistive layer 3c and more uniform application of the conductive coating material to the circumferential surface 3g of the core 3b. The coating may be performed either by a dry process or by a wet process. After the coating is completed, the core 3b is removed from the masking/bearing member 3q. 
Referring to FIG. 4E, finally, a tape-shaped film that has ends cut obliquely and is wider than the circumferential surface 3g1 of the core 3b in the axial direction is prepared. As described above, one of the ends of the film is fixed to the circumferential surface 3g1 without the resistive layer 3c disposed therebetween by direct adhesion or bonding. The film is then wound around the circumferential surface 3g1 by one turn in the direction opposite the rotational direction α of the charge roller 3a in use and perpendicular to the axial direction of the charge roller 3a. The film is further wound around the first turn of the film and is fixed by adhesion or bonding. The film is wound so that the left side 3e3 of the film protrudes to the adjacent annular groove of the resistive layer 3c in the axial direction and that the right side 3e4 of the film protrudes to the right beyond the right end surface 3b2 of the core 3b in the axial direction. Thus, the charge roller 3a is completed.
The resistive layer 3c may also be formed of an elastic conductive rubber film having a predetermined width, rather than the inelastic conductive coating described above.
The charge unit 3 further includes a cleaning member 3o, such as a sponge tube roller, which cleans the charge roller 3a. This cleaning member 3o is brought into contact with the circumferential surface 3g of the charge roller 3a and the pair of gap members 3d and 3e at a predetermined pressure. The cleaning member 3o is rotatable in the direction opposite the rotational direction of the charge roller 3a. While the charge roller 3a uniformly charges the photosensitive member 2 without contact, the cleaning member 3o cleans the charge roller 3a to remove foreign matter, such as toner and dust, deposited on the charge roller 3a. 
In FIG. 2, a drive gear 8 for rotating the photosensitive member 2 is attached to the right rotating shaft 2b of the photosensitive member 2, and a drive gear 9 for rotating the charge roller 3a is attached to the right rotating shaft 3i of the charge roller 3a. The drive gear 8 transmits a driving force produced by a motor (not shown) to the photosensitive member 2 to rotate the photosensitive member 2 and also transmits the driving force to the drive gear 9 to rotate the charge roller 3a. 
The optical writing unit 4 writes an electrostatic latent image on the photosensitive member 2 by, for example, laser light. The developing unit 5 includes a developing roller 5a, a toner supply roller 5b, and a toner-limiting member 5c. The toner supply roller 5b supplies a toner T serving as a developer onto the developing roller 5a. The toner-limiting member 5c limits the thickness of the toner T on the developing roller 5a before the developing roller 5a conveys the toner T to the photosensitive member 2. The developing unit 5 thus develops the electrostatic latent image with the toner T to form a toner image on the photosensitive member 2.
The transfer unit 6 includes a transfer roller 6a that transfers the toner image from the photosensitive member 2 to a transfer medium 13 such as transfer paper or an intermediate transfer medium. If the toner image is transferred to transfer paper, a fusing unit (not shown) fuses the transferred image on the paper. If the toner image is transferred to an intermediate transfer medium, the image is further transferred to transfer paper, and the fusing unit fuses the transferred image on the paper.
The cleaning unit 7 includes a cleaning member 7a such as a cleaning blade. This cleaning member 7a cleans the photosensitive member 2 to remove and recover residual toner from the photosensitive member 2 after the transfer.
In the image-forming apparatus 1 having the structure described above, the circumferential surfaces of the second layers of the gap members 3d and 3e come into contact with the photosensitive member 2 to define a uniform, predetermined charge gap G between the photosensitive member 2 and the charging portion 3f of the charge roller 3a at any position in the circumferential direction of the charge roller 3a. The width of the charge gap G is twice the thickness of the films of the gap members 3d and 3e. 
In FIG. 1, the charge roller 3a rotates counterclockwise while the photosensitive member 2 rotates clockwise. Accordingly, the end 3e1 of the gap member 3e is the end at which the gap member 3e starts entering the contact position between the photosensitive member 2 and the gap member 3e. The end 3e1 of the gap member 3e does not come into contact with the photosensitive member 2 when entering the nip between the photosensitive member 2 and the gap member 3e because the end 3e1 is covered by the second layer of the film. This prevents the photosensitive member 2 from exerting a force having such a direction as to peel the gap member 3e on the end 3e1 of the gap member 3e. Although the photosensitive member 2 exerts a force on the second layer of the film when it enters the nip and comes into contact with the photosensitive member 2, no force having such a direction as to peel the gap member 3e acts on the end 3e1 when it passes through the nip. The end 3e1 of the gap member 3e does not peel off the charge roller 3a after extended image-forming operation (printing operation) of the image-forming apparatus 1 because the end 3e1 is protected by the second layer of the film.
As the charge roller 3a rotates, the photosensitive member 2 also exerts a force on the other end 3e2 of the gap member 3e. This force, however, does not peel the end 3e2 off the first layer of the film because the force has such a direction as to press the end 3e2 onto the first layer of the film, rather than to peel the film. The same holds true for the other gap member 3d. In addition, the gap members 3d and 3e have the same thickness (twice the thickness of the films) at any position in the circumferential direction of the charge roller 3a. The gap members 3d and 3e can therefore maintain a uniform, stable charge gap G to perform excellent charging of the photosensitive member 2 for high-quality image formation over an extended period of time.
Furthermore, each of the films is wound so that the left side 3e3 of the film protrudes to the adjacent annular groove of the resistive layer 3c and that the right side 3e4 of the film protrudes to the right beyond the right end surface 3b2 of the core 3b. These protrusions prevent abnormal discharge (leakage of charge) between the exposed portion of the core 3b and the photosensitive member 2.
In the image-forming apparatus 1 according to this embodiment, the gap members 3d and 3e extend in the axial direction at every position in the circumferential direction of the charge roller 3a so as to have a uniform thickness. In addition, the end of each gap member at which it starts entering the contact position between the charge roller 3a and the photosensitive member 2 is covered by the second layer of the film of the gap member so as not to come into contact with the photosensitive member 2 when entering the nip. This prevents the peeling of the gap members 3d and 3e off the charge roller 3a after extended image-forming operation (printing operation). In particular, the peeling of the gap members 3d and 3e can be prevented more effectively by forming the resistive layer 3c with a material having a relatively low elastic coefficient, such as a conductive rubber, so that the resistive layer 3c can readily be elastically deformed by a pressure applied at the contact position (nip) between the charge roller 3a and the photosensitive member 2.
In addition, little foreign matter such as toner particles adheres to the ends of the gap members 3d and 3e because they are seamless. In particular, the end of the film of each gap member at which it starts entering the contact position can be covered and protected by the second layer of the film to prevent the peeling of the end of film more effectively. The gap members 3d and 3e can therefore maintain a uniform, stable charge gap G to perform excellent charging of the photosensitive member 2 for high-quality image formation over an extended period of time.
Furthermore, a uniform, stable charge gap G can readily be defined over an extended period of time without peeling of the films simply by winding them to form two layers.
In addition, the annular grooves formed on the resistive layer 3c can inhibit intrusion of toner into the bottom sides of the ends of the films to prevent the peeling of the ends of the films over an extended period of time, and can also cancel out coating unevenness at both ends of the conductive coating.
Furthermore, each of the films is wound so that the left side 3e3 of the film protrudes to the adjacent annular groove of the resistive layer 3c and that the right side 3e4 of the film protrudes to the right (outward) beyond the right end surface 3b2 of the core 3b. These protrusions can prevent abnormal discharge (leakage of charge) between the exposed portion of the core 3b and the photosensitive member 2.
Each of the films is wound around the charge roller 3a by slightly less than two turns to form two layers in this embodiment, although the invention is not limited to the example above. Referring to FIGS. 5A to 5C, for example, the film of the right gap member 3e may be wound in layers around the charge roller 3a by slightly less than three turns without being shifted in the axial direction. Also, the film may be wound in layers around the charge roller 3a by slightly less than four turns or more without being shifted in the axial direction. The film of the left gap member 3d may be wound in layers by the same number of turns as the film of the right gap member 3e. 
That is, each of the films of the gap members 3d and 3e is wound by slightly less than n turns (wherein n≧2) to form n layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. The outermost circumferential surfaces of the films of the gap members 3d and 3e come into contact with the photosensitive member 2 to define the predetermined charge gap G between the photosensitive member 2 and the charging portion 3f of the charge roller 3a at any position in the circumferential direction of the charge roller 3a. 
If a film having a thickness of t is wound to form n layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a, the charge gap G corresponds to the difference between the thickness of the gap members 3d and 3e, namely n·t, and the thickness of the resistive layer 3c at the charging portion 3f of the charge roller 3a. To define the desired charge gap G, in other words, the thickness of the resistive layer 3c may be determined by subtracting the charge gap G from the thickness of the gap members 3d and 3e, namely n·t.
FIGS. 6A to 6C are schematic diagrams, similar to FIGS. 3A to 3C, of a charge roller according to another embodiment of the invention. FIG. 6A is a partial front view of the charge roller. FIG. 6B is a right side view of the charge roller. FIG. 6C is a sectional view taken along line VIC-VIC of FIG. 6B.
In the previous embodiment, the annular grooves are formed at both ends of the charge roller 3a, and the gap members 3d and 3e are directly fixed to the circumferential surfaces 3g1 of the core 3b, which are not covered by the resistive layer 3c. In this embodiment, as shown in FIGS. 6A to 6C, the charge roller 3a has no annular groove, and a beveled portion 3b3 is formed at the right side edge (right edge) of the core 3b. In addition, the resistive layer 3c covers the circumferential surface 3g, beveled portion 3b3, and right end surface 3b2 of the core 3b. The circumferential surface 3g of the core 3b has a uniform diameter along the axial direction of the charge roller 3a between the left and right beveled portions of the core 3b. Accordingly, the circumferential surface of the resistive layer 3c, which is formed on the circumferential surface 3g of the core 3b, is circular in cross section with a uniform diameter along the axial direction of the charge roller 3a. The right gap member 3e is fixed to the right end of the circumferential surface 3g of the core 3b. The left side of the core 3b and the left gap member 3d are similar to but symmetrical with the right side of the core 3b and the right gap member 3e. 
In this embodiment, the resistive layer 3c covers the beveled portion 3b3 and right end surface 3b2 of the core 3b to prevent abnormal discharge (leakage of charge) between the core 3b and the photosensitive member 2. The left side of the core 3b is similar to the right side. In addition, the gap members 3d and 3e are fixed to the resistive layer 3c to define the charge gap G with respect to the coating surface. This allows for improved dimensional accuracy if, for example, coating unevenness occurs.
The rest of the structure and the other operations and advantages of the image-forming apparatus 1 and the charge roller 3a according to this embodiment are the same as those of the embodiment shown in FIGS. 1 to 4A-4E except for the operations and advantages of the annular grooves.
Also, in this embodiment, each of the films of the gap members 3d and 3e is wound by slightly less than n turns (wherein n≧2) to form n layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. In addition, the resistive layer 3c may be formed of an elastic conductive rubber film having a predetermined width, rather than the inelastic conductive coating described above.
FIGS. 7A to 7C are schematic diagrams, similar to FIGS. 3A to 3C, of a charge roller of an image-forming apparatus according to another embodiment of the invention. FIG. 7A is a partial front view of the charge roller. FIG. 7B is a sectional view taken along line VIIB-VIIB of FIG. 7A. FIG. 7C is a sectional view taken along line VIIC-VIIC of FIG. 7B.
In the embodiment shown in FIGS. 3A to 3C, the annular groove 3b1 of the core 3b is rectangular in axial cross section, and the beveled portion 3b3 is not formed at the right edge of the core 3b. In this embodiment, as shown in FIGS. 7A to 7C, the annular groove 3b1 of the core 3b is arc-shaped in axial cross section, and the beveled portion 3b3 is formed at the right edge of the core 3b. The annular groove 3b1 may also be, for example, U-shaped or V-shaped in axial cross section.
In the embodiment shown in FIGS. 3A to 3C, additionally, the left side 3e3 of the film of the gap member 3e protrudes to the adjacent annular groove of the resistive layer 3c, and the right side 3e4 of the film protrudes to the right beyond the right end surface 3b2 of the core 3b. In this embodiment, on the other hand, the left side 3e3 of the film of the gap member 3e does not protrude to the adjacent annular groove of the resistive layer 3c, but covers the boundary between the annular groove 3b1 and circumferential surface 3g1 of the core 3b so that the boundary is not directly exposed. In this embodiment, additionally, the right side 3e4 of the first layer of the film is bent and fixed to part of the beveled portion 3b3 of the core 3b by adhesion or bonding, and the right side 3e4 of the second layer of the film is fixed to the first layer so that the second layer is bent along the bent portion of the first layer. The first and second layers of the film are thus bent away from the photosensitive member 2 at the right side 3e4 thereof. The left side of the core 3b and the left gap member 3d are similar to but symmetrical with the right side of the core 3b and the right gap member 3e. 
In this embodiment, the outer sides of the left and right films are bent away from the photosensitive member 2 to increase the adhesive strength of the films. In addition, the outer sides do not come into contact with the photosensitive member 2. The peeling of the gap members 3d and 3e can therefore be prevented effectively over an extended period of time even if parts of the gap members 3d and 3e come into contact with the photosensitive member 2 and the cleaning member 3o.
Furthermore, the left side 3e3 of the film covers the boundary between the annular groove 3b1 and circumferential surface 3g1 of the core 3b so that the boundary is not directly exposed, and the right side 3e4 of the film covers the beveled portion 3b3. The film can therefore prevent abnormal discharge (leakage of charge) between the boundary and beveled portion 3b3 of the core 3b and the photosensitive member 2. The left side of the core 3b is similar to the right side.
The rest of the structure and the other operations and advantages of the image-forming apparatus 1 and the charge roller 3a according to this embodiment are the same as those of the embodiment shown in FIGS. 1 to 4A-4E. The resistive layer 3c may be formed of an elastic conductive rubber film having a predetermined width, rather than the inelastic conductive coating described above. In addition, each of the films of the gap members 3d and 3e is wound by slightly less than n turns (wherein n≧2) to form n layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. 
FIGS. 8A to 8C are schematic diagrams, similar to FIGS. 3A to 3C, of a charge roller of an image-forming apparatus according to another embodiment of the invention. FIG. 8A is a partial front view of the charge roller. FIG. 8B is a right side view of the charge roller. FIG. 8C is a sectional view taken along line VIIIC-VIIIC of FIG. 8B.
In the embodiment shown in FIGS. 6A to 6B, the core 3b has the beveled portion 3b3, and the resistive layer 3c is formed of a conductive coating with a uniform thickness and covers the circumferential surface 3g, beveled portion 3b3, and right end surface 3b2 of the core 3b. In this embodiment, as shown in FIGS. 8A to 8C, the beveled portion 3b3 is not formed on the core 3b, and the resistive layer 3c is formed of a conductive coating that is thicker on the charging portion 3f of the circumferential surface 3g of the core 3b and is thinner at the right end of the circumferential surface 3g of the core 3b, including the area where the gap member 3e is fixed and the right end surface 3b2.
That is, the resistive layer 3c has a large-diameter portion 3c1 that is thicker and corresponds to the charging portion 3f, a small-diameter portion 3c2 that is thinner and corresponds to the area where the gap member 3e is fixed, and an annular step 3c3 between the large-diameter portion 3c1 and the small-diameter portion 3c2. The left side of the core 3b and the resistive layer 3c and the left gap member 3d are similar to but symmetrical with the right side of the core 3b and the resistive layer 3c and the right gap member 3e. That is, the small-diameter portions of the left and right ends of the resistive layer 3c are thinner and correspond to the areas where the gap members 3d and 3e are fixed, and the large-diameter portion 3c1 between the left and right ends of the resistive layer 3c is thicker than the small-diameter portions. The gap members 3d and 3e are fixed to the small-diameter portions of the left and right ends of the resistive layer 3c. 
A method for producing the charge roller 3a according to this embodiment will be described.
FIGS. 9A to 9E are diagrams illustrating the method for producing the charge roller 3a. FIGS. 9A to 9E illustrate only the right side of the charge roller 3a, and the left side thereof is not illustrated, as in FIGS. 4A to 4E. Reference numerals in parentheses indicate components on the right side of the charge roller 3a. 
Referring to FIG. 9A, first, the core 3b is prepared. This core 3b has the rotating shafts (3i) at both ends thereof and is formed of a metal shaft having a predetermined length and a predetermined diameter. Referring to FIG. 9B, a pair of masking/bearing members (3q) are provided so as to cover the circumferential surfaces 3g1 of the left and right ends of the core 3b, the left and right end surfaces (3b2), and parts of the rotating shafts (3i) adjacent to the core 3b and rotatably support the rotating shafts (3i). Referring to FIG. 9C, the thicker portion of the resistive layer 3c, namely, the large-diameter portion 3c1, is formed between the left and right ends of the core 3b by applying a conductive coating material to a portion of the circumferential surface 3g which is not covered by the masking/bearing members (3q) to a relatively large predetermined thickness while rotating the charge roller 3a in, for example, the β direction. The coating may be performed either by a dry process or by a wet process. After the coating is completed, the core 3b is removed from the masking/bearing members (3q).
Referring to FIG. 9D, a pair of second masking/bearing members (3q′) are provided so as to rotatably support the rotating shafts (3i). These second masking/bearing members (3q′) are separated from the left and right end surfaces (3b2) of the core 3b by a predetermined distance to define predetermined gaps between end surfaces of the second masking/bearing members (3q′) and the left and right end surfaces (3b2) of the core 3b. The thinner portions of the resistive layer 3c are formed at the left and right ends of the core 3b by applying a conductive coating material to the left and right end surfaces (3b2) and the circumferential surfaces 3g1, which are not covered by the second masking/bearing members (3q′) or the thicker portion of the resistive layer 3c, to a thickness smaller than that of the thicker portion while rotating the charge roller 3a in, for example, the β direction. The thinner portions of the resistive layer 3c correspond to the small-diameter portions (3c2). The annular steps (3c3) are formed between the large-diameter portion 3c1 and the small-diameter portions (3c2).
Referring to FIG. 9E, finally, tape-shaped films having ends cut obliquely with a predetermined width are prepared. As described above, one of the ends of each film is fixed to the corresponding small-diameter portion (3c2) of the resistive layer 3c by adhesion or bonding. The films are then wound around the small-diameter portions (3c2) of the resistive layer 3c by one turn in the direction opposite the rotational direction α of the charge roller 3a in use and perpendicular to the axial direction of the charge roller 3a. The films are further wound around the first layers of the films and are fixed by adhesion or bonding. Thus, the charge roller 3a is completed.
The resistive layer 3c may be formed by other methods so as to vary in thickness. For example, the small-diameter portions (3c2) may be formed by applying a conductive coating material to the overall circumferential surface of the core 3b before the large-diameter portion 3c1 is formed by masking areas of the coating where the gap members 3d and 3e are to be fixed and applying the coating material to an exposed portion of the coating.
The left and right edges of the core 3b, which are not beveled in this embodiment, may also be beveled as in the embodiments above.
In this embodiment, the charge roller 3a has the small-diameter portions at the left and right ends thereof, where the gap members 3d and 3e are fixed. The diameter of the small-diameter portions can be appropriately adjusted so that the desired charge gap G can easily be defined at low cost using commercially available films having the thickness corresponding to the charge gap G.
The rest of the structure and the other operations and advantages of the image-forming apparatus 1 and the charge roller 3a according to this embodiment are the same as those of the embodiments shown in FIGS. 1, 2, and 6A to 6C. The resistive layer 3c may be formed of an elastic conductive rubber film having a predetermined width, rather than the inelastic conductive coating described above. In addition, each of the films of the gap members 3d and 3e is wound by slightly less than n turns (wherein n≧2) to form n layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. 
FIGS. 10A to 10C are schematic diagrams, similar to FIGS. 3A to 3C, of a charge roller of an image-forming apparatus according to another embodiment of the invention. FIG. 10A is a partial front view of the charge roller. FIG. 10B is a right side view of the charge roller. FIG. 10C is a sectional view taken along line XC-XC of FIG. 10B. Reference numerals in parentheses indicate components on the right side of the charge roller.
In the embodiment shown in FIGS. 8A to 8B, the core 3b has a uniform diameter, and the resistive layer 3c is formed on the core 3b so as to vary in thickness. In this embodiment, as shown in FIGS. 10A to 10C, the core 3b includes small-diameter portions (3b4) at the left and right ends thereof, a large-diameter portion 3b5 between the left and right ends thereof, and steps (3b6) between the small-diameter portions (3b4) and the large-diameter portion 3b5. The resistive layer 3c is formed on the left and right small-diameter portions (3b4), large-diameter portion 3b5, and left and right end surfaces (3b2) of the core 3b so as to have a substantially uniform thickness. Accordingly, the resistive layer 3c includes small-diameter portions (3c2) at the left and right ends thereof, a large-diameter portion 3c1 between the left and right ends thereof, and steps (3c3) between the small-diameter portions (3c2) and the large-diameter portion 3c1. The gap members 3d and 3e are fixed to the small-diameter portions (3c2) of the left and right ends of the resistive layer 3c. 
A method for producing the charge roller 3a according to this embodiment will be described.
FIGS. 11A to 11C are diagrams illustrating the method for producing the charge roller 3a. FIGS. 11A to 11C illustrate only the right side of the charge roller 3a, as in FIGS. 4A to 4E, and the left side thereof is not illustrated.
Referring to FIG. 11A, first, the core 3b is prepared. This core 3b has the rotating shafts (3i) at both ends thereof and is formed of a metal shaft having a predetermined length. The core 3b includes the small-diameter portions (3b4) at the left and right ends thereof, the large-diameter portion 3b5 between the left and right ends thereof, and the steps (3b6) between the small-diameter portions (3b4) and the large-diameter portion 3b5. Referring to FIG. 11B, a pair of second masking/bearing members (3q′) are provided so as to rotatably support the rotating shafts (3i). These second masking/bearing members (3q′) are separated from the left and right end surfaces (3b2) of the core 3b by a predetermined distance to define predetermined gaps between end surfaces of the second masking/bearing members (3q′) and the left and right end surfaces (3b2) of the core 3b. The resistive layer 3c is formed by applying a conductive coating material to the left and right end surfaces (3b2), large-diameter portion 3b4, and small-diameter portions (3b5) of the core 3b while rotating the charge roller 3a in, for example, the β direction. The resistive layer 3c includes the small-diameter portions (3c2) at the left and right ends thereof, the large-diameter portion 3c1, and the annular steps (3c3) between the small-diameter portions (3c2) and the large-diameter portion 3c1.
Referring to FIG. 11C, finally, tape-shaped films having ends cut obliquely with a predetermined width are prepared. As described above, one of the ends of each film is fixed to the corresponding small-diameter portion (3c2) of the resistive layer 3c by adhesion or bonding. The films are then wound around the small-diameter portions (3c2) by one turn in the direction opposite the rotational direction a of the charge roller 3a in use and perpendicular to the axial direction of the charge roller 3a. The films are further wound around the first layers of the films and are fixed by adhesion or bonding. Thus, the charge roller 3a is completed.
The rest of the structure and the other operations and advantages of the image-forming apparatus 1 and the charge roller 3a according to this embodiment are the same as those of the embodiments shown in FIGS. 1, 2, and 8A-8C. The resistive layer 3c may be formed of an elastic conductive rubber film having a predetermined width, rather than the inelastic conductive coating described above. In addition, each of the films of the gap members 3d and 3e is wound by slightly less than n turns (wherein n≧2) to form n layers extending in the axial direction at every position in the circumferential direction of the charge roller 3a. 
In the image-forming apparatus 1 according to each of the embodiments described above, as shown in FIG. 2, the drive gear 9 for driving the charge roller 3a is driven by the drive gear 8 for driving the photosensitive member 2 to directly rotate the charge roller 3a, although the invention is not limited to that driving mechanism. For example, the charge roller 3a may be rotated by friction with the photosensitive member 2 and the cleaning member 3o. Referring to FIG. 12, specifically, a drive gear 11 for driving the cleaning member 3o is fixed to a right rotating shaft 3p of the cleaning member 3o. The drive gears 8 and 11 are coupled by an intermediate gear 12 rotatably supported by the main body of the apparatus 1. The drive gear 8, as described above, transmits a driving force produced by a motor to the photosensitive member 2 to rotate the photosensitive member 2. The driving force is also transmitted to the drive gear 11 via the intermediate gear 12 to rotate the cleaning member 3o. The charge roller 3a is pressed between the photosensitive member 2 and the cleaning member 3o so that the charge roller 3a is rotated by friction therebetween as the photosensitive member 2 and the cleaning member 3o rotate.
If the films are wound in layers to form the gap members 8d and 8e as described above, the photosensitive member 2 suffers from discharge during noncontact charging using a superimposed bias containing DC and AC voltage components. The discharge decreases the thickness of the charged portion of the photosensitive member 2 with increasing number of prints. In the embodiments of the invention, the circumferential speeds of the photosensitive member 2 and the charge roller 3a may be controlled to a predetermined circumferential speed ratio. If the photosensitive member 2 and the charge roller 3a are rotated at different circumferential speeds, friction occurs between the gap members 3d and 3e and portions of the photosensitive member 2 which come into contact with the gap members 3d and 3e. 
While the thickness of the charged portion decreases after a large number of prints, friction with the gap members 3d and 3e decreases the thickness of the portions which come into contact therewith, thus reducing the difference in thickness between the charged portion and the portions which come into contact the gap members 3d and 3e. The charge gap G can therefore be maintained at a predetermined width or less to perform stable, excellent charging of the photosensitive member 2. The photosensitive member 2 and the charge roller 3a can thus be rotated at different circumferential speeds to prolong the life of the photosensitive member 2.
Next, experiments conducted on examples belonging to the invention and comparative examples that do not belong to the invention will be described to demonstrate the operations and advantages of the charge roller 3a and the image-forming apparatus 1 described above. These experiments include a first set of experiments where the photosensitive member 2 and the charge roller 3a were rotated at a circumferential speed ratio of 1 (including ratios of substantially 1 because the ratio is difficult to precisely adjust to 1) and a second set of experiments where the photosensitive member 2 and the charge roller 3a were rotated at substantially different circumferential speeds. The image-forming apparatus used in each experiment was a commercially available printer, LP-9000C, manufactured by Seiko Epson Corporation. This printer was partially modified by replacing its original scorotron charge unit with a noncontact charge unit and providing an external power supply for applying an AC voltage to the charge unit. The replacement parts used, including toner, a photosensitive member, a transfer unit, and a fusing unit, were original parts of the printer LP-9000C.
The first set of experiments will be described. The first set of experiments relates to the peeling of the films of the gap members 3d and 3e and includes ten experiments, namely, Experiment Nos. 1 to 10. Table 1 shows the types of charge rollers and gap members of image-forming apparatuses used in Experiment Nos. 1 to 10.










TABLE 1





No.
Charge roller
Gap member
Type of film


















1
Metal shaft + conductive
Double-layer winding
Polyester tape



coating (inelastic)
Oblique cut
Manufactured by Sumitomo 3M Limited




G: 30 μm
No. 9391 (thickness: 22 μm)


2
Metal shaft + conductive
Double-layer winding
Polyester tape



rubber (elastic)
Oblique cut
Manufactured by Sumitomo 3M Limited




G: 32 μm
No. 9391 (thickness: 22 μm)


3
Metal shaft + conductive
Spiral winding by slightly
Polyester tape



coating (inelastic)
more than one turn
Manufactured by Sumitomo 3M Limited




G: 50 μm
No. 9390 (thickness: 50 μm)


4
Metal shaft + conductive
Spiral winding by slightly
Polyester tape



rubber (elastic)
more than one turn
Manufactured by Sumitomo 3M Limited




G: 50 μm
No. 9390 (thickness: 50 μm)


5
Metal shaft + conductive
Single-layer winding
Polyester tape



coating (inelastic)
Oblique cut
Manufactured by Sumitomo 3M Limited




G: 50 μm
No. 9390 (thickness: 50 μm)


6
Metal shaft + conductive
Single-layer winding
Polyester tape



rubber (elastic)
Oblique cut
Manufactured by Sumitomo 3M Limited




G: 50 μm
No. 9390 (thickness: 50 μm)


7
Metal shaft + conductive
Spiral winding by slightly
Kapton ® film tape



coating (inelastic)
more than one turn
Manufactured by Teraoka Seisakusho Co., Ltd.




G: 35 μm
No. 650S (#12) (thickness: 35 μm)


8
Metal shaft + conductive
Spiral winding by slightly
Kapton ® film tape



rubber (elastic)
more than one turn
Manufactured by Teraoka Seisakusho Co., Ltd.




G: 35 μm
No. 650S (#12) (thickness: 35 μm)


9
Metal shaft + conductive
Triple-layer winding
Kapton ® film tape



coating (inelastic)
Oblique cut
Manufactured by Teraoka Seisakusho Co., Ltd.




G: 45 μm
No. 650S (#12) (thickness: 35 μm)


10
Metal shaft + conductive
Triple-layer winding
Kapton ® film tape



rubber (elastic)
Oblique cut
Manufactured by Teraoka Seisakusho Co., Ltd.




G: 45 μm
No. 650S (#12) (thickness: 35 μm)









The photosensitive member 2 used in Experiment Nos. 1 to 10 was the original photosensitive member of the printer LP-9000C. This photosensitive member was composed of an aluminum pipe coated with an organic photosensitive material to form a photosensitive layer and had a runout accuracy of not more than 0.01.
The charge unit 3 used instead of the scorotron charge unit of the printer LP-9000C was a noncontact charge unit including the charge roller 3a. This charging unit was produced so that it could be mounted on the printer LP-9000C. FIGS. 13A to 13H show types of charge rollers used in the experiments. FIGS. 13B, 13D, 13F, and 13H are sectional views, similar to FIG. 3C, of FIGS. 13A, 13C, 13E, and 13G, respectively.
The charge roller 3a used in Experiment Nos. 1 to 10 included a nickel-plated SUM22 shaft having a diameter of 10 mm as the core 3b. This metal shaft was formed in such a shape that it could be mounted on the modified printer described above.
The core 3b used in Experiment Nos. 1 and 2, as shown in FIGS. 13A and 13B, was similar to that shown in FIGS. 3A to 3C, that is, had annular grooves similar to those shown in FIGS. 3A to 3C at both ends thereof. Also, the core 3b used in Experiment Nos. 9 and 10, as shown in FIGS. 13G and 13H, had annular grooves similar to those shown in FIGS. 3A to 3C (or FIGS. 5A to 5C) at both ends thereof. These annular grooves had a width of 1 mm and a depth of 0.2 mm. The portions of the circumferential surface 3g of the core 3b where the gap members 3d and 3e were to be fixed outside the annular grooves had a width of 4 mm (the length in the axial direction of the charge roller 3a).
The core 3b used in Experiment Nos. 3 and 4, as shown in FIGS. 13C and 13D, was similar to that shown in FIGS. 6A to 6C, that is, had beveled portions similar to those shown in FIGS. 6A to 6C at both edges thereof. Also, the core 3b used in Experiment Nos. 7 and 8, as shown in FIGS. 13E and 13F, had beveled portions similar to those shown in FIGS. 6A to 6C at both edges thereof. The beveled portions had a width of about 2 mm.
In each of Experiment Nos. 1 to 10, the core 3b had the rotating shafts 3h and 3i at the ends thereof, and the metal shaft used therefor was processed to a runout accuracy of not more than 0.01 by centerless polishing.
The resistive layer 3c was formed on the metal shaft of the charge roller 3a used in each experiment. The resistive layer 3c used in Experiment Nos. 1, 2, 9, and 10, as shown in FIGS. 13A, 13B, 13G, and 13H, was similar to that shown in FIGS. 3A to 3C, that is, was formed on the portion of the circumferential surface of the metal shaft corresponding to the charging portion 3f and in the annular grooves of the metal shaft. The resistive layer 3c used in Experiment Nos. 3 to 8, as shown in FIGS. 13C to 13F, was similar to that shown in FIGS. 6A to 6C, that is, was formed on the circumferential surface, beveled portions, and end surfaces of the metal shaft except for the rotating shaft 3h and 3i. 
In Experiment Nos. 1, 3, 5, 7, and 9, the resistive layer 3c was composed of a conductive layer formed by spraying a coating liquid prepared by mixing conductive tin oxide (SnO2) and polyurethane (PU) in a weight ratio of 1:9 and dispersing the mixture in water containing an ionically conductive material. Table 2 shows conductive SnO2 products available from Jemco Inc., as detailed in its home page.









TABLE 2





Name
Physical properties
Application



















Sn—Sb oxides
(1)
Form: Blue gray powder

Antistatic agent


Trade name: T-1
(2)
Powder resistivity: 1-3 Ω · cm (under

A transparent thin conductive film can be




pressure of 100 kg/cm2)

formed because the particle size is smaller



(3)
Particle shape: Spherical

than visible light wavelengths.



(4)
Primary particle size: 0.02 μm



(5)
Specific gravity: 6.6


Sn—Sb oxide
(1)
Form: Blue liquid (aqueous)

Antistatic agent


aqueous dispersion
(2)
Solid content: 17 wt %

This is an aqueous dispersion of tin oxide


Trade name: TDL
(3)
Solid content average particle size:

doped with antimony oxide. It can form a




100 nm

transparent conductive film.



(4)
Specific gravity: 1.17


Sn—Sb oxide
(1)
Form: Blue liquid
(1)
Antistatic agent


paint/dispersion
(2)
Coating surface resistance
(2)
Near infrared shield


Trade name: ES

(measured by Jemco Inc.): 106-9

A highly transparent thin conductive film and a




Ω/square

near infrared shield film can be formed






because the size of particles contained in the






paint is smaller than visible light wavelengths.


TiO2/Sn—Sb oxides
(1)
Form: Gray white powder

Antistatic agent


Trade name: W-1
(2)
Powder resistivity: 3-10 Ω · cm

This is a white conductive material that can be




(under pressure of 100 kg/cm2)

colored by mixing a resin.



(3)
Particle shape: Spherical



(4)
Primary particle size: 0.2 μm



(5)
Specific gravity: 4.6









The conductive SnO2 used in the examples and the comparative examples was “T-1” (a trade name of Jemco Inc.), which is tin-antimony oxide, although other types of conductive SnO2 may also be used. The ionically conductive material was used to provide conductivity for the coating material. The ionically conductive material used in the examples and the comparative examples was “YYP-12” (manufactured by Marubishi Oil Chemical Co., Ltd.).
The thickness of the charging portion 3f of the charge roller 3a was adjusted according to the thickness and number of turns of the films of the gap members 3d and 3e so as to define the gaps G shown in Table 1 (described later in detail). When the coating liquid used in the experiments was applied onto an aluminum plate to form a film having a thickness of 20 μm, its volume resistivity was measured to be 1.0 to 5.0×1010 Ω·cm.
In Experiment Nos. 2, 4, 6, 8, and 10, the resistive layer 3c was formed of a conductive rubber. The conductive rubber used was a 166-series rubber manufactured by Hokushin Corporation (rubber hardness: 48° in terms of JIS-A). The thickness of the charging portion 3f of the charge roller 3a was adjusted according to the thickness and number of turns of the films of the gap members 3d and 3e so as to define the gaps G shown in Table 1 (described later in detail). Charge rollers having conductive rubber layers with the thicknesses described above were outsourced from Hokushin Corporation.
In Experiment Nos. 1 and 2, the gap members 3d and 3e were formed of polyester tapes manufactured by Sumitomo 3M Limited (No. 9391; thickness: 22 μm; width: 5 mm). In Experiment Nos. 3 to 6, the gap members 3d and 3e were formed of polyester tapes manufactured by Sumitomo 3M Limited (No. 9390; thickness: 50 μm; width: 5 mm). In Experiment Nos. 7 to 10, the gap members 3d and 3e were formed of Kapton® film tapes manufactured by Teraoka Seisakusho Co., Ltd. (No. 650S(#12); thickness: 35 μm; width: 5 mm).
In Experiment Nos. 1 and 2, as shown in FIGS. 13A and 13B, the gap members 3d and 3e were formed by cutting the ends of the polyester tapes obliquely at 45° with respect to the longitudinal direction thereof, winding the tapes in layers by slightly less than two turns (with the ends thereof separated from each other in the circumferential direction), and fixing the tapes by adhesion. In Experiment Nos. 3 and 4, as shown in FIGS. 13C and 13D, the gap members 3d and 3e were formed by spirally winding the polyester tapes by slightly more than one turn with the ends thereof aligned in parallel in the axial direction of the charge roller, and fixing the tapes by adhesion. The tapes were wound by slightly more than one turn such that the trailing ends thereof were shifted from the beginning ends in the axial direction so as not to overlap with the beginning ends and were positioned beyond the beginning ends in the circumferential direction. In Experiment Nos. 5 and 6, as shown in FIGS. 13E and 13F, the gap members 3d and 3e were formed by cutting the ends of the polyester tapes obliquely at 45° with respect to the longitudinal direction thereof, winding the tapes by slightly less than one turn (with the ends thereof separated from each other in the circumferential direction), and fixing the tapes by adhesion. In Experiment Nos. 7 and 8, as shown in FIGS. 13C and 13D, the gap members 3d and 3e were formed by spirally winding the Kapton® film tapes by slightly more than one turn with the ends thereof aligned in parallel in the axial direction of the charge roller, and fixing the tapes by adhesion. The tapes were wound by slightly more than one turn such that the trailing ends thereof were shifted from the beginning ends in the axial direction so as not to overlap with the beginning ends and were positioned beyond the beginning ends in the circumferential direction. In Experiment Nos. 9 and 10, as shown in FIGS. 13G and 13H, the gap members 3d and 3e were formed by cutting the ends of the polyester tapes obliquely at 45° with respect to the longitudinal direction thereof, winding the tapes in layers by slightly less than three turns (with the ends thereof separated from each other in the circumferential direction), and fixing the tapes by adhesion. In Experiment Nos. 1, 2, 9, and 10, the tapes were fixed to the core 3b so as to protrude to the annular grooves by a length of 0.5 mm and also protrude outward beyond the end surfaces of the core 3b in the axial direction by the same length.
The width of the charge gap G was adjusted to 30 μm in Experiment No. 1, 32 μm in Experiment No. 2, 50 μm in Experiment Nos. 3 to 6, 35 μm in Experiment Nos. 7 and 8, and 45 μm in Experiment Nos. 9 and 10. The charge gap G was defined by adjusting the thickness of the resistive layer 3c according to the thickness of the gap members 3d and 3e, that is, the thickness and number of turns of the tapes.
As is obvious from the description above, Experiment Nos. 1, 2, 9, and 10 are examples of the invention, and Experiment Nos. 3 to 8 are comparative examples.
In each experiment, the charge roller 3a was pressed against the photosensitive member 2 by applying the load of the compression springs 3m and 3n to the bearings 3j and 3k (at a distance of 10 mm outward from the gap members 3d and 3e, respectively). The charge roller 3a, which was positioned below the photosensitive member 2 in the image-forming apparatus used in the experiments, was pressed against the photosensitive member 2 by applying a spring load of 300 gf in any of Experiment Nos. 1 to 10.
In each experiment, the cleaning member 3o was pressed against the charge roller 3a, as shown in FIG. 2. The cleaning member 3o used was a sponge roller (trade name: “Real Sealer”; manufactured by Bridgestone Kaseihin Tokyo Co., Ltd.). This sponge roller had an outer diameter of 10 mm. The depth of the contact of the sponge roller with the charge roller 3a was adjusted to 0.5 mm so that the pressure of the cleaning member 3o on the charge roller 3a was significantly smaller than that of the charge roller 3a on the photosensitive member 2. The cleaning member 3o was thus used to remove foreign matter such as toner and additives deposited on the charge roller 3a. 
In each experiment, the charge roller 3a and the cleaning member 3o were directly driven as shown in FIG. 2.
In the image formation of the experiments, the photosensitive member 2 and the cleaning member 3o were rotated clockwise in FIG. 1, and the charge roller 3a was rotated counterclockwise in FIG. 1. The photosensitive member 2 and the charge roller 3a were rotated at substantially the same circumferential speed, namely, about 210 mm/s, in each experiment.
In each experiment, the voltage Vc (V) applied to the charge roller 3a contained a DC voltage component VDC (V) and an AC voltage component VAC (V), as represented by the following equation:

VC=VDC+VAC=−650+(1⁄2)Vpp·sin 2πft

(where Vpp=1,700 V, f=1.3 kHz, and VAC is a sine wave). The bias voltage used for development contained a DC voltage component (VDC=−200 V) and an AC voltage component having a rectangular waveform (Vpp=1,400 V and f=3.0 kHz). Monochrome halftone printing (print density: 25%; full-page solid image) was performed on A4 normal paper in room environment, namely, at a temperature of 23° C. and a humidity of 60%.

The printed paper was sampled and evaluated by visual observation after 50, 100, 500, 1,000, and 5,000 prints. Table 3 shows the evaluation results. If no print error occurred after 5,000 prints, the charging was determined to be acceptable. If a print error occurred before 5,000 prints, the charging was determined to be unacceptable.











TABLE 3





No.
Charge roller
Gap member
Evaluation
Remarks



















1
Metal shaft + conductive
Double-layer winding
Acceptable
No tape peeling occurred



coating (inelastic)
Oblique cut

after 5,000 prints


2
Metal shaft + conductive
Double-layer winding
Acceptable
No tape peeling occurred



rubber (elastic)
Oblique cut

after 5,000 prints


3
Metal shaft + conductive
Spiral winding by slightly
Unacceptable
Tape peeling occurred after



coating (inelastic)
more than one turn

322 prints


4
Metal shaft + conductive
Spiral winding by slightly
Unacceptable
Tape peeling occurred after



rubber (elastic)
more than one turn

455 prints


5
Metal shaft + conductive
Single-layer winding
Unacceptable
Tape peeling occurred after



coating (inelastic)
Oblique cut

233 prints


6
Metal shaft + conductive
Single-layer winding
Unacceptable
Tape peeling occurred after



rubber (elastic)
Oblique cut

451 prints


7
Metal shaft + conductive
Spiral winding by slightly
Unacceptable
Tape peeling occurred after



coating (inelastic)
more than one turn

231 prints


8
Metal shaft + conductive
Spiral winding by slightly
Unacceptable
Tape peeling occurred after



rubber (elastic)
more than one turn

711 prints


9
Metal shaft + conductive
Triple-layer winding
Acceptable
No tape peeling occurred



coating (inelastic)
Oblique cut

after 5,000 prints


10
Metal shaft + conductive
Triple-layer winding
Acceptable
No tape peeling occurred



rubber (elastic)
Oblique cut

after 5,000 prints









In Table 3, the examples of the invention, that is, Experiment Nos. 1, 2, 9, and 10, were determined to be acceptable because excellent charging could be performed without print errors such as peeling of the films (tapes). On the other hand, print errors occurred after 322 prints in Experiment No. 3, after 455 prints in Experiment No. 4, after 233 prints in Experiment No. 5, after 451 prints in Experiment No. 6, after 231 prints in Experiment No. 7, and after 711 prints in Experiment No. 8. These comparative examples were determined to be unacceptable because the observation found the peeling of the films at the ends at which the films started entering the contact positions (nips) between the charge roller and the photosensitive member. The peeling resulted from decreased adhesion due to foreign matter, such as toner, deposited at the ends of the films. Consequently, the width of the charge gap G exceeded 50 μm, and charging defects occurred.
These experiments demonstrated that the operations and advantages of the embodiments described above could be achieved in noncontact charging by fixing the ends of the films at which they start entering the nips between the charge roller 3a and the photosensitive member 2 to the core 3b of the charge roller 3a and winding the films in layers by slightly less than two turns in a direction opposite the rotational direction α of the charge roller 3a without shifting the films in the axial direction.
The second set of experiments will be described. The second set of experiments relates to the decrease in the thickness of the charged portion of the photosensitive member 2 in the case where the gap members 3d and 3e are formed by winding the films in layers. The second set of experiments includes six experiments, namely, Experiment Nos. 11 to 16. Table 4 shows the types of charge rollers and gap members used in Experiment Nos. 11 to 16.







TABLE 4







(Circumferential speed of photosensitive member: 210 mm/s)















Circumferential


No.
Charge roller
Gap member
Type of film
speed





11
Metal shaft +
Double-layer winding
Polyester tape
199.5 mm/s



conductive coating
Oblique cut
Manufactured by Sumitomo 3M Limited
 (95%)



(inelastic)
G: 30 μm
No. 9391 (thickness: 22 μm)


12
Metal shaft +
Double-layer winding
Polyester tape
203.7 mm/s



conductive rubber
Oblique cut
Manufactured by Sumitomo 3M Limited
 (97%)



(elastic)
G: 32 μm
No. 9391 (thickness: 22 μm)


13
Metal shaft +
Double-layer winding
Polyester tape
220.5 mm/s



conductive coating
Oblique cut
Manufactured by Sumitomo 3M Limited
(105%)



(inelastic)
G: 25 μm
No. 9391 (thickness: 22 μm)


14
Metal shaft +
Double-layer winding
Polyester tape
216.3 mm/s



conductive rubber
Oblique cut
Manufactured by Sumitomo 3M Limited
(103%)



(elastic)
G: 28 μm
No. 9391 (thickness: 22 μm)


15
Metal shaft +
Double-layer winding
Polyester tape
 210 mm/s



conductive coating
Oblique cut
Manufactured by Sumitomo 3M Limited
(100%)



(inelastic)
G: 25 μm
No. 9391 (thickness: 22 μm)


16
Metal shaft +
Double-layer winding
Polyester tape
 210 mm/s



conductive rubber
Oblique cut
Manufactured by Sumitomo 3M Limited
(100%)



(elastic)
G: 28 μm
No. 9391 (thickness: 22 μm)









As shown in Table 4, the charge rollers used in Experiment Nos. 11 to 16 were of the same type as the charge roller 3a shown in FIGS. 13A and 13B. The charge rollers used in Experiment Nos. 11 and 12 were identical to those used in Experiment Nos. 1 and 2, respectively, in the first set of experiments. The charge rollers used in Experiment Nos. 13 and 15 were identical to that used in Experiment No. 11 except that the width of the charge gap G was adjusted to 25 μm. The charge rollers used in Experiment Nos. 14 and 16 were identical to that used in Experiment No. 12 except that the width of the charge gap G was adjusted to 28 μm.
The rotational directions of the photosensitive member 2, the charge roller 3a, and the cleaning member 3o in the second set of experiments were the same as those in the first set of experiments. The circumferential speed of the photosensitive member 2 was adjusted to 210 mm/s, which was the same as in the first set of experiments. The circumferential speed of the charge roller 3a was adjusted to 199.5 mm/s (98% relative to the circumferential speed of the photosensitive member 2) in Experiment No. 11, 203.7 mm/s (97%) in Experiment No. 12, 220.5 mm/s (105%) in Experiment No. 13, 216.3 mm/s (103%) in Experiment No. 14, and 210 mm/s (100%) in Experiment Nos. 15 and 16. Separate power supplies were provided for the photosensitive member 2 and the charge roller 3a to rotate them at different circumferential speeds.
For the voltage Vc (V) applied to the charge roller 3a, VDC=−700 V, Vpp=1,800 V, f=1.3 kHz, and VAC was a sine wave. The rest of the structure of the image-forming apparatus used and the other image-forming conditions were identical to those in the first set of experiments.
Monochrome halftone printing (print density: 25%; full-page solid image) was performed on A4 normal paper. The other printing conditions were identical to those in the first set of experiments.
The printed paper was visually observed. When the observation found a print error (unevenness) due to abnormal charging, the printing was stopped to determine the number of prints at that time. Table 5 shows the number of prints at the time when a print error occurred.







TABLE 5







(Circumferential speed of photosensitive member: 210 mm/s)

















Number of








prints at the





Circumferential
time when print
Thickness
Tape


No.
Charge roller
Gap member
speed
error occurred
difference
peeling





11
Metal shaft +
Double-layer winding
199.5 mm/s
18,000 prints
3 μm
Not



conductive
Oblique cut
(95%)


peeled



coating (inelastic)
G: 30 μm


12
Metal shaft +
Double-layer winding
203.7 mm/s
16,000 prints
3 μm
Not



conductive rubber
Oblique cut
(97%)


peeled



(elastic)
G: 32 μm


13
Metal shaft +
Double-layer winding
220.5 mm/s
17,000 prints
4 μm
Not



conductive
Oblique cut
(105%)


peeled



coating (inelastic)
G: 25 μm


14
Metal shaft +
Double-layer winding
216.3 mm/s
16,000 prints
5 μm
Not



conductive rubber
Oblique cut
(103%)


peeled



(elastic)
G: 28 μm


15
Metal shaft +
Double-layer winding
 210 mm/s
 9,000 prints
11 μm 
Not



conductive
Oblique cut
(100%)


peeled



coating (inelastic)
G: 25 μm


16
Metal shaft +
Double-layer winding
210 mm/s
 9,100 prints
11 μm 
Not



conductive rubber
Oblique cut
(100%)


peeled



(elastic)
G: 28 μm









As shown in Table 5, the number of prints at the time when a print error occurred was 18,000 prints in Experiment No. 11, 16,000 prints in Experiment No. 12, 17,000 prints in Experiment No. 13, 16,000 prints in Experiment No. 14, 9,000 prints in Experiment No. 15, and 9,100 prints in Experiment No. 16. Table 5 also shows the difference in thickness between the charged portion of the photosensitive member 2 and the portions thereof which came into contact the gap members 3d and 3e at the numbers of prints above. In Table 5, the difference in thickness was 3 μm in Experiment No. 11, 3 μm in Experiment No. 12, 4 μm in Experiment No. 13, 5 μm in Experiment No. 14, 11 μm in Experiment No. 15, and 11 μm in Experiment No. 16.
The tapes of the gap members 3d and 3e did not peel in any of Experiment Nos. 11 to 16.
The results shown in Table 5 demonstrated that the difference in thickness between the charged portion of the photosensitive member 2 and the portions thereof which come into contact the gap members 3d and 3e can be reduced in noncontact charging using a superimposed bias voltage containing DC and AC voltage components by rotating the photosensitive member 2 and the charge roller 3a at different circumferential speeds to perform excellent charging over an extended period of time. If the photosensitive member 2 and the charge roller 3a are rotated at different circumferential speeds, the gap members 3d and 3e wear the portions of the photosensitive member 2 which come into contact the gap members 3d and 3e. The thickness of the contact portions is thus decreased as the thickness of the charged portion is decreased with increasing number of prints. This allows for a reduction in the difference in thickness between the contact portions and the charged portion. The charge roller 3a can therefore maintain the charge gap G at a predetermined width or less. The above results thus confirmed that the life of the photosensitive member 2 can be prolonged by rotating the photosensitive member 2 and the charge roller 3a at different circumferential speeds.
As described above, a charge roller according to an embodiment of the invention has gap members formed of tape-shaped films wounded around both ends thereof and defines a predetermined charge gap between the gap members and an image-bearing member to charge the image-bearing member without contact. This charge roller can be suitably used for image-forming apparatuses including electrophotographic apparatuses such as electrostatic copiers, printers, and facsimiles.
The entire disclosure of Japanese Patent Application No. 2005-310809, filed Oct. 26, 2005 is expressly incorporated by reference herein.

## Claims

1. A charge roller comprising:
a core;
a resistive layer disposed on a circumferential surface of the core to charge an image-bearing member without contact; and
gap members formed of tape-shaped films fixed to both ends of the charge roller by winding each of the films in a direction opposite a rotational direction of the charge roller in use and perpendicular to the axial direction thereof to form n layers (wherein n≧2) extending in the axial direction at every position in the circumferential direction of the charge roller, the gap members being pressed against a circumferential surface of an image-bearing member to define a charge gap between the image-bearing member and the charge roller, wherein
the core has annular grooves at both ends thereof;
the resistive layer is disposed on a portion of the core between the annular grooves and in the annular grooves; and
the gap members are fixed to portions of the circumferential surface of the core between the annular grooves and the ends of the core.

2. The charge roller according to claim 1, wherein
one side of each of the films protrudes to the adjacent annular groove; and
the other side of the film protrudes outward beyond the adjacent end surface of the core.

3. A method for producing the charge roller according to claim 1, comprising:
forming the annular grooves at both ends of the core;
covering with masks the portions of the circumferential surface of the core between the annual grooves and the ends of the core;
forming the resistive layer by applying a conductive coating material to the annual grooves and the portion of the core between the annular grooves while rotating the core;
removing the masks from the portions of the circumferential surface of the core between the annual grooves and the ends of the core; and
forming the gap members by winding the films around the portions of the circumferential surface of the core between the annular grooves and the ends of the core in the direction opposite the rotational direction of the charge roller in use and perpendicular to the axial direction of the charge roller to form the n layers.

4. An image-forming apparatus comprising:
an image-bearing member on which an electrostatic latent image or a developer image is formed;
the charge roller according to claim 1, charging the image-bearing member without contact;
a writing unit that writes an electrostatic latent image on the image-bearing member;
a developing unit that develops the electrostatic latent image with a developer to form a developer image on the image-bearing member; and
a transfer unit that transfers the developer image from the image-bearing member.

5. The image-forming apparatus according to claim 4, wherein the image-bearing member and the charge roller are rotated at different circumferential speeds.

6. A charge roller comprising:
a core;
a resistive layer disposed on a circumferential surface of the core to charge an image-bearing member without contact; and
gap members formed of tape-shaped films fixed to both ends of the charge roller by winding each of the films in a direction opposite a rotational direction of the charge roller in use and perpendicular to the axial direction thereof to form n layers (wherein n≧2) extending in the axial direction at every position in the circumferential direction of the charge roller, the gap members being pressed against a circumferential surface of an image-hearing member to define a charge gap between the image-bearing member and the charge roller, wherein
the resistive layer includes thinner portions at both ends of the core and a thicker portion between the ends of the core; and
the gap members are fixed to the thinner portions of the resistive layer.

7. A method for producing the charge roller according to claim 6, comprising:
covering both end portions of the circumferential surface of the core with masks;
forming the thicker portion of the resistive layer by applying a conductive coating material to a portion between the end portions of the circumferential surface of the core to a predetermined thickness while rotating the core;
removing the masks from the end portions of the circumferential surface of the core;
forming the thinner portions of the resistive layer by applying the conductive coating material to both ends of the core to a thickness smaller than that of the thicker portion; and
forming the gap members by winding the films around the thinner portions of the resistive layer in the direction opposite the rotational direction of the charge roller in use and perpendicular to the axial direction of the charge roller to form the n layers.

8. A charge roller comprising:
a core;
a resistive layer disposed on a circumferential surface of the core to charge an image-bearing member without contact; and
gap members formed of tape-shaped films fixed to both ends of the charge roller by winding each of the films in a direction opposite a rotational direction of the charge roller in use and perpendicular to the axial direction thereof to form n layers (wherein n≧2) extending in the axial direction at every position in the circumferential direction of the charge roller, the gap members being pressed against a circumferential surface of an image-bearing member to define a charge gap between the image-bearing member and the charge roller, wherein
the core includes small-diameter portions at both ends thereof and a large-diameter portion between the ends thereof;
the resistive layer is formed on circumferential surfaces of the small-diameter portions and the large-diameter portion so as to have a substantially uniform thickness; and
the gap members are fixed to portions of the resistive layer which cover the small-diameter portions of the core.

9. A method for producing the charge roller according to claim 8, comprising:
forming the resistive layer by applying a conductive coating material to the small-diameter and large-diameter portions of the core to a predetermined thickness while rotating the core; and
forming the gap members by winding the films around the portions of the resistive layer which cover the small-diameter portions of the core in the direction opposite the rotational direction of the charge roller in use and perpendicular to the axial direction of the charge roller to form the n layers.