Apparatus, Process for Charging Toner Particles

The present invention relates generally to a unique development system, and more specifically the present invention is directed to an apparatus and process for charging insulating toner particles. In one embodiment the present invention is directed to an apparatus and process for simultaneously metering and charging insulating toner particles to a positive or negative polarity, by delivering such particles into rubbing contact with a metering/charging means, such as a metering/charging roll. Such a system enables the efficient and effective rapid charging of insulating toner particles, without utilizing carrier particles as commonly employed in the prior art.

The development of images by numerous methods, including electrostatographic means is well known. In such systems toner particles are deposited on an electrostatic latent image contained on an insulating surface, such as selenium, using for example the development methods as described in U.S. Pat. No. 3,618,552, cascade development, U.S. Pat. Nos. 2,874,063, 3,251,706 and 3,357,402, magnetic brush development; U.S. Pat. No. 2,217,776 powder cloud development, and U.S. Pat. No. 3,166,432, touchdown development. The cascade development method and powder cloud development method are especially well adopted for the development of line images common to business documents. Images which contain solid areas are, however, sometimes not faithfully reproduced by these methods, accordingly, magnetic brush development systems are employed to reproduce both lines and solid areas.

Magnetic brush development systems employing two-component developer mixtures comprised of toner particles and carrier particles are thus extensively used in electrophotographic devices, since such systems generally provide for the production of high quality images, including dense solid areas, and also reduce unwanted toner deposition in background areas. Nevertheless, there continues to be problems in the design of simple, inexpensive and efficient two-component systems with long-term stability, which problems are in part caused by the need to generate a triboelectric charge on the toner particles with a desired polarity of sufficient magnitude. Also, in the prior art systems, vigorous developer mixing, which is accomplished in a reservoir or sump using a mixing means such as a paddle-wheel, so as to provide for the continual multiple contacts between toner particles, and carrier particles, is required to quickly charge uncharged toner particles added to the developer mixture. This, continual mixing of the developer composition causes toner smearing on the carrier particles, and consequently irreversible degradation in the ability of the carrier particles to triboelectrically charge the toner particles, such degradation usually resulting in inferior copy quality, including undesirable increased background development. Additionally, the xerographic development properties of two-component developer compositions is dependent on the concentration of toner particles in the developer mixture, therefore in order to maintain stable xerographic development properties during cyclic machine operation, the toner concentration is monitored by a device which controls the rate at which toner particles are dispersed to the developer reservoir. The components and hardware required for such toner concentration control devices adds complexity and cost to two-component systems.

Furthermore, present two-component magnetic brush systems are generally inherently inefficient primarily because only a small amount of toner particles which are transported through the development zone are available for deposition onto the image bearing member, since for example, the magnetic field in the development zone tends to stiffen the developer, thus only those toner particles immediately adjacent to the imaging member are available for development. Should the developer composition in such systems be electrically insulating, an additional limitation is imposed on the development efficiency, as developer particles entering the development zone have a neutral charge, and deposition of charged toner particles onto the imaging member produces a layer of oppositely charged developer which opposes further toner deposition. The utilization of conductive developer compositions, however, improves development efficiency since a net-charged developer layer ordinarily produced by toner deposition onto the imaging member is dissipated by such compositions. In these systems, the developer composition conductivity is a complex function of, for example, the composition of the carrier materials used, the concentration of the toner particles, and the intensity of the magnetic field, therefore achieving high quality development for extended time periods with conductive developer compositions continues to be a problem.

In view of some of the disadvantages of two component systems, there has been considerable efforts directed to designing systems which utilize toner particles only, reference for example, U.S. Pat. No. 2,846,333, which discloses single component developer compositions that are comprised of resins, colorants, and magnetic materials. Generally, these systems eliminate the need for a developer reservoir, a toner dispenser, and toner concentration control means. Most of the single component development systems, especially those systems that are in commercial use, consume conductive toner particles, whereby imagewise toner deposition onto the imaging member is obtained by induction toner charging. The electrostatic transfer of conductive toner particles to plain paper is, however, usually inefficient, since the charge on the toner particles can be reversed by induction charging with plain (conductive) paper. Electrophotographic systems employing conductive single component toner particles, therefore, usually require a special (overcoated) paper to achieve sufficient electrostatic toner transfer.

Additionally, in single component development systems containing conductive toner particles, the control of undesirable background, or background suppression cannot be achieved with electrostatic forces, as the toner particles are inductively charged, and deposited on the image bearing member, which is not the situation in two component development systems, wherein the control of background development is accomplished by an electrostatic force acting on the triboelectrically charged toner particles, causing such particles to be directed away from the image bearing member. Should background suppression be desired in single component systems using conductive toner particles, it is usually obtained by reducing the electrostatic force to near zero, followed by generating a magnetic force, which force is derived from a magnetic field originating from a magnet assembly acting on the conductive toner particles loaded with magnetic particles. Since the magnetic force acting on such toner particles is usually weaker than electrostatic forces, background control with single component systems utilizing conductive toner compositions has not always been satisfactory.

Another disadvantage associated with single component development compositions is that a large amount of magnetic material is necessary, at least about 50 percent in some instances, in order to allow for toner transport, and to provide for proper background control. Accordingly, the optical density of toner particles loaded with magnetic materials, such as magnetite, is sufficiently high to negate the effect of adding other light absorbing materials, such as carbon black. Further, the strongly light absorbing properties of magnetic toner particles precludes the production of colored magnetic toner for use in color imaging systems, by the addition of dyes and pigments.

While improvements have been made in the process, apparatus and materials for the development of latent electrostatic images, there continues to be a need for processes and aparatus which will improve the quality of development, are efficient, simple in design, and economical. In particular, there is a need for a single-component imaging system wherein insulative, non-magnetic, and colored toner particles are appropriately charged, and there is obtained two-component image quality utilizing a single-component development method, apparatus and insulative single-component toner particles so as to enable the efficient electrostatic transfer of such particles to plain paper. Also there is a need for processes and apparatus, where single-component toner particles are metered onto a transporting member, and simultaneously rapidly charged to a desired polarity. Further, there is a need for the provision of an apparatus and process, where background is substantially controlled and eliminated by electrostatic forces, and where the reliability of the system hardware, and materials is increased. Additionally, there continues to be a need for an apparatus and process which will allow the uniform development of both fine lines, and large solid areas of an electrostatic latent image, while obtaining minimum background density.

It is therefore a feature of the present invention to provide a development process, and a development apparatus which overcomes the above-noted disadvantages.

It is a further feature of the present invention to provide a single component development system, wherein two component image quality is obtained.

Yet another feature of the present invention is the provision of an improved development apparatus, wherein toner particles are simultaneously metered and charged by a metering/charging means, such as a metering/charging roll.

An additional feature of the present invention is the provision of a process and apparatus which allows the rapid charging of toner particles to a desired polarity, either positive, or negative, such charging being consistent over extended periods of time, and not being dependent on the interaction of toner particles with numerous carrier particles.

Another feature of the present invention is the provision of a process and apparatus, wherein a single effective carrier particle, or bead, is employed to accomplish the charging of the toner particles.

An additional feature of the present invention is the provision of an apparatus and process which provides for the excellent transfer of toner particles to plain bond paper, and allows for the control of undesirable background utilizing electrostatic forces.

Another feature of the present invention is the provision of an apparatus and process which allows the development of color images without utilizing magnetic materials.

A further additional feature of the present invention is the provision of an improved apparatus, and process which provides for the transport of toner particles utilizing a non-magnetic electrostatic transport system.

These and other features of the present invention are accomplished in one aspect by providing a system, apparatus and process, for charging non-magnetic insulating toner particles, the system containing a moving donor means, such as a donor electrode means, and an adjacent electrically biased charging means, such as a charging roll means, which also simultaneously meters toner particles, said means being overcoated with a triboelectrically active material, and moving in a direction opposite to the direction of movement of the donor means. Movement of the donor means directs non-magnetic insulating toner particles to the charging means, and more specifically, to a nip or charging zone situated adjacent the charging means, as illustrated hereinafter, whereat the frictional rubbing between the coating on the charging means, and the toner particles causes such particles to be charged in accordance with the triboelectric relationship existing between the toner particles, and the coating material. The application of an electrical bias to the charging means, such as a charging roll means, causes electrostatic forces to act on the charged toner particles in close proximity to the entrance of the charging nip, or charging zone, thus toner particles which have been charged to the same polarity as the biased roll are electrostatically directed and attracted to the donor means, while toner particles containing the opposite charge, referred to as wrong sign toner, cling to the roll means as a result of electrical attraction forces. Accordingly, the entrance to the charging nip functions similar to an electrostatic toner charge filtering means. Also the system of the present invention allows the desirable extensive agitation and tumbling of toner particles in the toner supply means.

The wrong-sign charged toner particles referred to hereinbefore, which are transported by the charging means in a direction opposite to that of the donor means contact a doctor-blade seal means, which remove and return the particles to a developer reservoir. It is desirable to remove the wrong-sign charged toner particles otherwise these particles are deposited on the donor means at the exit region of the charging nip, which would adversely affect the charge distribution of the toner particles contained on the donor means.

The net charge on the toner particles contained in the supply reservoir or developer sump is near zero, however, such a charge is distributed with approximately equal numbers of positive and negative charges, as illustrated in FIG. 1, for example. Those toner particles which are electrostatically attracted to the donor means in the region prior to the charging nip are drawn therethrough while the toner charge is amplified by extensive rubbing between the toner particles and the triboelectrically active coating contained on the charging means. This rubbing action provides the toner particles with an appropriate charge in a rapid time period. Subsequently, the charged toner particles emerge from the charging nip exit and can be conveyed, by electrical attraction to the donor means, to an electrostatic latent image bearing member, where they are imagewise deposited therein by electrostatic attraction, with unused toner particles remaining on the donor substrate until they are returned to the toner reservoir.

The present invention in one aspect is thus directed to an apparatus for charging toner particles comprised in operative relationship of a means for charging insulating toner particles, and a means for transporting insulating toner particles, said means for charging, and said means for transporting, biased to a predetermined potential.

In another illustrative embodiment, the present invention is directed to an apparatus for simultaneously metering and charging non-magnetic insulating toner particles, comprised in operative relationship of a means for simultaneously metering and charging non-magnetic insulating toner particles, a means for transporting the toner particles, a means for supplying non-magnetic insulating toner particles to the transporting means, a means for applying a bias to the metering charging means, a means for applying a bias to the transport means, a means for removing toner particles from the metering/charging means, wherein toner particles are charged to the appropriate polarity and magnitude in a charging zone situated between said metering/charging means, and said transport means.

The present invention in a further illustrative embodiment is directed to an apparatus for simultaneously metering and charging non-magnetic insulating toner particles comprised in operative relationship of a metering/charging roll means, a triboelectrically active coating contained on said metering/charging roll means, a doctor blade means for said metering/charging roll means, a toner supply reservoir means containing therein weakly charged insulating toner particles possessing about an equal number of positive and negative charges thereon, a transport-donor belt means, a drive roll means, an idler means, a tensioning means, an imaging means, a voltage source means for the metering/charging roll means, a voltage source means for the drive roll means and the transport-donor belt means, said metering/charging roll means moving in a direction opposite to the direction of movement of the transport-donor belt means.

Another illustrative embodiment of the present invention encompasses an apparatus for simultaneously metering and charging non-magnetic insulating toner particles, which comprises in operative relationship a metering/charging roll means containing thereon a triboelectrically active coating, a transporting means, a drive roll means, an idler roll means, said transporting means forming a path of movement around said drive roll means and said idler roll means, a toner supply reservoir means, containing therein weakly charged insulating toner particles possessing about an equal number of positive and negative charges thereon, a voltage source means for the metering/charging roll means, a voltage source means for the drive roll means, and the transporting means, a tensioning means, an imaging member means, wherein the transporting means is positioned so as to maintain a constant fixed distance between said charging/metering roll means and said transport means, and/or is self-spaced from the charging roll means by insulating toner particles, said metering/charging roll means moving in a direction opposite to the direction of movement of the transport means; and an apparatus for metering and charging non-magnetic insulating toner particles comprised in operative relationship of a metering/charging roll means, containing thereon a tribo-electrically active coating, a compliant transport-donor roll means, a toner supply reservoir means containing therein weakly charged toner particles, a voltage source means for the metering/charging roll means, and a voltage source means for the compliant roller means, wherein toner particles are charged in a zone encompassed by said metering/charging roll means, and said compliant roll means, said metering/charging roll means moving in a direction opposite to the direction of movement of said compliant roll means.

The present invention in another illustrative embodiment is directed to an electrostatographic imaging device comprised of a charging means, an imaging means, a development means, a fixing means, and a fusing means, the improvement residing in the development means which is comprised of an apparatus for charging toner particles comprised in operative relationship of a means for charging insulating toner particles, and a means for transporting insulating toner particles, said means for charging, and said means for transporting, biased to a predetermined potential, and a process for charging insulating toner particles which comprises (1) providing a means for charging insulating toner particles, which means contains thereon a triboelectrically active coating, (2) providing a means for transporting toner particles, (3) depositing weakly charged toner particles on the transporting means and (4) contacting the weakly charged toner particles with the triboelectrically active coating in a charging zone situated between the means for charging and the means for transporting, whereat charges on the toner particles are amplified to a positive or negative polarity.

The process and apparatus of the present invention and various alternative embodiments will now be described with reference to the Figures wherein:

FIG. 1 is a schematic view of an embodiment of the apparatus and process of the present invention.

FIG. 2 is a schematic view of another embodiment of the apparatus and process of the present invention.

FIG. 3 is a schematic view of a further embodiment of the apparatus and process of the present invention.

FIG. 4 is a schematic view of yet another embodiment of the apparatus and process of the present invention.

FIG. 5 is a schematic view of another embodiment of the apparatus and process of the present invention.

FIG. 6 is a schematic illustrating the use of the apparatus and process of the present invention as shown in FIG. 1, in an electrostatographic imaging system.

FIG. 7 is a schematic illustrating the use of the apparatus and process of the present invention as shown in FIG. 2, in an electrostatographic imaging system.

FIG. 8 is a schematic illustrating the use of the apparatus and process of the present invention as shown in FIG. 4, in an electrostatographic imaging system.

Illustrated in FIG. 1 is the apparatus and process of the present invention, generally designated 7 comprising a charging roll means 12, referred to hereinafter in some instances, as a metering/charging roll, a triboelectrically active coating 13 contained on the metering/charging roll means 12, a doctor blade means 14, illustrated at one angle, or doctor blade means 14a, illustrated at another angle in relationship to roll 12, a toner supply reservoir means 16, containing weakly charged toner particles 17, possessing an approximate equal number of positive and negative charges thereon, a transport or donor belt means 18, positively charged toner particles 19, a drive roll means 20, an idler roll means 22, a tensioning means 24, a flexible photoreceptor imaging member means 26, a pressure blade means 28, a voltage source means 30 (V.sub.c) for roll 12, a voltage source means 32 (V.sub.B) for drive roll 20, and donor belt means 18, a metering charging zone 34 (L.sub.c), a development zone 36 (L.sub.D), with the direction of movement of the various components being illustrated by the arrows 38. Thus, as shown, in zone 34 (L.sub.c), the metering/charging roll means 12 is moving in a direction opposite to the direction of movement of the donor belt means 18.

In operation, the weakly charged insulating toner particles 17, within the reservoir 16, undergo circular flow primarily since the walls of the reservior as constituted by the donor belt means 18, and the metering/charging roll means 12 are continually moving in opposite directions by means such as motors not shown, which promote toner tumbling and agitation. The frictional rubbing between the toner particles 17 and coating 13 of the metering/charging roll means 12, charges the toner particles by triboelectric charging. An additional source of toner charge is obtained at the doctor blade means 14, or 14a, where the accumulation and removal of charged toner particles clinging to the metering/charging roll means 12 induces air breakdown (ions) causing neutralization of the charged toner layer. The toner particles 17 in the reservoir 16 are primarily weakly charged with approximately equal amounts of positive and negative charges. Accordingly, for example, when a positive potential, V.sub.c of about 100 volts is applied to the metering/charging roll means 12, those toner particles with a positive charge are electrostatically deposited on the donor belt means 18 at the entrance to the metering/charging zone 34. Frictional rubbing, in zone 34, of the toner particles with coating 13 on the metering/charging roll means 12, moving in a direction opposite to the movement of the donor belt means 18, increases the positive charge on the insulating toner particles as a result of triboelectric charging between the coating 13, which is comprised of an electronegative material in this illustration, and the electropositive toner particles 17. The positively charged toner particles then emerge from the charging zone 34 and can be transported to the flexible imaging member 26. During transport, the positively charged toner particles adhere to the donor belt means 18, by electrostatic attraction.

The deflected donor belt means 18 forms a path around drive roller means 20, and idler roll means 22, which allows the positively charged insulating toner particles 19 to be transported into rubbing contact with an electrostatic latent image, not shown, on the flexible imaging member 26. As illustrated, the donor belt means 18 is subjected to a tensioning means 24, the belt being positioned in such a manner so as to cause it to be wrapped in an arc in close proximity to roll 12, with the donor belt 18 being self spaced from roll 12 by the toner particles contained therebetween. Generally, the arc of belt 18 ranges from about 10 degress to about 50 degrees.

The toner particles 19 are transferred from the donor belt means 18, to the flexible imaging member means 26 as a result of voltage 32 (V.sub.B), and the imagewise attraction for such particles by the imaging member 26, charged to a negative potential. Pressure blade 28 provides a sufficient force to insure intimate contact of the positively charged toner particles 19, with the imaging member 26 for the distance 36 (L.sub.D), the imaging member 26, being self spaced from the donor belt means 18, by the positively charged insulating toner particles 19 contained therebetween. Unused toner particles 19 not deposited on imaging member 26 are returned to the toner reservoir 16 by belt 18. The doctor blade means 14 or 14a, contains the toner particles in the toner reservoir 16, and also serves to remove any toner particles on roll 12 so that they will not deposit on belt 18, and adversely effect charging and metering. Coating 13 generally has dispersed therein a charge dissipating material, such as carbon black for the purpose of accepting and eliminating negative charges obtained from the toner particles 17. When it is desired to impart a negative polarity to the toner particles 17, the coating 13 is selected so as to have a negative triboelectric relationship with the particles 17, that is, it is electropositive, and voltage V.sub.c is negative, instead of positive.

While it is not desired to be limited by theory, in the embodiment shown it is believed that negative charges are attracted from the insulating toner particles 17, to roll 12, and positive charges are supplied to the toner particles 17, by coating 13, as a result of the triboelectric charging relationship between coating 13, and the toner particles 17, thereby resulting in positively charged toner particles. The weakly positively charged particles 17, lose negative charges, and gain positive charges as a result of their rubbing contact with roll 12, in charging zone 34, (L.sub.c). The resulting positively charged toner particles adhere to belt 18 as they migrate to and around roll 20, in view of the electrostatic attraction of the particles to the belt, thus additives such as magnetic pigments are not needed.

The metering/charging roll 12 is an important feature of the present invention, in that it not only functions as a source of charge, similar to carrier particles in a two component system, but also controls or meters the amount of toner particles allowed to deposit on belt 18. Thus the density of toner particles present on donor belt means 18, which density is a primary factor in establishing and maintaining the distance of separation between belt means 18, and roll means 12, is controlled by the metering/charging roll 12 means, and the process conditions associated with this roll.

Illustrated in FIG. 2 is another embodiment of the process and apparatus of the present invention generally designated 9, comprising a metering/charging roll means 12, containing a triboelectrically active coating 13 thereon, a doctor blade seal means 14, a toner supply means 16, containing toner particles 17, possessing an approximate equal number of weakly charged positive, and weakly charged negative toner particles, a donor belt means 18, positively charged toner particle 19, a drive roll means 20, an idler roll means 22, a tensioning means 24, a flexible imaging member means 26, a roll means 27, a pressure blade means 28, a pressure blade means 29 for the metering/charging zone 34, a voltage source 30 (V.sub.c), a voltage source 32 (V.sub.B), a charging zone 34 (L.sub.c), a development zone 36 (L.sub.D), with the components moving in the direction as shown by the arrows 38.

The process and apparatus illustrated in FIG. 2, operates in substantially the same manner as described herein with reference to FIG. 1, acordingly thus in summary the weakly charged insulating toner particles 17 are deposited on the donor belt means 18 as a result of movement of the components, gravitational forces, and the electrostatic force from voltage source means 30 (V.sub.c), wherein the toner particles are brought into rubbing contact with the metering/charging roll means 12, in the charging zone 34 (L.sub.c) thus resulting in positively charged toner particles 19. As contrasted to FIG. 1, the donor belt means 18 is not arced in relationship to roll 12, rather, belt 18 makes a tangential contact with roll means 13, and is self-spaced therefrom by insulating toner particles with the nip pressure being supplied by a compliant blade means 29 positioned on the backside of the belt 18. The positively charged toner particles 19 are then transported on the donor belt 18, until contacting the flexible imaging member 26, in the development zone (L.sub.D), wherein they are transferred to the imaging member, which has been charged negatively. Pressure blade 28 provides sufficient force to insure contact of the positively charged toner particles, with the imaging member 26, for the distance 36 (L.sub.D). Unused positively charged toner particles are, as shown, returned to the toner reservoir 16, for reuse in the system.

Illustrated in FIG. 3 is another embodiment of the apparatus and process of the pesent invention generally designated 11, comprising a metering/charging roll means 12, containing a triboelectrically active coating thereon 13, a toner supply reservoir means 16, containing weakly charged insulating non-magnetic toner particles 17, positively charged toner particles 19, a compliant donor roll 20, a rigid photoreceptor imaging member means 27, a doctor blade seal means 40, a wiper blade seal means 42, a voltage source 30 (V.sub.c), a voltage source 32 (V.sub.B), a charging zone 34 (L.sub.c), a development zone 36 (L.sub.D), with the components moving in the directions as shown by the arrows 38. In this simplified version of the apparatus and process of the present invention, toner particles 17 are supplied to the charging nip 34 between the metering/charging roll means 12, and a compliant donor roll means 20. As a result of the contact between toner particles 17, and the coating 13 of metering/charging roll, in charging zone 34, the toner particles 17 acquire a positive charge thereon. The positively charged toner particles 19 are then transported by the compliant donor roll means 20, such partcles adhering to the roll as a result of electrostatic attraction, to the rigid imaging member means 27, wherein they are attracted thereto in the development zone 36. Unused toner particles are returned to the toner supply reservoir 16, as shown. In this embodiment the charging metering roll means 12 may also be compliant, thus both rolls 12 and 20 can be compliant. Generally the compliant rolls can be comprised of numerous materials such as an electroformed nickel sleeve having foam bonded thereto, and the like.

Illustrated in FIGS. 4 and 5 are other embodiments of the apparatus and process of the present invention. These embodiments illustrate important different configurations of FIG. 3, one embodiment containing a flexible imaging means, FIG. 4, and one embodiment containing a rigid imaging means, FIG. 5. In these Figures like components are indicated by identical reference numerals as described with regard to the other Figures, especially FIG. 3, and the operation of the apparatus and process as illustrated in FIGS. 4 and 5 is substantially identical to the operation of the apparatus and process illustrated in FIG. 3. Shown in FIGS. 4 and 5 are metering/charging roll means 12, containing a triboelectrically coating 13 thereon, toner supply reservoir means 16, containing weakly charged non-magnetic toner particles 17, a compliant donor roll means 20, idler roll means 22, FIG. 4 only, a flexible photoreceptor imaging member means 26, a rigid photoreceptor means 27, FIG. 5 only, a doctor blade seal means 40, a wiper blade seal means 42, a voltage source 30 (V.sub.c), a voltage source 32 (V.sub.B), a charging zone 34 (L.sub.c), a development zone 36 (V.sub.D), with the components moving in the direction of the arrows 38.

In these versions of the apparatus and process of the present invention, in summary, weakly charged toner particles 17 are supplied to the charging nip 34 between the metering/charging roll means 12 and a compliant donor roll means 20. As a result of the movement of roll means 13, and roll means 20, toner particles 17 contact coating 13, in charging zone 34 (L.sub.c), causing toner particles to acquire a positive charge thereon. The positively charged toner particles 19 are then transported by the compliant donor roll means 20, to the flexible imaging member 26, FIG. 4 or to the rigid imaging member 27, FIG. 5, wherein they are attracted thereto in the development zone 36 (L.sub.D). Unused toner particles are returned to the toner reservoir 16, by roll means 20, as shown.

The apparatus and process of the present invention can be utilized in various imaging systems, including electrostatic latent imaging systems as shown for example in FIGS. 6, 7, and 8. In FIG. 6 there is illustrated a xerographic imaging system generally designated 50, employing an imaging member 52, which corresponds to the imaging member 26, of FIGS. 1, 2 and 4. In this embodiment of the present invention the imaging member 52, can be comprised of a substrate, overcoated with a transport layer containing N,N,N',N'-tetraphenyl-[1,1'-biphenyl] 4,4'-diamine, or similar diamines dispersed in a polycarbonate, which in turn is overcoated with a generating layer of trigonal selenium. Imaging member 52 moves in the direction of arrow 54 to advance successive portions of the imaging member sequentially through the various processing stations disposed about the path of movement thereof. The imaging member is entrained about a sheet-stripping roller 56, drive roller 60, and rollers 61 and 63. The system can also include a tensioning means, not shown, for the purpose of maintaining imaging member 52 at the desired flexibility, or pressure, which level of tension is relatively low permitting member 52 to be easily deformed. With continued reference to FIG. 6, drive roller 60 is mounted rotatably and in engagement with member 52. Motor 66 rotates roller 60 to advance member 52 in the direction of arrow 54. Roller 60 is coupled to motor 66 by suitable means such as a belt drive. Sheet-stripping roller 56 is freely rotatable so as to readily permit member 52 to move in the direction of arrow 54 within a minimum of friction.

Initially, a portion of imaging member 52 passes through charging station H. At charging station H, a corona generating device, indicated generally by the reference numeral 68, charges the photoconductive surface of imaging member 52 to a relatively high, substantially uniform potential.

The charged portion of the photoconductive surface is then advanced through exposure station I. An original document 70 is positioned face down upon transparent platen 72. Lamps 74 flash light rays onto original document 70, and the light rays reflected therefrom are transmitted through lens 76 forming a light image thereof. Lens 76 focuses the light image onto the charged portion of the photoconductive surface to selectively dissipate the charge thereon. This records an electrostatic latent image on the photoconductive surface, which corresponds to the informational areas contained within original document 70.

Thereafter, imaging member 52 advances the electrostatic latent image recorded thereon to station J wherein it is contacted with positively charged insulating toner particles 19, station J including essentially all the components as shown in FIG. 1, namely in summary, a metering/charging roll means 12, a triboelectrically active coating 13 contained on the metering/charging roll means 12, a doctor blade means 14, illustrated at one angle, or doctor blade means 14a, illustrated at another angle, in relationship to roll 12, a toner supply reservoir means 16, containing weakly charged non-magnetic insulating toner particles 17, possessing an approximate equal number of positive and negative charges thereon, a donor belt means 18, positively charged toner particles 19, a drive roll means 20, an idler roll means 22, a tensioning means 24, a pressure blade means 28, a voltage source 30 (V.sub.c), for roll 12, a voltage source means 32 (V.sub.B) for drive roll 20, and donor belt means 18, a metering charging zone 34 (L.sub.c), a development zone 36 (L.sub.D), with the direction of movement of the various components shown by the arrows 38. The details for charging and metering the toner particles, and deposition thereof on the imaging member is illustrated with reference to FIG. 1.

Imaging member 52 then advances the toner powder image to transfer station K. At transfer station K, the sheet of support material 80 is moved into contact with the toner powder image, which sheet is advanced to transfer station K by a sheet feeding apparatus (not shown). Preferably, the sheet feeding apparatus includes a feed roll contacting the uppermost sheet of a stack of sheets. The feed roll rotates so as to advance the uppermost sheet from the stack into a chute, which chute directs the advancing sheet of support material into contact with the photoconductive surface of member 52 in a timed sequence, in order that the toner powder image developed thereon contacts the advancing sheet of support material at transfer station K.

Transfer station K includes a corona generating device 82 which sprays ions onto the backside of sheet 80, allowing for the attraction of the toner powder image from the photoconductive surface to sheet 80. After transfer, sheet 80 moves in the direction of arrow 54 onto a conveyor (not shown) to fusing station L.

Fusing station L includes a fuser assembly, indicated generally by the reference numeral 84, which permanently affixes the transferred toner powder image to sheet 80. Preferably, fuser assembly 84 includes a heated fuser roller 86 and a back-up roller 88. Sheet 80 passes between fuser roller 86 and back-up roller 88 with the toner powder image contacting fuser roller 86. In this manner, the toner powder image is permanently affixed to sheet 80. After fusing, a chute guides the advancing sheet 80 to a catch tray for subsequent removal from the printing machine.

Invariably, after the sheet of support material is separated from the photoconductive surface of imaging member 54 some residual particles remain adhering thereto. These residual particles are removed from the photoconductive surface at cleaning station M. Cleaning station L includes a rotatably mounted fibrous brush 90 in contact with the photoconductive surface. The particles are cleaned from the photoconductive surface by the rotation of brush 90 in contact therewith. Subsequent to cleaning, a discharge lamp (not shown) floods the photoconductive surface of member 52 with light to dissipate any residual electrostatic charge remaining thereon prior to the charging thereof for the next successive imaging cycle.

In FIG. 7 and 8 there is illustrated a substantially similar xerographic imaging apparatus and process as described with reference to FIG. 6, with the exception, for example, that FIG. 7, includes components of FIG. 2, and FIG. 8 includes components of FIG. 4. The operation of the apparatus and process of FIG. 7 is as described herein with reference to FIGS. 2 and 6, while the operation of the apparatus and process of FIG. 8 is as described herein with reference to FIGS. 4 and 6.

It is believed that the foregoing description is sufficient for purposes of the present invention to illustrate the general operation of an electrophotographic printing machine incorporating the features of the present invention therein.

The core of metering/charging roll means 12 can be hollow or solid, and can be comprised of numerous known suitable materials including for example, aluminum, steel, iron, polymeric materials and the like, providing they are of sufficient strength to be operable in the system. The preferred core material is aluminum. Generally the radius of the core is from about 0.25 inches to about 2 inches, and preferably is from about 0.5 inches to about 1 inch. Idler roll means 22 can be comprised of the same materials as roll 12, this roll ranging in diameter of from about 0.25 inches to about 1 inch.

The coating 13 contained on the metering/charging roll means 12 can be selected from numerous suitable materials known in the art, including many of the same materials that are employed for coating carrier particles. The coating is selected according to the charge that is desired to be imparted to the toner particles, thus if it is desired to impart a positive charge to the toner particles, a coating capable of acquiring a negative charge thereon is employed, these coatings including various electronegative materials such as polymers, including copolymers of trifluorochloroethylene and vinyl chloride commercially available as FPC 461. Examples of other electronegative materials that can be employed include highly halogenated polymers, such as polyvinylidene fluoride, polytetrachlorofluoroethylenes, perfluoroalkoxylated ethylenes, polytetrafluoroethylenes, polyvinyl chlorides and the like. Should it be desired to impart a negative charge to the insulating toner particles, a coating capable of acquiring a positive charge thereon is employed; examples of such coatings including various electropositive materials like polyvinylpyridenes, terpolymers of methacrylates, such as polymethylmethacrylate, polystyrene/n-butylmethacrylate silane terpolymer, polycaprolactum, and the like. Additionally, there can be employed as coatings 13, materials analogous to thermoplastic toner resins, as described hereinafter, containing charge control agents for the purpose of imparting a positive, or negative charge to the toner particles 17. Various suitable charge control agents can be employed, including alkylpyridinium halides, such as cetylpyridinium chloride, quaternary ammonium compounds as disclosed in U.S. Pat. No. 3,970,571, morpholinium compounds, hydrazonium compounds, and the like. Generally, the charge control agent is present in an amount of from about 0.1 percent to about 10 percent.

The thickness of the coating 13 can vary over a wide range and is dependent on many factors including economical considerations, however, generally the thickness of the coating is from about 0.1 mils to about 5 mils, and preferably is from about 1 mil to about 3 mils. In a preferred embodiment, the thickness of the coating 13 is 1 mil, as such a thickness, particularly when employed in the embodiments of the present invention, results in superior overall performance.

The donor belt means 18 illustrated, for example, in FIGS. 1 and 2, can be comprised of numerous suitable materials including, for example, aluminized Mylar overcoated with a carbon black loaded paint (polymer matrix), or dopants which are conductive agents for the polymers, such as quaternary ammonium salts, a seamless electroformed nickel belt overcoated with a Krylon ultraflat black paint, commercially available as Krylon 1602, a seamless extruded polymer sleeve containing a conductive agent such as carbon black, or a bare electroformed nickel sleeve processed in a manner which imparts a texture to the surface. It is preferred that the belt be seamless to prevent toner metering defects. The peak-to-peak variation in the surface texture on the donor belt means 18 ranges from 0.5 micrometers to 5 micrometers, with a spatial variation ranging from 5 micrometers to 100 micrometers. The length of the donor belt is dependent on the configuration within which it is used, thus in FIGS. 1 and 2 the length varies from about 4 inches to about 20 inches. As indicated herein the donor belt means 18 in FIG. 1 forms an arc in relationship to roll 12, while in FIG. 2 donor belt means 18 does not form an arc. In the embodiment shown in FIG. 3, a belt is not utilized.

The drive roll means 20 in FIG. 1 is generally comprised of a conductive material, such as conducitve rubber and the like, this roll having a diameter of from about 0.25 inches to 1.5 inches, and preferably from about 0.5 inches to 1 inch. The drive roll means 20 and idler roll means 22 of FIG. 2 are generally comprised of many conductive rubber segments formed by slots in both the circumferential and axial directions, which rubber segments enable tracking of the donor belt with the aid of belt edge guiding members. The compliant donor roll 21 shown in FIG. 3 generally consists of an elastic core, such as polyurethane foam or silicone rubber, overcoated with a seamless, flexible and conductive sleeve such as electroformed nickel or a carbon black loaded, extruded polymer. The conductive sleeve such as electroformed nickel can be overcoated with materials described hereinbefore for the donor belt 18 shown in FIGS. 1 and 2.

Illustrative examples of the image bearing member means 26, and 27, include inorganic and organic photoreceptor materials such as amorphous selenium, selenium alloys, including alloys of selenium-tellurium, selenium arsenic, selenium antimony, selenium-tellurium-arsenic, cadmium sulfide, zinc oxide, polyvinylcarbazole, layered organic photoreceptors, such as those containing as an injecting contact, carbon dispersed in a polymer, overcoated with a transport layer, which in turn is overcoated with a generating layer, and finally an overcoating of an insulating organic resin, such as those described in U.S. Pat. No. 4,251,612. Also, included within the scope of the present invention are imaging members comprised of a substrate, a transport layer such as a diamine dispersed in a polymer, and a generating layer such as trigonal selenium, as described in U.S. Pat. No. 4,265,990.

Other organic photoreceptor materials include, 4-dimethylamino-benzylidene, benzhydrazide; 2-benzylidene-amino-carbazole, 4-dimethylamino-benzylidene, 2-benzylidene-amino-carbazole, polyvinyl carbazole; (2-nitro-benzylidene)-p-bromo-aniline; 2,4-diphenyl quinazoline; 1,2,4-triazine; 1,5-diphenyl-3-methyl pyrazoline 2-(4'-dimethyl-amino phenyl)benzoxazole; 3-amino-carbazole; polyvinylcarbazole-trinitrofluorenone charge transfer complexes; phthalocyanines and mixtures thereof, and the like. Generally, positively charged toner compositions are employed when the photoreceptor is charged negatively as is the situation with most organic photoreceptors, while negatively charged toner particles are employed when the photoreceptor is charged positively, as is the situation with most inorganic photoreceptors such as selenium.

By flexible imaging member as used herein is meant generally a material that can be easily deformed, such as the members as described in U.S. Pat. No. 4,265,990. Examples of the use of flexible imaging members is shown in FIGS. 1, 2, 4, 6, 7 and 8. In contrast, a rigid imaging member as shown in FIGS. 3 and 5 cannot be easily deflected, such members being stiff or hard, like amorphous selenium which has not been deposited on a flexible substrate.

The speed ratios of the components, the charging zone length, the development zone length, the voltages V.sub.c, V.sub.B, and other parameters of the apparatus and process of the present invention may vary depending on the configuration within which they are employed. Thus for example with reference to FIG. 1, the speed ratio of the metering/charging roll 13 to the donor belt 18 varies from about -4 to about -1, and preferably is from about -2 to about -3. Accordingly, the metering/charging roll 12 in this embodiment is moving at a more rapid rate of speed than the speed of the donor belt 18. In this embodiment, the speed ratio of the donor belt means 18 to the imaging member means 26 ranges from about 1 to about 4, and preferably is from about 2 to about 3, accordingly, the donor belt means 18 is moving from about 1 to about 4 times faster than the flexible photoreceptor imaging member means 26.

In reference to FIG. 2, the speed ratio of the charging/metering roll 12, to the donor belt 18 ranges from about -2 to 0, and is preferably from about -1/2 to -1/3. Accordingly, in this embodiment, donor belt 18 is moving from about 2 times as fast as the metering/charging roll 12, to a speed that is equal to the speed of the metering/charging roll 12. In reference to FIG. 3, the speed ratios of the metering/charging roll 12, and compliant donor roll 20 are essentially identical to the speed ratio as described herein with reference to these components in FIG. 2.

With further reference to FIG. 1, the length L.sub.c of the metering/charging zone 34, ranges from about 0.08 inches to 1 inch, and is preferably from about 0.3 inches to 0.5 inches, while the length of the development zone 36 (L.sub.D) ranges from about 0.05 inches to 0.5 inch and is preferably from about 0.06 inches to 0.1 inches. These distances can be greater or less providing they accomplish the objectives of the present invention. p In further reference to FIG. 2, the length L.sub.c ranges from about 0.05 to about 0.1 inches, and is prefeably about 0.08 inches, while the length L.sub.D is substantially identical to the length L.sub.D with regard to FIG. 1. The lengths in FIG. 3, namely L.sub.c and L.sub.D are substantially identical to the lengths described herein with regard to FIG. 2, that is, for example a distance L.sub.C of from about 0.05 inches to about 0.1 inches, and preferably about 0.08 inches, with a length L.sub.D of approximately 0.05 inches, to about 0.5 inches and preferably from about 0.06 inches to about 0.10 inches.

The pressure in the charging zone L.sub.C between the roll 12 and donor belt 18 is obtained by dividing the tension per unit width of donor belt 18 as applied by spring 24, by the radius of the roll. Generally the pressure ranges from about 0.1 to about 1 pounds per inch squared, and is preferably from about 0.2 pounds per inches per squared, to about 0.7 pounds per inches squared. The pressure in the development zone between the donor electrode 18 and imaging member 26, which pressure is applied by a pressure blade 28 should be of sufficient magnitude to allow the toner particles to continually contact the imaging member. Generally, this pressure ranges from about 1 pound per inch squared to about 10 pounds per inch squared, and is preferably from about 2 pounds per inch squared to about 4 pounds per inch squared. With reference to FIG. 2, the force per unit blade length exerted by blade 28 ranges from about 0.3 to 1 pound per inch and preferably from about 0.5 to about 0.7 pounds per inch.

The blade 14 or 14a is at an angle of from about 30 to about 180 degrees, and preferably is at an angle from about 30 to about 45 degees. For a blade greater than 90 degrees, the blade is a wiper with a preferred cleaning angle of 135 degrees to 180 degrees. The doctor blades can be of numerous suitable materials including plastics, nylon, steel, aluminum and the like.

For a positive toner charging system, the voltage V.sub.c ranges from about +25 volts to about +200 volts and is preferably from about +75 volts to about +125 volts with reference to FIGS. 1, 2 and 3. The voltage V.sub.B generally ranges from about +75 volts to about +450 volts or from about -75 volts to -450 volts and is preferably from about -200 volts to -250 volts for photoreceptors negatively charged to an image potential of approximately -500 volts and a background potential of approximately -100 volts. The photoreceptor potentials are typical for an organic photoreceptor approximately 27 micrometers thick with a dielectric constant of 3.

With reference to the apparatus shown in FIG. 1, the speed ratio in a preferred embodiment is -3, to voltage V.sub.C is +100 volts, the voltage V.sub.B is -250 volts, the speed of the donor belt 18 to the imaging member 26 is +2, the nip length L.sub.C is 0.4 inches, and the nip length L.sub.D is 0.08 inches.

In each illustration, charging of the toner particles occurs in a charging zone situated between the metering/charging roll, and a second component such as a donor belt or another roll. These components are self-spaced from each other by the toner particles situated therebetween, such spacing generally being equivalent to about one layer of toner particles. This distance may be less or more than one layer of toner particles, however, numerous layers may be undesirable in that the bottom layers, those furthest removed from roll 12, may not be adequately charged by the metering/charging roll.

The amount of toner particles 17 metering onto the donor belt means can be controlled as desired by varying the parameters of the system, however, generally the amount of toner particles deposited depends primarily on six factors, which are as follows:

1. The triboelectric charging relationship between the coating 13, and insulating toner particles 17.

2. The metering charging roll bias V.sub.C.

3. The relative speed ratios between the metering/charging roll means 12, and the donor belt means 18.

4. The length of the nip distance 34 (L.sub.c), between the metering/ charging roll means 12 and the donor belt means 18.

5. The amount of pressure applied to the donor belt means 18. For example, if a high amount of pressure is applied there is virtually no spacing between the metering/charging roll means 12 and the donor belt means 18, thus preventing toner particles 17 from moving into the charging nip L.sub.c.

6. The degree of surface texture on the donor belt means 18.

Generally, the amount of toner particles deposited on the donor belt means 18 or compliant roll 20, can range from about 1 monolayer of toner particles to several layers of toner particles. The amount of toner particles deposited can, for example, range from about 0.1 milligrams per centimeter squared to 3 milligrams per centimeter squared and is preferably from about 0.5 milligrams per centimeter squared to 1 milligram per centimeter squared. The thickness of the toner layer deposited as indicated hereinbefore determines the distance between the metering roll and the donor belt or other roll as shown in the Figures.

As the toner layer is transported by movement of the donor belt, for example, the rubbing length, Lr, between the toner and metering/charging roll is represented by the expression L.sub.r =[V-1]L.sub.c wherein V is the ratio of the metering/charging roll speed, to the donor speed and L.sub.c is the length of the toner charging zone 34. As V is negative for the two surface moving in opposite directions, a rubbing length of 1.6 inches is obtained when V is equal to -3, and L.sub.c is equal to 0.4 inches. The rubbing length needed for adequate toner charging depends, for example, primarily on the charging nip pressure, and the triboelectric charging between the toner, and metering/charging roll. The charging nip pressure is established by the belt tension, and the radius of the metering/charging roll, it being noted that additional pressure can be supplied by a foam pad positioned against the back of the donor.

The development system described herein does not require magnetic toner, however, a mechanical and/or electrical means can be used to seal the ends of the development unit. Any materials such as foam or felt are suitable for this purpose. A magnetic seal with ferrofluid represents another sealing method. Furthermore, magnetic sealing could be obtained by simply using magnetic (insulative) toner, and appropriate magnets.

The agitated toner particles contained in the toner reservoir, can comprise numerous suitable insulating materials, and more specifically toner resins and colorants. Further, there can be contained in the toner composition charge enhancing additives, which will provide a mechanism by which the toner particles can be rapidly charged while at the same time maintaining such a charge.

Illustrative examples of resin materials include for example polyamides, epoxies, polyurethanes, vinyl resins and polymeric esterification products of a dicarboxylic acid and a diol comprising a diphenol. Any suitable vinyl resin may be employed in the toners of the present system including homopolymers or copolymers of two or more vinyl monomers. Typical of such vinyl monomeric units include: styrene, p-chlorostyrene vinyl naphthalene, ethylenecally unsaturated monoolefins such as ethylene, propylene, butylene, isobutylene and the like; vinyl esters such as vinyl chloride, vinyl bromide, vinyl fluoride, vinyl acetate, vinyl propionate, vinyl benzoate, vinyl butyrate and the like; esters of alphamethylene aliphatic monocarboxylic acids such as methyl acrylate, ethyl acrylate, n-butylacrylate, isobutyl acrylate, dodecyl acrylate, n-octyl acrylate, 2-chloroethyl acrylate, phenyl acrylate, methylalphachloroacrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate and the like; acrylonitrile, methacrylonitrile, acrylamide, vinyl ethers such as vinyl methyl ether, vinyl isobutyl ether, vinyl ethyl ether, and the like; vinyl ketones such as vinyl methyl ketone, vinyl hexyl ketone, methyl isopropenyl ketone and the like; vinyldene halides such as vinylidene chloride, vinylidene chlorofluoride and the like; and N-vinyl indole, N-vinyl pyrrolidene and the like; and mixtures thereof.

Also esterification products of a dicarboxylic acid and a diol comprising a diphenol may be used as a preferred resin material for the toner composition of the present invention. These materials are illustrated in U.S. Pat. No. 3,655,374, totally incorporated herein by reference, the diphenol reactant being of the formula as shown in column 4, beginning at line 5 of this patent and the dicarboxylic acid being of the formula as shown in column 6 of the above patent. The resin is present in an amount so that the total of all ingredients used in the toner total about 100%, thus when 5% by weight of the alkyl pyridinium compound is present and 10% by weight of pigment such as carbon black is present, about 85% by weight of resin material is used.

The toner resin particles can vary in diameter, but generally range from about 5 micrometers to about 30 micrometers in diameter, and preferably from about 10 micrometers to about 20 micrometers.

Various suitable pigment or dye may be employed as the colorant for the toner particles, such materials being well known, and including for example, carbon black, nigrosine dye, aniline blue, calco oil blue, chrome yellow, ultramarine blue, DuPont oil red, methylene blue chloride, phthalocyanine blue and mixtures thereof. The pigment or dye should be present in sufficient quantity to render it highly colored so that it will form a clearly visible image on the recording member. For example, where conventional xerographic copies of documents are desired, the toner may comprise a black pigment such as carbon black or a black dye such as Amaplast black dye available from the National Aniline Products Inc. Preferably the pigment is employed in amounts from about 3 percent to about 20 percent by weight based on the total weight of toner, however, if the colorant employed is a dye, substantially smaller quantities of the color may be used.

As indicated herein, there can be incorporated in the toner (resin plus colorant) various enhancing additives, primarily for the purpose of imparting a positive charge to the toner resin. Examples of such aditives include quaternary ammonium compounds, as described in U.S. Pat. No. 3,970,571, and alkyl pyridinium halides, such as cetyl pyridinium chloride.

Other modifications of the present invention will occur to those skilled in the art upon a reading of the present disclosure. These are intended to be included within the scope of the present invention.