Apparatus for dispersing and transporting particulates

Abstract: A development apparatus (100) for developing images, such as xerographic images, with particulate material. The apparatus includes a plate member (122) for dispersing and transporting particles such as toner particles that may be prone to agglomeration in a particle dispensing system. Movement and/or vibration of the dispersing and transporting plate member by a motor (125) serves to break up, clear and prevent particle agglomerations. Perforations, slits or mesh areas in the upper surface of the plate member can prevent oversize particles/agglomerations from passing through the system, while side walls, fins or disposing the plate member at a angle can channel the dispersion of the particles contacting the upper surface of the plate member, ensuring the required distribution of the particles.

Description: The present invention relates to an apparatus for use in, for example, a toner supply dispenser such as in a xerographic copier or printer. More specifically, the present invention relates to such an apparatus which disperses and transports toner dispensed into a developer housing. In certain types of electrophotographic printers, particularly those of the "high-volume" or "mid-volume" variety, it is common to provide an external supply of pure toner, which is gradually introduced into the toner-carrier mixture forming the developer as toner is depleted from the toner-carrier mixture in the course of use. This pure toner supply is typically in the form of a separately-purchasable toner bottle. When handled in bulk, toner particles require careful flow control in order to avoid problems such as leakage, clumping, or clogging of the toner supply. Ordinarily, toner comprises very fine particles in combination with a flow agent, and thus flows readily from even the smallest cracks in a toner supply system. Simultaneously, various temperature and humidity conditions may cause toner particles to clump or agglomerate, within a toner supply, thus disturbing the desired constant flow of toner into a system. Such agglomerated toner may then clog or "bridge," between internal surfaces or areas of a toner dispensing system. In a large system, it is desirable to know whether there is an appreciable quantity of toner present at any given point along the toner supply and dispensing system, and to add toner to the system when appropriate. For detecting the presence of toner in a certain location, various types of sensors are well known in the prior art. For example, optical sensors, in which the opacity or light-absorptive qualities of toner are exploited, are known, as are magnetic detectors which are useful in those systems wherein the toner is designed to have a magnetic property associated therewith. Another type of toner sensor which has recently found favor is the vibrational sensor. In such a sensor, These changes in characteristics may be detected electronically, and may be used to control the system or indicate to the user that, for example, the external toner supply bottle is empty. One type of vibrational sensor, made by Motorola, Inc., of Albuquerque, NM, comprises a sandwiched ceramic piezoelectric member, generally forming a plane approximately 1 centimeter square, which forms a "fin" which is intended to extend into a cavity of a container for toner particles. When the cavity is full of toner particles and the fin is thus substantially in contact with toner particles, the fin will vibrate in one detectable way (such as at one frequency), and when the container is empty of toner particles, the fin will be caused to vibrate in another detectable way (such as at another frequency). While such a vibrating fin may enhance sensor operations, it has no effect on other toner agglomeration problems in a copier or printer. Certain products currently commercially available which include this type of vibrational detector are the Xerox Corporation Models No. 5100, as well as certain of the models No. 4850 or "DocuTech" (a trademark of Xerox Corporation) and many other machines. Another Xerox product, the 813 copier, includes a toner dispensing system in which a plate having discharge passages uses wires which move/vibrate once with each copy toner for dispensing toner particles from a hopper (which also vibrates). Other common configurations have a toner bottle oriented so that toner will pour by gravity into an opening adjacent to a rotating auger which in turn is used to distribute toner particles along a length of a developer housing, as is known in the art. The above-mentioned Xerox Corporation products and others often employ systems wherein toner particles negotiate a narrow path from the toner supply bottle through a port to an auger, and further out of a set of ports aligned across the width of the developer housing. It has been found that agglomeration or clumping of toner particles dispensed in a stream to fall from this set of metering ports can occur, potentially causing print defects such as streaking or cometing. These problems are generally manifested by the formation of spots or steaks on the copy or print sheet in background or less than fully toned areas, greatly detracting from the quality of the final produced image. Various approaches have been employed to sift, screen, move or sort particles in addition to the sensor devices described above, including the following disclosures that may be relevant: US-A-5,341,939 discloses a vibrating multi-level device for screening materials. Independently framed vibrating screen decks are angled and used to separate the various sized materials; material guides are provided between screen decks. US-A-5,307,128 discloses a toner supplying device for supplying toner to a developing device in an electrophotographic image forming apparatus comprising a toner hopper for containing and feeding new toner, a recycle device for introducing toner from a cleaner which collects residual toner on an electrostatic latent image carrying member to an outlet of the hopper or the vicinity thereof, a toner agitating chamber opposed to the outlet of the hopper and an outlet of the recycle device, a toner agitating member disposed in the toner agitating chamber, and a toner feeder for feeding the toner from the toner agitating chamber to the developing device. US-A-5,260,746, US-A-5,233,393, US-A-5,095,341, and US-A-5,019,870 disclose the measurement or testing of toner fluidity which includes the vibration of toner through a series of #200, #100 and #60 mesh screens, and thereafter measuring residual toner on the #100 and #60 mesh screens. US-A-5,019,870 discloses an apparatus in which developer material is transported to the latent image. Toner particles are attracted from the carrier granules of the developer material to the latent image. The developer material is in a chamber of a housing and additional toner particles are supplied thereto. Undersized toner particles are removed from the chamber of the housing through a screen using a charged brush. US-A-4,113,371 discloses a development apparatus in which a plurality of differently colorer particles are dispensed into a common sump. Differently colored particles are dispensed in a pre-selected ratio by vibrating toner containers holding different colored toners. The toner containers have floor perforations so as to meter particles into the sump by shaking the container, so as to form a resultant mixture of particles in the sump having a pre-selected color. This mixture is subsequently deposited on a latent image rendering the image visible in the pre-selected color. US-A-4,078,520 discloses a vibrating screen covering a toner density measuring sensor to prevent the sensor from clogging. US-A-3,941,470 discloses an apparatus in which a quantity of particles is stored and gradually dispensed to a mix thereof. A plate having discharge passages moves to dispense toner particles from a hopper. Bridging and caking of the particles is prevented by forming grooves and moving a dispenser plate under the hopper itself each time a document is printed, thus providing an amount of toner for forming a toned image on a photoreceptor. US-A-3,655,033 discloses a toner feed mechanism for use in xerographic reproduction apparatus. The mechanism is characterized by the provision of a container and a structure for vibrating the container so that the toner moves up an internal spiral ramp to an outlet from which the toner phases from the container to a vertically disposed conduit communicating therewith. A screen is provided at the transition between the container and the conduit to prevent passage of irregularly shaped chips which serve to optimize the movement of toner to the outlet and to effect return of the chips to a sump area in the container. US-A-3,654,900 discloses a latent electrostatic image effected by vibrating a mass of two-component developer on a support surface to maintain the developer mass in a fluidized state in close proximity to a latent electrostatic image bearing surface whereby toner is attracted to image areas to effect development thereof. The toner is replenished by passing toner from a suitable toner supply, such as a toner powder cloud, through apertures in the supporting surface which are larger than the toner particles and smaller than the carrier particles, whereby an adequate toner supply is maintained in the development zone without recirculating the carrier. US-A-3,692,403 discloses a reciprocating gate toner dispenser having an override control for manually selecting toner concentrations in a xerographic imaging system to prevent overtoning. A drive mechanism responsive to copy production incrementally moves a toner metering element having slots/wires for pushing toner to openings for dispensing. US-A-3,621,816 discloses an apparatus for developing a latent electrostatic image wherein the developer material is circulated in a highly mobile manner past the image bearing surface. The high mobility of the developer is achieved by the use of interlaced vibrating electrode members wherein the relative movement thereof causes developer material to be circulated about an inner electrode means thereby achieving a high degree of circulation of the carrier material in the developer. The high degree of circulation particles alleviates the problem of sticking of the carrier material to the image bearing surface and overcomes insufficient leading edge development of solid image areas. US-A-3,528,386 discloses an apparatus for dispensing particulate material in a predetermined pattern onto a subjacent surface. The apparatus includes a frame which resiliently supports a material holding hopper with its bottom wall above and facing the subjacent surface. The bottom wall of the hopper is open in the predetermined pattern and a reticulated means, preferably wire mesh, is connected across the open pattern. The openings in the reticulated means are sized so as to be only slightly larger than the average maximum cross-section of the material particles. Additionally, selectively actuatable power means are arranged to impart a relatively high frequency, short amplitude vibration to the hopper. The openings in the mesh are selected so that the material will not pass through the mesh until the hopper is vibrated. This, in effect, provides a valving action without the complexity and limitations inherent in standard valve structures. US 4,122,981 discloses a toner dispensing device in which the toner tank is divided into two portions by a stabilizing plate. A reciprocating toner supplying plate dispenses toner from a plurality of openings in the plate and also strikes against the stabilizing plate to allow toner to be supplied from the upper portion of the hopper into the lower portion of the hopper through openings in the stabilizing plate. According to a first aspect of the present invention, there is provided a development apparatus for developing images with particulate material, including: a hopper for containing the particulate material; a dispenser assembly having at least one dispensing port for dispensing particulate material from the hopper in streams from the dispensing ports; a developer unit; a moveable plate positioned between the dispenser assembly and the developer unit and having an upper surface for contacting the streams of particles; and means operatively associated with the plate for repetitively moving the plate relative to the streams of falling particles so as to disperse the particles contacting the plate. According to a second aspect of the present invention, there is provided a printing machine including a development apparatus according to the first aspect of the present invention. A development apparatus in accordance with the invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is an elevational view of a portion of a developer unit as would be used in an electrophotographic copier or printer; Figure 2A is a top view of a toner dispersing and migrating member of the present invention, shown in isolation; Figure 2B is a top view of another embodiment of the toner dispersing and migrating member of the present invention, shown in isolation; Figure 2C is a top view of another embodiment of the toner dispersing and migrating member of the present invention, shown in isolation; Figure 2D is a top view of another embodiment of the toner dispersing and migrating member of the present invention, shown in isolation; Figure 3A is an elevational view of a toner dispersing and migrating member and system of the present invention; Figure 3B is an elevational view of a another embodiment of the toner dispersing and migrating member and system of the present invention; Figure 3C is an elevational view of a another embodiment of the toner dispersing and migrating member and system of the present invention; and Figure 3D is an elevational view of a another embodiment of the toner dispersing and migrating member and system of the present invention. Figure 1 is a detailed view of a developer unit 100 in which a toner bottle 38, which is inverted to be neck-down, causes toner to be discharged into developer unit 100. Such an arrangement is seen, for example, in the Xerox Corporation Models mentioned above. Bottle 38 opens onto a rotating auger assembly 110, such as is well known in the art of developer units, and which functions to distribute incoming toner in the inboard-outboard directions in a developer housing, so that the developer mix will not be caused to overconcentrate toner at one portion of the developer housing at the expense of another. The developer mix in the developer unit is eventually "picked up" by, for example, magnetic transport or mixing rolls such as rollers 39 for conveyance to or from the latent image on the photoreceptor, as is well known in the art of xerography. Figure 1 shows an exploded view of a developer unit 100 embodying aspects of the present invention. Main toner hopper 38 is shown with a dispense hole 108, below which the auger assembly 110 is positioned. The auger assembly 110 comprises a helical auger blade 112 mounted on a shaft 114, for pulling toner from dispensing port 108. The auger assembly 110 has an upper cover 109 above it and a lower cover 116 beneath it. The lower cover 116 includes a series of dispensing ports 118. A toner distributing member 122 underlies these dispensing ports 118. The toner distributing member 122, which is arranged to make repetitive movements relative to the stream of toner particles which fall onto it, transports and disperses the toner partices as will be described below. As auger blade 112 pulls toner from port 108 of hopper 38, toner is metered from dispensing ports 118 in lower cover 116 across the length of the developer housing (inboard-outboard direction) and in the width (process direction) of a screened/perforated portion of the toner distributing member 122. Member 122 is shown mounted in one embodiment at one end with a flexible hanging member 129, for example of elastomeric material, suspended from a hanging point (not shown) in the side of lower developer housing portion 104. At the opposite end a connector 127 joins member 122 to a linear motor 125 through hole 123 at the opposite end of member 122. In one embodiment, motor 125 moves member 122 in a back and forth motion across the width of developer unit 100, preventing agglomerated toner clumps or balls from passing directly from toner dispensing ports 118 into a series of ports 120 in the lower housing 104. In a preferred embodiment, a linear drive mechanism such as that incorporated into the Model AM-3 air pump manufactured by Apollo Enterprises, Inc., which like other embodiments may be powered by an electrical power supply source (not shown) in the vicinity of developer unit 100 to impart movement to member 122 across the width of developer unit 100. The fresh toner dispensed from hopper 38 is thereby dispersed and transported into position in the inboard-outboard and process directions in developer unit 100 so as to be used to replenish toner levels in the developer unit 100, from which it is transported by rollers 39. Various other embodiments of the toner distributing member and the associated motivating devices are described in greater detail in association with Figures 2A through 2D and Figures 3A through 3D below. Figure 2A shows toner distributing member 122 in isolation, with masked areas 130 preventing toner from spilling off of the lead and trail edges of member 122. Member 122 is further shown with a honeycomb structure of perforations 102 in the dispensing zone of member 122. The motion of member 122 prevents toner agglomerations or clumps much smaller than honeycomb perforations 102 from passing through member 122. (Figure 3D shows another toner distributing member 198 with a similar cross-sectional structure to member 122 shown in Figure 2A, in which toner particles 210 are distributed into the desired entry position over the entire area of ports 120.) Figure 2B shows another embodiment of a toner distributing member 132, in which a planar surface 134 (without perforations) is used to disperse and transport toner to a desired dispensing position off a forward or lead edge of planer surface 134. As particles fall onto member 132, its movement and/or vibration gently cause clumps of toner to disperse. The movement of member 132 prevents particle pile-up or bridging. When one edge of moving member 132 is lower than the other (such as shown by the angled perforated portion 198 of member 192 as shown in Figure 3D), particles can be directed to fall only off of that lower edge. Figure 2C shows another embodiment of toner distributing member 142 in which sidewalls 144 and 146 and accompanying masked portions are used to transport and disperse toner toward the center of transport, such as may be dispensed through the zone of screen area 148. (Figure 3C shows a side view of another embodiment of a member 182 in this case using a screen area 189 and sidewalls 186, which is shaped like member 142.) Figure 2D shows another embodiment of a toner distributing member 152 which includes a wall 154 for preventing toner from spilling from one edge of member 152. Member 152 includes open slit areas 158, from which toner directing fins 156 are folded upwards from the surface of member 152. In this manner, a pattern of slits 158 and fins 156 can transport and channel toner in an angular direction away from each toner dispensing port 118 as shown in Figure 1. (Figure 3B shows a side view of another embodiment of a member 172, which is shaped like member 152, without slits 158 and fins 156.) Figure 3A shows an end profile of a toner distributing member 162, which may in alternative embodiments include solid portions, screen holes, fins, slit, honeycomb perforations or other dispensing areas as previously described in association with Figures 2A through 2D. Figure 3A shows an end view of an embodiment of member 162 which includes one or more piezoelectric elements for creating the desired motion and vibration to transport and disperse toner. A flexible insulating layer 168, typically made of a ceramic material, is coupled with an electrode structure (described below) and causes vibration at a certain frequency while portions of member 162 are in contact with toner particles. The vibrational characteristics of the member 162 will vary depending on whether the vibrating member is in contact with an appreciable amount of toner particles. When there are very few toner particles in contact with the vibrating member 162, such as when the particular location is substantially empty of toner particles, the vibrating member 162 will assume a characteristic vibrational behavior, different from that in the case where the member is vibrating against a mass of toner particles. A rigid rod 170 is shown in end view attached at one edge of flexible insulating layer 168 of vibrating member 162. An upper conductive member 164 overlies flexible insulating layer 168 while a lower conductive member 166 underlies flexible insulating layer 168. Each end of rigid rod 170 is affixed to the side walls of lower developer housing portion 104, in place of the motor 125, member 122, connector 127 and hanger 129 of Figure 1. A voltage is alternatingly applied across upper conductive member 164 and lower conductive member 166 by power source wires (not shown), causing the entire member 162 to oscillate or vibrate generally in the direction of arrows "A" as shown. As member 162 vertically oscillates, toner agglomerations and particles are dispersed as they impact member 162, and are transported off the lower edge of member 162 into ports 120 (as shown in Figure 1). Figure 3B shows an end view of another embodiment of toner distributing member 172 which includes a motor 180, shaft 176 and elliptical cam 178 for impacting the upper surface member 172. As shaft 176 of motor 180 rotates, eccentric/elliptical cam 178 rotates so as to move into and out of contact with the upper surface of member 172, thus imparting the vibration to transport and disperse agglomerations and individual toner particles dispensed onto the upper surface of member 172. Elastomeric support 174 supports the end of member 172, while permitting vertical and other vibrational movement of member 172. Figure 3C shows an end view of another embodiment of the toner distributing member 182 of the present invention. Member 182 includes a screened area 189 and sidewalls 186. Sidewalls 186 prevent toner from spilling from the front and rear edges of member 182. A motor 185 rotates flywheel 187. A pivot 184 connects arm 183 of member 182 to flywheel 187; as motor 185 rotates, flywheel 187 thus imparts a circular motion to member 182 so as to transport and disperse agglomerations and individual toner particles dispensed onto the upper surface of member 182. Figure 3D shows another embodiment of the toner distributing member 192 of the present invention. In this embodiment, member 192 includes a wall and masked area 196 and a wall area 194 for preventing toner from spilling from the front and rear edges of member 192. Toner particles and agglomerations fall into member 192. Perforated area 198 permits toner to be dispersed in all directions while in aggregate transporting toner into ports 120. In this embodiment, a permanent magnet 200 is mounted at one end of member 192. Motor 204 includes a reversible field coil 206, mounted on the opposite side of developer housing wall 105. In this manner, inboard-outboard motion is imparted to member 192 without the need for a hole in housing wall 105, thus preventing any leakage or spillage of toner from lower housing 104. This embodiment, in addition to others described herein, is particularly useful as a retrofit to counteract the print defects that can occur as a result of undispersed toner agglomerations. As shown in Figure 3D, toner particles/agglomerations 210 are dispensed into member 192, dispersed and broken up on masked area 196, transported by the motion/vibration of member 192 to perforated area 198, and cascadingly dispensed across the width (as shown) and length of perforated area 198 into ports 120 of developer housing lower portion 104 (Figure 1). It is to be understood that the present invention is particularly effective in breaking up, clearing and preventing toner agglomerations, and that many combinations of the disclosed motion/vibration imparting motors and devices, as well as perforated and unperforated, walled or unwalled particle/toner dispersing and transporting members, and various motion and vibration-inducing devices may be employed in accordance with the present invention.

Claims: A development apparatus for developing images with particulate material, including: a hopper (38) for containing the particulate material; a dispenser assembly (110:116) having at least one dispensing port (118) for dispensing particulate material from the hopper (38) in streams from the dispensing ports (118); and a developer unit (100); characterised in that a moveable plate is positioned between the dispenser assembly (110;116) and the developer unit (100) having an upper surface for contacting the streams of particles; and the apparatus further comprises means (125) operatively associated with the plate for repetitively moving the plate relative to the streams of falling particles so as to disperse the particles contacting the plate. The development apparatus according to claim 1, wherein a first portion of said plate is movably suspended by a flexible member (129) and wherein a second portion of the plate is connected to said moving means (125). The development apparatus according to claim 1 or claim 2, wherein the upper surface of said plate includes at least one upstanding side wall for preventing particles from falling from an edge of the upper surface of said plate. The development apparatus according to any one of claims 1 to 3, wherein the plate includes a set of perforations for permitting flowthrough of particles. The development apparatus according to any one of claims 1, to 3, wherein the plate includes a mesh area for permitting flowthrough of particles. The development apparatus according to claim 4 or claim 5, wherein the plate includes masked areas for transporting particles to the set of perforations or the mesh in said plate. The development apparatus according to claim 4, wherein the upper surface of said plate includes a set of fins for channeling the particles to the perforations. The development apparatus according to any one of claims 1 to 7, wherein said plate moves in directions substantially perpendicular to the stream of falling particles. A printing machine including a development apparatus according to any one of claims 1 to 8.

Inventors: BERGEN GEORGE F, DENNIE RICHARD H, DENTON GARY A, JENKINS DAVID R, PACER JAMES M, BERGEN, GEORGE F., DENNIE, RICHARD H., DENTON, GARY A., JENKINS, DAVID R., PACER, JAMES M.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1995
Main classification: G03G15
IPC codes: G03G15