Patent Publication Number: US-9891583-B2

Title: Remanufacturing method of developer accommodating unit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation of U.S. application Ser. No. 14/920,575, filed Oct. 22, 2015, which claims the benefit of Japanese Patent Application No. 2014-218518, filed Oct. 27, 2014, all of which are hereby incorporated by reference herein in their entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to a remanufacturing method of a developer accommodating unit for refilling developer. 
     An image forming apparatus forms an image on a recording medium using an electrophotographic image forming process. Examples of image forming apparatuses include electrophotographic copying machines, electrophotographic printers (for example, laser beam printers and light emitting diode (LED) printers), facsimile apparatuses, and word processors. 
     A developing device includes developer, and a developing roller as a developer bearing member for developing an electrostatic latent image formed on a photosensitive drum as an image bearing member. The developing device is detachably attached to an image forming apparatus or a photosensitive drum unit including a photosensitive drum. 
     A cartridge (process cartridge) integrally includes a photosensitive drum and a developing roller, and is detachably attached to an image forming apparatus. 
     Description of the Related Art 
     Japanese Patent No. 3320403 discloses a remanufacturing method of a cartridge having a developing device, more specifically, a remanufacturing method of a cartridge for refilling, using a funnel, toner into a storage container for storing toner, after removing a developing roller and a developing blade. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a remanufacturing method of a developer accommodating unit including a flexible container. 
     According to an aspect of the present invention, a remanufacturing method of a developer accommodating unit including a flexible container provided with an opening and configured to accommodate developer, and a frame member configured to accommodate the flexible container, includes refilling the developer into the frame member. 
     Further features of the present invention will become apparent from the following description of embodiments with reference to the attached drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a sectional view illustrating an image forming apparatus. 
         FIG. 2  is a sectional view illustrating a cartridge. 
         FIG. 3  is a perspective view illustrating the cartridge viewed from a drive side. 
         FIG. 4  is a perspective view illustrating the cartridge viewed from a non-drive side. 
         FIG. 5  is an exploded perspective view illustrating a developing unit. 
         FIG. 6  is a perspective view illustrating a frame member in which a funnel is inserted. 
         FIG. 7A  is a sectional view illustrating the developing unit, and  FIG. 7B  is a perspective view illustrating a flexible container. 
         FIG. 8A  is a sectional view illustrating the frame member before insertion of a flaring member, and  FIG. 8B  is a sectional view illustrating the frame member after insertion of the flaring member. 
         FIG. 9A  is a perspective view illustrating a configuration of a frame member and an unsealing member according to a third embodiment, and  FIG. 9B  is a perspective view illustrating a state where the unsealing member is removed from the frame member according to the third embodiment. 
         FIGS. 10A and 10B  are perspective views illustrating a process for separating a supply roller from the frame member during a developing unit separation process. 
         FIG. 11A  is a sectional view illustrating a process for separating a sealing member and an unsealing member from the frame member, and  FIG. 11B  is a sectional view illustrating a process for refilling developer into a flexible container inside the frame member. 
         FIG. 12  is a sectional view illustrating the frame member in which a funnel is inserted. 
         FIG. 13A  is a sectional view illustrating a frame member after a supply roller is removed according to a fourth embodiment, and  FIG. 13B  is a sectional view illustrating a process for separating a sealing member from an unsealing member and taking out the sealing member from the frame member according to the fourth embodiment. 
         FIG. 14A  is a perspective view illustrating a state before the sealing member is separated from the unsealing member, and  FIG. 14B  is a perspective view illustrating a process for separating the sealing member from the unsealing member. 
         FIG. 15A  is a sectional view illustrating a state after the sealing member is separated from the frame member, and  FIG. 15B  is a sectional view illustrating a process for separating a flexible container from the frame member. 
         FIG. 16  is a sectional view illustrating a process for processing a first communication hole on a frame member of a developing unit separated in a unit separation process according to a fifth embodiment. 
         FIGS. 17A and 17B  are sectional views illustrating a process in which developer is refilled into the frame member and a flexible container is folded. 
         FIG. 18  is a sectional view illustrating a process for sealing the first communication hole. 
         FIG. 19A  is a sectional view illustrating the frame member in which a funnel is inserted before developer is refilled, and  FIG. 19B  is a sectional view illustrating the frame member in which a push-in member is inserted before developer is refilled. 
         FIG. 20  is a sectional view illustrating a process for processing a second communication hole on a frame member. 
         FIG. 21  is a sectional view of the frame member illustrating a process for compressing the flexible container using a pushing-in member to make a capacity of the flexible container smaller than a capacity of the flexible container filled with developer. 
         FIG. 22  is a sectional view illustrating the frame member when the developer is refilled. 
         FIG. 23  is a sectional view of the frame member illustrating a process for sealing the second communication hole. 
         FIGS. 24A, 24B, and 24C  are perspective views illustrating a process for detaching the sealing member from the flexible container. 
     
    
    
     DESCRIPTION OF THE EMBODIMENTS 
     Embodiments of the present invention will be described in detail below with reference to the accompanying drawings. However, sizes, materials, shapes, and relative positions of elements described in the embodiments are not limited thereto, and can be appropriately modified depending on the configuration of an apparatus according to the present invention and other various conditions. Unless otherwise specifically described, the scope of the present invention is not limited to the embodiments described below. Elements in subsequent embodiments that are identical to those in preceding embodiments are assigned the same reference numerals, and descriptions in the preceding embodiments will be incorporated by reference. 
     In the following descriptions, a developer accommodating unit includes at least a frame member and a flexible container. A developing device includes at least a developer bearing member. Further, a process cartridge includes at least an image bearing member. In the embodiments, a developer accommodating unit has the same concept as a developing device. In the embodiments, a developing unit may be independently configured as a developing device. 
     First Embodiment 
       FIG. 1  is a sectional view illustrating an image forming apparatus  1 . The image forming apparatus  1  performs full color image formation, and is provided with an apparatus body  2 . Inside the apparatus body  2 , four cartridges P are detachably attached. In the following descriptions of the image forming apparatus  1 , the front surface is on the right side, the rear surface is on the left side, the drive side is on the rear side, and the non-drive side is on the front side, as illustrated in  FIG. 1 . The cartridges P attached to the apparatus body  2  are the following four cartridges: a first cartridge PY, a second cartridge PM, a third cartridge PC, and a fourth cartridge PK. These cartridges P are disposed in a horizontal direction. 
     These cartridges P have an approximately similar configuration expect for different toner colors. The first cartridge PY accommodates yellow developer, the second cartridge PM accommodates magenta developer, the third cartridge PC accommodates cyan developer, and the fourth cartridge PK accommodates black developer. The image forming apparatus  1  performs color image formation on a recording material S. The image forming apparatus  1  is a cartridge type image forming apparatus in which the cartridges P are detachably attached to the apparatus body  2  and a color image is formed on the recording material S. 
     A mechanism inside the cartridge P is driven by a rotational driving force received from a drive output unit (not illustrated) of the apparatus body  2 . Internal devices in the cartridge P is supplied with bias voltages (a charging bias voltage, a developing bias voltage, etc.) from the apparatus body  2 . 
     An exposure device  200  is disposed above the plurality of cartridges P. The exposure device  200  is a laser scanner unit for irradiating a photosensitive drum  4  with laser light LS based on information transmitted from a controller  50  in the apparatus body  2 . This laser light LS passes through an exposure window portion  10  (refer to  FIG. 2 ) inside the cartridge P, and the surface of the photosensitive drum  4  is exposed to the laser light LS to be scanned. 
     An intermediate transfer belt unit  11  is disposed below the plurality of cartridges P. The intermediate transfer belt unit  11  includes a transfer belt  12 , and a drive roller  13  and tension rollers  14  and  15  for stretching the transfer belt  12 . The transfer belt  12  is made of a flexible material. 
     The bottom surface of the photosensitive drum  4  inside the cartridge P contacts the upper surface of the transfer belt  12 . The relevant contact portion is a primary transfer portion. Inside the transfer belt  12 , primary transfer rollers  16  are disposed to surface respective photosensitive drums  4 . A secondary transfer roller  17  is disposed at a position facing the tension roller  14  via the transfer belt  12 . The contact portion between the secondary transfer roller  17  and the transfer belt  12  is a secondary transfer portion. 
     A feed unit  18  is disposed below the intermediate transfer belt unit  11 . The feed unit  18  includes a tray  19  on which recording materials S are stacked, and a feed roller  20 . A fixing unit  21  and a discharge unit  22  are disposed at the upper left position of the cartridge P. A discharge tray  23  is formed on the upper surface of the apparatus body  2 . The recording material S is fixed by the fixing unit  21  and then discharged onto the discharge tray  23 . 
       FIG. 2  is a sectional view illustrating the cartridge P. The cartridge P includes a photosensitive unit  8  and a developing unit  9 . The photosensitive unit  8  includes the photosensitive drum  4  as an “image bearing member”, a charging roller  5 , and a cleaning member  7 . The charging roller  5  uniformly charges the surface of the photosensitive drum  4 . The cleaning member  7  is a blade for removing residual toner that has been developed on the surface of the photosensitive drum  4 , but has not been transferred onto the primary transfer roller  16 . 
     The developing unit  9  includes a developing roller  6  as a “developer bearing member”, a supply roller  61 , and an agitating member  74 . The developing roller  6  develops an electrostatic image on the surface of the photosensitive drum  4  using toner. The supply roller  61  supplies developer to the developing roller  6 . The agitating member  74  agitates the developer inside the developing unit  9 . 
     Operations of the image forming apparatus  1  will be described below with reference to above-described  FIGS. 1 and 2 . The surface of the photosensitive drum  4  is uniformly charged by the charging roller  5  and then is exposed to light by the exposure device  200 , so that an electrostatic image is formed on the surface of the photosensitive drum  4 . When the electrostatic image is developed by the developing unit  9  using the developer, a developer image is formed. The developer image on the surface of the photosensitive drum  4  is transferred onto the transfer belt  12  rotating in a forward direction (the direction indicated by an arrow C illustrated in  FIG. 1 ) of the rotational direction of the photosensitive drum  4 . Yellow, magenta, cyan, and black developer images are primarily transferred sequentially from the respective photosensitive drums  4  of the first to the fourth cartridges P onto the transfer belt  12  to be superimposed upon one another. 
     Meanwhile, the recording materials S stacked on the tray  19  are separated and fed one by one at a predetermined control timing. Each of the recording materials S is conveyed to the secondary transfer portion between the secondary transfer roller  17  and the transfer belt  12 . At the secondary transfer portion, the developer image on the surface of the transfer belt  12  is secondarily transferred onto the recording material S. 
     The developing unit  9  includes a sealing member  253  for sealing openings  251   h  ( 251   h   1  to  251   h   5 ) and exposing the openings  251   h   1  to  251   h   5  when being moved, and an unsealing member  254  attached to the sealing member  253 , for moving the sealing member  253 . The developing unit  9  further includes a fixing portion  29   b  for fixing a flexible container  251  to the frame member  29 . 
       FIG. 3  is a perspective view illustrating the cartridge P viewed from the drive side.  FIG. 4  is a perspective view illustrating the cartridge P viewed from the non-drive side. As illustrated in  FIGS. 3 and 4 , the photosensitive unit  8  and the developing unit  9  are integrally formed by covers  24  and  25 . Therefore, the photosensitive unit  8  includes the photosensitive drum  4 , the charging roller  5 , the cleaning member  7 , a cleaning container  26 , and the covers  24  and  25 . The photosensitive drum  4  is rotatably supported on the cleaning container  26  by the covers  24  and  25 . 
     One end side of the photosensitive drum  4  in the longitudinal direction is provided with a coupling member  4   a  for transmitting a driving force to the photosensitive drum  4 . When the coupling member  4   a  is engaged with a drum drive output unit of the apparatus body  2 , the driving force of the drive motor (not illustrated) of the apparatus body  2  is transmitted to the photosensitive drum  4 . The charging roller  5  is supported by the cleaning container  26  so that the charging roller  5  can be rotatably driven with being in contact with the photosensitive drum  4 . The cleaning member  7  is supported by the cleaning container  26  so that the cleaning member  7  contacts the circumferential surface of the photosensitive drum  4  at a predetermined pressure. 
     Residual developer removed from the circumferential surface of the photosensitive drum  4  by the cleaning member  7  is stored in the cleaning container  26 . Holes  24   a  and  25   a  for rotatably supporting the developing unit  9  are formed on the covers  24  and  25 , respectively. 
       FIG. 5  is an exploded perspective view illustrating the developing unit  9 . The flexible container  251  illustrated in  FIG. 2  is stored in the developing unit  9  illustrated in  FIG. 5 . As illustrated in  FIG. 5 , the developing unit  9  includes the developing roller  6 , a developing blade  31 , the frame member  29 , bearings  45  and  46 , and a cover  32 . The developing unit  9  refers to a unit including at least the flexible container  251 , the sealing member  253 , and the unsealing member  254  inside the frame member  29  (refer to  FIG. 2 ). The developing unit  9  includes the flexible container  251  for storing developer T, and the frame member  29  for storing the flexible container  251 . The flexible container  251  is provided with the openings  251   h   1  to  251   h   5  for discharging the developer T. 
     As illustrated in  FIG. 2 , the flexible container  251  is provided with a fixed member  251 Z on which a hole  251   a  for fixing the flexible container  251  to the frame member  29  is formed, an accommodating portion  251   b  for accommodating (storing) the developer, and the openings  251   h  ( 251   h   1  to  251   h   5 ) for discharging the developer. When the cartridge P is new, since the openings  251   h  ( 251   h   1  to  251   h   5 ) are covered by the sealing member  253  detachably welded to the flexible container  251 , the developer is sealed inside the flexible container  251 . 
     The sealing member  253  is coupled to the unsealing member  254 . The unsealing member  254  is supported so as to be rotatable in the direction indicated by an arrow J by receiving a driving force from the apparatus body  2 . When the new cartridge P is used, the cartridge P is attached to the apparatus body  2 . Then, the unsealing member  254  receives a driving force from the apparatus body  2  to rotate. 
     At this timing, the sealing member  253  is detached from the flexible container  251  and is rolled up by the unsealing member  254 . Thus, the openings  251   h  ( 251   h   1  to  251   h   5 ) of the flexible container  251  are exposed, enabling the developer in the flexible container  251  to be discharged into the frame member  29 . 
     The developing blade  31  for regulating the layer thickness of the developer on the circumferential surface of the developing roller  6  is fixed to the frame member  29 . The bearings  45  and  46  illustrated in  FIG. 5  are fixed at both ends of the frame member  29  in the longitudinal direction. Gears  70 ,  69 , and  68  are disposed on the drive side end. The shaft of the supply roller  61  is fitted into the gear  70 . The shaft of the developing roller  6  is fitted into the gear  69 . The shaft of the agitating member  74  ( FIG. 2 ) is fitted into the gear  68 . 
     The gear  69  is set to rotate when the gear  68  rotates. The bearing  45  is provided with the gears  68 ,  69 , and  70 . The cover  32  is fixed to the outside of the gears  68 ,  69 , and  70 . End seals  62  are disposed at both ends of the shaft of the supply roller  61  to seal between the supply roller  61  and the frame member  29 . 
     As illustrated in  FIG. 5 , the cover  32  is provided with a cylindrical portion  32   b . A drive transmission portion  68   a  (refer to  FIG. 3 ) of the gear  68  is exposed through an opening  32   d  inside the cylindrical portion  32   b . When the cartridge P is attached to the apparatus body  2 , the drive transmission portion  68   a  of the gear  68  is engaged with an apparatus body drive transmission member (not illustrated), so that a driving force from a drive motor (not illustrated) provided in the apparatus body  2  is transmitted. The driving force input from the apparatus body  2  to the gear  68  is transmitted to the developing roller  6  via the gear  69 . 
     [Photosensitive Unit and Developing Unit Assembling Process] 
     As illustrated in  FIGS. 3 and 4 , when assembling the developing unit  9  and the photosensitive unit  8 , the outer diameter portion of the cylindrical portion  32   b  of the cover  32  is fitted into the hole  24   a  of the cover  24  on one end side. Then, a protruding portion  46   b  protruding from the bearing  46  is fitted into the hole  25   a  of the cover  25  on the other end side. Thus, the developing unit  9  is supported so as to be rotatable with respect to the photosensitive unit  8 . The developing unit  9  is rotatable around an axis line connecting the hole  24   a  of the cover  24  and the hole  25   a  of the cover  25 . The rotation center of the developing unit  9  is referred to as a rotation center X. 
     As illustrated in  FIG. 2 , the developing unit  9  is urged by a pressure spring  95  as an elastic member so that the developing roller  6  contacts the photosensitive drum  4  around the rotation center X. More specifically, the developing unit  9  is pressed in the direction indicated by an arrow G illustrated in  FIG. 2  by an urging force of the pressure spring  95  so that a moment in the direction indicated by an arrow H acts around the rotation center X. 
     Referring to  FIG. 5 , the gear  68  receives a rotational driving force in the direction indicated by the arrow H (refer to  FIG. 2 ) from an apparatus body drive transmission member (not illustrated) provided on the apparatus body  2 . The gear  69  engaged with the gear  68  thereby rotates in the direction indicated by an arrow E. Likewise, the developing roller  6  thereby rotates in the direction indicated by the arrow E. When a driving force required for rotating the developing roller  6  is input to the gear  68 , a rotational moment in the direction indicated by the arrow H arises in the developing unit  9 . 
     A pressing force of the above-described pressure spring  95  (refer to  FIG. 2 ) and a rotational driving force from the apparatus body  2  cause the developing unit  9  to receive a moment in the direction indicated by the arrow H around the rotation center X. Then, the developing roller  6  contacts the photosensitive drum  4  at a predetermined pressure. Although, in the first embodiment, two forces, i.e., the pressing force by the pressure spring  95  and the rotational driving force from the apparatus body  2  are used to press the developing roller  6  against the photosensitive drum  4 , only either one force may be used for the relevant purpose. 
     With the cartridge P being attached to the inside of the apparatus body  2 , image formation is performed while consuming the developer inside the developing unit  9 . The remanufacturing method of the cartridge P of refilling the developer into the developing unit  9  after consuming the developer inside the developing unit  9  will be sequentially described below. 
     [Unit Separation Process] 
     A unit separation process for separating the photosensitive unit  8  and the developing unit  9  of the cartridge P will be described below. As illustrated in  FIG. 3 , when the covers  24  and  25  are removed from the cleaning container  26 , the developing unit  9  and the photosensitive unit  8  can be separated. As described above, since the covers  24  and  25  and the cleaning container  26  rotatably support the photosensitive drum  4 , the above-described unit separation process enables the separation of the photosensitive drum  4  from the photosensitive unit  8 . 
     [Developing Unit Disassembling Process] 
     A process for disassembling the developing unit  9  will be described below with reference to  FIG. 5 . First of all, the cover  32  provided at the drive side end of the developing unit  9  is separated from the frame member  29 . When the cover  32  is fixed to the bearing  45  and the frame member  29  with a screw  93 , the screw  93  is removed and then the cover  32  is separated from the developing unit  9 . 
     Then, on the drive side of the developing unit  9 , the gears  68 ,  69 , and  70  disposed inside the cover  32  in the longitudinal direction are separated from the developing unit  9 . The gear  68  is slidably supported by the cover  32  and the bearing  45 , and the gear  69  is fitted into an end of the shaft of the developing roller  6 . The gear  70  is fitted into the shaft of the supply roller  61 . Therefore, the gears  68 ,  69 , and  70 , the developing roller  6 , and the supply roller  61  can be easily separated from the developing unit  9 . 
     Then, the bearings  45  and  46  and the developing roller  6  are separated from the developing unit  9 . When the bearing  45  is fixed to the frame member  29  with a screw, the screw is removed and then the bearing  45  is separated from the frame member  29 . In the present embodiment, the bearing  45  and the cover  32  are fixed together to the frame member  29  with the screw  93 . Since the screw  93  has been removed when the cover  32  is separated from the frame member  29 , the bearing  45  can be easily separated from the frame member  29 . Likewise, when the bearing  46  is fixed to the frame member  29  with a screw, the bearing  46  can be separated from the frame member  29  after the screw is removed. 
     As described above, the developing roller  6  is slidably supported on the frame member  29  by the bearings  45  and  46 . Therefore, in a state where the bearings  45  and  46  are separated from the frame member  29 , the developing roller  6  can be easily separated from the frame member  29 . Although, in the above descriptions, a process for separating both the bearings  45  and  46  from the frame member  29  is performed to separate the developing roller  6  from the frame member  29 , the method is not limited thereto. For example, after only the bearing  46  is separated from the frame member  29 , the developing roller  6  may be pulled out toward the non-drive side to separate the developing roller  6  from the frame member  29 . 
     Then, the developing blade  31  is separated from the frame member  29 . When the developing blade  31  is fixed to the frame member  29  with screw  91  and  92 , the screws  91  and  92  are removed and then the developing blade  31  is separated from the frame member  29 . 
       FIGS. 24A, 24B, and 24C  are perspective views illustrating a process for detaching the sealing member  253  from the flexible container  251 . The flexible container  251  is accommodated (stored) inside the frame member  29 . When the unsealing member  254  rotates, the sealing member  253  is separated from an attachment and detachment area  500  around the openings  251   h   1  to  251   h   4  of the accommodating portion  251   b  of the flexible container  251 . Although four openings  251   h  are illustrated in  FIGS. 24A, 24B, and 24C , there are five openings  251   h  in the present embodiment. 
     The attachment and detachment area  500  has two different portions on the downstream side in the detachment direction: parallel portions  80   b  parallel to the axis direction of the developing roller  6 , and mountain-shaped portions  80   c  having a mountain shape toward the downstream side in the detachment direction. The attachment and detachment area  500  further includes a detachment start portion  80   a  parallel to the axis direction of the developing roller  6 , at the upstream side in the detachment direction. The sealing member  253  is pulled in the direction indicated by an arrow O 1  and the direction indicated by the arrow O 2  to be detached in states illustrated in  FIGS. 24A, 24B, and 24C  in this order. 
     (Flexible Container Compression Process) 
       FIG. 6  is a perspective view illustrating the frame member  29  in which a funnel  101  inserted.  FIG. 7A  is a sectional view illustrating the frame member  29  before the developer T is refilled. A process for compressing the flexible container  251  to make the capacity of the flexible container  251  inside the frame member  29  smaller than the capacity of the flexible container  251  filled with the developer T will be described with reference to  FIGS. 6 and 7A . In the compression process, the tip portion of the funnel  101  is inserted into an exposed opening  29   a  of the frame member  29  as illustrated in  FIG. 6 . In this case, the tip portion of the funnel  101  reaches the inside of the frame member  29  as illustrated in  FIG. 7A . 
     When air is injected into the funnel  101  in the direction indicated by an arrow M, the injected air advances in the directions indicated by arrows A (A 1  to A 3 ) inside the frame member  29 . Then, the pressure of the injected air compresses the flexible container  251  in the directions indicated by arrows B (B 1  to B 3 ) to reduce the capacity of the flexible container  251 . Injecting air into the frame member  29  in this way enlarges a refilling space  255 , which is provided inside the frame member  29  and outside the flexible container  251 . Hereinafter this space will be referred to as the refilling space  255 . 
     The above-described procedures are summarized as follows. The remanufacturing method of the developing unit  9  includes a compression process. In the compression process, the capacity of the flexible container  251  is reduced by injecting air into the refilling space  255 . In the compression process, the flexible container  251  is folded by pressing the flexible container  251  with a pressing member. Thus, the remanufacturing method of the developing unit  9  includes a compression process for compressing the flexible container  251  inside the frame member  29  to make the capacity of the flexible container  251  smaller than the capacity of the flexible container  251  filled with the developer T. The compression process enlarges the refilling space  255 . 
     (Developer Refilling Process) 
       FIG. 7B  is a sectional view illustrating the frame member  29  after filling the developer. The refilling process for refilling the developer into the frame member  29  will be described below with reference to  FIG. 7B . In the developer refilling process, the developer T is injected into the funnel  101  in the direction indicated by the arrow M as illustrated in  FIG. 7B . The injected developer T falls into the frame member  29  from the tip portion of the funnel  101 , and the developer T is refilled into (or accumulated in) the refilling space  255  between the frame member  29  and the flexible container  251  (refilling process). In this way, the developer T is refilled into the frame member  29 . Using a fixed-rate feeding device having an auger instead of the funnel  101  enables efficient injection of the developer T into the frame member  29 . 
     Although, in the present embodiment, the funnel  101  is inserted into the opening  29   a  of the frame member  29 , the flexible container  251  is compressed, and the developer T is refilled, the method is not limited thereto. More specifically, the above-described compression process and refilling process may be performed after a hole is formed on the frame member  29  and then the tip portion of the funnel  101  is inserted into the frame member  29 . 
     Although, in the present embodiment, the flexible container  251  is compressed using air in the compression process so as to efficiently compress the flexible container  251 , the method is not limited thereto. More specifically, in the developer refilling process, the flexible container  251  may be compressed using the developer T injected from the funnel  101  and the developer T may be filled into the frame member  29 . 
     [Developing Unit Assembling Process] 
     As described above, the developer is refilled into the frame member  29  and then the cartridge P is reassembled. The cartridge P can be reassembled by performing the above-described separation process in reverse order. The reassembling method of the developing unit  9  will be described below with reference to  FIG. 5 . 
     First of all, the supply roller  61  is fitted into the frame member  29 . The gap between the shaft of the supply roller  61  and the frame member  29  is sealed by the end seals  62 . The developing blade  31  is fixed to the frame member  29  with the screws  91  and  92 . Then, the developing roller  6  is placed in the frame member  29 , and the bearings  45  and  46  are attached to the frame member  29  from both ends in the longitudinal direction. 
     Then, the gear  68  is fitted into the bearing  45 , the gear  69  is fitted into an end of the developing roller  6 , and the gear  70  is fitted into an end of the supply roller  61 . Then, the cover  32  is fixed to the outside of the frame member  29  or the bearing  45  in the longitudinal direction with the screw  93  so as to cover the gears  68  and  69 . Upon completion of the above-described procedure, the assembling process of the developing unit  9  is completed. 
     [Unit Combining Process] 
     A unit combining process for combining the photosensitive unit  8  and the developing unit  9  will be described below with reference to  FIG. 3 . In this process, the cleaning container  26 , the photosensitive drum  4 , and the developing unit  9  are simultaneously sandwiched between the covers  24  and  25 . To hold the developing unit  9  so as to be rotatable with respect to the photosensitive unit  8 , the outer diameter portion of the cylindrical portion  32   b  of the cover  32  is fitted into the hole  24   a  of the cover  24 . The protruding portion  46   b  protruding from the bearing  46  is fitted into the hole  25   a  of the cover  25 . 
     Upon completion of the above-described procedure, the assembly of the cartridge P is completed as illustrated in  FIG. 2 . Note that the cartridge P that has undergone the above-described processes is equivalent to the cartridge P illustrated in  FIG. 2  except that the flexible container  251  is removed. The above-described remanufacturing method of the cartridge P achieves a simplified remanufacturing method of the cartridge P. 
     Second Embodiment 
     The second embodiment differs from the first embodiment in the flexible container compression process, out of the cartridge disassembling process, the flexible container compression process, the developer refilling process, and the cartridge assembling process. The flexible container compression process will be described below. 
     (Compression Process) 
       FIG. 8A  is a sectional view illustrating the frame member  29  before insertion of a flaring member  256 .  FIG. 8B  is a sectional view illustrating the frame member  29  after insertion of the flaring member  256 . A compression process for compressing the flexible container  251  inside the frame member  29  to make the capacity of the flexible container  251  smaller than the capacity of the flexible container  251  filled with the developer T will be described below with reference to  FIGS. 8A and 8B . As illustrated in  FIG. 8A , the flaring member  256  is expandable and foldable. When the flaring member  256  is folded, it can be inserted through a small opening such as the opening  29   a  of the frame member  29 . 
     As illustrated in  FIG. 8B , when the folded flaring member  256  is inserted into the frame member  29 , the flaring member  256  expands in the directions indicated by arrows C 1  to C 4  illustrated in  FIG. 8B  inside the frame member  29 . In this case, the flexible container  251  receives a force from the flaring member  256  and is compressed. Thus, the flaring member  256  compresses the flexible container  251  inside the frame member  29 . In the compression process, the flaring member  256  is inserted at the position of the flexible container  251  and expands while pushing the flexible container  251 , thereby reducing the capacity of the flexible container  251 . At the same time, the refilling space  255  between the frame member  29  and the flexible container  251  is expanded. 
     The flaring member  256  is a flexible sheet made of polyethylene terephthalate with a 200-μm thickness. The material of the flaring member  256  may be other flexible materials. The flaring member  256  may be left inside the frame member  29  after being inserted therein, or may be taken out through the opening  29   a  to the outside of the frame member  29  afterwards. 
     Although, in the present embodiment, the flaring member  256  is inserted through the opening  29   a  of the frame member  29 , the flexible container  251  is compressed, and the developer T is refilled, the method is not limited thereto. More specifically, the refilling process may be performed after a hole is formed on the frame member  29  and the flaring member  256  is inserted into the frame member  29 . 
     Third Embodiment 
       FIG. 9A  is a perspective view illustrating the configuration of the frame member  29  and the unsealing member  254  according to the third embodiment.  FIG. 9B  is a perspective view illustrating a state where the unsealing member  254  is removed from the frame member  29  according to the third embodiment. An unsealing gear  67  is fitted into a hole  254   b  of the unsealing member  254  from the outside on the drive side of the frame member  29 . On the non-drive side, a shaft  254   a  of the unsealing member  254  is fitted into a hole  29   c  formed inside the frame member  29 . The unsealing member  254  is configured to receive a driving force from the apparatus body  2  to be rotatable in the direction indicated by the arrow J illustrated in  FIG. 2 . Before removing the unsealing member  254 , the user needs to complete the separation process of the photosensitive unit  8  and the developing unit  9 . 
       FIGS. 10A and 10B  are perspective views illustrating a process for separating, from the frame member  29 , the supply roller  61  in the separation process of the developing unit  9 . As illustrated in  FIG. 10A , when the shaft of the supply roller  61  is fitted into the hole  29   c  of the frame member  29  and the gap between the shaft of the supply roller  61  and the frame member  29  is sealed by the end seals  62 , the end seals  62  are taken out and then the supply roller  61  is separated from the frame member  29 . 
     Although the user may perform the removing process of both of the respective end seals  62  on the drive side and the non-drive side, the method is not limited thereto. For example, after performing the removing process only for the end seal  62  on the non-drive side, the supply roller  61  may be pulled out toward the non-drive side to separate it from the frame member  29 . 
     Although, in the above descriptions, the supply roller  61  is fitted into the frame member  29 , the supply roller  61  may be fixed to the frame member  29  via a fixing member  63  of the supply roller  61  (refer to  FIG. 10B ). In this case, the fixing member  63  of the supply roller  61  is separated from the frame member  29 . Then, the supply roller  61  is separated from the frame member  29 . 
     Although the user may perform the process for separating the fixing member  63  of the supply roller  61  from the frame member  29  on both of the non-drive side and the drive side, the user may perform the removing process only on either one of the non-drive side and the drive side. For example, when the removing process of the fixing member  63  of the supply roller  61  is performed only on the non-drive side, the supply roller  61  can be separated from the frame member  29  by pulling out the supply roller  61  toward the non-drive side. 
     [Sealing Member and Unsealing Member Separation Process] 
       FIG. 11A  is a sectional view illustrating a process for separating the sealing member  253  and the unsealing member  254  from the frame member  29 .  FIG. 11B  is a sectional view illustrating a process for refilling the developer into the flexible container  251  inside the frame member  29 . Since the sealing member  253  and the unsealing member  254  are engaged with each other, they can be simultaneously separated from the frame member  29 . In other words, the remanufacturing method includes a separation process of the sealing member  253  and the unsealing member  254  for separating the sealing member  253  and the unsealing member  254  from the developing unit  9 . First of all, the unsealing gear  67  (refer to  FIG. 9A ) fitted into the hole  254   b  of the unsealing member  254  from the outside of the surface on the drive side of the frame member  29  is removed. 
     On the non-drive side, the shaft  254   a  of the unsealing member  254  is fitted into the hole  29   c  formed inside the frame member  29 . In a state where the unsealing gear  67  on the drive side has been taken out from the unsealing member  254 , the shaft  254   a  can be easily pulled out from the hole  29   c . As illustrated in  FIG. 11A , the unsealing member  254  is moved through the opening  29   a  in the direction indicated by an arrow I, so that the unsealing member  254  is separated from the frame member  29 . 
     Then, the unsealing gear  67  once removed is reattached to the frame member  29 . Although the unsealing gear  67  is reattached to the frame member  29  in the present embodiment, the hole on the frame member  29  in which the unsealing gear  67  had been inserted may be blocked by a sealing member. In the above-described separation process, the sealing member  253  and the unsealing member  254  are separated from the frame member  29 . 
     [Flexible Container Compression Process] 
       FIG. 12  is a sectional view illustrating the frame member  29  in which the funnel  101  is inserted. A compression process for compressing the flexible container  251  inside the frame member  29  to make the capacity of the flexible container  251  smaller than the capacity of the flexible container  251  filled with the developer T will be described below with reference to  FIG. 12 . 
     As illustrated in  FIG. 12 , in the compression process, the tip portion of the funnel  101  is inserted into the exposed opening  29   a  of the frame member  29 . In this case, the tip portion of the funnel  101  reaches the inside of the frame member  29 . When air is injected into the funnel  101  in the direction indicated by the arrow M, the injected air advances in the directions indicated by the arrows A (A 1  to A 3 ) inside the frame member  29 . Then, the pressure of the injected air compresses the flexible container  251  in the directions indicated by the arrows B (B 1  to B 3 ) to reduce the capacity of the flexible container  251 . Injecting air into the frame member  29  in this way compresses the flexible container  251  to form a space in the frame member  29 . Hereinafter, this space is referred to as a refilling space  255 . 
     Although, in this compression process, the flexible container  251  is compressed by injecting air into the frame member  29 , it is also possible to directly flare the flexible container  251  using a flaring member (not illustrated) to compress the flexible container  251 . 
     [Developer Refilling Process] 
       FIG. 11B  is a sectional view illustrating a process for refilling the developer into the frame member  29 . A process for refilling the developer will be described below with reference to  FIG. 11B . In the developer refilling process, the funnel  101  injects the developer T in the direction indicated by the arrow M. The injected developer T falls into the frame member  29  from the tip portion of the funnel  101 , and is accumulated in the refilling space  255  inside the frame member  29 . In this way, the developer T is filled into the frame member  29 . 
     According to the above-described method, since the unsealing member  254  is separated from the frame member  29 , the injection of the developer T is not disturbed by the unsealing member  254 . Further, the injection of the developer T is not blocked by the sealing member  253 . Therefore, the developer T can be efficiently injected. Using a fixed-rate feeding device having an auger instead of the funnel  101  enables efficient injection of the developer T into the frame member  29 . 
     Although, in the present embodiment, air is used in the compression process to efficiently compress the flexible container  251 , the method is not limited thereto. More specifically, in the developer refilling process, the developer T injected from the funnel  101  may be used to compress the flexible container  251  and the developer T may be filled into the frame member  29 . 
     [Developing Unit Reassembling Process] and [Unit Combining Process] 
     Subsequently, a reassembling process of the developing unit  9  and a unit combining process of the photosensitive unit  8  and the developing unit  9  are performed. Upon completion of the above-described procedure, the assembly process of the cartridge P is completed as illustrated in  FIG. 2 . The above-described remanufacturing method of the cartridge P enables achievement of a simplified remanufacturing method of the cartridge P. 
     Fourth Embodiment 
       FIG. 13A  is a sectional view illustrating the frame member  29  after the supply roller  61  is removed according to the fourth embodiment.  FIG. 13B  is a sectional view illustrating a process for separating the sealing member  253  from the unsealing member  254  and then taking out the sealing member  253  from the frame member  29  according to the fourth embodiment. The sealing member  253  is engaged with the unsealing member  254  through, for example, thermal welding, ultrasonic welding, or adhesion. 
     The unsealing member  254  is manually rotated so that a free end  253   a  of the sealing member  253  is positioned at the opening  29   a . A portion of the sealing member  253  excluding an engaged portion  253   b  engaged with the unsealing member  254  is cut off in the longitudinal direction using a cutter. As illustrated in  FIG. 13B , the sealing member  253  is separated from the frame member  29  through the opening  29   a . The above-described process can be summarized as follows. The remanufacturing method includes a separation process of the sealing member  253  for partly separating the sealing member  253  from the developing unit  9 . In the separation process, the sealing member  253  is cut off at a “portion other than the engaged portion” engaged with the unsealing member  254  (including a separation cutoff line  253   c  illustrated in  FIGS. 14A and 14B ) and then separated from the frame member  29 . 
     In the present embodiment, the sealing member  253  excluding the engaged portion  253   b  engaged with the unsealing member  254  is cut off. However, in the case of welding or adhesion in which the engaged portion  253   b  and the unsealing member  254  are easy to be detached, the sealing member  253  may be detached including the engaged portion  253   b . In other words, in this separation process, the engaged portion  253   b  engaged with the unsealing member  254  is disengaged, and the sealing member  253  is thereby separated from the frame member  29  of the developing unit  9 . 
       FIG. 14A  is a perspective view illustrating a state before the sealing member  253  is separated from the unsealing member  254 .  FIG. 14B  is a perspective view illustrating a process for separating the sealing member  253  from the unsealing member  254 . As illustrated in  FIG. 14B , the separation cutoff line  253   c  to be used for cutting the sealing member  253  from the unsealing member  254  is formed on the sealing member  253 , making it easier to separate the sealing member  253 . 
     [Flexible Container Separation Process] 
       FIG. 15A  is a sectional view illustrating a state after the sealing member  253  is separated from the frame member  29 . Since the flexible container  251  is fixed to the frame member  29  by the fixing portion  29   b  of the frame member  29 , the fixing portion  29   b  is first unfixed. In the present embodiment, as a method for fixing the fixing portion  29   b , a boss of the frame member  29  is put through a hole on the flexible container  251  and then the boss is crushed through ultrasonic swaging. 
       FIG. 15B  is a sectional view illustrating a process for separating the flexible container  251  from the frame member  29 . As illustrated in  FIG. 15B , if the above-described boss is cut off, the flexible container  251  can be taken out from the frame member  29 . 
     Although, in the present embodiment, the fixing portion  29   b  is unfixed and then the flexible container  251  is taken out from the frame member  29 , the flexible container  251  may be detached from the frame member  29  by cutting off a portion excluding the fixing portion  29   b . After the flexible container  251  is detached from the frame member  29  in this way, the flexible container  251  is pulled out and separated through the opening  29   a . According to the above-described method, in the developer refilling process, the developer T is efficiently injected into the frame member  29  without the opening  29   a  being blocked by the sealing member  253 . 
     Although, in the fourth embodiment, only the sealing member  253  is separated from the unsealing member  254  and the flexible container  251  is thereby separated from the frame member  29 , the method is not limited thereto. More specifically, similar to the third embodiment, the sealing member  253  may be separated from the frame member  29  together with the unsealing member  254  and the flexible container  251  may be thereby separated from the frame member  29  in the method according to the fourth embodiment. 
     Although, in the third embodiment, the sealing member  253  is separated from the frame member  29  together with the unsealing member  254 , the method is not limited thereto. More specifically, similar to the fourth embodiment, only the sealing member  253  may be separated from the unsealing member  254  and the flexible container  251  may be thereby separated from the frame member  29  in the method according to the third embodiment. 
     Fifth Embodiment 
     In the fifth embodiment, the remanufacturing method of the developing unit  9  includes a communication hole processing process for processing a first communication hole  109  for refilling the developer T into the frame member  29 , and a communication hole sealing process for sealing the first communication hole  109  to seal the developer T filled in the frame member  29 . The remanufacturing method will be described in detail below. 
     [Communication Portion Processing Process] 
       FIG. 16  is a sectional view illustrating a process for processing the first communication hole  109  on the frame member  29  of the developing unit  9  separated by the unit separation process according to the fifth embodiment. First of all, it is desirable to hold the developing unit  9  so that the surface having the fixing portion  29   b  is oriented downward in the gravity direction. Then, the first communication hole  109  is processed on the vertically upper surface of the frame member  29  in the above-described orientation. A developer refilling device is to be inserted into the first communication hole  109  from the outside of the frame member  29  in the developer refilling process (described below). Therefore, the first communication hole  109  needs to be larger than the tip portion of the developer refilling device. However, the first communication hole  109  may have any shape as long as it is larger than the tip portion of the developer refilling device. 
     [Developer Refilling Process] 
       FIGS. 17A and 17B  are sectional views illustrating a process in which the developer is directly refilled into the frame member  29  and the flexible container  251  is folded. In the developer refilling process, as illustrated in  FIG. 17A , the developer T is injected in the direction indicated by the arrow M using the funnel  101 . The injected developer T falls into the frame member  29  from the tip portion of the funnel  101 , and is accumulated in the refilling space  255  inside the frame member  29 . In this case, the flexible container  251  receives a force in the directions indicated by the arrows A (A 1  to A 3 ) illustrated in  FIG. 17A  by the gravity applied to the developer T, and is thereby compressed. Then, as illustrated in  FIG. 17B , the developer T is filled into the flexible container  251 . 
     Although, in the present embodiment, the funnel  101  is used for refilling the developer T, the device used for refilling the developer T is not limited thereto. For example, a fixed-rate feeding device having an auger may be used instead of the funnel  101 . Using a fixed-rate feeding device having an auger enables efficient injection of the developer T into the frame member  29 . 
     [Communication Portion Sealing Process] 
       FIG. 18  is a sectional view illustrating a process for sealing the first communication hole  109 . This process is performed for attaching a resealing member  103  for sealing the communication portion, to the first communication hole  109  using a two-sided tape  104  so as to seal the first communication hole  109 , and thereby preventing leakage of the developer T from the frame member  29 . It is desirable to attach the resealing member  103  in a similar orientation to that when refilling the developer T, as illustrated in  FIG. 18 , i.e., in a state where the developing unit  9  is held so that the first communication hole  109  is oriented vertically upward. Then, the resealing member  103  is attached to the frame member  29  so as to cover the first communication hole  109 . 
     The resealing member  103  may have any shape as long as it covers the first communication hole  109  to prevent leakage of the developer T from the frame member  29 . Further, the resealing member  103  may be attached by using an adhesive instead of a two-sided tape. Further, the resealing member  103  may not necessarily be a member to be attached using the two-sided tape  104  or an adhesive, and may be a member to be fitted into the first communication hole  109 , such as a cap. In the above-described processes, the developing unit  9  refilled with the developer T has been remanufactured. 
     [Unit Combining Process] 
     Subsequently, the user performs the unit combining process for combining the photosensitive unit  8  and the developing unit  9 . 
     Sixth Embodiment 
     [Compression Process] 
       FIG. 19A  is a sectional view illustrating the frame member  29  in which the funnel  101  is inserted, before the developer is refilled. A compression process for compressing the flexible container  251  inside the frame member  29  to make the capacity of the flexible container  251  smaller than the capacity of the flexible container  251  filled with the developer T will be described below with reference to  FIG. 19A . In the compression process, as illustrated in  FIG. 19A , the tip portion of the funnel  101  is inserted into the first communication hole  109 . In this case, the tip portion of the funnel  101  reaches the inside of the frame member  29 . When compressed air is injected into the funnel  101  in the direction indicated by the arrow M, the injected air advances in the directions indicated by the arrows J (J 1  to J 3 ) inside the frame member  29 . Then, the pressure of the injected air compresses the flexible container  251  in the directions indicated by arrows K (K 1  to K 3 ) to reduce the capacity of the flexible container  251 . 
     Although, in the sixth embodiment, compression using air is performed as a compression process, the compression method is not limited thereto. For example, the flexible container  251  may be compressed using a pushing-in member  105  having higher rigidity than the flexible container  251 , as illustrated in  FIG. 19B . When the pushing-in member  105  is used, the flexible container  251  can be folded along the frame member  29  by compressing it in the directions indicated by arrows L (L 1  to L 2 ). 
     Performing the above-described compression process after the communication portion processing process and before the developer refilling process enables more stable execution of the developer refilling process even when the flexible container  251  has high elasticity. Further, reducing the capacity of the flexible container  251  enables refilling of larger amount of developer T. 
     Seventh Embodiment 
     In the seventh embodiment, since the unit separation process included in the fifth embodiment is not performed, the communication portion processing process and subsequent processes will be described below. In the seventh embodiment, the remanufacturing method of the developing unit  9  includes a communication hole processing process for processing a second communication hole  110  for refilling the developer T into the frame member  29 , and a communication hole sealing process for sealing the second communication hole  110  to seal the developer T filled in the frame member  29 . The remanufacturing method will be described in detail below. 
     [Communication Portion Processing Process] 
       FIG. 20  is a sectional view illustrating a process for processing the second communication hole  110  on the frame member  29 . First of all, it is desirable to hold the cartridge P in a similar orientation to that when installing it in the image forming apparatus  1 . Then, the second communication hole  110  is processed on the vertically upper surface of the frame member  29  in the above-described orientation. A developer refilling device is to be inserted into the second communication hole  110  in the developer refilling process (described below). Therefore, the second communication hole  110  needs to be larger than the tip portion of the developer refilling device. However, the second communication hole  110  may have any shape as long as it is larger than the tip portion of the developer refilling device. 
     [Compression Process] 
       FIG. 21  is a sectional view of the frame member  29  illustrating the compression process for compressing the flexible container  251  using the pushing-in member  105  to make the capacity of the flexible container  251  smaller than the capacity of the flexible container  251  filled with the developer T. The pushing-in member  105  having higher rigidity than the flexible container  251  is used to compress the flexible container  251 . The pushing-in member  105  is inserted into the frame member  29  through the second communication hole  110  downward in the gravity direction, and then a force is applied to the flexible container  251  in the directions indicated by arrows N (N 1  to N 2 ). The flexible container  251  is thereby folded and the capacity of the flexible container  251  is reduced. Compressing the flexible container  251  in this way forms the refilling space  255 . 
     [Developer Refilling Process] 
       FIG. 22  is a sectional view illustrating the frame member  29  when the developer is refilled. A method for refilling the developer T is similar to that according to the fifth embodiment, in which the funnel  101  is used. In the developer refilling process, as illustrated in  FIG. 22 , the developer T is injected into the frame member  29  downward in the gravity direction using the funnel  101 . The injected developer T falls into the frame member  29  from the tip portion of the funnel  101 , and is accumulated in the refilling space  255  inside the frame member  29 . Similar to the fifth embodiment, the device used for refilling the developer T is not limited to the funnel  101 . For example, a fixed-rate feeding device having an auger may be used instead of the funnel  101 . 
     [Communication Portion Sealing Process] 
       FIG. 23  is a sectional view of the frame member  29  illustrating a process for sealing the second communication hole  110 . Similar to the fifth embodiment, this process is performed for attaching the resealing member  103  for sealing the second communication hole  110 , to the second communication hole  110  using the two-sided tape  104 , and thereby preventing leakage of the developer T from the frame member  29 . It is desirable to attach the resealing member  103  in a similar orientation to that when refilling the developer T, as illustrated in  FIG. 23 , i.e., in a state where the cartridge P is held so that the second communication hole  110  is oriented vertically upward. Then, the resealing member  103  is attached to the frame member  29  so as to cover the second communication hole  110 . 
     The resealing member  103  may have any shape as long as it covers the second communication hole  110  to prevent leakage of the developer T from the frame member  29 . Further, the resealing member  103  may be attached by using an adhesive instead of a two-sided tape. Further, the resealing member  103  may not necessarily be a member to be attached using a two-sided tape or an adhesive, and may be a member to be fitted into the second communication hole  110 , such as a cap. The above-described process enables achievement of a simplified remanufacturing method of the cartridge P, as illustrated in  FIG. 23 , without requiring the unit separation process and the unit combining process. 
     According to the configurations of the first to the seventh embodiments, the remanufacturing method of the developing unit  9  becomes simplified as compared with the conventional technique. The configurations or processes according to the first to the seventh embodiments can be suitably combined. 
     Although, in the first to the seventh embodiments, the description has been given of the cartridge P including the developing unit  9  and the photosensitive unit  8 , the configuration is not limited thereto as long as the cartridge P includes the developing unit  9 . In other words, the first to the seventh embodiments are also applicable to a developing device, a cartridge, and an image forming apparatus as long as these include the developing unit  9 . 
     According to an embodiment of the present invention, it is possible to provide a remanufacturing method of a developer accommodating unit including a flexible container. 
     While the present invention has been described with reference to embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.